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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a gas circulation fan for an excimer laser apparatus. More specifically, the present invention relates to a gas circulation fan for an excimer laser apparatus that emits laser, by circulating halogen gas such as fluorine gas.
[0003] 2. Description of the Background Art
[0004] In a conventional excimer laser apparatus, rolling bearing has been used as a bearing for the laser gas circulation fan. Generation of an impurity gas resulting from a reaction between the halogen gas such as fluorine included in the laser gas and bearing lubricant, and generation of dust from rolling surface of the bearing ball, however, degraded laser gas, affecting the laser output. As a solution to this problem, recently, a magnetic bearing has come to be used.
[0005] [0005]FIG. 6 is a block diagram showing a configuration of a mechanical body unit and a controller of a conventional magnetic bearing apparatus for the gas circulation fan. Referring to FIG. 6, on a main shaft 1 , a fan 2 is attached, forming a rotary body 3 . Gas 21 is circulated, as fan 2 rotates in a chamber 20 . Rotary body 3 has one side pivotally supported by a magnetic bearing 41 , and the other side pivotally supported by a magnetic bearing 42 . Magnetic bearing 41 on one side includes an electromagnet 51 positioned in a housing 23 and supporting, in non-contact manner, one side of rotary body 3 , and a position sensor 61 detecting position of rotary body 3 . Magnetic bearing 42 on the other side includes an electromagnetic 52 positioned in a housing 24 and supporting, in a non-contact manner, the other side of rotary body 3 , and a position detection sensor 62 detecting the position of rotary body 3 .
[0006] Magnetic bearings 41 and 42 are connected to a controller 7 through cables 81 and 82 , respectively. Controller 7 includes a position detection sensor circuit 9 processing signals from position sensors 61 and 62 and converts an amount of displacement of rotary body 3 to a voltage ratio; an offset adjuster 10 electrically correcting position mechanical deviation from the center of the floating position of rotary body 3 ; a sensor feedback gain adjuster 11 adjusting gain of an output representing displacement of position detection sensor circuit 9 ; a filter circuit 12 for reducing bending natural frequency or the like of rotary body 3 ; a phase compensating circuit 13 for stabilizing control system; and a power circuit 14 supplying current to electromagnets 51 and 52 .
[0007] In the conventional magnetic bearings 41 and 42 shown in FIG. 6, when a characteristic of mechanical body unit 25 such as a bearing gap or a main shaft natural frequency changes because of variation in processing accuracy, for example, position detection sensor circuit 9 , offset adjuster 10 , sensor feedback gain adjuster 11 and filter circuit 12 must be finely adjusted to address the change of mechanical body unit 25 , and it has been difficult to maintain compatibility between mechanical body unit 25 and controller 7 . For example, when controller 7 fails and is exchanged by a new controller, various portions of controller 7 must newly be adjusted. This is very troublesome in adjusting and maintaining the apparatus, and has an influence on productivity of the apparatus.
SUMMARY OF THE INVENTION
[0008] Therefore, an object of the present invention is to provide a gas circulation fan of an excimer gas laser apparatus, in which a mechanical body unit and a control circuit have full compatibility.
[0009] The present invention provides a gas circulation fan for an excimer laser apparatus in which laser gas in a chamber is circulated by fan rotation, including: a rotary shaft on which the fan is attached; a controllable magnetic bearing supporting, in non-contact manner, the rotary shaft; a control circuit controlling the controllable magnetic bearing; a motor for rotating the rotary shaft; and a compensator provided between the controllable magnetic bearing and the controlling circuit, compensating for characteristic variation resulting from individual difference of the controllable magnetic bearing.
[0010] As the variation in characteristics derived from individual difference is compensated in this manner, compatibility between the controllable magnetic bearing and the control circuit is established.
[0011] The compensator includes a detector detecting a sensor signal of the controllable magnetic bearing, an offset adjusting circuit correcting positional deviation from the center of the rotary shaft based on the sensor signal detected by the detector, a feedback gain adjusting circuit adjusting the gain of detection output of the detector, and a filter circuit for reducing proper oscillation of the rotary shaft.
[0012] Accordingly, proper oscillation of individual controllable magnetic bearing can be compensated for by the compensator, and compatibility between the controllable magnetic bearing and the control circuit is ensured.
[0013] Further, the gas circulation fan includes a housing accommodating the controllable magnetic bearing, and the compensator is provided in the housing.
[0014] As the compensator is accommodated in the housing of the controllable magnetic bearing, even when the control circuit fails, what is necessary is simply to replace the failed circuit with a new control circuit, and adjustment operation can be eliminated.
[0015] According to another aspect, the present invention provides a gas circulation fan for an excimer laser apparatus circulating laser gas in a chamber by fan rotation, including: a rotary shaft on which the fan is attached; a controllable magnetic bearing supporting, in a non-contact manner, the rotary shaft; a control circuit controlling the controllable magnetic bearing; a motor for rotating the rotary shaft; and an adjusting member for adjusting natural frequency of the rotary body rotating integrally with the rotary shaft.
[0016] In this manner, by the adjusting member for adjusting the natural frequency, variation in natural frequency of the mechanical body can be minimized.
[0017] Further, the adjusting member includes a weight detachably attached to the rotary shaft.
[0018] Thus, by adjusting the mass of the weight, variation of natural frequency can be suppressed.
[0019] Further, the adjusting member includes a female screw formed along the axial direction from one end surface side of the rotary shaft, and a natural frequency adjusting member having a male screw portion formed on an outer circumferential surface and moved forward/downward engaged with the female screw portion.
[0020] As the natural frequency adjusting member is provided, the addition of the center of gravity of the screw can be changed by changing the amount of screwing, and hence the natural frequency of the entire rotary shaft can be adjusted.
[0021] According to a still further aspect, the present invention provides a gas circulation fan for an excimer laser apparatus circulating laser gas in a chamber by fan rotation, including: a rotary shaft on which the fan is attached; a controllable magnetic bearing supporting, in a non-contact manner, the rotary shaft; a control circuit controlling the controllable magnetic bearing; and a motor for rotating the rotary shaft; wherein the control circuit includes a bandpass filter for removing natural oscillation frequency of the rotary shaft, and a frequency setting circuit for setting the set frequency of the bandpass filter to the natural frequency of the rotary shaft.
[0022] Therefore, even when the natural frequency of the rotary shaft varies, the frequency of the bandpass filter can automatically be adjusted on the side of the control circuit.
[0023] The foregoing 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
[0024] [0024]FIG. 1 shows a configuration of the magnetic bearing for a gas circulation fan of an excimer laser apparatus in accordance with a first embodiment of the present invention.
[0025] [0025]FIG. 2 shows a configuration of a mechanical body unit and a relay representing a modification of the first embodiment of the present invention.
[0026] [0026]FIGS. 3A and 3B represent configurations of the magnetic bearing for gas circulation fan of an excimer laser apparatus in accordance with a second embodiment of the present invention.
[0027] [0027]FIGS. 4A to 4 D represent the main shaft natural frequency adjusting mechanism of the excimer laser apparatus in accordance with a third embodiment of the present invention.
[0028] [0028]FIG. 5 shows a filter tuning mechanism for attenuating main shaft natural frequency of the excimer laser apparatus in accordance with a fourth embodiment of the present invention.
[0029] [0029]FIG. 6 shows a configuration of a magnetic bearing for gas circulation fan of a conventional excimer laser apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] [0030]FIG. 1 is a block diagram representing a configuration of a mechanical unit and an electrical configuration, of the first embodiment of the present invention.
[0031] Referring to FIG. 1, in the present embodiment, portions that have limited compatibility between mechanical unit 25 and controller 7 shown in FIG. 6 are accommodated in relays 15 and 16 . More specifically, in the conventional example shown in FIG. 6, compatibility between mechanical body unit 25 and controller 7 has been limited by position detection sensor circuit 9 , offset adjuster 10 , sensor feedback gain adjuster 11 and filter circuit 12 .
[0032] Therefore, in the embodiment shown in FIG. 1, the circuit configurations that have limited the compatibility are accommodate in relays 15 and 16 . More specifically, relay 15 includes position detection sensor circuit 151 , offset adjuster 152 , feedback gain adjuster 153 and filter circuit 154 , while relay 16 includes position detection sensor 161 , offset adjuster 162 , feedback gain adjuster 163 and filter circuit 164 . Relay 15 is connected to magnetic bearing 41 by means of a cable 81 , and relay 16 is connected to magnetic bearing 42 by means of a cable 82 . Further, relay 15 is connected to controller 7 by means of a cable 83 , and relay 16 is connected to controller 7 by means of a cable 84 . Only phase compensating circuit 13 and power circuit 14 are provided in controller 7 .
[0033] Respective circuits in relay 15 are finely adjusted in accordance with the characteristics of magnetic bearing 41 , while relay 16 is finely adjusted in accordance with the characteristics of magnetic bearing 42 . Therefore, it becomes possible to attain compatibility between mechanical body unit 25 including relays 15 and 16 and controller 7 . When controller 7 fails, for example, repair is completed simply by exchanging controller 7 , which does not require any fine adjustment, and therefore, the adjusting operation can be eliminated.
[0034] [0034]FIG. 2 shows a modification of the mechanical body unit and the controller in accordance with an embodiment of the present invention. In the embodiment shown in FIG. 2, relays 15 and 16 shown in FIG. 1 are combined to be one relay 15 . Relay 15 contains position detection sensor circuit 156 , offset adjuster 157 , feedback gain adjuster 158 and filter circuit 159 each having circuits corresponding to magnetic bearings 41 and 42 , the relay 15 is connected to magnetic bearings 41 and 42 by cables 81 and 82 , respectively, and the relay 15 is connected to external controller 7 by cable 83 .
[0035] In this embodiment also, position detection sensor circuit 156 , offset adjuster 157 , feedback gain adjuster 158 and filter circuit 159 that have limited compatibility between mechanical body unit 25 and controller 7 are accommodated in relay 15 . Therefore, compatibility between controller 7 and mechanical unit 25 including relay 15 can be attained.
[0036] [0036]FIGS. 3A and 3B represent configurations of the mechanical unit and the controller in accordance with the second embodiment of the present invention. In the embodiment shown in FIGS. 3A and 3B, position detection sensor circuit 151 , offset adjuster 152 , feedback gain adjuster 153 and filter circuit 154 constituting relay 15 shown in FIG. 1 are provided on an inner substrate 30 within a housing 23 , while position detection sensor circuit 161 , offset adjuster 162 , feedback gain adjuster 163 and filter circuit 164 constituting relay 16 are mounted on an inner substrate 31 in a housing 24 . As respective circuit components are mounted on inner substrate 30 and 31 , relays 15 and 16 shown in FIG. 1 can be eliminated, enabling further reduction in size. In this structure also, compatibility between mechanical body 25 and controller 7 can be attained.
[0037] [0037]FIGS. 4A to 4 D represent a third embodiment of the present invention. When natural frequency of rotary body 3 including main shaft 1 varies because of processing accuracy error in manufacturing main shaft 1 , it becomes necessary to readjust frequencies of filter circuits 154 , 164 and 159 in the relay in inner substrates 30 and 31 , to be in accordance with the natural frequency of rotary body 3 , as described in the first and second embodiments.
[0038] In contrast, in the embodiment shown in FIGS. 4A to 4 D, variation in proper oscillation of main shaft 1 is minimized, so as to eliminate adjustment of the set frequency of filter circuit 12 . More specifically, in the example shown in FIG. 4A, a natural frequency adjusting weight 17 is attached to one end of main shaft 1 , and in the example shown in FIG. 4B, natural frequency adjusting weight 17 is attached on the other side of main shaft 1 . By attaching natural frequency adjusting weight 17 on main shaft 1 , the mass is adjusted such that the natural frequency of main shaft 1 has a prescribed value (prescribed frequency of filter circuit 12 shown in FIG. 6).
[0039] Though natural frequency adjusting weight 17 is attached on one side or on the other side of main shaft 1 , it may be attached to other position. By this method, individual difference in natural frequency of rotary body 3 including main shaft 1 can be eliminated. Therefore, it becomes unnecessary to arrange filter circuit 12 in relays 15 and 16 or on inner substrates 30 and 31 , and a filter circuit can be arranged in controller 7 . Thus, readjustment of set frequency of filter circuit 12 becomes unnecessary.
[0040] In the example shown in FIG. 4C, a natural frequency adjusting screw 18 is attached on one end surface of main shaft 1 , in place of natural frequency adjusting weight 17 . In this example, a female screw 22 is formed on one end of main shaft 1 , and natural frequency adjusting screw 18 having male screw formed therein is engaged therewith. By changing the amount of screwing of natural frequency adjusting screw 18 , the position of the center of gravity of the screw changes as shown in FIG. 4D, and hence the natural frequency of main shaft 1 as a whole can be adjusted.
[0041] [0041]FIG. 5 shows configurations of mechanical body unit 25 and the controller in accordance with the fourth embodiment of the present invention. Similar to the third embodiment, in the present embodiment, when natural frequency of rotary body 3 including main shaft 1 varies because of processing accuracy error in manufacturing main shaft 1 , the filter frequency is automatically adjusted by a digital control circuit 19 of controller 7 . More specifically, in digital control circuit 19 , a filter tuning control circuit 26 sets the frequency of filter circuit 12 to an expected natural frequency of rotary body 3 and activates magnetic bearings 41 and 42 , and the frequency of filter circuit 12 is changed from a frequency little lower than the expected natural frequency of rotary shaft 3 to a frequency a little higher than the expected frequency, while measuring frequency characteristics at respective frequencies. Filter tuning control circuit 26 finds the frequency of filter circuit 12 at which the peak of proper oscillation becomes the smallest, and sets the thus found frequency as the prescribed frequency of the apparatus. By setting the frequency of the filter circuit 12 to the prescribed frequency thereafter, optimal control can automatically be attained.
[0042] Therefore, in accordance with the present embodiment, even when there is an individual difference in natural frequency of rotary body 3 , the filter frequency can automatically be adjusted by digital control circuit 19 . Therefore, it is unnecessary to take into consideration compatibility of mechanical unit 25 .
[0043] As described above, according to the embodiments of the present invention, full compatibility between the mechanical body and the controller can be attained. Therefore, it is expected that efficiency in operation is improved at the site of production, and maintenance is facilitated. For example, at the site of production, a plurality of mechanical bodies may be adjusted by using one controller.
[0044] Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims.
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In a gas circulation fan, a main shaft is supported in a non-contact manner, by magnetic bearings. Between each of the magnetic bearings and a controller, a relay is provided. Each relay includes a position detection sensor circuit, an offset adjuster, a feedback gain adjuster and a filter circuit. Thus, compatibility between a mechanical body unit and the controller is attained.
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REFERENCE TO RELATED APPLICATIONS
This application is a divisional of co-pending U.S. patent application Ser. No. 08/508,238 filed Jul. 27, 1995.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to photoactivatable compounds and to methods for using the compounds for diagnosing and treating medical conditions.
2. Prior Art
Photodynamic Therapy (PDT) is used for treating various diseases including cancer, psoriasis, vascular disease, non-cancerous hyperplastic disease such as benign prostatic hyperplasia, macular degeneration, glaucoma, and certain viral infections. PDT requires concentrating a photosensitizer drug in a target tissue then photoactivating the compound with a device which includes a light source providing light at a particular wavelength and power level. The drugs administered for PDT are commonly known as photosensitizers (PS) due to their inherent ability to absorb photons of light and transfer that energy to oxygen which then converts to a cytotoxic or cytostatic species. Table 1 presents a list of classes of photosensitizer compounds commonly employed in PDT, which PS's are referred to hereinafter in the alternative as "ROPPs" (Reactive Oxygen Producing Photosensitizer molecules) and "LEPs" (Light Emitting Photosensitive molecules). While not exhaustive, the list of PDT photosensitizer drugs presented in Table 1 is exemplary of the variety of ROPPs and LEPs currently used in the art.
The photoactivating device employed for PDT usually comprises a monochromatic light source such as a laser, the light output of which may be coupled to an invasive light delivery catheter for conduction and delivery to a remote target tissue. Such interventional light delivery catheters are well known in the art and are described, for example, in U.S. Pat. Nos. 5,169,395; 5,196,005; and 5,231,684. Other devices which are frequently used in conjunction with a light source and light delivery catheter include drug delivery devices and/or a balloon perfusion catheter (U.S. Pat. No. 5,213,576) and/or various medicament-dispensing stents for the slow localized release of the photosensitizer. PDT is presently an approved procedure in Canada, Japan, and The Netherlands for the treatment of various cancers.
In addition to cancer therapy, PDT is being tested for the treatment of psoriasis. Extra-corporal PDT of blood is being evaluated for the prevention of intimal hyperplasia following transplant surgery. PDT is also being evaluated for the treatment of vascular disease; most commonly the prevention of intimal hyperplasia following angioplasty. ROPPs are presently in clinical trials for the treatment of cutaneous cancers such as basal cell carcinoma, basal cell nevus syndrome, squamous cell carcinoma, and AIDS related Kaposi's sarcoma. ROPPs are also being investigated for the treatment of a cancer precursor, Barrett's esophagus. In addition, ROPPs may have utility for treating invasive cancers, cancer precursors, psoriasis, non-cancerous urological disorders, viral inactivation, macular degeneration, glaucoma and various vascular diseases.
TABLE 1______________________________________ROPPs and LEPs______________________________________Pyrrole-derived macrocyclic Texaphyrins and derivatives compounds thereof (11) Naturally occurring or synthetic Phenoxazine dyes and derivatives porphyrins and derivatives thereof (12) thereof (1)* Phenothiazines and derivatives Naturally occurring or synthetic thereof (13) chlorins and derivatives thereof (2) Chalcoorganapyrylium dyes and Naturally occurring or synthetic derivatives thereof (14) bacteriochlorins and derivatives Triarylmethanes and derivatives thereof (3) thereof (15) Synthetic isobacteriochlorins and Rhodamines and derivatives derivatives thereof (4) thereof (16) Phthalocyanines and derivatives Fluorescenes and derivatives thereof (5) thereof (17) Naphthalocyanines and derivatives Azaporphyrins and derivatives thereof (6) thereof (18) Porphycenes and derivatives Benzochlorins and derivatives thereof (7) thereof (19) Porphycyanines and derivatives Purpurins and derivatives thereof (8) thereof (20) Pentaphyrin and derivatives Chlorophylls and derivatives thereof (9) thereof (21) Sapphyrins and derivatives Verdins and derivatives thereof (10) thereof (22)______________________________________ *(m) refers to the compound having molecular structure indicated at (m) i the specification where m is an integer between 1 and 22.
ROPPs and LEPs such as those indicated in Table 1, and as illustrated in FIGS. 1-23, have been shown to selectively accumulate, both in vitro and in vivo, in catheter induced atheromatous plaques in rabbit and swine models as evidenced by laser induced fluorescence and chemical extraction (HL Narciso, et al, Retention of tin ethyl etiopurpurin (SnET2) by atheromatous plaques: Studies in vitro & in vivo rabbits, Proceedings of SPIE: Diagnostic and Therapeutic Cardiovascular Interventions IV, 1994, 2130:30-41). In vitro studies utilizing human cadaver aortas demonstrate the passive accumulation of photosensitizers such as ROPPs and LEPs into naturally occurring atheromatous plaques. Certain ROPPs and LEPs have the ability to penetrate the nuclear membrane within a cell and to intercalate into the nuclear DNA, particularly ROPPs bearing a positive charge (cationic).
Psoralen-type compounds have also been investigated for their ability to prevent intimal hyperplasia. Psoralens and other furocoumarins (furane fused to coumarin and derivatives thereof) are also photosensitive compounds which have been used in the treatment of psoriasis for over 40 years. Such psoralen-based phototherapy is alternatively referred to herein as PUVA; Psoralen activated with UltraViolet A light. An exemplary list of some furocourmarin compounds is presented in Table 2. Systemically administered psoralen-type compounds penetrate the nuclear membrane of cells and may intercalate with the nuclear DNA in target tissue cells. Following intercalation with the target tissue's nuclear DNA, the psoralen compound is photoactivated with ultraviolet light or short wavelength visible light (see, for example, FP Gasparro, et al, The excitation of 8-Methoxypsoralen with visible light: Reversed phase HPLC quantitation of monoadducts and cross-links, Photochem. Photobiol., 1993, 57(6):1007-1010.), which UV light is preferably delivered only to the target tissue by a light delivery catheter or similar delivery device, to cause DNA crosslinking and ultimately a mutagenic effect in the cells comprising the target tissue. (KL March, et al, 8-Methoxypsoralen and longwave ultraviolet irradiation are a novel antiproliferative combination for vascular smooth muscle, Circulation, 1993, 87:184-91; BE Sumpio, et al, Control of smooth muscle cell proliferation by psoralen photochemotherapy, J. Vasc. Surg, 1993, 17:1010-1018; KW Gregory, et al, Photochemotherapy of intimal hyperplasia using psoralen activated by ultraviolet light in a porcine model, Lasers in Surg. Med., 1994, (Suppl 6): 12 Abstract).
Furocoumarins are photochemical agents showing potential for both diagnostic and therapeutic applications in medicine. The DNA cross-linking by furocoumarins such as described above proceeds by a two step process. Following injection of the fuorocoumarin into the body of an animal, the (planar) furocoumarin molecule first intercalates within the double helix of intracellular DNA or RNA. Following intercalation, the covalent addition of the furocoumarin to the polynucleic acid is achieved through the addition of light energy within the absorption band of the specific furocoumarin. Either furocoumarin -RNA or -DNA monoadducts or cross-links may be created upon illumination of the intercalated species. By forming covalent cross-links with base-pair structures, furocoumarins can alter the metabolic activity of a cell and induce cytostasis (GD Cimino, HB Gamper, ST Isaacs, JE Hearst, Psoralens as photoactive probes of nucleic acid structures and function: Organic chemistry, and biochemistry, Ann. Rev. Biochem., 1985, 54:1154-93).
TABLE 2______________________________________Furocoumarins.sup.‡______________________________________Compounds containing Furocoumarin sub-components (23)* Psoralens and derivatives thereof (24) Isopsoralens (angelicins) and derivatives thereof (25) Pseudopsoralens and derivatives thereof (26) Pseudoisopsoralens and derivatives thereof (27) Allopsoralens and derivatives thereof (28) Pseudoallopsoralens and derivatives thereof (29)______________________________________ *(m) refers to the compound having the structure indicated at FIG. m in the appended figures where m is an integer 23 ≦ m ≦ 29. .sup.‡ The furocoumarins may be either naturally occurring or synthetic.
Coronary artery disease is thought to be initiated by a disruption of fatty streaks which form early in life on the vessel wall which disruption, in turn, promotes thrombus formation. Over time the thrombus becomes organized and provides structure for the accumulation of fatty lipids, foam cells, cholesterol, calcium, fibrin, and collagen. A fibrous cap forms over this collection of lipid-rich material. Periodically this fibrous cap ruptures; releasing some of the lipid-rich material and exposing the remaining plaque materials to the circulating blood. Growth factors within the blood initiate the migration of smooth muscle cells (SMCs), from the media to the intima where proliferation of the SMCs begins. The ulcerated plaque induces the deposition of platelets and thrombus formation in a "response to injury" mode. This cycle recurs until eventually the plaque ruptures, the distal coronary artery is occluded by an thrombus and a heart attack occurs (V. Fuster, et al, Clinical-Pathological Correlations of Coronary Disease Progression and Regression, Supplement to Circulation, Vol. 86, No. 6, 1992:III-1-III-11 and JJ Badimon, Coronary Atherosclerosis, A Multifactorial Disease, Supplement to Circulation, Vol. 87, No. 3, 1993:II-3-II-16).
Restenosis occurs when coronary disease is treated with an interventional therapy such as Percutaneous Transluminal Coronary Angioplasty, PTCA, or atherectomy, or laser angioplasty, or stenting, or a myriad of newer technologies. Restenosis refers to the over-aggressive autogenous repair of an injury to a blood vessel by the body. Intimal hyperplasia or the hyperproliferation of medial (and possibly adventitial) smooth muscle cells (SMCs,) is a major contributing factor to restenosis. Hyperproliferating SMCs form a neo-intima which can reduce the bore of the arterial lumen and thus the capacity of the artery to deliver oxygen rich blood. This reduction in cross-sectional luminal area can be more severe than the original constricted area which was treated. The foregoing problems are representative of some medical conditions which the compounds of the present invention may have particular application.
DNA cross-linking by furocoumarins results in the reduction of smooth muscle cell (SMC) proliferation and, since their DNA cross-linking activity is cytostatic, furocoumarins may have certain advantages over cytotoxic photosensitizers (ROPPs and LEPs) in the prevention of intimal hyperplasia as described by March, et al, U.S. Pat. No. 5,116,864 and Deckelbaum, et al, U.S. Pat. No. 5,354,774 the teachings of which patents are incorporated herein by reference thereto. The cytotoxicity of ROPPs and LEPs currently used in PDT results in the extravasation of intracellular organelles, cytoplasm, and cytokines which, in turn, elicits an inflammatory response. The inflammatory response elicited by extravasation of cellular contents is hypothesized as a key contributing factor to restenosis. The disadvantage of employing psoralens to prevent restenosis (when compared to photosensitizers such as ROPPs and LEPS) is that psoralens do not exhibit a selective affinity for atheromatous plaques over normal intimal tissue.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide a photoactivatable compound which can be used to treat a variety of diseases.
It is an object of the present invention to provide a photoactivatable therapeutic compound which causes cytostasis but not cytolysis when bound to a cell and activated with light.
It is another object of the present invention to provide a photoactivatable compound which has a selective affinity for rapidly proliferating cells.
It is still a further object of the present invention to provide a photoactivatable compound which will reduce the incidence of restenosis following phototherapy of atheromatous plaque.
It is a further object of the present invention to provide a photoactivatable compound which can cause cytostasis when activated by a specific wavelength of light.
It is still a further object of the present invention to provide a photoactivatable compound which can cause cytostasis when activated by one particular wavelength of light and cause cytolysis when activated with light having a different wavelength.
It is yet a further object of the present invention to provide a method for treating such diseases as atherosclerosis, restenosis, cancer, cancer precursors, noncancerous hyperproliferative diseases, psoriasis, macular degeneration, glaucoma and viruses employing photoactivatable compounds.
It is a further object of the present invention to provide a method for employing such photoactivatable compounds for diagnosing such diseases as atherosclerosis, restenosis, cancer, cancer precursors, noncancerous hyperproliferative diseases, psoriasis, macular degeneration, glaucoma and viruses.
The features of the invention believed to be novel are set forth with particularity in the appended claims. However, the invention itself, both as to composition and manner of use, together with further advantages of these compounds may best be understood by reference to the following description of preferred embodiments.
BRIEF DESCRIPTION OF THE FIGURES
FIGS. 1-22 present the chemical structures of various photosensitive pyrrole-derived macrocyclic compounds which exhibit as follows:
FIG. 1 illustrates the chemical structure of photoactivatable compositions comprising a porphyrin core.
FIG. 2 shows clorin compounds.
FIG. 3 shows bacterioclorin-derived compounds.
FIG. 4 illustrates isobacteriochlorin compounds.
FIG. 5 shows phthalocyanines.
FIG. 6 shows naphthalocyanine compounds.
FIG. 7 illustrates porphycene-containing compounds.
FIG. 8 is porphycyanine compounds.
FIG. 9 is pentaphyrin derivatives.
FIG. 10 shows sapphryin and derivatives thereof.
FIG. 11 illustrates texaphyrin and derivatives thereof.
FIG. 12 shows the chemical structures of phenoxazine dyes and derivatives thereof.
FIG. 13 is phenothizine and derivatives thereof.
FIG. 14 illustrates chalcoorganapyrylium dyes.
FIG. 15 shows triarylmethane derivatives.
FIG. 16 gives the structure of rhodamine and derivatives thereof.
FIG. 17 is fluorescene derivatives.
FIG. 18 shows azaporphyrin and derivatives thereof.
FIG. 19 shows benzochlorin and derivatives thereof.
FIG. 20 illustrates the structure of purpurin and derivatives thereof.
FIG. 21 shows chlorophyll and derivatives thereof.
FIG. 22 is verdin and derivatives thereof.
FIG. 23 shows the chemical structure of compounds containing furocoumarin sub-components.
FIG. 24 illustrates psoralens and derivatives thereof.
FIG. 25 shows the structure of isopsoralens (angelicins) and derivatives thereof.
FIG. 26 is the chemical structure of pseudopsoralens and derivatives thereof.
FIG. 27 illustrates the chemical structure of pseudoisopsoralen compounds.
FIG. 28 shows allopsoralen and derivatives thereof.
FIG. 29 is pseudoallopsoralen and derivatives thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A problem encountered when using conventional cytotoxic photosensitizer compounds such as those listed in Table 1 for PDT is the post-administration inflammatory sequella such as restenosis of a blood vessel. While photosensitizers such as ROPPs and LEPs exhibit enhanced selectivity and avidity for rapidly proliferating cells in comparison with normal, more quiescent cells, the cytotoxic and cytolytic activity of such compounds may be undesirable.
A problem encountered when using PUVA for the treatment of hyperproliferative conditions is that furocourmarins exhibit little, if any, specificity and avidity for hyperproliferative cells over normal cells. Notwithstanding the foregoing, furocourmarins have the advantage that upon photoactivation with light they may either form a monoadduct to DNA or crosslink the nuclear DNA, thereby rendering the cell quiescent. Such cytostatic activity does not produce inflammation to the same extent as PDT employing ROPPs and LEPs. A novel class of photosensitizer compounds exhibiting the enhanced specificity of ROPPs and LEPs for hyperproliferating cells and the photocytostatic activity of furocourmarin compounds is described.
The compounds of the present invention form a super-class of compounds characterized by a furocoumarin compound or component thereof, alternatively referred to hereinafter as "F", conjugated with one or more of the following photosensitive molecules: (a) a ROPP (Reactive Oxygen Producing Photosensitizer) or a component thereof, or (b) a LEP (Light Emitting Photosensitizer) or a component thereof to form a F-ROPP or F- LEP. The individual compounds within this super-class of compounds are useful for the diagnosis and treatment of a myriad of diseases as previously described. F-ROPPs contained within this super-class of compounds are classes of compounds containing all possible combinations of any of the compounds set forth in Table 1 conjugated to compounds listed in Table 2. Additional compounds not explicitly listed in Tables 1 and 2 which exhibit the photosensitive and/or tissue specificity properties exemplified by ROPPs or LEPs conjugated to furocoumarins (F-ROPPs) should be construed as included within, and part of, this super-class of compounds. Each class of compound contains a plethora of specific compounds differing only in the particular functional groups attached to the basic structure.
For example, furocoumarins and derivatives thereof can be conjugated with porphyrins, chlorins, bacteriochlorins, isobacteriochlorins, phthalocyanines, naphthalocyanines, porphycenes, porphycyanines, pentaphyrin, sapphyrins, texaphyrins, phenoxazine dyes, phenothiazines, chaloorganapyrylium dyes, rhodamines, fluorescenes, azoporphyrins, benzochlorins, purpurins, chlorophylls, verdins and triarylmethanes and derivatives thereof, thereby creating 23 new classes of compounds. Compounds within each class are conveniently referred by first specifying the particular furocoumarin followed by the particular ROPP or LEPP. For example, isopsoralen conjugated with chlorin would be isopsorachlorin.
As a further example, furocoumarins such as naturally occurring or synthetic psoralens, as well as derivatives thereof, can be conjugated with one of the following photosensitive compounds from Table 1: porphyrins, chlorins, bacteriochlorins, synthetic isobacteriochlorins, phthalocyanines, naphthalocyanines, porphycenes, porphycyanines, pentaphyrin, sapphyrins, texaphyrins, phenoxazine dyes, phenothiazines, chaloorganapyrylium dyes, rhodamines, fluorescenes, azoporphyrins, benzochlorins, purpurins, chlorophylls, verdins and triarylmethanes, as well as derivatives of such photosensitizers. The foregoing conjugates form new classes of compounds which may conveniently be referred to, for example, as: Psoraporphyrins, Psorachlorins, Psora-bacteriochlorins, Psoraisobacteriochlorins, Psoraphthalocyanines, Psoranaphthalocyanines, Psoraporphycenes, Psoraporphycyanines, Psorapentaphyrin, Psorasapphyrins, Psoratexaphyrins, Psoraphenoxazine dyes, Psoraphenothiazines, Psorachaloorgana-pyrylium dyes, Psorarhodamines, Psorafluorescenes, Psoraazaporphyrins, Psorabenzo-chlorins, Psorapurpurins, Psorachlorophylls, Psoraverdins, and Psoratriarylmethanes, and derivatives thereof, respectively.
The following examples presenting the synthesis of particular photosensitizer compounds in accordance with the present invention are representative of the variety of photoactive furocourmain-photosensitizer conjugates which can be made and the conditions therefor.
Example 1
Pyropheophorbide linked 8-MOP. (8-MOP PPhe)
Pyropheophorbide (300 mg) was dissolved in dry tetrahydrofuran (100 mL) and 1,3-dicyclohexylcarbodiimide (100 mg) and dimethylaminopyridine (100 mg) were added. After stirring at room temperature for 15 min., a solution of 5-aminomethyl-8-methoxypsoralen (250 mg) in dry tetrahydrofuran (60 mL) was added. The solution was stirred at room temperature overnight. The solvent was removed by rotary evaporation, and the residual solid dissolved in dichloromethane, washed with dilute HCl then sodium carbonate solution. The organic layer was collected, dried over sodium sulfate, filtered and evaporated to dryness on a rotary evaporator. The crude residue was chromatographed on silica using methanol/dichloromethane (2%) and the major green band collected and evaporated. The residue, 8 Methoxypsorapyropheophoribide (Structure I below), was crystallized from dichloromethane/methanol.
Example 2
Meso-Pyropheophorbide linked 8-MOP. (8-MOP MPPhe)
Meso-Pyropheophorbide (300 mg) was dissolved in dry tetrahydrofuran (100 mL) and 1,3-dicyclohexylcarbodiimide (100 mg) and dimethylaminopyridine (100 mg) were added. After stirring at room temperature for 15 min., a solution of 5-aminomethyl-8-methoxypsoralen (250 mg) in dry tetrahydrofuran (60 mL) was added. The solution was stirred at room temperature overnight. The solvent was removed by rotary evaporation, and the residual solid dissolved in dichloromethane, washed with dilute HCl then sodium carbonate solution. The organic layer was collected, dried over sodium sulfate, filtered and evaporated to dryness on a rotary evaporator. The crude residue was chromatographed on silica using methanol/dichloromethane (2%) and the major green band collected and evaporated. The residue, 8-Methoxymesopyropeophoribide (Structure II below), was crystallized from dichloromethane/methanol.
Example 3
2-(1-Hexyloxvethyl) pyropheophorbide linked 8-MOP. (8-MOP HPPhe)
2-(1-Hexyloxyethyl) pyropheophorbide (200 mg) was dissolved in dry tetrahydrofuran (100 mL) and 1,3-dicyclohexylcarbodiimide (100 mg) and dimethylaminopyridine (100 mg) were added. After stirring at room temperature for 15 min., a solution of 5-aminomethyl-8-methoxypsoralen (170 mg) in dry tetrahydrofuran (60 mL) was added. The solution was stirred at room temperature overnight. The solvent was removed by rotary evaporation, and the residual solid dissolved in dichloromethane, washed with dilute HCl then sodium carbonate solution. The organic layer was collected, dried over sodium sulfate, filtered and evaporated to dryness on a rotary evaporator. The crude residue was chromatographed on silica using methanol/dichloromethane (2%) and the major green band collected and evaporated. The residue, 8-MOP HPPhe (Structure III), was crystallized from dichloromethane/methanol.
Example 4
Octaethylbenzochlorin linked 8-MOP. (8-MOP OEBCS)
To a stirred solution of octaethylbenzochlorin sulfonylchloride (300 mg) in dry dichloromethane (50 mL), was added 5-aminomethyl-8-methoxypsoralen (170 mg) in dry dichloromethane (20 ml) and dry triethylamine (0.1 mL). The resulting solution was stirred at room temperature for 1 hr and the solvent removed by rotary evaporation. The crude residue was columned on silica using dichloromethane and the major grey band collected and recrystallized from dichloromethane/methanol to give the title compound (Structure IV below).
Example 5
Zinc octaethylbenzochlorin linked 8-MOP. (8-MOP ZnOEBCS)
To a stirred solution of octaethylbenzochlorin sulfonylchloride (300 mg) in dichloromethane (50 mL), was added 5-aminomethyl-8-methoxypsoralen (150 mg) in dichloromethane (20 ml) and dry triethylamine (0.1 mL). The resulting solution was stirred at room temperature for 1 hr. Zinc acetate (200 mg) dissolved in methanol (10 mL) was added to the reaction solution and the solution was warmed on a hot water bath until metallation of the benzochlorin was complete by Uv/vis spectroscopy (as seen by a band I absorption at 673nm). The solvent was then removed by rotary evaporation and the crude residue redissolved in dichloromethane (5 mL) and chromatographed on silica using dichloromethane. The major green band collected and recrystallized from dichloromethane/methanol to give the title compound (Structure V below).
Example 6
Cu iminium octaethylbenzochlorin linked 8-MOP. (8-MOP Cu Im OEBCS)
To copper octaethylbenzochlorin sulfonic acid (300 mg) dissolved in dichloromethane (100 mL) was added (chloromethylene) dimethylammonium chloride (500 mg) and the solution stirred overnight at room temperature, protected from moisture. The solution was poured into ice cold water quickly, the organic layer washed with water rapidly, separated and dried over sodium sulfate. The solution was filtered to remove sodium sulfate and 5-aminomethyl-8-methoxypsoralen (200 mg) in dichloromethane (20 mL) was added. The solution was stirred for 20 minutes at room temperature, then poured into water. The organic layer was washed with dilute HCl and dried over sodium sulfate. The solution was filtered and evaporated to dryness. The resulting reside was chromatographed on silica using 2% methanol/dichloromethane and the major green band collected and evaporated. The title compound (Structure VI below) was obtained as a green powder by precipitation from dichloromethane/hexane.
Example 7
Indium texaphyrin linked 8-MOP. (8-MOP InT)
To a solution of Indium texaphyrin-16-carboxylic acid (200 mg) was dissolved in dry terahydrofuran (50 mL) and 1,3-dicyclohexylcarbodiimide (50 mg) and dimethylaminopyridine (50 mg) added. After stirring at room temperature for 15 min., a solution of 5-aminomethyl-8-methoxypsoralen (100 mg) in dry terahydrofuran (20 mL) was added. The solution was stirred under argon at room temperature overnight. The solvent was removed by rotary evaporation, and the residual solid dissolved in dichloromethane and washed with dilute HCl and finally with water. The organic phase was separated, dried over sodium sulfate, revaporated under reduced pressure and chromatographed on silica using methanol/dichloromethane (2%). The major green band was collected and evaporated. The residue, 8-MOP InT (Structure VIII below), was crystallized from dichloromethane/hexane.
Example 8
Protoporphyrin linked 8-MOP. (8-MOP PP)
Protoporphyrin (200 mg) was dissolved in oxalyl chloride (3 mL) and the solution warmed at 40° C. for 1hr, while being protected from moisture. The excess oxalyl chloride was removed under high vacuum and dry dichloromethane (5 mL) was added. This was also removed under high vacuum, to give a purple residue that was protected from moisture via a drying tube. Dry dichloromethane (10 mL) and dry triethylamine (1 mL) were added to the residue, followed by a solution of 5-aminomethyl-8-methoxypsoralen (160 mg) in dry dichloromethane (20 mL). The solution was stirred overnight, protected from moisture via a drying tube. The solution was then poured into water and the organic phase washed well with water, collected and dried over sodium sulfate. After filtration and evaporation to dryness, the resulting residue was columned on silica using 2% acetone/dichloromethane as eluent. The major red band was collected and recrystallized from dichloromethane/methanol to yield the title compound VIII.
Example 9.
Tetraphenylporphyrin linked 8-MOP. (8-MOP TPP)
Meso-terakis-(4'-carboxyphenyl) porphyrin (200 mg) was dissolved in oxalyl chloride (5 mL) and the solution warmed at 40° C. for 1 hr, while being protected from moisture. The excess oxalyl chloride was removed under high vacuum and dry dichloromethane (5 mL) was added. This was also removed under high vacuum, to give a green residue that was protected from moisture via a drying tube. Dry dichloromethane (10 mL) and dry triethylamine (1 mL) were added to the residue and a solution of 5-aminomethyl-8-methoxypsoralen (400 mg) in dry dichloromethane (20 mL) was added. The solution was stirred overnight, protected from moisture via a drying tube. The solution was then poured into water and the organic phase washed well with water, collected and dried over sodium sulfate. After filtration and evaporation to dryness, the resulting residue was columned on silica using 2% acetone/dichloromethane as eluent. The major red band comprised 8-MOP TPP (Structure IX) and was collected and recrystallized from dichloromethane/methanol.
Example 10
2,8,12,18-Tetraethyl-3,7,13,17-tetramethyl-5,15-bis(2'-furan) porphyrin. (5,15-DFP).
4,4`-Diethyl-3,3'-dimethyl-2,2'-dipyrrylmethane (4.0g) and 2-furaldehyde (1.67g) were dissolved in methanol (100 mL) and the solution deaerated by bubbling with argon for 15min. 4-Toluenesulfonic acid (0.95g) was added and the solution stirred for 2hrs in the dark, then refrigerated overnight. The precipitated porphyrinogen was collected, washed with ice cold methanol (20 mL) and resuspended in methanol (100 mL). o-Chloranil (6.0g) was added and the solution stirred in the dark for 2hrs. Triethylamine (2 mL) was added and the precipitated porphyrin was collected by filtration, washed well with methanol and dried under high vacuum. The porphyrin was recrystallized from dichloromethane/methanol to yield the title compound (X).
Example 11
Texas red linked 8-MOP. (8-MOP TR)
Sulforhodamine 101 acid chloride (200 mg) was dissolved in dry tetrahydrofuran (100 mL) and 5-aminomethyl-8-methoxypsoralen (100 mg) added, followed by triethylamine (0.1 mL). The solution was left overnight at room temperature. The following day the solution was evaporated to dryness, redissolved in dichloromethane and columned on silica using 2% methanol/dichloromethane as eluent. The major fluorescent red fraction was collected and evaporated to dryness. The residue, comprising 8-MOP TR (Structure XI) was recrystallized from dichloromethane/hexane.
Example 12
Rhodamine B linked 8-MOP. (8-MOP RB)
Sulforhodamine B acid chloride (200 mg) was dissolved in dry tetrahydrofuran (100 mL) and 5-aminomethyl-8-methoxypsoralen (100 mg) added, followed by dry triethylamine (0.1 mL). The solution was left overnight at room temperature. The following day the solution was evaporated to dryness, redissolved in dichloromethane and columned on silica using 2% methanol/dichloromethane as eluent. The major fluorescent red fraction was collected and evaporated to dryness. The residue (Structure XII) was recrystallized from dichloromethane/hexane.
Example 13
Porphocyanine linked 8-MOP. (8-MOP Pocy)
2,3,21,22-tetraethyl-12-(4'-carboxyphenyl) porphocyanine (200 mg) was dissolved in dry tetrahydrofuran (100 mL) and 1,3-dicyclohexylcarbodiimide (100 mg) and dimethylaminopyridine (100 mg) were added. After stirring at room temperature for 15min., a solution of 5-aminomethyl-8-methoxypsoralen (300 mg) in dry tetrahydrofuran (60 mL) was added. The solution was stirred at room temperature overnight. The solvent was removed by rotary evaporation, and the residual solid dissolved in dichloromethane, washed with dilute HCl then sodium carbonate solution. The organic layer was collected, dried over sodium sulfate, filtered and evaporated to dryness on a rotary evaporator. The crude residue was chromatographed on silica using methanol/dichloromethane (2%) and the major green band collected and evaporated. The residue (Structure XIII) was crystallized from dichloromethane/methanol.
Example 14
Phthalocyanine linked 8-MOP. (8-MOP Pth)
Phthalocyanine tetra sulfonate (200 mg) was dissolved in phosphorus oxychloride (20 mL) and the solution refluxed for 2 hrs. The excess phosphorus oxychloride was removed by rotary evaporation and the residue dissolved in dry, cold pyridine (10 mL). A solution of 5-aminomethyl-8-methoxypsoralen (300 mg) in dry pyridine (60 mL) was added. The solution was stirred at room temperature overnight. The solvent was removed by rotary evaporation, and the residual solid dissolved in dichloromethane, washed with dilute HCl then sodium carbonate solution. The organic layer was collected, dried over sodium sulfate, filtered and evaporated to dryness on a rotary evaporator. The crude residue was chromatographed on silica using methanol/dichloromethane (5%) and the major green band collected and evaporated. The residue (Structure XIV) was crystallized from dichloromethane/methanol. ##STR1##
The preceding super-class of photosensitizing compounds may be characterized by: a) a furocoumarin attached to a Reactive Oxygen Producing Photosensitizer type compound, F-ROPP; b) a furocoumarin sub-component attached to a ROPP, FS-ROPP; c) a cationic furocoumarin attached to an ROPP (neutral or cationic), to produce either CF-ROPP or CFS-ROPP; d) a cationic ROPP attached to a furocoumarin (neutral or cationic); e) any one of the above compounds wherein the ROPP is metalized; and f) a furocoumarin conjugated with a light emitting photosensitizer, F-LEP.
The foregoing super-class of conjugated compounds can be used to treat a variety of diseases such as atherosclerosis, restenosis, cancer, cancer precursors, non-cancerous hyperproliferative diseases, psoriasis, macular degeneration, glaucoma, and certain viruses. These compounds are light activatable drugs which may or may not be photodynamically active (i.e. produce singlet oxygen and/or oxygen radicals to mediate cytotoxicity), but will be photoactive (i.e. exhibit photochemical cross-linking with DNA or RNA or the production of monoadducts of the compound therewith) to modulate the metabolic activity of cells. More specifically, these novel photoactive compounds will retain the ability of the ROPP or LEP to localize to a greater extent in the target tissue and the ability of the furocoumarin (such as psoralen) to intercalate into target tissue DNA and form cross-linked and/or monoadducts adducts upon the addition of light energy.
Previous studies indicate that utilizing a cationic ROPP or LEP to synthesize a CF- ROPP or CF-LEP facilitates the intercalation of the compound into target cell DNA. Once the F-ROPP or CF-ROPP is localized in target cells, light activation can be used therapeutically and/or diagnostically. The use of these novel compounds for the detection and/or treatment and the prevention of restenosis and intimal hyperplasia following cardiac transplantation surgery (or AV shunt procedures such as dialysis) is an exemplary application which is discussed in particular detail to teach and illustrate a use for the invention, but it should be kept in mind that such an application is illustrative and should not be construed as a limitation of this invention.
For example, another application for the photosensitizer compounds described herein is the light activated treatment of a target tissue which does not selectively concentrate either ROPPs or furocoumarins. An F-ROPP, selected as described below from the super-class of compounds described above, can be administered systemically to a biological organism, which organism could be an animal, a plant or even a single cell or a polynucleic acid fragment. Following systemic administration of the F-ROPP, and while the F-ROPP is present in the animal's serum, a light source operating at a strong absorption wavelength of the furocoumarin component of the F-ROPP, is directed toward the volume of target tissue in which high concentrations of the F-ROPP are desired. The selection of the particular furocoumarin used in the F-ROPP is preferably a species which creates mono-adducts with polynucleic acids when activated with UV or short wavelength visible light. By administering the activating light to the target tissue, mono-adducts of F-ROPPs with DNA and RNA are formed. Increasing the intensity of the activating light delivered to the target tissue increases the DNA-bound F-ROPP therein. When the F-ROPP reaches the desired concentration in the target tissue, a longer wavelength of light which activates the ROPP portion of the F-ROPP may be used to photoactivate the cell bound F-ROPP in the target tissues to selectively destroy or modify the target tissue. In effect, the F-ROPP creates a light-induced selectivity of the F-ROPP for binding to the target tissue because only the target tissue is illuminated with the shorter wavelength of light thereby causing covalent bonding of F-ROPP only in the DNA/RNA of the target tissue.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the impending claims all such changes and modifications that are within the scope of this invention.
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A broad class of photosensitive compounds having enhanced in vivo target tissue selectivity and versatility in photodynamic therapy. Many furocoumarin compounds, such as psoralens, exhibit cytostatic activity when photoactivated but exhibit little in vivo specificity for selectively accumulating in any particular target tissue such as atheromatous plaques. Reactive Oxygen Producing Photosensitizers ("ROPPs") are photoactivatable compounds having an affinity for hyperproliferating cells (such as atheromatous plaque cells), which when photoactivated, produce cytotoxic reaction products. The photoactivity of a ROPP, such as a porphyrin, may be reduced by metalating the porphyrin while the selective affinity of the metalized ROPP for hyperproliferating tissue remains substantially unchanged. By linking a furocoumarin compound to a ROPP to form a F-ROPP, the cytostatic properties of the furocoumarin portion of the F-ROPP can be exploited while the selective affinity of the ROPP portion of the compound for hyperproliferating cells such as atheromatous plaque provides enhanced tissue selectivity without cytotoxicity. In vivo, certain F-ROPPs may be forced to selectively accumulate in a target tissue by illuminating only the target tissue with light having a wavelength operable for photoactivating the F portion of the F-ROPP thereby causing the F-ROPP to either form a monoadduct with or crosslink the cellular DNA in the target tissue. Light of a second wavelength can then be delivered to the target tissue to photoactivate the ROPP portion causing further interference with cellular activity.
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This is a continuation of application Ser. No. 07/614,633, filed Nov. 16, 1990 which was abandoned upon the filing hereof.
BACKGROUND OF THE INVENTION
The present invention relates to an improved sealing cover for a coupling.
A conventional armadillo-like sealing cover having a plurality of spherical shells was disclosed in the Japanese Patent Application (OPI) No. 200024/87 (the term "OPI" as used herein means an "unexamined published application"). However, the conventional sealing cover has problems that the sealing property thereof is not high enough to prevent external muddy water or dust from entering into the cover, and the cover does not have a positive means for sufficient lubrication of the sliding portions of the cover. In addition, the cover has a problem that since the spherical shells are less flexible, smooth sliding is less likely to be obtained when two shafts become eccentric except where the shafts perform a predetermined joint-like swing relative to each other.
BRIEF SUMMARY OF THE INVENTION
The present invention was made in order to solve the above-mentioned problems.
It is an object of the invention to provide a sealing cover fitted on a coupling which connects an input and an output shaft to each other to make it possible to move the shafts relatively to each other as in a bone joint or universal joint and includes an outer member having an outside spherical surface and connected to one of the shafts. The sealing cover comprises a first part spherical shell having an outer part made of a low flexibility material and having an inside spherical surface slidably fitted on the outside spherical surface of the outer member, and a part spherical groove, opening or channel open at the end of the shell near the other of the shafts; a second part spherical shell slidably inserted at one end thereof into the part spherical channel and fitted at the other end thereof on the latter shaft; a first sealing portion provided near one end of the first part spherical shell and located in contact with the outside part spherical surface of the outer member; and a second sealing portion provided near the other end of the first shell and 8 located in contact with the outside part spherical surface of the second shell. The first and second sealing portions are provided at the ends of the first shell, which is the outermost part of the sealing cover, to enhance the sealing property of the cover. It is convenient that the first shell having the part spherical channel is made of inner and outer portions between which the channel is located. The inner and outer portions of the first shell and the first and second sealing portions may be separately manufactured parts assembled with each other. The first and second sealing portions may be integrally formed on the inner portion of the first shell. To increase the volume inside the first shell, the portion of the shell, which is located outside the channel thereof in the radial direction of the sealing cover, may be partly expanded so that one end portion of the second shell slides on the outside surface of the other portion of the first shell, which is located inside the channel thereof in the radial direction of the cover.
When the sealing cover is applied to the members of the coupling of the driving system of a motor vehicle, the plural spherical shells of the cover are gradually operated according as the angle between the axes of the members of the coupling increases to about 45 degrees, whereby problems might occur with regard to the sealing property, lubricating property and eccentricity coping property of the sealing cover. However, any such problems are solved by the invention.
To enhance the lubricating property of the sealing cover, at least part of at least one of the sliding surfaces of the cover and the outer member of the coupling may be provided with recesses to make it more likely for the surface to hold a lubricant. The recesses provided in the inside surface of the first shell may be a large number of radially extending grooves. The recesses provided in the outside surface of the outer member may be made due to the roughness of the surface. The recesses provided in the outside surface of the portion of the first shell, which is located inside the channel thereof in the radial direction of the sealing cover, may be labyrinth-like recesses. The recesses may thus be provided to produce a sufficient lubrication effect. To otherwise enhance the lubricating property of the sealing cover, at least one sliding part is rounded at the edge thereof to prevent the scraper phenomenon of the edge to make it more likely for the lubricant to be introduced in between the sliding parts. To yet otherwise enhance the lubricating property of the sealing cover, the portion of the first shell, which is located inside the channel thereof in the radial direction of the cover, may be provided with a desired number of holes for supplying the lubricant to the portion and the sliding portion of the second shell on the former portion by the centrifugal force at the time of rotation of the cover. To yet otherwise enhance the lubricating property of the sealing cover, the end face of the portion of the first shell, which is located inside the channel thereof in the radial direction of the cover, may be cut to obliquely extend to diverge from the inside of the portion toward the outside thereof to supply the lubricant to the sliding parts of the cover by the centrifugal force at the time of rotation thereof. Although each of these lubricating property enhancement means is effective by itself, they may be combined with each other to be more effective.
The second part spherical shell is slidably inserted at one end thereof into the part spherical channel of the first shell so that the inside part spherical surface of the second shell slides on the outside part spherical surface of the first shell. Since the sliding is likely to be performed deep in the spherical groove, it could occur that the lubricant sealed inside the sealing cover is not sufficiently supplied for the sliding and the sliding parts of the shells are therefore worn and damaged. To reduce or prevent the wear of the sliding parts, grooves or recesses for holding the lubricant may be provided or sliding members having part spherical sliding surfaces and low coefficient of friction may be provided. The lubricating property of the sealing cover can thus be yet otherwise enhanced.
To enhance the sealing property of the sealing cover, the first and the second sealing portions may be constituted by lip seals of high sealing property and fitted with scrapers on the fronts of the lips of the seals so as to scrape down clinging extraneous substances from the outer member. Filters made of a non-woven fabric may be attached to the fronts of the scrapers to collect small extraneous substances on the filters. To otherwise enhance the sealing property of the sealing cover, the end portion of the second shell, which is fitted on the shaft, may be provided with a lip seal of high sealing property. To yet otherwise enhance the sealing property of the sealing cover, a slinger may be provided at the end of the first shell so that muddy water gathering to the end or like part is slung away.
The first and second shells of a conventional sealing cover are fitted at the ends of the shells on an input shaft so that the shells cannot move relative to the input shaft. The input and output shafts are likely to have a clearance between them in the axial direction thereof, or play in that direction, so that the shells are moved together with the input shaft to increase the resistance to the sliding of the sliding parts or sealing parts of the sealing cover to cause heating and wearing. To solve this problem, the first or second shell of the sealing cover provided in accordance with the present invention may be slidably fitted on one of the input and output shafts by a fitting member made of a rubber-like elastic material and having a bellows-like portion.
To enhance the eccentricity coping property of the sealing cover, the second shell may be provided with an easily-deformable annular thin part near the end of the shell. To otherwise enhance the eccentricity coping property of the sealing cover, the second shall may be provided with an annular bent part at the end of the shell and with ribs for reinforcing the part.
Each of the particular means mentioned above may be applied to a conventional armadillo-like sealing cover to produce a particularly good effect.
The inside part spherical surface of the first shell of a conventional sealing cover is set at the same curvature as the outside part spherical surface of the outer member of a coupling and slides on the latter surface. For that reason, when the sliding part or first shell of the sealing cover is thermally expanded because of heating due to the sliding, the thermal expansion is likely to fail to be absorbed by the cover, to increase the contact pressure on the sliding part or first shell thereof to cause a problem such as the impossibility of the smooth sliding thereof. To solve the problem, the sliding part or first shell of the sealing cover in accordance with the present invention may be provided with a recess for absorbing the thermal expansion of the sliding part of the first shell. The recess is an annular or non-annular groove, a notch, a slot or the like.
DESCRIPTION OF THE DRAWINGS
The invention will now be described in detail with reference to the accompanying drawings wherein:
FIG. 1 is a cross-sectional view of a sealing cover in accordance with one embodiment of the present invention;
FIGS. 2 and 3 are views similar to FIG. 1 of the sealing cover in various states of operation;
FIGS. 4 and 5 are views similar to FIG. 1 of other embodiments of the present invention;
FIGS. 6 and 7 are cross-sectional views of the inner portions of sealing covers of yet other embodiments of the present invention;
FIGS. 8 and 9 are enlarged fragmentary cross-sectional views of the sealing portions of sealing covers of other embodiments of the present invention;
FIG. 10 is an enlarged fragmentary cross-sectional view of the fitted portion of the second spherical shell of a sealing cover of yet another embodiment of the present invention;
FIGS. 11 and 12 are enlarged fragmentary cross-sectional views of the sliding parts of sealing covers of still other embodiments of the present invention;
FIG. 13 is a front view of the second spherical shell of a sealing cover of yet another embodiment of the present invention;
FIGS. 14 and 15 are partial elevational views of inner portions of sealing covers which are yet other embodiments of the present invention;
FIGS. 16 and 17 are partial cross-sectional views of sealing covers of further embodiments of the present invention;
FIGS. 18, 19 and 20 are partial cross-sectional views of major parts of sealing covers of still further embodiments of the present invention;
FIG. 21 is a partial side view of a major part of a sealing cover which is yet another embodiment of the present invention;
FIG. 22 is a partial front view of the major part shown in FIG. 21; and
FIG. 23 is an enlarged fragmentary cross-sectional view of a major part of a sealing cover of a further embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Embodiments of the present invention are hereafter described in detail with reference to the drawings wherein 1, 2 and 3 are an input shaft, an output shaft and an outer member, respectively. The outer member 3 is included in an equal-speed coupling and is connected to the output shaft 2, and has an outside part spherical surface (i.e. segment of a spherical surface) 3a. The input and the output shafts 1 and 2 are connected to each other by the coupling.
FIG. 1 shows a sealing cover of one of the embodiments having an inside part spherical surface (i.e. segment of a spherical surface) 5a slidably fitted on the outside part spherical surface 3a of the outer member 3 of the coupling. The sealing cover includes a first part spherical shell 4, a second part spherical shell 8, a first sealing portion 9, and a second sealing portion 10. The first part spherical shell 4 is made of a less flexible material, and has a part spherical groove, opening or channel 7 open at the end of the cover near the input shaft 1. The second part spherical shell 8 is made of a less flexible material, slidably fitted at one end thereof on which a sealing rib 8a is provided in the part spherical groove 7 of the first part spherical shell 4, and mounted at the other end 8b thereof on the input shaft 1. For brevity, the part spherical shells and surfaces will be hereafter referred to as spherical. The first sealing portion 9 is provided near the end 4a of the first spherical shell 4, and located in contact with the outside spherical surface 3a of the outer member 3. The second sealing portion 10 is provided near the other end 4b of the first spherical shell 4, and located in contact with the outside spherical surface 8c of the second spherical shell 8. The first spherical shell 4 includes an inner portion 5 and an outer spherical portion 6 between which the port spherical channel 7 is located. The inner portion 5, the outer spherical portion 6, the second spherical shell 8, the first sealing portion 9 and the second sealing portion 10, which are separately manufactured elements, are hermetically assembled with each other to constitute the sealing cover to seal a lubricant inside it. The outer spherical portion 6, which is the outermost part of the sealing cover, is made of a less flexible material such as various kinds of metal and resin. The inner portion 5 and the second spherical shell 8 are made of a less flexible material such as various kinds of highly wear-resisting resin including polyester resin. The first and the second sealing portions 9 and 10 are made of lips 13 and 14 of urethane rubber, nitrile rubber or the like and fitted rings 11 and 12 fitted on the outer spherical portion 6, respectively. The lips 13 and 14 are stuck to the fitted rings 11 and 12 by heating.
As shown in FIGS. 2 and 3, the sealing cover is gradually moved together with the input shaft 1 according as the input shaft and the output shaft 2 swing relative to each other during their rotation. Since the exclusive sealing portions 9 and 10 are provided at both ends of the outer spherical portion 6 which is the outermost part of the sealing cover, the cover has a high sealing property.
FIG. 4 shows a sealing cover of another embodiment. The difference of this sealing cover embodiment from that shown in FIGS. 1, 2 and 3 is that the inner portion 5' and outer spherical portion 6 of the first spherical shell 4 of the cover shown in FIG. 4 and the first and second sealing portions 9' and 10' thereof are made of a less flexible material such as a hard resin and a hard urethane rubber, the inner portion 5' and the first sealing portion 9' are integrally formed with each other, and the outer spherical portion 6 and the second sealing portion 10' are integrally formed with each other. For that reason, the manufacturing of the sealing cover shown in FIG. 4 and the cost thereof are easier and lower than those of the preceding sealing cover, respectively. The first and second sealing portions 9' and 10' of the sealing cover shown in FIG. 4 are made of lip seals.
FIG. 5 shows a sealing cover which is yet another of the embodiments. The difference of the sealing cover from those shown in FIGS. 1, 2, 3 and 4 is that the spherical portion 6' of the first spherical shell 4' of the sealing cover, which is located outside the spherical channel 7' of the shell in the radial direction of the cover, has an outer part 6a expanded outward in the radial direction so as to be larger in diameter than the other part of the portion. Thus, the volume inside the spherical portion 6' is increased without expanding the whole shell 4', so that a larger amount of the lubricant can be sealed inside the cover. One end portion 8a' of the second spherical shell 8' of the sealing cover slides on the outside spherical surface 5c of the inner part 5b of the inner portion 5 of the first spherical shell 4' thereof. The inner part 5b is located inside the spherical channel 7' of the first spherical shell 4'.
As for the sealing covers, at least part of each of the inside and outside spherical surfaces 5a and 5c of the inner portion 5, which is a sliding portion, and at least part of the outside spherical surface 3a of the outer member 3 of the coupling may be provided with thin recesses for holding the lubricant to reduce the frictional resistance to the sliding parts of the inner portion and the outer member to enhance the lubrication of the sliding parts. The form and size of the thin recesses are not limited in particular. It is preferable that the thin recesses of the inside spherical surface 5a of the inner portion 5 are constituted by a large number of axially extending grooves, 15' as shown in FIGS. 6 or 7, the thin recesses of the outside spherical surface 3a of the outer member 3 are made due to the roughness 16, preferably large surface roughness, of the surface as shown in FIG. 5, and the thin recesses of the outside spherical surface 5c of the inner portion 5 are constituted by thin labyrinth-like grooves.
As for the sealing covers, the inner portion 5, the second spherical shell 8 and the outer member 3 may be rounded at the sliding edges of the inside and outside surfaces 5a and 5c of the inner portion, the sliding edge of the second spherical shell and the sliding edge of the outside spherical surface 3a of the outer member along the total circumferences of them so as to prevent the scraper phenomenon of the edges to enhance the lubrication of the inner portion, the shell and the outer member. The radius of the curvature of the rounding is not limited in particular.
FIG. 14 shows the inner portions 5" of a sealing cover which is yet another of the embodiments. The difference from those shown in FIGS. 1, 2, 3 and 4 is that the portion 5d" which is located inside the channel 7 in the radial direction of the cover, has a desired number of grooves 140 for holding the lubricant to positively lubricate the sliding parts of the cover to reduce the resistance to the sliding of the parts to prevent them from being worn.
FIG. 15 shows an embodiment of inner portion 5''' having dimples 150 rather than grooves 140 for holding lubricant for the same purpose as the FIG. 14 embodiment.
FIG. 16 shows the first spherical shell of a sealing cover which is yet another of the embodiments. The difference of the sealing cover from those shown in other figures is that the portion 5d"" of inner portion 5"", which is located inside the channel 7 in the radial direction of the cover, is fitted with a desired number of sliding rings 160 which are made of a material having lower frictional properties than polyurethane rubber and have spherical sliding surfaces 160a, to reduce the resistance to the sliding of the sliding parts of the cover to prevent the parts from being worn. The sliding rings 160 are fitted in the grooves 101 portion of 5d"" so that it is separated from the second spherical shell 8 of the sealing cover.
FIG. 17 shows the first spherical shell of a sealing cover which is yet another of the embodiments. The difference from those shown in other figures is that the portion 5d''''' of inner portion 5''''' is fitted with a sliding sheet 170 made of the same material as the sliding rings 160 and has a spherical peripheral sliding surface 170a, to reduce the resistance to the sliding of the sliding parts of the cover to prevent the parts from being worn. The thickness of the sliding sheet 170 depends on the size of the sealing cover, but is preferably 0.15 mm to 0.5 mm.
As shown in FIG. 12, the part 5b of the inner portion 5, which is located inside the channel 7 in the radial direction of the sealing cover shown in FIG. 5, may have a desired number of holes 17 for supplying the lubricant to the sliding surfaces of the part 5b and the second spherical shell 8' by the centrifugal force at the time of rotation of the sealing cover so as to enhance the lubrication of the sliding surfaces. In that case, as shown in FIG. 13, the bent portion 8d' of the second spherical shell 8' at one end 8a' thereof may be provided with a number of inward projections 18 to set an appropriate clearance to more enhance the lubrication.
The end face of the part 5b of the inner portion 5, which is located inside the channel 7 in the radial direction of each of the sealing covers, may be cut to obliquely extend at a prescribed angle Θ3 (FIG. 1) to diverge from the inside of the part toward the outside thereof to better supply the lubricant by the centrifugal force at the time of rotation of the cover to enhance the lubrication of the sliding parts of the cover.
The lip seals for the first and the second sealing portions 9 and 10 have a pressure self-increasing property, and function to cope well with eccentricity. The portions 9 and 10 are made of the lip seals to utilize these features to the utmost.
As shown in FIGS. 8 and 9, annular scrapers 19, 19' may be fitted on the fronts of the lips 13 and 14 so that extraneous substances and lubricant solidifications clinging to the outside spherical surface 3a of the outer member 3 are removed therefrom by the scraper. Filters 20 may be fitted on the fronts of the scrapers 19, 19' to collect minute extraneous substances. It is preferable that the scrapers 19, 19' are made of relatively soft brass or the like so that they will not scratch the outer member 3, and the filters 20 are made of a non-woven fabric of high collecting property. The scrapers 19, 19' also function to prevent the lips 13 and 14 from being opened due to the centrifugal force at the time of rotation thereof. The lip seals may be of such a type that they are directly fixed, such as by adhesive for example, to the outer portion 6 of the first spherical shell 4.
As shown in FIG. 10, a lip seal 21, which is a kind of a whisker seal, may be attached to the fitted end portion 8b of the second spherical shell 8 to enhance the sealing property of the portion.
As shown in FIGS. 1 and 5, a slinger 22 may be attached to the end of the outer portion 6 of the first spherical shell 4 so that muddy water gathering to the end is slung away to enhance the sealing property of the sealing cover.
As shown in FIG. 10, the second spherical shell 8 may be provided with one or more thin parts 23 near the end 8b of the shell so that the influence of eccentricity of the shafts 1 and 2 on the sealing cover is limited to secure the smoothness of the sliding action thereof. The smoothness can be secured in that the shell 8 fixed to the input shaft 1 is prevented from becoming eccentric to the outer member 3. If the shell 8 is provided with the thin parts 23, the portion of the shell, which is located nearer the outer member 3 than the thin parts, is less likely to become eccentric, thus securing the smoothness of the sliding action of the sealing cover.
As shown in FIG. 11, the bent portion 8d of the second spherical shell 8 at the end 8a thereof may be provided with ribs 24 for reinforcing the bent portion to make the shell less likely to become eccentric, thus securing the smoothness of the sliding action of each of the sealing covers.
FIG. 18 shows an inner portion of a sealing cover which is yet another embodiment. The difference of the sealing cover from those shown in other figures is that the inside spherical surface 5a of the inner sliding portion 5 has an annular groove 180 for absorbing the thermal expansion of the portion. The annular groove 180 is located so that the side edge of the groove at the largest diameter of the portion 5 is on the outside spherical surface 3a of the outer member 3.
FIG. 19 shows yet another embodiment wherein the difference of the sealing cover from those shown in other figures is that the inner sliding portion 5 is provided with one or more notches 190 in mutually symmetric positions on the end of the portion at the largest diameter thereof so as to absorb the thermal expansion of the portion.
FIG. 20 shows yet another embodiment wherein the difference of the sealing cover from those shown in other figures is that the inner sliding portion 5 is provided with an annular slot 200 on the end of the portion at the largest diameter thereof so as to absorb the thermal expansion of the portion.
FIGS. 21 and 22 show yet another embodiment wherein the difference of the sealing cover from those shown in other figures is that the inner sliding portion 5 is provided with redial slots 210 in the peripheral surface of the portion so as to absorb the thermal expansion thereof.
The cross-sectional form, size, number and position of the grooves 180, notches 190 and slots 200 and 210 of the sealing covers shown in FIGS. 18, 19, 20, 21 and 22 are appropriately determined in consideration of the material and temperature of the inner sliding portion 5, the fitting load, sliding load and detaching load thereon.
FIG. 23 shows a part of a sealing cover which is yet another of the embodiments. The difference of the sealing cover from those shown in other figures is that the end portion 8b of the second spherical shell 8 of the cover is slidably fitted on the input shaft 1 by a annular fitting member 230 made of a rubber-like elastic material. The fitting member 230 includes a portion 230a fitted on the end portion 8b of the shell 8, a portion 230b fitted on the input shaft 1, and a bellows-like portion 230c extending between the portions 230a and 230b so as to expand or contract to offset the influence of the clearance between the input and the output shafts 1 and 2 or of the play thereof. The end portion 8b of the shell 8 is provided with a projection 8d engaged with the portion 230a of the fitting member 230 on the facets of the portions, which extend perpendicularly to the axial direction of the sealing cover. The fitting member 230 also functions as a seal to prevent lubricant inside the sealing cover from leaking out and external dust from entering into the cover. The influence of the clearance between the input and the output shafts 1 and 2 or of the play thereof is thus offset by the expansion or contraction of the bellows-like portion 230c to prevent heating or wear so as to lengthen the life of the sealing cover.
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A sealing cover fitted on a coupling which connects an input shaft (1) and an output shaft (2) to each other for relative movement as in a U-joint including an outer member (3) having an outer spherical surface (3a) and connected to one of said shafts (2), comprises a first spherical shell (4) having an outer part made partly of a low flexibility material and having an inside part spherical surface slidably fitted on the outer spherical surface (3a), and a part spherical channel (7) open at the end of the shell near the other of the shafts (1), a second part spherical shell (8) slidably inserted at one end thereof into the channel (7) and fitted at the other end thereof on the shaft (1), a first sealing portion provided near one end of the first shell (4) in contact with the outer surface (3a) of the outer member (3), and a second sealing portion (10) provided near the other end of the first shell in contact with the outer part spherical surface (8c) of the second shell (8).
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to provisional patent application No. 60/213,057, filed Jun. 21, 2000 and claims the benefit of the filing date of that application.
FIELD OF THE INVENTION
This invention is in the field of speaker systems and in particular to speaker enclosures intended for operation at the lower or bass frequencies of the audio range.
BACKGROUND
Speaker enclosures have been used as long as sound was reproduced by a conventional electro-mechanical speaker. Enclosures were used as a structural support to hold the speaker in place and to baffle or reduce the effect of noises or out of phase sound waves, created by the operation of the speaker and which interfered with the reproduction of the a true sound intended to be reproduced. In connection with speakers used to produce bass 13 tones at the low frequency end of the audible range, for example from 150 Hz and below the speaker enclosure had to be made large enough so pressures produced with the creation of the sound frequency waves, did not interfere with the extended movement of the speaker cone at those lower frequencies.
As background, speaker enclosures were built with baffles to extend the path for backwardly projected out of phase audio waves emanating from the rear of the speaker, to prevent these waves from interfering with the forward directed waves from the front of the speaker, because of the production of undesirable elements for example standing waves, air turbulence port noise, whistling, and port chuffing. In the case of speaker enclosures at the lower frequency ranges, the enclosure size had to be large enough to accommodate the pressures created at these lower frequencies which prevented the reduction in the size of the enclosure and prevented the enclosure from being made small so that pressure could not be properly vented without producing the before mentioned undesirable sound effects.
Many attempts have been made to solve the problems created by low frequency enclosures for the purpose of making a smaller size enclosure which do not suffer sound degradation associated with higher internal pressures or backwardly directed waves. For example, U.S. Pat. Nos. 5,517,573 and 4,196,792 show ways of using ports to vent the enclosure so low frequency sounds may be reproduced and whistling diminished and so the size of the speaker enclosure could be made smaller. However, these devices were limited as the use of ports to release the speaker internal pressures while effectively managing the standing wave problem from the backwardly projected waves, prevented a reduction in the size of the enclosure. In connection with the projected sound, a large portion of the sound energy in the backwardly projected sound was lost as the object was to reduce the effect of the speaker on the air mass inside the speaker enclosure and the efficiency of the speaker was reduced as the energy associated with the backwardly projected sound wave were not effectively utilized to enhance the sound produced by the speakers. While U.S. Pat. No. 4,231,445 made an attempt to disperse the backwardly or rearwardly projected sound waves, relative to the forward projected sound waves from the front of the speaker, the rearward sound waves were not utilized to project the sound around the speaker enclosure or to extend the sound path relative to the length of the sound waves at the lower frequency range to prevent or minimize degradation of the total sound from the speaker.
SUMMARY OF THE INVENTION
The venturi expander invention disclosed herein in its preferred embodiments and according to the principles of the disclosed invention, overcomes the problems of the prior art devices in removing or relieving the pressures in the speaker enclosure which impede the movement of the speaker cone at low frequencies, for example at 150 Hz. and below, without the accompanying distortion of port noise such as whistling or port chuffing. The venturi expander operates with improved venting; reducing the internal pressure of the enclosure, and permits the volume and size of the enclosure to be reduced. Speaker size reduction using the venturi expander can be accomplished without sacrificing an extended audio path to disperse the backwardly or rearwardly projected out of phase sound waves so their reflections do not create cancellation by the mixing of out of phase rearward sound waves with the forward projected sound waves from the front of the speaker.
The efficiency of the speaker enclosure is enhanced by the venturi expander by providing a path for dispersing the backwardly or rearward projected sound waves, in an extended path through surfaces which direct the movement of the sound waves out of the enclosure in a compound path transverse to and through bell ports placed in the speaker enclosure, extending the path of the sound waves by reflection in the transverse direction while the propagation of the sound waves is through the bell ports. An air port tube in line with the rear of the speaker and opposed to the rear of the speaker is vented at the rear wall of the enclosure, providing a tube like path for relieving the pressure built up in the enclosure around the speaker. The sound waves propagating in a compound path out of the bell ports are in a pattern that causes reflection of the sound waves from the sides, top and bottom of the speaker enclosure and residual sound waves via air port tube exhaust. These sound waves contribute to a 360-degree pattern when combined with the sound waves projecting from the front of the speaker.
The compound sound propagation path is through the speaker enclosure rear wall port opening and the inlet to the bell ports and through the bell ports to the bell port opening, and projecting the rearward sound waves at an angle to the forward sound waves projected from the front of the speaker. The effect is that of a surround sound or 360 degree sound, so for example, in a live performance musicians playing at the sides or rear of an instrument amplified by a venturi expander design speaker enclosure may hear the sound waves from that instrument as do those musicians sitting in the path of the forward projected sound waves.
The bell ports, according to the principles of the venturi expander and as shown in a preferred embodiment of the invention, receive the sound waves emitted from the rear of the speaker and reflected from the interior side walls of the speaker enclosure and exterior of air port tube, and are arranged to reflect the sound back and forth against the rear exterior wall of the speaker enclosure and the sides of the bell ports. In a preferred embodiment, the sides of the bell port are stepped with the distance between the sides of the bell port and the rear wall of the speaker increasing in the direction of propagation from the bell port inlet to the bell port opening. In this way the reflected waves will move obliquely with a direction component transverse to the direct propagation path through the bell port, extending the propagation path and reducing the effect out of phase sound waves would have on the forward propagated waves from the front of the speaker. At the same time, the energy in the rearward-propagated sound waves is not lost or reduced to produce the effect of 360-degree sound wave dispersion.
In accordance with the principles of the invention and the preferred embodiments disclosed, the air port tube extending through the rear wall of the enclosure and through the venturi expander, is in line with, and opposed to the rear of the speaker and vents the higher than ambient air pressure out from the enclosure. The tube may be of a varying size and is placed opposed to the rear of the speaker to effectively vent the internal pressure created by the operation of the speaker. The small size of the air port tube inlet port relative to the cross sectional area of the speaker at the inlet port, allows the flow of air and the release of pressure without interfering with the backwardly projected sound waves reflected internally from the walls of the speaker and the exterior radial wall of the air port tube and out the bell ports. The air tube cross sectional area may be reduced where the size of the speaker is made smaller and may be blocked where the size of the speaker does no create pressure levels impeding the movement of the speaker cone. In this way, the air port tube may be adjusted to accommodate any size speakers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the interior of the speaker enclosure in a top view down into the enclosure with the speaker top removed and with the venturi expander attached to the rear wall of the speaker enclosure.
FIG. 1 a shows the interior of the speaker enclosure, as shown in FIG. 1 . and with circular stepped walls of the venturi expander forming a continuous bell port, corresponding to the rear view of FIG. 2 a.
FIG. 2 Shows the venturi expander in a rear view with the rear wall and the opening in the rear wall through which sound waves may propagate from the rear of the speaker to the venturi expander.
FIG. 2 a shows the venturi expander in a rear view as shown in FIG. 2, with circular stepped walls of the venturi expander forming a continuous bell port, corresponding to the top view of FIG. 1 a.
FIG. 3 shows the venturi expander is schematic form to show the propagation paths of sound from the rear of the speaker to the bell ports and to ambient from the port bell openings.
FIG. 4 shows the venturi expander with a circular port bell and with the wall of the circular bell port being made continuous
DESCRIPTION OF THE INVENTION
The invention according to its disclosed inventive principles, is now shown and described with reference to its preferred embodiments and to the Figures where the same numerals are used to identify the same or similar parts with the same or similar functions.
FIG. 1 in a top view generally shows a preferred embodiment as a speaker enclosure 10 . The enclosure is shown in a top view looking into the enclosure with the top cover removed. The speaker enclosure 10 as seen in this top view, is made of front wall 23 , side walls 11 and 19 and rear wall 21 . Projecting through the front wall 23 is the front or forward propagation direction 14 of speaker 13 . The venturi expander is shown generally by numeral 33 and is mounted to the rear wall 21 by means of mounting pins 47 and 49 . Passing through rear wall 21 is an air port tube 35 extending into the speaker enclosure 31 , with an inlet port 39 opposed to the rear of speaker 13 , shown generally by numerals 12 and 25 , and a flared portion 41 terminating in outlet port 37 . Surrounding the air port tube 35 is a circular port opening through rear wall 21 shown by numeral 22 and having a radial width shown by numerals 24 .
As may be seen in FIG. 1, the venturi expander includes one or more bell ports shown as bell ports 66 and 68 , with respective bell port openings to ambient 67 and 69 , located to receive sound from the rear 12 , of speaker 13 propagated toward the venturi expander, through circular port 22 opening in rear wall 21 . An air port tube 35 shown in a preferred embodiment as in line and opposed to the rear 25 of the speaker 13 , extends through rear wall 21 and terminates in a flared section 41 opening 37 to ambient. The inlet of the air port tube is proximate the rear 12 of speaker 13 to place the inlet in an area of higher pressure relative to ambient. The bell ports 66 and 68 , as shown in a preferred embodiment, may be formed of stepped sides as shown in FIG. 1 or in a continuous side as shown in FIG. 4, arranged so the stepped side or the continuous side, are increasingly displaced from the rear wall 21 in the direction of direct sound propagation from the rear of the speaker 13 through the bell port inlet, formed in a preferred embodiment as shown in FIG. 1, by the circular port opening 22 , the rear wall 21 and the reflective surface 57 and the bell port comprising the bell port reflective surfaces 57 , 59 , 61 , 63 and 65 and the bell port openings 67 and 69 , creating or defining a passage of increasing width in the direction of the bell port openings 67 and 69 . Bell port walls are shown by numerals 59 and 61 in stepped relation with each other and with bell wall 57 and forming bell port 66 with bell port opening 67 , and by bell port walls 63 and 65 in stepped relation with each other and with bell wall 57 and forming bell port 68 with bell port opening 69 . As shown in FIG. 4, a continuous bell port wall 57 may be used instead of the stepped walls as described. As would be understood by those skilled in the art, the bell port walls as shown by numerals 59 , 61 , 63 , and 65 , may extend beyond the side walls 11 and 19 and the top 16 and bottom 18 , of speaker enclosure 10 , as shown in FIGS. 2 and 2 a , or be coextensive with, or less than the dimensions of these speaker wall 11 , and 19 or top 16 or bottom 18 . The bell port walls 59 , 61 , 57 , 63 , and 65 , may be arranged relative to each other in a coaxial fashion as shown in FIGS. 1 a and 2 a , or be one continuous wall as shown in FIG. 4, or may be varied in any other suitable way, consistent with the principles of the disclosed invention.
The circular port opening 22 is shown in phantom in rear wall 21 with radial width 24 extending from the outer wall of the air port tube 35 to the outer radial edge of the circular port 22 . As would be understood by those skilled in the art, the circular port opening 22 , in the propagation path of the sound waves from rear 12 of speaker 13 , to the venturi expander 33 , may be varied in shape and size and be made in one continuous opening or may be discontinuous sections in the same radial distance from the axis of the air port tube 35 or in a plurality of continuous openings centrally or non centrally placed in the rear wall 21 of speaker enclosure 10 .
The seams where the stepped walls over lap are shown by numerals 71 , 73 , 75 and 77 . As shown in FIGS. 1 a and 2 a , where the stepped walls are concentric or coaxial, the seams are shown as circular.
The rear of the venturi expander is shown in FIG. 2 . in which the same numerals as in other Figures show the same or similar parts, with rear wall 21 of the speaker shown in phantom. Mounting pins 47 , 47 a and 49 and 49 a are shown supporting the venturi expander 33 on speaker enclosure rear wall 21 . The outlet port 37 of the air port tube 35 is shown with its flared portion 41 . Surrounding the air port tube 35 is the circular port 22 in rear wall 21 and extending radially from the air port tube 35 to the outer edge 26 of the circular port 22 , in the radial width shown by numeral 24 in FIG. 1 .
Referring to FIG. 1, the bell ports 66 and 68 are shown with the stepped walls 57 and 63 and 65 for bell port 68 and it bell port opening 69 to ambient and 59 and 61 for bell port 66 and its bell port opening 67 to ambient and extending away from the rear wall to define an increasing opening in the direction of direct propagation of the sound from the interior 31 of the speaker through the circular port 22 and to the stepped walls of the bell ports 67 and 68 . As would be apparent to one skill in the art, the stepped walls may be circular, or coaxial or arranged in any other suitable arrangement which achieves the effect of a widening sound port in the direction of propagation. In a preferred embodiment, the stepped walls overlap each other in circular seams as shown in FIG. 2 and FIG. 2 a , the venturi expander bell ports may extend beyond side walls 11 and 19 and top 16 and 18 , all shown in phantom view.
A preferred embodiment as shown in FIG. 1 a . and FIG. 2 a , shows a continuous circular bell port instead of the two separate bell ports 67 and 69 as shown in FIG. 1 . The outer most stepped circular wall is shown by numeral 59 , the intermediate stepped circular wall is shown by numerals 61 , and the overlapping seams by numerals 77 and 75 . A top view of the venturi expander as shown in FIG. 1 . is as shown in FIG. 1 a with circular walls as shown in FIG. 2 a . As would be known to those skilled in the art, the shape or size of the reflecting walls and the shape and size of the opening shown, may be varied without departing from the principles of disclosed invention. In particular, the bell ports may be constructed with reflecting surfaces separate from the surfaces of the rear wall, without departing from the disclosed inventive principles.
As would be understood by one skilled in the art, the bell ports 66 and 68 as shown in FIG. 1 and FIG. 2 or the circulars bell port as shown in FIGS. 1 a , and 2 a , may be varied by sectioning the continuous bell port of FIGS. 1 a and 2 a or making the outer stepped wall extend beyond or coextensive with the top, bottom and sides of the speaker enclosure side walls 11 and 19 and top and bottom 16 and 18 , or of a smaller dimension or change the shape or location of the circular port 22 . In accordance with the principles of the invention, the cross section of the air port tube 35 , the distance between the stepped walls of the bell ports 67 , 69 , and the size and shape placement of the port 22 in rear wall 21 , may be varied from that shown in a preferred embodiment to derive the best performance of the venturi expander consistent with the size of the speaker and the speaker enclosure.
As seen in FIGS. 1 and 2, the outermost stepped wall of the bell ports 66 , 68 , extend beyond the side walls 11 and 19 of the speaker enclosure. Depending on the performance desired from the venturi expander, the bell ports as formed by the stepped walls, may be extended beyond the top 16 and bottom 18 of the speaker, as explained above.
The operation of the venturi expander as shown in preferred embodiments above or as may be varied by one skilled in the art is explained with reference to FIG. 3, wherein the venturi expander is shown in schematic form showing the sound propagation scheme of the venturi expander. In the schematic of FIG. 3, the same numerals are used to show the same or similar parts as in all other drawings. The arrows shown without numerals represent the sound energy in the form of acoustic sound waves produced by speaker 13 from its front 14 in the form of forward propagated sound waves and to the rear from its back 12 in the form of rear propagated sound waves. Sound waves propagated from the rear 12 of speaker 13 , are in a path toward the rear wall 21 along air port tube 35 and reflected from the sides 11 and 19 . The air port tube 35 placed in line and opposed to speaker 13 , provides an exhaust for the higher than ambient air pressure produced by the movement of the cone of speaker 13 and serves as an exhaust for that pressure as would be well known to those skilled in the art. With the exhaust of the air through air, port tube 35 is residual sound, which is passed to ambient through air port tube outlet port 37 .
The sound directed to the sides and along the sides of air port tube 35 , propagates out the circular port opening, as shown in a preferred embodiment 22 and to the stepped reflecting surfaces 57 , 63 and 65 and 57 , 61 and 59 and out to ambient through respective bell port openings 67 and 69 . These reflecting surfaces cause the sound waves to move in a reflective path in an oblique path with a directional element transverse to the direct sound propagation path from the bell port inlets through the bell ports 66 , 68 , to the bell port opening and out of out bell ports openings 69 and 67 , As the sound waves propagate through the widening path of the port bells shown in FIGS. 1, 1 a , 3 , and 4 , the sound propagation pattern of the sound waves is spread about the bell port at its openings 67 and 68 into ambient causing the sound waves to be directed out from the speaker, with a portion of the sound energy being directed to, and reflected off the sides 11 , 19 , or in the case where the venturi expander extends beyond the top 16 or bottom 18 , of the speaker enclosure, as shown in FIGS. 1 a and 2 a , with a portion of the sound energy being directed to and reflected off the top or the bottom of the speaker enclosure. In this way, the sound from the speaker sides produces the effect of sound radiating around the speaker with reference to the front to back direction of the speaker enclosure from the front wall 23 to the rear wall 21 .
The propagation path of the sound waves from the rear 12 of speaker 13 is extended or elongated by reflection within the speaker enclosure 31 , by the interior of the side walls 11 and 19 and the exterior of air port tube 35 and by reflection within the bell ports 66 and 68 which alter the direct sound propagation path and extend it by directing the sound waves obliquely to the direct sound propagation path with a directional element transverse to the direct sound propagation path by reflection between the reflective surfaces of the bell ports, as shown in FIG. 3 . As the sound waves propagate, through the widening path of the port bells, 66 and 68 , the sound waves are caused to move more slowly, reducing the potential for interference with the forward propagating sound waves from the front 14 of speaker 13 . The sound waves propagating out of bell port outlets 67 and 69 , are dispersed obliquely to, or directly with, or sideways from, the front to back direction of the speaker enclosure, or the direction of sound propagation in a forward direction from the front of the speaker, and substantially around the speaker enclosure, for example radiating substantially about the axis of the air port tube 35 and radiating towards the front of the speaker enclosure and to the rear of the speaker enclosure as shown in FIG. 3, by propagation paths from the bell ports 66 , 68 , or from the bell ports to and from the sides 11 , 19 , or top 16 or bottom 18 , of the speaker enclosure 10 and by the residual sound from the air port vent tube 35 . In this way, the object of spreading the sound about the speaker enclosure radially outward from the sides of the speaker enclosure is so musicians sitting at the side of the amplified sound of another musician, can hear the same music or sounds as those in front of the speaker enclosure.
Various adjustments may be made to the shape of the port bells, the air port tube, the size of the ports used in the propagation path and the distances between the elements without departing from the principles of the invention. For example, as shown in FIG. 4, the circular port bell shown in FIGS. 1 a , and 2 a , may be a continuous wall instead of a stepped wall. As would be known to those skilled in the art, the sound patterns may varied by varying the configuration, size and spacing of the various parts of the venturi expander, without departing from the principles of the invention as shown and disclosed.
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A venturi expander is mounted on a speaker enclosure to receive the rearward-propagated sound waves and to extend the propagation path. The venturi expander's reflective sides direct the rearward sound to the sides or top or bottom of the speaker enclosure to produce a reflected sound surrounding the speaker enclosure and producing sound to the sides of the speaker substantially as projected from the front of the speaker.
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RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of, and claims priority from: U.S. application Ser. No. 12/883,672, filed Sep. 16, 2010, which, in turn, claims priority from U.S. application Ser. No. 11/406,500, filed Apr. 19, 2010 which, in turn, claims priority from U.S. Provisional Application No. 60/674,345 entitled “Autonomous or Controlled Robot for Undervehicle Inspection” filed Apr. 19, 2005; U.S. Provisional Application No. 60/674,346 entitled “Sensor/Camera Back Pack Lift” filed Apr. 19, 2005; and U.S. Provisional Application No. 60/755,054 entitled “Zipper Mast Lift” filed Dec. 30, 2005, assigned to the assignee hereof. All of the above-listed applications are hereby expressly incorporated by reference herein.
[0002] The present application further claims priority from U.S. Provisional Application No. 61/766,297 entitled “ZipperMast dual lock system” filed Feb. 19, 2013, and U.S. Provisional application Ser. No. 13/779,877 entitled “Situational Awareness Mast” filed Feb. 28, 2013.
TECHNICAL FIELD
[0003] The disclosed embodiments relate to lift mechanisms, and more particularly, to apparatus and methods for extending a retractable mast.
[0004] Lift mechanism technology includes, but is not limited to, hydraulic, pneumatic, and link type structures that may be combined together to form a rigid structure.
BACKGROUND
[0005] Extendable masts have seen applications in both the commercial and military markets. For example, electronic packages mounted atop retractable masts include communication and sensor devices, i.e., antennas, cameras and microphones, for collecting sensory data and/or transmitting the collected data to a remote location.
[0006] As the deployment of mobile surveillance and communication systems increases, lightweight, portable, mobile, and reliable retractable platform support systems may be desirable.
SUMMARY
[0007] A method for extending a retractable mast having at least three flexible bands is disclosed. Each band including a left edge portion, a right edge portion, and a flat body therebetween, each of the right edge portion and the left edge portion of the band has a series of alternating teeth and tabs disposed thereon, each tooth having a slot disposed therein.
[0008] The method includes extending the retractable mast by drawing together, by an engagement rotor, flexible bands, wherein the left edge portion of one of the bands engages the right edge portion of an adjacent band of the at least three flexible bands.
[0009] A first locking mechanism includes interlocking teeth disposed on the left edge portion of one flexible band with teeth disposed on the right edge portion of an adjacent flexible band. Each tooth includes a crown portion having an upper bent portion and a lower bent portion, and interlocking the teeth includes interlocking the upper bent portion within a notch cut at a lower base portion of an upper opposing tooth, and interlocking the lower bent portion within a notch cut at an upper base portion of a lower opposing tooth, the upper and lower bent portions angled in a same direction so as to extend over the adjacent flexible band.
[0010] A second locking mechanism includes a slot, disposed in each tooth, receiving a tab disposed between adjacent teeth on an adjacent band.
[0011] The housing further comprises a feed mechanism to draw the at least three band together from respective spools, causing the locking mechanisms to engage and form a rigid mast. When operated in reverse, the feed mechanism retracts the mast, separates the bands, and allows the bands to rewind on their respective spools.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The disclosed embodiments will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the disclosed embodiments, wherein like designations denote like elements, and in which:
[0013] FIG. 1 is a perspective drawing of a lift mechanism extending a retractable mast from a set of flexible bands, according to an example of the present disclosure;
[0014] FIG. 2 is a view taken along lines 2 - 2 of FIG. 1 , according to an example of the present disclosure;
[0015] FIG. 3 is perspective view of a portion of the flexible band, according to an example of the present disclosure;
[0016] FIG. 4 is a plan view of a portion of the flexible band, according to an example of the present disclosure;
[0017] FIG. 5 is perspective view of a bottom portion of the retractable mast, according to an example of the present disclosure.
[0018] FIG. 6A is a perspective drawing of a cable being drawn from a cable pan during the extending of a retractable mast, according to an example of the present disclosure;
[0019] 6 B is a perspective drawing of a cable being coiled in a cable pan during retraction of a mast, according to an example of the present disclosure;
[0020] FIG. 7 is a perspective drawing of another example of the present disclosure;
[0021] FIG. 8 is a block diagram of the lift mechanism, according to an example of the present disclosure;
[0022] FIG. 9 is a perspective drawing of one embodiment of a retractable shield for the lift mechanism, according to an example of the present disclosure;
[0023] FIG. 10 is an embodiment of a robotic device incorporating the lift mechanism, according to an example of the present disclosure.
DETAILED DESCRIPTION
[0024] FIG. 1 illustrates one embodiment of an apparatus 10 for extending a retractable mast 100 . The retractable mast 100 includes a platform 194 on which a device or devices 168 may be mounted. The retractable mast 100 is formed from at least three flat flexible bands 102 , 104 , 106 , each band having a set of alternating tabs and slotted teeth disposed along opposite edges of the bands. The teeth of one band engage the teeth of an adjacent band in a first interlocking relationship to hold the bands in a rigid formation. Further still, a tab disposed between adjacent teeth of one band engages a slot in each tooth of the interlocked band to form a second interlocking relationship to further secure the bands and form a stable mast that will resist unraveling under adverse conditions.
[0025] In one embodiment, the apparatus 10 of FIG. 1 illustrates a camera/sensor and microphone package 168 being elevated by mast 100 rising from a base unit 78 that comprises three pairs of spaced apart upright support members 70 . Each pair of upright support members 70 respectively supports a spool 82 , 84 , 86 of coiled bands 102 , 104 , and 106 rotatably mounted along a horizontal axis.
[0026] FIG. 1 further depicts a feed mechanism that includes engagement rotor 156 that is operable to draw together bands 102 , 104 , and 106 from spools 82 , 84 , and 86 into a mast having a substantially triangular cross section (see FIG. 2 ). The bands may pass beneath rollers 76 that guide the bands towards the engagement rotor 156 . Turning of engagement rotor 156 causes the bands to interlock extends mast 100 , elevating platform 194 that in at least one embodiment supports camera/sensor package 168 .
[0027] In some embodiments, engagement rotor 156 is rotatably mounted to the base 78 along an axis of rotation in a direction of the extension and retraction of the mast, and may be positioned at a center of a triangular formation of the three bands 102 , 104 and 106 as best depicted in FIG. 2 . FIG. 2 further shows a section view of mast 100 illustrating the inward camber 108 , 110 , 112 of bands 104 , 106 , 108 respectively, that may result from flexing the bands when the opposing edges of the bands are engaged according to a primary interlocking mechanism and a secondary interlocking mechanism to be discussed in detail below.
[0028] Rotated by a motor 170 mounted on the base 78 via a chain drive or other appropriate linkage arrangement, the engagement rotor 156 comprises a helical thread 157 and is operable to extend or lower the mast 100 by engaging at least one row of angled drive slots 144 disposed along a center length of at least one of bands 102 , 104 , and 106 . In the embodiment depicted in FIG. 5 , engagement rotor 156 engages three slots 144 of each band to elevate and lower mast 100 . As engagement rotor 156 rotates, rotor 156 continually accepts the next slot 144 in an adjacent band. Alternatively, engagement rotor 156 may engage only one or some number of bands less than the number of bands extending the mast 100 . For example, in one embodiment, only one band may have angled drive slots 144 and the engagement rotor is configured to engage only the band comprising the angled slots 144 .
[0029] FIG. 1 further illustrates a high limit switch 120 to provide a signal when the mast is fully extended and. Low limit switch 122 provides a signal when the mast is fully retracted.
[0030] FIGS. 3 and 4 illustrate flexible band 102 of a set of three flexible bands 102 , 104 , and 106 that when engaged, form mast 100 . Each band 102 , 104 , and 106 includes two rows of spaced apart teeth 304 disposed along opposite edges of a flat middle body portion 318 of each band. Each tooth 304 on both sides of each band includes a crown portion wherein an upper projecting portion 310 (defined as that portion closest to a top of the mast 100 ), and a lower projecting portion 312 , both projecting portions bent approximately 20-25 degrees towards the adjacent band, to facilitate interlocking with the adjacent band. In order to ensure a compact storage of bands 102 , 104 , and 106 on respective spool assembly 82 , 84 , and 86 (see FIG. 1 ), the length of teeth 304 are progressively longer starting from a bottom tooth 304 having a length L2, that corresponds to the bottom of mast 100 , towards the top of the mast 300 where a length L1 of an uppermost tooth 304 is longer than length L2. Based upon the progressively longer teeth 304 , overlapping layers of a band on a spool lay flat over the underlying layer, the tooth including the projecting portion 301 and 312 of an underlying layer of spooled band resting beneath the longer tooth of the above layer, thus allowing for compact spooling of the band.
[0031] Because the bands are drawn together via helical thread 157 , at any point in time, the three bands 102 , 104 , and 106 engage three different sections of the helical thread 157 . In order for the teeth 304 of adjacent bands to interlock, the teeth 304 on the three bands are differently placed, relative to the angled slot. Accordingly, the three bands 102 , 104 , and 106 form a set, each of bands being unique and non-interchangeable with the other two bands to ensure that the three bands properly engage and interlock.
[0032] The bands 102 , 104 , and 106 are designed to provide a dual locking mechanism, comprising a primary locking mechanism and a secondary locking mechanism. The primary locking mechanism is based on each tooth 304 of each band interlocking between two teeth 304 of an adjacent band. Projecting portions 310 and 312 of each tooth 304 engage a notch 311 disposed at a base portion of an upper tooth 304 and a lower tooth 304 , respectively, an opposing band. In at least one embodiment, the notch 311 is semi-circular shaped. Once each tooth is locked between two opposing teeth, the notches provide an additional impediment preventing the teeth from separating.
[0033] The secondary locking mechanism is provided by the engaging of a tab 306 , disposed between each of two adjacent teeth on one band, engaging a slot 308 disposed in the center of each opposing tooth 304 on an adjacent band. The tabs 306 and the slots 308 are shaped such that the edges of tab 306 bind within an inside edge of slot 308 . This dual locking mechanism advantageously minimizes twist and provides greater mast stability.
[0034] FIG. 5 illustrates wherein mast 300 is formed by bands 102 , 104 , and 106 , drawn together and upwards by the rotation of engagement rotor 156 , the helical thread 157 of rotor 156 engaging at least one angled slot 144 of each band. As described above, each tooth 304 of a band is locked between two teeth 304 of an adjacent band to form the primary lock. Each tab 106 disposed between two teeth 304 on a band engages a slot 308 disposed within tooth 304 of the adjacent band to form a secondary lock.
[0035] Once the primary and secondary interlocks are engaged, the outward force created by the camber 108 , 110 , and 112 , as depicted in FIG. 2 , operates to maintain the rigidity of the mast 300 .
[0036] FIG. 5 further depicts wherein a bottom portion of rotor 156 has a curved flange portion 158 that makes contact with the bands, guiding the bands 102 , 104 , and 106 towards the threads 157 as the mast is extended, and facilitating separating the bands as the mast 100 is retracted.
[0037] FIG. 5 further depicts an anti-sway device 300 disposed at the upper end of the mast 100 below platform 194 to apply tension on the interlocked bands via a pair of set screws 302 that apply pressure against each band. Thus, based on the primary and secondary interlocking mechanisms and the anti-sway device 300 , the mast 100 is sufficiently rigid for use in environments experiencing external forces such as vibration and wind.
[0038] Bands 102 , 104 , and 106 are designed to self-wind into spools 82 , 84 , and 86 (see FIG. 1 ) when the mast 300 is lowered. In one embodiment, the bands 102 , 104 , and 106 are laser cut from 0.015-0.032 inch thick Type 301 , full hard, high yield stainless steel, which provides extra high strength and is able to resist the external forces that may operate to twist the mast, or cause the bands 302 a - c to disengage. The bands are cut so that the direction of the steel bands runs along a lengthwise axis corresponding to a direction when unrolled from a roll of steel used to supply the band material. When cut from steel stock, taking into account the curvature of the supply roll, unrolling and rolling the band on the mast's spool assembly during operation of the mast is facilitated.
[0039] Each band 102 , 104 , and 106 is rolled to form a spool of a predetermined inside and outside diameter. The diameters are predetermined based upon the desired height of the mast and the condition that when coiled, teeth 304 are in radial alignment so as to lie flat against an underlying tooth of smaller length. The inner and outer diameters of the wound band 302 are maintained while the wound band 302 is heated for approximately 2-4 hours in an oven preheated to about 650-800 degrees Fahrenheit (preferably 3 hours in an oven preheated to about 700 degrees Fahrenheit), after which time the band 302 is removed and is cooled, e.g., air cooled in at least some embodiments.
[0040] In at least one embodiment, each band may be composed of 0.025 inch thick Type 301 , full hard, high yield stainless steel. In other embodiments, the flexible bands may be made of a synthetic material, such as plastic, a flexible ceramic, or a composite material.
[0041] Although the exemplary embodiments illustrated and discussed herein may comprise three bands, other embodiments may employ more bands based upon user specific operational requirements.
[0042] Coaxial bore 88 is formed within the engagement rotor 156 and may permit at least one signal cable 98 to extend from cable pan 166 (see FIG. 6A and FIG. 6B ) mounted within base 78 of the apparatus 10 , through a passageway formed by bands 102 , 104 , and 106 through the length of the mast 100 . The at least one signal cable 98 may interconnect at least one device, i.e., camera/sensor 168 , mounted on top of platform 194 at the top of the mast 100 to components though a connector 167 disposed in an edge of cable pan 166 .
[0043] FIG. 6A depicts a cable 98 being drawn from cable pan 166 located at the bottom of base unit 78 as the mast 100 is extended. In one embodiment, cable 98 transmits power and communication signals from the base of the mast 100 to the one or more devices at the top of the mast 100 through the center of the mast 100 . The cable 98 is coiled on the bottom the cable pan 166 , one end of cable 98 being fixed to a stationary portion of cable pan 166 . The stationary portion may include a cable connector 167 that may be further connected to control module 162 , power module 172 and/or other devices supplying signals to or receiving signals from the mast mounted devices 168 . As the mast is extended, cable 98 is drawn from the cable pan 166 . The cable pan 166 includes a cable diverter 179 comprising a raised center point disposed in the center of a bottom of the cable pan 166 .
[0044] FIG. 6B depicts a cable 98 being coiled in a cable pan during retraction of mast 100 . When the mast 100 is retracted, cable 98 is lowered into the cable pan 166 and is guided by diverter 179 outwards from the center of the cable pan 166 . To facilitate extending a compact spiral of cable 98 within the cable pan 166 , surface 181 of cable pan 166 is inclined downward and away from the diverter 179 to allow the cable 98 to slide along the inclined surface 181 and form a spiral of coil cable 98 .
[0045] FIG. 7 depicts a mechanism that allows for automatically stopping the extending or retracting of the mast. FIG. 7 depicts upper limit switch 120 and lower limit switch 122 that provide signals when the mast 100 is fully extended, and fully retracted, respectively. Upper limit switch 120 is activated by a rotating member 802 that is rotated by operation of a contact rod 804 that is biased by a spring 806 to maintain contact rod 804 in contact with the outer layer of spooled band 102 . As the mast 100 is formed, band 102 is drawn from the spool, reducing the diameter of spooled band 102 , causing the contact rod 804 to rotate downward. Rotating member 802 follows the rotation of contact rod 804 . When an amount of spooled band 102 is reduced to a predetermined diameter such that the mast 100 is fully extended, rotating member 802 actuates the upper limit switch 120 and provides a signal over leads 66 to a control module 162 (see FIG. 9 ).
[0046] In one embodiment, lower limit switch 122 is activated by a rod 810 extending downward from a base plate, not shown, that is depressed by platform 194 as it is lowered. Upon activation, lower limit switch 120 provides a signal 67 indicating that the mast is in a fully retracted state.
[0047] FIG. 8 is a block diagram illustrating the control logic for the lift mechanism 10 of FIG. 1 . Control interface 164 provides a user with an interface to extend and retract the mast 100 .
[0048] Control interface 164 is operated by a user to extend and retract the mast 100 and communicates with a control module 162 via a wired or wireless data link.
[0049] Control module 162 may include an application-specific integrated circuit (“ASIC”), or other chipset, processor, logic circuit, or other data processing device. Control module 162 may also include memory, which may comprise volatile and nonvolatile memory such as read-only and/or random-access memory (RAM and ROM), EPROM, EEPROM, flash, or any memory common to computer devices.
[0050] Control module 162 may further comprise logic that calculates the height of the mast 100 based upon a predetermined formula based upon a run time of the motor 170 . An indication of the mast height provided to the user may allow the user to extend the mast 100 to a user determined length/height, or may allow the control module 162 to extend the mast 100 to a predetermined height by controlling the activation time of the motor 170 . Furthermore, the control module 162 may comprise inputs and outputs 160 that may be connected to other lift mechanisms 10 so as to permit multiple lift mechanism 10 to operate in a master/slave relationship. For example, synchronizing the extending and retracting of a plurality of masts 100 to the same or to different heights based upon predetermined or user selectable inputs may be useful in situations requiring addition support, for example, to form a horizontal surface large enough to support the landing or take-off of an Unmanned Aerial Vehicle (UAV).
[0051] Further still, control module 162 automatically stop extending mast 100 in response to a determination that the mast is fully extended based upon a signal received from high level limit switch 120 . Similarly, control module 162 may automatically stop lowering the mast 100 in response to a determination that the mast 100 is fully retracted based upon a signal received from low level limit switch 122 .
[0052] Power module 172 may comprise any source of power suitable for use by the lift mechanism 10 and may include AC or DC inputs as well as AC and DC output capability. Non-limiting, the power module 172 may include a power cable to a source of AC power as well as NiMH and Li-ion rechargeable batteries. The power module 172 is operable to deliver required power to the control interface 164 , control module 162 , the lift motor(s) 170 , the devices on top of the mast 100 , as well as any other devices requiring electric power.
[0053] In one embodiment, the controller module 162 and the power module 172 are mounted in a sealed center section of the base unit 78 above cable pan 166 .
[0054] FIG. 9 illustrates one embodiment of an automatically deployable and retractable mast shield apparatus 174 . In certain environments, the mast 100 may be subject to potentially destructive material which may threaten proper operation of the lift mechanism. For example, rain may pass through openings in the mast 100 and potentially enter the base of the lift mechanism. Furthermore, dust or dirt may clog the slots and freezing rain may lock up the mast 100 . Accordingly, a mast shield apparatus 174 that operates to automatically surround the mast 100 as the mast is extended and automatically retracts when the mast is retracted may be beneficial. Furthermore, in some applications, e.g., trade shows, a mast shield apparatus having an esthetically pleasing covering is appropriate.
[0055] In some embodiments, mast shield apparatus 174 includes a housing 171 that is mounted over a lift mechanism (not shown). In one embodiment the housing 171 includes three pairs of upright support members 173 mounted on a partially shown support surface 77 . Each pair of support members 173 is operable to support roller 176 , which comprises a spool of shield material 175 to shield each band 102 , 104 , and 106 . In some embodiments, the shield material 175 is made of canvas, a synthetic material, or any suitable material, each shield material having a width larger than a width of the flexible bands that comprise the mast 100 . The shield material has a length to encompass the length of the mast 100 . Furthermore, a top portion of each length of shield material 175 is securely fastened to the top of the mast 100 or may be fastened to platform 194 .
[0056] As the mast is extended, the attached shield material 175 is drawn from rollers 176 , causing the rollers 176 to rotate, applying tension to a spring (not shown) disposed within each roller 176 . Non-limiting, tensioned rollers are known to those of ordinary skill in the art, and any suitable spooling mechanism may be incorporated.
[0057] In one embodiment, a retaining rail 181 is operable to align the shield material 175 in front of the mast 100 , at which point a guide mechanism 186 may operates to force the edges 178 , 179 of the shield 175 together as the shield material is 175 are drawn off their respective spools 176 . Opposing edges 178 , 179 of adjacent shields material sections may employ an attachment mechanism, e.g., Velcro, a plastic or metal zipper arrangement, or other known mechanism, to removably connect the sections of shield material 175 together as the mast is extended. As the mast is retracted, the tensioned rollers 176 winds up the shield material, causing the edges 178 , 179 disengage after passing through the guide mechanism 186 .
[0058] FIG. 10 illustrates a robotic lift apparatus 208 comprising the lift mechanism of FIG. 1 incorporated within a robotic device 210 . Such a robotic lift apparatus 208 may be beneficial to military and law enforcement agencies in providing surveillance at different elevations.
[0059] Mounted in a housing 210 equipped with a transport system, e.g., treads 214 , a mast 100 may be extended through an opening 218 in the housing 210 , raising a camera 168 and/or other devices, e.g., lamp 206 and microphone 192 , mounted on a platform 194 . A housing mounted antenna 190 and controller within the housing allows the robotic device and lift apparatus 208 to be operated wirelessly from a remote device. A power module (not shown) mounted within the housing 210 may comprise rechargeable batteries that may be recharged using an external mounted terminal 216 . Although treads 214 may be incorporated in the robot lift apparatus 208 , robots and robot drive units are known. Accordingly, the transport system may comprise wheels or any other available mechanism.
[0060] While the foregoing disclosure shows illustrative embodiments, it should be noted that various changes and modifications could be made herein without departing from the scope of the described embodiments as defined by the appended claims. For example, the apparatus 10 may modified to extend a retractable mast in a downward or other direction based upon a specific application.
[0061] Furthermore, although elements of the described embodiments may be described or claimed in the singular, the plural is contemplated unless limitation to the singular is explicitly stated.
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Apparatus and methods for extending a retractable mast include engaging at least three flexible bands such that each band forms a side of a mast. Each band includes a right edge side and a left edge side, each edge having disposed thereon a set of spaced teeth, each tooth having a slot disposed therein and a tab disposed between adjacent teeth, the tab configured to engage the slot of an opposing tooth.
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FIELD OF THE INVENTION
This invention relates in general to machining applications, and in particular to a linear compensator tool for drill countersinking and seal groove machining. The linear compensator tool ensures accurate drill countersinking and seal groove machining capabilities without control system feedback.
BACKGROUND OF THE INVENTION
Current fabrication processes for trimming and drilling, and machining fuel seal grooves in composite and metallic aircraft panels utilize standard 3, 4, and 5 axis Numerically Controlled (NC) machine tools. Numerous machines of this type exist at aerospace companies which do not have integrated capabilities for machining operations to achieve specific seal groove widths/depths. Furthermore, these machines typically do not have integrated capabilities for performing drill countersinking operations to achieve specific countersink sizes/depths, and are relegated to drill-only operations which do not require specific depth control.
NC machines required to perform these types of processes are forced to integrate a complicated, expensive, and time consuming process of measuring and recording surface profile variations prior to actual machining and drilling. These recorded part surface variations are then used to adjust, or offset, the NC program to account for the deviations from the engineered nominal surface. NC Machines outfitted with the capability to perform these types of processes are substantially more expensive and complicated due to the added components and control hardware and software to operate the system. The lack of viable low-cost drill countersinking tools forces companies to convert these machines into accurate drill countersinking machines with expensive modifications and/or total machine replacement. This situation is prevalent throughout the aircraft industry, both in the commercial and military sectors.
Numerous machines exist today in production throughout the world without the capability to accurately machine seal grooves and drill countersink without substantial additional processes to accommodate the variations seen in composite and/or metallic panels, including surface profile variations. Numerically Controlled machines are programmed to move to a specific point in space without regard to where the actual part might be located. It is assumed that the part is located within a specific tolerance within the machine's work cell to achieve the desired level of accuracy during processing. Very small variations in machine accuracy and part location (i.e., as small as 0.001″—smaller than the thickness of a human hair) will result in seal groove widths and depths, and countersink diameters out of tolerance.
The primary issues with accurate seal groove machining and drill countersinking of composite or metallic parts is knowing or being able to reference the part's surface profile that will be machined, or the part's surface that will be drilled. All seal grooves and countersinks are referenced by this surface. There is currently no Commercial-Off-The-Shelf (COTS) seal groove machining system available in industry which can accurately machine a seal groove to a specified width and depth while adjusting to varying part surface profiles real time without some type of control system feedback or extensive measurement operations to identify the actual part surface profile.
In an expensive and complicated Automated Drilling Machine or Intelligent Drilling System the capability of sensing this surface location is incorporated into the machine and control system. This allows the machine to countersink to a depth relative to the sensed part surface. When the surface is located physically, or by non-contact methods, the drill countersink tool is fed a specific distance into the part relative to that surface to achieve the desired countersink diameter/depth.
Retrofitting existing machines without the specific designed-in countersinking and seal groove machining capabilities is very expensive and results in substantial machine downtime during retrofit. Most NC Machines have no or limited available control lines to die spindle for intelligent drilling systems. Integration costs for intelligent drilling systems are extremely costly and impact machine operations during installation/debugging.
SUMMARY OF THE INVENTION
The drill countersinking and seal groove machining tool proposed in this patent application precludes having to implement substantial changes to the machine and/or additional processes to accommodate an accurate drill countersinking or seal groove machining operation. The functionality of the linear compensator tool allows it to be used like any other standard tool which does not require any interface to the control system or special NC Programming allowances. This tool can be setup and adjusted off-line of the machine, unlike many of the specially designed drill countersinking machines. This tool can be stored as a standard tool in the machine's automated tool storage/retrieval system.
This tool effectively turns an ordinary NC milling machine into an automated drilling machine at a much lower cost and allows the use of existing machines without upgrading or replacing the equipment. This tool effectively turns an ordinary NC milling machine into an accurate seal groove milling machine without the need for elaborate measurements of the part surface profiles.
The seal groove machining and drill countersinking tool incorporates a linear compensator design which applies sufficient force to react to the drilling or seal groove machining process, but not so much force as to distort the work piece being drilled or machined. Additionally, the linear compensator design ensures that the reactant force does not exceed the machine force override allowances. Varying spring rates and/or air pressures on the linear compensator system will accommodate most applications. The tool is designed to absorb over travel of the machining tool, in order to ensure that the surface to be machined is always in contact with the tool. Incorporation of the linear compensator system provides countersinking and seal groove machining capabilities that do not require some form of control system feedback.
The linear compensator design can be adapted to virtually any numerical control machine spindle interface (i.e., HSK Holders, CAT Tapered Holders, etc.) with very minor modifications to the machine. A variety of adjustable micro-stop countersinking and seal groove machining assemblies can be adapted to the linear compensator system, enabling reaction to part surface profile variations and producing an accurate countersink or seal groove real time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a standard tool holder connected to a NC machine.
FIG. 2 is a schematic sectional view of a hollow shaft air cylinder linear compensator tool attached to a standard tool holder and NC machine.
FIG. 3 is a schematic side view of a micro-stop nose piece.
FIG. 4 is an exploded isometric view of the micro-stop nose piece of FIG. 3 .
FIG. 5A is a schematic sectional view of the linear compensator tool of FIG. 2 at the beginning of a machining operation of a maximum thickness panel.
FIG. 5B is a schematic sectional view of the linear compensator tool of FIG. 2 at the beginning of a machining operation of a nominal thickness panel.
FIG. 5C is a schematic sectional view of the linear compensator tool of FIG. 2 at the beginning of a machining operation of a minimum thickness panel.
FIG. 6A is a schematic sectional view of the linear compensator tool of FIG. 2 when first contacting the maximum thickness panel.
FIG. 6B is a schematic sectional view of the linear compensator tool of FIG. 2 when first contacting the nominal thickness panel.
FIG. 6C is a schematic sectional view of the linear compensator tool of FIG. 2 when first contacting the minimum thickness panel.
FIG. 7A is a schematic sectional view of the linear compensator tool of FIG. 2 after drill countersinking a maximum thickness panel.
FIG. 7B is a schematic sectional view of the linear compensator tool of FIG. 2 after drill countersinking a nominal thickness panel.
FIG. 7C is a schematic sectional view of the linear compensator tool of FIG. 2 after drill countersinking a minimum thickness panel.
FIG. 8 is a schematic sectional view of a linear bearings with springs linear compensator tool.
FIG. 9 is a schematic sectional view of the linear compensator tool of FIG. 8 after absorbing over travel.
FIG. 10 is a schematic sectional view of a mechanical sleeve with spring linear compensator tool.
FIG. 11 is a schematic sectional view of the linear compensator tool of FIG. 10 after absorbing over travel.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , standard tool holder 21 has a shaft 25 with a splined receptacle capable of receiving and rotating a tool. In this instance, the tool is a countersinking drill bit 24 . Tool holder 21 may hold one of a number of machining tools, including a seal groove cutter.
Referring to FIG. 2 , a linear compensator tool (LCT) is connected to a standard tool holder 21 to ensure accuracy in machining processes. The standard tool holder 21 is connected to a spindle of an NC machine 19 . The LCT can exist in a number of embodiments including a linear bearing with springs LCT 121 ( FIGS. 8 and 9 ) and a mechanical sleeve with spring LCT 141 ( FIGS. 10 and 11 ). In this example, the LCT is a hollow shaft air cylinder LCT 31 . As illustrated by FIG. 2 , LCT 31 is connected to tool holder 21 by means of a clocking ring 51 and a bearing (not visible). The bearing (not visible) is connected to clocking ring 51 by means of connector snap 55 . The bearing (not visible) and clocking ring 51 are connected to tool holder 21 by means of connector snap 53 . Locking pin 57 extends vertically from the top surface of ring 51 , and slides into a bushing (not visible) on the face of NC machine 19 . Clocking ring 51 , the bearing (not visible), and locking pin 57 ensure that the body of LCT 31 is fixed and does not rotate with tool holder 21 and countersinking drill bit 24 .
Attached to the bottom of clocking ring 51 is outer casing 33 of LCT 31 . Casing 33 is generally cylindrical in shape with the exterior portion of casing 33 being smooth. In an alternate embodiment, casing 33 could take other forms such as a square or rectangle. The interior surface of casing 33 is machined in a manner to enable it to receive inner casing 37 . The upper interior surface of casing 33 forms a downward facing shoulder 34 .
Inner casing 37 , generally cylindrical in shape, slidingly engages outer casing 33 . In an alternate embodiment, casing 37 could take other forms such as a square or rectangle. The outer surface of casing 37 forms a flange section 38 . Flange section 38 and shoulder 34 limit the movement of casing 37 within casing 33 . O-ring seals 39 , 41 ensure that the contact surfaces between outer casing 33 and inner casing 37 are properly sealed. A cap 35 is placed around inner casing 37 , on the bottom of LCT 31 , and is secured to outer casing 33 . Cap 35 is generally circular in shape and has a T-shaped cross section that produces a small annulus between inner casing 37 and cap 35 . O-ring seal 43 ensures that the contacting surfaces between inner casing 37 and cap 35 are sealed. Inner casing 37 is free to telescope in and out of casing 33 , but is limited in range by cap 35 and shoulder 34 .
A spring 45 surrounds inner casing 37 , and is located in the annulus between inner casing 37 and cap 35 . Spring 45 acts to compress inner casing 37 as far as possible towards clocking ring 51 . Air ports 47 , 49 are located in outer casing 33 . Port 47 is connected to a compressed air line, whereas port 49 is open to the atmosphere.
Micro-stop nose piece 61 is attached to the bottom of inner casing 37 by way of mounting flange 77 . As illustrated by FIGS. 3 and 4 , micro-stop nose piece 61 is comprised of various components. These components include nose piece 63 , locking collar 65 , locking ring 67 , threaded fixture 69 , shaft 79 , and tool casing 85 . Locking ring 67 is threaded, and is screwed on to threads 71 on fixture 69 . Locking collar 65 slides onto fixture 69 , and is positioned around threads 71 . A pin (hot visible) is located on the inner surface of collar 65 , and slides into slot 75 on fixture 69 . The pin (not visible), captured in slot 75 , ensures that collar 65 can not rotate around fixture 69 . One end of collar 65 is saw tooth patterned. Nose piece 63 is threaded on one end 63 b , and is screwed onto the threads 73 on fixture 69 . End 63 b of nose piece 63 has teeth that align with the teeth on collar 65 , preventing rotation of nose piece 63 . End 63 a of nose piece 63 has an aperture that extends from the main body of the nose piece 63 , and allows a machining tool to pass through the aperture, forming a shoulder.
One end of shaft 79 is splined, and the other extends through fixture 69 , where tool collar 85 surrounds it. Just above collar 85 , a thrust bearing 83 is placed on shaft 79 . Pinned collar 81 , located just above bearing 83 , holds bearing 83 in place on shaft 79 . The shaft assembly is inserted into nose piece fixture 69 . Section 87 of the nose piece assembly 61 contains a close tolerance pilot that controls the center line of shaft 79 . Just above section 87 is a locking ring 89 which locks the pilot in place. Just above the locking ring 89 is another locking ring 91 which locks shaft 79 into the micro-stop nose piece assembly 61 . Once mounted to inner casing 37 , the splined end of shaft 79 is connected to the tool holder shaft hub 25 . Shaft 79 can move axially within LCT 31 due to the splined end and hub.
As illustrated by FIGS. 5A , 5 B, and 5 C, hollow shaft air cylinder LCT 31 is connected to a standard tool holder 21 for countersinking. Standard tool holder 21 is connected to a spindle of NC machine 19 . LCT 31 is connected to tool holder 21 as previously discussed.
A countersinking drill bit 24 is inserted into the micro stop nose piece assembly 61 . Bit 24 has a counterbore portion 24 a at its upper end that extends below end 63 a of nose piece 63 . Referring back to FIGS. 3 and 4 , nose piece 63 is adjusted to ensure the desired countersink depth. The desired depth is determined by the extent that bit 24 , and in particular counterbore portion 24 a extends below the aperture on end 63 a of nose piece 63 . Nose piece 63 is adjusted by screwing ring 67 toward connector flange 77 . Locking collar 65 is then free to move up or down on fixture 69 . Nose piece 63 is then rotated on threads 73 in order to control the extent that counterbore portion 24 a of bit 24 extends below end 63 a . Once the desired depth is set, locking collar 65 is positioned to lockingly engage the teeth on end 63 b of nose piece 63 . Locking ring 67 is then tightened securely against collar 65 , locking the nose piece 63 in position and ensuring the desired drill depth of bit 24 .
NC machine 19 is programmed to lower tool holder 21 from a starting point 106 to a point 107 based on the thickness of the minimum thickness panel 105 . Programming will ensure that counterbore portion 24 a of bit 24 cuts to the proper depth of the panel regardless of whether the panel is one of maximum thickness 101 , nominal thickness 103 , or minimum thickness 105 . Typical variations in panel thickness are illustrated by 109 , and in one embodiment, may be less than 0.020 inches.
The programmed point 107 is the same point in space regardless of the thickness of panels 101 , 103 , 105 . Programmed point 107 is determined by measuring the amount of travel it takes for end 24 a to form the counterbore in minimum thickness panel 105 to the correct depth. The travel of tool holder 21 to point 107 should equal the distance d in FIG. 5C . The traveled distance of tool holder 21 to point 107 will be slightly greater than the distance d′; which is the distance counterbore end 24 a travels to cut the counterbore to the proper depth in medium thickness panel 103 ( FIG. 5B ). The traveled distance of LCT 31 to point 107 will be even greater than the distance d″, which is the distance counterbore end 24 a travels to cut the counterbore to the proper depth in maximum thickness panel 101 ( FIG. 5A ).
Referring hack to FIG. 2 , pressure is supplied to LCT 31 by an air source (not shown), which pumps air into LCT 31 . Air enters LCT 31 through port 47 and fills the annulus between outer casing 33 and inner casing 37 . As LCT 31 is pressurized, inner casing 37 fully extends outwards from casing 33 . As inner casing 37 extends outwards from casing 33 , port 49 ensures that any air trapped below flange 38 in the annulus between casing 37 and casing 33 is vented to the atmosphere. When casing 37 is fully extended, a gap 112 exists between shoulder 34 and flange 38 . Gap 112 is designed to absorb over travel of tool holder 21 , and in one embodiment, gap 112 is designed to absorb up to 0.100 inches of over travel. The air pressure is sufficient so that drill bit 24 will not cause shoulder 34 to move toward flange 38 as it drills. However, when nose piece end 63 a contacts the surface of one of the panels 101 , 103 , 105 it will stop downward travel of flange 38 ( FIG. 7 ).
As illustrated by FIGS. 5A , 5 B, and 5 C, the tool holder 21 starts at the same elevation 106 and ends at the same elevation 107 . NC machine 19 rotates countersinking drill bit 24 and begins lowering tool holder 21 and bit 24 toward programmed point 107 . Given the different thicknesses of panels 101 , 103 , 105 , tool holder 21 is at a different distance from the panel depending on the panel thickness.
Considering minimum thickness panel 105 , when bit 24 first contacts panel 105 , the pressure of LCT 31 is such that bit 24 will penetrate the panel surface and continue toward the desired point 107 without any change in the position of flange 38 , as illustrated by FIG. 6C . As NC machine 19 continues to lower tool holder 21 , bit 24 rotates and continues downwards until it has penetrated the panel and drill bit counterbore portion 24 a has eat the proper counterbore depth in panel 105 . The pressure of LCT 31 is regulated such that the once the shoulder on end 63 a contacts the panel surface, the force acting upwards against nose piece 63 is greater than the force acting downwards on inner casing 37 . However, when machining the minimum thickness panel 105 , end 63 a contacts the surface when tool holder 21 is at point 107 , as illustrated by FIG. 7C . The NC machine 19 stops drilling once tool holder 21 has reached point 107 .
Considering nominal thickness panel 103 , bit 24 starts drilling sooner than with panel 105 because it contacts panel 103 at a lesser distance d′. The pressure of LCT 31 is such that bit 24 will penetrate the panel surface and continue toward the desired point 107 without any change in the position of flange 38 , as illustrated by FIG. 6B . When nose piece 63 a contacts panel 103 , tool holder 21 is not yet at point 107 . The resistance of nosepiece 63 a overcomes the air pressure, causing shoulder 34 to advance toward flange 38 . As shoulder 34 advances toward flange 38 , shaft 79 advances further into receptacle 25 ( FIG. 2 ). Drill bit 24 does not move further downward, however, as it has fully cut the counterbore and nosepiece 63 a prevents further downward movement.
For maximum thickness panel 101 , the same occurs as with nominal thickness panel 103 . Bit 24 starts drilling sooner than with panels 105 , 103 because it contacts panel 101 at a lesser distance d″. The pressure of LCT 31 is such that bit 24 will penetrate the panel surface and continue toward the desired point 107 without any change in the position of flange 38 , as illustrated by FIG. 6A . Drill bit counterbore 24 a will have cut to the full depth before LCT 31 has reached point 107 . As LCT 31 moves further downward, nosepiece 63 a prevents further downward movement of drill bit portion 24 a , causing shoulder 34 to advance toward flange 38 . As shoulder 34 advances toward flange 38 , shaft 79 advances further into receptacle 25 ( FIG. 2 ).
As illustrated by FIGS. 7A , 7 B, and 7 C, LCT 31 continues downward until reaching point 107 . The amount of over travel absorbed by LCT 31 varies with the panel thickness. As illustrated by FIG. 7C , when drilling a panel of minimum thickness 105 , LCT 31 absorbs the least amount or no over travel. Due to the thickness of panel 105 , the shoulder formed by the aperture on end 63 b of nose piece 63 contacts the panel surface when tool holder 21 reaches point 107 , which is programmed for the minimum thickness panel 105 . In one example, there is no over travel to be absorbed. Accordingly, at the end of the machining operation, the original gap 112 between flange 38 and shoulder 34 remains.
As illustrated by FIG. 7B , when drilling a panel of nominal thickness 103 , LCT 31 absorbs over travel. Due to the thickness of panel 103 , the shoulder formed by the aperture on end 63 b of nose piece 63 contacts the panel surface before tool holder 21 reaches point 107 , which is programmed for the minimum thickness panel 105 . As a result, LCT 31 must absorb the over travel distance 110 , which is equal to the difference between d′ and d ( FIGS. 5B and 5C ). In one example, shoulder 34 has advanced towards flange 38 , leaving a gap 113 .
Referring to FIG. 7A , when drilling a panel of maximum thickness 101 , LCT 31 absorbs the greatest amount of over travel. Due to the thickness of panel 101 , the shoulder formed by the aperture on end 63 b of nose piece 63 contacts the panel surface before tool holder 21 reaches point 107 , which is programmed for the minimum thickness panel 105 . As a result, LCT 31 must absorb the over travel distance 111 , which is equal to the difference between d″ and d ( FIGS. 5A and 5C ). In one example, the over travel distance 111 is equal to original distance 112 that LCT 31 was designed to absorb. Accordingly, when tool holder 21 reaches point 107 , flange 38 is in contact with shoulder 34 .
LCT 31 operates as previously discussed when connected to a standard tool holder 21 for seal groove machining. The only change in regard to the operation of LCT 31 when seal groove machining is countersinking drill bit 24 is replaced with a seal groove cutting tool. As explained above, the gap between flange 38 and shoulder 34 allows LCT 31 to absorb over-travel by the tool holder, which guarantees nosepiece 63 contacts the panel surface resulting in a consistent seal groove width/depth regardless of the panel thickness. The variations in panel thickness illustrated above may be present over the surface profile of a single panel sought to be machined. During the seal groove machining process, LCT 31 responds to variations in the surface profile of a panel by compressing (absorbing over travel) or extending depending on the panel thickness at a given point.
Referring to FIGS. 8 and 9 , an alternate embodiment LCT is illustrated in the form of linear bearings with spring LCT 121 . LCT 121 is connected to tool holder 21 by means of clocking ring 51 and a bearing (not visible). Bearing (not visible) is connected to clocking ring 51 by means of connector snap 55 . Bearing (not visible) and clocking ring 51 are connected to tool holder 21 by means of connector snap 53 . Locking pin 57 extends vertically from the top face of ring 51 , and slides into abashing (not visible) on the face of the NC machine. Clocking ring 51 , bearing (not visible), and locking pin 57 ensure that the body of LCT 121 is fixed and does not rotate with tool holder 21 and drill countersinking bit 24 .
A plurality of flanged linear bearings 127 are attached to the bottom of clocking ring 51 . Bearings 127 extend downward towards mounting plate 123 . Mounting plate 123 is circular in shape, but in an alternate embodiment could take other forms such as a square or rectangle. A rod 129 travels through each linear bearing 127 and extends downward before connecting to mounting plate 123 . Locking nuts 130 are attached to the end of rods 129 opposite mounting plate 123 . Nuts 130 ensure that rods 129 are fixed between clocking ring 51 and mounting plate 123 . Rods 129 can move axially in linear bearings 127 , but are limited in range of movement due to nut 130 on one end and linear bearing 127 on the other.
Surrounding each rod 129 and linear bearing 127 is a spring 131 , which is connected between clocking ring 51 and mounting plate 123 . Spring 131 acts to ensure that LCT 121 is fully extended in its natural state, ensuring a maximum gap between clocking ring 51 and mounting plate 123 . Plate 125 is connected to the bottom of mounting plate 123 .
Micro-stop nose piece 61 is attached to the bottom of plate 125 by way of mounting flange 77 . Once micro-stop nose piece assembly 61 is mounted to plate 125 , the splined end of shaft 79 is connected to tool holder shaft hub 25 . Shaft 79 can move axially within LCT 121 due to the splined end and hub.
Linear bearings with spring LCT 121 performs just as LCT 31 . FIG. 8 illustrates LCT 121 in a natural state, prior to contacting a workpiece. Gap 133 between linear bearings 127 and mounting plate 123 is the largest when plate 123 is fully extended. FIG. 9 illustrates LCT 121 absorbing over travel, as indicated by the decreased size of gap 133 .
Referring to FIGS. 10 and 11 , an alternate embodiment LCT is illustrated in the form of spring actuated cylinder LCT 141 . LCT 141 is connected to tool holder 21 by means of clocking ring 51 and a bearing (not visible). Bearing (not visible) is connected to clocking ring 51 by means of connector snap 55 . Bearing (not visible) and clocking ring 51 arc connected to tool holder 21 by means of connector snap 53 . Locking pin 57 extends vertically from the top face of ring 51 , and slides into a bushing (not visible) on the lace of the NC machine. Clocking ring 51 , bearing (not visible), and locking pin 57 ensure that the body of LCT 141 is fixed and does not rotate with tool holder 21 and drill countersinking bit 24 .
Attached to the bottom of clocking ring 51 is mounting plate 143 . Mounting plate 143 is generally cylindrical and flat, with a T-shaped cross section 144 on each side. Outer casing 145 is machined to slide over and connect securely to mounting plate 143 of LCT 141 . Casing 145 is generally cylindrical in shape with the exterior portion of casing 145 being smooth. In an alternate embodiment, casing 145 could take other forms such as a square or rectangle. The interior surface of casing 145 is machined in a manner to enable it to receive inner casing 147 . The lower interior surface of casing 145 forms an upward facing shoulder 146 .
Inner casing 147 , generally cylindrical in shape, slidingly engages outer casing 145 . In an alternate embodiment, casing 147 could take other forms such as a square or rectangle. The outer surface of casing 147 forms a flange section 148 . Flange section 148 of casing 147 , shoulder 146 of casing 145 , and T-cross section 544 of plate 143 limit the movement of casing 147 within casing 145 . Plate 143 , outer casing 145 , and inner casing 147 are machined to connect to one another with extremely close tolerances to form a mechanical sleeve. A small annulus if formed between the inner casing 147 and T-shaped cross section 144 of plate 143 . Inner casing 147 is free to telescope in and out of casing 145 , but is limited in range by section 144 of plate 143 and shoulder 146 of outer casing 145 .
A spring 149 surrounds inner casing 147 , and is located in the annulus between inner casing 147 and outer casing 145 . Spring 149 acts to ensure that LCT 141 is fully extended in its natural state, ensuring a maximum gap between flange 148 and T-section 144 . Air ports 151 are located on the exterior of outer casing 145 . Airports 151 are open to the atmosphere and ensure that LCT 141 does not become pressurized with the telescoping movement of inner casing 147 .
Micro-stop nose piece 61 is attached to the bottom of inner casing 147 by way of mounting flange 77 . Once micro-stop nose piece assembly 61 is mounted to casing 147 , the splined end of shaft 79 is connected to the tool holder shaft hub 25 . Shaft 79 can move axially within LCT 141 due to the splined end and hub.
Spring actuated cylinder LCT 141 performs just as LCT 31 and LCT 121 . FIG. 10 illustrates LCT 141 in a natural state prior to contacting a workpiece. Gap 153 , between flange 148 and T-section 144 is the largest when casing 147 is fully extended. FIG. 11 illustrates LCT 141 absorbing over travel, as indicated by the decreased size of gap 153 .
While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes without departing from the scope of the Invention. For example, linear compensator tool could be used in a number of various machining applications requiring material surface accuracy.
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A drill countersinking and seal groove machining tool to accommodate an accurate drill countersinking and seal groove machining operation. The linear compensator tool applies sufficient force to react to the drilling or seal groove machining process, but not so much force as to distort the work piece being drilled or machined. The tool ensures that the reactant force does not exceed the machine force override allowances. Varying spring rates and/or air pressures on the linear compensator system will accommodate most applications. The tool absorbs over travel of the machining tool, in order to ensure that the surface to be machined is always in contact with the machining tool.
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CLAIM FOR PRIORITY
[0001] This application claims priority to German Application No. 10226344.2 which was filed on Jun. 7, 2002.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to a method and arrangement for accessing call number portability data, and in particular, data which is stored in a Mobile Number Portability (MNP) memory in a mobile radio network.
BACKGROUND OF THE INVENTION
[0003] In the course of liberalizing telecommunications markets, numerous countries throughout the world are developing methods to allow mobile radio subscribers to retain their mobile radio call number (MSISDN=Mobile Station ISDN Number) when changing from one mobile radio network operator to a different mobile radio network operator (for example in the same country). These methods are known by the term “Mobile Number Portability” (MNP). MNP databank systems (MNP memories) are likewise generally known in mobile radio networks, and make it possible for the respective mobile radio network operators to store or to call up associations between mobile radio call numbers and mobile radio networks in the respective country, in a national context. MNP memories such as these are accessed within the mobile radio network of the respective mobile radio network operator.
SUMMARY OF THE INVENTION
[0004] The invention discloses a method and an arrangement which widens the usage capabilities for call number portability data being stored in MNP memories.
[0005] According to one embodiment of the invention, there is a method for accessing MNP data, which is stored in an MNP memory in a mobile radio network, by a network-external data processing device, in which a network interface, which in terms of signal flow is arranged between the network-external data processing device and the MNP memory, checks whether the network-external data processing device is authorized to access the MNP data, if the authorization is present, an identification for a communication terminal is transmitted by the network interface from the network-external data processing device to the MNP memory, MNP data which is associated with the communication terminal is read from the MNP memory, and the MNP data is transmitted via the network interface to the network-external data processing device. In this case, it is particularly advantageous for a network-external data processing device, that is a device which is not located in the mobile radio network (with which the MNP memory is associated) to be able to access the MNP data in the MNP memory using the network interface. It is also advantageous, before allowing access, for the network interface to check whether the external data processing device is authorized to access the MNP data, or to use the MNP data.
[0006] In another embodiment of the invention, an authentication and authorization of the data processing device are carried out by the network interface in order to check the authorization of the data processing device. This advantageously on the one hand confirms the identity of the external data processing device, and on the other hand confirms the access authorization to MNP data.
[0007] In another embodiment of the invention, the authentication and authorization are carried out by a network interface, which is in the form of an OSA intermediate node, in accordance with “Open Service Access” (OSA) requirements. The use of an OSA intermediate node (OSA gateway) as a network interface is particularly advantageous since the OSA technology makes use of a technology that is known per se, but has until now been used for other purposes, to allow accesses by network-external MNP data users to MNP memories. The invention can thus be implemented with little complexity and thus particularly costeffectively.
[0008] According to one preferred embodiment, the MNP data is transmitted via a network interface which has an access unit in the form of an OSA-conformal application programming interface (API). One aspect of the access unit in advantageously allows the security mechanisms and security infrastructures that are provided in the OSA Standards to be used during access to the MNP data.
[0009] In still another embodiment of the invention, an identifier for the home mobile radio network of the communication terminal is transmitted as the MNP data. This embodiment advantageously makes it possible for the network-external data processing device to determine the home mobile radio network of the communication terminal.
[0010] The invention can also be carried out such that an address of an entry switching center for the home mobile radio network of the communication terminal is transmitted as the MNP data. In this case, information is transmitted to the network-external data processing device, which makes it possible for this device to communicate with the home mobile radio network.
[0011] In another embodiment of the invention, the access data for a payment system, which is associated with the communication terminal, for the home mobile radio network of the communication terminal is transmitted as the MNP data. The transmission of the access data for the payment system advantageously makes it possible for the network-external data processing device to make contact with the payment system and to use its services for handling payments which relate to the communication terminal, or to a user of the communication terminal.
[0012] In yet another embodiment of the invention, a data processing device which operates as a payment system and is associated with some other mobile radio network transmits an access request, relating to the MNP memory, to the network interface, if an authorization for the data processing device is present, a mobile radio call number is transmitted to the MNP memory as an identification for the communication terminal, the access data for the payment system, which is associated with the communication terminal, for the home mobile radio network of the communication terminal is then read from the MNP memory as MNP data, and this access data is transmitted to the data processing device. One advantageous feature is that the access data for the payment system which is responsible for the home mobile radio network of the communication terminal is transmitted to the payment system for the other mobile radio network (which is acting as a data processing device). This makes it possible for the payment system for the other mobile radio network to initiate or implement payments which relate to that communication terminal, in collaboration with the payment system for the home mobile radio network of this communication terminal.
[0013] In another embodiment of the invention, there is an arrangement having an MNP memory for a mobile radio network, which includes MNP data in the form of association data between identifications for communication terminals and devices in the home mobile radio networks of these communication terminals, and a network interface for the mobile radio network, which allows a network-external data processing device to have access to the MNP data. This arrangement according to the invention advantageously allows the network interface for the mobile radio network to access the MNP data for a data processing data which is arranged outside the mobile radio network.
[0014] In this arrangement, the network interface may be in the form of an intermediate node which operates in accordance with “Open Service Access” requirements. The use of the OSA intermediate node makes it possible to use the OSA technology, which is known per se, to provide a network interface which allows network-external computers to have access to MNP databanks. The arrangement can thus be implemented with little complexity and cost-effectively.
[0015] The arrangement according to the invention may have a subscriber payment system for the mobile radio network, whose access data is stored as MNP data in the MNP memory. This embodiment of the arrangement according to the invention advantageously allows the network-external data processing device to have access to access data to the subscriber payment system. This allows communication between the network-external data processing device and the subscriber payment system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention is described below in detail with reference to the drawings, in which:
[0017] [0017]FIG. 1 shows one exemplary embodiment of an arrangement according to the invention and of a method according to the invention.
[0018] [0018]FIG. 2 shows a further exemplary embodiment of the arrangement according to the invention and of the method according to the invention for carrying out payment processes in mobile radio networks.
DETAILED DESCRIPTION OF THE INVENTION
[0019] [0019]FIG. 1 shows an MNP memory 1 (MNP databank) which is associated with a mobile radio network. MNP data is stored in the MNP memory. The expression MNP data means data which includes or describes an association between an identification for a communication terminal (for example the mobile radio call number MSISDN) and its home mobile radio network, its home network operator or devices in this home mobile radio network. In this case, the home mobile radio network for a communication terminal is, for example, that network for which a contract exists between the respective mobile network operator and the respective communication terminal operator.
[0020] The MNP memory 1 is connected to a network interface 2 , which is in the form of a connecting node or intermediate node which operates in accordance with the requirements of the “Open Service Access” Standard. An OSA connecting node such as this is also referred to as an OSA gateway. A unit FW (FW=OSA framework) and an access unit MNP-API are shown as major components of the network interface 2 . The functions of the unit FW and of the access unit MNP-API will be explained in more detail in the following text.
[0021] The upper part of FIG. 1 shows a network-external data processing device 4 . This is, for example, a data processing device which is arranged outside the mobile radio network, as is indicated by the dashed line 6 .
[0022] One exemplary embodiment of a procedure for the method according to the invention will be described in the following text. It is assumed that the network-external data processing device 4 wishes to access the MNP memory 1 , in order to read MNP data that is stored in this memory. To do this, the data processing device 4 sends an access request to the network interface 2 via a first information channel 8 . This access request is passed to the unit FW. The unit FW prevents unauthorized access by network-external data processing devices to the MNP memory 1 . To do this, the unit FW carries out functions which are known per se from the standardized Open Service Access mechanisms and are described, by way of example, in the documents “3GPP TS 29.198-3, V4.4.0, (2002-03), Technical Specification, 3rd Generation Partnership Project; Technical Specification Group Core Network; Open Service Access (OSA); Application Programming Interface (API); Part 3: Framework (Release 4)” and “3GPP TS 22.127, V5.3.0, (2003-03), Technical Specification, 3rd Generation Partnership Project; Technical Specification Group Services and System Aspects; Service aspects; Stage 1 Service Requirement for the Open Service Access (OSA) (Release 5)”. The unit FW carries out authentication functions, that is confirms the identity of the requesting data processing device. It carries out authorization functions, that is it confirms whether the network-external data processing device 4 has authorization to access the MNP memory, and grants it such authorizations. If the result of a check is positive, the unit FW allows the network-external data processing device 4 to access the MNP memory 1 (grant of access). In this way, the unit FW provides the security that is necessary for access to sensitive MNP data.
[0023] Once the unit FW has checked the authorizations, the access unit MNP-API (MNP-API=Mobile Number Portability Application Programming Interface) is used according to the invention to allow the data processing device 4 to have direct access to the MNP data in the MNP memory 1 . The access unit MNP-API thus represents the actual MNP data interface between the MNP databank 1 and the MNP data user 4 (and is thus a unit that is significant to the invention). The access unit MNP-API in this example is based on OSA technology and thus represents an OSA-conformal “Application Programming Interface” (API). This access unit MNP-API allows devices which are external to the mobile radio network to ask a question, which includes an identification of a communication terminal, to the MNP memory 1 , and a data channel 9 is used for this purpose. By way of example, one such identification for a communication terminal is the mobile radio call number MSISDN of a mobile radio subscriber. The access unit MNP-API also allows the network-external data processing device 4 to check MNP data which is stored in the MNP memory 1 (and which is associated with the identification for the communication terminal). By way of example, as MNP data such as this, it is possible to check and to read from the MNP memory: the association between the communication terminal or its user (mobile radio subscriber) and a mobile. radio home network operator, the association between the communication terminal and an address of an entry switching center (gateway MSC, GMSC) for the home network of the mobile radio subscriber, and/or an association between the communication terminal and an address of a payment system which is associated with the mobile radio subscriber. However, further data which is stored as MNP data in the MNP memory 1 may also be checked via the access unit MNP-API.
[0024] The access unit MNP-API may, for example, be based on JAVA and/or CORBA technologies, using the “JAVA Database Connectivity” technology from Sun Microsystems. Alternatively, it is also possible to use the “Interface Definition Language” from the “Object Management Group”. This solution is advantageously independent of language and implementation. The access unit MNP-API is integrated in the OSA intermediate node (OSA gateway). An OSA intermediate node such as this may also provide other Application Programming Interfaces (APIs).
[0025] Thus, in summary, the network interface 2 uses the unit FW (framework) to offer the functions of authentication, authorization and grant of access, and carries out these functions. The network interface uses the access unit MNP-API to create the actual databank access to the MNP databank 1 , in the process, the data processing device 4 asks a question (which, for example, includes the mobile radio call number of the communication terminal) of the MNP databank 1 , and the MNP databank 1 provides information about stored MNP data relating, for example, to a network operator, gateway MSC or payment systems.
[0026] In this case, the method may be carried out in such a way that, once a single read authorization check has been carried out by the unit FW, a number of accesses may be made to the MNP memory. This may relate, for example, to the read requests which are transmitted within a context or via a tie line 9 from the data processing device 4 to the access unit MNP-API.
[0027] The connection between the MNP databank 1 and the network interface 2 may, for example, be provided using the “Lightweight Directory Access Protocol Version 3” (LDAPv3).
[0028] A first mobile radio network MFN 1 is shown on the left-hand side of FIG. 2, and a second mobile radio network MFN 2 is shown on the right-hand side. The first mobile radio network MFN 1 may, for example, be the mobile radio network of the D2 Vodafone company in Germany. The second mobile radio network MFN 2 may, for example, be the Italian mobile radio network Omnitel. A communication terminal KEG of a mobile radio subscriber who signed a mobile radio contract with the D2 Vodafone Company is shown on the right-hand side of FIG. 2. In consequence, the first mobile radio network MFN 1 is the home mobile radio network for the communication terminal KEG.
[0029] The mobile radio call number allocated as the MSISDN to the communication device KEG is “0049 171 98765”. To be precise, the mobile call number MSISDN is not allocated to the communication terminal KEG, but is generally stored on a smart data card (SIM card). This SIM card can be inserted into the respective mobile telephone to be used by a mobile radio subscriber, after which that mobile telephone can be called at this mobile telephone number. However, since the SIM card is only inserted in one mobile radio telephone when making a mobile radio call, and must be connected to it, it can be said that the mobile radio call number MSISDN is allocated to this communication terminal KEG for this communication connection. The wording as mentioned above should be understood in this context.
[0030] The first mobile radio network MFNI has a first associated payment system ZS 1 , via which payments made with regard to the communication terminal KEG (and which may occur, for example, when using the communication terminal KEG for buying and selling purposes in what is referred to as mobile commerce) are handled. For this purpose, the first payment system ZS 1 is connected to an invoice production device BL and to a prepaid debiting device PPS. The first payment system ZS 1 is also connected via a financial interface FG, which is referred to as “Financial Gateway”, to a debiting system CC for a credit card organization, and to a debiting system BK for a bank.
[0031] The first payment system ZS 1 is likewise connected to a network interface 12 , which is designed in the same way as the network interface 2 explained in conjunction with FIG. 1. The network interface 12 accordingly likewise has a unit FW and an access unit MNP-API. The latter is connected to an MNP memory 11 , which is designed in the same way as the MNP memory 1 explained in conjunction with FIG. 1.
[0032] The second mobile radio network MFN 2 , which is shown on the right-hand side of FIG. 2, has a second payment system ZS 2 , which is used for initiating and implementing payments that are incurred in conjunction with the use of the second mobile radio network MFN 2 . The second payment system ZS 2 is connected to a sales device VE, at least at times. A sales device VE such as this is represented, by way of example, by a computer via which a provider of goods or services offers his goods or services to customers who are interested in them, and/or also handles the sales and debiting procedures.
[0033] Both the first payment system ZS 1 and the second payment system ZS 2 are in each case operated by what is referred to as a payment service provider. The task of the payment service provider is to use the respective payment system to handle payments between those making payments and those receiving payments. A person making a payment may, for example, be a customer who is purchasing goods or services; a person receiving a payment may, for example, be a dealer who is offering goods or services.
[0034] The separation between the first mobile radio network MFN 1 and the second mobile radio network MFN 2 is symbolized by a vertical dashed line 16 . This line 16 corresponds to the horizontal dashed line 6 shown in FIG. 1.
[0035] One exemplary embodiment of the invention will be described in the following text in the context of a sales procedure.
[0036] The user of the communications terminal KEG makes a mobile telephone call T to the sales device VE of an Italian dealer, and purchases an item via this mobile telephone connection T. The call number 0049 171 98765 of the communication terminal is transmitted via the mobile telephone connection T to the dealer's sales device VE; the dealer uses this mobile radio call number to debit the purchase price of the item bought.
[0037] The operator of the sales device VE is a mobile radio customer in the second mobile radio network MFN 2 . The second mobile radio network MFN 2 in consequence represents the home network of the sales device operator. In consequence, the sales device VE uses the second payment system ZS 2 for the second mobile radio network MSN 2 as standard for handling payment procedures. An appropriate contract may exist between the operator of the second mobile radio network MFN 2 and the sales device VE.
[0038] As has already been explained above, the operator of the communication terminal KEG is registered in the first mobile radio network MFN 1 . The first mobile radio network MFN 1 thus represents the home network of the operator of the communication terminal, and thus also represents the home network of the communication terminal. In consequence, the purchasing procedures which are initiated or carried out using the communication terminal KEG are debited as standard using the first payment system ZS 1 for the first mobile radio network MFN 1 .
[0039] For this reason, in order to handle this international purchasing procedure for the second payment system ZS 2 , it is necessary to identify the payment system which is associated with the communication terminal KEG and will handle these payments (that is to say the payment system ZS 1 ). In this context, identification for the communication terminal (in this case the mobile radio call number which was transmitted by the sales device KE to the second payment system ZS 2 ) is known by the second payment system ZS 2 . The national dialing code (“0049”) in the mobile radio call number tells the second payment system that the home network of the communication terminal KEG is in Germany. However, the second payment system cannot directly determine the home network of the communication terminal from the network code (“171”) in the mobile radio call number. This is because the second payment system ZS 2 does not know whether the subscriber with the communication terminal KEG has already changed his mobile radio provider on one or even more occasions, and has retained his originally allocated mobile radio call number on the basis of mobile number portability.
[0040] This is because it is possible for different mobile radio providers to make use of a number of payment systems as well in a country where there are a number of mobile radio networks (for example one payment system for the first mobile radio network MFN 1 , and a further payment system for a further mobile radio network, which is not shown). Thus, in the illustrated example, the second payment system ZS 2 cannot use the mobile radio call number to unambiguously decide whether the first payment system ZS 1 for the first mobile radio system or the further payment system (which is not illustrated) for the further mobile radio network (which is not illustrated) is responsible for the purchasing procedure carried out by means of the communication terminal KEG. For this reason, the second payment system ZS 2 now accesses the MNP memory 11 .
[0041] The rest of the procedure corresponds to the procedure already described in conjunction with FIG. 1. First, the second payment system ZS 2 uses an information channel 18 to set up a connection to the network interface 12 . The second payment system ZS 2 authenticates itself with the framework FW of the OSA gateway 12 via this connection 18 . After this, the OSA gateway authorizes this second payment system ZS 2 to use the access unit MNP-API. Once this authorization has been obtained, the second payment system ZS 2 can access the MNP memory 11 via the access unit MNP-API, and can make appropriate access requests to the MNP databank 11 . When an access request such as this occurs, the second payment system ZS 2 transmits the mobile radio call number MSISDN of the mobile telephone of the subscriber wishing to make a purchase via a data channel 19 to the network interface 12 . The network interface 12 then asks the MNP memory 11 for the network operator (in this case the operator D2) associated with the communication terminal KEG, and for the server address of the responsible first payment system ZS 1 . The information about the network operator and about the server address is transmitted with the aid of the access unit MNP-API in a response message from the network interface 12 via the data channel 19 to the second payment system ZS 2 .
[0042] The second payment system ZS 2 now has the necessary information to make contact with the first payment system ZS 1 . Using the server address for this first payment system ZS 1 , it sets up a data link 21 to the first payment system ZS 1 (“Inter-Payment Service Provider Routing”). Payments can now be handled correctly between the second payment system ZS 2 and the first payment system ZS 1 (“Inter-Payment Service Provider Payment”).
[0043] So far, it has been assumed in this exemplary embodiment that the subscriber with the communication terminal KEG has not changed his original mobile radio network. In consequence, the first mobile radio network MFN 1 was entered in the MNP memory 11 as the home network, and the first payment system ZS 1 was entered in the MNP memory 11 as the responsible payment system. However, if the corresponding subscriber had already changed the mobile radio network (for example to the further mobile radio network which has already been mentioned above but is not shown), then the further mobile radio network would be entered in the MNP memory 11 as the home mobile radio network, and the further payment system for the further mobile radio network would be entered in the MNP memory 11 as the responsible payment system. Consequently, the server address for this further payment system would then have been transmitted to the second payment system ZS 2 , in response to which the second payment system would have set up a data link to the further payment system, in order to handle the payment.
[0044] The invention can also advantageously be used when a land line subscriber is calling a ported mobile radio subscriber (that is to say a mobile radio subscriber who has churned, taking his original mobile radio number with him). In order to set up cost-effective rerouting directly from the land line network to the currently responsible network for the mobile radio subscriber for a telephone call such as this, the land line network operator likewise requires MNP data stored in the MNP memory 11 . This data can also be checked from the MNP memory analogously to the exemplary embodiment described above using the network interface with the framework unit FW and the access unit MNP-API by a data checking device in the land line network (which represents a network-external data processing device with regard to the mobile radio network).
[0045] A method and an arrangement have been described which allow secure access from devices external to mobile radio networks to number porting data which is stored in “Mobile Number Portability” databanks. This method and this arrangement can be cost-effectively embedded in existing network infrastructures since, according to the invention, an access unit for access to MNP data is provided by means of the OSA technology, which is known per se. This method allows, for example, cost-effective rerouting from land line networks to mobile radio networks when called mobile radio subscribers have ported. International processing and payment procedures supported by mobile radio are likewise made possible for ported mobile radio subscribers using their payment systems.
[0046] It is particularly advantageous for the access unit MNP-API to be designed to be compliant with the OSA Standard. This makes it possible, according to the invention, to use security mechanisms and security infrastructures which.are known from the OSA Standard—for example in the framework unit—for access to the MNP data; this allows smooth interaction, for example, between the access unit and the framework unit.
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The invention relates to a method for accessing MNP data, which is stored in an MNP memory in a mobile radio network, by a network-external data processing device. The network interface, which in terms of signal flow is arranged between the network-external data processing device and the MNP memory, checks whether the network-external data processing device is authorized to access the MNP data. If the authorization is present, an identification for a communication terminal is transmitted by the network interface from the network-external data processing device to the MNP memory, MNP data which is associated with the communication terminal is read from the MNP memory, and this MNP data is transmitted via the network interface to the network-external data processing device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to graft polymers of the ABS type which are produced in emulsion, and to thermoplastic moulding compositions which are based thereon and which exhibit a very considerably increased notched bar impact strength compared with known ABS moulding compositions and which at the same time exhibit high hardness values or high modulus values and good thermoplastic processability.
2. Description of the Prior Art
ABS moulding compositions are two-phase synthetic materials comprising:
I: a thermoplastic copolymer of styrene and acrylonitrile, in which the styrene may be completely or partially replaced by α-methyl styrene or methyl methacrylate; this copolymer, which is also termed SAN resin or matrix resin, forms the external phase;
II: at least one graft polymer, which has been produced by a graft reaction of one or more of the monomers cited in I. on to a butadiene homo- or copolymer ("graft base"). This graft polymer ("elastomer phase" or "graft rubber") forms the disperse phase in the matrix resin.
For the same matrix, the toughness of an ABS moulding composition is substantially determined by the graft rubber contained therein. However, the toughness which can be obtained, with the requisite reliability, using customary ABS moulding compositions is not always sufficient for highly stressed mouldings, or high toughness values are obtained, but to the detriment of other properties of the mouldings.
There is therefore a need for highly effective graft rubbers, based on which ABS moulding compositions having a very high toughness can be produced without their other properties being altered in a negative sense.
It has now been found that with the simultaneous use of a special mixture of at least two accurately defined rubber latices and defined added amounts of special radical initiator compounds and emulsifiers during the production of the graft rubber, and preferably with the maintenance of special reaction conditions, ABS moulding compositions which have very high impact toughness values can be obtained.
The use of rubber latex mixtures in the production of graft rubbers for ABS moulding compositions is in fact known, although the quality requirements are not fulfilled.
Thus, for example, tough ABS moulding compositions which exhibit good processability are known from DE-AS 1 813 719; these are obtained by the single-stage emulsion graft polymerisation, which proceeds under pressure, of 75 to 90 parts by weight of a monomer mixture on to 10 to 25 parts by weight of a mixture of two rubber latices, one of which is a pure polybutadiene and the other is an SBR latex with a styrene content <50% and with a defined particle size.
U.S. Pat. No. 3,509,238 describes ABS products which are produced using two graft polymers, one of which is weakly grafted, the other of which is strongly grafted. These products have unsatisfactory properties at low temperatures, however.
U.S. Pat. No. 3,928,494 describes ABS products comprising two graft polymers comprising different degrees of grafting, in which the more weakly grafted, finely divided material is layered together during spray-drying or during coagulation to form particle aggregates. Aggregates of this type constitute loosely bound formations which are torn apart again under the action of high temperatures and shear forces, such as those which can occur in injection moulding processing for example, and do not then result in satisfactory product toughnesses.
EP-A 116 330 describes ABS moulding compositions based on two different butadiene polymers, with a special grafting site spacing of the graft polymers produced from the butadiene polymers. These products in fact exhibit good toughness at room temperature, but their hardness values and their thermoplastic flowability are not adequate for severe demands.
SUMMARY OF THE INVENTION
The present invention relates to thermoplastic moulding compositions of the ABS type, comprising
I) at least one graft polymer, obtained by the emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 90:10 to 50:50, wherein styrene and/or acrylonitrile can be completely or partially replaced by α-methylstyrene, methyl methacrylate or N-phenylmaleinimide, in the presence of at least two butadiene polymer latices of type (A) and (B), which each contain 0 to 50% by weight of a further copolymerised vinyl monomer and wherein the weight ratio of the monomers used to the butadiene polymers used is 20:80 to 80:20, preferably 30:70 to 75:25, and
II) at least one copolymer of styrene and acrylonitrile in a weight ratio of 90:10 to 50:50, wherein styrene and/or acrylonitrile can be completely or partially replaced by α-methylstyrene, methyl methacrylate or N-phenylmaleinimide,
characterised in that
i) butadiene polymer latex (A) has a particle diameter d 50 ≦320 nm, preferably 260 to 310 nm, a particle size distribution range (measured as d 90 -d 10 from the integral particle size distribution) from 30 to 100 nm, preferably from 40 to 80 nm, and a gel content ≦70% by weight, preferably 40 to 65% by weight, and butadiene polymer latex (B) has a particle diameter d 50 ≦370 nm, preferably 380 to 450 nm, a particle size distribution range (measured as d 90 -d 10 from the integral particle size distribution) from 50 to 500 nm, preferably from 100 to 400 nm, and a gel content ≦70% by weight, preferably 75 to 90% by weight,
ii) at least one compound of general formula R ##STR1## wherein R'=C 2 H 5 , C 3 H 7 , C 4 H 9 , is used in amounts of 1 to 5% by weight, preferably 1.5 to 3% by weight (with respect to the monomers in each case) as a radical former for the production of the graft polymer, and
iii) the weight ratio of radical former R:emulsifier which is used in the graft polymerisation is 1:1 to 1:5, preferably 1:1 to 1:3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The graft polymerisation is preferably conducted by feeding the monomers into the mixture of butadiene polymer latices (A) and (I3) in such a way that 55 to 90% by weight, preferably 60 to 80% by weight, and most preferably 65 to 75% by weight of the monomers are added during the first half of the monomer feed period.
In a further preferred embodiment of the present invention, the graft polymerisation is conducted by feeding in the monomers and adding the initiator together with the emulsifier solution in a separate feeding operation.
Apart from the polymer resin components cited above, the moulding compositions according to the invention may contain other, rubber-free thermoplastic resins which are not synthesised from vinyl monomers.
A mixture of at least two butadiene polymer latices, one of type (A) and one of type (B), is used for the graft polymerisation. The weight ratio of (A):(B) with respect to the respective solids content of the latex is preferably 90:10 to 10:90, most preferably 60:40 to 30:70.
Butadiene polymer latices (A) and (B) can be produced by the emulsion polymerisation of butadiene. This polymerisation is known, and is described, for example, in Houben-Weyl, Methoden der Organischen Chemie, Makromolekulare Stoffe, Part 1, page 674 (1961), Thieme Verlag Stuttgart. Up to 50% by weight (with respect to the total amount of monomer used for the production of the butadiene polymer) of one or more monomers which are copolymerisable with butadiene can be used as comonomers.
Examples of monomers such as these include isoprene, chloroprene, acrylonitrile, styrene, α-methylstyrene, C 1 -C 4 alkyl styrenes, C 1 -C 8 alkyl acrylates, C 1 -C 8 alkyl methacrylates, alkylene glycol diacrylates, alkylene glycol dimethacrylates and divinylbenzene; butadiene is preferably used on its own. It is also possible firstly to produce a finely divided butadiene polymer by known methods and subsequently to agglomerate it in the known manner to produce the requisite particle size.
Relevant techniques have been described (see EP-PS 0 029 613; EP-PS 0 007 810; DD-PS 144 415; DE-AS 1 233 131; DE-AS 1 258 076; DE-OS 2 101 650; U.S. Pat. No. 1,379,391).
What is termed the seed polymerisation technique can also be employed, in which a finely divided butadiene polymer is first produced and is then polymerised further to form larger particles by further reaction with monomers containing butadiene.
In principle, butadiene polymer latices (A) and (B) can also be produced by the emulsification of finely divided butadiene polymers in aqueous media (see Japanese Patent Application 55 125 102).
Butadiene polymer latex (A) has an average particle diameter d 50 ≦320 nm, preferably 260 to 310 nm, a particle size distribution range (measured as d 90 -d 10 from the integral particle size distribution) from 30 to 100 nm, preferably from 40 to 80 nm, and a gel content ≦70% by weight, preferably 40 to 65% by weight.
Butadiene polymer latex (B) has a particle diameter d 50 ≧370 nm, preferably 380 to 450 nm, a particle size distribution range (measured as d 90 -d 10 from the integral particle size distribution) from 50 to 500 nm, preferably from 100 to 400 nm, and a gel content ≧70% by weight, preferably 75 to 90% by weight.
Determination of the average particle diameter d 50 and of the d 10 and d 90 values can be effected by ultracentrifuge measurements (see W. Scholtan, H. Lange: Kolloid Z. u. Z. Polymere 250, pages 782 to 796 (1972)); the values given for the gel content are based on a determination by the wire cage method in toluene (see Houben-Weyl, Methoden der Organischen Chemie, Makromolekulare Stoffe, Part 1, page 307 (1961), Thieme Verlag Stuttgart).
The gel contents of butadiene polymer latices (A) and (B) can be adjusted, in a manner which is known in principle, by employing suitable reaction conditions (e.g. a high reaction temperature and/or polymerisation up to a high conversion, and optionally the addition of substances with a crosslinking action in order to obtain a high gel content, or, for example, a low reaction temperature and/or termination of the polymerisation reaction before the occurrence of too strong a crosslinking effect and optionally with the addition of molecular weight regulators such as n-dodecyl mercaptan or t-dodecyl mercaptan, for example, in order to obtain a low gel content). The usual anionic emulsifiers can be used as emulsifiers, such as alkyl sulphates, alkyl sulphonates, aralkyl suiphonates, soaps of saturated or unsaturated fatty acids, as well as alkaline disproportionated or hydrogenated abietic or tall oil acids; emulsifiers containing carboxyl groups (e.g. salts of C 10 -C 18 fatty acids, disproportionated abietic acid) are preferably used.
The graft polymerisation may be conducted by continuously adding the monomer mixture, so that it is continuously polymerised, to the mixture of butadiene polymer latices (A) and (B).
In the course of this operation, particular monomer:rubber ratios and a defined procedure for the addition of monomer to the rubber latex are preferably adhered to.
In order to produce the products according to the invention, preferably 25 to 70 parts by weight, most preferably 30 to 60 parts by weight, of a mixture of styrene and acrylonitrile which may optionally contain up to 50% by weight (with respect to the total amount of monomers used in the graft polymerisation) of one or more comonomers, are polymerised in the presence of what is preferably 30 to 75 parts by weight, most preferably 40 to 70 parts by weight (with respect to the solid in each case) of the butadiene latex mixture of (A) and (B).
The monomers used in this graft polymerisation are preferably mixtures of styrene and acrylonitrile in a weight ratio of 90:10 to 50:50, most preferably in a weight ratio of 65:35 to 75:25, wherein styrene and/or acrylonitrile can be completely or partially replaced by copolymerisable monomers, preferably by α-methylstyrene, methyl methacrylate or N-phenylmaleinimide.
Molecular weight regulators can be used in addition in the graft polymerisation, preferably in amounts of 0.05 to 3% by weight, most preferably in amounts of 0.1 to 2% by weight (with respect to the total amount of monomer in the graft polymerisation stage in each case).
Examples of suitable molecular weight regulators include n-dodecyl mercaptan, t-dodecyl mercaptan, dimeric α-methylstyrene, and terpineols.
Compounds of general formula ##STR2## wherein R'=C 2 H 5 , C 3 H 7 , C 4 H 9 ,
and wherein the isomeric radicals n-C 3 H 7 , i-C 3 H 7 , n-C 4 H 9 , i-C 4 H 9 , t-C 4 H 9 are included, are suitable as radical formers for the graft polymerisation; a compound R where R'=C 2 H 5 is particularly preferred.
The radical formers are preferably used in amounts of 1 to 5% by weight, preferably 1.5 to 3% by weight (with respect to the monomers used in each case).
The reaction temperature is 40° C. to 120° C., preferably 45° C. to 100° C., and most preferably 50° C. to 90° C.
The aforementioned compounds can be used as emulsifiers; emulsifiers containing carboxyl groups are preferred.
In order to achieve the effect of a very high toughness according to the invention, the amounts of emulsifier used in the graft reaction must be selected so that the weight ratio of radical former:emulsifier does not exceed a value of about 1:0.9. A weight ratio of radical former R:emulsifier of 1:1 to 1:5 is preferably used, most preferably of 1:1 to 1:3.
In order to produce the products according to the invention, the graft polymerisation is preferably conducted by feeding in the monomers in such a way that 55 to 90% by weight, preferably 60 to 80% by weight, and most preferably 65 to 75% by weight of the total monomers to be used in the graft polymerisation are added during the first half of the total monomer feed period; the remaining proportion of monomers is added over the second half of the total monomer feed period.
Finally, the graft polymer produced is mixed with at least one thermoplastic resin. This can be effected in various ways. If the thermoplastic resin itself has been produced by emulsion polymerisation, the latices can be mixed, and can be jointly precipitated and worked up. If the thermoplastic resin has been produced by solution or bulk polymerisation, the graft polymer must be isolated by known methods, for example by spray-drying or by the addition of salts and/or acids, washing the precipitated products and drying the powder, and thereafter is mixed with the thermoplastic resin, which preferably exists in the form of granules (preferably in multi-cylinder mills, mixing extruders or internal kneaders); this method is preferably employed.
Copolymers of styrene and acrylonitrile in a weight ratio of 90:10 to 50:50 are preferably used as the vinyl resins, wherein styrene and/or acrylonitrile can be replaced completely or partially by α-methylstyrene and/or methyl methacrylate; proportions of up to 30% by weight with respect to the vinyl resin, of a further monomer from the series comprising maleic anhydride, maleic acid imide, N-(cyclo)-alkylmaleinimide or N-(alkyl)-phenylmaleinimide may optionally be used in conjunction.
Details of the production of these resins are described in DE-AS 2 420 358 and DE-AS 2 724 360, for example. Vinyl resins produced by bulk or solution polymerisation have proved to be particularly suitable.
Apart from thermoplastic resins of this type, which are synthesised from vinyl monomers, it is also possible to use aromatic polycarbonates, aromatic polyester carbonates, polyesters or polyamides, for example, as resin components in the moulding compositions according to the invention.
Suitable thermoplastic polycarbonates or polyester carbonates are known (see DE-AS 1 495 626, DE-OS 2 232 877, DE-OS 2 703 376, DE-OS 2 714 544, DE-OS 3 000 610, DE-OS 3 832 396, DE-OS 3 077 934, for example), and can be produced, for example, by the reaction of diphenols of formulae (I) and (II) ##STR3## wherein
A a single bond, a C 1 -C 5 alkylene, a C 2 -C 5 alkylidene, a C 5 -C 6 cycloalkylidene, --O--, --S--, --SO--, --SO 2 -- or --CO--,
R 5 and R 6 represent, independently of each other, hydrogen, methyl or a halogen, particularly hydrogen, methyl, chlorine or bromine,
R 1 and R 2 denote, independently of each other, hydrogen, a halogen, preferably chlorine or bromine, a C 1 -C 8 alkyl, preferably methyl or ethyl, a C 5 -C 6 cycloalkyl, preferably cyclohexyl, a C 6 -C 10 aryl, preferably phenyl, or a C 7 -C 12 aralkyl, preferably a phenyl-C 1 -C 4 alkyl, particularly benzyl,
m is an integer from 4 to 7, preferably 4 or 5,
n is 0 or 1,
R 3 and R 4 can be selected individually for each X and denote, independently of each other, hydrogen or a C 1 -C 6 alkyl, and
X denotes carbon,
with carbonic acid halides, preferably phosgene, and/or with aromatic dicarboxylic acid halides, preferably benzene dicarboxylic acid halides, by the phase boundary process, or with phosgene by the homogeneous phase process (the so-called pyridine process), wherein the molecular weight can be adjusted in the known manner by a corresponding amount of known chain terminators.
Examples of suitable diphenols of formulae (I) and (II) include hydroquinone, resorcinol, 4,4'-dihydroxydiphenyl, 2,2-bis-(4-hydroxyphenyl)-propane, 2,4-bis-(4-hydroxy-phenyl)-2-methylbutane, 2,2-bis-(4-hydroxy-3,5-dimethylphenyl)-propane, 2,2-bis-(4-hydroxy-3,5-dichlorophenyl)-propane, 2,2-bis-(4-hydroxy-3,5-dibromophenyl)-propane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 1,1-bis-(4-hydroxyphenyl)-3,3-dimethylcyclohexane, 1,1-bis-(4-hydroxyphenyl)-3,3,5,5-tetramethylcyclohexane or 1,1-bis-(4-hydroxyphenyl)-2,4,4,-trimethylcyclopentane.
The preferred diphenols of formula (I) are 2,2-bis-(4-hydroxyphenyl)-propane and 1,1-bis-(4-hydroxyphenyl)-cyclohexane; the preferred phenol of formula (II) is 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane.
Mixtures of diphenols can also be used.
Examples of suitable chain terminators include phenol, p-tert.-butylphenol, long chain alkyl phenols such as 4-(1,3-tetramethyl-butyl)phenol according to DE-OS 2 842 005, monoalkyl phenols, dialkylphenols containing a total of 8 to 20 C atoms in their alkyl substituents according to DE-OS 3 506 472, such as p-nonylphenol, 2,5-di-tert- butylphenol, p-tert.-octylphenol, p-dodecylphenol, 2-(3,5-dimethylheptyl)-phenol and 4-(3,5-dimethylheptyl)-phenol. The requisite amount of chain terminators is generally 0.5 to 10 mole % with respect to the sum of diphenols (I) and (II).
Suitable polycarbonates or polyester carbonates may be linear or branched; branched products are preferably obtained by the incorporation of 0.05 to 2.0 mole %, with respect to the sum of the diphenols used, of trifunctional compounds or compounds with a functionality greater than three, e.g. those containing three or more than three phenolic OH groups.
Suitable polycarbonates or polyester carbonates may contain an aromatically bonded halogen, preferably bromine and/or chlorine; they are preferably halogen-free.
They have average molecular weights (M W , weight average), as determined by ultracentrifuging or by the measurement of scattered light, of 10,000 to 200,000, preferably from 20,000 to 80,000.
Suitable thermoplastic polyesters are preferably polyalkylene terephthalates, namely reaction products of aromatic dicarboxylic acids or reactive derivatives thereof (e.g. dimethyl esters or anhydrides) and aliphatic, cycloaliphatic or arylaliphatic diols, and mixtures of reaction products such as these.
The preferred polyalkylene terephthalates can be produced by known methods from terephthalic acids (or reactive derivatives thereof) and aliphatic or cycloaliphatic diols containing 2 to 10 C atoms (Kunststoff-Handbuch, Volume VIII, page 695 et seq., Carl Hanser Verlag, Munich 1973).
In the preferred polyalkylene terephthalates, 80 to 100, preferably 90 to 100 mole % of the dicarboxylic acid radicals are terephthalic acid radicals, and 80 to 100, preferably 90 to 100 mole % of the diol radicals are ethylene glycol and/or 1,4-butanediol radicals.
Apart from ethylene glycol or 1,4-butanediol radicals, the preferred polyalkylene terephthalates may contain 0 to 20 mole % of radicals of other aliphatic diols containing 3 to 12 C atoms or of cycloaliphatic diols containing 6 to 12 C atoms, e.g. radicals of 1,3-propanediol, 2-ethyl-1,3-propanediol, neopentyl glycol, 1,5-pentanediol, 1,6-hexanediol, cyclohexane-di-1,4-methanol, 3-methyl-1,3-pentanediol and -1,6-pentanediol, 2-ethyl-1,3-hexanediol, 2,2-diethyl-1,3-propanediol, 2,5-hexanediol, 1,4-di(β-hydroxy-ethoxy)-benzene, 2,2,-bis-4-hydroxycyclohexyl)-propane, 2,4-dihydroxy-1,1,3,3-tetramethyl-cyclobutane, 2,2-bis-(3-β-hydroxyethoxyphenyl)-propane and 2,2-bis-(4-hydroxypropoxyphenyl)-propane (DE-OS 2 407 647, 2 407 776, 2 715 932).
The polyalkylene terephthalates can be branched by the incorporation of relatively small amounts of tri- or tetrahydric alcohols or of tri- or tetrabasic carboxylic acids, such as those which are described in DE-OS 1 900 270 and U.S. Pat. No. 3,692,744. Examples of preferred branching agents include trimesic acid, trimellitic acid, trimethylolethane and -propane, and pentaerythritol. It is advisable to use not more than 1 mole % of the branching agent with respect to the acid component.
The polyalkylene terephthalates which are particularly preferred are those which have been produced solely from terephthalic acid and reactive derivatives thereof (e.g. dialkyl esters thereof) and ethylene glycol and/or 1,4-butanediol, and mixtures of these polyalkylene terephthalates.
The preferred polyalkylene terephthalates also include copolyesters which are produced from at least two of the aforementioned alcohol components: poly-(ethylene glycol-1,4-butanediol)-terephthalates are particularly preferred copolyesters.
The preferred polyalkylene terephthalates which are suitable generally have an intrinsic viscosity of 0.4 to 1.5 dl/g, preferably 0.5 to 1.3 dl/g, particularly 0.6 to 1.2 dl/g, measured in each case in phenol-chlorobenzene (1:1 parts by weight) at 25° C.
Suitable polyamides comprise known homopolyamides, copolyamides and mixtures of these polyamides. These may be partially crystalline and/or amorphous polyamides.
Polyamide-6, polyamide-6,6, and mixtures and corresponding copolymers of these components are suitable as partially crystalline polyamides. Partially crystalline polyamides are also suitable in which the acid component completely or partially consists of terephthalic acid and/or isophthalic acid and/or suberic acid and/or sebacic acid and/or azelaic acid and/or adipic acid and/or cyclohexanedicarboxylic acid, the diamine component of which completely or partially consists of m- and/or p-xylylene-diamine and/or hexamethylenediamine and/or 2,2,4-trimethylhexamethylenediamine and/or 2,2,4-trimethylhexamethylenediamine and/or isophoronediamine, and the composition of which is known in principle.
Polyamides are also suitable which are produced completely or partially from lactams with 7-12 C atoms in their ring, optionally with the use in conjunction of one or more of the aforementioned starting components.
The polyamides which are particularly preferred are polyamide-6 and polyamide-6,6 and mixtures thereof. Known products can be used as amorphous polyamides. They are obtained by the condensation polymerisation of diamines such as ethylenediamine, hexamethylenediamine, decamethylenediamine, 2,2,4- and/or 2,4,4-trimethylhexamethylenediamine, m, - and/or p-xylylene-diamine, bis-(4-aminocyclohexyl)-methane, bis-(4-aminocyclohexyl)-propane, 3,3'-dimethyl-4,4'-diamino-dicyclohexylmethane, 3-aminomethyl,3,5,5,-trimethylcyclohexylamine, 2,5- and/or 2,6-bis-(aminomethyl)-norbornane and/or 1,4-diaminomethylcyclohexane with dicarboxylic acids such as oxalic acid, adipic acid, azelaic acid, azelaic acid, decane-dicarboxylic acid, heptadecane-dicarboxylic acid, 2,2,4- and/or 2,4,4-trimethyladipic acid, isophthalic acid and terephthalic acid.
Copolymers which are obtained by the condensation polymerisation of a plurality of monomers are also suitable, as are copolymers which are produced with the addition of amino-carboxylic acids such as ε-aminocaproic acid, ω-aminoundecanoic acid or ω-aminolauric acid or lactams thereof.
Amorphous polyamides which are particularly suitable are the polyamides produced from isophthalic acid, hexamethylenediamine and other diamines such as 4,4'-diamino-dicyclohexylmethane, isophoronediamine, 2,2,4- and/or 2,4,4-trimethylhexanethylenediangine, 2,5- and/or 2,6-bis-(aminomethyl)-norbornene; or from isophthalic acid, 4,4'-diamino-dicyclohexylmethane and ε-caprolactam; or from isophthalic acid, 3,3'-dimethyl-4,4'-diamino-dicyclohexylmethane and laurolactam; or from terephthalic acid and the mixture of isomers comprising 2,2,4- and/or 2,4,4-trimethylhexamethylenediamine.
Instead of pure 4,4'-diaminodicyclohexylmethane, mixtures of the positional isomers of diaminodicyclohexylmethane can also be used which comprise
70 to 99 mole % of the 4,4'-diamino isomer,
1 to 30 mole % of the 2,4'-diamino isomer,
0 to 2 mole % of the 2,2'-diamino isomer, and
optionally of correspondingly higher condensed diamines which are obtained by the hydrogenation of diaminodiphenylmethane of industrial quality. Up to 30% of the isophthalic acid may be replaced by terephthalic acid.
The polyamides preferably have a relative viscosity (measured on a 1% by weight solution in m-cresol at 25° C.) from 2.0 to 5.0, most preferably from 2.5 to 4.0.
The proportion of graft rubber in the moulding compositions according to the invention can be varied within wide limits; it is preferably 10 to 80% by weight, most preferably 20 to 75% by weight.
The requisite or advisable additives may be added to the moulding compositions according to the invention during their production, work-up, further processing and final moulding, e.g. antioxidants, UV stabilisers, peroxide destroyers, antistatic agents, slip additives, demoulding agents, flame retardants, fillers or reinforcing agents (glass fibres, carbon fibres, etc.) and colorants.
Final moulding can be effected in customary processing units, and comprises injection moulding processing, sheet extrusion, optionally with subsequent thermoforming, cold forming, extrusion of tubes and sections and calendering for example.
The parts quoted in the following examples are always parts by weight, and the percentages quoted are always percentages by weight, unless indicated otherwise.
EXAMPLES
Examples 1 to 7
20 parts by weight (calculated as the solid) of an anionically emulsified polybutadiene latex which was produced by radical polymerisation (latex A), which had a d 50 value of 271 nm, a d 90 -d 10 value of 43 nm and a gel content of 51% by weight, and 20 parts by weight (calculated as the solid) of an anionically emulsified polybutadiene latex which was produced by radical polymerisation (latex B), which had a d 50 value of 434 nm, a d 90 -d 10 value of 111 nm and a gel content of 85% by weight, were made up with water to a solids content of about 20% by weight, after which the mixture was heated to 63° C. and treated with the initiators given in Table 1. Thereafter, 60 parts by weight of a mixture of 73% by weight styrene and 27% by weight acrylonitrile and 0.15 parts by weight tert-dodecyl mercaptan were added over 4 hours, in such a way that 70% by weight of the total amount of monomers was added to the reaction mixture within the first two hours; in parallel with this, the amounts given in Table I (calculated as the solid substance) of the sodium salt of a resin acid mixture (Dresinate 731, dissolved in water made alkaline) were added over 4 hours.
After a subsequent reaction time of 4 hours, the graft latices were each coagulated, after the addition of about 1.0 parts by weight of a phenolic antioxidant, by the addition of a magnesium sulphate/acetic acid mixture, and after washing with water the resulting powders were dried at 70° C. in vacuum.
40 parts by weight of the respective graft polymer were mixed with 60 parts by weight of a styrene/acrylonitrile copolymer resin (72:28, M W ≈115,000, M W /M n -1≦2), 2 parts by weight of ethylenediamine-bis-stearylamide and 0.1 parts by weight of a silicone oil in an internal kneader and were subsequently processed to form test bars.
The following data were determined:
The notched bar impact strength at room temperature according to ISO 180/1A (units: kJ/m 2 ),
the indentation hardness (H c ) according to DIN 53 456 (units: N/mm 2 ), the thermal deformation resistance (Vicat B) according to DIN 53 460 (units: °C.), and
the thermoplastic processability, by determining the requisite filling pressure at 240° C. (see F. Johannaber, Kunststoffe 74 (1984), 1, pages 2 to 5).
The results are summarised in Table 2. It can be seen from these results that it is only the moulding compositions according to the invention which exhibit very high toughnesses without negative effects on their other properties.
TABLE 1______________________________________Amount and type of initiators used, and amounts of emulsifiers used Amount of Amount of initiator emulsifier [parts by [parts byExample Type of initiator weight] weight]______________________________________1 R with R' = C.sub.2 H.sub.5.sup.*) 1 12 R with R' = C.sub.2 H.sub.5.sup.*) 1 1.53 R with R' = C.sub.2 H.sub.5.sup.*) 1 24 (comparative) R with R' = C.sub.2 H.sub.5.sup.*) 1 0.55 (comparative) R with R' = C.sub.2 H.sub.5.sup.*) 0.5 16 (comparative) K.sub.2 S.sub.2 O.sub.8 0.5 17 (comparative) R with R' = CH.sub.3.sup.**) 1 1______________________________________ .sup.*) Vazo 67 (DuPont) .sup.**) Vazo 64 (DuPont)
TABLE 2______________________________________Test data for the moulding compositions from Examples 1 to 7 Filling a.sub.k H.sub.c Vicat B pressureExample (kJ/m.sup.2) (N/mm.sup.2) (° C.) (bar)______________________________________1 40.1 97 101 1842 42.6 96 101 1763 38.8 98 100 1754 (comparative) 35.5 96 99 1855 (comparative) 35.1 99 100 1806 (comparative) 32.5 97 100 1687 (comparative) 34.6 96 98 175______________________________________
Examples 8 to 12
50 parts by weight (calculated as the solid) of an anionically emulsified polybutadiene latex which was produced by radical polymerisation and which had the composition given in Table 3, were made up with water to a solids content of about 20% by weight, after which the mixture was heated to 63° C. and treated with the initiators given in Table 3. Thereafter, 50 parts by weight of a mixture of 73% by weight styrene and 27% by weight acrylonitrile and 0.15 parts by weight tert-dodecyl mercaptan were added over 4 hours, in such a way that 70% by weight of the total amount of monomers was added to the reaction mixture within the first two hours; in parallel with this, the amounts given in Table 3 (calculated as the solid substance) of the sodium salt of a resin acid mixture (Dresinate 731, dissolved in water made alkaline) were added over 4 hours.
After a subsequent reaction time of 4 hours, the graft latices were each coagulated, after the addition of about 1.0 parts by weight of a phenolic antioxidant, by the addition of a magnesium sulphate/acetic acid mixture, and after washing with water the resulting powders were dried at 70° C. in vacuum.
32 parts by weight of the respective graft polymer were mixed with 68 parts by weight of a styrene/acrylonitrile copolymer resin (72:28, M W ≈15,000, M W /M n -1≦2), 2 parts by weight of ethylenediamine-bis-stearylamide and 0.1 parts by weight of a silicone oil in an internal kneader and were subsequently processed to form test bars on which the aforementioned data were determined.
The results are summarised in Table 4.
TABLE 3______________________________________Rubber compositions; amounts and type ofinitiators and emulsifiers added Latex A Latex B from from Examples Examples Amount of Amount of 1 to 7 1 to 7 initiator emulsifier [parts by [parts by Type of [parts by [parts byExample weight] weight] initiator weight] weight]______________________________________8 25 25 R with R' = 1 1 C.sub.2 H.sub.5.sup.*)9 25 25 R with R' = 0.3 1(com- C.sub.2 H.sub.5.sup.*)parative)10 25 25 K.sub.2 S.sub.2 O.sub.8 0.5 1(com-parative)11 50 0 R with R' = 1 1(com- C.sub.2 H.sub.5.sup.*)parative)12 0 50 R with R' = 1 1(com- C.sub.2 H.sub.5.sup.*)parative)______________________________________ .sup.*) Vazo 67 (DuPont)
TABLE 4______________________________________Test data for the moulding compositions from Examples 8 to 12 Filling a.sub.k H.sub.c Vicat B pressureExample (kJ/m.sup.2) (N/mm.sup.2) (° C.) (bar)______________________________________8 36.6 103 102 1729 (comparative) 31.8 102 101 17310 (comparative) 25.3 103 102 17511 (comparative) 33.3 101 102 16912 (comparative) 30.5 100 100 170______________________________________
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This invention relates to graft polymers of the ABS type which are produced in emulsion, and to thermoplastic molding compositions which are based thereon and which exhibit a very considerably increased notched bar impact strength compared with known ABS molding compositions and which at the same time exhibit high hardness values or high modulus values and good thermoplastic processability.
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FIELD OF THE INVENTION
[0001] The present invention relates to barrier closure systems and is particularly concerned with obstruction detection.
BACKGROUND OF THE INVENTION
[0002] For automatic barriers such as gates or doors it is important to stop the gate motion when an obstruction is in the path of the gate. This issue has typically been addressed with mechanical contact sensors, for example as is commonly seen on elevator doors. Another approach is the use of beams, typically infrared, located next to the gate, or other non-contacting sensors, such as capacitance sensors taught in U.S. Pat. No. 5,337,039 and U.S. patent application 2003/0071727 published 17 Apr. 2003.
[0003] For opposed sliding gates, that is one gate coming from each side of an opening and moving horizontally, it is desirable to have the gates come close together in the closed position and retract fully into the housing when in the open position. For a capacitance edge sensor this poses a problem because the capacitance between the housing in the open position and between the two sensors in the closed position can be much larger than the change caused by the presence of an obstruction, for example a hand.
[0004] Previous attempts to address this issue have simply reduced the sensitivity and in some cases turned the safety device off when the gate was approaching the limits of its travel.
SUMMARY OF THE INVENTION
[0005] An object of the present invention is to provide an improved gate closure system.
[0006] In accordance with an aspect of the present invention there is provided an obstacle detection system for a barrier closure system comprising a sensor for measuring a predetermined parameter as it varies during a closure of a barrier, a memory for storing the measured parameter to establish a first parameter profile and a threshold value associated therewith and a detection module for comparing a current value of the predetermined value to a corresponding barrier position of the first parameter profile and if the current value differs by more than a threshold value, setting an obstacle detection state.
[0007] In accordance with another aspect of the present invention there is provided a method of obstacle detection for a barrier closure system comprising the steps of:
1) sensing and storing a predetermined parameter as it varies during a closure of a barrier to establish a first parameter profile, 2) on subsequent closures, sensing the predetermined parameter and comparing a current value of the predetermined value to a corresponding barrier position of the first parameter profile, and 3) if the current value differs by more than a threshold value, setting an obstacle detection state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention will be further understood from the following detailed description with reference to the drawings in which:
[0012] FIG. 1 illustrates a pair of turnstiles with sliding doors and including a sensor for detecting obstructions in accordance with an embodiment of the present invention;
[0013] FIG. 2 illustrates a pair of turnstiles with angel wing doors or gates and including a sensor for detecting obstructions in accordance with an embodiment of the present invention;
[0014] FIG. 3 illustrates in a perspective view detail of one turnstile of FIG. 1 ;
[0015] FIG. 4 graphically illustrates a capacitance profile for the sensor of FIG. 1 ;
[0016] FIG. 5 illustrates in a block diagram the gate closure system for the turnstile of FIG. 1 ;
[0017] FIG. 6 illustrates in a block diagram the signal and data flow for the system of FIG. 5 ;
[0018] FIG. 7 illustrates, in a flow chart, sensor and obstruction detection control logic for the system of FIG. 5 ;
[0019] FIG. 8 illustrates, in a flow chart, the step of acquiring a base profile of FIG. 7 ;
[0020] FIG. 9 illustrates, in a flow chart, the step of obstacle detection of FIG. 7 ; and
[0021] FIG. 10 illustrates, in a flow chart, the step of process detection algorithm of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Referring to FIG. 1 , there is illustrated a pair of turnstiles with sliding doors including a sensor for detecting obstructions in accordance with an embodiment of the present invention. Each turnstile 10 includes a sliding gate 12 having an edge-mounted sensor 14 .
[0023] Referring to FIG. 2 , there is illustrated a pair of turnstiles with angel wing doors or gates including a sensor for detecting obstructions in accordance with an embodiment of the present invention. Each turnstile 20 includes a pivoting gate 22 having an edge-mounted sensor 24 .
[0024] Referring to FIG. 3 , there is illustrated in a perspective view detail of one turnstile of FIG. 1 . The internal gate closure mechanism is shown with outer housing removed. A detailed section thereof 26 shows a portion of the sliding gate 12 with its edge-mounted sensor 14 connected via a coaxial cable 28 and a coax connector 30 to a sensor circuit card 32 .
[0025] Referring to FIG. 4 , there is graphically illustrated a capacitance profile for the sensor of FIG. 1 . A base profile 40 is established by measuring capacitance during a plurality of door operations with out foreign objects present (no obstacles). Then during each subsequent operation, the capacitance profile is compared to the base profile 40 . When an obstacle is present, a shift in the capacitance profile occurs as shown in curve 42 . This shift is used by the obstacle detection system as described herein below.
[0026] Referring to FIG. 5 , there is illustrated in a block diagram the gate closure system for the turnstile of FIG. 1 . The gate closure system 50 includes a motor control module 52 , motor and drive electronics 54 and sensor electronics 56 . Sensor electronics 56 uses a Motorola MC 33794 as the capacitance sensing electronics. This chip energizes the sensor 14 with a very stable 120 kHz signal and measures the drop across a resistor to determine the loading due to the sensor (and hence its capacitance). The sensor 14 , in the case of a non-metallic gate, can be almost any metallic strip. For example, an adhesive backed aluminum foil and a stainless steel strip about 1.5 cm wide in a plastic tube have both provided very good performance. It is important to insure the sensor remains firmly fixed to the gate to avoid unexpected changes in capacitance, i.e. changes not associated with the movement of the gate. The sensor electronics 56 are connected to the sensor 14 with a short length of coaxial cable 28 . At the electronics end 56 the cable shield is connected to the shield terminal of the MC 33974 and the center conductor to the E1 terminal (or E2 to E9 if they are selected). At the sensor end 14 the center conductor is connected to the metallic strip and the shield is left unconnected. This configuration ensures that the coax cable 28 is not sensitive. It is important to keep the coax cable 28 relatively short to avoid excess capacitive loading that would reduce system sensitivity. Lengths up to 1 meter have been found to be quite practical.
[0027] As an alternative, a QT300 chip from Quantum Research Group could be used for the sensor electronics. This chip operates around 250 kHz and has a digital output as opposed to the analog output of the MC 33974. Either chip works quite well for this application. In fact almost any circuit that responds to capacitance changes can be used. For example, a relaxation oscillator could be used.
[0028] Referring to FIG. 6 , there is illustrated in a block diagram the signal and data flow for the system of FIG. 5 . FIG. 6 shows the motor control module 52 in further detail. The motor control module 52 includes a microprocessor 60 , having barrier 62 and sensor and obstruction detection 64 control logic, servo motor control logic 66 and analog input and filtering 68 .
[0029] In an embodiment of the present invention, the problem of varying capacitance illustrated in FIG. 4 is addressed by recording the capacitance as a function of position as the gate travels from the open to the closed position during a calibration run and then using this stored data to compare to the measured capacitance during operation. Any deviation from the stored pattern indicates an object in proximity to the sensor. This causes a signal to be sent to the motor control module to stop the gate moving or to reverse direction as desired.
[0030] Once the gate is stopped due to a foreign object, the capacitance can continue to be monitored. If the object is removed, then gate motion can be resumed. If the object comes closer, the gate can be backed off to maintain a separation between the object and the gate.
[0031] Environmental changes that occur slowly (for example, wear in the mechanism or a buildup of dirt) can be compensated for with an adaptive algorithm that records the capacitance versus position profile for each gate operation and adjusts the stored profile by a small fraction of the currently measured profile. If an obstruction is detected or a high dynamic response is seen on the capacitance readings during a move, the adaptive algorithm can be disabled, thereby ensuring that only the true gradual environmental changes are worked into the stored profile.
[0032] A second variation of this technique records the capacitance as a function of time. For this implementation the system does not need a continuous reading of gate position but instead assumes that the gate moves with the same position vs. time profile each time it operates. The only information needed is the time the gate starts moving and the time it stops moving. This makes the system somewhat less sensitive because of variations of how the gate moves with time due to different loadings, machine wear etc., but these changes could be compensated for by an adaptive algorithm that learns the capacitance vs. time profile as the gate operates. The advantage of this second approach is that the sensor is less intimately connected to the gate mechanism and thus becomes easier to retrofit to existing systems.
[0033] Referring to FIG. 7 , there is illustrated, in a flow chart, operation of the sensor and obstruction detection control logic for the system of FIG. 5 . The sensor and obstruction control logic begins operation with power up 70 , program initialization 71 and acquire base profile 72 steps. A decision block 73 determines if the barrier (gate or door) is starting to close, if No the process loops back and continues to query until a Yes occurs causing counters to initialize 74 , followed by obstacle detection 75 and a decision block 76 querying if movement of the barrier has ended. A Yes loops the process back to before decision block 73 while a No loops the process back prior to the obstacle detection 75 .
[0034] Referring to FIG. 8 , there is illustrated, in a flow chart, the step of acquiring a base profile of FIG. 7 . The acquire profile step 72 of FIG. 7 begins at a block 80 . Sensor readings are stored as the barrier is closed as represented by a capture readings on barrier close block 81 . A process and generate base profile block 82 creates an initial capacitance profile 40 . This profile is error checked 83 and if passed is followed by initializing thresholds 84 associated with the base profile 40 . If an error check fails an error handler block 85 is called. A return block 86 completes the acquire profile step 72 .
[0035] Referring to FIG. 9 , there is illustrated, in a flow chart, the step of obstacle detection of FIG. 7 . The obstacle detection step 75 of FIG. 7 begins at a block 90 . Current sensor readings and current position readings are obtained as represented by a block 91 . A process detection algorithm block 92 compares the current readings to the capacitance profile 40 . A decision block 93 determines if a trigger threshold is exceeded. If Yes, an announce obstruction detection block 94 is called. A return block 95 completes the obstacle detection step 75 .
[0036] Referring to FIG. 10 , there is illustrated, in a flow chart, the step of process detection algorithm of FIG. 9 . The process detection algorithm step 92 of FIG. 9 begins at a block 100 . Current sensor readings and current position readings are compared the current readings to the capacitance profile 40 as represented by a block 101 . A decision block 102 queries whether a trigger threshold is exceeded. A Yes leads to an increase triggerAccum block 103 . A No leads to a decrease triggerAccum block 104 . A return block 105 completes the process detection algorithm step 92 .
[0037] Hence, one possible algorithm detects obstacles by looking at how fast the capacitance readings are moving away from the base profile. This is achieved by building a running deviance value, low pass filtered over the move. Each reading as it is received is weighted into the running deviance and then compared to that deviance. An ‘obstruction trigger count’ is adjusted according to the difference between the readings' deviance from the base profile and the running deviance. The present scheme uses weighted increments and decrements to achieve a more accurate response to obstructions and at the same time to filter out transients.
[0000] This technique serves 2 major purposes:
[0000]
(i) Base Profile Drift: By considering only how fast the readings are moving away from the profile any uniform drift in the actual profile (i.e. resultant of environment changes) are factored out.
[0039] (ii) Increased Sensitivity and Early Detection: The capacitance readings are subject to a number of high frequency error sources. Any one reading has a potential error of +/−10 mV in the test setup employed. The technique used here is parameterized to trigger only on encountering relatively large number of successive reading differences. Early detection is still achieved as thresholds can be set near 2 mV with this approach.
[0040] Note that the algorithm and mathematics can be implemented in a number of ways as is best suited for the performance of the particular microcontroller.
[0041] Also note that this approach is and can be used in conjunction with a number of other thresholds schemes to produce an optimum response.
[0042] The present invention is not restricted to dual opposed sliding gates and can be used with many different types of moving gates such as single gates, “angel wing gates”, lift gates, horizontal barrier arm gates and car park barrier arms.
[0043] For simplicity of the description, embodiments of the present invention have been described with capacitance-based sensors. However the present invention is not restricted to capacitance-based sensors only but could apply to any non-contact sensor providing a signal that varies significantly with gate position and reacts to the presence of obstacles. Embodiments of the present invention can also include more than one type of sensor, for example IR beams may be combined with a capacitance sensor. Such a dual technology system could be used to provide redundancy for increased safety.
[0044] Numerous modifications, variations and adaptations may be made to the particular embodiments of the invention described above without departing from the scope of the invention, which is defined in the claims.
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An obstacle detection method and system for a barrier closure system comprising a sensor for measuring a predetermined parameter as it varies during a closure of a barrier. Memory stores the measured parameter to establish a first parameter profile and a threshold value associated therewith. A detection module compares a current value of the predetermined parameter to a corresponding barrier position of the first parameter profile and if the current value differs by more than a threshold value sets an obstacle detection state. Conveniently the profile is recalibrated to compensate for changes in the barrier closure system such as wear, and environmental conditions that may vary over time. Preferably the sensor includes a capacitance component.
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BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates generally to an orthopedic support. More particularly, the invention relates to abduction pillows. Specifically, the invention relates to abduction pillows used to immobilize legs after arthroplasty or endoprosthetic hemiarthroplasty surgery to accelerate the recovery and healing process.
2. Background Information
Post-operative management of patients having undergone total hip arthroplasty or endoprosthetic hemiarthroplasty usually includes measures to prevent early dislocation of the hip. Adduction generally increases the risk of dislocation of the hip and as such, pillows are used to immobilize the legs after surgery to facilitate and accelerate the healing process. Despite variations in base material, usually some form of foam rubber and associated covering, most pillows have basically the same design and makeup. This design includes a triangular shape such that the apex fits between the thighs near the patient's groin, and the broader base fits between the ankles, thereby maintaining the desired abduction. Retention straps attached to the pillow are then used to secure it in place by encircling the legs above and below each knee.
While the known abduction pillows are presumably sufficient for the purpose for which they are intended, several problems have been associated with their use. Specifically, decubitus ulcers, or bedsores, can result from the extended recumbent position of the patient thereby causing permanent stretch injuries to soft tissue. More particularly, the design of the current abduction pillows utilizes retention straps above and below the knees as set forth hereinabove. Because the pillow itself is generally fairly rigid, it acts as a splint to maintain the knee in full extension. With the legs cinched against the pillow, a situation can arise in which the buttocks proximally and the heel distally are the only firm points of contact between the leg and the bed. The heel then supports a large portion of the weight of the leg, distributing it over a very small surface area.
This condition is aggravated by the fact that in the immediate post-operative state, the patient is usually heavily sedated, and often is given high doses of narcotic analgesics. As a result, the normal protective sensations, the body telling you when damage will occur, can be markedly impaired by theses medications. The situation is even more dramatic for a patient in whom spinal anaesthesia has been used, as that they may have no protective sensation in the lower extremities of their body for hours. To overcome the above problems the patient is turned many times through the day to assure that no particular point of the patient's body is subject to localized pressures for an extended period of time. However, the constant turning requires a significant number of pillows and supports to assure that the patient, when turned, remains turned.
A second problem generally associated with the prior art abduction pillows relates to the use of straps to cinch the leg against the pillow. In operation, the straps must be sufficiently tight to assure that the leg will not move with respect to the abduction pillow positioned between the patient's leg. However, if the straps are set too tight, neurovascular complications can result within the leg. Such complications can be avoided by designing an abduction pillow wherein the use of straps to cinch the leg against the abduction pillow is unnecessary.
Moreover, current abduction pillows are bulky and difficult to store. Also, a few days after a total hip arthroplasty surgery, the patient is removed from the bed several times a day in an attempt to get the patient onto his feet and moving about once again. The current abduction pillow makes this difficult, as the pillow must be completely removed from the patient, taken from in between the patient's legs, and stored while the patient attempts to walk.
Lastly, current abduction pillows inevitably result in difficulties with elimination and perennial care. These arise from the fact that conventional abduction pillows fit quite high between the thighs, such that in order to use a bedpan or a urinal, it is necessary to remove the retention straps and either completely remove the pillow or to slide it distally a significant distance. The same holds true for the performance of routine perennial care.
SUMMARY OF THE INVENTION
Objectives of the invention include providing an improved orthopedic device for supporting and positioning the lower extremities of a patient that has had hip arthroplasty.
Another objective is to provide an orthopedic device which will support and position the patients legs in two separate positions to aid in the healing process, and prevent decubiti from forming on the patient's bony prominences.
Yet another objective is to provide an orthopedic device which will support and elevate the patients heel to prevent decubitus ulcers from forming on the patients heels due to the patient rubbing his or her heel on the mattress causing friction.
Another objective is to provide an orthopedic device which allows the care giver to provide the necessary elimination and perennial care to the patient without completely removing the abduction pillow.
A further objective is to provide an abduction pillow which will be easily removed when the patient is out of bed, and requires little or no storage when not in use.
A still further objective is to provide an air inflatable abduction pillow which provides the necessary rigidity to support the patient's legs, while simultaneously providing the necessary forgiveness to assure that decubitus ulcers do not form on any portion of the patients legs.
Yet a further objective of the present invention is to provide an air inflatable abduction pillow which provides two support positions allowing the patient to be turned, with each position keeping the patient's legs in the correct abduction position, without employing cinching straps about the patient's legs.
A still further objective is to provide such an orthopedic support which is of a simple construction, which achieves the stated objectives in a simple, effective, and inexpensive manner, and which solves problems and satisfies needs existing in the art.
These and other objectives and advantages of the invention are obtained by the abduction pillow of the present invention used for supporting the lower extremities of an orthopedic patient, the general nature of which may be stated as including a wedge-shaped body tapered outwardly in a divergent manner from a first end adapted to be located adjacent a groin area of the patient, toward a wider second end, and an upper surface inclined downwardly from the second end toward the first end; and a longitudinally extending recess formed in the upper inclined surface having a depth sufficient to support one of the patient's legs therein with the vertical distance between a plane in which the other of the patient's leg lies and a bottom of said longitudinal recess being generally equal to the width of said wedge-shaped body along any transverse plane taken through said body.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the invention illustrative of the best mode in which applicant has contemplated applying the principles, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.
FIG. 1 is a perspective view of the improved abduction pillow supported on a mattress;
FIG. 2 is an end elevational view with portions broken away and in section, of the abduction pillow and mattress shown in FIG. 1;
FIG. 3 is a perspective view of a patient laying on the mattress and using the abduction pillow as shown in FIG. 1; and
FIG. 4 is a perspective view similar to FIG. 3 showing the patient after having been turned on his/her side.
Similar numerals refer to similar parts throughout the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference initially to FIG. 1, it will be seen that an abduction pillow 10 in accordance with the present invention, includes a generally wedge-shaped body portion indicated generally at 12, having a pair of divergent sides 14 and 16. Sides 14 and 16 terminate at a first or anterior end 18 and an opposing wider distal end 20. In the preferred embodiment, anterior end 18 is within the range of from 4 inches to 8 inches, with 6 inches being the preferred width such that it may be placed easily between the upper thighs of a patient 17 as shown particularly in FIG. 3. Distal end 20 is significantly wider than anterior end 18 and in the preferred embodiment, is within the range of from 12 inches to 16 inches with 14 inches being the preferred width. As such, sides 14 and 16 are divergent from anterior end 18 to distal end 20. Body 12 has a bottom surface 19 and an upper surface 22, which are hermetically sealed to the edges of sides 14 and 16 as well as ends 18 and 20, and are substantially planar in configuration.
In accordance with one of the main features of the invention, top surface 22 is formed with an arcuate recess 24 having a curved bottom surface 25 which extends along the longitudinal axis of surface 22 and provides a pair of spaced flat support surfaces 26 and 28 extending longitudinally on either side of the recess. There exists an imaginary horizontal plane depicted at A (FIG. 1), which bisects body 12 with the end of the plane near distal end 20 including the top surfaces of two protruding heel supports 32 and 34. Plane "A" intersects anterior end 18 at bottom surface 19. In essence, imaginary plane "A" lies at the approximate angle of elevation of the patient's legs.
In accordance with the present invention, the distance for imaginary plane "A" to surface 25 of arcuate recess 24 is equal to the width of body portion 12 in any given vertical plane taken transverse to the longitudinal axis of pillow 10. This relation will provide separate equal positions of abduction, and as such provide two positions for a patient to be placed without sacrificing the consistency of the relative position of the patient's legs. Moreover, this relationship will aid in supporting the patient's entire leg. Upper surface 22 is inclined upwardly from anterior end 18 toward distal end 20 to create the similarity between the distance from surface 25 to plane "A" and the width of the body portion 12 in any given vertical plane taken transverse to the longitudinal axis of the pillow lo. Similarly, the incline is necessary to assure that the patient's entire leg is supported.
By way of example, at distal end 20, the distance from surface 25 of arcuate recess 24 to plane "A" is equal to the width of distal end 20, which in the preferred embodiment is approximately 14 inches. Similarly, at anterior end 18, the distance between surface 25 and plane "A" is equal to the width of anterior end 18, which in the preferred embodiment is approximately 6 inches. Thus, the incline of upper surface 22 rises from 6 inches at anterior end 18 to 14 inches at distal end 20. It should be apparent to one skilled in the art that these heights and widths may be altered without departing from the spirit of the invention so long as the height of surface 25 with respect to the imaginary plane "A" remains similar to the width of body 12 in all vertical planes transverse to the longitudinal axis of pillow 10.
The height of support surfaces 26 and 28 above bottom surface 25 of recess 24 can be altered without departing from the spirit of the present invention. However, such height is preferably 2 inches. The height of such support surfaces 26 and 28 may be lessened as long as they will adequately support the lateral weight of the patient's leg. Moreover, the height could be increased so long as the abduction of the leg is not compromised by raising the leg over surfaces 26 and 28 to place the leg in arcuate recess 24.
Abduction pillow 10 may be created as a single hollow air inflatable unit formed of an air impervious material and inflated through a usual inflation valve 30 or inlet/outlet fluid port located in a convenient location on body 10. It also may be created from a plurality of independent air inflatable units, each having a separate inflation valve. In the preferred embodiment, body 12 is created from a plurality of interconnected tubes 42 as shown in FIG. 2, thereby providing the necessary rigidity to support the orthopedic patient's legs while simultaneously providing the necessary forgiveness to provide a more uniform weight distribution of the weight over the pillow's surface. Preferably the hollow interiors of the tube communicate with each other through passages 43 so that the tubes inflate and deflate simultaneously. If desired, pillow 10 may be liquid filled or formed of a resilient foam material, although an air inflatable unit is believed to best achieve the objective of the invention.
Extending from the lower portions of divergent sides 14 and 16 near the distal end 20, are a pair of heel supports 32 and 34, respectively. Heel supports 32 and 34 extend outwardly in a direction transverse to the longitudinal axis of body 12 and are of a sufficient height to elevate the patient's heel off of a support mattress 36 as shown particularly in FIG. 3. Heel supports 32 and 34 preferably have hollow interiors which communicate with the hollow interior of body 12 so that it will inflate and deflate with body 12.
A pair of foot supports 40 preferably are formed integrally with body 12 and extend outwardly from distal end 20 closely adjacent arcuate recess 24 for selectively supporting the feet of patient 17, when the patient is lying in an orthopedic position as shown in FIG. 4.
When in use, pillow 10 will be supported on mattress 36 adjacent an end thereof. Mattress 36 may be of any conventional construction to which the abduction pillow may be attached by straps, Velcro strips 37, or any convenient attachment means. Mattress 36 may be a conventional foam-filled, spring-filled, or air-filled mattress. However, mattress 36 may also be integrally connected to abduction pillow 10 such that the mattress 36 and pillow 10 are a single unit. In such a situation, mattress 36 would be hermetically sealed apart from abduction pillow 10, such that the pillow could be inflated and deflated without affecting the inflation of mattress 36.
Having now described the orthopedic support of the present invention in detail, the use of the support for immobilizing the legs of orthopedic patients is set forth below. Referring then to FIG. 3, there is shown a patient 17 recumbent on mattress 36 in the first position of abduction with pillow 10 being employed to prevent damage to the hip after having total hip arthroplasty and endoprosthetic hemiarthroplasty. In an effort to prevent early dislocation, the patient is recumbent on mattress 36 with body 12 of pillow 10 interposed between the patient's legs such that legs 44 and 46 are positioned proximal to sides 14 and 16, respectively. The patient's ankles are then supported by heel supports 32 and 34 to elevate the patient's heels off of mattress 36 thereby preventing decubitus ulcers from forming on the heels of the patients. In this position, the patient's legs remain a consistent distance apart as dictated by the width of abduction pillow 10.
Just as decubitus ulcers can form on a patient's heels when recumbent for an extended period of time, such ulcers can form at many other bony prominences on the patient's body which carry the majority of the patient's weight and distribute it upon a comparatively small cross-sectional area. While the use of mattress 36 aids in weight distribution in that the mattress forms more closely to the patient's body, the patient still must be frequently turned to prevent such ulcers from forming. As such, a second position for abduction is necessary, and is shown in FIG. 4. Specifically, the patient is turned forty-five degrees with his leg being lifted over either surface 26 or 28 depending upon the direction the patient is turned, and placed into arcuate recess 24. Inasmuch as the distance between the bottom surface 25 of arcuate recess 24 and plane A of body 12 is equal to the width of the abduction pillow in any plane transverse to the longitudinal axis of the pillow 10, the distance between the legs 44 and 46, and consequently the percent of abduction, remains constant. In this manner, the present invention provides two independent positions of abduction with each position presenting the exact same abduction as the other which allows the patient to be turned without upsetting the abduction of the legs 44 and 46.
As is evident in FIG. 4, the patient in the second position of abduction is lying at an angle of approximately forty-five degrees. As such, the patient's back and neck must be supported in the same plane as that of the elevated leg to assure that the hip does not rotate. In the prior art, the patient is supported with a series of pillows that must be repeatedly checked and secured by the care givers. In order to prevent the need for care givers to constantly check the back and neck support of the orthopedic patient, the present invention also provides a wedge-shaped pillow 38, to be fitted under the patient's back to support the patient in the inclined position. Pillow 38 may be integrally formed with air mattress 36 such that when separately inflated through a inflation valve 50, it will actually move the patient as it is inflated. Thus, such a mattress would be provided with a pair of inflatable pillows 38 to be selectively used, depending upon whether the right or the left leg is to be moved. As shown in FIG. 4, a left wedge-shaped pillow 38 is in the inflated position supporting the user. Alternatively, pillow 38 may be a separate unit unattached to mattress 36 such that the pillow 38 can be moved from side to side as is necessary. It should also be apparent that the wedge-shaped pillow could be formed of any standard material such as foam, padding etc. without departing from the spirit of the present invention.
As described above, the patient's back and neck must be supported when in the second orthopedic support position of FIG. 4. In this position, the patient's foot extending from arcuate recess 24 must also be supported. The adjacent foot support 40 thus prevents the weight of the foot from causing the foot to hang downward.
It is thus seen that an abduction pillow has been provided which permits the patient to be turned in the bed or positioned on his side while the limbs are supported and fixed against rotation. The continuous support is provided for the full length of the leg and the support may be readily personalized by increasing or decreasing the air inflation to suit individual patients. The leg is supported at all times in a manner to prevent foot drop and to prevent cutting off of circulation as might result in the formation of decubitus ulcers. The attention time of nurses and other hospital personnel to the patient is reduced since the patient may be left unattended for greater periods of time due to the secure support provided by pillow 10.
Accordingly, the orthopedic support of the present invention is simplified, provides an effective, safe, inexpensive, and efficient device which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.
In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.
Having now described the features, discoveries and principles of the invention, the manner in which the improved orthopedic support is constructed and used, the characteristics of the construction, and the advantageous, new and useful results obtained, the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.
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An abduction pillow used to immobilize a patient's legs after hip surgery has a wedge-shaped body constructed of a resilient deformable material which positions the legs in a forgiving, fixed divergent position. The body is wedge-shaped and preferably air filled, and has a pair of opposing sides which taper outwardly in a divergent manner from a narrow anterior end adapted to be located adjacent the groin area of a patient, toward a wider distal end. The body has an upper surface which inclines downwardly from the distal end toward the anterior end. A longitudinal arcuate recess is formed in the upper inclined surface and has a depth sufficient to support one of the patient's legs. The vertical distance between a plane in which the other of the patient's legs lies and the bottom of the longitudinal arcuate recess, is equal to the width of the wedge-shaped body at any transverse plane taken through the pillow. This dimensional relationship insures that the patient's legs and hips remain immobilized and at a constant spaced relationship even after the patient is turned onto either side.
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RELATED APPLICATIONS
This application is a continuation-in-part of Ser. No. 08/927,116 filed Aug. 29, 1997 which is a continuation-in-part of Ser. No. 08/555,524 filed Nov. 9, 1995, now U.S. Pat. No. 5,663,286.
FIELD OF THE INVENTION
This invention relates to a fiber comprising a water soluble polyamide and articles constructed therefrom. The invention further relates to a method of using certain water soluble polyamides for producing a fiber and water soluble or water dispersible webs. The water soluble polyamide may be used alone or in combination with conventional thermoplastic fiber forming materials such as water insoluble polyethylene, polypropylene, polyester and polyamide. The water soluble polyamide may also be combined with biodegradable or selectively dispersible material to form fibers having various combinations of properties. Such water soluble fibers and webs have utility in the manufacture of disposable absorbent articles such as disposable diapers, feminine napkins, incontinent products and cellulosic articles such as tissues and towels, as well as for water soluble heat fusible webs for the textile industry.
BACKGROUND OF THE INVENTION
Melt blown and spunbond webs typically comprise insoluble and nondegradable polymer fibers such as water insoluble polyethylene, polypropylene, polyester and polyamide. Such webs are used in the manufacture of a variety of disposable products such as disposable diapers, feminine napkins, surgical gowns, laundry bags, bed pads, and the like. Such articles are designed to absorb and contain bodily fluids and/or provide a physical barrier to such fluids. Water soluble and biodegradable nonwoven webs may provide some solutions to environmental concerns regarding the disposal of such items.
Heat fusible webs are used for a variety of uses. In the textile industry, heat fusible webs are used to hold pieces of fabric, such as a patch pocket, in place prior to being sewn. These heat fusible webs are also used to create hems on pants or for a variety of ornamental craft appliques. Webs currently available for such uses are typically low viscosity at application temperature and insoluble in water. Upon activation with heat these materials often soak into the fabric workpiece causing the fabric to become stiff. Often the melted web soaks in to the extent that it fails to form the intended bond and reapplication is necessary.
A water soluble nonwoven comprising polyvinyl alcohol (PVOH) is taught in Dever et al., JP 59041260. Modifying the rate of water solubility of a PVOH based melt blown material using two different chemical treatments is described in the Development and Evaluation of Water Soluble Melt Blown Nonwovens, Dever, Benson, and Pair, INDA JNR, Vol. 5, No. 2, published 1993.
PVOH as a base polymer for the formation of a water soluble web suffers from several disadvantages. Due to its high melt point and poor thermal stability, it is very difficult to thermally process. An extruder, rather than merely a melt tank, is required to process the PVOH into a web. Additionally, once the web is formed, it has poor heat seal properties such that it would need to be heat sealed at temperatures that adversely affect the integrity of the substrate.
Water soluble polyamides prepared from an aliphatic dicarboxylic acid, a modifying acid, and an aliphatic diamine are reported by Fagerberg et al., U.S. Pat. No. 3,882,090. The polyamides are useful as textile sizing agents, coatings, and adhesives. Column 4, lines 28-33 states, "The various methods of preparing polyamides are well known in the art as well as a number of polymers which contain ether linkages in the polymer chain. These however, are basically fiber forming polyamides and therefore not contemplated by the present invention."
Speranza et al., U.S. Pat. Nos. 5,053,484; 5,086,162; 5,324,812 and 5,118,785 are directed to certain polyamides having good water absorbency for use as fibers. Collectively, the polyamides taught therein either exhibit a high melt point, much like the PVOH, requiring an extruder for processing into a nonwoven web, or in the case of those polyamides having lower melt points, are disadvantageous in that the polyamides, once formed into a fiber or nonwoven web, tend to block. At column 1, lines 21-16 the 5,324,812 patent discusses that several nylon manufacturers incorporate polyoxyalkyleneamines into their products to modify the final properties. The polyether backbone of these components improves the comfort feel, wickability and dyeability of textile grades. However, no such compositions have been used to form a water soluble nonwoven web.
The Applicants have found that certain water soluble polyamides exhibit improved melting characteristics for manufacturing fibers as well as spunbond and melt blown nonwoven webs. Further, the resulting fibers and webs are water soluble, humidity resistant and nonblocking, meaning the web can be rolled upon itself and subsequently unwound without adjacent layers adhering to each other.
SUMMARY OF THE INVENTION
The present invention discloses a water soluble fiber and water soluble nonwoven web comprising a polyamide and articles constructed therefrom. The invention further relates to a method of using certain polyamides to form fibers and water soluble or water dispersible nonwoven webs. The polyamide is water soluble and selected from the group consisting of:
a) the reaction product of at least one dicarboxylic acid or an ester thereof with a polyalkylene glycol diamine having the formula:
NH.sub.2 --(CH.sub.2).sub.3 --(OCH.sub.2 --CH.sub.2).sub.2 --O--(CH.sub.2).sub.3 --NH.sub.2 ;
b) the reaction product of at least one polyalkylene glycol diamine with at least one dicarboxylic acid or an ester thereof, and at least one monocarboxylic acid and/or monoamine, said polyalkylene glycol diamine having the formula:
NH.sub.2 --(CH.sub.2).sub.x --(OCH.sub.2 --CH.sub.2).sub.y --O--(CH.sub.2).sub.x --NH.sub.2
wherein X ranges from 2 to 3 and Y ranges from 1 to 2;
c) up to about 99 wt-% of the reaction product of at least one polyalkylene glycol diamine with at least one dicarboxylic acid or an ester thereof, said polyalkylene glycol diamine having the formula:
NH.sub.2 --(CH.sub.2).sub.x --(OCH.sub.2 --CH.sub.2).sub.y --O--(CH.sub.2).sub.x --NH.sub.2
wherein X ranges from 2 to 3 and Y ranges from 1 to 2; and about 1 to about 50 wt-% of at least one ingredient selected from the group consisting of waxes, tackifiers, crystalline polymers, monocarboxylic acids, monoamines and mixtures thereof.
The water soluble polyamide may be a single polyamide produced from each of the distinct categories described above or a mixture of such polyamides. The resulting fiber and web produced from such polyamides is nonblocking and humidity resistant.
The water soluble polyamide may be used alone or in combination with conventional thermoplastic fiber forming materials such as water insoluble polyethylene, polypropylene, polyester and polyamide. The water soluble polyamide may also be combined with biodegradable or selectively dispersible material to form fibers and nonwoven webs having various combinations of properties. The nonwoven web or fibers may be formed from spunbond and melt blown techniques as well as be sprayed molten or sprayed as an aqueous dispersion of the water soluble polyamide.
Furthermore, the polyamide may be sprayed or dispersed in water to be used as a binder bonding fiber in air laid or wet laid processes. This aspect is particularly useful for improving the strength of cellulosic absorbent products such as tissues and towels.
The resulting fibers and nonwoven webs can be used to form laminates such as those found in disposable articles to incorporate hydrophilic and water soluble features into the product. Such water sensitivity may facilitate recycling and composting efforts related to solid waste management as well as improve fluid transfer and acquisition. Additionally, nonwoven webs comprising a water soluble polyamide are useful for making water soluble heat fusible webs. A 4,7,10 trioxatridecane-1,13-diamine is preferred due to its low melt temperature. Since the resulting web will dissolve during washing, such a web will overcome the problems of insoluble heat fusible webs used for temporary bonding in the textile industry.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a fiber comprising a water soluble polyamide. The resulting fiber is water soluble or water dispersible. Such polyamides are the reaction product of at least one polyalkylene glycol diamine with at least one dicarboxylic acid or esters thereof.
The polyalkylene glycol diamine has the formula:
NH.sub.2 --(CH.sub.2).sub.x --(OCH.sub.2 --CH.sub.2).sub.y --O--(CH.sub.2).sub.x --NH.sub.2
wherein X ranges from 2 to 3 and Y ranges from 1 to 2.
Representative examples include triethylene glycol diamine, wherein X=2 and Y=1, and tetraethylene glycol diamine, wherein X=2 and Y=2. Commercial diamines include Jeffamine® 148 amine and Jeffamine® 192 amine available from Huntsmen Chemical Co., Houston, Tex. A preferred diamine is 4,7,10-trioxatridecane-1,13-diamine (TTD diamine) available from BASF, Parsippany, N.J., wherein X=3 and Y=2. Other amines such as Jeffamine® D-230, D-400, ED-600, ED-900, and ED-2000 are also useful provided a chain terminator acid is employed during the reaction and/or additional ingredients such as waxes, tackifiers, crystalline polymers, and monoacids are subsequently combined with the reacted polyamide. For example, when adipic acid is reacted with TTD diamine and Jeffamine® D-230, the resulting polyamide is relatively slow setting with respect to reacting adipic acid with TTD diamine alone.
The polyalkylene glycol diamine is reacted with an equal stochiometric ratio of a dicarboxylic acid. Suitable dicarboxylic acids are those having from 5 to 36 carbon atoms including adipic acid, pimelic acid, azelaic acid, sebacic acid, suberic acid, dodecanedioic acid, terephthalic acid, isophthalic acid, t-butyl isophthalic acid, dimer acid and mixtures thereof. The esters and anhydrides of these acids may also be used. Adipic acid is preferred.
The resulting water soluble polyether amide preferably has a melt point of about 190° C. or less as in the case when adipic acid is reacted with Jeffamine® 148. In case of melt spinning fiber processes, higher melt point water soluble polyether amide may also be employed. More preferably, the melt point is about 155° C. or less as in the case when adipic acid is reacted with Jeffamine® 192. The most preferred water soluble polyether amide has a melt point about 150° C. or less as in the case when adipic acid is reacted with TTD diamine. This particular combination results in a faster setting, strong, easily processed water soluble polyether amide. The low melt temperature makes this combination particularly preferred for heat fusible webs. Often heat fusing such webs at temperatures above 150° C. adversely affects the integrity of the substrates to be bonded. The resulting fibers and web formed from such, are insoluble in dry cleaning solvent rendering the article (fabric) dry cleanable when necessary.
The Applicants have found that certain polyamides may be used alone, uncompounded with additional ingredients, to form a water soluble fibers and webs that are nonblocking and humidity resistant. Polyamides exhibiting such properties are those which are produced by reacting polyalkylene glycol diamine with at least one dicarboxylic acid or an ester thereof, the polyalkylene glycol diamine having the formula:
NH.sub.2 --(CH.sub.2).sub.3 --(OCH.sub.2 --CH.sub.2).sub.2 --O--(CH.sub.2).sub.3 --NH.sub.2.
In this embodiment, adipic acid is the preferred dicarboxylic acid. However, other acids may also be employed provided the mole percent of the additional acids is about 10 mole percent or less with respect to the total acid content. When an additional acid is employed at a concentration greater than about 10 mole percent, particularly at about 25 mole percent or greater with respect to the total acid content, the resulting polyamide exhibits a longer set time prior to becoming completely non-blocking. Accordingly, it is often desirable to add an additional ingredient to increase the rate of set as described in further embodiments as follows.
Additionally, other polyamides are also useful for forming nonblocking, humidity resistant webs and fibers provided a chain terminator is employed during the reaction and/or the polyamide is further combined with at least one additional ingredient including waxes, solid tackifiers, monocarboxylic acids, and crystalline polymers. In these embodiments, the polyamide is produced by reacting at least one polyalkylene glycol diamine with dicarboxylic acid or an ester thereof, said polyalkylene glycol diamine having the formula:
NH.sub.2 --(CH.sub.2).sub.x --(OCH.sub.2 --CH.sub.2).sub.y --O--(CH.sub.2).sub.x --NH.sub.2
wherein X ranges from 2 to 3 and Y ranges from 1 to 2.
Chain terminators include monoacids and/or monoamines and are useful in an amount less than about 5 wt-%, preferably 0.5-2.5 wt-% based on total acid weight to control the molecular weight. Representative examples of useful monocarboxylic acids include stearic acid, benzoic acid and montannic acid such as Wax S available from Hoechst Celanese. In the absence of a chain terminator, the resulting polyamide, particularly those taught by Speranza in U.S Pat. Nos. 5,053,484, 5,086,162, 5,324,812, and 5,118,785 are deficient in at least one property including exhibiting a high melt point, slow rate of set, poor humidity resistance, and/or poor blocking resistance.
In addition or in the alternative, the polyamide produced may be combined with at least one ingredient selected from the group consisting of waxes, tackifiers, crystalline polymers, monocarboxylic acids and mixtures thereof. The monocarboxylic acids and monoamines have been found to be useful not only as a reactant as previously described but also as an ingredient to be added after the polyarnide is formed.
The additional ingredient necessary to the invention for this embodiment is present in an amount from about 1 wt-% to about 50 wt-%, preferably from about 1 wt-% to about 30 wt-%, and most preferably from about 1 wt-% to about 10 wt-%. Surprisingly as little as 1 wt-% of an additional ingredient, particularly a wax, exhibits a dramatic affect on the blocking resistance of the polyamide. However, if the additional ingredient selected is also water soluble, such ingredient may be present in amounts greater than 50 wt-%.
Waxes useful herein are preferably polar in nature and include representative examples including 12-hydoxysteramide, N-(2-hydroxy ethyl 12-hydroxy steramide (Paracin 220 from CasChem), sterarnide (Kemamide S from Witco), glycerin monosterate, sorbitan monosterate, and 12-hydroxy stearic acid. Also useful in combination with the above are less polar waxes such as N,N'-ethylene-bis steramide (Kemamide W-40 from Witco), hydrogenated castor oil (castor wax), oxidized synthetic waxes, and functionalized waxes such as oxidized polyethylene waxes (Petrolite E-1040).
Suitable crystalline thermoplastic polymers include ethylene-vinyl acetate copolymers containing about 12 to 50% vinyl acetate, ethylene acrylic acid, ethylene methyl acrylate and ethylene n-butyl acrylate copolymers as well as polylactide, caprolactone polymers, and poly (hydroxy-butyrate/hydroxyvalerate), polyvinyl alcohol, linear saturated polyesters such as Dynapol or Dynacoll polymers from Huls, poly (ethylene oxide)polyether amide and polyester ether block copolymers available from Atochem (PeBax) or Hoechst Celanese (Rite-flex) respectively, and polyamide polymers such as those available from Union Camp (Unirez) or Hulls (Vestamelt) or EMS-Chemie (Griltex). The polymers added may be amorphous or crystalline, but at least 5% of a crystalline polymer is required to achieve adequate properties.
Tackifying resins, particularly those having high softening points may be employed to reduce the blocking tendencies. However, in most instances it is necessary to employ a wax and/or crystalline polymer in combination with a tackifying resin to achieve the desired web and fiber properties. The tackifying resins useful herein are generally polar in nature and have a Ring & Ball softening point greater than 60° C. and include any compatible resins or mixtures thereof such as natural and modified rosins such as gum rosin, wood rosin, tall oil rosin, distilled rosin, hydrogenated rosin, dimerized rosin, and polymerized rosin; rosin esters such as glycerol and pentaerythritol esters of natural and modified rosins such as for example, the glycerol ester of pale, wood rosin, and the glycerol ester of hydrogenated rosin, the glycerol ester of polymerized rosin, and the pentaerythritol ester of hydrogenated rosin, and the phenolic-modified pentaerythritol ester of rosin; phenolic modified terpene or alpha-methyl styrene resins as well as the hydrogenated derivatives thereof such as the resin product resulting from the condensation, in an acidic medium of a bicyclic terpene and a phenol.
Representative examples of polar tackifiers include material such as Foral NC available from Hercules; non-ionin materials such as Foral AX also from Hercules, alpha methyl styrene phenolics such as Uratal 68520 from DSM Resins, rosin esters such as Unitac R100L available from Union Camp and terpene phenolic tackifiers such as Nirez 300 and Nirez V2040 available from Arizona Chemical.
It may also be desirable to incorporate up to 20 wt-% of certain hydrophilic non-crystalline polymers such as hydroxyethyl cellulose, hydroxypropyl cellulose, polyvinyl methyl ether, polyvinylpyrrolidone, polyethyloxazoline, starch or cellulose esters, particularly the acetates.
The resulting polyamide may be formed into a fiber or web by means of known melt blown or spunbond techniques. Alternatively, the polyamide may be sprayed molten or as an aqueous dispersion during other nonwoven manufacturing processes such as air laid or wet laid processes to bind fibers and impart strength.
Additionally, fibers may be formed by drawing-down the molten polyamide or by extrusion with a hot melt adhesive applicator. For commercial manufacturing of fibers, melt spinning processes as well as dry spinning and wet spinning may be employed. In the case of wet spinning, it is preferred to employ a 25-30 wt-% aqueous solution of the water soluble polyamide. For melt spinning, it is preferred that the polyamide have a viscosity of about 30,000 cPs or greater, more preferably about 50,000 cPs or greater, and more preferably about 70,000 cPs or greater. Additionally, it is preferred that that viscosity of the polyamide exhibit only a slight variation within the expected temperature fluctuation of the fiber extrusion line, contain a moisture content below about 0.3 wt %, and employ spinnerets with orifice diameters smaller than 0.8 mm. The fiber can then be formed into yarns by means of melt spinning as well as convention spinning processes such as those typically employed for non-thermoplastic fibers.
The polyamide fibers may be used alone or in combination with other polymers to create a variety of useful properties in the resulting web, fiber or yarn. In addition to the absorbent disposable industry, such fibers also find utility in embroidery and hosiery applications. By combining the water soluble polyamide with conventional insoluble polymers such as polyethylene, polypropylene, polyester or polyamide sequentially during web or fiber forming process, as the resulting web will have a water soluble matrix. Preferably, the insoluble polymer is applied to form a discontinuous web. The water soluble polyamide is then applied to the discontinuous regions such that the resulting web dissolves at the locations of the polyamide leaving small portions of the insoluble portions intact. Alternatively, the water soluble polyamide may be applied as a continuous phase with discontinuous regions of the insoluble polymer. This technique creates a low cost flushable web. By combining the water soluble polyamide with at least one insoluble polymer simultaneously, it is possible to create webs and fibers having hydrophilic character that do not disperse in water. Additionally, for fibers, it is desirable to create an insoluble fiber case having a water soluble sheath.
The polyamide may additionally be combined with biodegradable materials or selectively dispersible materials to create nonwoven webs and fibers having unique combinations of properties. As in the case of the more conventional polymers, depending on the method, sequences and ratios by which they were combined, the web or fiber may or may not be water dispersible. If the polyamide is added sequentially during the web or fiber forming process, each material tends to maintain its unblended properties, whereas simultaneously combining the polyamide in the melt phase with at least one other polymer results in webs and fibers with properties intermediate between the unblended polymers. The polymer present at the higher concentration tends to govern the overall properties of the nonwoven web.
Useful biodegradable polymers include those which are photodegradable, microbiologically and hydrolytically degradable, as well as cellulosics so long as the polymer can be incorporated into a web either alone or combined with a compatible carrier. Representative examples include polylactic acid, polyhydroxybutyrate, polyhydroxybutyrate-valerate, polycaprolactone, and mixtures thereof.
Selectively dispersible polymers include those which are dispersible in aqueous environment under prescribed conditions, yet are not dispersible in all aqueous environments. Examples include materials that are alkaline dispersible or saline insoluble. The Eastman AQ copolyesters, which are water dispersible yet saline insoluble are preferred for articles intended to absorb body fluids.
The invention is further illustrated by the following non-limiting examples:
EXAMPLES
Test Methods:
1. Melt Viscosity is determined in accordance with the following procedure using a Brookfield Laboratories DVII+Viscometer in disposable aluminum sample chambers. The spindle used is a SC-27 hot-melt spindle, suitable for measuring viscosities in the range of from 10 to 100,000 centipoise. The sample is placed in the chamber, which is in turn inserted into a Brookfield Thermosel and locked into place. The sample chamber has a notch on the bottom that fits the bottom of the Brookfield Thermosel to ensure that the chamber is not allowed to turn when the spindle is inserted and spinning. The sample is heated to the desired temperature, with additional sample being added until the melted sample is about 1 inch (2.5 cm) below the top of the sample chamber. The viscometer apparatus is lowered and the spindle submerged into the sample chamber.
Lowering is continued until brackets on the viscometer align on the Thermosel. The viscometer is turned on, and set to a shear rate which leads to a torque reading in the range of 30 to 60 percent. Readings are taken every minute for about 15 minutes, or until the values stabilize, which final reading is recorded.
2. Blocking Resistance is determined by preparing a polyamide coated sheet of 20# bleached kraft paper (standard copy paper) having a polyamide thickness ranging from about 0.6 to 1 mil using a suitable coating device or draw-down technique. The polyamide coated paper is then cut into 1" strips and conditioned at 50% relative humidity for two hours. At least three strips of the polyamide coated paper are placed on a tray and a piece of uncoated paper placed on top of the polyamide sandwiching the polyamide between two paper layers. A 500 g weight is place on top of each strip resulting in a force of 500 g/sq. inch and the tray is placed in a 140° F. oven for 24 hours. After 24 hours, the uncoated paper is removed noting the extent of polyamide sticking or picking to the uncoated paper. The extend of blocking is characterized as follows:
"excellent"--no picking, paper falls from polyamide without resistance
"good"--the uncoated paper must be removed by hand and exhibits very slight picking
"okay"--the uncoated paper must be removed by hand and exhibits significant picking, but no fiber tear
"poor"--the uncoated paper must be removed by hand and exhibits fiber tear
3. Humidity Resistance is tested in the same manner as blocking resistance with the exception that the test is conducted at 100° F. and 90% relative humidity for 24 hours.
During the preparation of the following polyamide examples as follows the reaction conditions were maintained at a temperature of about 400° F. or as low as possible to insure the resulting polyamide is light in color.
Example 1
A water soluble polyamide was produced by reacting 39.37 parts adipic acid with 58.41 parts of TTD diamine such that the resulting polyamide had a viscosity of about 10,000 cps to about 12,000 cps at 400° F. as measured by a Brookfield viscometer. Stearic acid (Emersol-132) is utilized at concentrations of about 0.72 parts and may be employed at concentration ranging from about 0.5-2 wt-% to control the viscosity of the resulting polyamide. The polyarnide was sprayed with a Bayer and Otto hotmelt spray gun to form a nonwoven web which consists of a plurality of fibers randomly fused in a continuous manner. The polyamide was premelted at 400° F. in an oven and sprayed onto release paper while maintaining an application temperature ranging from about 390° F. to 400° F. At a pressure of about 40 psi, the basis weight of the web was 72.5 g/m 2 whereas at a pressure of 60 psi the basis weight was reduced to 33.9 g/m 2 . The Applicants surmise that nonwoven web may be formed with commercial meltdown or spunbond web forming equipment at temperatures ranging from about 375° F. to 400° F. The polyamide was also used to form a nonwoven web with J & M meltblown hot melt spray applicators at a temperature of 400° F. Both webs were readily soluble in tap water such that a 1"×1" piece will solubilize in approximately 20 minutes without agitation. The polyamide was fast setting and exhibited excellent blocking resistance at 100° F./90% RH.
Example 2
A second polyamide was produced from the same reactants as Example 1 without stearic acid such that the viscosity is about 35,000 cps at 400° F. In the absence of the chain terminator monoacid, the viscosity is nearly three times that of Example 1. The polyamide was sprayed with a Bayer and Otto hotmelt spray gun at a temperature of about 400° F. The basis weight can be adjusted with the air pressure as in Example 1. The resulting nonwoven web resembled conventional spunbond nonwoven formed from water insoluble polyester or polypropylene, yet the web is readily soluble in tap water.
Example 3
The polyamide of Example 2 was combined with a compatible water insoluble polyamide produced by reacting primarily dimer acid with ethylene diamine such that the viscosity of the water insoluble polyamide was about 58,000 cps at 400° F. The polyamides were melted and combined at a ratio of 4 parts water soluble polyamide to 1 part insoluble polyamide and at a ratio of 1 part water soluble polyamide to 4 parts water insoluble polyamide. The blended polyamides were then sprayed with a Bayer and Otto spray gun at a temperature ranging from about 410° F. to 420° F. to form a web resembling conventional meltblown or spunbond nonwoven. The web formed from 4 parts water soluble polyamide readily disperses in tap water. The web formed from 1 part water soluble polyamide is not dispersible in water, yet is hydrophilic. Therefore, blends of small concentrations of water soluble polymers with insoluble polymers are useful for imparting hydrophilicity into nonwoven webs. This is particularly useful for creating hydrophilic zones in-line for disposable absorbent products.
Example 4
An Eastman AQ copolyester having an intrinsic viscosity of about 0.2 was sprayed on both sides of the water soluble web formed in Example 1. The Eastman AQ copolyesters are soluble in water, yet saline or body fluid insoluble. The resulting web disperses in water yet is not dispersible upon submersion in saline for 45 minutes.
Example 5
The water soluble polyamide of Example 1 was sprayed simultaneously with an experimental biodegradable polymer, Eastman Polyester 14766, to form a fused nonwoven web. Upon placing the web in water, some dissolution was observed yet the web remained intact due to the presence of the polyester. This combination is particularly preferred for disposable diapers as a possible solution for solid waste management concerns. When the water soluble polyamide was combined with the Eastman Polyester 14766 sequentially, the discreet webs could be easily separated from each other. Applicants surmise the polyamide could be sprayed simultaneously with any water insoluble polymer that is suitable for web forming processes.
The water soluble webs of Examples 1 and 2 are heat fusible. Examples 3-5 may also be heat fusible, but will no longer be 100% soluble.
Comparative Example A
In order to compare the properties of the improved water soluble web of the present invention, it was compared to PVOH. Although nonwoven web comprising PVOH are known, such webs are not commercially available. Applicants attempted to create a nonwoven web with hot melt spray applications as in Examples 1-5.
Vinex 2019, PVOH commercially available from Air Products was heated at 170° C. After 30 minutes the Vinex 2019 had turned light brown due to degradation. Since the material was unflowable at 170° C., the temperature was increased to about 210° C. upon which the Vinex 2019 turned very dark in appearance and fumed. Therefore, such attempts were unsuccessful due to the poor thermal stability and processability to PVOH.
Since a nonwoven web could not be formed from PVOH without the extrusion meltblown equipment taught by Dever, Benson and Pair in the INDA publication mentioned above, the applicants formed a film from an aqueous emulsion to compare the heat seal properties. A 15% aqueous solution of Vinex 2019 and a 15% aqueous solution of the water soluble polyamide of Example 1 were used to cast films. Upon drying, the thickness of the resulting films was about 1 to 2 mils.
The films were cut into pieces and used to heat seal standard copy paper with a small iron. Table 1 depicts the results of the heat seal bonds and this demonstrates the improved properties of the water soluble polyamide with respect to PVOH.
TABLE 1______________________________________Temperature Time Result______________________________________290-305° F. 1 Minute Vinex 2019 did not bond the paper. It stuck to the side which was pressed by iron but peeled off easily when cooled. No fiber tear.290-305° F. 1 Minute Example 1 exhibited excellent bond or 30 Seconds strength resulting in fiber tear.390-410° F. 1 Minute Vinex 2019 only bonded to the paper side which was directly in contact with iron, but did not bond paper on both sides.390-410° F. 30 Seconds Example 1 gave excellent bonds resulting in fiber tear.______________________________________
Example 7
A water soluble polyamide was produced by reacting 49.03 parts adipic acid with 48.84 parts of EDR-148 diamine, 1.50 parts of Irganox 1098 and 0.59 parts of stearic acid (Emersol-132) to control the viscosity. The resulting polyamide had a viscosity of about 12,000 cps at 400° F. as measured by a Brookfield viscometer. The polyamide exhibited no blocking at 100° F./90% RH. Alternatively, this polyamide may be produced in the absence of the monoacid and then be further combined with waxes, tackifiers, crystalline polymer, and mixtures thereof as demonstrated in the following Example 8.
Example 8
A water soluble polyamide was produced by reacting 395.2 g adipic acid with 292.3 g of EDR-192 diamine and 21.0 g of Naugaurd antioxidant. The resulting polyamide had a viscosity in the range of 8800 to 10,000 cps at 400° F. as measured by a Brookfield viscometer. The resulting polyamide was subsequently combined with Kenamide W-40 at concentrations of 1, 2 and 5 wt-%. The resulting blends exhibited good blocking resistance at 1 and 2 wt-% of Kenamide W-40 and very slight blocking at 5 wt-% at 100° F./90% RH.
Comparative Example B
A water soluble polyamide was produced by reacting 395.2 g of adipic acid with 292.3 g of EDR-192 diamine in accordance with the teachings of Speranza. The reactants are identical to inventive Example 8. The resulting polyamide had a viscosity in the range of 8800 to 10,000 cps at 400° F. as measured by a Brookfield viscometer. The polyamide was slow setting and exhibited poor blocking resistance at 100° F./90% RH.
Example 9
A water soluble polyamide was produced by reacting 42.57 parts adipic acid with 55.18 parts of EDR-192 diamine, 1.48 parts of Irganox 1098 and 0.77 parts of stearic acid (Emersol-132). The resulting polyamide had a viscosity of about 4,000 cps at 400° F. as measured by a Brookfield viscometer and exhibited good blocking resistance with some blocking around the edges of the weight at 100° F./90% RH, but no fiber tear. Hence by employing a chain terminator reactant into the polyamide of Comparative Example B, the blocking resistance is greatly improved.
Comparative Example C
A water soluble polyamide was produced by reacting 146.1 g of adipic acid, 143.1 dimer acid with 192.0 g of EDR-192 diamine, 150 g of ED-600, 9.5 g of Irganox 1098, and 0.4 g of Dow DB100 antifoaming agent in accordance with the teachings of Speranza. The resulting polyamide had a viscosity of about 39,000 cps at 400° F. as measured by a Brookfield viscometer. The polyamide was slow setting and blocked at 100° F./90% RH.
Example 10
Comparative Example C was further blended with Kenamide W-20 wax at concentrations of 1, 2 and 5 wt-%. The resulting blends exhibited good blocking resistance.
Comparative Example D
A water soluble polyarnide was produced by reacting 164.4 g of adipic acid, 71.3 g of azelaic acid, 205.8 g of EDR-148 diamine, 61.8 g of Jeffamine® D-400, and 7.5 g of Irganox 1098 in accordance with the teachings of Speranza. The resulting polyamide had a viscosity of about 5700 cps at 400° F. as measured by a Brookfield viscometer. The polyamide was slow setting and blocked at 100° F./90% RH.
Example 11
Comparative Example D was further blended with Kenamide W-40 wax at a concentration of 4 wt-%. The resulting blend exhibited good blocking resistance and the wax component had no measurable effect on the solubility/dispersibility in standard repulpability tests.
Comparative Example E
A water soluble polyamide was produced by reacting adipic acid, EDR-148 diamine, and Jeffamine® D-230, and 7.5 g of Irganox 1098 in accordance with the teachings of Speranza. The resulting polyamide had a viscosity of about 2100 cps at 350° F. as measured by a Brookfield viscometer. The polyamide is tacky and slow setting.
Example 12
Comparative Example E was further blended with Kenamide W-40 wax at a concentration of 5 wt-%. The resulting blend was fast setting and non-blocking.
Example 13
The polyamide of Example 2 was formed into fibers on a small fiber extrusion line consisting of a small, 2" single screw extruder with 0.8 mm, 48 hole spinnerets. There were three independently controlled heating zones in the extruder and one at the spin pump. The cooling zone below the spinneret was approximately 1 meter long and the cooled air supplied perpendicular to the fiber. A fiber finish application roll was positioned just above the take-up roll, approximately 2 meters below the spinneret. The extrusion line was equipped with 3 additional draw rolls and a winder with a maximum winding speed of 1400 m/minute. A 500 mesh screen was employed to increase the back pressure. The temperature settings were as follows:
Extruder Zone 1: 150° C.
Extruder Zone 2: 150° C.
Extruder Zone 3: 155° C.
Extruder Zone 4: 145° C.
Under these temperature settings a back pressure of 1100 to 1400 psi was recorded. The pressure at the spin pump gradually increased from 260 psi to 600 psi, surmised to be caused by the somewhat lower extrusion temperature at the end of the run. Filament fibers were formed which solidified in the cooling zone sufficiently that the fibers could be transported to the take up roll. The tensile strength was marginal in that fiber breakage occurred when the fiber was brought in contact with the fiber finish application roll. To reduce the friction caused by the application roll, a lower viscosity finish was employed which reduced the stress on the fibers sufficiently such that further processing of the fibers was possible.
The filament fibers were threaded over the remaining draw rolls and onto the package winder under two different drawing conditions, conditions A and B. The ratio between the weight of the polymer pumped through the spinneret and the winder speed determines the linear density of the fiber. Since the polymer flow through the spinneret was constant, the denier (diameter) size of the fiber is therefore only dependent on the speed of the winder. The tenacity and elongation were measured on a tensile tester with a crosshead speed of 300 mm/min and a gap of 10 cm.
______________________________________ Condition A Condition B______________________________________Speed of take-up roll: 500 m/min 360 m/minSpeed of draw roll 2: 900 m/min 900 m/minSpeed of draw roll 3: 1100 m/min 1400 m/minSpeed of winder: 1400 m/min 1400 m/minWeight of 47 9.8 grams 8.8 gramsfibers @ 90 meters:Weight of 47 980.0 grams (denier) 880.0 grams (denier)fibers @ 9000 meters:Weight of 1 20.9 grams (denier) 18.7 grams (denier)filament @ 9000 meters:Tenacity per 47 1382 g (1.41 g/denier) 1129 g (1.28 g/denier)filaments:Elongation at Break 125% 75%Fiber Modules: 2.33 g/denier 4.44 g/denier______________________________________
The extruded fibers have sufficient tensile strength and integrity to be drawn at a draw ratio of 1:4. It is surmised that fiber could be drawn at even higher ratios.
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This invention relates to a nonwoven web and fibers comprising a water soluble polyamide and articles constructed therefrom. The water soluble polyamide may be used alone or in combination with conventional thermoplastic web and fiber forming materials such as water insoluble polyethylene, polypropylene, polyester and polyamide. The water soluble polyamide may also be combined with biodegradable or selectively dispersible material to form nonwoven webs and fibers having various combinations of properties. Such water soluble webs and fibers have utility in the manufacture of disposable absorbent articles such as disposable diapers, feminine napkins, incontinent products and cellulosic articles such as tissues and towels, as well as for water soluble heat fusible webs for the textile industry.
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention refers to a reagent for the detection and quantitative determination of leukocytes in samples of human and animal body fluids, and to a method of using it.
The detection of leukocytes in body fluids, such as, e.g., urine, is very useful in the diagnosis of some types of infections, e.g. in the uro-genital tract.
2. Discussion of the Background
For the detection of leukocytes in the urine two different methods are at present employed: the microscopic examination and the determination of particular enzyme activities which can be correlated with the pressure of leukocytes themselves.
The microscopic examination of sample represents the classical method for detecting leukocytes and is considered as the reference method in that it allows the objective control of the presence of the cells (leukocytes) in the test sample, directly or after enrichment by centrifugation. However, such a method, besides being too laborious for extensive utilization in analysis laboratories, does not allow the indentification of leukocyte cells having undergone lysis caused by excessive alkalinity of sample or a too wide time interval elapsed from the taking of the sample and its microscopic examination, which represents a serios drawback. For strongly alkaline samples, as it often happens in case of infection of urinary ducts, cell lysis can reach completion even within one hour. Under such circumstances, the risk of considering as negative samples, which are on the contrary positive, is very high.
Esterases are the enzymes at present employed for the indirect detection of leukocytes, in that they split particular synthetic substrates by hydrolysis delivering groups which spontaneously become coloured by air oxidation of after reaction with other appropriate substances. This method is th one typically employed in reactive stripes which contain the reagents dried on inert supports and are used for detection of leukocytes in urine. The reaction stripes containing the dried reagents to be dipped in the test sample allow a semi-quantitative determination of leukocyte esterase activity, which requires a time period of at least 60-120 seconds per sample. The detection of leukocytes carried out through the measurement of peroxidase enzyme activity is also known from a long time. In U.S. Pat. No. 3,087,794 a method is described, which is useful for distinguishing the peroxidase activity of leukocytes from that of erythrocytes. The utilization of hydrogen peroxides (or another peroxide) at different concentrations in the two cases permits such a differentation: o-tolidine, which is a cancerous substance, is the employed chromogen.
The method described in the above-mentioned U.S. Patent, however, does not reach the sensitivity level which are at present requested and is not even able to distiguish leukocytes from erythrocytes with certainty, if the concentration of these latter is much higher than that of the former.
The leukocytes typically present in urine in csae of renal and uro-genital infections are neutrophilic granulocytes.
They have the typical microbicidal function correlated to the phagocytosis, that is carried out through different mechansims, not yet perfectly understood. Among them, the most important one appears to be the microbicidal and detoxicating MPO-H 2 O 2 -halide system. With MPO it is hereinafter meant the leudocyte myleoperoxidase enzyme.
MPO is an enzyme present in large amount in polymorphonuclear leukocytes (neutrophils granulocytes), representing up to 5% of the whole cell mass.
The determination of MPO activity can therefore allow the detection of the presence of the above mentioned leukocytes in biological samples or in human or animal body fluds. When the halide compund in MPO-H 2 O 2 -halide system is iodide (I - ), the following reactions can take place: ##STR1##
J. Bos et al. (Infect. Immun. 1981, 32, 427) exploy just the reactions (a) and (b) for determining the myeloperoxidase activity of neutrophils and the peroxidase activity of eosinophils in blood, by carrying out spectrophotometric readings at 360 nm of the reaction production (I 3 ). However, the UV spectrophotometric reading involves many practical drawbacks and brings about many non-specificities when applied to samples having extremely variable compositions, such as urine.
Methods are also known for determining the MPO activity in blood, which are comparable to the ones already extensively employed for the peroxidase of vegetable origin (HRPO) and employ o-dianisidine, o-tolidine or guaiacol as acceptor-chromogens. These methods too are however non-specific because they do not distinguish among peroxidase activity, MPO activity and hemoglobin pseudo-peroxidase activity.
SUMMARY OF THE INVENTION
It has now been surprisingly found a reagent suitable both for the detection and for the quantitative determination of leukocytes in biological samples through the measurement of MPO activity, enough sensitive for disclosing even only a few leukocytes, having such a specificity that hemoglobin does not bring about interference at all even in the presence of several erythrocytes and being suitable for photometric readings in the visible spectrum region.
The reagent according to the present invention comprises a MPO specific substrate, such as an alkali metal halide compound; 4-aminoantipyrine as chromogen; a buffer for maintaining the optimum desired pH value; a surface-active agent for aiding and accelerating the lysis of leukocytes in order to release MPO making it immediately avaialble for the reactions of interest; a hydroperoxide compound, and optionally a promoter for increasing the systen sensitivity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
More particularly, such reagent comprises as components at least a buffer selected from the group consisting of citrate, succinate, acetate, and formate in concentration of 2.5-500 mmol/l; a chromogen represented by 4-aminoantipyrine in concentration of 5-1000 mmol/l; at least a surface-active agent selected from the group formed by non-ionic and anionic surface-active agents, in concentration of 0.05-2%; at least an alkali metal halide in concentration of 2-1000 mmol/l; and at least a hydroperoxide compound in concentration of 2-100 mmol/l.
Preferably the buffer is in concentration of 2.5-50 mmol/l; the chromogen is in a concentration of 200-500 mmol/l; the surface-active agent is in concentration of about 0.2% the alkali metal halide is in a concentration of 10-20 mmol/l; and the hydroperoxide compound is selected from the group consisting of hydrogen peroxide in a concentration of about 2-25 mmol/l and magnesium monoperoxyphthalate in a concentration of about 40-60 mmol/l.
Hydroperoxide compunds other than hydrogen peroxide and magensium monoperoxyphtalate can be used, such as urea hydrogen peroxide, both alone and in mixture with each other in the reagent. Substances such as MPO (3-(N-morpholine)propane-sulfonic acid), imidaxole and/or 8-aminoquinoline, in concentrations from 10-300 mmol/l can be present, for increasing the reagent sensitivity.
Expecially 8-aminoquinoline can bring about a clear promoting effect, preferably in concentration of 30-40 mmol/l so as to increase reaction sensitivity.
The reaction involved by the chromogen activity is considered to be as follows: ##STR2##
The reaction rate which can be achieved for the detection and quantatitive determination of leukocytes allows the examination of the sample in about 30 seconds when the components are used in the above specified optimum amounts; if said components are used in amounts which are not the optimum ones but falling within the indicated ranges, an effective detection and quantitative determination of the leukocytes is still effectively possible even if the operating time is longer. For the practical utilization of reagent and method according to the present invention the essential thin is a conventional filter photometer for readings in the visible spectrum region, even if the utilization of more comples and sophisticated instruments, particularly suitable for automation and acceleration of analytical procedures cannot be excluded.
The reagent of the present invention can be employed when its components are included in only one or even in two compartment parts.
When the reagent is used in an only component part containing all the above-mentioned components, it is necessary to do the detection and quantitative determination of leukocytes quickly with precision because the components immediately react with the biological substrate; the components of the reagent can also be split into two component parts which are, one after the other, let to react with the biological fluids. A component part can in fact include the alkali metal halide and the other part the hydroperoxide compund, the remaining components being included in one or both component parts, except chromogen being only in the component part that is first added to the biological fluid sample.
The chromogen 4-aminoantipyrine allows a coloured oxidized compound to be formed, its colour intensity being such as to allow the determination of MPO activity by means of spectrophotometric readings in the visible spectrum region (520-540 nm) with sufficient sensitivity and specificity.
The alkali metal halide, preferably potassium iodide, is used as MPO specific substrate in the reagent.
The buffers preferably used are citrate (because it gives more stability to the reagent) or formate (because it increases reaction sensitivity).
In order to accelerate the leukocyte lysis for releasing MPO and making it immediately available for the reaction of interest, 0.1-2%, preferably about 0.2%, of a nonionic surface-active agent, such as polyoxyethylene(20 )sorbitan monolaurate (Tween 20®), polyoxyethylene(20)-sorbitan monoleate (Tween 80.sup.®), polyxyethylene(23)lauryl ether (Brij 35.sup.®), higher alcohol polyoxyethylene ethers (Triton x-67.sup.® ; Triton x-100.sup.® ; Triton x-305.sup.®), preferably polyethylene glycol p-isooctylphenyl ether (Triton x-100 2 ®) can suitably be added to the reagent.
The following Examples as illustrative, but not limitative of the present invention.
EXAMPLES
EXAMPLE 1
A reagent is prepared formed by a first component part, consisting of citrate buffere (196 mmol/l, pH 5.0) containing 4-aminoantipyrine (62 mmol/l), potassium iodide (130 mmol/l), 8-aminoquionoline (28 mmol/l) and Triton x-100.sup.® (10 g/l), and by a second component part, consisting of hydrogen peroxide (20 mmol/l) in distilled water.
In a spectrophotometry cuvette, thermoregulated at 37° C. and having 1 cm of optical path, are successively mixed: 2.0 ml of distilled water and 0.5 ml of a fresh urine sample containing varied amounts of leukocytes, previously measured by microscopic counting of the sediment obtained by centrifugation of the sample.
After addition of 0.5 ml of the first component part, the absorbance (A 1 ) at 540 nm is measured and then 0.1 ml of the second component part is added.
The resulting mixture has pH 5.0. Exactly 30 seconds after the addition of the second component part, the absorbance (A 2 ) at 540 nm is measured.
The calculated absorbance variation (A 2 -A 1 ) obtained in 30 seconds is then correlated with the leukocyte content of the sample. The obtained results are summarized in Table I.
TABLE I______________________________________Leukocytesper μl (A.sub.2 - A.sub.1)______________________________________ 0 0.036 0 0.042 0 0.028 0 0.04025 0.07025 0.07025-30 (28) 0.07875 0.08575-80 (78) 0.092500 0.702700 0.908______________________________________ Leukocytes per μl: number of leukocytes per μl of fresh urine, measured by microscopic counting of the sediment obtained by centrifugation of the sample. (A.sub.2 - A.sub.1): Absorbance variation obtained in 30 seconds.
Example 2
The same procedure of Example 1 is repeated, with the exception that the reagent consists of a first component part, containing succinate buffer (20 mmol/l, pH 7.2), 4-aminoantipyrine (62 mmol/l), potassium iodide (130 mmol/l), 8-aminoquinoline (28 mmol/l), and Triton x-100® (20 g/l), and of a second component part, containing hydrogen peroxide (20 mmol/l) in citrate buffer (100 mmol/l, pH 4.7).
The resulting mixture has the same pH 5.0 as the Example 1, not withstanding the different pH of the compositions. The calculated absorbance variation (A 2 -A 1 ) obtained in 30 seconds is correlated with the leukocyte content of the sample.
The obtained results are summarized in Table II.
TABLE II______________________________________Leukocytes per μl (A.sub.2 - A.sub.1)______________________________________ 0 0.040 0 0.044 0 0.032 0 0.04025 0.08125 0.07825-30 (28) 0.07875 0.09275-80 (78) 0.093500 0.775700 1.010______________________________________ Leukocytes per μl: number of leukocytes per μl of fresh urine, measured by microscopic counting of the sediment obtained by centrifugation of the sample. (A.sub.2 - A.sub.1): Absorbance variation obtained in 30 seconds.
Example 3
In a spectrophotometry cuvette, thermoregulated at 37° C. and having 1 cm of optical path, are successively mixed: 2.0 ml of distilled water and 0.5 ml of a fresh urine sample composed by a mixture of a group of negative urines or by a mixture of a group of positive urines containing 200 leukocytes/ul, determined by microscopic counting in the sediment obtained by centrifugation of the sample.
After addition of 0.5 ml of the reagent first component part consisting of acetate buffer (100 mmol/l, pH 4.8) containing 4-aminoantipyrine (40 mmol/l), 8-aminoquinoline (25 mmol/l), Triton X-100® (15 g/l) and potassium iodide in concentrations ranging between 100 and 175 mmol/l, the absorbance (A 1 ) at 530 nm is measured and then 0.1 ml of the second component part, consisting of hydrogen peroxide (20 mmol/l), is added. Exactly 30 seconds after the addition, the absorbance (A 2 ) at 530 nm is measured. The calculated absorbance variation (A 2 -A 1 ) in 30 seconds is correlated with the iodide concentration.
The obtained results are summarized in Table III.
TABLE III______________________________________Iodide mmol/lin the reagent in the cuvette N P (P - N)______________________________________100 16.12 0.032 0.211 0.179125 20.16 0.048 0.320 0.272150 24.80 0.098 0.388 0.290175 28.22 0.148 0.387 0.239______________________________________ N = (A.sub.2 - A.sub.1) at 530 nm per 0.5 ml of a sample of the group of negative urines P = (A.sub.2 - A.sub.1) at 530 nm per 0.5 ml of a sample of the group of positive urines (P - N) = difference between the (A.sub.2 - A.sub.1) values of the positive sample and those of the negative sample.
Example 4
The same procedure of Example 3 is repeated, with the exception that, in this case the reagent comprises a first component part, consisting of acetate buffer (100 mmol/l, pH 4.8) containing 4-aminoantipyrine (40 mmol/l), 8-aminoquinoline (25 mmol/l), Triton X-305® (20 g/l) and hydrogen peroxide in concentrations ranging from 5 to 7 mmol/l, and a second component part, consisting of potassium iodide (600 mmol/l), and the following results are obtained, as reported in Table IV.
TABLE IV______________________________________Peroxide mmol/lin the Reagent in the cuvette N P (P - N)______________________________________5 0.81 0.048 0.410 0.3626 0.96 0.105 0.460 0.3557 1.13 0.180 0.500 0.320______________________________________ N = (A.sub.2 - A.sub.1) at 530 nm per 0.5 ml of a sample of the group of negative urines P = (A.sub.2 - A.sub.1) at 530 nm per 0.5 ml of a sample of the group of positive urines (P - N) = difference between the (A.sub.2 - A.sub.1) values of the positive sample and those of the negative sample.
Example 5
The same procedure of Example 3 is repeated, whith the exception that, in this case, the reagent comprises a first component part, consisting of acetate buffer (100 mmol/l), 8-aminoquinoline (25 mmol/l), potassium iodide (140 mmol/l), Triton X-67® (2.5 g/l) and 4-aminoantipyrine in concentrations ranging from 40 to 320 mmol/l, and a second component part, consisting of hydrogen peroxide (25 mmol/l) in citrate buffer (100 mmol/l, pH 4.8). The employed samples are formed by a mixture of a group of negative urines and by a mixture of a group of positive urines containing 70 and 250 leukocytes/ul, measured by microscopic counting of the sediment obtained by centrifugation of the sample.
The obtained results are summarized in Table V.
TABLE V______________________________________4-aminoantipirine mmol/lIn the reagent in the cuvette N P70 P250______________________________________40 6.45 0.048 0.142 0.48880 12.90 0.060 0.145 0.512120 19.35 0.058 0.140 0.470160 25.81 0.056 0.148 0.465320 51.61 0.045 0.150 0.413______________________________________ N = (A.sub.2 - A.sub.1) at 530 nm per 0.5 ml of a sample of the group of negative urines P70 = (A.sub.2 - A.sub.1) at 530 nm per 0.5 ml of a sample of the group o positive urines containing 70 leukocytes/μl P250 = (A.sub.2 - A.sub.1) at 530 nm per 0.5 ml of a sample of the group of positive urines containing 250 leukocytes/μl
Example 6
In a spectrophotometry cuvette, having 1 cm of optical path and thermoregulated at 37° C., are successively mixed: 2.0 ml of distilled water and 0.5 ml of a fresh urine sample formed by a mixture of a group of negative urines or by a mixture of a group of positive urines containing 250 leukocytes/ul, measured by microscopic counting of the sediment obtained by centrifugation of the sample.
After the addition of 0.5 ml of a first component part of the reagent, consisting of acetate buffer (100 mmol/l, pH 4.8) containing 4-aminoantipyrine (40 mmol/l), potassium iodide (140 mmol/l), Tween-20® (10 g/l) and 8-aminoquinoline in concentrations ranging from 15 to 40 mmol/l, the absorbance (A 1 ) at 530 nm is measured and then 0.1 ml of a second component part of the reagent, consisting of magnesium monoperoxyphthalate (50 mmol/l), is added. The calculated absorbance variation (A 2 -A 1 ) in 30 seconds is correlated with the concentration of 8-aminoquinoline. The obtained results are summarized in Table VI.
TABLE VI______________________________________8-Aminoquinoline mmol/lin the reagent in the vessel N P (P - N)______________________________________15 2.42 0.041 0.405 0.36420 3.23 0.045 0.460 0.41530 4.84 0.047 0.458 0.41140 6.45 0.051 0.461 0.410______________________________________ N = (A.sub.2 - A.sub.1) at 530 nm per 0.5 ml of a sample of the group of negative urines P = (A.sub.2 - A.sub.1) at 530 nm per 0.5 ml of a sample of the group of positive urines (P - N) = difference between the (A.sub.2 - A.sub.1) values of the positive sample and those of the negative sample.
Example 7
In a spectrofotometry cuvette, having 1 cm of optical path and thermoregulated at 37° C., are mixed successively 2.0 ml of distilled water and 0.5 ml of a fresh urine sample containing varied amounts of leukocytes, measured by microscopic counting of the sediment obtained by centrifugation of the sample.
After the addition of 0.5 ml of the first component part of the reagent, consisting of citrate buffer (175 mmol/l, pH 4.8) containing 4-aminoantipyrine (50 mmol/l), potassium iodide (120 mmol/l) and Tween-80® (10 g/l), the absorbance (A 1 ) at 540 nm is measured in two series of tests carried out in the presence or not of 8-aminoquinoline as promoter (31 mmol/l) in the first component part.
Then, 0.1 ml of a second component part of the reagent, consisting of hydrogen peroxide (25 mmol/l) in citrate buffer (100 mmol/l, pH 4.8) is added. Exactly 30 seconds after the addition, the absorbance (A 2 ) at 540 nm is measured. The calculated absorbance variation (A 2 -A 1 ) in 30 seconds is correlated with the leukocyte content of the sample sediment; the obtained results are summarized in Table VII.
TABLE VII______________________________________ (A.sub.2 - A.sub.1) Reagent without Reagent withLeukocytes per μl promoter promoter______________________________________ 0 (Negative) 0.025 0.040 25 0.050 0.085 50 0.065 0.110100 0.150 0.223200 0.220 0.370300 0.345 0.580______________________________________ (A.sub.2 - A.sub.1): absorbance variation in 30 seconds Leukocytes per μl = Number of leukocytes per μl of fresh urine measured by microscopic counting of the sediment obtained by centrifugation of the sample.
Example 8
In a spectrophotometry cuvette having 1 cm of optical path and thermoregulated at 37° C., are mixed successively: 2.0 ml of distilled water and 0.5 ml of a urine sample formed by a mixture of a group of negative urines or by a mixture of a group of positive urines containing 250 leukocytes/ul, measured by microscopic counting of the sediment obtained by centrifugation of the sample.
After addition of 0.5 ml of the first component part of the reagent, consisting of citrate buffer (100 mmol/l) at pH ranging from 4.0 to 7.0 and containing 4-aminoantipyrine (40 mmol/l), potassium iodide (140 mmol/l), 8-aminoquinoline (25 mmol/l) and Triton X-100® (15 g/l), the absorbance (A 1 ) at 530 nm is measured, 0.1 ml of a second component part of the reagent, consisting of hydrogen peroxide (25 mmol/l) in distilled water, is then added and, exactly 30 seconds after the addition of this latter, the absorbance (A 2 ) at 530 nm is measured.
The obtained results are summarized in Table VIII.
TABLE VIII______________________________________(A.sub.2 - A.sub.1)pH N P (P - N)______________________________________4.0 0.050 0.061 0.0114.5 0.037 0.400 0.3634.8 0.045 0.415 0.3705.0 0.044 0.408 0.3645.5 0.047 0.368 0.3216.0 0.038 0.288 0.2506.5 0.010 0.120 0.1107.0 0.012 0.012 0.000______________________________________ N = (A.sub.2 - A.sub.1) at 530 nm per 0.5 ml of a sample of the group of negative urines P = (A.sub.2 - A.sub.1) at 530 nm per 0.5 ml of a sample of the group of positive urines (P - N) = difference between the (A.sub.2 - A.sub.1) values of the positive sample and those of the negative sample.
Example 9
In a spectrophotometry cuvette having 1 cm of optical path and thermoregulated at 37° C., are mixed successively 1.6 ml of distilled water, 0.5 ml of fresh urine sample containing leukocytes or erythrocytes in known varied amounts, determined by microscopic counting of the sediment obtained by centrifugation of the sample, and 0.5 ml of the first component part of the reagent, consisting of citrate buffer (20 mmol/l, pH 7.2) containing 4-aminoantipyrine (62 mmol/l), potassium iodide (132 mmol/l) and Brij-35® (2 g/l). The absorbance (A 1 ) at 530 nm is measured and then 0.5 ml of a second component part of the reagent, containing citrate buffer (200 mmol/l, pH 4.4), hydrogen peroxide (6.0 mmol/l) and 8-aminoquinoline (30 mmol/l) are added.
Exactly after 30 seconds after the addition of second component part, the absorbance (A 2 ) at 530 nm is measured. The calculated absorbance variation (A 2 -A 1 ) is correlated with the leukocyte or erythrocyte content of the sample. The obtained results are summarized in Table IX.
TABLE IX______________________________________Leukocytes/μl Erythrocytes/μl (A.sub.2 - A.sub.1)______________________________________0 0 0.0350 0 0.04415 0 0.05820 0 0.06835 0 0.102250 0 0.3990 10 0.0380 50 0.0360 250 0.0420 500 0.040______________________________________ (A.sub.2 - A.sub.1): Absorbance variation after 30 seconds.
Example 10
In a spectrophotometry cuvette, having 1 cm of optical path and thermoregulated at 37° C., are mixed successively 1.6 ml of distilled water, 0.5 ml of a fresh urine sample containing leukocytes and erythrocytes in known varied amounts, determined by microscopic counting of the sediment obtained by centrifugation of the sample, and 0.5 ml of the first component part of the reagent, consisting of formate buffer (20 mmol/l, pH 7.1) containing 4-aminoantipyrine (120 mmol/l), potassium iodide (130 mmol/l) and Triton x-100® (2 g/l); the absorbance (A 1 ) at 530 nm is measured and then 0.1 ml of a second component part of the reagent, consisting of a buffer (300 mmol/l pH 4.4) of a compound selected from citrate, formate succinate or acetate, containing hydrogen peroxide (5.7 mmol/l) and 8-aminoquinoline (31 mmol/l) are added.
Exactly 30 seconds after the addition of the second component part, the absorbance (A 2 ) at 530 nm is measured.
The calculated absorbance variation (A 2 -A 1 ) is correlated with the leukocyte or erythrocyte content of the sample.
The obtained results are summarized in Table X.
TABLE X______________________________________ (A.sub.2 - A.sub.1) Reagent Reagent Reagent ReagentLeuko- Erythro- with with with withcytes/μl cytes/μl citrate formate succinate acetate______________________________________0 0 0.034 0.048 0.046 0.0390 0 0.038 0.049 0.044 0.03715 0 0.059 0.074 0.068 0.06225 0 0.081 0.107 0.090 0.08575 0 0.164 0.210 0.187 0.190500 0 0.872 1.204 0.920 0.8980 10 0.032 0.061 0.059 0.0420 50 0.041 0.055 0.058 0.0380 250 0.039 0.057 0.054 0.0380 500 0.044 0.057 0.060 0.0390 1000 0.052 0.066 0.062 0.051______________________________________ (A.sub.2 - A.sub.1): Absorbance variation after 30 seconds
Example 11
In a spectrophotometry cuvette, having 1 cm of optical path and thermoregulated at 37° C., are mixed successively; 2.0 ml of distilled water, 0.5 ml of a fresh urine sample formed by a mixture of a group of negative urines or by a mixture of a group of positive urines containing 250 leukocytes/ul, measured by microscopic counting of the sediment obtained by centrifugation of the sample, and 0.5 ml of the reagent consisting of succinate buffer (100 mmol/l, pH 4.8) containing 4-aminoantipyrine (123 mmol/l), potassium iodide (132 mmol/l), 8-aminoquinoline (31 mmol/l); hydrogen peroxide (6 mmol/l) and varied surface-active agents (3.0 g/l). The absorbance at 520 nm is measured immediately (A 1 ) and exactly after 30 seconds (A 2 ).
In table XI are summarized the obtained results.
TABLE XI______________________________________ (A.sub.2 - A.sub.1)Surface-active agent N P (P - N)______________________________________None 0.033 0.092 0.059Teepol 610 ® 0.018 0.088 0.070Litium dodecyl sulfate 0.008 0.118 0.110Sodium dodecyl sulfate 0.011 0.099 0.088Sodium dioctylsulphosuccinate 0.011 0.069 0.058Sodium pentanesulfonate 0.019 0.110 0.091Sodium hexanesulfonate 0.018 0.106 0.088Brij 35 ® 0.032 0.420 0.388Triton x-67 ® 0.048 0.502 0.454Triton x-100 ® 0.041 0.496 0.455Triton x-305 ® 0.037 0.377 0.340Tween 20 ® 0.035 0.501 0.466Tween 80 ® 0.023 0.491 0.468______________________________________ N = (A.sub.2 - A.sub.1) at 520 nm per 0.5 ml of a sample of the group of negative urines. P = (A.sub.2 - A.sub.1) at 520 nm per 0.5 ml of a sample of the group of positive urines. (P - N) = difference between the (A.sub.2 - A.sub.1) values of the positive sample and those of the negative sample.
Example 12
In a spectrophotometric cuvette, having 1 cm of optical path and thermoregulated at 37° C., are mixed successively; 2.0 ml of distilled water, 0.8 ml of a fresh urine sample containing varied amounts of leukocytes, previously measured by microscopic counting of the sediment obtained by centrifugation of the sample, and 0.5 ml of the first component part of the reagent, consisting of citrate buffer (5 mmol/l, ph 8.0) containing 4-aminoantipyrine (400 mmol/l), potassium iodide (14.5 mmol/l) and Triton x-100® (2 g/l) in distilled water; after the addition of 0.5 ml of the second component part of the reagent, consisting of citrate buffer (266 mmol/l), ph 4.4), hydrogen peroxide (18 mmol/l), and 8-aminoquinoline (31 mmol/l) in dimethylsulfoxide (112 ml/l) in distilled water, the variation of absorbance (A 2 -A 1 ) is misured at 546 nm for 20 sec. The calculated absorbance variation (A 2 -A 1 ) is correlated with the leukocyte contents of the sample.
The obtained results are summarized in Table XII.
TABLE XII______________________________________LEUKOCITES per ul (A.sub.2 - A.sub.1)______________________________________ 0 0.038 0 0.036 0 0.02710-15 0.04520 0.04925 0.05525-30 0.05970-80 0.082100-130 0.110600 0.398900 0.588______________________________________ (A.sub.2 - A.sub.1): Absorbance variation for 20 seconds.
|
A reagent for the detection and quantitative determination of leukocytes by measuring the myeloperoxidase (MPO) activity of biological samples, which is sensitive for disclosing even only a few leukocytes, without interferences caused by hemoglobin even in the presence of several erythrocytes, and suitable for photometric readings in the visible spectrum region. The reagent comprises a buffer, a chromogen, a surface-active agent, at least an alkali metal halide, a hydroperoxide compound and optionally a reaction promoter.
| 8
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefits of priority from:
i) Application Number 0426323.2, entitled “PROCESSING SEISMIC DATA,” filed in the United Kingdom on Dec. 1, 2004; and ii) Application Number PCT/GB2005/004600, entitled “PROCESSING SEISMIC DATA,” filed under the PCT on Dec. 1, 2005;
All of which are commonly assigned to assignee of the present invention and hereby incorporated by reference in their entirety.
This invention relates to the processing of seismic data. It particularly relates to a process for processing a number of seismic data traces to provide a composite data trace. The invention may be used to for example, attenuate random noise and interference in the original data traces so as to provide better-quality images of the earth's interior.
BACKGROUND
In seismic surveys, a seismic source is actuated to induce seismic waves at or near the surface of the earth. Explosive sources, vibrating devices and airguns are examples of seismic sources. The seismic waves propagate into and through the earth and are reflected, refracted, and diffracted by geological formations within the earth. Some seismic waves are directed back to the earth's surface, and can be detected by a plurality of seismic receivers (or seismic sensors), such as geophones or hydrophones, deployed at the earth's surface. Each such receiver monitors and records the seismic wavefield at the receiver's location. Typically a receiver monitors the seismic wavefield for a given period after actuation of a seismic source. The data received and recorded by a receiver are in the form of a record of the variation over time of one or more components of the seismic wavefield (such as, for example, the pressure or a component of the particle velocity), and are collectively called a trace. The collection of traces is stored for further processing in known ways to obtain information about the earth's subsurface. Such information is commonly interpreted by geophysicists to detect the possible presence of hydrocarbons, or to monitor changes in hydrocarbon bearing rocks in the subsurface.
FIG. 1 is a schematic illustration of a seismic surveying arrangement that includes a seismic source 1 and five seismic receivers 2 - 6 spaced from the source 1 . FIG. 1 shows a land-based seismic survey in which the seismic source 1 and the seismic receivers 2 - 6 are provided at the earth's surface. When the seismic source 1 is actuated to emit seismic energy, some of the emitted seismic energy is detected by the seismic receivers 2 - 6 . The receivers measure a component of the seismic wavefield, and provide a data trace showing how that component varies with time.
FIG. 2 is a schematic illustration of traces acquired by the receivers 2 - 6 of FIG. 1 when the seismic source 1 is actuated to emit seismic energy. Trace X 2 is the trace acquired by receiver 2 and so on. (Most seismic receivers in use today are digital receivers that repeatedly sample the seismic wavefield and so output a series of discrete values rather than a continuous trace, but the traces are represented as continuous traces in FIG. 2 for simplicity.) The horizontal axis in FIG. 2 represents the time after actuation of the seismic source 1 , and the vertical axis of FIG. 2 represents the offset of the trace (the “offset of a trace is the horizontal distance between the source and the receiver used to acquire the trace). The traces X 2 to X 6 are arranged in order of increasing offset. Within a trace, the horizontal axis represents the amplitude of the component of the seismic wavefield measured by the receiver, as a function of time.
The traces X 2 to X 6 represent a “common source gather” of traces. Each trace was acquired following actuation of the source 1 .
Each trace X 2 -X 6 contains a number of seismic “events”. Event 7 is the “direct event” and represents the arrival at the receiver of seismic energy that has travelled direct from the source 1 to the receiver 2 - 6 along the path 8 shown in FIG. 1 . Event 9 is a “reflection event”, and represents the arrival at the receiver of seismic energy that was transmitted into the earth's interior and has travelled to the receiver 2 - 6 along a path such as the path 11 shown in FIG. 1 , which involves a reflection at a geological structure 10 within the earth that acts as a partial reflector of seismic energy. The time at which an event occurs in a trace is known as the “arrival time” or the “travel time” of the event, and is equal to the time taken for seismic energy to travel from the source to the receiver via the respective path.
Each of the traces X 2 to X 6 in FIG. 2 contains a direct event 7 and the reflection event 9 . However, the events do not occur at the same times in each trace, because the length of the path of seismic energy from the source to the receiver varies from one trace to another. In the case of the direct event 7 , the length of the path of seismic energy from the source to the receiver is equal to the distance from the source to the receiver (i.e. is equal to the offset). The travel time of the direct event therefore varies linearly with offset. In the case of the reflection event 9 , however, the relationship between offset and the travel time is not linear—if the velocity of propagation of seismic energy is assumed to be constant and isotropic within the earth then the travel time of the reflection event will, as is well known, show a hyperbolic dependence on offset.
Seismic data in general contains noise signals, which may be coherent or incoherent, as well as the desired seismic reflection signals. These noise signals, hereafter referred as just “noise”, interfere with the interpretation of the seismic signals, and degrade the quality of the subsurface images that can be obtained by processing the recorded seismic data. Travel time readings taken from seismic data traces can also be degraded by travel time fluctuations between traces (known as “time-jitter”). If the traces X 2 to X 6 of FIG. 2 contain significant random noise and/or time-jitter it would be difficult to make an accurate determination of the travel time of the reflection event 9 occurs. It is therefore very desirable to suppress or attenuate noise and time-jitter that is present in recorded seismic data traces before processing the data to obtain an image of the earth's interior.
One method of attenuating incoherent noise (noise that varies randomly from one trace to another) or time-jitter is to make use of traces in a gather that are adjacent to the trace being processed. For example, if seismic receivers in a seismic survey are deployed close to one another it is likely that the seismic wavefield sampled by a receiver will not be significantly different from the seismic wavefield sampled by an adjacent receiver. However, the incoherent noise or time-jitter will vary randomly from one trace to another. Thus, if adjacent traces are combined the noise and time-jitter in one trace should cancel the noise and time-jitter in another trace (if the noise and time-jitter are random).
In the example of FIG. 2 , one method to improve the accuracy of the determination of the travel time of the reflection event 9 in trace X 4 would be to make use of the adjacent traces on either side or even of the adjacent two traces on either side. By determining a composite travel time t′ according to:
t′=t 3 +t 4 +t 5 (1)
(where t k denotes the travel time of the reflection event 9 in the k th trace) or according to:
t′=t 2 +t 3 +t 4 +t 5 +t 6 (2)
and subsequently dividing the composite time t′ by the number of traces used in its determination, the effect of random noise on the measured travel time of the reflection event in the trace X 4 should be reduced.
As explained above, the travel time of a seismic event varies from one trace to another, and in the case of a reflection event varies non-linearly with offset. It is therefore not possible simply to sum traces acquired at different offsets together. The conventional procedure is therefore to pick the travel time of the event in each data trace, correct the picked travel times for changes in offset, and add the corrected travel times together. This process can be time-consuming. Furthermore, inaccuracy in picking the travel times in the data traces can lead to inaccuracy in the final result.
There are other occasions where it is desired to sum travel times of events in more than one seismic trace. For example, a linear trend removal filter generates a composite travel time according to:
t′=− ½ +t k−1 t k −½ t k+1
Again, a linear trend filter is conventionally implemented by picking the individual travel times in individual traces, and summing the picked travel times.
SUMMARY OF THE INVENTION
The present invention provides a method of processing seismic data comprising convolving at least first and second seismic data traces or respective portions of at least first and second seismic data traces thereby to form a composite trace; and determining the travel time of an event in the composite trace. The method eliminates the need to pick travel times in each individual data trace used, and only requires one picking operation. Furthermore, since random noise is attenuated in the convolution step, picking the travel time of an event in the composite trace should provide a more accurate result.
In principle, the method may be effected by convolving complete data traces. It may however be computationally more efficient to perform the convolution using selected portions of data traces rather than complete traces. For example, the method may be carried out by defining a time window around an event of interest in the data traces, and performing the convolution using only the portions of data traces in the time window.
The first and second traces may be members of a gather of traces. They may be members of a common source gather, although the invention is not limited to a common source gather. The first and second traces may be adjacent traces in the gather.
The method may comprise convolving a trace with n traces that are adjacent on one side and with m traces that are adjacent on the other side. The number of traces n on one side of the gather used in the convolution need not be equal to the number of traces m on the other side of the gather used in the convolution, although it may be that m=n.
The method may comprise multiplying the time axis of each of the data traces by a respective constant before the step of convolving the traces or the portions of the traces. This allows a composite travel time that involves a weighted summation to be determined by the method of the invention.
The constant for a selected one of the traces may be less than zero, corresponding to a reversal of the time axis. The constant for a selected one of the traces may have a magnitude of less than one, corresponding to a contraction or “squeeze” of the time axis. Alternatively, the constant for a selected one of the traces may have a magnitude greater than one, corresponding to a stretch of the time axis.
The method may comprise determining the composite trace according to X k ′ (t)=* j=−m n X k+j (α j t), where X k (t) denotes the k th trace, n and m are natural numbers, a j denotes a constant, * denotes the convolution operation, and X k ′(t) denotes a composite trace.
The convolution may alternatively be performed in the frequency domain.
A second aspect of the invention provides an apparatus for processing seismic data, the apparatus comprising means for convolving at least first and second seismic data traces or respective portions of first and second seismic data traces thereby to form a composite trace; and determining the travel time of an event in the composite trace.
The apparatus may comprise a programmable data processor.
A third aspect of the invention provides a storage medium containing a program for the data processor of an apparatus of the second aspect.
A fourth aspect of the invention provides a storage medium containing a program for controlling a programmable data processor to carry out a method of the first aspect of the invention.
Preferred embodiments of the present invention will now be described by way of illustrative example with reference to the accompanying figures in which:
DESCRIPTION OF DRAWINGS
FIG. 1 shows a typical seismic surveying arrangement;
FIG. 2 is a schematic illustration of seismic data traces acquired by the seismic surveying arrangement of FIG. 1 ;
FIG. 3 illustrates a first embodiment of a method of the invention;
FIG. 4 shows a set of synthetic seismic data traces;
FIG. 5 shows the data traces of FIG. 4 after processing by the first embodiment of the invention;
FIG. 6 shows the data traces of FIG. 4 after processing by a second embodiment of the invention;
FIG. 7 shows the data traces of FIG. 4 after the addition of random noise;
FIG. 8 shows the data traces of FIG. 7 after processing by the second embodiment of the invention; and
FIG. 9 is a block schematic diagram of an apparatus according to the invention.
DETAILED DESCRIPTION
The generation of a composite travel time t′ of an event can be expressed generally as:
t
′
=
∑
j
=
-
m
n
a
j
t
k
+
j
(
4
)
In this summation, t′ denotes a composite travel time, t j denotes the travel time of the event in the j th trace of a gather of seismic data traces, n denotes the number of traces of the gather on one side of the subject trace (the j th trace) that are included in the summation, m denotes the number of traces of the gather on the other side of the subject trace that are included in the summation, and a j is the weighting coefficient applied to the j th trace.
In the case of the linear trend removal filter given above, for example, n=m=1 so that the k th , (k−1) th and (k+1) th traces are included in the summation, with a k−1 =a k+1 =−−½ and a k =1. No other traces are used in the convolution, so the coefficients for the (k−2) th or lower traces and for the (k+2) th or higher traces are zero (so a k−2 =a k−3 =. . . =0, a k+2 =a k+3 =. . . =0). In general, this summation is applied in a rolling manner to a gather, so that the summed travel time is calculated for every trace in the gather—i.e., a travel time sum is calculated for k=2 (from the first, second and third traces), for k=3 (from the second, third and fourth traces) and so on up to k=N−1 (for which the N−2, N−1 and Nth traces are used) where there are N traces in a gather. (If there are fewer than m traces to the left of the subject trace as will be the case for the first trace in the gather, or fewer than n traces to the right of the subject trace as will be the case for the last trace in the gather, the actual number of available traces may be used to create the composite trace to enable a composite trace to be created for each original trace of the gather.)
According to the invention, the summation of picked travel times of equation (4) is replaced by a convolution carried out on the original data traces to obtain a composite trace. In one embodiment, the convolution is of the form:
X k ′( t )=* j=−m n X k+j (a j t ) (5)
where X k (t) denotes the k th trace (which is a function of time as shown in FIG. 2 ), X′(t) denotes the composite trace obtained by the convolution, and * denotes the convolution operation. The remaining terms have the same meaning as in equation (4). Thus, rather than picking travel times of an event in, for example, three adjacent traces of a gather and summing the picked travel times as in the prior art, according to the invention the three adjacent traces of the gather are convolved with one another to produce a composite trace X′ k (t). The travel time of the event is then picked in the composite trace.
Equation (5) shows how the weighting coefficients a k are taken into account during the convolution. Before the traces are convolved, the time axis of each trace involved in the convolution is multiplied by the weighting coefficient for that trace. Where a k ∫1, this has the effect of “squeezing” the time axis of the trace (if |a k |<1) or “stretching” the time axis of the trace (if |a k |>1). Where a k <0, this also has the effect of reversing the direction of the time axis.
If the convolution is performed on the entire seismic data traces, the term X k+j (α j t) in equation (5) would represent a seismic data trace over the complete time range for which the trace was acquired. If however the convolution is performed on portions of the data traces rather than on the complete data traces, the term X k+j (α j t) in equation (5) would be zero outside a defined time window.
FIG. 3 is a schematic illustration of the method of the invention as applied to the linear trend removal filter described above, in which the travel times of an event in the k, k−1 and k+1 traces are included in the summation with a k−1=a k+1 =−½ and a k =1. In the method of the invention the summation is replaced by a convolution of three adjacent traces in the gather. The original data traces X k (t) are shown at the top of FIG. 3 .
FIG. 3 initially indicates the step of adjusting the time axes of the traces involved in the convolution according to the weighting coefficients a k . In the example of the linear trend removal filter with a k−1 =a k+1 =−½, the time axes of the (k−1) th and (k+1) th traces are “squeezed” by being multiplied by a factor of ½; the time axes of these are also reversed since the coefficients a k−1 , a k+1 are negative. The time axis of the k th trace is not altered, since the weighting coefficient a k =1. Thus, this step transform X k−1 (t) to X k−1 (−½t), leaves X k (t) unaltered, and transform X k+1 (t) to X k+1 (−½t).
The convolution operation is represented in FIG. 3 by the {circle around (x)} symbol, and FIG. 3 shows the three adjacent traces of the gather, X k−1 , X k , X k+1 being input into the convolution operator, after their time axes have been adjusted as described above, to produce a composite data trace X′ k (t).
Finally, the travel time of the event may be picked in the composite data trace.
In general, where the original data are a gather of seismic data traces it will be required to generate a composite trace corresponding to each of the original data traces. The method illustrated in FIG. 3 is therefore a “rolling” method that is performed for each of the input traces X 1 to X N . Thus, the method is performed on X 1 , X 2 and X 3 to generate X 2 ′, on X 2 , X 3 and X 4 to generate X 3 ′, and so on. (Again, if there are fewer than m traces to the left of the subject trace, or fewer than n traces to the right of the subject trace, the actual number of available traces may be used to create the composite trace so that a composite trace may be created for each original trace.)
The method of equation (5) is performed in the time domain. Most seismic receivers in current use produce a digital output trace consisting of a sequence of values of a seismic wavefield parameter (such as the pressure or a particle velocity component), so that the traces may be processed in the time domain using any suitable computational technique. This is a routine procedure for a skilled worker. However, it can sometimes be more convenient to perform the convolution in the frequency domain, as this can simplify the calculation and so can be more efficient.
If both sides of equation (4) are multiplied by 2πif, where i denotes the square root of −1 and f is frequency, and the exponential of both sides is taken, this yields
exp
(
2
π
if
t
′
)
=
exp
(
∑
j
=
-
m
n
2
π
if
a
j
t
k
+
j
)
(
6
)
That is to say, a linear combination of travel times in the time domain, as in equation (1) for example, translates into a weighted average of travel times as the argument of the exponential term. The exponential of the summation on the right hand side of equation (6) may be re-written as the product of the exponentials of the individual terms, giving
exp
(
2
π
if
t
′
)
=
∏
j
=
-
m
n
exp
(
2
π
if
a
j
t
k
+
j
)
(
7
)
Thus, the exponential summation term of equation (6) indicates a simple convolution of data traces as described above with regard to equation (7). Equation (7) is the counterpart in the frequency domain to equation (5) in the time domain, and is one way in which the invention may be carried out in the frequency domain.
FIGS. 4 and 5 illustrate results obtained by the invention. FIG. 4 illustrate synthetic seismic data traces simulated for a seismic surveying arrangement containing one seismic source and a large number of seismic receivers. The data were simulated for receivers arranged in a linear array with a constant spacing between each two neighbouring receivers, for a typical earth model. The amplitude of the data traces is proportional to the velocity of particle motion at the receiver location. Each trace in FIG. 4 was simulated for a different receiver, as a consequence of actuation of seismic energy by the seismic source, so that the traces form a common source gather and also form a “shot record” (a gather of all traces for an individual shot). The vertical axis in FIG. 4 represents the time after actuation of the seismic source; the vertical axis is labelled with the number of the time sample, with each two adjacent time samples being 2 ms apart. Thus, the label “200” on the vertical axis in FIG. 4 represents 200 time samples (i.e., 400 ms) after the actuation of the seismic source. The horizontal axis of FIG. 4 represents the offset of the trace, and is labelled with the index numbers of the traces. The traces are arranged in order of increasing offset. The first event occurring in the traces is the direct event, and it can be seen that the arrival time of the direct events increases generally linearly with offset, and show a good linear behaviour for traces up to approximately trace No. 55 . The arrival time of the direct event becomes less linear at around trace 55 owing to variations in the subsurface velocity and owing to near-surface discontinuities. Later arrivals than the first arrival have been muted out of the simulated data traces.
The amplitude of the vertical component of the particle velocity simulated for each trace is represented by shading, against a background corresponding to zero amplitude. The scale at the right of FIG. 4 represents the amplitude of the simulated vertical component of the particle velocity. In general, the direct event shown in FIG. 4 is manifested as a positive maximum A in the vertical component of the particle velocity followed by a negative minimum B.
FIG. 5 shows the composite traces generated by applying the method of FIG. 3 to the simulated data traces of FIG. 4 . That is, FIG. 5 shows the composite traces generated by applying equation (5) with n=m=1 and a k−1 =a k−1 =−½ and a k =1 to the simulated traces of FIG. 4 . This corresponds to application of a conventional linear trend removal filter.
It will be seen that the effect of applying the linear trend removal filter is to make the arrival time of the direct event substantially independent of offset. The new zero time sample is now at sample 100 , just in the middle of the time axis. (In the original data of FIG. 4 , the zero time sample corresponds to the time when the source was actuated, but after the convolution process the zero time sits in the middle at sample 100 —energy at samples lower than 100 would reflect a time-delay, and energy at higher samples would reflect a time-advance.)
In the composite traces of FIG. 5 , the direct event is now manifested as a weaker maximum A′ followed, in sequence, by a strong minimum B, a strong maximum A, and a weaker minimum B′ in the vertical component of the particle velocity.
FIGS. 6 to 8 illustrate another application of the invention. FIG. 6 shows the result of applying, to the simulated data traces of FIG. 4 , a five-term smoothing filter that uses two adjacent traces on either side of the subject trace. That is, FIG. 6 shows the composite traces obtained by applying equation (6) to the data traces of FIG. 4 , using n=m=2. The filter gives equal weight to each of the traces, so a k−2 =a k−1 =a k =a k+1 =a k+2 =1. No other traces are used in the convolution, so the coefficients for the (k−3) rd or lower traces and for the (k+3) rd or higher traces are zero (so a k−3 =a k−4 =. . . =0, a k+3 =a k+4 =. . . =0).
In the composite traces of FIG. 6 , the direct event is now manifested as a weak maximum A′ 0 followed, in sequence, by a strong minimum B, a strong maximum A, and a weak minimum B′ in the vertical component of the particle velocity.
It will be seen in FIG. 6 that the variation in offset with the arrival time of the direct event is generally smoother in FIG. 6 than in FIG. 4 . It will also be seen that the direct event is compressed in time in FIG. 6 , compared to FIG. 4 , and this is a side effect of performing smoothing by the method of the invention.
FIG. 7 shows simulated data traces that generally correspond to the data traces of FIG. 4 but that contain random noise. The traces of FIG. 7 contain high wavenumber random time jitter, and it will be seen that the arrival time of the direct event is less stable, and is less well-defined, in FIG. 7 . In general, the direct event shown in FIG. 7 is, as in FIG. 4 , manifested as a positive maximum A in the vertical component of the particle velocity followed by a negative minimum B.
FIG. 8 shows the results of applying the five-term smoothing filter using two adjacent traces on either side of the subject trace. That is, FIG. 8 shows the composite traces obtained by applying equation (6) to the data traces of FIG. 7 , using n=m=2. The filter gives equal weight to each of the traces, so a k−2 =a k−1 =a k =a k+1 =a k+2 =1. It will be seen that the results of FIG. 8 are very similar to those of FIG. 6 , showing that the method of the invention is effective at removing random noise. In the composite traces of FIG. 8 , the direct event is again manifested as a weak maximum A′ followed, in sequence, by a strong minimum B, a strong maximum A, and a weak minimum B′ in the vertical component of the particle velocity.
FIG. 9 is a schematic block diagram of a programmable apparatus 12 according to the present invention. The apparatus comprises a programmable data processor 13 with a program memory 14 , for instance in the form of a read-only memory (ROM), storing a program for controlling the data processor 13 to perform any of the processing methods described above. The apparatus further comprises non-volatile read/write memory 15 for storing, for example, any data which must be retained in the absence of power supply. A “working” or scratch pad memory for the data processor is provided by a random access memory (RAM) 16 . An input interface 17 is provided, for instance for receiving commands and data. An output interface 18 is provided, for instance for displaying information relating to the progress and result of the method. Data for processing may be supplied via the input interface 17 , or may alternatively be retrieved from a machine-readable data store 19 .
The programme for operating the system and for performing any of the methods described hereinbefore is stored in the program memory 14 , which may be embodied as a semi-conductor memory, for instance of the well-known ROM type. However, the programme may be stored in any other suitable storage medium, such as magnetic data carrier 14 a , such as a “floppy disk” or CD-ROM 14 b .
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A method of processing seismic data including convolving at least first and second seismic data traces or respective portions of at least first and second seismic data traces to forma composite trace. The travel time of an event may then be determined in the composite trace. This provides an improved method compared to the prior art technique of picking the travel time of an event individually in each one of a number of seismic data traces and averaging the individual picked travel times.
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BRIEF SUMMARY OF THE INVENTION
The present invention relates to fuel injection systems of the rotary distributor type used for delivering fuel under high pressure for sequential operation of the fuel injection nozzles of an internal combustion engine for injection of measured charges of fuel into the engine cylinders. More particularly, the present invention relates to a new and improved fuel injection system snubber valve assembly for preventing undesirable secondary nozzle operation and resulting secondary fuel injection immediately after primary fuel charge injection.
In the operation of internal combustion engines where liquid fuel injection is employed, a metered charge of fuel is delivered under high pressure to each engine cylinder nozzle for injection of fuel into the cylinder in synchronism with the engine operating cycle. The nozzle is hydraulically operated by a high pressure pulse of fuel to inject a metered charge into the engine. As the nozzle operating pressure decreases, the nozzle closes and a reverse pressure wave or pulse is thereby generated. Under certain engine operating conditions, for example, during relatively high speed engine acceleration, a reverse pressure wave or pulse of relatively high pressure can be generated which is reflected back downstream to the nozzle by an upstream fuel distributor or delivery valve to form a secondary nozzle operating pulse of sufficient magnitude to cause undesirable secondary fuel injection.
Accordingly, it is a primary object of the present invention to provide a new and improved fuel injection snubber valve assembly for automatically damping reverse pressure waves from the fuel injection nozzle for preventing undesirable secondary fuel injection.
It is another object of the present invention to provide a new and improved fuel injection system snubber valve assembly useful with fuel pumps of the type having a fuel distributor and positive displacement delivery valve upstream of the distributor and wherein the snubber valve assembly has a pressurizing valve operable for preventing fuel cavitation at the delivery valve.
It is a further object of the present invention to provide a new and improved fuel snubber valve assembly for rotary distributor fuel injection pumps of conventional design which permits the pump to be used without undesirable secondary fuel injection.
It is a further object of the present invention to provide a new and improved fuel injection system fuel snubber valve assembly having an economical design which provides a long service free life.
It is a still further object of the present invention to provide a new and improved fuel injection system fuel snubber valve assembly which may be employed with a fuel pump having a rotary distributor and charge measure governing.
Other objects will be in part obvious and in part pointed our more in detail hereinafter.
A better understanding of the invention will be obtained from the following detailed description and the accompanying drawings of illustrative applications of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 includes a side elevation section view, partly broken away and partly in section, of a fuel pump having a snubber valve assembly of the present invention and a side view of a fuel injection nozzle connected to the fuel pump;
FIG. 2 is an enlarged perspective exploded view, partly broken away and partly in section, showing in detail the several parts of a first embodiment of a snubber valve assembly of the present invention;
FIG. 3 is an enlarged partial longitudinal section view, partly broken away and partly in section, of the snubber valve assembly;
FIG. 4 is a plan view of a stamped plate which is rolled to form a combined spacer and stop sleeve of the snubber valve assembly; and
FIG. 5 includes enlarged longitudinal section views, partly broken away and partly in section, of a fuel delivery valve of the fuel pump and a second embodiment of a snubber valve assembly of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in detail, a fuel pump 10 is shown in FIG. 1 of the type shown and described in U.S. Pat. No. 3,704,963 of Leonard N. Baxter, dated Dec. 5, 1972, and entitled "Fuel Pump". Briefly, the fuel pump 10 is adapted to supply measured pulses or charges of fuel to the several fuel injection nozzles 11 (only one of which being shown) of an internal combustion engine (not shown). A pump housing 12 having a cover 14 secured by fasteners 16 rotatably supports a pump rotor 18 having a drive shaft 20 with a tapered end for receiving a drive gear, not shown, to which the shaft 20 is keyed.
A vane-type transfer or low pressure supply pump 22 driven by the rotor 18 receives fuel from a reservoir, not shown, and delivers fuel under pressure via an annulus 31 and axial bore 30 to a metering valve 32.
A high pressure charge pump 36 driven by the rotor 18 comprises a pair of opposed plungers 38 reciprocable in a diametral bore of the rotor. The charge pump 36 receives metered fuel from the metering valve 32 through a plurality of angularly spaced radial passages 40 adapted for sequential registration with a diagonal inlet passage 42 of the rotor as the rotor 18 is rotated. Fuel under high pressure is delivered by the charge pump 36 through an axial bore 46 in the rotor 18 to a radial distributor passage 48 adapted for sequential registration with a plurality of angularly spaced distributor outlet passages 50 which communicate with respective individual fuel injection nozzles 11 (only one of which being shown) of the engine via snubber valve assemblies 51 spaced around the periphery of the housing 12. A positive displacement fuel delivery valve piston 52 of a delivery valve is reciprocably mounted in the axial bore 46 and is axially biased to a closed position shown in FIG. 1 by a suitable return compression spring. The delivery valve provides in a conventional manner for achieving a sharp cut-off of fuel to the nozzles and thereby eliminate fuel dribble into the engine combustion chamber after fuel injection. The angularly spaced radial inlet passages 40 to the charge pump 36 and the angularly spaced outlet passages 50 of the rotary distributor are located to provide registration respectively with the diagonal pump inlet passage 42 during the intake stroke of the plungers 38 and with the outlet passage 48 during the compression stroke of the plungers 38.
An annular cam 54 having a plurality of pairs of diametrically opposed camming lobes is provided for actuating the charge pump plungers 38 inwardly together for periodically pressurizing the charge of fuel therein and for thereby periodically delivering pulses of pressurized fuel for injection of fuel charges into the engine cylinders. A pair of rollers 56 and roller shoes 58 are mounted in radial alignment with the plungers 38 by a rotor driven carrier, not shown, for camming the plungers inwardly. For timing the distribution of the pressurized fuel to the fuel nozzles in proper synchronism with the engine operation, the annular cam 54 is adapted to be angularly adjusted by a suitable charge timing mechanism 55.
A plurality of governor weights 62, angularly spaced about the pump shaft 20, provide a variable governing bias on a sleeve 64 which engages a governor plate 66 to urge it clockwise as viewed in FIG. 1 about a support pivot 68. The governor plate 66 is urged in the opposite pivotal direction by a compression spring 70 having a bias which is adjustable by a lever 72 operated by a throttle shaft 74 connected to a throttle arm 75. The governor plate 66 is connected for controlling the angular position of the metering valve 32 by a control arm 76 fixed to the metering valve and by a link 78 pivotally connected to the control arm 76 and normally biased by a tension spring, not shown, into engagement with the governor plate 66.
As is well known, the quantity or measure of the charge of fuel delivered by the charge pump 36 is readily controlled by varying the inlet fuel restriction with the metering valve 32. The pump governor controls the angular position of the metering valve 32 to maintain the engine speed under varying engine load conditions at the speed established by the throttle shaft 74. Rotation of the metering valve 32 under the control of the pump governor varies the metering valve restriction between the passages 30 and 40 and thus varies the fuel delivered by the pump to maintain the associated engine at a speed determined by the setting of the governor.
In accordance with the present invention, the fuel pump snubber valve assembly 51 provides for automatically preventing undesirable secondary fuel injection by damping reverse pressure waves or pulses from the fuel nozzle 11 which occur when the fuel nozzle 11 closes at the end of primary or normal fuel charge injection.
A first embodiment 100 of a snubber valve assembly incorporating the present invention is shown in detail in FIGS. 2 and 3. The snubber valve assembly 100 comprises as shown in FIG. 2, an elongated valve body 102 having an axially extending bore 104 therethrough and threaded male connector fittings 105, 106 at both longitudinal ends for mounting the valve assembly 100 on the body 12 of the fuel pump 10 as shown in FIG. 1 and for securing a suitable fuel conduit to the snubber valve assembly 100 for connecting the snubber valve assembly to the respective fuel nozzle 11.
The axial bore 104 of the valve body 102 has upstream, intermediate and downstream cylindrical bore sections 108-110 respectively of increasing diameter. An annular radial shoulder 112 is formed between the intermediate and downstream bore sections 109, 110 and the downstream bore section 110 is internally threaded for receiving an externally threaded snubber valve retainer 113.
A snubber valve generally denoted by the numeral 114 is mounted within the downstream bore section 110 for damping the reverse or upstream pressure wave or pulse from the fuel injection nozzle 11 occurring at nozzle closure at the end of fuel injection. In general, the amplitude of the reverse pressure wave or pulse increases with engine speed and with the size of the injected charge and therefore is relatively high during for example, relatively high speed engine acceleration. The snubber valve 114, in damping the reverse or upstream pressure wave, provides for substantially reducing the intensity of any resultant reflected secondary pressure wave or pulse rebounding downstream in the nozzle fuel line normally from the delivery valve or the rotary fuel distributor.
The snubber valve 114 comprises in axially spaced engagement, an upstream circular valve seat plate 116, a snubber valve plate 150, an intermediate combined spacer and valve member stop sleeve 120 and the threaded annular retainer 113. The valve seat 116, intermediate sleeve 120 and retainer 113 have aligned coaxial fuel passageways 122-124 for conducting fuel through the snubber valve 114. The valve seat 116 has a chamfered upstream peripheral circular edge 126 and is held in engagement with the valve body shoulder 112 at the upstream end of the large snubber valve bore section 110. The intermediate sleeve 120 is formed by first stamping an elongated flat plate 128 (shown in FIG. 4) having approximately half-width cut-outs or slots 129 at each end of the plate 128 and intermediate full-width cut-outs or slots 130 and together forming three lands or projections 132 of equal width and spacing. The flat stamped plate 128 is then suitably rolled to form a castellated generally annular sleeve 120 having three equiangularly spaced circumferential slots 134-136 and intermediate axially extending circumferential projections 138 and an axially extending slot 140 at the circumferential ends of the rolled plate. The annular spacer sleeve 120 is rolled to have an outer diameter slightly less than the bore section 110 and so that the sleeve 120 can be readily inserted into the bore 110 with its projections 138 in engagement with the valve seat 116 to hold the valve seat 116 in place against the valve body shoulder 112. Also, the annular spacer sleeve 120 is preferably rolled to be mounted on an inner reduced axial end 144 of the retainer 113 which assists in holding the rolled sleeve 120 in position. The spacer sleeve 120, annular retainer 113 and a snubber valve plate 150 hereinafter described, are preferably installed together in the bore section 110, and the axial passageway 124 in the retainer 113 is shown having a hexagonal cross section to receive a suitable wrench for inserting and removing the retainer 113.
The snubber valve plate 150 is mounted between the valve seat 116 and spacer sleeve 120 and is formed with three equiangularly spaced radial projections 152 for receipt within the three axial slots 134-136 of the spacer sleeve 120. The spacer sleeve slots 134-136 have a constant axial dimension which is slightly greater than the thickness of the valve plate 150 to permit the valve plate 150 to be hydraulically shifted by the fuel between an upstream relatively closed axial position in engagement with the valve seat 116 and a downstream relatively open axial position limited by the slots 134-136. The valve member 150 is contoured to permit relatively free flow of fuel around the plate 150 and through the axial fuel passageway 123 in the intermediate annular sleeve 120 when the valve member 150 is in its downstream open position and whereby the valve plate 150 permits fuel to flow downstream to the fuel injection nozzle without substantial restriction. The valve plate 150 has a central axial snubber port or restriction 154 so that the valve plate 150 in its upstream relatively closed position dampens a reverse pressure wave or pulse from the fuel injection nozzle when it closes. In that regard, the snubber port 154 functions to split or diffuse the reverse pressure wave energy by permitting part of the wave energy to continue upstream, thereby preventing secondary fuel nozzle injection by minimizing the intensity of any resultant reflected secondary pressure wave or pulse. Accordingly, the present invention provides a low cost snubber valve having a valve seat 116, valve member 150 and spacer sleeve 120 adapted to be economically manufactured from flat plates and a retainer 113 adapted to be economically manufactured with a screw machine from commercially available bar stock. The spacer sleeve 120 is economically formed by stamping a slotted plate 128 and then rolling the slotted plate into the annular sleeve 120. Also, the spacer sleeve 120 can be preassembled with the retainer 113, snubber valve plate 150 and valve seat 116 for facilitating snubber valve installation.
A second embodiment 160 of a snubber valve assembly of the present invention shown in FIG. 5 comprises an elongated valve body 162 generally like the valve body 102, but having a different axial bore 164. Specifically, the valve body bore 164 has a cylindrical pressurizing bore section 166 with an upstream generally conical shoulder or seat 168 between that bore section 166 and an upstream reduced bore section 170 which is adapted to be connected as shown in FIG. 5 for receiving fuel from the fuel pump distributor and delivery valve. Also the axial bore 164 comprises a downstream cylindrical snubber valve bore section 172 (which is not internally threaded as in the embodiment of FIGS. 2 and 3) as well as an intermediate cylindrical bore section 174 having a diameter intermediate that of the snubber valve bore section 172 and the pressurizing bore section 166.
A snubber valve 176 mounted in the snubber valve bore section 172 has a snubber valve plate 150 and spacer sleeve 120 preferably formed as described with reference to the embodiment to FIGS. 2 and 3. A press-fit partly spherical annular retainer 180 is shown provided in place of the threaded annular retainer 113. Also, the valve seat plate 182 is made thicker and is formed with an upstream recess 184 for receiving a downstream end of a pressurizing valve compression spring 186.
A spherical ball 190 is formed to be closely received within the cylindrical pressurizing bore section 166 to provide a pressurizing piston for pressurizing the fuel upstream of the piston with the bias of the return spring 186. Accordingly, when the positive displacement or volume retraction fuel delivery valve 152 is returned to its upstream or closed position by its return spring 192 at the end of each fuel charge pulse by the plungers 38 of the charge pump 36, the pressurizing valve provides for reducing or preventing cavitation immediately downstream of the delivery valve piston 152. Such a pressurizing valve is particularly desirable where a snubber valve is employed since the snubber valve restricts the rate of reverse fuel flow to the delivery valve.
The pressurizing valve return spring 186 provides for example, a 250 psi differential fuel pressure across the ball piston 190 with the piston 190 floating at a closed position in the pressurizing cylinder 166 just upstream of an open position in part within the larger intermediate bore section 174 where fuel is permitted to flow around the ball piston 190. The differential or pressurizing pressure is substantially less than the pressure (e.g. of the order of 2500 psi) required for hydraulically operating the fuel injection nozzle 11 and whereby normal fuel injection is not substantially effected by the provision of a pressurizing valve in the nozzle fuel line. Accordingly, the ball piston 190 provides (a) a valve member for permitting substantially normal fuel flow downstream to the fuel injection nozzle and (b) for pressurizing the upstream fuel to the pump delivery valve at the completion of the fuel injection charge pulse from the charge pump. Thus, the embodiment 160 of the snubber valve assembly of the present invention shown in FIG. 5 provides a low cost and reliable combination of pressurizing and snubber valves having parts which can be mass produced and easily assembled.
As will be apparent to persons skilled in the art, various modifications, adaptations and variations of the foregoing specific disclosure can be made without departing from the teachings of the present invention.
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A liquid fuel injection system with a snubber valve assembly with a low cost, four-part snubber valve mounted within a valve body and in addition in a second embodiment a low cost, two-part fuel pressurizing valve mounted within the valve body upstream of the snubber valve.
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RELATED APPLICATION
[0001] This application claims the benefit of and priority to Great Britain Patent Application No. GB0403235.5 filed Feb. 13, 2004, the disclosure of which is hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to mechanical seals, especially mechanical seals with a so-called self aligning mechanism.
BACKGROUND OF THE INVENTION
[0003] A mechanical seal comprises a “floating” component which is mounted axially movably around the rotary shaft of, for example a pump and a “static” component which is axially fixed, typically being secured to a housing. The floating component has a flat annular end face, i.e. its seal face, directed towards a complementary seal face of the static component. The floating component is urged towards the static component to close the seal faces together to form a sliding face seal, usually by means of one or more springs. Alternatively, instead of one or more springs, a metal bellows unit may be employed as the floating component.
[0004] In use, one of the floating and static components rotates; this component is therefore referred to as the rotary component. The other of the floating and static components does not rotate and is referred to as the stationary component.
[0005] Those seals whose floating component is rotary are described as rotary seals. If the floating component is stationary, the seal is referred to as a stationary seal.
[0006] If the sliding seal between the rotary and stationary components are assembled and pre-set prior to despatch from the mechanical seal manufacturing premises, the industry terminology for this is “cartridge seal”. If the rotary and stationary components are despatched individually (unassembled) from the mechanical seal manufacturing premises, the industry terminology for this is “component seal”.
[0007] Cartridge seal assemblies generally contain a single member that axially positions the respective components that make up the seal assembly. This member is typically referred to as a cartridge sleeve. The cartridge sleeve is conventionally radially disposed to the mechanical seal faces and extends axially beyond the mechanical seal faces.
[0008] A mechanical seal with one rotary face and one stationary face is referred as single seal. If there are two rotary faces or two stationary faces used in a mechanical seal assembly, it is referred as double seal.
[0009] Mechanical seals are used to prevent the leakage of a media, which is referred as product media, from one side of the sealing faces to the other side, on a rotary shaft, however it is known in the industry that a very small amount of leakage through the seal face always happen. This leakage will also help to increase the life of the seal faces at the contacting areas. This pair of seal faces are extremely flat to each other and their flatness are measured in Helium light bands. Any distortion or deviation from this flatness can cause the mechanical seal to leak and be unfit for its intended duty and can increase the amount of the leakage through the seal faces, in which it is referred as seal failure.
[0010] One of the well-known disturbances is, when the rotating shaft is not aligned with the sealing housing. This means the rotary face will not have a parallel rotating axis to the centre of stationary face. In this situation, there will be over compression at one side of the sealing faces and separation on the other side of the sealing faces. The compression can wear off the sealing faces and separation increases the leakage. One method of overcoming this problem is described U.S. Pat. No. 4,509,762 and used a self-aligning seat for stationary seal.
[0011] The present invention is an improvement on U.S. Pat. No. 4,509,762, and uses the self-aligning mechanism in a double seal to prevent seal failure due to misalignment.
[0012] A double mechanical seal, which may also be cartridge mounted, provides extra security against leakage. For example, where a product to be sealed from the environment is noxious (e.g. an acidic or carcinogenic product), or the product media is very hot or very cold, or it has a large pressure differential in between OD & ID of the sealing faces, a double seal is used. Often it is essential to use a media, which is usually referred in the industry as “barrier media”, in between the primary and secondary pairs of sealing faces in a double seal.
[0013] The primary sealing faces are always in contact with the product media from outside and barrier media from the inside, or vice versa. The secondary sealing faces are therefore in contact only with barrier media from either inside or outside in a double seal.
[0014] The barrier media is used for one or combination of following reasons:
(i) to neutralise the more noxious of the product media, (ii) to reduce the effect of high pressure from product media on primary sealing faces, by applying high pressure on barrier media, to reduce differential pressure at sealing faces, (iii) to reduce or even in some cases to increase the temperature of the sealing faces, due to high or low Product media temperature, or dispensing the frictional heat generated from the sealing faces.
[0018] An improved circulation of the barrier media in the cavity in between the primary and secondary sealing faces provides a better heat dispensation to adjust the temperature on the sealing faces.
[0019] One of the major issues that is considered on designing a mechanical seal is to fit the sealing faces into a very small available space. Therefore this cavity area in between the primary and secondary sealing faces can be very tight and small and designing and fitting an adequate circulating system for barrier media requires some innovations.
[0020] There are many inventions in this regard, which for example use, a pumping vane device within the sealing chamber, eccentricity, a combination of cut-water and pumping vanes, a combination of eccentricity and cut-water or the use of a combination of pumping vanes, eccentricity and cut-water.
[0021] An object of the present invention is to improve on all above inventions by using a self-aligning seal face mechanism in combination with a cut-water, and/or eccentricity, and/or pumping vane used in a mechanical seal assembly.
SUMMARY
[0022] According to a first aspect of the invention there is provided a mechanical seal assembly for sealing a rotatable shaft to a fixed housing, said seal having a first annular self-aligning member surrounding a shaft and attachable to a second stationary housing member, and a third annular member having a radial face for mating which preferably corresponds to a radial face of a fourth rotary member, said first and third members have a means for permitting relative pivotal movement about a first axis between said first and third members and about a second axis at right angles to the first axis between the first annular member and second stationary housing, the assembly further including means for modifying fluid flow radially inwardly of said first member.
[0023] Preferably the flow modifying means comprises a cut water in the form of a radially extending, part circumferential fin.
[0024] Even more preferably the cut water feature is located adjacent to a communication orifice between the inner and outer most radial parts of the stationary housing.
[0025] In an alternative embodiment of the invention the flow modifying means comprises a radially extending eccentric annular member.
[0026] Even more preferably the cut water feature and/or the eccentric annual feature is located adjacent to at least one radially extending feature on the rotating member.
[0027] In a further preferred embodiment the seal comprises at least one set of counter rotating seal faces, at least one of which one is mounted on the self-aligning device containing the cut water feature adjacent to at least one communication orifices between the inner most part and outer most part of gland/housing member.
[0028] Preferably the rotating seal face which is mounted on the self-aligning device is the stationary seat.
[0029] In a further preferred embodiment of the invention the seal comprises at least one set of counter rotating seal faces, one of said seal faces, preferably the stationary seat being mounted on a self-aligning device containing an eccentric stationary member adjacent to the rotating member. Preferably the rotating seal face that is mounted on the self-aligning device is the stationary seat.
[0030] In a further embodiment of the invention the rotatable member contains at least one circumferential radially displaced pumping vane.
[0031] In a further embodiment of the invention the mechanical seal includes two rotary assemblies with radial faces and two stationary assemblies.
[0032] Preferably the two stationary assemblies are positioned back to back and are arranged along the self-aligning ring member such that an annular gap channel is provided between the two stationary assemblies.
[0033] Even more preferably the stationary assemblies have the same axes of pivotal movement.
[0034] In a further embodiment of the invention the self-aligning ring is provided with at least one communication orifice extending from an inner surface to an outer surface, said orifice opening into the annular gap channel to allow access from the inside of the self-aligning ring to the outer surface of the self-aligning ring.
[0035] In a further embodiment of the invention the pivotal movement between the gland-insert member and the self-aligning ring within the stationary assemblies is generated by the use of at least two lugs or pins provided on at least the gland-insert or the self-aligning ring.
[0036] Preferably the lugs are common for the both of said stationary faces.
[0037] Even more preferably each of said lugs or pins is located around 180° away from the other lug or pin along the annular surface of the self-aligning ring.
[0038] Even more preferably still four lugs and/or or four pins or any combination of such are provided on the self-aligning ring. Preferably two lugs or pins are provided for each of said stationary faces, and wherein for each stationary face, one lug or pin is located at around 180° along the annular surface of the self-aligning ring from the other lug or pin.
[0039] Preferably the lugs or pins described are positioned such that they create a cut-water effect on the barrier media within the gap channel.
[0040] Even more preferably the lugs extending into the gap channel have a curved profile for facilitating the flow of barrier media into and out of this channel.
[0041] According to a further embodiment of the invention the rotational shaft or sleeve is eccentric to the centre of the two stationary faces, thereby creating a pressure differential in the barrier media resulting in flow from an orifice provided within the self-aligning ring into the gap channel located in the back of said stationary faces.
[0042] More preferably the distance between the rotational sleeve or shaft and the stationary faces is reduced by said eccentricity.
[0043] Even more preferably still the barrier media travels in the same rotational direction, along the gap channel, as the rotational shaft or sleeve.
[0044] In a further preferred embodiment of the invention the in and out ports' slots on the ring are used in an opposite way to as previously described, in which the barrier media flows into the gap channel from the orifices located in the area that the distance in between the shaft or sleeve and the said stationary faces are increased by the eccentricity, and the barrier media exits from the said gap channel from the other slot on the said self-aligning ring.
[0045] In a preferred embodiment of the invention the self-aligning ring is provided with at least one orifice to allow the barrier media to flow in or out of the channel gap in between the back of said two stationary faces and said self-aligning ring.
[0046] In a further preferred embodiment of the invention at least one pumping vane or groove is provided on the rotational shaft or sleeve for circulating the barrier media in the gap channel. Preferably the rotational shaft or sleeve is provided with at least one pumping vane and at least one pumping groove. Preferably the vane or groove is orientated parallel to the axis of rotation of the shaft or sleeve. Alternatively the pumping vane or groove is orientated at an angle to the axis of the rotation on the shaft or sleeve thereby providing an axial pumping effect on the barrier media. The vanes or grooves may be of the same or different sizes. The vanes or grooves may be orientated in the same or different axial directions.
[0047] In a further preferred embodiment of the invention the self-aligning ring assembly is comprises at least two parts.
[0048] A mechanical seal assembly according to any preceding claim, wherein the inner surface of the self-aligning ring is provided with at least one vane or groove for directing the flow of the barrier media.
[0049] In a still further preferred embodiment of the invention the in- and/or out-ports provided on the gland and/or gland insert are adapted to facilitate the flow of the barrier media into and out of the self aligning ring. Preferably the ports are substantially curved shaped.
[0050] In a yet further preferred embodiment of the invention the self-aligning ring extends underneath at least one of the stationary faces thereby directing the barrier media underneath the seal face.
[0051] The mechanical seal assembly according to the present invention may comprise a single seal, a double seal or a triple seal.
[0052] A mechanical seal assembly as substantially as herein described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] This is described by way of example only, with reference to the accompanying illustrative drawings, of which:—
[0054] FIG. 1 is a prior art, which illustrates a double seal design with one in-port and one out-port for the barrier media and one self-aligning ring on back of two stationary seal faces.
[0055] FIG. 2 is a longitudinal cross section through a double seal of the invention.
[0056] FIG. 3 corresponds to FIG. 2 and illustrates the cross sectional view of the invention concept to present the location of cut-water mechanism located just before the out-port at the bottom section of FIG. 2 .
[0057] FIG. 4 illustrate a cross sectional view of a prior art seal without a self-aligning mechanism in operation.
[0058] FIG. 5 illustrate a cross sectional view of the current invention where a self-aligning mechanism is used to compensate the misalignment in between the rotary shaft and the seal housing.
[0059] FIG. 6 illustrate the self-aligning mechanism on a dual seal of a prior art system and few designs for the current invention.
[0060] FIG. 7 illustrate a longitudinal cross section and end view of the use of pumping vanes on the sleeve within this invention.
[0061] FIG. 8 illustrates a longitudinal cross section and end view of the use of eccentricity within the current invention.
[0062] FIG. 9 illustrates a longitudinal cross section and end view of the use of cut-water and eccentricity within the current invention.
[0063] FIG. 10 illustrates a longitudinal cross section and end view of the use of cut-water, eccentricity and pumping vanes within the current invention.
[0064] FIG. 11 illustrate the view of a gland and a gland-insert in this invention.
[0065] FIG. 12 illustrates the cross-sectional view of the barrier media into the seal as an example in the current invention.
[0066] FIG. 13 illustrates a longitudinal cross section of a sleeve with staggered pumping vanes and grooves on the current invention.
[0067] FIG. 14 illustrate a longitudinal cross section of an extended self-aligning mechanism under the seal faces, for a better barrier media path inside of the seal.
[0068] FIG. 15 illustrates a longitudinal cross section of the self-aligning mechanism in a single seal.
DETAILED DESCRIPTION
[0069] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the claims. Like reference numbers signify like elements throughout the description of the figures.
[0070] It will be understood that when an element or layer is referred to as being “on,” “connected to,” or “coupled to” another element or layer, it can be directly on, connected, or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Like numbers refer to like elements throughout the description.
[0071] Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top” may be used herein to describe one element's relationship to another element as illustrated in the figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The exemplary term “lower” can, therefore, encompass both an orientation of “lower” and “upper,” depending of the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The exemplary terms “below” or “beneath” can, therefore, encompass both an orientation of above and below.
[0072] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0073] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0074] The skilled person will understand that the invention may be employed for different seal face arrangements in a double or triple mechanical seal whether designed in a cartridge seal or component seal format.
[0075] The invention may be used with metallic components as well as non-metallic components.
[0076] From FIG. 1 , an experienced reader will note that the groove 132 in the self-aligning mechanism is the only way that allows the barrier media flow from in-port 20 to the gap channel 210 at the back of two stationary faces 5 and 7 . The barrier media flows through this channel to the space in between underneath of the stationary faces and the sleeve, to the cavity 17 and 37 close to rotary faces 4 and 9 respectively. The barrier media is then flows out of this area through out-port 21 . The pressure difference in between the in-port 20 and out-port 21 is the only mechanism that helps the Barrier media travel through the mechanical seal.
[0077] FIGS. 2 & 3 present the current invention by using the prior art self-aligning mechanism 7 . This self-aligning ring is eccentric to the shaft as it is presented in these figures that space 30 is larger than space 33 . A cut-water 34 and pumping vane 40 on the sleeve are also illustrated in FIG. 3 . Self-aligning mechanism 7 compensates any misalignment in between the rotating sleeve 1 and the seal housing 12 . This misalignment can also be in between the shaft 16 and the main housing 14 or any other combinations. The cutwater mechanism shown in FIG. 3 is by modifying the location of pins 130 in FIG. 1 to be away from the out-port 21 (in FIG. 2 ). The pins are in a larger size, to block the gap channel 210 to provide cutwater effect on barrier media.
[0078] In a prior art design, where a self-aligning mechanism is not used, if there was a misalignment in between the rotary shaft axis and the housing axis, the faces will not be in full contact along their flat surfaces. This is presented in FIGS. 4 - a & 4 - b.
[0079] FIG. 4 - a presents the rotating axis (S) of the shaft ( 16 ) is not parallel to the axis (H) of the housing ( 12 , 14 ). The stationary faces are connected to the housing by the stationary assemblies and the axis (F) of the stationary faces ( 5 , 8 ) will be aligned with axis (H) of the housing. This will cause the rotary faces 4 & 9 have a point contact with the stationary faces 5 & 8 respectively. This point contact is magnified for Faces 4 & 5 in FIG. 4 - b . It is shown in FIG. 4 - a that if the shaft and housing have a misalignment of g degrees, this will be projected on the contact surfaces in between the rotary face 4 and the stationary face 5 at the same amount of angle g in FIG. 4 - b.
[0080] A centrifugal force is applied on the barrier media around the sleeve, during the seal operation, while the shaft is rotating. This is shown as an example on a particle Q 1 from barrier media in FIG. 4 - a . Particle Q 1 is located in between the rotating shaft/sleeve 16 and stationary face 5 . This particle is also located in the region marked ABCD in FIG. 4 - a.
[0081] The region ABCD is magnified in FIG. 4 - b , to clearly illustrate the movement of particle Q 1 in this region in a simple format. A radial/centrifugal force f 1 is applied on Particle Q 1 due to the shaft rotation. Due to this radial force, this particle will hit surface CD at Q 2 . This particle will then deflect from this surface along f 2 , which is symmetric to line f 1 based on line m. Line m is perpendicular to surface CD at point Q 2 . The angle in between lines m and f 1 is equal to g, which is the misalignment angle in between the shaft and the housing. If the axis of the shaft or sleeve and the axis of the housing were aligned together, angle g will be equal to zero. In this situation, f 2 will be on top of f 1 but in an opposite direction. f 2 also represents the force that is applied on deflected barrier particle Q 2 after hitting surface CD.
[0082] In a situation when there is misalignment in between the shaft and the housing exists at angle g, it is shown in FIG. 4 - b that force f 2 can be projected into two components: one is the radial force f r and the other is a tangential force ft. Radial force f r will cause the barrier particle Q 2 move towards the shaft, however force ft will cause the particle Q 2 to move away from line BC. It is clear from FIG. 1 compared to FIG. 4 - a that the in-port or the out-port on the gland of the mechanical seal are around line BC in FIGS. 4 - a and 4 - b . Therefore in the top part of the seal (as shown in FIGS. 4 - a & 4 - b ) the barrier particle is moving away from the seal's in-port. A similar state happens on the other half of the seal, where the barrier particle will be moving towards the seal's out-port.
[0083] One may argue this is useful on circulating the barrier media from the seal's IN-Port to underneath of the seal faces at the top half, then move the barrier media towards the out-port at the bottom half of the seal. This is very rare to happen and be beneficial as it is possible that the seal's out-port can be located at top part and the in-port being at the bottom part. In this case, the barrier media will be trapped in the seal and it will prevent the circulation of the barrier media in the mechanical seal. The misalignment in between the shaft and the housing can happen at any direction and it is not possible for definite to claim that the in-port always remain at top and the out-port always remain at the bottom as mentioned in the previous example. Therefore it is better to avoid relying on chance, and remove such axial force on barrier particles (f t ) that is generated by misalignment in between the shaft/sleeve and the housing.
[0084] The best way of removing the axial force (f t ) on the barrier particle Q 2 in FIG. 4 - b is to get rid of the angle g. Angle g is the misalignment in between the shaft/sleeve 16 and the housing 14 in FIG. 4 - a . The self-aligning ring 7 that is illustrated in FIGS. 5 - a and 5 - b would align the axis (F) of the stationary faces ( 5 & 8 ) to the axis of shaft (S) and eliminates angle g in between contacting surface in between rotary and stationary faces. This is done by rotating the stationary assembly around pin 150 in FIG. 5 - a along a 1 direction, when there is such a misalignment. In this case the axis (F) of the stationary faces 5 and 8 , will be aligned with the axis (S) of the rotary shaft/sleeve 16 or the rotary faces 4 and 9 , while the housing axis H still is not aligned with (S). In this situation no axial force is generated on barrier media particles, if such a misalignment exists in between the shaft/sleeve and the housing. Therefore it is possible now to adequately use other mechanisms for circulating the barrier media in the mechanical seal. These mechanisms are now designed within the self-aligning ring 7 . Therefore this invention is based on improving the previous invention on self-aligning mechanism disclosed in U.S. Pat. No. 4,509,762, to include eccentricity, cut-water or pumping vanes on the sleeve, or any combination of them in the mechanical seal.
[0085] The present invention is also an improvement on the prior art that use any combination of eccentricity, cut-water or pumping vanes without a self-aligning mechanism in the mechanical seal, because the barrier media can become trapped in the seal chamber as a result of any misalignment between the shaft and the housing. Furthermore the seal faces will be in point contact which may result in damage leading to seal failure.
[0086] FIG. 6 - a illustrates the prior art of using Self-Aligning mechanism in a double seal, and FIG. 6 - b illustrates the current invention by moving and changing the size of the drive pins 130 and 131 to 134 and 135 . These pins provide the cut-water mechanism effect on barrier media. The in-port 132 and out-port 133 in FIG. 6 - b are slightly modified compared to FIG. 6 - a . This is to allow the barrier media flow into the ring 7 from port 132 , then travel along path 160 in between the sleeve and the ring. The barrier media is stopped by pins 135 , which has the cut-water effect, and it is lead out of the ring 7 from out-port 133 in FIG. 6 - b.
[0087] FIGS. 6 - c and 6 - d refer to a same ring from different view. The fin shaped section 142 on the ring 7 provides the cut-water concept in a more effective way. The edges on this fin have got a slight angle at the in-port 132 to lead the barrier media into the ring and then by using an angle at the end of this fin, it works in a better way as cut-water to lead the barrier media to out-port 133 . The barrier media travels inside of the ring 7 along path 160 .
[0088] FIG. 6 - e illustrates a further embodiment of the self-aligning ring. A Shorter fin 142 compare to FIG. 6 - c or 6 - d on the ring 7 provides the cutwater concept in a more effective design. The position of in & out ports 132 & 133 , are similar to FIG. 6 - c , and the ports are formed radially in an angle to provide a better path for the barrier media stream. There are also two more ports in this ring to ease its assembly in the seal, despite the location of the in-port and out-port on the seal. However this design can also be used when the in & out ports of the Mechanical seal are located on a different angle compared to the ones illustrated here that are along the in & out ports of ring 7 in FIG. 6 - b.
[0089] As an example, when the seal is in operation and the shaft rotates counter clock-wise (CCW) in FIG. 6 - b , the barrier media flows from IN port 132 into the space between the ring 7 and sleeve. The barrier media then travels toward the out-port 133 along path 160 . However some of the barrier media may travel longitudinally along the sleeve by using different mechanisms, to reach around the contact sealing faces. The path from the in-port to the out-port where, the barrier media is travels ( 160 ), is referred as up-stream. The space 161 behind the pins 134 & 135 , where the barrier media is trapped in FIG. 6 - b is referred as down-stream in the industry.
[0090] FIG. 7 - a illustrates the effect of the pumping vanes 60 on the sleeve to circulate the barrier media from the in-port 132 to out-port 133 . These vanes or grooves can be aligned with the axis of the shaft/sleeve to apply only centrifugal movement on the barrier media particles. These vanes can also have slight angles with the axis of rotation of the Shaft/Sleeve, to create some axial movement on barrier media particles. The vanes in FIG. 7 - a have a slight angle with the axis of the shaft/sleeve. On the other hand the grooves in the sleeve in FIG. 7 - b are aligned along the axis of the shaft/sleeve and therefore do not apply any axial movement on barrier media in the seal chamber. However an experienced reader will note the vanes can also be parallel to the axis or the grooves on the sleeve can also have an angle with the axis of the shaft/sleeve. The number of the vanes or grooves can also be reduced or increased. All the grooves or the vanes can have the same angle with the axis of the shaft/sleeve, or some of them have a different angle to the other ones. The type of the angles of the vanes or grooves can vary in a manner previously disclosed in GB 2,347,180.
[0091] FIG. 8 illustrates the effect of the eccentricity in between the rotary sleeve and self-aligning mechanism. This provides pressure differential in between the in & out ports of the self-aligning ring, and the barrier media will travel along the up-stream path 160 in this arrangement, from in-port 132 towards out-port 133 .
[0092] FIG. 9 illustrates the effect of cut-water and eccentricity in between the ring 7 and sleeve 1 . Pressure differential is generated in between the in-port 132 and out-port 133 due to the eccentricity of the rotating shaft and ring 7 . Some part of the barrier media also rotates within ring 7 , due to the frictional force in between the barrier media and the rotating shaft and also the viscosity of the barrier media. Whilst the barrier media is rotating around the ring 7 , pin 135 provides an obstacle on front of the barrier media and leads the barrier media to the out-port 133 at the end of up-stream path 160 . A rotational movement on the barrier media is also generated at the down-stream area 161 , in which will have a tendency to move out of the ring from in-port 132 or out-port 133 in FIG. 8 . This will reduce the amount of circulating the barrier media in the seal. However obstacle 134 in FIG. 9 prevents the circulating barrier media particles in the down-stream 161 to pass behind this point, and thus it will not interfere with the stream of the Barrier media at the in-port 132 . Therefore the down-stream path 161 will be a dead zone for the barrier media that cannot radially escape from the space in between the sleeve 1 and ring 7 . Pins 135 and 134 are referred as cutwater in this invention.
[0093] FIG. 10 is similar to FIG. 9 , but illustrates the use of grooves 40 on the sleeve 1 to provide a better centrifugal force on the barrier media along the up-stream 160 .
[0094] FIG. 11 illustrate the gland and the gland insert used in the mechanical seal of the invention. The ports on the gland 12 and gland insert 6 are designed to allow an easy path for the barrier media to travel into and out of the Ring 7 . It is clear for a skilled person that the area around the in-port 20 and out-port 21 in FIG. 11 - a , can be shaped as area 201 to allow the barrier media flow easily from the in-port 20 on the gland into the other parts, like ring 7 . The same principle applies on the out-port 21 of the gland.
[0095] The same modification is also applied on the gland insert 6 to provide an smooth path for the barrier media to travel from the IN-Port 20 on the gland into the ring 7 . These modifications on the gland Insert are shown as 203 and 204 on FIG. 11 - b.
[0096] FIG. 12 illustrates a cross sectional view of the gland 12 , gland-insert 6 , Self-aligning ring 7 and rotary sleeve 1 in the seal assembly. This is to illustrate the path of the barrier media from the in-port 20 of the gland 12 into the in-port 132 of the self-aligning ring 7 . The circumferential path ( 160 ), called up-stream, of the barrier media in the seal is also presented in this Figure. The angles on the gland and gland insert and also self-aligning ring at their in-ports, including the angle on the fin 142 would help to lead the barrier media towards up-stream path 160 . There are some angles on the gland 12 , gland-insert 6 , and self-aligning ring 7 at the out-port that would help to lead the barrier media to exit the seal. The cutwater angle on fin 142 , and the angle on exit port 133 of ring 7 and gland-insert 6 would help to lead the Barrier media to OUT-Port 21 on the gland 12 . The sleeve is slightly off-centered to provide eccentricity effect on the barrier media. The sleeve contains some grooves to provide the pumping vane effect and fin 142 provides the cut-water effect. Two pins 150 on ring 7 provide pivoting effect on this ring relative to gland-insert 6 .
[0097] FIG. 13 illustrates a number of staggered vanes ( 60 ) and grooves ( 40 ) on the sleeve 1 . This is to illustrate the use of any combination of grooves and vanes on the sleeve which could provide a better distribution of the barrier media axially along the seal and also to help the barrier media to travel into and out of the seal via the in & out ports.
[0098] The self-aligning ring can be designed in different shapes, if there is enough space available in the seal chamber. FIGS. 14 - a and 14 - b illustrate two different designs for the self-aligning ring 7 . The barrier media travels via the in-port 132 radially into the seal chamber and travels along the seal in FIG. 14 - a . The self-aligning ring 7 is extended underneath of the stationary faces 5 & 8 . This extension can also be designed in a format to provide eccentricity in between the rotary sleeve 1 and ring 7 . Some angles at the inner side of the ring 7 , where it extends underneath of the stationary faces, will work as deflector to lead the barrier media axially towards the seal faces. Some grooves are also located on the sleeve to work as pumping vanes in this assembly. These grooves may also be used to pump the barrier media axially to and from underneath of the faces from the in or to the out ports of the eing 7 respectively.
[0099] FIG. 14 - b is similar to FIG. 14 - a , but with extra axial holes on the self-aligning ring 7 . Hole 180 will lead the barrier media from the IN-Port 132 to underneath of the seal faces 4 and 5 . The angle 250 on the ring 7 work as deflector to move the barrier media axially to underneath of the seal faces. The barrier media then flows axially along the sleeve to the right hand side on this Figure. This flow can be helped by the use of eccentricity and pumping vanes. The pumping grooves 40 provide radial centrifugal force on the barrier media particles. The barrier media will reach underneath of the faces 8 & 9 . The use of angle 251 at this side of the ring 7 would also help. The hole 181 will lead the barrier media to out-ports 133 and 21 . It is considered self evident that different angles on ring 7 can be used as angles 180 and 181 , to provide a better barrier media circulation. The whole body of ring 7 can also have a slight axial angle to help the barrier media circulation in FIG. 14 - b . Pumping vanes can be used instead of grooves in this arrangement, and the position of the vanes or grooves can be altered along the sleeve for a more efficient pumping effect. The length of the extension of ring 7 underneath of either of the faces can also be modified for different type of barrier media or different applications. The size of axial holes 180 & 181 in ring 7 can also be modified based on the seal application. Some grooves or vanes can also be designed at the inner surface of the ring 7 , close to sleeve 1 to help the barrier media circulation.
[0100] FIG. 15 illustrates the use of self-aligning mechanism in a single seal, where the outboard faces are simple lip-seals where they are referred as 8 & 9 . This is considered self evident to an experienced reader that barrier media can be used in this type of single seals, and its circulation can be improved in the same way as it was explained for a double seal in previous figures.
[0101] The invention provides a number of advantages over the prior art. Self aligning technology is to align the axis of the rotating shaft and therefore the axis of rotary faces, to the axis of stationary faces. The eccentricity, cut-water and pumping vanes/grooves illustrated in FIGS. 8, 9 & 10 are only applied on the barrier media in the space 210 (in FIG. 5 - a & 5 - b ).
[0102] It is considered self evident that the eccentricity can be positioned at any direction in the self-aligning mechanism in this invention. The cut-water effect can also be applied at any location inside the self-aligning mechanism. The vanes or grooves on the sleeve can also be provided by using an extra part on the sleeve and can be in any shape or numbers or at any angles.
[0103] The in-ports and out-ports on the self-aligning mechanism, the gland insert or the gland can also be shaped in a different format to allow the barrier media easily flow from the in-port on the gland into the inside of the seal nearby the seal faces, and then from the inside of the seal to the out-port on the gland as shown in FIG. 12 . The number of the ports as in-port or out-port can also be altered for different applications. The angle of the in-port and out-port relative to the axis of the rotating shaft/sleeve or the axis of the housing, can also be modified to provide an easier path to the barrier media stream The shape of the pins on the self-aligning mechanism can also be altered.
[0104] The invention can be used in a triple seal as a rotary arrangement. This invention can also be applied on non-metallic parts or parts with different materials.
[0105] In concluding the detailed description, it should be noted that many variations and modifications can be made to the embodiments without substantially departing from the principles of the present invention. All such variations and modifications are intended to be included herein within the scope of the present invention, as set forth in the following claims.
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A mechanical seal includes at least one self-aligning member and has the capability to modify fluid flow radially inwardly of the self aligning member. The fluid flow may be modified by one or more of cutwater or pumping vanes/grooves in an eccentric arrangement.
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BACKGROUND OF THE INVENTION
The present invention relates to a method, a circuit arrangement and an apparatus for a non-contacting real time determination of velocities of one or a plurality of movements at an object in a direction perpendicular to a coherent radiation impinging on the object, with the scattered light of the coherent radiation producing a spatial speckle pattern over a speckle spectrum, and with the speckle pattern becoming time dependent due to the movements at the object.
If a laser beam of wavelength λ impinges on an object in the x direction, and the average distance Δx between scatter centers is >>λ, the scattered light forms a granular structure, called speckles. This is the case, for example, on all normal surfaces. The intensity distribution of the speckles is irregular. Certain mathematical interrelationships exist for the statistic distribution of the speckles. These mathematical interrelationships do not depend on the characteristics of the object, as long as the requirement of Δx>>λ is met.
With the laser at rest and the object at rest, the speckle pattern is stationary. Under certain conditions of mutual position of laser, object and observation point, the speckle pattern moves as a whole if the object itself moves. This results in a specific speckle velocity V s which, in suitable cases, is proportional to the velocity of the object. One way to record speckle movement is to measure the light intensity of the scattered light on an effective detector surface which is small compared to the average speckle size σ.
Such a detector produces a signal I proportional to the light intensity on its surface and there now exist various ways to determine the speckle velocity from the time-dependent form, I(t), of that signal. One of these methods is the so-called correlation method. Here, the incident light intensities are detected at two spatially separate locations and the resulting intensity signals are recorded. Two time dependencies result for the intensity. Both intensity time dependencies are stored. The correlation function calculated therefrom has a peak from whose position the speckle velocity can be determined.
The drawback of this method is that it requires a large amount of electronic equipment and that the velocity is not determined in real time (Pusey, J. Phys. D 9 (1976) page 1399). In principle, this method does not utilize any specific speckle characteristic.
Only a single time dependent signal I(t) is required for the method employing time integration of the signal I(t). Initially, average values N i are formed from the speckle intensity signal I(t) by way of integration over a succession of time intervals, with a computer calculating the standard deviation S and an overall average N. The quotient of both values, S/N, is a non-linear measure for the speckle velocity. The drawback of this method is again the high costs for the electronic computer and the fact that it is not a real-time method. In principle, the fact that the contrast of the speckle signal is known to go toward zero with increasing integration time, is utilized here (J. Ohtsubo, T. Asakura, Opt. Quant. Electr. 8 (1976) 523).
An earlier patent application, in the Federal Republic of Germany, No. P 3,242,771.9, discloses the so-called speckle counting process. This method counts the points of intersection between the intensity signal I(t) and a threshold level S. The threshold level S is set to be proportional to the average intensity value I. The advantage of this method is that the costs for electronic equipment are reduced and the method has real-time characteristics.
However, the drawback of this method is that noise is superposed on the speckle signal. Particularly at low velocities, this noise results in erroneous measurements because the velocity indicated is too high. In principle, this method utilizes the speckle characteristic that the time interval Δt between two counts has an average Δt which is given by Δt being approximately const·σ/V. None of the prior art methods is suitable to separate superposed velocities.
SUMMARY OF THE INVENTION
It is an object of the present invention to record the movement of a speckle pattern in such a manner that the resulting data permit a determination of the speckle velocity independently of other superposed velocities. In particular, it is an object of the invention to determine the blood circulation velocity near the skin surface or in other parts of the human body.
The above and other objects are achieved, according to the invention, by a method and apparatus for determining the velocity of an object in a given direction without contacting the object, by directing coherent radiation to the object in a direction substantially perpendicular to the given direction to cause radiation to be scattered from the object to produce a speckle pattern exhibiting a speckle spectrum, the speckle pattern at a location spaced from the object having a time dependency which is a function of movement of the object, detecting the speckle pattern intensity at the location spaced from the object, producing a first signal representative of the detected speckle intensity, and producing, from the first signal, a velocity-dependent intensity signal having a value which is weighted as a function of the frequency of the first signal.
The method according to the invention takes advantage of the fact that, for an object at rest, I(t)=constant and no frequencies unequal to 0 occur. If the object moves, then frequencies unequal to zero do occur. Thus, measuring the intensity of the signal, which is normally an electrical signal, at frequencies unequal to zero is a measure for the velocity v s . The invention particularly utilizes the fact that the speckle pattern as a whole has a granular structure. If a change is made to not simply determine the intensity above a frequency ν 0 , but to first suitably modify the signal, then the intensity formation produces a measured value which is proportional to velocity v s . This measure resides in that the amplitudes A(υ) of the spectrum must first be amplified by a factor which is proportional to υ.
On the basis of the specific shape of the speckle spectrum, the intensity of the thus formed signal is proportional to velocity v s . This proportionality has been proven by theoretical derivation and experimental data.
Due to the intensity formation, measured value P is also proportional to the average intensity I at the point of observation. To avoid interference resulting from laser output intensity fluctuations and changes in reflection conditions, such interference can be eliminated by dividing the measured value by the average light intensity I.
The advantage of the method is that the cost of the required electronic equipment can be kept low. The frequency dependent weighting is effected by time differentiation and the intensity formation by a power meter.
It is also not absolutely necessary to simultaneously measure the total intensity. In the worst case, the dependency is linear with variations in intensity. If thus great differences in velocity are to be measured and, on the other hand, a stable laser is available, this can be omitted.
In the above-described, previously proposed speckle counting method described in Federal Republic of Germany Application No. P 3,242,771.9, this is not the case. In that method, the counting rate is very sensitively dependent upon threshold S and thus on the measured average intensity I.
An important condition for speckle formation is that the laser light is scattered at scatter centers which have an average distance Δx>>λ. In normal moving objects, all scatter centers move at the same velocity. However, when observing blood flow near the skin surface of a living subject, the scatter centers may have different velocities. The resulting speckle pattern now moves under the influence of the velocity, v H , of the skin surface and of the velocity, v B , of the red blood cells. Since this is a coherent superposition of two speckle patterns according to the two velocities, a new speckle pattern is created which in appearance does not differ from the speckle pattern of a normal object. Only its behavior over time is different.
With the prior art speckle methods it is not possible to separate these two velocity components from one another or to separate even other such velocities. With these methods, the result would simply be that either a slightly higher velocity is indicated without it being possible to distinguish whether this was the result of increased skin velocity or increased movement of the blood. In any case, in no experiments was it possible to determine a difference between skin through which blood flowed and skin through which no blood flowed.
In the first-mentioned prior art methods, there probably exists no possibility at all to determine, in principle, a difference between skin through which blood flows and skin through which no blood flows. Even if this were possible, such a method could not be used in practice, because the measuring periods are very long and the amount of apparatus required would be too large.
Since the major portion of the light is scattered over the skin surface and the skin cells, the movement of the speckle pattern is also primarily determined by the skin velocity v H . Only a small portion of the light penetrates into the blood vessels and is there scattered back to return back to the outside. Therefore, the proportion of blood movement in the respective speckle pattern is always low.
If a strip of textile were glued to the skin and then a measurement were made or the blood supply to one part of the skin were suppressed, an approximate measured value for the skin velocity would result. The spectrum of signal I(t) for such a measurement is composed of a superposition of a plurality of velocities. Measurement at the skin at a location where blood flow occurs produces a spectrum in which high frequencies are more prevalent compared to measurements made at skin through which no blood flows. This permits the conclusion that the average velocity v B of the movement of blood is higher than the average velocity, v H , of the movement of skin.
Roughly, the spectrum can be composed of two parts: movement of the skin and movement of the blood. Due to the difference between the average velocities v H and v B , it is now possible to separate the signal components associated with these two velocities. A signal amplitude representation is formed only of that portion of the spectrum signal whose frequency lies above υ g , and the portion with a frequency less than υ g is suppressed. In the spectrum, this would correspond to integration over a frequency interval of υ g to infinity.
In principle, the separation of the two velocity ranges is possible even with intensity formation of the electrical signal without the use of weighted amplification. The frequency dependent amplification increases the signal differences between skin through which blood flows and skin through which no blood flows.
There exists no uniform definition of blood flow. However, it is considered to be appropriate to set the blood flow to be proportional to the velocity and the quantity of the blood, respectively. Thus, the method permits a determination of blood flow since the signal is proportional to the velocity, because of the frequency dependent weighting and also proportional to the quantity of moving blood. If more moving blood enters into the area through which the laser light penetrates, the signal becomes larger of course.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a simplified pictorial view of a measuring arrangement for carrying out the present invention.
FIG. 2 is a block diagram of a circuit for producing velocity information according to the invention.
FIGS. 3a through 3h are waveform diagrams illustrating the operation of the circuit of FIG. 2, FIGS. 3a, c, e and g being signal vs. time waveforms and FIGS. 3b, d, f and h being frequency spectrum diagrams.
FIGS. 4-6 are diagrams illustrating the measurement results achieved with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a pictorial illustration of a measuring arrangement or device with which velocity can be determined. A laser beam 15 is directed to a measuring point 5 on an object 6. Due to the surface roughness of object 6, the light scattered therefrom forms a granular pattern, i.e. speckles, where the average size σ of the speckles at the locus of observation 16 is determined only by the wavelength λ of the light employed (e.g. He-Ne laser, λ=633 nm), the size of the beam spot of beam 15 at point 5 and the distance from measuring point 5 to locus 16. With a suitable optical arrangement, the speckle pattern moves as a whole so that a speckle velocity v s can be defined.
For small angles between laser beam 15 and the optical axis 14 of the observation device there exists a simple relationship as described above.
The speckles are detected at an aperture 30 which, in order to substantially maintain the speckle contrast, is smaller than the average speckle size σ. In order to obtain a small angle between laser beam 15 and observation device optical axis 14, and to additionally assure flexible access to the desired measuring points, light conductors, or optical fibers, 7, 8, 10 are utilized. The beam from a laser 1 is focussed through a lens 2 into an optical fiber, or fiber bundle, 3. The exciting beam is highly divergent so that it is collimated by lens 4 to form beam 15 which is directed toward measuring point 5 on object 6.
The diameter, D, of the beam spot at measuring point 5 must be as small as possible so that the speckle size σ reaches the maximum size required for detection. Yet, the distance between measuring point 5 and the locus of observation 16 must not be too large because then the available light intensity would not be sufficient for detection. On the other hand, the diameter D must not depend greatly on the distance between lens 4 and object 6 because then even a slight change in the distance would result in a great change in speckle size σ, which would again bring about an error in the velocity measurement. The beam profile must therefore have a long, narrow waist 17. This is brought about by carefully matching the divergence of the laser beam exiting from optical fiber 3, the focal length of lens 4 and the distance between lens 4 and the end of optical fiber 3. Thus the diameter of the beam 15 does not change considerably within e.g. a distance from 55 to 65 mm in front of the lens.
Fiber bundle 7 forms part of the detection system and starts at locus of observation 16, which is as close as possible to the end of light conductor 3 and to lens 4 to keep the angle small between the incident laser beam 15 and the direction of observation 14. To detect speckle movement and produce therefrom a time dependent speckle intensity signal I(t), a single fiber 10 of bundle 7 leads from locus 16 to a light detector 11. Since the effective diameter of the individual fiber 10 is the effective aperture 30 for the speckle detection, the distance between measuring point 5 and locus of observation 16 must be selected such that the speckle size σ is somewhat larger than the diameter of fiber 10.
If the object 6 moves, the speckles move past the end of the individual fiber 10 so that light detector 11, e.g. a photomultiplier, at the end of the individual fiber 10 indicates time-dependent speckle intensity I(t). The individual fiber 10 is disposed in the center of the remaining fibers 8 of bundle 7. Fibers 8 form a bundle which leads to a further detector 9. Since fiber bundle 8 is composed of approximately 400 individual fibers each having a diameter equal to the speckle size σ, and since the light incident on those fibers is measured in a common detector 9, the signal produced by detector 9 represents the average speckle intensity I at the same location at which speckle intensity I is measured with the aid of detectior 11. The quality of the average formation G is given by
Gα√N,
where
G is the standard deviation of the average values divided by the mean of the average values,
N is the number of the optical fibers with a diameter equal to the speckle size 6, and
α means proportional to.
A tubus 18 serves to maintain the optimum distance between measuring head 19 and object 6. A filter 12 permits only light at the laser wavelength to pass and thus reduces the noise on the input signals to detectors 9 and 11 caused by scattered light of other wavelengths. Measuring head 19 carries the output end of fiber 3, as well as lens 4, the fiber bundle at locus 16 and filter 12.
I(t) is thus the time-dependent signal of the speckle intensity whose spectrum is determined by the spatial spectrum of the speckle pattern and by the velocity of the object.
Prerequisite for use of the method according to the present invention is that the intensity I(t) be determined by means of a detector 11 whose effective measuring surface area is smaller than the average speckle size. The effective surface area may be defined by the detector itself, by a small aperture placed onto it or, as in the embodiment of FIG. 1, by the cross section of the associated light conductor.
In contrast to the speckle counting method, the velocity determination procedure is not sensitively dependent on the total intensity of the scattered light. Therefore, it is not necessary, in principle, to determine total intensity. If the total light intensity fluctuates by no more than 5%, the determined velocity also contains an error of 5%. But this possible error can also be compensated.
Simultaneous measurement of the laser light intensity and a mathematical division operation eliminates the influence of fluctuations in laser light intensity. Simultaneous measurement of the total intensity of the scattered light and division also eliminates the influence produced by changes in reflection from object 6.
Simultaneous measurement of the total intensity of the scattered light I at the same location as the determination of speckle intensity I also eliminates the influence of direction dependent scattering.
I and I can be determined in various ways, e.g. by means of a beam splitter or by means of a glass fiber arrangement as shown in FIG. 1. The benefit of the glass fiber arrangement is its good maneuverability, which is particularly important in connection with measurements on the skin.
If in a stationary speckle pattern, the speckle pattern is scanned by means of a small aperture 30, a locus dependency I r (y) results with a local spectrum.
r indicates that I r is a space dependent function.
y is a space coordinate.
The function I y (y) could be obtained by scanning the speckle pattern.
The local spectrum of the speckle pattern is generally known from the literature. If now the speckle pattern moves at a velocity V and is observed at one location, a time-dependent light intensity I(t) results behind the aperture at I(t)=I r (vt).
v is the velocity.
I is a time-dependent function.
To illustrate the occurrence in connection with the speckle pattern, let us observe a sine-shaped light intensity distribution which is brought past the aperture at a velocity V S . The sine-shaped intensity has a locus dependency ##EQU1## The corresponding time dependency is ##EQU2## Obviously a high velocity results in the occurrence of higher frequencies in both time-dependent functions. In these functions i indicates functions concerning the example with a sine-shaped light intensity,
I o is the amplitude and y o is the wave length in space of the sine-shaped light intensity distribution.
In order to incorporate the velocity in the amplitude, a one-time time differentiation is made. ##EQU3## where
v is the velocity (see above),
y o is the wavelength in space (see above).
Now the intensity of the signal I(t) is determined to obtain the velocity. ##EQU4## P(v) is defined by this equation.
For the illustrated embodiment, the following calculations then apply: ##EQU5## (P i (v) is the equivalent function to P(v), now applied for the example with the sine-shaped light intensity. ##EQU6## M i (v) is defined by the first equation. It follows that M i (v) is proportional to velocity v.
For the speckle pattern, the value P(v) can be calculated only as the statistical average because the local spectrum of the speckles is known.
According to one theorem (the Power theorem), the following applies: ##EQU7##
This is the square of the Fourier transform of I(t), the "power spectrum".
ν is the frequency. ##EQU8##
This is so because in the spectrum, time differentiation corresponds to a multiplication with the frequency. 1/v results from a type of substitution rule. ##EQU9## This is the spectrum of the spatial speckle pattern known from literature. The expression is inserted to get the following equation. ##EQU10## where I is the average intensity and σ is the average speckle size. ##EQU11## This results in: ##EQU12## A comparison with the result of the sine-shaped intensity shows:
y.sub.o =√3σ
Time averaging, i.e. the intensity determination, corresponds to integration of the spectrum. If two velocities are superposed, skilled selection of the frequency intervals makes it possible to effect a separation. The position of the frequency interval could be obtained by interpreting the spectra of the speckle intensity signal I(t). For example, measuring at the skin a separation of the blood flow velocity from other moving objects (body, skin, other cells . . . ) is achieved by selecting an intervall from 50 Hz to 1500 Hz.
If now only given frequency intervals are utilized for the intensity formation, the velocity measurements are separated. A reduction to practice is realized in that the time-dependent signal is changed by means of active filters. It is known, for example, that a highpass filter suppresses the low frequencies and thus serves to detect high velocities. The same applies correspondingly for a lowpass filter and low velocities.
The measured value M(v s ) can be realized by means of the electronic circuit shown in FIG. 2, with FIGS. 3a through 3h showing the functions of the individual components in the circuit arrangement.
The signal I(t) from detector 11 is amplified in amplifier 20. This signal has the time dependency shown in FIG. 3a and the spectrum A(ν) shown in FIG. 3b. The signal from amplifier 20 passes through a linear filter 21 or a differentiating member, respectively, in which it is amplified proportionally to frequency ν by means of an adjustable proportionality constant, producing the output signal and spectrum shown in FIGS. 3c and 3d. The simplest way to realize this is in the form of an RC member as a passive component. Higher demands for linearity and dynamics can be met by an active circuit.
Noise from photomultiplier and laser are superposed on the speckle signal. Active lowpass filter 23 serves to constrict the observed frequency range, e.g. to a limit frequency ν T , without adversely affecting linearity, if limit frequency ν T is greater than the maximum frequency of I which is fixed by speckle size σ and the maximum velocity. The output signal of lowpass filter 23 and related spectrum are shown in FIGS. 3g and 3h.
In practice, an RMS power/DC converter 24 performs an integration and determines the total intensity, P, of the time-dependent signal. In principle, the integration is a "specific" integration over time of the time-dependent signal. However, it is mire clearly seen in the spectrum in which a frequency integration is effected over a certain frequency interval. The value of the integrated signal from converter 24 is mathematically divided in divider 26 by an average intensity signal I which is derived from detector 9 and amplified in amplifier 25. The result of this division then represents the measured value M(v S ). After time integration in integrator 28, which determines the accuracy of the measurement, M(v S ) is displayed in display device 29.
The noise from photomultiplier nd laser does of course also occur in the frequency range under observation. This share of measured signal M(v s ) can be eliminated by generating a fixed, settable signal value F in a signal generator 27 and subtracting value F from the quotient of P/I.
Since the influence of the blood flow movement is best determined in the higher frequency portion, the average velocity of inadvertent body movement is less than that of the movement of the blood. This difference is utilized for the separation of the two velocities. An active highpass filter 22 whose output signal and spectrum, respectively, are shown for limit frequency υ H in FIGS. 3e and 3f, is connected into the circuit for this purpose. On the one hand, this filter 22 must sharply separate the two velocity ranges, i.e., it must have a sharp edge. On the other hand, in order to maintain linearity, it must be frequency independent for frequencies above υ H . For example, the filter 22 may be given by a 4-pole Butterworth filter with a cut-off-frequency at 50 Hz.
If the plane of observation varies by ±5 mm from its nominal position, no change appears in the velocity signal in the circuit arrangement or apparatus according to FIG. 1. The linearity achieved with the method according to the invention is shown in FIG. 4. Deviations at slower velocities are the result of the beam spot not being square as in the theoretical derivation but having an e -x .spsp.2 profile and the speckle movement being measured by means of an aperture which is not negligibly small compared to the speckle size.
In FIG. 4 the circles are measuring values A (in Volts) by the equipment at different velocities of a test object. The different sensitivities indicated by the slope of the two lines are achieved by applying speckle patterns of different speckle size 6.
The time dependence of the flow of blood, with the blood supply suppressed during time interval ΔT, is shown in FIG. 5 and the change in blood movement due to the use of a circulation enhancing ointment is shown in FIG. 6.
In practice, it may turn out to be appropriate to note that, in the determination of a value B indicating the flow of blood, other weightings bring about more easily distinguished or more stable measured values than the weightings discussed above. Weighting proportional to ν 2 or ν 3 would emphasize, in particular, the proportion of high velocities. Moreover, a step-type filter, a suitable highpass filter, which, on the one hand, suppresses the frequencies in the spectrum near zero, which are caused by the proportion of constant light in the speckle intensity, and, on the other hand, amplifies the remainder independently of frequency, can be used to generate a measured signal which indicates, for example, the amount of blood movement independently of velocity.
These weightings can be realized with a modified circuit arrangement. Amplification proportional to ν 2 would correspond to twice performed differentiation, and amplification proportional to ν 3 would require a special amplifier having such a characteristic. Filter 21 would then have to be more generalized to an element which amplifies the signal with specific frequency weighting.
Measurements made according to the method of the invention indicate that velocities up to several 100 microns per second can be detected. This lower limit is given by the available measuring aperture 30 of several microns in diameter, since in this way a minimum size is set for the speckles. To measure higher velocities, it is necessary to broaden the covered frequency range, so that the noise increases. This again can be compensated for by increasing the laser intensity.
For an exemplary embodiment of the invention see FIGS. 1 and 2. Specification of the components:
1: 7 mW HeNe-Laser, 633 nm
2: 80 mm focal-length lens
3: Optical fiber, diameter 0.3 mm
4: 16 mm focal-length lens
5: Diameter of the laser-spot 1.5 mm
7: Fiber bundle of 400 fibers with 70 μm diameter each
8: Fiber bundle leading to photocell 9
9: Silicon photocell with a sensitive area of 1.2×1.2 mm 2
10: Single fiber leading to the photomultiplier
11: Photomultiplier with a bialkali cathode
12: 633 nm interference filter
20: Amplifier with variable gain (≈10)
21: Differentiator with a characteristic frequency f d =210 Hz
22: Active high pass filter, 4-pole Butterworth, cut-off-frequency 50 Hz
24: 2% accuracy RMS/DC-Converter (Root-Mean-Square Processing)
25: Amplifier with variable gain (≈100)
26: 2% accuracy divider
28: Integratior with variable time-constants from 0.1 s to 4 s
30: Effective aperture for speckle-detection given by the diameter of one fiber: 70 μm
Angle between beam 15 and axis 14: 15°
Distance lens 4-aperture 30: 220 mm
Distance lens 4-laser spot 5: 60 mm
23: Active lowpass filter, 4-pole Butterworth, cut-off-frequency 1500 Hz
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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Method and apparatus for determining the velocity of an object in a given direction without contacting the object, by: directing coherent radiation to the object in a direction substantially perpendicular to the given direction to cause radiation to be scattered from the object to produce a speckle pattern exhibiting a speckle spectrum, the speckle pattern at a location spaced from the object having a time dependency which is a function of movement of the object, detecting the speckle pattern intensity at the location spaced from the object, producing a first signal representative of the detected speckle intensity, and producing, from the first signal, a time-dependent intensity signal having a value which is weighted as a function of the frequency of the first signal.
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[0001] The present application is a continuation of U.S. patent application Ser. No. 10/746,764, filed Dec. 23, 2003. This application relates to an improved grip for golf clubs.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Applicant has previously developed resilient grips which successfully reduce impact shock to the muscle and arm joints of the user's of golf clubs and also provide a feeling of tackiness between a player's hands and the grip. See, for example, U.S. Pat. No. 5,797,813 granted to Applicant on Aug. 25, 1998 and U.S. patent application Ser. No. 10/392480 filed by Applicant on Mar. 18, 2003.
[0004] 2. Description of the Related Art
[0005] The earliest of these grips utilize a polyurethane-felt strip which is spirally wrapped around an underlisting sleeve that is slipped onto and adhered to a golf club handle. The sides of the strips are formed with overlapping heat depressed recessed reinforcement edges. While such grips have proven satisfactory in reducing impact shock, their fabrication is labor intensive, particularly since the strip must be wrapped manually about the underlisting sleeve within specific pressure parameters. Additionally, it is difficult to accurately align the adjoining side edges of the strip as such strip is being spirally wrapped about the underlisting sleeve. These wrapped grips can become twisted during the wrapping process, allow for only limited display of decorative designs and allow for only a limited placement of colors.
[0006] Applicant's Ser. No. 10/392480 application seeks to overcome two of the aforementioned disadvantages of existing spirally wrapped grips while providing the same resistance to shock afforded by such grips, as well as providing tackiness. The disadvantages are eliminated by forming a structurally integral grip from a single polyurethane-felt panel having a configuration corresponding to the exterior shape of an underlisting sleeve. While this design removes the twisting problems associated with the wrapping process and offers more area to display decorative designs, it is limited in its ability to accommodate multiple color schemes which are so popular in today's modern world of golf.
SUMMARY OF THE INVENTION
[0007] Embodiments of the golf club grip of the present invention overcome the aforementioned disadvantages of the existing spirally wrapped grips and the single panel grips while providing the same resistance to shock afforded by such grips, as well as providing tackiness. Desirably, a structurally integral grip is formed from multiple, initially distinct, two-layer panels.
[0008] One preferred embodiment is a grip, including a preferably resilient underlisting sleeve, a first panel and a second panel. The first panel and the second panel are wrapped about and adhered to the underlisting sleeve. The underlisting sleeve has an opening at one end sized so that the sleeve is telescopically slippable onto the handle of a golf club. The underlisting sleeve also includes a cap with a downwardly facing circumferential slot and a nipple with an upwardly facing circumferential slot. The first panel includes a polyurethane outside layer bonded to a felt inside layer, a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge, where the inside layer defines an inner surface of the first panel. The second panel includes a polyurethane outside layer bonded to a felt inside layer, a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge, where the outside layer defines an outer surface of the second panel. The first panel of this embodiment defines a skived backside bottom edge having skiving extending from the inside layer to the outside layer so as to form an obtuse angle (α in FIG. 36A ) with the inner surface of the first panel and the second panel defines a skived frontside top edge having skiving extending from the outside layer to the inside layer so as to form an obtuse angle (β in FIG. 36A ) with the outer surface of the second panel. The bottom edge of the first panel abuts the top edge of the second panel, so that the bottom edge of the first panel and the top edge of the second panel cooperate to form a substantially horizontal seam.
[0009] One embodiment is a grip, including a resilient underlisting sleeve, a first panel and a second panel. The first panel and the second panel are wrapped about and adhered to the underlisting sleeve. The underlisting sleeve has an opening at one end sized so that the sleeve is telescopically slippable onto the handle of a golf club. The first panel includes a polymeric outside layer bonded to a fabric inside layer, a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge. The second panel includes a polymeric outside layer bonded to a fabric inside layer, a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge. The first panel of this embodiment defines a skived bottom edge and the second panel defines a skived top edge. The bottom edge of the first panel abuts the top edge of the second panel, so that the bottom edge of the first panel and the top edge of the second panel cooperate to form a substantially horizontal seam.
[0010] Another embodiment is a grip, including an underlisting sleeve, a first panel and a second panel. The first panel and the second panel are wrapped about and adhered to the underlisting sleeve. The underlisting sleeve has an opening at one end sized so that the sleeve is telescopically slippable onto the handle of a golf club. The first panel includes a polymeric outside layer bonded to a fabric inside layer, a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge. The second panel includes a polymeric outside layer bonded to a fabric inside layer, a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge. The inside layer and the outside layer of the bottom edge of the first panel are skived. The inside layer and the outside layer of the top edge of the second panel are skived. The inside layer of the first panel abuts the inside layer of the second panel and the bottom edge of the first panel is secured to the top edge of the bottom panel. The bottom edge of the first panel and the top edge of the second panel cooperate to form a seam transverse to the longitudinal axis of the sleeve.
[0011] Yet another embodiment is a grip, including an underlisting sleeve, a first panel and a second panel. The first panel and the second panel are wrapped about and adhered to the underlisting sleeve. The underlisting sleeve has an opening at one end sized so that the sleeve is telescopically slippable onto the handle of a golf club. The first panel includes a polymeric outside layer bonded to a fabric inside layer, a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge. The second panel includes a polymeric outside layer bonded to a fabric inside layer, a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge. The inside layer and the outside layer of the bottom edge of the first panel are skived from the inside layer to the outside layer so as to form an obtuse angle with the inner surface of the first panel. The inside layer and the outside layer of the top edge of the second panel are skived from the outside layer to the inside layer so as to form an obtuse angle with the outer surface of the second panel. The bottom edge of the first panel abuts the top edge of the second panel. The bottom edge of the first panel and the top edge of the second panel cooperate to form a substantially horizontal seam.
[0012] Yet another embodiment is a method of making a grip for the handle of a golf club, including the following steps: providing an underlisting sleeve that is telescopically slippable onto the handle of a golf club; providing a first panel including a polymeric outside layer bonded to a fabric inside layer, the first panel having a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge; providing a second panel including a polymeric outside layer bonded to a fabric inside layer, the second panel having a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge; skiving the inside layer and the outside layer of the bottom edge of the first panel from the inside layer to the outside layer so as to form an obtuse angle with the inner surface of the first panel; skiving the inside layer and the outside layer of the top edge of the second panel from the outside layer to the inside layer so as to form an obtuse angle with the outer surface of the second panel; abutting the bottom edge of the first panel to the top edge of the second panel; wrapping the first panel about and adhering the first panel to the underlisting sleeve; wrapping the second panel about and adhering the second panel to the underlisting sleeve, whereby, upon completion of the securing step and the wrapping step, the bottom edge of the first panel and the top edge of the second panel cooperate to form a substantially horizontal seam.
[0013] Another embodiment is a grip, including an underlisting sleeve, a first panel, a second panel and a third panel. The first panel, the second panel and the third panel are wrapped about and adhered to the underlisting sleeve. The underlisting sleeve having a top end and a bottom end and being telescopically slippable onto the handle of a golf club. The first panel includes a polyurethane outside layer bonded to a felt inside layer, the first panel having a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge. The second panel includes a polyurethane outside layer bonded to a felt inside layer, the second panel having a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge. The third panel includes a polyurethane outside layer bonded to a felt inside layer, the third panel having a top edge, a bottom edge and two side edges extending between the top edge and the bottom edge. The top edge of the first panel is positioned adjacent the top end of the sleeve and the bottom edge of the second panel is positioned adjacent the bottom end of the sleeve. The first panel of this embodiment defines a skived backside bottom edge having skiving extending from the inside layer to the outside layer so as to form an obtuse angle (α′ in FIG. 80A ) with the inner surface of the first panel. The second panel of this embodiment defines a skived frontside top edge having skiving extending from the outside layer to the inside layer so as to form an obtuse angle (β′ in FIG. 80A ) with the outer surface of the second panel. The third panel of this embodiment defines a skived frontside top edge having skiving extending from the outside layer to the inside layer so as to form an obtuse angle (γ′ in FIG. 80A ) with the outer surface of the third panel and a skived backside bottom edge having skiving extending from the inside layer to the outside layer so as to form an obtuse angle (δ′ in FIG. 80A ) with the inner surface of the third panel. The bottom edge of the first panel abuts the top edge of the third panel so that the bottom edge of the first panel and the top edge of the third panel cooperate to form a substantially horizontal seam. The bottom edge of the third panel abuts the top edge of the second panel so that the bottom edge of the third panel and the top edge of the second panel cooperate to form a transverse and, preferably, substantially horizontal seam.
[0014] The inside layer is preferably a fabric layer, and more preferably a felt layer. The outside layer is preferably a polymer layer, and more preferably a polyurethane layer. In the case of a two-panel grip, the bottom edge of the first panel abuts the top edge of the second panel. These edges are desirably adhered together to define a generally horizontal seam. Two or more panels may be used to create a single, multi-segment, multi-colored panel grip. In grips with three or more panels, the top most and bottom most panels are desirably skived like the two-panel grip. The connecting panels are desirably skived with parallel edges such that their edges abut to define generally horizontal seams extending though the contiguous panel. The side edges of such multi-segment single panels desirably abut one another and are adhered together to define a longitudinal seam extending through the completed grip. A heat formed recessed sealing channel may be formed in the exterior portion of the polyurethane layer at the outer end of the seam to strengthen such seam. Hot polyurethane may be deposited along the seam or within the channel, after such polyurethane has hardened it may be buffed to smoothly blend into the surface of the grip. In another modification, a mold may be utilized to emboss a friction enhancing pattern over the deposited polyurethane to match any friction enhancing pattern pressed into the outside layer of the grip.
[0015] Embodiments of the present invention may be manufactured at considerably less cost than existing spirally wrapped grips since it eliminates the intensive labor of spirally wrapping a strip around an underlisting sleeve within specific pressure parameters. Additionally, embodiments of the multi-segment single panel grip will not twist either during manufacture or after it is adhered to an underlisting sleeve. My new grip desirably has an appearance similar to conventional molded rubber grips so as to appeal to professional golfers and low-handicap amateurs, and also provides a greater area for the application of decorative designs. Further, embodiments of the present invention can also accommodate multiple color combinations that would not have been possible with the single panel grips, thus appealing to golfers and college programs who wish to display their school colors while playing the sport they love. Embodiments of the present invention are very easy to install.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Further objects, features and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying figures showing illustrative embodiments of the invention, in which:
[0017] FIG. 1A is a front view of a first polyurethane-felt panel member of a multi-segment golf club grip;
[0018] FIG. 1B is a front view of a second polyurethane-felt panel member of a multi-segment golf club grip;
[0019] FIG. 2A is a vertical cross-sectional view taken along the line 2 A- 2 A of FIG. 1A ;
[0020] FIG. 2B is a vertical cross-sectional view taken along the line 2 B- 2 B of FIG. 1B ;
[0021] FIG. 3A is a horizontal cross-sectional view taken along line 3 A- 3 A of FIG. 1A ;
[0022] FIG. 3B is a horizontal cross-sectional view taken along line 3 B- 3 B of FIG. 1B ;
[0023] FIG. 4 shows the bottom edge of the first panel member S 1 of FIG. 1A being skived;
[0024] FIG. 5 shows the top edge of the second panel member S 2 of FIG. 1B being skived;
[0025] FIG. 6A is a rear view showing adhesive being applied to the skived bottom edge of the first panel member S 1 ;
[0026] FIG. 6B is a front view showing adhesive being applied to the skived top edge of the second panel member S 2 ;
[0027] FIG. 7 is a front view of a multi-segment polyurethane-felt panel member of a golf club grip prior to being press cut to its working shape;
[0028] FIG. 8 is a vertical cross-sectional view showing the horizontal seam 100 taken along the line designated 8 - 8 in FIG. 7 ;
[0029] FIG. 9A is a front view of the multi-segment polyurethane-felt panel member after being press cut to its final working shape;
[0030] FIG. 9B is a side view of the multi-segment polyurethane-felt panel member of a golf club grip after being press cut to its final working shape;
[0031] FIG. 10 is a horizontal cross-sectional view showing a first mold which may be utilized in forming a multi-segment single panel grip;
[0032] FIG. 11A is a vertical cross-sectional view taken along line 11 A- 11 A of FIG. 10 ;
[0033] FIG. 11B is a vertical cross-sectional view of an alternative mold which may be utilized in forming a multi-segment single panel grip from a view corresponding to the view taken along line 11 A- 11 A of FIG. 10 ;
[0034] FIG. 12A is an enlarged view of the encircled area designated 12 A in FIG. 11B ;
[0035] FIG. 12B is an enlarged view of the encircled area designated 12 B in FIG. 11B ;
[0036] FIG. 13 is an enlarged view of the encircled area designated 13 in FIG. 10 ;
[0037] FIG. 14 is a front view of the multi-segment single panel of FIG. 9 after it is removed from the mold shown in FIG. 10 ;
[0038] FIG. 15 is a front view of the multi-segment single panel of FIG. 9 after it is removed from another version of the mold shown in FIG. 10 ;
[0039] FIG. 16 is a front view of the multi-segment single panel of FIG. 9 after it is removed from yet another version of the mold shown in FIG. 10 ;
[0040] FIG. 17 is a vertical cross-sectional view taken along line 17 - 17 of FIG. 15 ;
[0041] FIG. 18 shows the top and bottom edges of the multi-segment single panel being skived;
[0042] FIG. 19 shows a first side edge of the multi-segment single panel being skived;
[0043] FIG. 20 shows a second side edge of the multi-segment single panel being skived;
[0044] FIG. 21 shows the interior surface of the multi-segment single panel after the top, bottom and side edges thereof have been skived in the manner depicted in FIGS. 18, 19 , and 20 ;
[0045] FIG. 22 is a front view of an underlisting sleeve member of the multi-segment single panel grip of the present invention;
[0046] FIG. 23 is a vertical cross-sectional taken along the line 23 - 23 of FIG. 22 ;
[0047] FIG. 24 is an enlarged view of the encircled area designated 24 in FIG. 23 ;
[0048] FIG. 25 is an enlarged view of the encircled area designated 25 in FIG. 23 ;
[0049] FIG. 26 is a front view showing adhesive being applied to the exterior of the underlisting sleeve;
[0050] FIG. 27 is a front view showing adhesive being applied to the interior surface of the multi-segment single panel;
[0051] FIG. 28 is a front view showing a first step in wrapping and adhering the multi-segment single panel to an underlisting sleeve;
[0052] FIG. 29 is a front view showing a second step in wrapping and adhering the multi-segment single panel around an underlisting sleeve;
[0053] FIG. 30 is a front view showing the multi-segment single panel adhered to an underlisting sleeve;
[0054] FIG. 31 is a horizontal cross-sectional view of FIG. 28 ;
[0055] FIG. 32 is a horizontal cross-sectional view of FIG. 29 ;
[0056] FIG. 33 is a horizontal cross-sectional view taken along line 33 - 33 of FIG. 30 ;
[0057] FIG. 34 is an enlarged view of the encircled area designated 34 in FIG. 32 ;
[0058] FIG. 35 is an enlarged view of the encircled area designated 34 in FIG. 33 ;
[0059] FIG. 36 is a vertical cross-sectional view taken along line 36 - 36 of FIG. 30 ;
[0060] FIG. 36A is an enlarged view of the encircled area designated 36 A in FIG. 36 ;
[0061] FIG. 37 is a side view showing a heat depressed sealing channel being formed along the top portion of the seam shown in FIG. 35 ;
[0062] FIG. 38 is a vertical cross-sectional view taken along line 38 - 38 in FIG. 37 ;
[0063] FIG. 39 shows the parts of FIG. 38 after the sealing channel has been formed;
[0064] FIG. 40 is an enlarged view of the encircled area designated 40 in FIG. 39 ;
[0065] FIG. 41 is a front view of a completed multi-segment single panel grip according to an embodiment of the present invention;
[0066] FIG. 42 is a vertical cross-sectional view taken along the line designated 42 - 42 of FIG. 41 ;
[0067] FIG. 43 is a vertical cross-sectional view taken along the line designated 43 - 43 of FIG. 41 ;
[0068] FIG. 44 is a broken front view showing a first step in making a modification of the grip of FIG. 39 ;
[0069] FIG. 45 is a broken front view showing a second step in making a modification of the grip of FIG. 39 ;
[0070] FIG. 46 is a horizontal cross-sectional view taken along line 46 - 46 of FIG. 45 ;
[0071] FIG. 47 is an enlarged view of the encircled area designated 47 in FIG. 46 ;
[0072] FIG. 48 is a front view of a multi-segment single panel grip as in FIG. 30 , ready for modification;
[0073] FIG. 49 is a broken front view showing a first step in the modification of the grip shown in FIG. 48 ;
[0074] FIG. 50 is a broken front view showing a second step in the modification of the grip shown in FIG. 48 ;
[0075] FIG. 51 is a front view of the grip made in accordance with FIGS. 48-50 ;
[0076] FIG. 52 is a broken front view showing another modification of the grip shown in FIG. 48 ;
[0077] FIG. 53 is a horizontal cross-sectional view taken along the line 53 - 53 of FIG. 52 ;
[0078] FIG. 54 is an enlarged view of the encircled area designated 54 in FIG. 53 ;
[0079] FIG. 55 is a broken front view showing another modification of the grip shown in FIG. 48 ;
[0080] FIG. 56 is a horizontal cross-sectional view taken along the line 56 - 56 of FIG. 55 ;
[0081] FIG. 57 is an enlarged view of the encircled area designated 57 in FIG. 56 ;
[0082] FIG. 58 is a side view of a die utilized in modifying the grips of FIGS. 52 and 55 ;
[0083] FIG. 59 is a horizontal cross-sectional view taken along line 59 - 59 in FIG. 58 ;
[0084] FIG. 60 is a vertical cross-sectional view taken along line 60 - 60 of FIG. 58 ;
[0085] FIG. 61 is an enlarged view of the encircled area designated 61 of FIG. 58 ;
[0086] FIG. 62 is a front view of a grip made in accordance with FIGS. 58-61 ;
[0087] FIG. 63 is a perspective view of an underlisting sleeve of a putter grip according to an embodiment of the present invention;
[0088] FIG. 64 is a rear view of the underlisting sleeve of FIG. 63 ;
[0089] FIG. 65 is a horizontal cross-sectional view taken along the line 65 - 65 of FIG. 63 ;
[0090] FIG. 66 is a vertical cross-sectional view taken along the line 66 - 66 of FIG. 64 ;
[0091] FIG. 67 is a vertical cross-sectional view taken along the line 67 - 67 of FIG. 64 ;
[0092] FIG. 68A is a front view of the multi-segment polyurethane-felt panel member of a golf club putter grip according to an embodiment of the present invention;
[0093] FIG. 68B is a side view of the multi-segment polyurethane-felt panel member of a golf club putter grip according to an embodiment of the present invention;
[0094] FIG. 69 is a perspective front view of a completed multi-segment single panel putter grip according to an embodiment of the present invention;
[0095] FIG. 70 is a rear view of the putter grip of FIG. 69 ;
[0096] FIG. 71 is a horizontal sectional view taken along the line 71 - 71 of FIG. 69 ;
[0097] FIG. 72A is a front view of a top polyurethane-felt panel member S 1 ′ of a multi-segment golf club grip;
[0098] FIG. 72B is a front view of a middle polyurethane-felt panel member S 2 ′ of a multi-segment golf club grip;
[0099] FIG. 72C is a front view of a bottom polyurethane-felt panel member S 3 ′ of a multi-segment golf club grip;
[0100] FIG. 73A is vertical cross-sectional view taken along the line 73 A- 73 A of FIG. 72A ;
[0101] FIG. 73B is vertical cross-sectional view taken along the line 73 B- 73 B of FIG. 72B ;
[0102] FIG. 73C is vertical cross-sectional view taken along the line 73 C- 73 C of FIG. 72C ;
[0103] FIG. 74A is a horizontal cross-sectional view taken along line 74 A- 74 A of FIG. 72A ;
[0104] FIG. 74B is a horizontal cross-sectional view taken along line 74 B- 74 B of FIG. 72B ;
[0105] FIG. 74C is a horizontal cross-sectional view taken along line 74 C- 74 C of FIG. 72C ;
[0106] FIG. 75 shows the top edge of the middle segment S 3 ′ of FIG. 72B being skived;
[0107] FIG. 76 shows the bottom edge of the middle segment S 3 ′ of FIG. 72B being skived;
[0108] FIG. 77A is a front view showing adhesive being applied to the skived edge of the panel member;
[0109] FIG. 77B is a front view showing adhesive being applied to the skived edge of the panel member;
[0110] FIG. 77C is a front view showing adhesive being applied to the skived edge of the panel member;
[0111] FIG. 78 is a front view of a multi-segment polyurethane-felt panel member of a golf club grip prior to being press cut to its working shape;
[0112] FIG. 79 is a vertical cross-sectional view taken along the line designated 79 - 79 in FIG. 78 ;
[0113] FIG. 80 is a vertical cross-sectional view of a completed grip;
[0114] FIG. 80A is an enlarged view of the encircled area designated 80 A of FIG. 80 ;
[0115] FIG. 81 is a perspective view of a golf club provided with a multi-segment single panel grip according to an embodiment of the present invention;
[0116] FIG. 82 is a perspective view showing a putter provided with a multi-segment single panel grip according to an embodiment of the present invention.
[0117] Throughout the figures, the same reference numerals and characters, unless otherwise stated, are used to denote like features, elements, components or portions of the illustrated embodiments. Moreover, while the subject invention will now be described in detail with reference to the figures, it is done so in connection with the illustrative embodiments. It is intended that changes and modifications can be made to the described embodiments without departing from the true scope and spirit of the subject invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0118] Referring to the drawings, in FIG. 81 , a multi-segment single panel grip G embodying the present invention is shown attached to the shaft 55 of a golf club GC. In FIG. 82 , a multi-segment single panel putter grip PG is shown attached to the shaft 57 of a putter P. Referring now to the remaining drawings, a preferred form of grip G includes a multi-segment single panel S formed of multiple panels of bonded-together layers of polyurethane 60 and a felt 62 which is then wrapped about and adhered to a resilient underlisting sleeve U of conventional construction. Throughout the application, the term top is used to refer to that which is closest to the butt end of the club opposite the club head, i.e. the end closest to the golfer if that golfer were to be swinging or stroking the club. Similarly, the term bottom is used to define the panel or edge furthest from the butt end of the club.
[0119] FIG. 1A shows a first two-layer panel S 1 with an outside layer 60 a and an inside layer 62 a ( FIG. 2A ). FIG. 1B shows a second two-layer panel S 2 that will abut against and be bonded to the first panel S 1 to form a multi-segment single panel MP ( FIG. 7 ). In particular, the first panel S 1 has a bottom edge 81 that, after processing, will abut against a top edge 82 of the second panel S 2 . It is understood that the panels used to form any particular grip will be constructed generally the same, differing principally in their color and size.
[0120] The outside layer of the panels in this disclosure is generally referred to as a polyurethane layer. Though polyurethane is the preferred material, other materials could be used and achieve some advantages. In particular, other polymeric compounds can be used to create the outer layer and achieve some advantages. Similarly, the inside layer is generally referred to as felt in this disclosure. Though felt is preferred, it is understood that other fabric layers can be used in alternative embodiments of this invention. Polyurethane and felt are used throughout as a matter of convenience. In another embodiment, the inside layer may comprise a polymer, more preferably ethylene vinyl acetate (EVA).
[0121] Referring to FIGS. 1, 2 and 3 , the felt layers 62 a , 62 b have their outer surfaces bonded to the inner surface of the polyurethane layers 60 a , 60 b , with such polyurethane layers 60 a , 60 b preferably being coagulated to define pores (not shown). Once bonded, the outside layer 60 a of the first panel S 1 has an outer surface 61 a, while the inside layer 62 a has an inner surface 63 a . As will be appreciated by those of skill in the art, the outer surface 61 a of the outside layer 60 a defines the outer surface of the first panel S 1 and the inner surface of 63 a of the inside layer 62 a defines the inner surface of the first panel S 1 . Similarly, the outside layer 60 b of the second panel S 2 has an outer surface 61 b , while the inside layer 62 b has an inner surface 63 b . Thus, the outer surface 61 b of the outside layer 60 b defines the outer surface of the second panel S 2 and the inner surface 63 b of the inside layer 62 b defines the inner surface of the second panel S 2 ( FIG. 8 ). The felt layer may be fabricated of wool, polyester, nylon or mixtures thereof. Preferably, a nylon polyester felt will be utilized. The polyurethane layers 60 a , 60 b may be formed in a conventional manner by coating one side of a felt strip with a solution of polyurethane (e.g., polyester, polyether) dissolved in dimethyl formamide (DMF), immersing the coated strip in water baths to displace the DMF and cause the urethanes to coagulate, and finally, driving off the water by the application of pressure and heat. The solids content of the polyurethane layer will vary in accordance with the desired hardness of such polyurethane layer. A preferred solids content solution is approximately 28.5-30.5%, with a viscosity range of about 60,000-90,000 cps measured at 25+/−0.5 degrees C. Suitable polyurethane ingredients can be purchased from the following companies:
Lidye Chemical Co., Ltd. 10F1 Lidye-Commercial Bldg. 22 Nanking W. Road, Taipei Taiwan, R.O.C. Lidye Chemical Co., Ltd. No. 17, Ching Chien 6 th Road Guan in Industrial Area, Guan In Shiang Taoyuan Hsien, Taiwan, R.O.C. Lidye Resin (Panyu) Co., Ltd. Xiadao Industrial Park Liye Road, Dongchong Town Panyu City, Guangdong Province, PRC
[0134] Preferably, the thickness of the polyurethane layer will be about 0.3-0.5 millimeters and the thickness of the felt layer about 0.8-1.7 millimeters. The polyurethane layer of the panels provides a cushioned grasping surface for a golfer's hands on a golf club and also enhances the golfer's grip by providing increased tackiness between the player's hand and the grip. In each panel, the felt layer provides strength to the polyurethane layer and serves as a means for attaching the bonded-together polyurethane and felt multi-segment single panel to an underlisting sleeve U.
[0135] The multiple panels that will form the basis of the multi-segment single panel MP are desirably prepared. Referring now to FIG. 4 , the first panel S 1 is shown having its bottom edge 81 skived by a single rotating knife 79 downwardly and outwardly from the inside layer 62 a to the outside layer 60 a , thereby creating skived edge 81 . The first panel S 1 is placed felt or inside layer 62 a up and a pressure plate 83 is utilized to secure the panel S 1 on a base 84 during the skiving operation. Preferably, the skived edge 81 will have a width of about 4.0-6.0 millimeters. In FIG. 5 , the second panel S 2 is shown secured to base 84 felt side 62 b down while the rotating knife 50 skives its top edge 82 from the outside layer 60 b to the inside layer 62 b to form skived edge 82 .
[0136] FIG. 6A shows the application of an adhesive 90 by means of a nozzle, brush or the like to the skived edge 81 of the first panel S 1 . Similarly, FIG. 6B shows the application of an adhesive 90 by means of a nozzle, brush or the like to the skived top edge 82 of the second segment S 2 .
[0137] After application of the adhesive 90 , the skived edges 81 , 82 abut and are pressed together such that the once separate polyurethane-felt panels S 1 , S 2 now form a contiguous multi-segment panel MP with a substantially horizontal seam 100 , as shown in FIG. 7 .
[0138] FIG. 8 is a horizontal sectional view taken along the line designated 8 - 8 in FIG. 7 . Note the felt-felt bond between the felt layer 62 a of the first panel S 1 and the felt layer 62 b of the second panel S 2 . This felt-felt bonding section adds structural integrity to the panel MP.
[0139] The preferred method is to skive the bottom edge 81 of the first panel S 1 downwardly and outwardly from its inside layer 62 a to its outside layer 60 a ( FIG. 4 ) while skiving the top edge 82 of the second panel S 2 in a similar manner ( FIG. 5 ), noting that the second panel S 2 is secured outside layer 60 b facing up towards the pressure plate 83 , where as the first panel S 1 is skived with its inside layer 62 a facing up towards the pressure plate 83 . Desirably, the outer surface 61 b of the second panel S 2 and the skived top edge 82 of the second panel S 2 form an included obtuse angle, more preferably an included obtuse angle of over 110 degrees, more preferably an included obtuse angle of roughly 130-160 degrees and, most preferably, an included obtuse angle of roughly 135 degrees. The inner surface 63 a of the first panel S 1 and the skived bottom edge 81 of the first panel S 1 desirably form a similar included obtuse angle to the angle formed by the outer surface 61 b of the second panel S 2 and the skived top edge 82 of the second panel S 2 .
[0140] While there are other ways to practice the invention, this structure is preferred for several reasons. One common tendency of golfers is to stroke downwardly with their thumbs as they prepare to hit the ball. This could place pressure on the horizontal seam. Our preferred configuration allows this downward stroking without encouraging the panels to separate from the underlisting sleeve. That is, the thin uppermost portion of the top edge 82 is protected from rolling downward by the overlapping bottom edge 81 of the first panel. Significantly, this thin felt uppermost portion of the top edge 82 of the second panel S 2 is glued to the structurally strong felt portion of the bottom edge 81 of the first panel S 1 . The grip G would be much less effective at preventing premature unraveling if it had an exposed thin upward facing edge. The only thin upward facing portion of the edge at the seam 100 , the thin uppermost portion of the top edge 82 of the second panel S 2 , is safely enclosed on the inside of the grip G and securely attached to the underlisting sleeve U. While the outside of the grip G is exposed by definition, the portion of the seam 100 that is exposed is the lowermost portion of the bottom edge 81 of the first panel S 1 . This lowermost portion of the bottom edge 81 is downward facing and thus naturally allows the thumb to roll over it without encouraging premature unraveling. Even if the two panels were somewhat misaligned, so that a portion of the upwardly facing edge of the top edge on the second panel S 2 were exposed, the exposed portion would be almost as thick as the body of the panel and, thus, structurally strong. Importantly, the large obtuse angle formed by the top edge of the second panel and the outer surface of the first panel would tend to guide the user's thumb outward and downward, away from the thin uppermost portion of the top edge of the second panel S 2 . As such, this preferred configuration discourages unraveling, even in the event of misalignment.
[0141] Further, it is less distracting for the golfer looking down at the handle when the seam is fluid, another advantageous result of our horizontal seam with the preferred skiving because the outer layer of the top panel flows over the lower panel. Regardless, the skiving is performed such that the polyurethane side 60 a of the first panel S 1 and the polyurethane side 60 b of the second panel S 2 are on the same side of the contiguous multi-segment panel MP to form a contiguous polyurethane outside layer 110 ( FIG. 7 ). Once each panel has its respective skived edge, the segments are ready to be bonded.
[0142] Once the panels are joined, the panel MP is press cut in the conventional way to form the shaped panel S found in FIG. 9A . The same press cut also forms notches N 1 , N 2 in the panel S at the center of the top and bottom edges, respectively. The notches N 1 , N 2 serve as markings to help center the panel on the underlisting sleeve U. Though there are other methods of centering the panel, these notches are preferred because they reduce cost and do not affect the contours of the finished grip G. By way of example, it is possible to have a raised or scored line running vertically along the underlisting G to indicate the central axis. This line could then correspond to a scored line on the panel grip, thus providing a means for centering the panel on the grip. However, because the lines on both the panel and the underlisting involve adding to or taking away from the respective piece, the lines have the potential of affecting the contours of the grip surface. The notches, on the other hand, reside under the cap and nipple (discussed below) and thus do not affect the contours of the grip.
[0143] FIG. 9B shows an edge view of shaped panel S. Note the horizontal seam 100 and dual contiguous layers 110 , 112 running the length of the panel S.
[0144] Referring now to FIGS. 10-17 there is shown a first mold M which is utilized to form a friction enhancing pattern 66 ( FIG. 14 ) on the polyurethane layer 110 . Mold M includes a base plate B and a heated platen 67 formed with a cavity 68 . The platen 67 is provided with depending protrusions 69 that engage the outer surface of the polyurethane layer 110 so as to form the depressed friction enhancing pattern 66 , as seen in FIG. 13 . The heated platen 67 may include depending protrusions 69 a that would form recessed side edges 70 , 71 on edges 134 , 136 , respectively, and recessed top and bottom edges (not shown) on top and bottom edges 130 , 132 on the polyurethane layer 110 , as shown in FIGS. 11 b, 12 a and 12 b . Alternatively, the preferred embodiment contains no such side oriented protrusions 69 a such that use of the mold M results only in the friction enhancing pattern 63 on the polyurethane layer 110 , as demonstrated by FIG. 11 a and FIG. 14 .
[0145] In alternative embodiments, other patterns may be formed on the polyurethane layer 110 . As seen in FIG. 15 , one alternative design leaves the majority of the outside layer 110 smooth while visual indicia, such as a logo 116 is placed near the bottom end of the panel S. In FIG. 16 , yet another embodiment of the friction enhancing pattern is shown. The second pattern 118 incorporates visual indicia extending the majority of the length of the panel surrounded by a tread pattern similar to the friction enhancing pattern 66 in FIG. 13 . FIG. 16 also shows an alternative means for imputing decorative designs or logos on the grip panel S. Stamped visual indicia, such as logo 114 , is ink stamped onto the polyurethane layer 110 using a suitable ink known to those of skill in the art. Preferably, the ink is waterproof and heat resistant and, more preferably, formulated to resist degradation when coming into contact with the lubrication fluid or solvent used to apply the completed grip G (underlisting U with panel S) over the end of a golf club GC shaft 55 ( FIG. 81 ) or a putter P shaft 57 ( FIG. 82 ). It is to be understood that these are representative and many other patterns and stamps may be used with this multi-segment single panel grip.
[0146] FIG. 17 is a cross-sectional view taken along the line designated 17 - 17 in FIG. 14 . It shows the friction enhancing pattern 66 formed on the contiguous polyurethane layer 110 .
[0147] Referring now to FIGS. 18-21 , the peripheral edges of the panel S are shown being skived by a pair of rotating knives 120 , 122 which engage the top and bottom edges 130 , 132 of the panel S ( FIG. 18 ), and a single rotating knife 124 ( FIG. 19 ) engaging side edges 134 , 136 . Knives 120 and 122 form top and bottom skived edges 130 , 132 , respectively. Knife 124 is shown forming skived edge 134 on one side of the panel S in FIG. 19 and the skived edge 136 in FIG. 20 after the first side has been skived. A pressure plate 83 is utilized to secure the panels on base 84 during the skiving operation. It will be noted that the skiving on the opposite sides of the panel S are parallel to one another, as seen in FIG. 20 . Preferably, the skiving will have a width of about 4.0-6.0 millimeters.
[0148] FIG. 21 is a rear view of the panel S after the rotating knives 120 , 122 , 124 have skived the edges 130 , 132 , 134 , 136 .
[0149] Referring now to FIGS. 22-25 there is shown an underlisting sleeve U formed of a resilient material such as a natural or synthetic rubber or plastic. Sleeve U includes an integral cap 85 at its top end, while the bottom end of the sleeve is formed with an integral nipple 86 . The underside of the cap is formed with a downwardly extending slot 87 . Preferably, the slot 87 wraps circumferentially around the underlisting U. The slot 87 receives the top skived edge 130 of the panel S as described hereinafter. Similarly, the integral nipple 86 of the underlisting U is formed with an upwardly extending slot 88 . The slot 88 is preferably circumferentially wrapped about the underlisting U. Preferably, underlisting sleeve U will be formed with centering notches N 3 , N 4 indicating a middle point for application of the completed grip panel S to the underlisting sleeve U to form complete grip G.
[0150] Referring now to FIGS. 26-35 the panel S is shown being applied to an underlisting sleeve U. In FIG. 26 , the exterior surface of the underlisting sleeve U is shown receiving an adhesive 90 by means of a nozzle, brush or the like. In FIG. 27 , the inner surface of the contiguous felt layer 112 is shown receiving an adhesive 90 by means of a nozzle, brush or the like.
[0151] FIG. 28 shows the panel S being wrapped around and adhered to the underlisting sleeve U. During this operation, the notches N 1 , N 2 of the panel S are disposed in alignment under notches N 3 , N 4 of the underlisting sleeve U. Also, the top edge 130 of the panel S will be manually inserted within the slot 87 of the underlisting cap 85 , while the bottom edge 132 of the panel S is manually inserted within the slot 88 formed within the nipple 86 by temporarily flexing the peripheral lip 89 outwardly.
[0152] As indicated in FIGS. 33, 34 , and 35 , the skived side edges 134 , 136 of the panel S will be adhered together by a suitable adhesive 90 so as to define a vertical seam 91 extending through the panel. Because of the skived side edges 134 , 136 , the seam 91 extends though the panel S at an angle relative to the depth of the panel S so as to increase the length of such seam as compared to a seam extending parallel to the depth of the panel. Increased length of the seam affords a stronger bond. The seam is particularly strong where it joins the inside layers together, i.e. the felt-felt bond as shown in FIG. 35 .
[0153] A suitable adhesive 90 has the chemical formula polychloroprene (C 4 H 5 Cl) and Toluene (CH 5 CH 3 ). As the panel S is being wrapped about and adhered to underlisting sleeve U, the sleeve will be temporarily supported on a collapsible mandrel 92 in a conventional manner.
[0154] In one embodiment, the seam 91 is left alone and the completed grip G- 1 resembles the grip in FIG. 30 . FIG. 36 shows a cross-sectional view taken along the line designated 36 - 36 ( FIG. 30 ) of the multi-segment single panel S and the underlisting U showing the horizontal seam 100 relative to the length of the grip G- 1 . It will be appreciated by those of skill in the art that various advantages of the invention can be achieved by other types of seams. However, a seam transverse to the longitudinal axis Y of the sleeve U and, therefore, the longitudinal axis of the grip G- 1 is preferred. As used herein, transverse seam is a broad term and includes diagonal seams, zigzag seams and wavy seams. Further, it is desirable that the seam is closer to horizontal than vertical. This view would be substantially the same for all grips G constructed as described above. The use of more panels would result in correspondingly more horizontal seams.
[0155] FIG. 36A is an enlarged view of the encircled portion designated 36 A in FIG. 36 . It shows the horizontal seam 100 . Further, it shows how the skived bottom edge of the first panel S 1 is skived from the inside layer 62 a to the outside layer 60 a so as to form an obtuse angle a with the inner surface 63 a of the first panel S 1 . It also shows how the skived top edge of the second panel S 2 is skived from the outside layer 60 b to the inside layer 62 b so as to form an obtuse angle β with the outer surface 61 b of the second panel S 2 . Notably, it is preferred that obtuse angle α and obtuse angle β are equal such that when panel S 1 is joined to panel S 2 , they form a substantially flat single panel S (viewed in cross-section as in FIG. 36A ).
[0156] FIGS. 42 and 43 show enlarged cross-sectional views along the lines designated 42 - 42 and 43 - 43 , respectively, in FIG. 41 . They demonstrate the final placement of the top and bottom edges 130 , 132 of the panel S after the panel S has been adhered to the underlisting U. It will be seen that the top edge 130 of the panel S is securely disposed within the cap slot 87 . Similarly, the bottom edge 132 is securely disposed within the nipple slot 88 . The complete grip is then removed from the mandrel 92 and is ready to be slipped onto and adhered to the shaft of a golf club GC in a conventional manner.
[0157] Referring now to FIGS. 37-39 , an embodiment is shown after the side edges 134 , 136 of the panel S have been adhered together. FIG. 37 shows the underlisting sleeve U supported by mandrel 92 upon a base 93 while a longitudinally extending heated pressure tooth 94 is urged against the polyurethane layer 110 at the outer edge of seam 91 . Such heated tooth forms a small depression 95 in the polyurethane layer 110 aligned with the outer edge of the seam 91 so as to further strengthen such seam. An embodiment of a completed grip G- 2 after the use of the tooth 94 is shown in FIG. 41 .
[0158] FIGS. 44-47 show another embodiment of a golf club grip G- 3 , similar in all respects to grip G- 2 with the exception that the channel 95 is filled with hot polyurethane 96 by a nozzle, brush or the like ( FIG. 44 ). After the polyurethane hardens, it can be buffed by a suitable brush 97 or the like to smoothly blend into the surface of the grip as shown in FIG. 45 . Alternatively, after channel 95 is not buffed after it is filled with hot polyurethane.
[0159] Referring now to FIGS. 48-51 , there is shown another embodiment of a grip G- 4 . Grip G- 4 does not use the channel 95 . Rather, seam 91 is coated by a small quantity of hot polyurethane 96 by means of a nozzle, brush or the like, as shown in FIG. 47 . After the polyurethane hardens, it may be buffed by a suitable brush 97 or the like to smoothly blend into the surface of the grip, as indicated in FIG. 51 . Alternatively, the polyurethane is not buffed or blended.
[0160] Referring to FIGS. 52-62 , there is shown a modification of the grips of FIGS. 28-51 . In FIGS. 52-54 , hot polyurethane 96 is shown being coated over the seam 91 by a nozzle, brush or the like. In FIGS. 55-57 , hot polyurethane 96 is shown filling the channel 95 by a nozzle, brush or the like. FIG. 58 shows a mold M- 2 having a heated platen 140 the underside of which is formed with a segment 66 a of the friction enhancing pattern 66 which is embossed on the surface of the polyurethane layer 110 of the grip. Such heated platen 140 is depressed against the outer surface of the polyurethane layer over the area of the seam 91 while the polyurethane is still hot. With this arrangement, the area of the exterior of the polyurethane layer 110 outwardly of the seam is formed with the friction enhancing segment of FIG. 59 whereby such segment merges with the friction enhancing pattern 66 molded on the main body of the outer surface of the grip. FIG. 62 shows such a grip G- 5 with the merged friction enhancing pattern 66 placed over and adhered to a golf club shaft 55 . Alternatively, in a preferred embodiment, the heated platen 140 may be urged against the naked seam 91 to form the friction enhancing pattern without first coating it with hot polyurethane 96 . Pressing the pattern 66 directly to the seam 91 eliminates a step in the production process and therefore reduces the costs of production.
[0161] Referring now to FIGS. 63-71 , there is shown a multi-segment single panel putter grip PG for use with a conventional putter. The grip PG includes a resilient underlisting sleeve UP ( FIGS. 63-67 ) which is generally similar to the aforedescribed underlisting U, except that underlisting sleeve UP is not of an annular configuration. Instead, the front surface 98 of the underlisting sleeve UP is of flat configuration in accordance with the design of most putters in general use. It should be understood that underlisting sleeve UP receives a multi-segment single panel SP of polyurethane-felt configuration, similar to the aforedescribed multi-segment single panel S. The side edges of the putter panel SP are generally straight giving the panel SP a somewhat trapezoidal appearance prior to being wrapped around and adhered to the underlisting sleeve UP.
[0162] Such single panel SP is wrapped about and adhered to the underlisting sleeve in the same manner as described hereinbefore with respect to the multi-segment single panel grips G- 1 -G- 4 , with like parts of the two grips marked with like reference numerals. Similarly, if a tooth 94 ′ is used to create a channel 95 ′, it may be left alone or filled with hot polyurethane 96 ′ and then left raw or buffed with a brush 97 ′ or the like (refer to FIGS. 37-62 for examples of possible modifications to the grips herein disclosed). In a preferred embodiment, the panel SP is smooth but for a visual indicia such as logo 114 ′ at the bottom end, as shown in FIG. 68 . Because a putter is generally subjected to less forces due to the shortened putting swing as compared to the generally longer swing associated with other clubs, the putter grip PG generally does not require the friction enhancing pattern 66 . However, it is contemplated that such a pattern can be molded into the putter panel SP as herein described above.
[0163] It should be noted that any number of panels may be bonded together to form a multi-segment single panel grip. Preferably, the number is between 2 and 10, more preferably, between 2 and 5 and, most preferably, between 2 and 3. Referring now to FIGS. 72-79 , another preferred embodiment is shown using 3 polyurethane-felt panels S 1 ′, S 2 ′ and S 3 ′, respectively. Like parts of the grips are marked with like reference numerals used above, distinguished by a prime symbol.
[0164] FIGS. 72 a , 72 b and 72 c are front views showing, respectively: the top panel S 1 ′, the bottom panel S 2 ′, and the middle panel S 3 ′. In one embodiment, the top and bottom panels S 1 ′, S 2 ′ are generally of equal size while the middle panel S 3 ′ is shorter. Despite their differing lengths, each of the panels S 1 ′, S 2 ′, S 3 ′ have substantially the same width such that when they are bonded together, they form a single, contiguous panel with side edges large enough to accept a press cut assembly to form a shaped panel S′ whose width substantially corresponds to the circumference of the underlisting sleeve U′.
[0165] FIGS. 73 a - 74 c show vertical and horizontal cross-sectional views of the panels in FIGS. 72 a - c taken along the designated lines. The panels in this three-panel embodiment and all other embodiments of differing numbers of panels are created as described above in reference to FIGS. 1-3 .
[0166] Similar to the two-panel multi-segment single panel MP, the three-panel multi-segment single panel MP′ requires some preparation. Top and bottom panels S 1 ′, S 2 ′ are skived as panels S 1 , S 2 above, resulting in skived edges 81 ′, 82 ′ ( FIGS. 77A and 77B ). See FIGS. 4 and 5 for the method used to skive panels S 1 ′, S 2 ′. FIGS. 75 and 76 show the skiving process for the middle panel S 3 ′. Knife 150 is shown skiving the top edge 160 of the middle segment S 3 ′ downwardly and outwardly from the outside layer 60 c ′ to the inside layer 62 c ′ ( FIG. 75 ) and the bottom edge 162 from the inside layer 62 c ′ to the outside layer 60 c ′ after the top edge 160 has been skived ( FIG. 76 ). A pressure plate 83 ′ is utilized to secure the panel on base 84 ′ during the skiving operation. It will be noted that the skiving on the opposite ends of the panel S 3 ′ are parallel to one another, as seen in FIG. 76 . Preferably, the skiving will again have a width of about 4.0-6.0 millimeters.
[0167] FIGS. 77 a - b are front views showing adhesive 90 being applied to edges 81 ′, 82 ′, 160 , 162 with a nozzle, brush or the like.
[0168] After application of the adhesive 90 , the edges 81 ′, 162 , 160 , 82 ′ are pressed together such that the once separate polyurethane-felt panels S 1 ′, S 2 ′, S 3 ′ now form a contiguous multi-segment panel MP′ with two substantially horizontal seams 100 a ′, 100 b ′, as shown in FIG. 78 .
[0169] FIG. 79 is a horizontal sectional view taken along the line designated 79 - 79 in FIG. 78 . Note the felt-felt bonds between the top panel S 1 ′ and the middle panel S 3 ′ and the middle panel S 3 ′ and the bottom panel S 2 ′. These felt-felt bonding sections add structural integrity to the contiguous panel MP′. The panels S 1 ′, S 2 ′, S 3 ′ are bonded together such that their polyurethane layers 60 a ′, 60 b ′, 60 c ′ form a contiguous polyurethane side 110 ′ and their felt layers 62 a ′, 62 b ′, 62 c ′ form a contiguous felt side 112 ′
[0170] FIG. 80 shows a cross-sectional view of a completed three-panel multi segment grip G′ showing the two substantially horizontal seams 100 a ′, 100 b ′ relative to the length of the grip G′.
[0171] FIG. 80A is an enlarged view of the encircled portion designated 80 A in FIG. 80 . It shows the substantially horizontal seams 100 a ′, 100 b ′. Particularly, it shows how seam 100 a ′ is constructed with the skived backside bottom edge of the first panel S 1 ′ abutting the skived frontside top edge of the third panel S 3 ′. The skived bottom edge of the first panel S 1 ′ is skived from the inside layer 62 a ′ to the outside layer 60 a ′ so as to form an obtuse angle α′ with the inner surface 63 a ′ of the first panel S 1 ′. The skived top edge of the third panel S 3 ′ is skived from the outside layer 60 c ′ to the inside layer 62 c ′ so as to form an obtuse angle γ′ with the outer surface 61 c ′ of the third panel S 3 ′. Seam 100 b ′ is shown in a similar fashion. The skived bottom edge of the third panel S 3 ′ is skived from the inside layer 62 c ′ to the outside layer 60 c ′ so as to form an obtuse angle δ′ with the inner surface 63 c ′ of the third panel S 3 ′. The skived top edge of the second panel S 2 ′ is skived from the outside layer 60 b ′ to the inside layer 62 b ′ so as to form an obtuse angle β′ with the outer surface 61 b ′ of the second panel S 2 ′. Notably, it is preferred that obtuse angle α′ and obtuse angle γ′ are equal such that when panel S 1 ′ is joined to panel S 3 ′, they form a portion of substantially flat single panel S′ (viewed in cross-section in FIG. 80A ). Likewise, it is preferred that obtuse angle δ′ and obtuse angle β′ are equal such that when panel S 3 ′ is joined to panel S 2 ′, they too form a portion of substantially flat single panel S′ (also viewed in cross-section in FIG. 80A ).
[0172] Referring now to FIG. 81 , there is shown a golf club GC having a handle 55 upon which has been telescopically secured a grip G made in accordance with the disclosure herein contained. FIG. 82 shows a putter grip PG which is telescopically applied to the handle 57 of a putter P.
[0173] It should be understood that the outer surface of a grip embodying the present invention may be coated by means of a brush, nozzle, spray or the like with a thin layer of polyurethane (not shown) to protect such surface, add tackiness thereto and increase the durability thereof.
[0174] A golf club grip of the present invention provides the advantages over the existing wrapped and single panel grips described hereinbefore. Additionally, such grip has the appearance of a molded, one-piece grip familiar to professional and low-handicap golfers. Although some of such golfers are reluctant to use a non-traditional wrapped club, they are willing to play with a structurally integral multi-segment grip of the present invention since such grip affords the shock absorbing and tackiness qualities of a wrapped grip. Further, many individual golfers and high school, college, and professional teams like the camaraderie and unification that can be achieved by putting team colors on their golf grips without sacrificing comfort, durability or tackiness. My present invention allows the application of the multiple colors to golf club and putter grips to allow these teams and individuals to express their spirit and enthusiasm in a way never before possible.
[0175] Further details of the single panel grip and its applications are described in U.S. patent application Ser. No. 10/392480, filed on Mar. 18, 2003, which is herein incorporated by reference in its entirety.
[0176] It will be understood that the foregoing is only illustrative of the principles of the invention, and that various modifications, alterations, and combinations can be made by those skilled in the art without departing from the scope and spirit of the invention.
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A grip for the handle of a golf club having multiple two layer panels that are wrapped about an underlisting sleeve. The edges of the panels are adhesively sealed together. The grip reduces impact shock and provides a feeling of tackiness in the manner of a spirally wrapped polyurethane-felt grip while allowing the use of multiple color panels and easy installation onto a golf club shaft.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a construction machine, in particular for generating vibrations. A construction machine of such type is designed with a transmission, at least one hydraulic drive and a hydraulic circuit for supplying the hydraulic drive with hydraulic fluid, wherein at least one lubrication line is branched off from the hydraulic circuit, by means of which the transmission can be supplied with hydraulic fluid as a lubricant.
2. Description of related art including information disclosed under 37 CFR §§1.97 and 37 CFR 1.98
A generic construction machine is known from DE 101 15 260 C2. The teaching of this printed publication is to connect the hydraulic circuit of a hydraulic drive with the lubricating circuit of a transmission so that the hydraulic fluid serves as a lubricating oil.
A vibrator used for homogenizing mixtures that has a combined hydraulic-lubricant-circuit is known from U.S. Pat. No. 4,039,167.
The object of the invention is to improve a generic construction machine in such a manner that whilst offering high versatility a particularly high operational reliability is achieved.
BRIEF SUMMARY OF THE INVENTION
In accordance with the invention the object is solved by a construction machinehaving a transmission, at least one hydraulic drive and a hydraulic circuit for supplying the hydraulic drive with hydraulic fluid, wherein at least one lubrication line is branched off from the hydraulic circuit, by means of which the transmission can be supplied with hydraulic fluid as a lubricant, wherein on the lubrication line a dosing device is provided, with which the supply of lubricant can be changed depending on an operating condition of the transmission.
The construction machine according to the invention is characterized in that on the lubrication line a dosing device is provided, with which the supply of lubricant can be changed depending on an operating condition of the transmission.
A fundamental idea of the invention can be seen in the fact that a dosing device is provided for the lubricant, with which the flow of lubricant flowing in the lubrication line can be set selectively, in particular controlled and/or regulated, between the hydraulic circuit and the transmission depending on the operating condition of the transmission. The invention is based on the idea that the demand for lubricant by the transmission can depend on its operating condition. A variable demand for lubricant can result for instance from the fact that in the case of higher rotational speeds of the transmission the lubricant stays for a shorter period of time at the lubricating points and/or that a greater amount of heat is to be dissipated. The variable flow of lubricant according to the invention can ensure in this connection a reliable lubrication even in the case of high rotational speeds of the transmission and at the same time assurance is made that in the case of low rotational speeds no unnecessarily high quantity of fluid is drawn from the hydraulic circuit leading perhaps to an undesired high quantity of lubricant accumulating in the lubricant-oil sump of the transmission.
Likewise, a demand for lubricant by the transmission depending on the operating condition can in particular be the case if the discharge of lubricant from the transmission is effected depending on the operating condition, more particularly depending on the rotational speed. In such case assurance can be made according to the invention that the ratio between the supply rate and the discharge rate of lubricant is always constant at the transmission irrespective of the operating condition. In particular, the rates can be set equal. In this way it can be ensured that even during longer periods of operation the transmission is neither filled to the maximum with lubricant nor does it run dry. In order to prevent the transmission from being filled to the maximum with lubricant provision is preferably made for the discharge rate from the transmission to be higher than the supply rate to the transmission. To prevent in this case the discharge pump from running dry balancing means can be provided that lead a part of the discharged lubricant back into the transmission.
By the term operating condition the rotational speed of the transmission can be understood for example. However, the operating condition can also be the filling level of lubricant in the transmission for example.
By means of the invention it can be ensured in particular that lubricant is passed into the transmission only during operation of the transmission, whereby prevention can be made of the transmission filling to the maximum with lubricant in the inoperative condition in particular. The supply of lubricant depending on the operating condition in accordance with the invention permits a dosed force-feed lubrication of the transmission.
The invention renders it possible to operate the construction machine at a variable rotational speed of the transmission, in which case an especially reliable lubrication of the transmission is provided irrespective of the rotational speed. Therefore, in accordance with the invention a construction machine is obtained that is both especially versatile and reliable. If the construction machine is designed for generating vibrations, especially as a vibrator, the variable rotational speed of the transmission makes it possible to drive different kinds of construction elements into the ground in a smooth and reliable manner even when varying soil geologies are prevailing.
In accordance with the invention it is especially advantageous for the dosing device to have a dosing pump that is coupled mechanically to the transmission. According to this embodiment the dosing pump that is responsible for conveying lubricant into the transmission is driven by at least one element of the transmission. The mechanical coupling permits a condition-dependent actuation of the dosing device in a particularly simple and reliable manner. In principle, it would also be possible e.g. to determine the operating condition of the transmission by means of an electronic sensor and to set the supply of lubricant to the transmission by means of an electronic setting member.
Furthermore, according to the invention it is especially preferred that a lubricant return device is provided with which lubricant can be discharged from the transmission depending on the operating condition of the transmission. According to this embodiment both the supply rate of lubricant to the transmission and the discharge rate of lubricant from the transmission is set depending on the operating condition.
It is particularly advantageous for the lubricant return device to have at least one lubricant return line, on which a lubricant return pump is arranged. By preference, the lubricant return pump is coupled mechanically to the transmission. Similarly to the dosing pump, the lubricant return pump according to this embodiment is driven mechanically by an element of the transmission. Basically, it would also be possible to set the discharge of lubricant from the transmission by an electronic setting member that is operated on the basis of the sensor-determined operating condition.
In connection with a discharge of lubricant from the transmission depending on the rotational speed the invention offers an especially wide range of advantages. If, in this case, the supply of lubricant to the transmission were set constant, as known from prior art, the pump size of the lubricant return pump would have to be dimensioned such that the supplied lubricant could be pumped out reliably even when the lowest rotational speed of the transmission is present. However, this brings about a certain over-dimensioning of the lubricant return pump. If the transmission were operated in this case at a higher rotational speed, in particular at nominal rotational speed, the over-dimensioned pump might convey more oil than is available in the transmission sump. This might in turn have the effect that undesired large amounts of air enter the lubricant return line and is conveyed from there into the hydraulic system of the base device which can lead to an undesired frothing of the oil. By comparison, according to the invention the amount of lubrication fluid supplied to the transmission is also set depending on the rotational speed. Hence, according to the invention the supplied and discharged amount of lubricant can be in a fixed ratio to each other. More particularly, according to the invention the lubricant return pump does not have to be over-dimensioned whereby an undesired oil frothing is counteracted. For best suitability, the amount conveyed by the dosing pump, preferably the amount of lubricant conveyed both by the dosing pump and by the lubricant return pump, is at any rate proportional to the rotational speed of the transmission.
The operational reliability can be increased further by the fact that in particular on the side of the lubricant return pump facing away from the transmission a balancing line is branched off from the lubricant return line, which leads into the transmission, preferably via a throttle. The balancing line can serve for example to return gas proportions, that are perhaps discharged from the transmission by the lubricant return pump, back to the transmission.
Moreover, by means of a balancing line a complete running-dry of the transmission can be counteracted.
To prevent in particular an undesired loss of fluid it is of advantage that a leak oil line is provided for discharging leak oil from the hydraulic drive and/or from the dosing pump. In order to reduce the amount of equipment involved it is advantageous that a common leak oil line is provided for discharging leak oil both from the hydraulic drive and from the dosing pump.
Furthermore, according to the invention it is preferred that a relief line is provided, with which the lubrication line, the lubricant return line and/or the leak oil line are each in line-connection via a pressure-limiting valve, with the relief line leading into the transmission. As a result, an excess pressure protection can be realized in an especially simple manner. For best suitability, the lubricant return line is in line-connection with the relief line downstream of the lubricant return pump.
The hydraulic fluid supplied as a lubricant to the transmission can be leak oil of the hydraulic drive in particular. In this case the lubrication line can be branched off from a leak oil line of the hydraulic circuit. Alternatively or additionally provision can be made for the transmission to be supplied with oil returned to the hydraulic drive. Therefore, a preferred improvement of the invention resides in the fact that the lubrication line is branched off from a return-flow line of the hydraulic circuit. According to this embodiment lubricant is diverted from the flow leaving the hydraulic motor. As a rule, in the leak oil line and/or the return-flow line of the hydraulic circuit comparatively low hydraulic pressure is present that is especially suitable for the lubricating function. It is also possible to supply to the transmission both return oil and leak oil as a lubricant, whereby an especially reliable supply of lubricant is ensured. For instance provision can be made for the transmission to be supplied with a basic flow from the return-flow line and with an additional flow supplied from the leak oil line depending on the operating condition.
Basically, according to the invention provision can be made for the hydraulic drive and the transmission to be actuated independently of each other. However, it is especially advantageous that the hydraulic drive is arranged for actuation of the transmission. According to this embodiment the hydraulic drive is suitably provided on a drive shaft of the transmission. The transmission can be a rotary transmission for example, more particularly a gear transmission. By preference, the hydraulic drive is a hydraulic rotary motor.
A construction machine that is particularly versatile and/or efficient is given in that at least two hydraulic drives with a respective return-flow line are provided for driving the transmission. To achieve an especially reliable lubrication it is, in particular, advantageous for the lubrication line to be in line-connection with the two return-flow lines.
For example for functional testing of the lubrication it is useful if a pressure switch is provided on the lubrication line, in particular on the side of the dosing pump facing towards the transmission.
To generate vibrations in an especially easy way it is of advantage for at least one unbalanced mass to be arranged on the transmission. For best suitability, several unbalanced masses are provided, the phase position of which can be changed in order to set the vibrational amplitude.
By preference, the construction machine according to the invention, which can also be referred to as a vibrator, is a soil working device, by means of which construction elements, such as foundation elements, sheet piles and/or soil working tools can be driven into the ground. For this purpose a mounting for a construction element is preferably provided on the transmission. The construction machine can be a top vibrator or a depth vibrator for example. The construction machine can also be provided for soil compaction in particular. The fluids in accordance with the invention are suitably liquids, especially oil. For actuation of the hydraulic drive at least one hydraulic pump is suitably provided that is arranged in the hydraulic circuit. Advantageously, the hydraulic pump is provided on a carrier device, on which the transmission is arranged in a displaceable manner together with the hydraulic drive. It is especially advantageous that means are provided for setting the rotational speed of the hydraulic drive. To this end the hydraulic pump is suitably provided in an adjustable manner. According to the invention the hydraulic circuit can be designed as an open or closed circuit.
The invention also comprises a method for producing a sheet pile wall, in which sheet piles are acted upon by mechanical vibration and driven into the ground by means of a construction machine according to the invention.
In the following the invention is described in greater detail by way of preferred embodiments that are shown schematically in the accompanying drawing, wherein:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 shows the hydraulic diagram of a construction machine according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
A construction machine in accordance with the invention is shown in FIG. 1 . The construction machine designed as a vibrator has a transmission 3 , in which two first unbalanced masses 6 and two second unbalanced masses 6 ′ are provided for generating vibrations. On the transmission 3 a hydraulic swing motor 61 is arranged, by means of which the phase position of the first unbalanced mass 6 can be set relative to the second unbalanced mass 6 ′. For actuation of the hydraulic swing motor 61 two operating lines 60 , 60 ′ for hydraulic fluid are provided on the said motor.
To drive the transmission 3 two hydraulic drives 5 , 5 ′ are provided that are mechanically connected with the unbalanced masses 6 , 6 ′. To supply hydraulic fluid to the hydraulic drive 5 a supply line 51 is arranged thereon. By analogy, to supply hydraulic fluid to the hydraulic drive 5 ′ a supply line 51 ′ is arranged thereon. To discharge hydraulic fluid from the hydraulic drives 5 and 5 ′ a return-flow line 50 and 50 ′ respectively is provided on the said drives. Between the supply line 51 and the return-flow line 50 of the hydraulic drive 5 a check valve 53 is arranged that permits a flow from the return-flow line 50 to the supply line 51 and blocks an opposite-directed flow. A check valve 53 ′ of analogous design is present between the supply line 51 ′ and the return-flow line 50 ′ of hydraulic drive 5 ′. For actuation of the hydraulic drives 5 , 5 ′ two hydraulic pumps not shown in the Figures are provided that are connected with lines 50 and 51 and respectively 50 ′ and 51 ′.
In accordance with the invention provision is made for operating fluid for the hydraulic drives 5 , 5 ′ to be also used for lubrication of the transmission 3 . For this purpose a lubrication line 10 is provided that is in line-connection both with the return-flow line 50 of hydraulic drive 5 and with the return-flow line 50 ′ of hydraulic drive 5 ′ and is thereby able to discharge from the return-flow lines 50 , 50 ′ fluid back-flowing to the hydraulic drives 5 , 5 ′ and to supply this fluid to the transmission 3 as a lubricating medium. In the transmission 3 fluid is passed from the lubrication line 10 to the lubricating points of the transmission 3 .
To set the quantity of fluid conveyed via the lubrication line 10 to the transmission 3 a dosing pump 16 is arranged on the lubrication line 10 . The dosing pump 16 is connected mechanically with the transmission 3 , more particularly with the unbalanced masses 6 , 6 ′, so that the rotational speed of the pump and therefore the flow of lubricating medium conveyed by the dosing pump 16 is determined by the rotational speed of the transmission, in particular by being proportional thereto.
In the area of the transmission 3 a pressure switch 19 is provided on the lubrication line 10 , which closes upon a previously determined pressure and in this way permits monitoring of a correct lubrication.
To discharge lubricant from the transmission 3 a lubricant return line 20 is provided that leads into the sump of the transmission 3 . Through this lubricant return line 20 lubricant is returned from the transmission 3 to a collecting tank not shown in the Figures, from which fluid can again be supplied by means of the hydraulic pumps to the supply lines 51 , 51 ′ of the hydraulic drives 5 , 5 ′. On the lubricant return line 20 a lubricant return pump 26 is arranged that is mechanically connected to the transmission 3 just as the dosing pump 16 so that the conveying capacity of the said lubricant return pump equally depends on the rotational speed of the transmission 3 . Due to the fact that the conveying capacity of both pumps 16 and 26 depends on the rotational speed assurance is made that during operation the transmission 3 is neither filled to the maximum with lubricant nor does it run dry.
With the lubricant return line 20 a balancing line 28 is connected that leads into the transmission 3 via a throttle 27 and can serve for example to return gas proportions from the lubricant return line 20 to the transmission 3 .
To discharge leak oil from the two hydraulic drives 5 , 5 ′ a leak oil line 30 is provided. This leak oil line 30 joins with another leak oil line 36 of the hydraulic swing motor 61 to a common leak oil return line. In addition, a further leak oil line 31 is provided on the two hydraulic drives 5 , 5 ′, which connects the two hydraulic drives 5 , 5 ′ to each other.
Through a connecting line 32 the dosing pump 16 is in line-connection with the leak oil line 30 and perhaps also with the leak oil line 31 of the hydraulic drives 5 , 5 ′. In this way the dosing pump can draw fluid from the leak oil lines 30 and/or 31 and supply it as a lubricant to the transmission 3 . However, the connecting line 32 can also serve for discharging leak oil that accumulates on the dosing pump 16 .
In addition, the device depicted in FIG. 1 has a relief line 40 , into which the lubrication line 10 via a pressure-limiting valve 41 , the lubricant return line 20 via a pressure-limiting valve 42 and the leak oil line 36 via a pressure-limiting valve 43 are led. The relief line 40 leads into the transmission 3 and is able to discharge fluid from the lines 10 , 20 and/or 30 into the transmission 3 for excess pressure protection.
The device of FIG. 1 has a further pressure switch 39 that is in line-connection with the leak oil lines 30 , 36 . This pressure switch 39 opens when a predetermined pressure is exceeded. Therefore, it can serve to detect a pressure increase in the leak oil lines 30 , 36 , from which conclusions can be drawn as to a possible functional defect of the hydraulic drives 5 , 5 ′ or the hydraulic swing motor 61 .
During operation of the device illustrated in FIG. 1 the hydraulic drives 5 , 5 ′ are acted upon by pressurized fluid via the supply lines 51 , 51 ′ and drive the transmission 3 . The fluid delivered by the hydraulic drives 5 , 5 ′ is discharged via the return-flow lines 50 , 50 ′. At least a part of the back-flowing fluid is supplied as a lubricant via the lubrication line 10 to the transmission 3 . The dosing pump 16 that is connected mechanically with the transmission 3 ensures in this case that an amount of lubricant depending on the rotational speed is supplied to the transmission 3 . At the same time lubricant is discharged in the bottom portion of the transmission 3 via the lubricant return line 20 . By means of the lubricant return pump 26 , which is also connected mechanically with the transmission 3 , the amount of lubricant discharged is set depending on the rotational speed of the transmission.
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The invention relates to a construction machine comprising a transmission, at least one hydraulic drive and a hydraulic circuit for supplying the hydraulic drive with hydraulic fluid, wherein at least one lubrication line is branched off from the hydraulic circuit, by means of which the transmission can be supplied with hydraulic fluid as a lubricant. The invention is characterized in that a dosing device is provided on the lubrication line, with which the supply of lubricant can be changed depending on an operating condition of the transmission.
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FIELD OF THE INVENTION
The present invention relates to the field of submergible equipment, such as pumping systems for use in wells, such as petroleum production wells, and other submerged environments. More particularly, the invention relates to a technique for coupling a support assembly, such as a length of conduit and internal cable, to submergible equipment, and for selectively releasing the equipment from the support assembly while leaving certain portions of the submergible equipment in place.
BACKGROUND OF THE INVENTION
In producing petroleum and other useful fluids from production wells, a variety of component combinations, sometimes referred to as completions, are used in the downhole environment. For example, it is generally known to deploy a submergible pumping system in a well to raise the production fluids to the earth's surface.
In this latter example, production fluids enter the wellbore via perforations formed in a well casing adjacent a production formation. Fluids contained in the formation collect in the wellbore and are raised by the submergible pumping system to a collection point above the surface of the earth. In an exemplary submergible pumping system, the system includes several components such as a submergible electric motor that supplies energy to a submergible pump. This system may further include additional components, such as a motor protector, for isolating the motor oil from well fluids. A connector also is used to connect the submergible pumping system to a deployment system. These and other components may be combined in the overall submergible pumping system.
Conventional submergible pumping systems are deployed within a wellbore by a deployment system that may include tubing, cable or coil tubing. Power is supplied to the submergible electric motor via a power cable that runs along the deployment system. For example, with coil tubing, the power cable is either banded to the outside of the coil tubing or disposed internally within the hollow interior formed by the coil tubing. Additionally, other control lines, such as hydraulic control lines and tubing encapsulated conductors (TECs) may extend along or through the deployment system to provide a variety of inputs or communications with various components of the completion.
When an electric submergible pumping system is deployed in a well, it often is convenient to utilize coil tubing to support the completion equipment and to channel power and other conductors, particularly when production fluids are located a substantial distance beneath the earth's surface. However, the weight of the coil tubing, power cable, any fluid within the coil tubing, control lines and completion equipment determines the length of coil tubing that can support the completion in the well, eventually reaching the material strength limit of the tubing. Accordingly, it is desirable to minimize forces associated with deploying and retrieving a completion, so that the coil tubing may be deployed to maximum depth without risking damage to the coil tubing or power cable.
For removal of the completion from the well, such factors must be considered as adding to the load which will be exerted on the deployment system. Other loads are also encountered upon retrieval. For example, a coil tubing deployment system may be filled with an internal fluid to provide buoyancy to the power cable running therethrough. However, the "loaded" coil tubing cannot be extended as far into a well as an unloaded coil tubing deployment system, because the weight of the internal fluid places additional force on the coil tubing. The fluid also adds to the load borne by the deployment system upon retrieval. Other forces and loads may result from drag within the wellbore (such as due to integral packers and similar structures), accumulated sand or silt, rock or aggregate fall-ins, and so forth. To provide for such loads, the deployment system is generally overdesigned or the completion is positioned substantially higher in the well than the mechanical strength limits of the deployment system would otherwise dictate.
When a submergible pumping system is deployed to substantial depth relative to the strength of the coil tubing, it has been proposed to release the completion and remove the coil tubing from the well separately from the completion. A work string, such as a high tensile strength coil tubing with a fishing tool, is then run downhole and latched to the completion for removal. Conventionally, submergible pumping systems have been separated from the coil tubing at the connector used to connect the coil tubing to the completion. Conventional connectors had separable components connected by shear pins or other frangible structures. Thus, to release the deployment system from the submergible pumping system, sufficient force was exerted on the deployment system to shear the pins. However, the strength to withstand the additional load required to produce this shear force must also be built into the deployment system. Moreover, this additional load potentially can damage the coil tubing and power cable. To avoid such damage, the length of the coil tubing must again be reduced to correspondingly reduce the weight supported in the wellbore. Such limits on the depth to which the submergible pumping system can be deployed are undesirable.
It would be advantageous to have a remotely actuated separation technique for releasing a deployment system from a completion, e.g. submergible pumping system, without placing undue added forces on the deployment system during the separation operation. Such a technique for separating the deployment system from the completion would facilitate placement of the completion at greater depth within the wellbore without otherwise changing the deployment system or submergible components.
SUMMARY OF THE INVENTION
The invention provides an innovative technique for coupling and separating a completion designed to respond to these needs. The technique may be used with a variety of completions, but is particularly well suited to powered completions, such as submergible pumping systems. Similarly, the technique may be used with a variety of deployment systems, but is particularly well suited for use in coil tubing deployed systems. The technique facilitates the coupling and deployment of the system upon initial installation or following servicing. When the completion or the deployment system is to be raised from the well, the completion may be easily released by actuation of a release assembly. Thereafter, the completion may be retrieved by a wire line fishing tool or the like. The release is controlled remotely from the earth's surface, such as by application of pressurized fluid to a release control line. In a particularly preferred embodiment, controlled release elements, such as shear pins, are broken by the release assembly to free upper and lower connector or interface assemblies from one another. Each connector or interface assembly may include sealed connectors or plugs for facilitating the transmission of data or power signals between the completion and equipment at the earth's surface. Additional control lines may be provided through the assembly. Upon release, the power and control lines are separated in a controlled manner, providing a predictable release.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
FIG. 1 is a front elevational view of a submergible pumping system positioned in a wellbore, according to a preferred embodiment of the present invention;
FIG. 2 is a cross-sectional view of a connector, generally along its longitudinal axis according to a preferred embodiment of the present invention;
FIG. 3 is a cross-sectional view taken generally along line 3--3 of FIG. 2;
FIG. 4 is a cross-sectional view taken generally along line 4--4 of FIG. 2;
FIG. 5 is a cross-sectional view taken generally along line 5--5 of FIG. 2;
FIG. 6 is a cross-sectional view similar to that of FIG. 2 but showing the connector separated;
FIG. 7 is a vertical sectional view of a mechanically opened check valve for forcing release of the assembly shown in FIG. 2 in accordance with certain aspects of the present technique;
FIG. 8 is a sectional view of the valve of FIG. 7 illustrated in the installed position;
FIG. 9 is a sectional view of the valve of FIG. 7 following partial release of the assembly;
FIG. 10 is a sectional view of the valve of FIG. 7 following full release of the assembly, and with a positive pressure on the valve to purge the hydraulic supply line;
FIG. 11 is a sectional view of the valve of FIG. 7 following release of the purge pressure to permit the valve to reseat;
FIG. 12 is a sectional view of the valve of FIG. 7 adapted for transmission of fluid to a downstream component; and
FIG. 13 is a sectional view of the valve of FIG. 7 adapted for exchange of data or power signals with a downstream component.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring generally to FIG. 1, a system 20 is illustrated according to a preferred embodiment of the present invention. System 20 may comprise a variety of components depending upon the particular application or environment in which it is used. However, system 20 typically includes a deployment system 22 connected to a completion, such as an electric submergible pumping system 24. Deployment system 22 is attached to pumping system 24 by a connector 26.
System 20 is designed for deployment in a well 28 within a geological formation 30 containing fluids, such as petroleum and water. In a typical application, a wellbore 32 is drilled and lined with a wellbore casing 34. The submergible pumping system 24 is deployed within wellbore 32 to a desired location for pumping wellbore fluids.
As illustrated, pumping system 24 typically includes at least a submergible pump 36 and a submergible motor 38. Submergible pumping system 24 also may include other components. For example, a packer assembly 40 may be utilized to provide a seal between the string of submergible components and an interior surface 42 of wellbore casing 34. Other additional components may comprise a thrust casing 44, a pump intake 46, through which wellbore fluids enter pump 36, and a motor protector 48 that serves to isolate the wellbore fluid from the motor oil. Still further components, and various configurations, may be provided depending on the characteristics of the formation and the type of well into which the completion is deployed.
In the preferred embodiment, deployment system 22 is a coil tubing system 50 utilizing a coil tube 52 attached to the upper end of connector 26. A power cable 54 runs through the hollow center of coil tube 52. Power cable 54 typically comprises three conductors for providing power to motor 38. Additionally, at least one control line 56 preferably runs through coil tube 52 to provide input for initiating separation of connector 26 from a remote location, as will be described in detail below. Additional lines, such as fluid or conductive control lines may run through the hollow interior of coil tube 52. Also, other types of deployment systems may be utilized with connector 26.
Referring generally to FIG. 2, a cross-sectional view of connector 26 is taken generally along its longitudinal axis. The illustrated connector 26 is a preferred embodiment of a separable connector. However, a variety of connector configurations can be utilized with the present inventive system and method. Accordingly, the present invention should not be limited to the specific details described.
With reference to FIG. 2, connector 26 includes an upper connector head 58 having an upper threaded region 60. A slip nut 62 is threadably engaged with threaded region 60. Slip nut 62 cooperates with connector head 58 and a retaining slip 64 to securely grip a lower end 66 of coil tubing 52. A plurality of seals 68 are disposed between connector head 58 and coil tubing 52. Additionally, a plurality of dimpling screws 70 are threaded through slip nut 62 in a radial direction for engagement with lower end 66 of coil tubing 52.
In the illustrated embodiment, power cable 54 extends through the center of coil tubing 52 into a hollow interior 72 of connector 26. Additionally, a flat pack 74, including control line 56, also extends through the center of coil tubing 52 into hollow interior 72. Flat pack 74 further includes, for example, a pair of fluid lines 76 and a conductive control line 78, such as a tubing encapsulated conductor, or TEC.
Power cable 54 is held within hollow interior 72 by an anchor base 80 attached to connector head 58 by a plurality of fasteners 82, such as threaded bolts, as illustrated in FIGS. 2 and 3. Additionally, an anchor slip 84 is disposed about power cable 54 and secured by an anchor nut 86 threadably engaged with anchor base 80.
An upper housing 88 is threadably engaged with connector head 58. A hydraulic manifold 90 is disposed within upper housing 88 and held between a lower internal ridge 92 of upper housing 88 and a plate 94 (see also FIG. 4). Plate 94 is held against the upper end of hydraulic manifold 90 by a split sleeve 96 disposed between connector head 58 and plate 94, as illustrated.
Manifold 90 includes a longitudinal opening 98 therethrough. Additionally, manifold 90 includes a plurality of fluid or conductive control line openings 100 extending longitudinally therethrough. Preferably, each opening 100 terminates at a recessed area 102 formed in manifold 90 for receiving a valve 104. Additionally, plate 94 includes an opening through which power cable 54 and control lines 56, 76 and 78 extend into connection with manifold 90 via couplings 106.
Disposed within opening 98 of manifold 90 is an upper plug connector 108 of an overall plug or plug assembly 110. Upper plug connector 108, manifold 90 and the above described components of connector 26 comprise an upper connector assembly 112 designed for separable engagement with a lower connector assembly 114.
Lower connector assembly 114 includes, for example, a lower housing 116 and a lower plug connector 118 of plug 110. Lower housing 116 and lower plug connector 118 are both designed for attachment to upper connector assembly 112. Specifically, lower housing 116 is designed to receive the lower portion of hydraulic manifold 90. Preferably, housing 116 is further attached to upper connector assembly 112 by a plurality of shear screws 119, or similar controlled release elements, extending radially through lower housing 116 into manifold 90, as illustrated in FIGS. 1 and 5.
Plug assembly 110 also is designed for separable engagement, such that upper plug connector 108 remains with upper connector assembly 112 and lower plug connector 118 remains with lower connector assembly 114 when connector 26 is separated. As illustrated, power cable 54 is routed to upper plug connector 108. The power cable includes a plurality of conductors 120, typically three motor conductors, that are routed through plug assembly 110. Each conductor also is separable along with plug assembly 110. For example, each conductor 120 may have a separation point formed by mating male terminals 122 and female receptacles 124 formed in corresponding portions of plug assembly 110. Conductors 120 are designed to provide power to the completion, and in the illustrated embodiment specifically to motor 38 of the electric submergible pumping system. Thus, the plug assembly permits connector 26 to be used with powered completions without causing damage upon separation of upper connector assembly 112 and lower connector assembly 114. Preferably, lower plug connector 118 is held within a longitudinal opening of lower housing 116 by a lower plate 126 and a support 128. In appropriate applications, a biasing member (not shown) may be provided adjacent to one or both plug connectors to urge the connectors toward electrical engagement. Similarly, hydrostatic pressures in the acting against plate 126 may be used to bias the lower plug connector 118 into engagement with upper plug connector 108.
Separation of upper connector assembly 112 from lower connector assembly 114 is accomplished by an appropriate separator mechanism. In the preferred embodiment, separator mechanism 130 comprises control line 56, in this case a hydraulic control line, disposed through upper connector assembly 112 and manifold 90. Separator mechanism 130 also includes valve 104 and a fluid discharge area 132 formed on lower housing 116 to create a pressure chamber 134 between upper connector assembly 112 and area 132. For release, pressurized hydraulic fluid is forced through control line 56 from a remote location, such as a control station at the earth's surface, to pressure chamber 134. Valve 104 permits the pressurized fluid to act against fluid discharge area 132 to pressurize pressure chamber 134. Upon sufficient increase in pressure acting between upper connector assembly 112 and lower connector assembly 114, the shear mechanism, e.g. shear screws 119, is sheared. This shearing permits separation of upper connector assembly 112 from lower connector assembly 114, as illustrated in FIG. 6. Simultaneously, upper plug connector 108 of plug assembly 110 is disengaged from lower plug connector 118. Thus, the connector 26 can be separated without placement of any undue force on either coil tubing 52 or power cable 54. Following separation, the preferred embodiment illustrated provides a predicable and uniform surface or surfaces which may be engaged by a fishing tool or similar device for removal of the completion from the well. The surfaces may define various retrieval profiles, either internal or external, such as profile 117 shown in FIGS. 2 and 6.
Also, other separator mechanisms could be incorporated into the present design. For example, an electrical signal could be delivered downhole to a dedicated electric pump connected to and able to pressurize chamber 134.
It should be noted that in the illustrated embodiment, opening 98 is disposed off 20 the axial center of manifold 90. With this embodiment, the shear screws 119 are grouped along the side of the manifold area that receives the greatest portion of the resultant force due to pressurized fluid flowing into pressure chamber 134. Specifically, the placement of four shear screws, as illustrated in FIG. 5, reduces the potential for "cocking" of manifold 90 within lower housing 116, and thereby facilitates separation of assemblies 112 and 114.
Upon separation, valve 104 closes control line 56 to prevent well fluid from contaminating the hydraulic fluid within control line 56, and to prevent wellbore fluids from escaping through the fluid lines. The preferred design and functions of valve 104 are explained in detail below.
Additional valves 104 may be disposed within manifold 90 for the fluid lines 76 as illustrated for control line 56 and as further described below. The use of valves 104 prevents contamination of the fluid control lines 76, that are disposed above lower connector assembly 114. Optionally, valves 104 can be placed in each of the control lines 76 extending along lower connector assembly 114 to prevent contamination of the control lines below upper connector assembly 112 when separated, and to prevent the escape of wellbore fluids. It also should be noted that the fluid line 76 shown beneath such additional valves 104 in FIG. 1, does not enter pressure chamber 134. Rather, it is the continuation of one of the fluid control lines 76 that provide fluid to a desired component, such as packer assembly 40.
In operation, connector 26 is attached to deployment system 22, e.g., coil tubing 52, and to a downhole completion, such as electric submergible pumping system 24. Thereafter, the entire 20 system is deployed in wellbore 32 to the desired depth. In appropriate applications, it may be desirable to lock the upper connector assembly 112 to the lower connector assembly 114 during deployment and potentially during use to avoid accidental disengagement. The connector assemblies can be locked together in a variety of ways depending on the specific design of connector 26. For example, J-slots, supported collect locks, releasable dogs or other appropriate locking mechanisms can be used.
After properly locating the system in the wellbore, packer assembly 40 is set via one of the lines 76, and production fluids are pumped to the surface through the annulus formed around deployment system 22. Preferably, any locking mechanism disposed on connector 26 is released prior to setting packer assembly 40. When it becomes necessary to service or remove pumping system 24, connector 26 is separated to permit removal of coil tubing 52.
The separation process is initiated by pumping hydraulic fluid through control line 56 and valve 104 to fluid discharge area 132. When the fluid pressure in control line 56 and pressure chamber 134 rises to a sufficient level, upper connector assembly 112 begins to separate from lower connector assembly 114 by movement of manifold 90. Upon sufficient movement of manifold 90 with respect to the walls of lower connector assembly 114, pins 119 are sheared, freeing the upper connector assembly to be withdrawn from the lower connector assembly. It should be noted that in the preferred embodiment, the connector plugs, as well as the fluid and electrical control lines remain sealed within their respective portions of the connector following separation. Also, the foregoing arrangement permits the release of the completion via straight-pull shearing of the pins in conjunction with or without hydraulic assistance. It should also be noted that in the present embodiment, the connector system is pressure biased in an engaged condition because the pressure in control line 56 is generally lower than that present in the well.
Turning now to a presently preferred construction of valve 104, FIGS. 7-12 illustrate presently preferred configurations of a valve for releasing the components of the connector assemblies described above. As shown in FIG. 7, valve 104 is lodged within recess 290 of manifold 90, and is held within the manifold by a retainer ring 300 secured within a groove 302. Valve 104 generally includes a spool-type valve member 304, a seat member 306 surrounding valve member 304, and a seat housing 308 surrounding a portion of seat member 306. Both valve member 304 and seat member 306 are movable, as described below, to permit the flow of fluid through the valve, and to open and close the valve selectively for normal and release operations. Moreover, member 308 is also preferably slightly movable within the valve to permit the equalization of forces within the valve assembly.
Referring more particularly now to a preferred construction of valve member 304, member 304 includes an elongated spool 310. Spool 310 has a seat portion 312 at its lower end, and a valve stop 314 at its upper end. Valve stop 314 is held in place by an annular extension 316, and a retainer ring 318. Moreover, valve stop 314 includes flow-through apertures 320 permitting fluid to flow through the stop during operation of the valve. Valve stop 314 is positioned adjacent to an upper end 322 of recess 290 as described below. At its lower side, valve stop 314 abuts a compression spring 324 which serves to bias both the valve member 304 and the seat member 306 toward mutually sealed positions. In the illustrated embodiment, seat portion 312 includes a tapered hard metallic seat surface 326, as well as a soft elastomeric seat 328 secured in an annular position to provide sealing during a portion of the movement cycle of the valve components. This arrangement provided redundancy in the sealing of the valve member and seat member.
Seat member 306 includes an elongated fluid passageway 330 in which spool 310 is disposed. Moreover, along its length, seat member 306 forms an upper extension 332, an enlarged central section 334, and a lower actuating extension 336. Seals are carried by the seat member to seal designated portions of the volumes of the valve. In the illustrated embodiment these seals include an upper T-seal 338 disposed about upper section 332, and an intermediate T-seal 340 disposed about central section 332. Upper T-seal 338 seals between the seat member and recess 290. Intermediate T-seal 340 seals between the seat member and an internal surface of seat housing 306 as described more fully below. Fluid passageways 342 are formed in seat member 306 to place an outer periphery of the seat member in fluid communication with passageway 330. In the release valve, additional passageways 344 are formed at the base of actuating extension 336. A lower seat surface 346 is formed to contact hard and soft sealing surfaces 326 and 328 to prevent flow through the value upon closure.
Seat housing 308 is positioned intermediate recess 290 and seat member 306. In the illustrated embodiment, seat housing 308 includes an enlarged bore 348 in which central section 334 of seat member 306 is free to slide. T-seal 340 seals central section 334 in its sliding movement within bore 348. Seat housing 308 also includes a reduced diameter lower portion 350 surrounding actuating extension 336 of seat member 306. An internal T-seal 352 is provided in lower portion 350 to seal against the actuating extension. Retaining ring 300 abuts lower portion 350 to maintain the seat housing in place. Below seat housing 308, within lower recess 353, a similar internal T-seal 354 is provided for sealing about actuating extension 336. As described below, in certain applications such as when the valve is used for hydraulic release, seal 354 may be omitted, particularly where sealing between the actuating extension and the lower recess is not required. In the present embodiment no seal 354 is provided in the release valve to permit pressurized fluid access pressure chamber 134.
In the embodiment illustrated in FIG. 7, lower recess 353 is blind, and is configured to receive actuating extension 336 of valve 104. In the installed position shown in FIG. 7, manifold 90 is fully engaged in lower connector assembly 114, such that actuating extension 336 contacts a lower end of recess 353 to force seat member 306 into an upper position along seat housing 308. The upward movement of seat member 306 compresses spring 324 to force valve member 304 into an upper position. A free flow path is thereby defined through control line 56, apertures 320 in valve stop 314, inner passageway 330, and downwardly around seat portion 312 of the valve spool. At the same time, pressure from the passageway 330 of seat member 306 is communicated to the region between central section 334 of the seat member and the lower portion 350 of the seat housing via passageways 342. Moreover, when the valve is used for hydraulic release the lower volume defined within actuating extension 334 below the spool is in fluid communication with pressure chamber 134 below seat housing 308. It should be noted that when the valve is mechanically held open, fluid may be permitted to flow in either direction through the valve.
Referring now to FIG. 8, for actuation of the valve, and release of the portions of the assembly from one another, pressure is applied at control line 56 such as via an above-ground pressure source. This pressure is transmitted through apertures 320, through passageway 330, into actuating extension 336, and thereby into pressure chamber 134. As the pressure increases, a parting force is exerted against areas adjacent to pressure chamber 134. At this time, all valve components are in pressure equilibrium. The valve assembly and manifold 90 are thereby forced away from lower connector assembly 114, as illustrated in FIG. 9. Spring 324 will bias the valve member 304 to contact seat member 306.
Following initial parting of the assembly members, valve member 304 will seat against seat member 306 as shown in FIG. 9. Application of additional pressurized fluid within control line 56 will force the fluid through central passageway 330, temporarily unseating the spool by relative movement of the valve member 304 and seat member 306 (within the valve recess), resulting in progressive displacement of the manifold in an upward direction under the influence of forces exerted against surfaces adjacent to pressure chamber 134. As noted above, in the blind arrangement shown in FIGS. 7 through 11, T-seal 354 may be eliminated, due to the free communication of fluid between the actuating extension 336 and pressure chamber 134.
The progressive displacement of the sections of the assembly with respect to one another may proceed under fluid pressure exerted through valve 104 until full disengagement of actuating extension 336 is obtained as shown in FIG. 10. Thereafter, further application of fluid pressure through the valve continues to unseat valve member 304 from seat member 306, and seat member 306 from seat housing 308, to progressively disengage the assembly sections from one another, thereby disconnecting conductors as explained above. Alternatively, once pins 119 or similar controlled release structures are sheared or actuated, the upper and lower connector sections may be separated by relative movement of the completion equipment and the deployment system. Following such full disengagement of the valve from its lower recess, valve 104 will seat as illustrated in FIG. 11.
Following full disengagement of the sections of the assembly, valve 104 serves as a check valve permitting purging of fluids which may infiltrate into control line 56. In particular, as shown in FIGS. 10 and 11, pressure may be exerted in control line 56 to unseat the valve member and seat member from one another, permitting such purging action. Following reduction in the pressure at control line 56, spring 324 and pressure surrounding valve member 304, force the valve member and seat member into seated engagement with one another. It should be noted that in the present embodiment illustrated in the figures, clearance is provided between valve stop 314 and upper end 322 of recess 290, to permit full seating of the valve and seat member on one another when connector components are separated as shown in FIG. 11.
Various adaptations may be made to valve 104 to permit control lines, instrument lines, and so forth, to communicate between upper and lower portions of the connector assembly, while preventing flooding of such lines upon parting or release. FIG. 12 illustrates one such adaptation incorporated into a valve of the basic structure described above. In particular, rather than the blind cavity described above used to force separation or release of the connector assembly, a fluid passageway or conduit 356 may be formed in communication with the lower fluid volume within actuating extension 336. In the embodiment shown in FIG. 12, a sealed fitting 358 is provided for transmitting fluid to or from a lower component, such as a packer, slide valve, and so forth. In such arrangements, fall engagement of the valve 104 during assembly of the connector system will define a flow path permitting the free exchange of fluid between manifold 90 and the lower component. Upon parting, however, T-seal 354 will prevent the exchange of pressurized fluid between pressure chamber 134 and fluid contained within the valve. It should be noted that in this embodiment, actuating extension 336 does not require fluid passageways 344 (refer to FIG. 7), but where such passageways are present, T-seal 354 prevents the exchange of fluids between the control line and pressure chamber 134. Upon full release of the connector assembly portions, the valve will seat, thereby preventing the flow of well bore fluids, water or other ambient fluids into line 76. As is described above, pressure applied as line 76 of such valves will, however, permit purging of the feed lines.
Also shown in FIG. 13, valve 104 may be adapted for accommodating an integral electrical conductor 360, such as for a gauge pack or other electrical device. In this adaptation, a central bore 362 is formed through valve member 304. Conductor 360 is fed through bore 362 and terminates in a bulkhead feed-through electrical connector 364. In the illustrated embodiment, connector 364 includes a wire plug connection 366. Such connector arrangements are available in various forms and configurations as will be apparent to those skilled in the art. For instance, one acceptable connector is available commercially from Kemlon, an affiliate of Keystone Engineering Company of Houston, Tex., under the commercial designation K25. Other connector arrangements may include bulkhead connectors configured to prevent flooding of the conduits. Also, coaxial, multi-pin, wet-connectable, and other connectors may be employed to insure continuity of the electrical connection through valve 104.
In a presently preferred configuration, conductor 360 extends through the valve and is in electrical connection with a tubing encapsulated conductor 368. As in the previous embodiments, valve 104 establishes a flow path upon full engagement of manifold 90 within the assembly. In the case of the valve illustrated in FIG. 12 equipped with an electrical conductor, the electrical conductor may be surrounded by a dialectric fluid medium, such as transformer oil. Alternatively, a sealed contact may be employed to provide a wet-connect arrangement. As the manifold is retracted from the assembly, the electrical connection is interrupted, and the upper line 78 within which the upper conductor 360 is located is closed by operation of the valve. Thereafter, the conductor is electrically isolated by the dialectric fluid within the passageway. As before, the passageway may be purged by exertion of fluid pressure within the passageway to unseat valve member 304 and seat member 306 from one another.
It will be understood that the foregoing description is of preferred embodiments of this invention, and that the invention is not limited to the specific form shown. For example, a variety of connector components can be used in constructing the connector; one or more control lines can be added; a variety of control lines, such as fluid control lines, optical fibers, and conductive control lines can be adapted for engagement and disengagement; the fluid control lines can be adapted for delivering fluids, such as corrosion inhibitors etc., to the various components of the completion; and the power cable can be routed through coil tubing or connected along the coil tubing or other deployment systems. Also, a variety of valve configurations may be employed for initial and progressive, controlled release. For example, various seals may be employed in the valve in place of the T-seals discussed above, such as metal-to-metal seals, cup seals, V packing, poly-seals and so forth. Similarly, data or power signals may be exchanged with a component of the completion via internal connections other than the plug arrangement and feedthrough valve structure described above. These and other modifications may be made in the design and arrangement of the elements without departing from the scope of the invention as expressed in the appended claims.
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A controlled release method for a submergible completion is disclosed wherein upper and lower interface assemblies are separated from one another in a predictable manner. A separation or release assembly is actuated remotely for forcing the interface assemblies apart. The release assembly may shear pins extending between portions of the interface assemblies. The interface assemblies may include multi-conductor electrical plugs or connectors which are separated during release.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/117,845 filed Jan. 29, 1999, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to oilfield downhole operations. More particularly, the invention relates to a swage device for reforming a deformable junction in a deviated wellbore.
2. Prior Art
As is well known to those of skill in the art, reformable deformed junctions have been known to the oilfield art. The benefit of a deformed junction is that the junction is easily transported through the casing of a wellbore or an open hole wellbore to its final destination at a junction between a primary and lateral borehole. Once the junction is properly positioned, it is reformed into a Y-shaped junction to assist in completing the wellbore. In the fully reformed condition of the junction, the outer dimensions are generally greater than the inside diameter (ID) of the casing or open hole. Thus, of course, it would be rather difficult to install the junction in its undeformed condition. Many methods have been used to reform the deformed junction in the borehole. One of the prior art methods has been to employ a swaging device. Swaging devices generally comprise a conical or frustoconical hardened member having an outside diameter (OD) as large as possible while being passable through the wellbore casing or the open hole. This swage is forced to travel through a previously positioned deformed junction whereby the junction is reformed into an operational position. Where the junction is located in a vertical or near vertical wellbore, setdown weight alone often is sufficient to generate the approximately 100,000 pounds of force required to reform the junction. Where the deformed junction is being placed in a highly deviated wellbore or a horizontal wellbore, however, setdown weight might not be sufficient to force the swage device through the junction. In this event, one of skill in the art will recognize the hydraulic procedure alternative to setdown weight. This hydraulic procedure includes an expansion joint located above the swage device, a drill tube anchor located above the expansion joint, and a ball seat located below the expansion joint such that by dropping a ball, pressure can be applied to the tubing string. This applied pressure forces the expansion joint to expand downhole, which in turn forces the swage device through the junction. Expansion joints are well known in the art, as are anchors and ball seats.
As also will be recognized by one of ordinary skill in the art, there is a significant drawback to the prior art swaging devices. The metal of the junction has a certain amount of resilience such that after the swage device has been forced through the junction, reforming the same, the junction itself will rebound to a smaller ID than the OD of the swage device by several thousandths of an inch. Because of the rebound it requires nearly as much lifting force on the swage device to remove it from the wellbore as is needed to initially force the swage through the deformed junction. This can be as much as 100,000 pounds. Although a drilling rig can easily pull ten times this weight, in a highly deviated or horizontal wellbore, the friction created on the curvature of the well can be high enough to absorb all of the force imparted at the surface and leave none available for the swage. Thus, the tool is stuck. The amount of force necessary to pull the swage through the newly reformed junction can also be sufficient to damage other well tools or junctions. Such damage can of course cost significant sums of money to repair and require significant time both to diagnose and to repair. Thus, the art is in need of a swage device that does not carry the drawbacks of the prior art.
SUMMARY OF THE INVENTION
The above-identified drawbacks of the prior art are overcome or alleviated by the flexible swage device of the invention.
The invention avoids the above set forth drawback by creating a two-part swage device comprising a support and a swage cup. The support is engaged with the swage cup during the swaging operation. The swage cup is moveable such that after the swaging operation is complete, the swage cup can be moved to a position where it is unsupported by the support and is therefore allowed to deflect several thousandths of an inch toward the mandrel. This deflection will significantly reduce drag on the swage cup through the reformed junction (and any other junctions uphole of the subject junction) during removal of the swage device from the wellbore. In an alternate embodiment, the swage cup contains longitudinal slots cut into it to impart increased flexibility characteristics to the swage cup. The flexible swage device of the invention is employable in place of a conventional swage, the function of which being fully assimilated in the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several FIGURES:
FIG. 1 is a side view of the invention in the swage position; and
FIG. 2 is a side view of the invention wherein the swage cup has been sheared to a second position, which is the retrieving position;
FIG. 3 is a cross section view of a second embodiment of the invention;
FIG. 4 is a perspective view of the swage cup; and
FIG. 5 is a perspective view of an alternate embodiment of the swage cup.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a flexible swage in the swaging position is shown generally at 10 . The invention is illustrated mounted on a mandrel 11 by a regular threaded connection 12 and a plurality of set screws 14 . Each set screw 14 is received in a groove 16 , the combination of which with screw thread 12 prevents movement of a support 18 . Support 18 is preferably a frustoconical annular element of a single piece although multiple pieces could be used to achieve the result of the invention. Support 18 is provided with at least one port 20 (preferably several ports 20 ) that exits support 18 uphole of a point of contact of the swage device with the inner wall of a junction being deformed (not shown). Port 20 also intersects a bore 22 of which there may be several and preferably will be as many as there are ports 20 , which extends through support 18 to a downhole end 24 thereof. Bore 22 is open to annular space 26 as illustrated. As should be understood, there may be several bores 22 that open into annular space 26 . Support 18 can be seen in the drawing (FIG. 1) to matingly receive and support a swage member 27 .
Referring now to FIG. 4, one embodiment of the swage member of the invention is shown separately from other components of the invention. The swage member is numeralled 27 . Swage member 27 comprises a swage cup 28 and a swage base 30 and is a frustoconical annular element preferably of a single piece. Alternately, multiple pieces could be used to form swage member 27 . In either case, swage cup 28 extends upwardly and outwardly from swage cup base 30 . A hole 29 extends axially through swage cup 28 and swage cup base 30 and is of a size sufficient to allow swage member 27 to receive mandrel 11 . An uphole end 33 of swage cup 28 is substantially hollowed out and configured to matingly accommodate support 18 , thereby preventing the deflection of the outer perimeter of swage cup 28 toward mandrel 11 .
Turning now to FIG. 5, an alternate embodiment of the swage member of the invention is illustrated generally at 227 . This alternate embodiment comprises swage cup 228 and swage cup base 230 . Swage cup 228 is still of a generally frustoconical shape and is still preferably fabricated from a single piece of material, as in the previous embodiment. However, swage cup 228 contains a plurality of longitudinal slots 235 cut therein and extending toward swage cup base 230 . Slots 235 render swage cup 228 more flexible than the first described embodiment. The greater flexibility, it will be understood, is due to the kerf width of slots 235 . Since it is possible during compression of swage cup 228 to “close” the kerf of slots 235 , a greater reduction in the outside diameter of swage cup 228 is achievable. Slots 235 make retrieval of the tool easier without compromising the swaging action of the tool in the first instance.
Referring back to FIG. 1, swage cup base 30 includes bore 32 open on a downhole end 34 of swage cup base 30 to the well fluid downhole of a contact area 31 of swage cup 28 with the inside dimension of a deformable junction 33 (shown in phantom lines). Bore 32 extends to an uphole end 36 which communicates with annular space 26 . Annular space 26 ensures communication between bore 32 and bore 22 thus effecting through-passage of well fluids from below contact area 31 of swage cup 28 with the inside dimension of deform able junction 33 (effectively a metal-to-metal seal) to the outlet of port 20 above contact point 31 . A means for fluid flow (such as bore 22 ) through swage 10 is necessary to provide an outlet for the build up of fluid pressure downhole of swage cup 28 . By providing a bore through swage cup 28 , the conditions allowing for the formation of this hydraulic lock under swage cup 28 , which would otherwise hinder and possibly prevent movement of swage 10 through the junction, are defeated.
Swage cup 28 and swage cup base 30 are located on mandrel 11 by shear screws 38 only. Swage cup 28 and swage cup base 30 are preferably a single annular component that is slideable along mandrel 11 . Therefore, some means of holding swage cup 28 and swage cup base 30 in the swaging position on support 18 is needed for the invention to function as intended. One embodiment of such means is through the use of shear screws 38 , which are received in groove 40 . It will be recognized by one of ordinary skill in the art that since shear screws 38 are the only means in this embodiment which hold swage cup 28 and swage cup base 30 in place, swage cup 28 and swage cup base 30 may rotate 360° around mandrel 11 relatively freely. The significance of annular space 26 then is to ensure that bore 32 is in fluid communication with bore 22 regardless of the orientation swage cup 28 and swage cup base 30 have relative to support 18 .
In the condition shown in FIG. 1, one of ordinary skill in the art will appreciate that as swage 10 is forced downhole, it will quite effectively reform a deformed junction similarly to prior art swages. Once the reformation is complete and it is desirable to remove swage 10 from the wellbore, an upward pull is necessary. Referring now to FIG. 2, upon pulling the tool in the upward direction, a point 42 of swage cup 28 will contact the inner walls of the junction due to the resilience of the junction as discussed hereinbefore. The pressure on point 42 will tend to prevent swage 10 from moving uphole. This force is translated through swage cup 28 and swage cup base 30 to screws 38 , which will then shear under that force. One of skill in the art will recognize that the particular amount of force required to shear screws 38 is engineerable in advance and should be matched to an appropriate amount of force to indicate that withdrawal of the tool is desired. Upon shearing of screws 38 , swage cup base 30 and swage cup 28 move downhole until downhole end 34 of swage cup base 30 is in contact with an uphole end 44 of a swage stop 46 . It should be briefly noted at this point that swage stop 46 is connected to mandrel 11 via a regular thread 48 and a plurality of set screws 50 . Swage stop 46 further includes an o-ring 52 to seal swage stop 46 against mandrel 11 .
Upon shifting swage cup 28 and swage cup base 30 downhole into contact with uphole end 44 of swage stop 46 , a gap 54 is formed between swage cup 28 and support 18 . Because of gap 54 , continued pulling on swage 10 causes swage cup 28 to deflect inwardly toward mandrel 11 to a degree which is sufficient to allow swage member 27 to slide through the junction. The deflection of swage cup 28 is typically several thousandths of an inch. Gap 54 may be as small as several thousandths of an inch, or it may be larger. The deflection of swage 28 will merely be what is necessary for swage 10 to move through the junction at a significantly reduced force as it is being withdrawn from the well.
In a second embodiment of the invention, referring now to FIG. 3, the general mode of operation of the swage remains the same, but the way in which it is carried out is slightly different. Since each of the components of this embodiment is slightly different than each of their counterparts in the first described embodiment, new numerals are used for each.
A mandrel 111 supports a swage 110 , which is activated through the movement of mandrel 111 . In the running position (shown), a swage ring support 114 is in position to support a swage ring 116 . Both swage ring support 114 and swage ring 116 in this embodiment “float” on mandrel 111 (i.e., they are not attached to mandrel 111 ). At the uphole end of mandrel 111 , swage ring support 114 is prevented from moving further uphole by a retaining ring 118 . Retaining ring 118 is threadedly connected to mandrel 111 by a thread 120 and prevented from moving on thread 120 by at least one set screw 122 , which is received in a groove 124 . In a preferred embodiment, mandrel 111 is “turned down” to form a shoulder 126 extending to the downhole end of swage 110 and is configured such that retaining ring 118 firmly abuts shoulder 126 . Configuring mandrel 111 to contain shoulder 126 provides more annular space between the “turned down” surface of mandrel 111 and the borehole or junction so that thicker swage components may be used. The “turn down” of shoulder 126 also lends extra stability to retaining ring 118 .
Swage support 114 abuts retaining ring 118 at interface 130 and includes fluid bypass 132 . Support for swage ring 116 is along interface 134 . As a unit, support 114 and swage ring 116 function as their counterparts did in the previous embodiment and indeed as do those of the prior art to reform a deformed junction. It is with the recovery of swage 110 that its unique construction is evident and beneficial. It should be noted that swage ring 116 includes at least one fluid bypass conduit 138 that communicates with an annulus 140 .
Downhole of swage ring 116 is a shear ring 142 . Swage ring 116 abuts shear ring 142 at interface 144 . Shear ring 142 is prevented from longitudinal movement on mandrel 111 by a plurality of shear screws 146 , which extend into groove 148 on mandrel 111 . Shear ring 142 , together with retaining ring 118 , maintains swage ring support 114 and swage ring 116 in the operative running and reforming position. It should be noted that slots 150 are provided on both the uphole and downhole sides of shear ring 142 in a preferred embodiment. While only the uphole end of shear ring 142 requires slots 150 to allow fluid bypass, placing slots 150 on both ends avoids the possibility that swage 110 might be assembled backwards.
At the downhole end of swage 110 in FIG. 3 (i.e., the right side of the drawing), a dual function nose swage 152 is threadedly attached to mandrel 111 at a thread 154 and locked in place by at least one set screw 156 received in groove 158 . Nose swage 152 acts to prevent shear ring 142 from falling off the end of mandrel 111 after shear screw(s) 146 are sheared and also acts as a pre-reforming swage to open up tightly deformed junctions.
In the operational condition, with shear screw(s) 146 intact, the space between uphole end 160 of nose swage 152 and downhole end 162 of shear ring 142 is preferably sufficient to allow full shearing of shear screw(s) 146 by displacement of shear ring 142 in the downhole direction before the noted surfaces touch. This prevents a partial shearing condition which may impede performance to some degree. The partial shearing, however, should not completely prevent swage 110 from performing.
Once swage 110 has been forced through the junction being reformed it will be withdrawn or pulled uphole. In the event that the swage encounters significant resistance, the features of the invention will be set in motion. Since both the swage ring support 114 and swage ring 116 are not connected to mandrel 111 , resistance provided by the deformed junction is translated directly to shear screw(s) 146 . At a predetermined amount of force, screw(s) 146 will shear and allow mandrel 111 to move uphole. At this point, support 114 has not been moved relative to swage ring 116 . Thus, the frictional engagement therebetween is rendered independent and not cumulative with respect to the amount of force necessary to shear screw(s) 146 . Upon the movement of mandrel 111 uphole, a snap ring 164 impacts a shoulder 166 on support 114 and will move support 114 out of its support position under swage ring 116 . This, as in the previous embodiment, allows swage ring 116 to flex, thereby allowing swage 110 to be retrieved. In practice, the disengagement of support 114 with swage ring 116 is assisted by a jarring action that normally results from the sudden shear of screw(s) 146 . It should be noted, however, that a straight pull on swage 110 would also dislodge support 114 from swage ring 116 . The jarring action is a likely mode of operation; however, it is not a required mode of operation. Overcoming the friction generated by flexible swage ring 116 being urged into contact with support 114 as a result of contact between the swage ring 116 and inner walls of the junction is all that is necessary. After shearing, swage ring 116 and shear ring 142 will rest on nose swage 152 while support shoulder 166 will rest on snap ring 164 . In this condition, support for swage ring 116 is not available and it is free to flex allowing swage 110 to be recovered from the junction. Commonly, the flexing that will occur is into a slight oval shape.
It should be appreciated that in both embodiments of the invention the shear release or other release mechanism may not be used in all conditions. Swage 10 may pull through the junction without needing to be flexible. Because these tools incorporate the invention, the tools are retrieved whether or not swage 10 gets stuck in the junction. If swage 10 does get stuck in the junction, shear screw(s) 146 will shear on continued pickup of swage 10 and swage 10 will operate as hereinbefore described.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.
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A flexible swage comprises a swage cup and a support receivable in a swage cup. The swage cup and support are separable in order to promote distinct purposes. The first purpose is to allow the swage to act as such and reform a deformed junction when the support is engaged with the swage cup thus supporting it against deflection. The second purpose is to remove the swage from the deformed junction at which time deflection in the swage cup is beneficial. Thus, the support is removed from engagement with the swage cup thereby allowing the swage cup to deform and be removed from the reformed junction more easily.
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FIELD OF THE INVENTION
The present invention relates to methods, machinery and products embodying WindoW treatments of the gathered shade type, such as Roman shades and puff shades, and more specifically to a novel gatherable shade that is neither lowered nor taken up by cables or cords; but rather, is driven to fold or extend by the urging of a movable sill or base element to which the shade is attached. The method and machinery disclosed herein relates specifically to unique machinery capable of removing flaws in the shade fabric as an adjunct to the main process of manufacturing the partitioned, foldable shade.
BACKGROUND OF THE INVENTION
The instant inventors have long been engaged in the design and production of coverings for fenestration openings. In both their experiences and after an exhaustive search of the literature and trade journals, as Well as the files of the United States Patent and Trademark Office, they determined that no modality of window treatment, relating to gatherable shades, exists that would be capable of gathering (collapsing) and extending (deploying) a shade fabric without the use of a draw cord(s) or fabric rolling means. In order to avoid the use of numerous pulleys and cords, as well as the shape-deforming shade rolling techniques, both methods currently in vogue through out the industry, the inventors developed and filed U.S. patent application, Ser. No. 07/018,189 for a window treatment system known as SMART SHADE.SM. (trademark of the Comfortex Corporation and assigned to Hunter Douglas USA, Inc.). The SMART SHADE.SM. window treatment system consists in a mobile header (sill) element which is used to extend and retract an accordion-type, foldable shade along a pair of rectilinear and curvilinear side tracks that are laterally mounted to fenestration openings. SMART SHADE.SM. is adaptable to both automatic and manual operation and derives its unique characteristics from a combination of factors involving the header-motivated shade collapse and deployment, the stepped and regularized (constrained) motion of the header over the tracks, a complete absence of gathering-deploying pulleys and cables and the maintenance of an extremely close fit between the shade fabric and the fenestration-mounted tracks so as to create within the space formed by the closed or deployed shade and the outside fenestration covering (generally, a glass window or solid door) a still air plenum. To the extent that the track-engaging, movable header system allows the gathering and deployment of a shade, without use of pulleys, cables or shade rollers, its adaptation from the SMART SHADE system is herein employed. Quite uniquely, however, the instant invention transcends SMART SHADE.SM. in that it contemplates the usage of a simple planar fabric, or film material, to be deployed over fenestration openings that are both horizontal as well as vertical, using suspension techniques not found in the present art.
In a most recent study of patents dealing with the background art of the instant invention, three disclosures of note, issuing between May and December 1987, were deemed relevant. Zommers (U.S. Pat. No. 4,665,964) discloses a Foldably Extensible And Collapsible Track-Mounted Shade Device For Skylight-Type Window; Dunbar, (U.S. Pat. No. 4,683,933) discloses a Motor Driven Shade Lowering and Raising Mechanism For Atrium Walls; and Bonacci et al. disclose (U.S. Pat. No. 4,712,598) a Screen Door Assembly.
Precedent to the aforementioned current state-of-the-art patent disclosures were those issued to Whitmore (U.S. Pat. No. 972,422) in 1910, for a Curtain, to Clark (U.S. Pat. No. 3,292,685) in 1966 for a Weatherproof Retractable Wall, and to Chen et al. (U.S. Pat. No. 4,088,157) in 1978 for a Hood System For Covering An Automatically Operating Machine.
Zommers discloses a device comprising a foldable, extensible and collapsible shade member as well as means for forming corresponding sets of laterally projecting trunnions at spaced intervals along opposing edges of the shade proper. The trunnions of the Zommers disclosure consist in semi-cylindrical projections which are captured in lateral fenestration tracks and are therein motivated by a series of pulleys and cables. Thus, in 1987, a somewhat remarkable work of art nonetheless relies upon the time-honored technique of motivating shade edges, albeit using shade stiffener and trunnion connectors, by use of pulleys and cables. Somewhat similarly, Dunbar discloses a motor driven device for raising and lowering shades, such shades being comprised of a flexible fabric in which stiffening rods have been inserted transverse the direction of opening and closing. The ends of the rods are suspended by hooks that are insertable in a series of eye and capstan devices which are movably captured in a fenestration guide rail. Motivation of the eye-capstans, carrying with them the rods, is by cable and pulley arrangement. In late 1987, Bonacci et al. disclosed a screen curtain assembly for large door openings in which the curtain is raised and lowered by draw pulley-supported ropes which are vertically threaded through rings sewn in the curtain material. Unique to this disclosure was the use of rod-in-pocket partitions which appeared to segment the door cover assembly and in which the bottom or base rod was weighted to form, in effect, a header element. Nonetheless, the Bonacci disclosure teaches the use of draw rope and pulley apparatus.
More relevant to the instant invention was the disclosure of Whitmore in 1910 for a curtain of flexible fabric and which contained therein parallel, transverse batts which were used to stiffen the fabric in its deployed mode. Extensions at the tips of the batts comprised guides which fitted into lateral double-railed tracks that were mounted along the sides of the fenestration opening. The batt extension, equipped in the alternative with rollers, fitted into the dual-flanged tracks and guided the shade as it was drawn over the opening. The Whitmore shade or curtain was rolled from the top of the opening and thus required an elaborate contrivance at the top of the track guide to allow the batt extensions to escape from the track proper and be rolled thereafter on the takeup reel. Whitmore clearly did not conceive of, and therefore not disclose, the continuous single flange track of SMART SHADE.SM. which is captured by, rather than captures, the ends or end guides of the moving shade panel. In the disclosures of both Clark and Chen et al., there is again revealed art that is characteristically a usage of the dual-flanged track, combined with stiffening rods that are extended to fit into capturing tracks, as well as the extensive use of pulleys and cables. Although pulleys and cables have been seen to operate favorably in certain, but limited, applications, the instant inventors hasten to point out that in applications where the deployment or retraction of a planar fabric is directed over both horizontal and vertical fields, pulley systems become extremely complex and, should the plane of travel change more than once, practically impossible. Needless to say, a dual flanged track, to provide the curvilinear groove, possesses inner and outer rails (flanges) of differing lengths and thus, were one to employ such a device, it would be necessary to fabricate and install separate track flanges in order to acquire the two radii of curvature. In window treatment systems, both the cable-pulley system and the plural flange/rail device become extremely complicated, costly and difficult to install and maintain.
The instant invention, hereinafter disclosed, obviates the aforementioned problems by eliminating the more onerous techniques and apparatus which have been heretofore used in the art. As will become apparent from the following descriptions, the shade and the machinery/method for its flawless manufacture shall have significant impact on the field.
In order to fully appreciate the method and machinery for the manufacture of the instant invention, the reader is referred to a previously discussed patent issued to Bonacci et al., U.S. Pat. No. 4,712,598, which issued on Dec. 15, 1987. The instant inventors desire to point out that, in this disclosure, one observes the current state of the art in the joining of a fabric (a panel or panels) to the transverse supporting rod structure. Essentially, Bonacci overlaps the trailing edge of one panel with the leading edge of another and, proximate the panel margins, sews two parallel stitches which form a pocket into which the rod or supporting member is inserted. As commonly practiced in the industry, when a continuous fabric or netting is used, being drawn off a continuous roll, supporting structures such as rods may be laid down on the fabric and glued or sewn thereto. Another technique, evident from the Bonacci art would be to simply gather a small portion of the fabric about the rod, catch the rod therein and stitch or sew at the contacting, retroverting surfaces of the fabric that come together around the rod. Machinery for performing these tasks is well known in the art and, although of immense usefulness, can be seen to have considerable limitation should flaws be detected in the fabric and require removal, before inclusion into a finished product.
Presently, should flawed fabric be detected prior to assembly of a shade or viewable window treatment, the manufacturer has one of two options to effect a cure. The process or manufacture may be allowed to continue until a unit product is formed and that unit product subsequently discarded or retailed (at a lower price) as an imperfect or second; or, the manufacturer may choose to halt the fabrication process, cut the material (thus removing the flawed portion), and rejoin the material, preferably at a rod-fabric juncture. As may be readily apparent, both of these processes (the latter being performed manually), not only entail considerable expense but often give rise to products that do not meet the rigid specifications of those produced by the instant inventors.
In order, therefore, to produce a quality product embodying this new form of window treatment, the instant inventors have devised a method of manufacture that, while producing a quality shade product, ensures that the highest aesthetic quality will be maintained by a subprocess which automatically removes flawed fabric and continues the shade fabrication process without the tedium of physically halting the shade fabrication machine and manually or automatically cutting the fabric.
As the reader will soon note, this disclosure defines a new type of shade fabrication for use with the instant inventors' SMART SHADE.SM. window treatment system which comprises a unique mobile header for retracting and extending the shade fabric. Also, a machine and process for manufacture of the shade proper is also provided that shall prove unique in their nonconformity with the present state of the art as well as their ability to produce a high-quality unit product, devoid of fabric flaws and mechanical imperfections.
SUMMARY OF THE INVENTION
The present invention consists in a collapsible-extendable, essentially planar, transverse rod-stiffened shade fabric which is motivated over a parallel track system that spans a fenestration opening. Collapsible retraction and the expansion, by extraction from a fixed border, is motivated by header which spans the side tracks of the fenestration opening and moves evenly, up and down the tracks, by virtue of header-contained guide and drive wheels so formed as to have circumferential projections and depressions which enmesh the racks, i.e. receptive, serial depressions in the tracks. It further consists in a method for the continuous manufacture of the rod-stiffened planar shade element as the fabric is cast off the source rolls; and, a machine which inculcates the method of manufacture, including a subprocess or submethod, for the continued production of shade product (that is, with support rod insertion) by effecting the removal of fabric discolorations and other imperfections.
To adapt a planar, foldable shade fabric for use with the SMART SHADE.SM. system, a system wherein a mobile header moves over a pair of geared tracks pushing or pulling a shade proper so as to collapse it towards or from a fixed border or margin, it is necessary to provide not only some form of integral support structure in the flexible fabric panel, but also to provide means for guiding or conforming the path of the integral support structure to the out-rigged, lateral track structure. The instant invention thus relies, to some extent, upon known art in that, at first blush, the integral support structure comprises a series of parallel rod-in-pocket fabrications. Unique to the invention, however, and the novelty allowing its embodiment with the SMART SHADE.SM. apparatus, is the support guide structure adapted to the ends of the fabric's transverse supporting rods. The support guides that allow the rod-in-pocket fabrication of the shade proper comprise slotted rod tips that are attached proximate the ends of the transverse rods and which are designed so as to engage, or be situate adjacent, the fabric portion of the shade. At a stand-off distance of but a few millimeters, the support guides contain a slotted, or "U" shaped, structure which is designed to slidably engage the tracks that are mounted on each side of the fenestration opening. Colocated in the stand-off portion of the support guide, generally proximate the bottom of the slot, is a toothed notch which is capable of accepting and retaining a cord element, that may be used for additional guidance in the deployed shade structure. Thus, it may be readily surmised that the flexible planar fabric, having therein a series of parallel support rods that are supported and guided by their engagement about the opposing tracks of the previously described SMART SHADE window treatment systems (Background of the Invention), is adaptable for use as the honeycomb "accordion-type" shade which is part of the SMART SHADE system. Further, the tracks used by the instant invention comprise a subsystem support-guide apparatus that in itself comprises two distinct components, the combination of which allows this subsystem to be used in practically any window treatment employing a sliding, retractable-extensible fenestration shade treatment. The opposing tracks comprise in singular ribbonous projections which lie in a plane coplanar to the glazing of the opening for which the retractable-extensible shade covering is being provided. The second portion of the track subsystem, not generally required when the fenestration framework is made of wood or contains therein longitudinal grooves or rabbeting that can accept a track root, is a track retainer element, also a continuous or ribbonous article. The track retainer may be characterized as a adapter element which allows the seating of the continuous, track root therein, and which may be attached to non-grooved or non-groovable surfaces. The most common usage of the track retainer element is to provide a groove for the seating of a track root in a metal window frame. An example of such usage is in greenhouses where, because the metal framework consists of a curvilinear, multipaneled array, it is both impractical and expensive to produce metal framework with specially extruded or machined grooves for accepting the roots of continuous, ribbonous track. The singularity of the track, that is, a track dissimilar to the current planar guide tracks such as found in sliding panels allows the track disposition along the lateral margins or frame of a fenestration opening and permits it to readily pass from vertical to horizontal, and back to vertical, orientations. If one were to seek this character in the commonly used double-flanged or railed track, it would be necessary to construct the track of two separate, ribbonous flanges or rails or to so bend (generally) metal material as to require the handling (i.e. packaging and shipping) of large, awkwardly shaped tracks. This follows because, as one passes from one plane of reference to another, say vertical to horizontal, the radius of the turn would be different for each of the rails or flanges of the track. This is a problem readily recognized to those familiar with railroad technology and becomes just as apparent to those wishing to employ novel and aesthetic window treatments such as embodied in the instant invention.
The process and machine for manufacture of the aforementioned product may well revolutionize the production of transverse rod-supported planar shades. Both process and machine are of the conventional type in that the front portion is identical to that used in the industry today. A feed roll or cast off roll dispenses the fabric, generally known as the web, continuously downstream to the first inspection station. At the first inspection station, scrutiny may be made by human visual or automatic optical means. Generally, if flaws are detected with either process, some form of marking or flaw identification is made, either in computer controller memory (time-control) or on the fabric itself (for optical detection).
The first operation to be performed on the fabric (material) is executed at the rod insertion/flaw removal (RIFR) station. The fabric is introduced to this station by passing it between two rollers, the first a metering roller which is driven by a stepping motor, and the second by a constraining roller known as the nip-roller. The rollers are longitudinally juxtaposed and in tensioned contact with each other and have, covering their cylindrical surfaces, a firm, resilient material, commonly rubber. It is the purpose of this roller pair to drive the material therebetween at a predetermined rate, hence the requirement to drive the first roller by a stepping motor, a motor which, under proper stimulus, moves a predetermined angular distance. The material is sequenced from between the two rollers into the station and past an optical or infrared detector (in one flaw detection option) which determines automatically whether the fabric has been flaw-marked. Flaw detection may be in computer memory in the non-optical option. If no flaw is detected, the manufacture process continues in its primary mode which comprises the following steps: first, at a time pre-determined and set in the machine's controller, a pressure pad is brought into contact with the fabric against a rigid surface of the its flow path, causing an immobilization of the fabric downstream of the metering first roller; the metering roller is then controller-commanded to advance through a single cycle and concurrently, a blast of air is inserted transverse the entire fabric and perpendicular to it, so as to divert the material from its path, at a point between rollers and the point of immobilization, into a second channel of flow; in the second channel of flow, the material is essentially folded back upon itself with the point of fold (or crease) impelled into the second channel of the machine by the continuous air blast to a point proximate the terminus of the second channel, known as the first index, or "A" index; the instant that the fabric crease reaches the "A" index, the stepping motor stops, the upper clamp closes to restrain the material, which action defines and locates the loop at the fold, and a rod is inserted into the fold; at the completion of rod insertion, a major component of the instant invention, the compound traveling stitcher-mender (to be described separately below), traverses the crease setting a stitch or fabric weld, between the second channel terminus and the rod, in order to secure the fabric of the web totally about the rod surface; and, thereafter, the traveling stitcher-mender is removed, a surface integral to the second channel of the aforementioned station is retracted, while the pressure pad which immobilized the web initially is also retracted (concurrently excess rod length is trimmed by associated cutters that flank each side of material in the fold region), and a take-up roller pulls the fabric-rod continuum hack through the second channel and into the remainder of the first channel, as the automatic controller of the machine sequences back to the first step of the normal fabrication process. The reader should now understand the normal operating mode of the shade fabrication machine and the process which it inculcates; however, before proceeding with the disclosure of the apparatus and process associated with the flaw removal mode, a digression to describe the unique traveling stitcher-mender device is warranted.
The traveling stitcher-mender comprises a machine with two heads, arranged in tandem, and which in operation traverses the aforementioned crease of the fabric, very close to the inserted rod. The first head is a conventional stitching or sewing head and is cantilevered over the rod so that its operative area lies between the terminus of the fabricating station's second channel and the inserted rod. In normal operating mode, as the traveling stitcher-mender (hereinafter, "traveler") traverses the seam, the overhanging sewing head sets a stitch and encloses the rod in the fabric pocket (crease). Those having ordinary skill in the art will recognize that the sewing head may be exchanged for the familiar heat weld and anvil heads should the fabric in use lend itself more readily to that means of sealing. In tandem with the sewing head, but on the other side of the rod, is the mending head which has two indices of operation. During normal operation, the mending head is indexed rearward of the sewing head and rod pair so that, although proximate the rod, during the traverse of the traveler it will not come in contact with the fabric encircling the rod. In the fault mode however, the mending head intercepts additionally fed (flawed) material. The mending head itself, gated to and physically disposed behind the sewing head, consists generally in three elements: an arcuate, elongate head, the arc of which conforms to the shape of a rod, and which is used to urge or form fabric about a rod--called the "former", an adhesive application element comprising one or a series of adhesive ejection ports--called the "applicator", and at an end of the former, an extremely sharp knife element called the "knife" which will cleanly sever any fabric encountered during the traverse operation. When the traveler is indexed to enter its flaw removal mode, it will traverse the rod-fabric margin in registry with the rod itself. Depending upon which direction the traveler initiates its operation, the knife, moving along and proximate the rod, cleanly severs any fabric exposed between the rod and the surface of the knife. Since the knife is generally straight (depending upon the diameter of the rod), some fabric will remain that can be drawn about the rod and the two fabric edges joined therewith. The aforementioned operation is performed by the other two elements which are compounded with the knife in the mender head. Immediately behind the cutting knife (whether traversing left or right), the adhesive applicator ejects adhesive onto the rod and the former conforms the fabric cut end together and around the rod so that they meet at the adhesive bead and are thus formed and joined, in a sense welded, to the rod. Concurrent with the mending operation, the sewing head has performed the stitch or welding operation on the other side of the rod and the rod insertion and securing process has been completed.
Having an idea now of the operation formed by the traveling, stitching-mending device, it is now appropriate to describe the subprocess constituting the entire flaw removal procedure. If a flaw has been detected and a marker set, such marker will be controller time-indexed or (optionally) picked up at the flaw marker detection station; and the flaw removal mode will be entered. As in the aforementioned normal operation mode, the downstream, properly fabricated flawless shade will be immobilized, the stepping motor for the metering roller is commanded, by the auto-controller, to double- or dual-cycle and the air injection is commanded to operate commensurate with the dual-cycle of the metering roller. The dual-cycle of both the metering roller and the air injector drive extra fabric, now containing the flawed portion, beyond "A" index to what is termed the "C" index, considerably beyond the station's second channel. The rod is then set in place at the normal index, called the "B" index. Immediately thereafter, the traveler is switched to the flaw removal mode and the compound stitching (at the "B" index) and mending is performed by the traveler, as described above. Immediately after the above-described stitching and mending operation, the normal operation mode is reentered and the second channel restrictive surface retracts to allow removal of the rod-in-pocket assembly. Those familiar with this form of sequential manufacture of continuous roll fabrics, will recognize that the take-up reel is of a form that will readily accept the fabricated shade as it moves downstream out of the fabrication station. In the instant invention, the take-up roll comprises a one-way clutch and slip-drive take-up tensioner and maintains tension on the downstream finished product web. The other minor details attendant the instant invention will be better understood and appreciated after the reader has had the opportunity to read the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
Of the Drawings:
FIG. 1A is an isometric illustration of the invention;
FIG. 1B is a top sectional view of the drive wheel-track apparatus taken vertically at section 1B of FIG. 1A;
FIG. 1C is a top sectional detail of a rod support-guide riding on the track as taken horizontally at section 1C of FIG. 1A;
FIG. 1D is a top view of the second embodiment of a rod support-guide similar to FIG. 1C;
FIGS. 2A and 2B partially sectionalized side views of the FIG. 1A apparatus in fully extended and partially retracted postures, respectively;
FIG. 3 is a partially sectionalized front view of the mobile header element disclosing engagement-disengagement mechanism for header driver-follower mechanism;
FIG. 4 is a partially cut-away isometric view of the support-guide of the instant invention;
FIGS. 5A and 5B are orthographic representations of one form of solid rod end support-guides;
FIGS. 5C and 5D are top and side elevations of an alternative rod and support-guide, for hollow rod usage;
FIG. 6A is an exploded isometric view of the header element and cap showing tandem drive wheels superposed over the continuous ribbonous guide track of the invention;
FIG. 6B is an end sectional view of a continuous dual track retainer element;
FIG. 6C is partial perspective end illustration of the element in FIG. 6B;
FIG. 6D is a cross sectional illustration of a single track retainer element;
FIG. 6E is an end sectional perspective of the single track retainer of FIG. 6D;
FIG. 7 is a schematic section of the support rod stitched-in-pocket;
FIG. 8 is a schematic cross section of a fabric inserted into the retaining hollow "C" sectioned rod;
FIG. 9 is a stylized schematic cross section of rod-fabric encapsulation technique;
FIG. 10A is a schematic illustration of the machine used in making invention product;
FIG. 10B a schematic drawing of the Rod Insertion-Flaw Removal Station;
FIG. 11 is a schematic cross section of the fabric with rod inserted and the salient indices disclosed in the method of manufacture;
FIG. 12A is a sectionalized isometric illustration of the traveler apparatus;
FIG. 12B is a front elevation of the traveler looking into the mender section;
FIG. 12C is a top view of the FIG. 12B apparatus sectioned at 12C, as indicated;
FIGS. 12D, 12E and 12F are cross sections of the mender of FIG. 12B taken at 12D, 12E and 12F showing knife, adhesive port and former, respectively; and
FIG. 13 is the sequence flow chart for the process Performed by the Rod Insertion-Flaw Removal Station mechanism of the instant invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description shall address the preferred embodiments for the product, process of manufacture and the machine by which a major portion of the product, the transversely strengthened (stiffened) planar fabric, is constructed and in which flaws found in the fabric sheet or web are eliminated.
Referring more particularly now to FIG. 1A, there is disclosed therein a stylized rendering of the invention product 10. The salient elements of the product readily seen in this isometric illustration consist in the framework 12 of a typical fenestration (window) opening. Laterally disposed in the framework 12 is a pair of single flanged ribbonous tracks 14, the details of which will be discussed later in the discussion of FIG. 6A. in FIG. 1A, the ribbonous track 14 is shown only in the cut-away portion at the lower right hand corner of the figure. The prominent features that are readily disclosed herein are the toothed track 16 which resides in a cusp 18, found on both sides of the track element 14, and the most prominent feature, the single ribbonous flange 20 which will act both as a supportive and guidance feature for the shade 22 proper. From the illustration of FIG. 1A the reader should take note of the major elements of the invention product 10 that are meant to be, and are, clearly visable to the ordinary user or observer: the shade 22, that is affixed at one margin 24 to a rigid framework such as the top or bottom of a window frame 12, or to a mantle or lintel in other applications; and the apparently sectionalized shade 22, drawable over and collapsible on side rails 20 and which become visable to the observer when the movable header 26 is caused to traverse the track 20. When the header 26 is motivated toward the fixed margin 24, the shade 22 is caused to fold regularly 22' between the stiffened transverse portions 28 of the shade fabric 22. Referring to the lower right hand cut-away of FIG. 1A, the reader may observe that the partitioning apparatus identified as 28 (above) is afforded by a high-elastic-modulus transverse rod 30 which is inserted in pockets (not shown) of the shade fabric 22, or is bonded thereto by suitable means. At both ends of stiffening rods 30 (as they shall hereinafter be termed) are located one of two embodiments of shade support-guides 32, 33. In FIG. 1A, the guides 32 are of the first desired embodiment, the type which are fitted over the tip of the rod 30 engaging not only the rod, but a portion of the shade 22 therewith. This support-guide 32 is further detailed at FIG. 1C, shown in its preferred alternate form (with a different embodiment of the rod), at FIG. 1D and, in both embodiments, discussed in detail with the exposition on FIGS. 5A-5D.
Digressing momentarily, the instant inventors would herein reiterate the salient motivation apparatus of the earlier mentioned SMART SHADE.SM. apparatus as it now applies to the instant invention. As mentioned above, the movable header 26 constitutes a movable sill that traverses the window side tracks 20. The header 26 is located opposite the fixed sill 24 and to it is attached the margin of shade 22 opposite that attached to sill 24. The internal mechanism of movable header 26 shall be discussed further at FIG. 3 and, details of its track-following adaptation shall be discussed at FIG. 6A. Note that a salient element of the header 26 comprises at least one drive shaft 34, which may be either motivated or placed in an idler-follower mode, and which has as its primary function the mechanical coupling (engagement) of at least one drive wheel 36 (in fact, a toothed or cogged wheel), located at each side of the header 26 to each of the parallel tracks 20. In order to lend clarity to this illustration, it has been necessary to omit a tandem wheel 36' which, like the illustrated drive wheel 36, rides in the cusp 18 located on the opposite side of the track and meshes with (engages) the gear teeth 16 located therein. Those of ordinary skill will recognize that the purpose of wheel 36' is not so much to drive the mechanism as it is to urge the drive wheel 36 into close registry with the cusp 18, so as to fully engage teeth 16. The remaining apparatus, seen in FIG. 1A, consists in the movable header 26 engaging-disengaging handle 38, which will be shown in sectionalized detail at FIG. 3. The purpose of handle 38 is to allow the user to engage motivation means colocated in header 26 or, if desired, to disengage the motivation means (not shown) so as to allow manual propulsion of the header along tracks 20, yet maintain an eveness of header motion (and consequently, shade collapsibility) by assuring that all drive and follower wheels 36, 36' remain properly gated along the identical, parallel track teeth 16.
A most important feature, indeed a feature without which neither the SMART SHADE.SM. nor the instant invention would have been possible comprises apparatus that are detailed in FIG. 1B. This top view is a schematic of the detail of FIG. 1A taken at 1B. The reader may clearly observe that drive wheel 36 being motivated by shaft 34 is in close registry with the follower wheel 36' being driven or merely mounted on idler shaft 34'. Indentical counterparts to wheels 36, 36' are located at the other ends of shafts 34, 34'. Each set of tandem wheels 36, 36' rides in the cusp 18 of a track 20. In actuality, the track 20 consists in a single ribbonous flange 21 contiguous with a double cusp 18 bearing teeth 16 in the col thereof, and further contiguous with a root extension 14 and a root 15, comprised of a barbed or other suitable gripping means. In FIG. 1A, the root extension 14 is a portion of the single track retainer. The common practice is to press the root 15 as far as possible into the frame media 12, herein wood, so that the lateral edges of the cusps 18 are in close registry with the frame 12. Note that the beveled shape of the wheels 36, 36' allow the geared wheels to ride in the toothed track, yet maintain a small, but finite, clearance 37 between the frame and the sides of the wheels 36, 36'. The track's projecting flange or tongue 21 may then be engaged by a support-guide 32, 33 in either the end-capping version 32 or the end insertion version 33.
FIGS. 1C and 1D essentially provide the reader with a top view of the 1C section taken from FIG. 1A while employing the rod end support-guide 32 cap type and insert type 33, respectively. Both versions of the rod tip support-guide 32, 33 will be discussed in greater detail at FIGS. 5A through 5D. In FIG. 1C the track 20 is inserted by its root 15 into the frame 12. Generally a groove or rabbet is provided of narrower gage than the track root 15 so that, once inserted into the groove, the root 15 with it retrograde restrictive means (here, barbs) cannot be easily removed. A groove of sufficient depth in the frame 12 will allow the tracks 20 to be seated close enough so that the outside margins of the cusps 18 rest snuggly against the framework 12. In the first support-guide 32, the rod end cap version, the reader can appreciate (FIG. 1C) that the shade 22 is brought into very close registry with the frame 12. This facility derives from the fact that the rod end cap version of the support-guide 32 fits over the rod-in-pocket portion of the fabric 22 completely but for approximately 1-1.5 millimeters of the support-guide tip. Further to the support-guide, end cap version 32, there is a vertical slotted portion 38 having two depths, a wide cut 39 to accomodate registry with and along the cusp 18 of track 20 and a slot orthogonal thereto 39' to accomodate insertion of the track tongue 21 therein. The registry of tongue 21 in slot 39 of support-guide 32 is a close registry, but also one of fairly easy slidability. The support-guide must not only provide fairly rigid support for the rod 30 to which it is appended, but it must also he capable of smooth, easy movement over the main guidance framework, that is, the tracks 20. Relative to the support-guide insert version 33, the pictorial cross section in FIG. 1D details all the salient elements found in the end cap version 32 with the notable exception that, because this embodiment of the invention entertains use of a longitudinally-split hollow rod 40 and the inventors have no desire to produce an end cap version 32 large enough to fit over the end of hollow rod 40, the most logical alternative is to provide the same interactive elements of the first-described version with a means for appending it to the hollow rod. To this end, support-guide 33, slidably registrable with track 20, through the slidable registry of vertical slot 39' with tongue 21 and cut-away 39 with cusp 18, is provided with a stand-off rod insert 35 that may be inserted into the tips of the hollow support rods 40, thus effecting the same vertical slot 39' relationship with the hollow rod 40 as was achieved with the end cap support-guide 32. Finally, in order to provide means for assisting the extension of the panel 22 at the urging of the moveable header 26, the inventors employ a connection of the sequentially aligned support-guides through a slender, flexible cord that is inserted into the support-guide (cap version 32 or insert version 33) and secured therein by capture in the cord "C" shaped trough 41, a groove that has been provided colinear to slot 39' along the inside margin 41' of the support-guides. It should be understood that the connector cord 42 (shown only in FIG. 4) is not obligatory for one practicing the invention but, in instances wherein the invention is applied to a fenestration opening which effects a curvilinear path, it is highly recommended and serves to maintain a proper spacing of the support-guides without placing undue stress on the shade 22 during its extension.
FIGS. 2A and 2B are partially sectionalized side elevations of the invention in its fully extended and partially retracted modes, respectively. All part numbers retain their previous identification and nomenclature with the addition of the decorative fixed sill angle iron 24' which is illustrated herein as one possible means for affixing the top, fixed margin of shade 22. FIGS. 2A and 2B are elevations of FIG. 1A sectioned, as indicated in FIG. 1A, at 2A. Thus, the left end of header 26 is shown bearing drive wheels 36, 36', the left hand side of the moveable header; while, portions above the header 26 reflect the cross sectional view of FIG. 1A taken at a point between the side rails and the inside edges of the support-guides 32. Also not disclosed under previous drawings, because it will be discussed in more detail during the exposition on FIG. 3, is handle 38 and butt plate 46. Rigidly affixed to the handle 38, the butt plate 46 provides a means for attaching additional mechanism peculiar to the engagement-disengagement apparatus.
Although it may be considered of mere passing interest in this disclosure, since it was the subject of the aforementioned SMART SHADE.SM. patent application, now allowed, the header 26, because of its high degree of utility in the instant invention, is disclosed briefly with reference to FIG. 3. This figure is a sectionalized, cut-away representation of the header element--including the engagement-disengagement mechanism, a right side track 20 clearly delineating the track tongue 21, with cusp 18 (and teeth 16) inserted into the wood frame 12 and engaged drive wheel 36 driven by shaft 34. As explained earlier, it is not necessary that shaft 34 be motivated; however, in the absence of any other form of motivation, such as the motor used in the SMART SHADE.SM. system, the header will have to be motivated manually after disengagement of the motor (not shown) by actuating the engagement-disengagement handle 38. Because the detail of FIG. 3 is concerned only with the engagement-disengagement mechanism of the header 26, the manner in which the header is secured to the track and by which it compels the constant registration of drive wheels 36, 36' with the track teeth 16, shall be deferred until the discussion of FIG. 6A. Referring particularly to FIG. 3, the engagement-disengagement mechanism is illustrated within the area defined by the dashed lines representing the external handle 38. For the sake of clarity and, in the desire to avoid redundancy relative to the SMART SHADE.SM. disclosure, the following discussion shall be directed toward a mechanism which merely locks (disengages) and unlocks (engages) the drive mechanism, that is the moveable header 26, of the instant invention. Those of ordinary skill will realize that a locking-unlocking mechanism may be redundantly employed in a header to engage, disengage and concurrently lock and unlock a drive shaft/gear network to, or from, motor drive means. The mechanism preferred in the instant invention for engagement of the drive wheels 36 may be readily ascertained by reference to the rear, cut-away view of the header 26 at FIG. 3. The dashed lines represent the external frame of the actuating handle 38. Handle 38 is moveable both left and right with reference to header 26 and when urged to do so it slides on flanges 42 which slidably engage the frame of the lock case 44. The flanges 42 are rigidly secured to handle 38 backing plate 46 which is a solid planar element and has mounted thereon a pawl 48 and at least one orthogonally projecting detent 50. Pivotally mounted to the side of box 44 is spring 54--biased detent engagement lever 52. Two notches in lever 52 allow the spring biased lever to engage detent 50 when handle backing plate 46 is moved so that detent 50 moves into the 50' position. When this is done, fixed pawl 48 engages gear 56 which is securely fixed to shaft 34 R. Thus, the fixed pawl locks rotating shaft 34, securing the mechanism (header 26) in its position at the time of disengagement from the motive means. Those of ordinary skill will recognize the fact that, as in the SMART SHADE.SM. invention, concurrent with the locking of the shaft (pinion) gear 56, additional apparatus on backing plate 46 disengages the motive means. Although not specifically detailed here, the reader should also note that it is possible to use the instant mechanism to disengage a motor drive through shaft 34L and sleeve 57 by manual movement of the handle to the detent 50' position to lock the mechanism. Many methods of acquiring such motivation and engagement-disengagement activity are available to those trained in the mechanical arts and it is not the purpose of this disclosure to go into any further detail regarding same.
Having been apprised of the method and apparatus used to motivate the shade 22 into its collapse-extend modes, it is now incumbent upon the instant applicants to further detail the primary support-guidance mechanism of the invention. Reference now being made particularly to FIG. 4, there is disclosed in partial isometric cut-away the shade 22, periodically partitioned by transverse rods 30, and stiffened thereby. At the end or tips of each rod (only a few are disclosed herein) are seated support-guide 32 end caps having therein vertical slots 39' by which they engage track 21 (shown in phantom). Further to maintenance of the periodic separation between support-guides 32 is the strain cord 42' (also shown mostly invisible, but partially visable). It may be readily seen that the combination, as well as the cooperation, between support-guides 32 (and, in alternative embodiments, guides 33) and the parallel tracks 20 perform the dual function of guiding the header and stiffened shade combination (with stiffening apparatus such as rods 30) while providing all of the support necessary to the suspension of the invention over any surface, whether horizontal or vertical. In fact, the unusual combination of functional elements within the instant invention not only lend to it the characteristics of high integral strength and durability, but concommitantly grant it broad versatility without the need for additional or adjunct apparatus. Noteworthily, adjunct apparatus relates more to fenestration frame work and consists in only two types of devices which will be explained more fully in the discussions of FIGS. 5A-5D and 6B-6E, an alternate version of stiffening and support-guidance for large, heavier shades and retention means for the parallel tracks, respectively.
Reference being had now to FIGS. 5A-5D, there is shown firstly, in FIG. 5A, a top view (lower illustration) and a side elevation (upper illustration) of the rod end capping support-guide 32. All parts of this element having been previously described herein, the reader's attention is called particularly in this illustration to the top view of support-guide 32, particularly to slot 31' which is contiguous with rod receiving channel 31. The purpose of slot 31' is to allow the shade fabric 22, outside of the rod-encircling portion, to pass out of chamber 31. This is pointed out more clearly in FIG. 5B, an end elevation of the lower drawing in FIG. 5A. Herein it may be readily discerned that rod 30, in a pocket of fabric 22 (upper illustration), may be inserted colinearly into chamber 31 and rigidly secured thereby. Secondly, in the alternative stiffening embodiment, digression has been made from the basic rod 30 design to that referred to in the detailed description of FIG. 1C, an essentially elongate, hollow rod 40 design having a cross section in the shape of a stylized "C". Reference to FIGS. 5C and 5D reveals the salient aspects of the hollow rod 40 tip support-guide 33 and the manner of shade 22 fabric cojoining (arrow) with the hollow stiffening rod 40, respectively. The reader's attention is first called to the support-guide 33 of FIG. 5C and the elements that it has commonly with rod cap support-guide 32, namely, track tongue 21-receiving slot 39', as well as cusp 18-receiving slot 39 and spacer cord-receiving trough 41. The unique nuance of support-guide 33 is the off-set rod 40 insertion tongue 35. As may be discerned from the illustration, tongue 35 is inserted into the ends of hollow rods 40 which already have captured (or been affixed to) shade 22 fabric. FIG. 5D represents, in cross section, two methods of inserting shade fabric 22 into the open portion of hollow rod 40. In the left hand view, a continuous fabric of shade 22 is transversely folded and forced into the lateral opening 50 of the "C" shaped hollow rod 40. Attention is called now to the recurved internal portions at the ends of the "C" cross section of hollow rod 40. It is the purpose of these recurved margins 48 to prevent retrograde motion of either the folded shade 22 fabric or the paired, cut ends (as seen in the right hand view) when the fabric is inserted into the rod openings 50. It should be noted that rod end support-guide 33, with tongue 35 inserted into hollow rod 40, has sufficient clearance, as illustrated in FIG. 5D, to avoid either the folded fabric bead 52 or cut ends 52'.
The remaining apparatus, peculiar to both SMART SHADE.SM. and the instant invention shall now be described with reference to FIG. 6A.
Having now given a detailed description of the major components comprising the invention product, it is proper to digress in order to take up a brief review of the motivating apparatus which drives the shade 22 to collapse and extend. Although discussed in the summary, as well as in the detailed description of the FIG. 1A apparatus, the header 26 should be further explained as to the manner in which the drive wheels 36, 36' are caused to engage track cusps 18, to be held in registry therewith, and move along toothed portions 16 as the ends of the header 26' encompass and traverse tracks 20. Referring more particularly now to FIG. 6A, the essential apparatus for carrying out, according to the instant invention, the aforementioned process consists in but a few essential elements which comprise a number of those found in the SMART SHADE.SM. system. The reader should recall, from the exposition of FIGS. 2A and 2B, that the header 26 possesses what may be described as end caps 26', through which project the drive/follower shafts 34 and which hold the drive shafts 34 in engagement with wheels 36, 36' by conventional means such as shaft-in-sleeve mechanism 37 or other suitable means. The reader may observe from the FIG. 6A illustration that both halves of the header 26 end caps 26' are spring biased, by spring clip 27, in order that they may be held in close registry. It can be seen that the projection or tongue 21 of track 20 is insertable into the channel G which exists between both havles of the end caps 26'. Thus, when tongue 21 is inserted into the channel G in the manner suggested by the directional line K, wheels 36, 36' may be caused to seat on their respective side tracks of cusp 18 so as to engage the teeth of the wheels (or frictional elements thereof) with the tracks' teeth 16 (or suitable friction means) and effect the tractor motion supplied through rotating shaft 34. The firmness of registry, that is, the amount of tension between the two halves of the end caps 26' is readily adjusted by the tensioning on bolt 29, or similar means. As can be readily seen now, it is necessary to provide traction or drive to only one shaft 34 while, as in the SMART SHADE.SM. sytem, wheels 36' (or wheels 36) may be cojoined by another idler shaft 34' and employed only to work cooperatively with the drive wheel in maintaining firm registry along track cusp 18.
Up to this point, the instant invention, as well as the invention from which its motivation means was derived (the mobile header and associated track system), have been discussed only in the context where its usage would embody a wooden frame sytem. In cases, however, where an existing fenestration system employs nonmachinable framework, it becomes necessary to provide some form of rooting device in order to accomodate track roots 15 so that tracks 20 might be properly situated, in opposition, in order to receive the major elements of the instant invention. FIGS. 6B through 6E relate to two versions of track-adapter elements known as the Dual Track Retainer (FIGS. 6B and 6C) and Single Track Retainer (FIGS. 6D and 6E). Reference being had to the Dual Track Retainer ensemble, there is disclosed a flat, ribbonous and essentially straight strip 100 of rigid material such as high temperature resistant plastic or aluminum. FIG. 6B is a cross sectional representation of the Dual Track Retainer, while FIG. 6C is an end sectional isometric illustration thereof. The salient features, contiguous with the basic strip 100, comprise the centrally located track root 115 which bears a marked resemblance to the track root 15 of the track 20 employed in the invention. The difference between the track root 15 and the track retainer root 115 is the central slot 102 running throughout the length of retainer root 115. The primary function of retainer root 115 is to accomodate the attachment of the Dual Track Retainer to the external or internal framework of individual, yet adjacent, fenestration frames. In most such frames, particularly of the extruded aluminum type, there exists a gap between the frames so as to allow the imposition of root 115 thereinto. In an alternate version of the Dual Track Retainer (not shown herein), the inventors dispense with the retainer root 115 and merely provide other suitable means for affixing the retainer strip to the surfaces of the fenestration frame. In the later discussion of FIGS. 6D and 6E, such an attachment means will be discussed. The remaining relevant apparatus of the Dual Track Retainer comprises at least one means for attaching track 20 root 15 to strip 100. This means comprises track root 15 retention head 106. Root retention head 106, as may be seen clearly in FIG. 6C, is a set of jaws 103, having a gap 110 therebetween and running contiguously the length of strip 100. The jaws 103 face outward with respect to the central root 115 and are meant to receive track 20 root 15 therein. The reader will notice that with such a device as a Dual Track Retainer centrally mounted between fenestration frames, at least one of the parallel tracks 20 may be root-mounted therein so as to form one half of the guide track structure necessary for a single unit of the invention. In instances where it is not feasible, nor possible, to employ the entire Dual Track Retainer, but a retainer of this type is required, (for mounting outwardly or inwardly of the fenestration opening), it may be manufactured in a longitudinally truncated version by cutting along the lines P, or J, as required. This variation, however, is readily apparent to those skilled in this particular art. Notably, it may be seen that the inventors have contemplated production of the Dual Track Retainer sans root 115, containing other mechanism for adhesion to a fenestration frame (such as screwing or stapling) and envisioned manufacture of strip 100 with means running longitudinally, i.e. coextensively with root slot 102 that would allow, by fracture therealong, the separation of one set of jaws 103 from the other set so that a single strip of the Dual Track Retainer may be utilized to provide track 20 root 15 retention head 106 on each side of the fenestration opening.
The Single Track Retainer is a more modest approach to solving the problem of the non-grooved or non-rabbitted fenestration frame. Here an "L" shaped device consisting of a ribbonous strip 101 is provided with a contiguous, orthogonally positioned root 15 retainer jaw 107. It may be readily seen that the track 20 root 15 would be insertable into gap 113 of jaw 107 and retained therein by engagement with nodes 111' in much the same fashion as they would have been captured by teeth 111 of retainer jaws 106, as seen in the Dual Track Retainer. As was discussed earlier and shown in FIG. 1A, the orthogonal flange or strip 101 of the Single Track Retainer is placed on the inside of the fenestration opening, allowing the track root 15 receptor 107 to project orthogonally therefrom and face its oppositely disposed member, at the other side of the fenestration opening, clearly adapted for presenting the track 20 projections 21 opposite one another as previously disclosed in FIG. 1A. A brief reference to that figure will apprise the reader of the fact that the earlier mentioned track root extension 14, as disclosed in FIG. 1A is, in reality, one of the oppositely disposed faces 107' of the Single Track Retainer. In this particular version, the means for affixing the Single Track Retainer is quite simple; ordinary screws 113 are used to affix the flange portion of the strip 101 to the inside portion of the fenestration frame through predrilled holes 112 or by other forms of adhesion.
Having thus disclosed and explained the apparatus comprising the preferred embodiment of the invention product, the inventors propose to reveal a few methods for effecting the ostensible rod-in-pocket structure of the shade proper, define the most cost-feasible embodiment thereof, and disclose the unique method and machinery for producing the preferred stiffened shade embodiment. Relative to the shade-rod structure, there are presently three methods envisioned by the instant inventors for acquiring the desired apparatus and such are detailed in FIGS. 7, 8 and 9.
Irrespective of the physical structure, the methodology presently employed by the inventors is a two-step process comprising the partitioning of the fabric 22 into a series of parallel segments and the addition of some form of stiffening along the borders of partition or demarcation. Thus, the shade product may be realized by the demarcation, whether it is marking, folding, cutting or all three, and a rigidification along the lines or border of demarcation, whether it is adhesion or sewing to a rib or fabric encaPsulation along the border to form a rib.
The first, known simply as the sewing or stitching method, is depicted in FIG. 7. Herein, one views the rod 30 and shade fabric 22 in cross section. The fabric 22 is brought around the rod 30 and stitched, by conventional sewing needle 120 and thread 121 close enough to the circumferential margin of the rod 30 so as to effectively capture the rod within the pocket 122 formed thereby. In FIG. 8, the cross sectional illustration reveals the ostensible rod-in-pocket apparatus using the hollow, split rod 40 which was first discussed during the exposition on FIG. 1D. In reality, this is not a true rod-in-pocket embodiment but rather a "captured" arrangement in which the fabric 22 is transversely folded and forcibly inserted into the transverse opening of the generally "C" or "U" shaped hollow rod 40. Once again as in FIG. 5D, the reader may see (perhaps more clearly), the gripping effect afforded by retaining edges 48 to prevent retrograde motion or back-movement of the inserted fabric 22. Whether node 52 is employed (or, as discussed in FIG. 5D, the fabric is transversely cut and both margins are inserted into hollow rod 40), appears irrelevant in that the gripping action of retainers 48 will prevent any retrograde motion of the fabric.
The shade-rod configuration of FIG. 9, although invented by the instant inventors and certainly providing a viable alternate embodiment, will not be discussed in too great a detail. Briefly, this method of obtaining the pseudo rod-in-pocket structure, most analogous to the FIG. 7 embodiment, consists in placing the folded portion, node 52 element of FIG. 8, or the separate margin embodiment of FIG. 5D, into a stationary mold having a mold cavity similiar to the cavity 40' of FIG. 8, and filling that cavity so as to surround node 52 with a rapidly curing plastic or other suitable composition. As the reader shall note, when reading the remainder of this disclosure, the instant inventors are particularly adept at devising moving types of forming apparatus. That is, as the sewing needle 120 of FIG. 7 traverses the fabric, effecting the stitch, other activities such as, cutting, mending or the applying of an adhesive are also employed, dynamically. Therefore, the instant inventors have also sought and developed methods and apparatus for effecting the "encapsulated" version of shade-rod combination disclosed in FIG. 9. Beyond the suggestion of such an apparatus, as presently disclosed herein, further aspects of this unique invention shall be reserved for later patent activity.
Having now provided the reader with a detailed description of the apparatus, as well as possible variations for practicing the invention, it is appropriate to take up the discussion of a preferred method of manufacture and the unique machinery for performing such manufacture. Hereinafter, reference will be had to the remaining figures accompanying this disclosure, notably FIGS. 10A-13. The inventors' reasons for developing the hereinafter described machinery is simply to provide a means for rapidly, reliably and inexpensively inserting stiffening elements transverse to the run (i.e., a continuous sheet) of a flexible fabric at accurately-controlled, regular intervals. Such periodic stiffening is done to allow the finished shade to be slidably suspended in any non-vertical orientation while suffering minimal visible sag and minimal induced friction between the sliding elements of the mechanism. Additionally, the machine also provides for the removal of existing fabric flaws which would be visible and detract from the aesthetic appearance of the finished product. The unique machine, thus provided, compounds the operation of rod insertion (i.e. the stiffening process) and flaw removal. This compound feature contributes greatly to the economy of operation by allowing the use of somewhat less than perfect material while producing a final product which is devoid of visible imperfections.
Having previously discussed the apparatus of FIGS. 7-9, the following summary concerning materials, in general, is offered so as to prepare the reader for the concepts and inventors' preferences that have been incorporated into the production mode and the machinery therefor. The first means chosen for the stiffening process is a method in which the fabric is transversely gathered, that is, uniformly across its width, into a fold or loop. Into the loop is placed (in the actual sequence of manufacture) a rod of suitably high elastic modulus material (one which intrinsically resists bending). The loop of material is then sealed around the rod, either by stitching (which is the preferred method) or other suitable means such as gluing or welding. The rod fixing method is then employed at periodic intervals along the length of the material or fabric in order to produce a transversely stiff lengthwise--flexible material that can be slidably suspended between parallel tracks, the tracks being arrayed along the material's (shade's) edges perpendicular to the stiffening rods. It is this machinery with its highly stylized and unique method of rod insertion and flaw removal that will be used as the basis hereinafter for the description of a production which rapidly and accurately converts flat goods to stiffened, or segmentally supported articles.
It shall become clear that much of the subsequent description will be applicable to other means of transfer stiffening. For example, a second means for providing the stiffening of the planar or flat goods involves the same gathering of a loop in the material to be stiffened, uniformly across its width, and alternatively pressing the loop into the cavity of a hollow rod by inserting in into a straight longitudinal slot. The rod would have a characteristic "C" shape and bear the same general appearance as to that illustrated in FIG. 8. As was noted therein, the "C" rod cavity is internally barbed or provided with suitable means so that the material loop, once pressed into the cavity, may not readily be extracted. A third option to proVide the requisite stiffening is simply to gather the loop of material, transverse to the length of the material, and encapsulate the loop in an adhesive or binding composition which, on curing, rigidifies the entrapped material into a form of exoskeletal rib (FIG. 9).
The aforementioned alternate stiffening methods share a number of common subprocedural requirements with the preferred (stitching) process. Specifically, all of the methods described require a means for precisely metering the advance of the material to be stiffened in order to assure the uniform spacing of the stiffeners. All methods require that, at these precise intervals or periods, the material sheet or web be gathered into a uniform transverse loop and held securely for the actual stiffening process. All the methods require a traversing device to make permanent the stiffening i.e., a stitching line, an insertion tool (e.g., a roller such as that used to fit or insert the retainer grommet in a window screen), or a binder applicator. Common also to all of these methods of manufacture is the concurrent curing, either photo-optically, thermally or by other radiative energy means, of any adhesive or binder compositions that are used throughout the fabricating process. It will be seen that the machine to be hereinafter described can easily be used to provide a wide range of related applications for accomplishing the desired periodic transverse stiffening.
Having disclosed and reviewed the disclosure of the options available for providing transverse stiffening, it is now appropriate to take up discussion of the machinery which is used to fabricate the invention employing the preferred method of structuring, that is, the stitching or sewing method of FIG. 7. Referring now to the illustration of FIG. 10A, there is illustrated a schematic representation of the machine 100 that is used in fabricating the shade product of the invention. It consists in three subsections, the supply section 150, the take-up section 152 and the rod insertion and flaw removal (RIFR) section 200. The first and third of the aforementioned sections perform operations in keeping with their titles and, for all practical purposes, are considered standard in the industry. The first, the supply section 150 comprises a supply reel 154 from which the planar fabric is cast off into the reel tensioner network 158. Similarly, take up section 152 consists in a take-up roll 156 with reel tensioners 158 practically identical to those of the supply section 150. Because the product taken up is physically different from that cast off from the supply section 150, it should be readily understood by those skilled in this art that the stylized representation of FIG. 10A is given merely for expository purposes. It is the intention of the applicant, in providing this disclosure, to concentrate on the apparatus and methodology employed in the central section, RIFR 200. In the center section of FIG. 10A, the reader views the most salient elements of the instant invention: the photo-inspection station 202; metering rollers 204; looping clamps 206; and the stitching-mending station 300; all of which are situate directly in front of the operator station 250. In the FIG. 10A illustation, apparatus immediately in front of and including a portion of the mending apparatus is sectioned at 10B and will be discussed hereinafter. In the normal sequence of manufacture, the fabric material is cast off supply section 150 and enters the RIFR 200 section at the upstream portion of the photo-inspection station 202. In order for the flaw removal portion of the manufacturing cycle to be activated when flaws actually occur in the material, the means required for identifying flaws in spacial relationship to the segment of material that is to be stiffened are employed at this point. Such a means, photo-inspecting and indexing of the material is provided automatically, but backed up by human visual observation. As the material approaches the metering rollers 204, from the supply section 150, it is made to pass over a smooth surface which emits light, such as a back-lighted translucent panel. The light used may be either visible or of some wave length that is readily adaptable to detection of the variations in translucency or opacity of the material. For the sake of clarity, the salient portions of the photo-inspection station are depicted, in gross, as the light source 210, in stand-apart registry with the detector array 212, and with the material 22 passing therebetween. The photo detector array 212 comprises a line of discrete photo detectors which are caused to traverse the material being inspected. The actual line of detectors is parallel to the material travel and essentially as long as a single material advance increment x, to be discussed hereinafter in greater detail. The sensing area (aperture) of each detector is immediately adjacent the neighboring detectors in the line, and the aperture size is smaller then the smallest flaw to be detected. At each cycle of the machine, between advances of the metering rolls, the detector 212 traverses the width of the material below it, across a band of material which is one advance increment wide and spaced exactly an integral number of advance increments from the material at the rod 30S, currently at the stitch position. As the detector array 212 (also termed "line") traverses the material 22, a signal is produced which is dependent on the intensity of light sensed passing into a discrete detector. Since the non-flawed fabric is regular in its opacity/translucency, the generated signal is steady within some definable range for the non-flawed material. If a flaw in the form of a void, such as a tear, hole or missing/dislocated fiber exists, a detector superimposed over the flaw, will detect more light than normal from the emitting surface behind the material, thus increasing the signal generated beyond the normal range. Should a flaw in the form of a dense spot, that is a knot, coating excess or previously applied flaw marking tag exist, the detector passing over that flaw will receive less than normal light, thus generating a signal of intensity below the normal range. In either case, the condition information (flawed and/or non-flawed) of each full-width scan, based upon detector-generated signal and detector location, is stored in the controller processor of the automatic control system for use some time later in the fabrication process. The data so stored may be in any form that will allow their use at some known number of cycles later in the process, when that particular scanned increment of material reaches the appropriate position in the RIFR and at which the flaw removal mode is begun.
To this point, most of the instant process is known in the art; however, to incorporate the flaw removal mode into the rod insertion process, it was necessary to develop an entirely different and novel process and to design an unique apparatus to perform the procedural steps.
The central portion of the RIFR 200 comprises the apparatus used to advance the material 22, form it for insertion of the rod 30, perform any necessary flaw removal and advance the material (with rod inserted) out of the RIFR station to the take-up section 152. Reference being had to FIG. 10B, the reader may observe that the material 22 enters the RIFR station at the left hand side, between the metering rollers 204, specifically the upper step roller and the lower nip roller 204'. It is directed into a transverse channel 213 which is situate essentially horizontal in the RIFR. Thereafter, a thickened channel extension 214 of the front channel 213 is created between the interior table 216' and a transverse pivotable upper plate 216. Upper plate 216 is thus hingeably disposed and traverses the width of extension 214, as well as the width of front channel 213. It is the purpose of this upper plate to provide a means for effecting, and then removing, an upper constraint in the formation of channel extension 214. As the reader will soon be apprised, this facility is mandated by the need to remove the double layer of fabric seen between the upper plate 216 and the lower table 216' once the rod 30S is inserted between layers at index "A". In the preoperational setup, material 22 is taken through channel 213 and directed orthogonally thereto to be brought generally downward over and adjacent guide anvil 222. In so doing, the material passes clamp 218 which, like upper plate 216, is pivotally mounted and runs the width of the RIFR, its purpose being to clamp and temporarily fix material 22 between it and guide anvil 222. At the point at which the material 22 is directed orthogonally out of channel 213, it passes a transverse air port 218. The line of, or a continuous (for the width of the RIFR) port(s) 218 is supplied by air chamber 220 and controlled by the aforementioned automatic controller. It is the function of chamber 220, and its associated port(s) 218, to provide a high intensity air blast for a period as directed by the process controller. At this point in the fabrication sequence, plate 216 has been raised so that in cooperation with table 216', channel extension 214 is formed. Concurrently, lower clamp 218 is in the retracted position (shown by the dashed lines) and the material advances downward as shown. At initiation of the rod insertion sequence, lower clamp 218 closes capturing material 22 between its pad and guide anvil 222. Concurrently, with the immobilization of the material relative to the self tensioning take-up roll, the metering rollers advance the material by a predetermined or preset increment, that is, in the normal fabrication mode, metering rollers 204, 204' advance material 22 precisely by a predetermined amount, in a typically known fashion, into the guide slot or first channel 213. Upper plate 216 is already raised by a predetermined amount, a continuous air blast is provided through air vent 218 and the force of air transversly ejected against the surface of the fabric (which has now been fixed at the lower portion adjacent clamp 218 and freed by the additional advance of material into channel 213), causes the fabric to billow into an inflated loop which propagates along channel extension 214 until it reaches the "A" index immediately outside of the channel. At this point, the amount of material advanced by the metering rollers is fully extended along channels 213 and extension 214 and the air-formed, transverse pocket is at index "A". Upper plate 216, acting as the channel extension 214 upper surface performs its secondary function and clamps the doubled fabric between itself and the machine table 216'.
A pocket having thus been formed in material 22 as depicted in cross section at FIG. 11, a rod 30 is projected by auxiliary apparatus (not disclosed herein) or manually into the pocket at index "A" and the sewing head/needle 302 stitches the two layers of fabric along transverse index "B", as shown. After the stitching process has been completed, plate-clamp 216 and lower clamp 218 are withdrawn and the take-up section 152, take-up roll 156 and tensioners 158 cooperate to remove the rod-inserted section 22K through the open extension channel and down along guide anvil 222. As depicted in FIG. 11, the fabric 22 has been stiffened by the insertion of rod 30S. If it has been necessary to remove a flaw, the fabric has been transversly cut at index "C" and the flawed portion 22' removed by ancillary means that are not shown herein. For a clearer understanding of the flaw removal process, which will be discussed hereinafter, it is suggested that the reader take note of the positions of indices "C" and "D". Their meaning and the value of these references will be appreciated at a point further in this disclosure.
Before proceeding with a description of the flaw removal mode of the instant machine and process invention, it is well for the reader to understand the normal fabricating operation. Summarizing, without reference to the particular elements, and reference being had to FIG. 13 which comprises a sequence flow chart for the normal rod insertion mode and the flaw removal mode, a cycle begins with both upper plate clamp and lower clamp opened, and the material advances under the take-up tension until it is held taut between the take-up and the metering rollers. The lower clamp then closes, releasing the material above it from the influence of the take-up tension. The metering rollers advance the material by the desired preset increment and the material, concurrently driven by the momentum from the air jets located near its orthogonal departure from its advancing direction, billows into an inflated loop proximate the open upper plate clamp. The meter advance distance is so matched with the size of the clamp and its associated parts that, when the upper clamp closes on the loop of material, a portion of that loop protrudes beyond the ends of the clamp and the table (anvil) faces of the channel extension. The protruding portion, that is, the transverse loop in the material receives the stiffening, in this case, rod insertion. Although the clamp has closed, the porosity of the material, and/or relief grooves in the faces of the clamp-table anvil allow air from the jets to escape, urging the continued opening of the protruding loop. A rod is then threaded through the length of the loop (transverse the material) from either a precut-rod feeder, or as preferred, from a continuous roll of rod. A travelling sewing machine, well known in the art, is then activated by a signal generated by the fed-in rod reaching the far side of the material (where it enters a receptacle which holds it in position during material flaw removal--see further in this description). The sewing machine traverses the material, riding guides 304 (see FIG. 10A), stitching between the rod and the adjacent face edges of the plate clamp and table anvil, thus completely capturing the rod in the air-formed loop (pocket). To precisely locate the rod and material, the foot of the sewing machine may be modified to fit around the rod, as in welting or piping practice. When the stitch has been completed across the material (in a single direction), the lower clamp is caused to open; it has been stimulated by a signal generated upon arrival of the sewing machine head, at its end of travel. Concurrent with the lower clamp opening, ancillary apparatus is employed to trim the rod. It is not the purpose of this disclosure, however, to disclose the ancillary rod trimming apparatus at this time. Upper and lower clamps opened, the stiffened material is drawn toward the take-up and, when completely drawn taut into the initial posture of the material, the rod insertion mode is reinitiated.
In the event that a flaw has been located in the advancing material, by means described earlier in this disclosure, a flaw removal mode is entered by the processing control equipment. When the flawed section of material has advanced to where, under normal fabricating mode, it lies within one period of spacing (i.e. a material advance increment x) of the most recently inserted rod, and before the rod is stitched in place, the impending stitch command is aborted, as well as is the normally subsequent lower clamp opening. Instead, the upper plate clamp reopens and the metering rollers advance another normal increment causing more material to billow into a larger loop through and beyond the "A" index to the "D" index shown in FIG. 11. As becomes readily apparent to the reader, the flawed material is contained somewhere within the larger loop, this larger loop beyond the "A" index. Should the flaw be very large, or another flaw detected in the next advancing increment, this special advance cycle can be repeated, as necessary until the material of the next advancing increment is deemed flawless. At that time, the upper plate-clamp closes and the stitching process proceeds according to the normal mode. It should be noted that the rod guide and receptacle, described generally above, will have retained at least the ends of the stiffener rod in the desired position for stitching, even though the enclosing loop of flawed material is too large to aid in rod location. The remaining portion of this description relates to the unique method and apparatus that are used to remove the flaw and mend the fabric about the prepositioned rod so that the normal operating mode might be rapidly reentered and the fabrication process continued.
Having seen how the machine proper operates to stiffen the material which is used to manufacture the shade, as well as the process for effecting a flaw removal stage or mode, there now remains the disclosure of matters and apparatus pertaining specifically to the mending of the material once a rod has been set up at the "A" index and the fabric loop extended to the desired limit at the "D" index. The reader should recall that, earlier in this paper, it was stated that the stitching process proceeds at the time that the upper plate-clamp closes according to the normal cycle. As far as the stitching apparatus (sewing machine) is functionally concerned, its function is always performed in the same manner, once the controller or processor signals that the rod is prepared for material capture. This signal will be generated whenever the material reaches the "A" or the "D" index whichever in pertinent in that mode. The stitcher is a standard commercial traversing sewing machine. The salient elements of the sewing machine as will be hereinafter discussed comprise, as shown in FIG. 12A, the foot 306 or boat element, the needle slot 307 located transverse the longitudinal axis of the foot movement, the foot support 308 which provides the requisite guidance and pressure for the foot element and the sewing machine or stitcher needle 302'. Associated with the stitcher, at a location substantially adjacent to the foot but across the rod from the needle (at the "C" index of FIGS. 12A and 12C), is a device which deals with the excess material in the oversized, flawed loops as shown in FIG. 11. After a flaw advance, and as the sewing machine stitches across the material along the "A" index (the reader will note that the A, B and C indices are parallel, transverse indices), this device, called the mender 310, cuts the large, flawed loop both above and below the rod, along the "C" index. Reference is made now to the mender 310 which is disclosed in FIGS. 12A through 12F. The mender is a compound head suspended, as previously noted, adjacent the foot and pivotally suspended from above the foot so that it may, upon command from the controller-processor, effect a 180 degree arc and present its reverse face in registry with the rod, still adjacent the foot, but on its other side. Reference to FIG. 12C will clarify for the reader that mender 310 is indeed symmetrical about its longitudinal center line so that, when traversing in the direction so indicated, face F 2 will present first its knife blade 312, followed by the adhesive port 314 and finally by the shaping col 316, the purpose of which will be explained hereinafter. When the mender 310 is configured as shown in FIGS. 12A, 12B and 12C, traversing as shown towards the left of the figures, it is said to be in the mend sub-mode M 2 . If there is no mending to be effected, the mender head may be moved to the null position, known as the "N" index. If the mend mode is entered when the left-right stitcher is at the left side (of the drawings), then the mend sub-mode M 1 is entered and the mender head 310 arcs around past the null index to the M 1 , presenting face F 1 in position along the "C" index. Thus, this unique apparatus allows both a stitching and mending process to take place literally at every sweep from left to right, or right to left. Adhesive material is supplied to adhesive ports 314 through a partitioned supply tube 315. Although not explained in great detail herein, supply tube 315 is partitioned so that the port 314 on face F 1 is separated from port 314' on face F 2 . At the base of supply tube 315 (not herein fully disclosed), are glue inlet ports which are shuttered and which are placed in registry with the main glue supply orifice (not herein shown) adjacent to, and at the base of, the sewing machine 300. This method is utilized as it requires only a single source of glue or adhesive to the machine and it is thereafter manifolded to the bases of supply tube 315, only as the appropriate adhesive port 314 is required to dispense the adhesive. Refering now particularly to FIGS. 12A and 12B, the reader will see that, as the foot 306 and mender head 310 traverse towards the left side of the illustration, the rod 30S having been positioned at the "A" index receives the stitch by needle 302' along the (invisible) "B" index as the rod is held captive at its ends and the fabric 22 held snugly thereabout by the cooperation of the foot 306 channel 320 pressing downward through the urging of its support 308 onto the RIFR anvil 304. It may be seen that, as the sewing machine stitches across the material, the knife cuts the flawed portion at index "C" and immediately thereafter adhesive is expelled through port 314 directly onto the rod 30S surface. Meanwhile, the loose margins of the cut fabric, both top and bottom, are captured in the mender head channel 311 and urged toward the channel 311 termination, the col 318. This channel, as well as the terminating col 318 provide folding guides which wrap the margins of the cut material closely around the rod pressing them into the adhesive. Additional curing aids for the adhesive (e.g., heat, cold, air, light), if required, follow immediately behind the folding guides. The excess, flawed material drops away to be collected and disposed of by the operator. In this manner, the rod is retained much as if by a continuous loop of non-flawed material. Since the stresses of operation (extending, collapsing and sliding) are substantially borne by the stitched seams on the other side of the rods, these adhesively mended loops do not present a weakening effect to the final product. Further, because the adhesively closed loops are essentially the same in size and appearance as the normal loops, no special mating parts requirements, or operational, or aesthetic penalties are incurred.
For further clarification, and so that the reader might fully appreciate the use of the compound stitcher and mender apparatus, further reference shall be had at this time to the drawings at FIGS. 12B, 12D, 12E and 12F. FIG. 12B, showing the front side of the stitcher and mender head, has been sectioned at 12C, 12D, 12E and 12F. The apparatus of FIG. 12C, having been fully described in conjunction with the isometric illustration of FIG. 12A, shall not be referred to at this time. The reader, in viewing the mender 310 from the front, immediately notices the two most salient elements, the knife 312 and the adhesive port 314. As mentioned earlier, if the machine were traversing to the right, rather than to the left, this figure would be, except for the foot support 308, symmetrically about the center line (C). It can be readily seen here that the support 316 for the mender head 310 may swing about the center line and to be positioned to the left hand side of the foot 306. In FIGS. 12D-12F, the reader sees cross sectional views of the mender head taken through the knife 312, through the adhesive port 314, and through the last one third of the mender channel 311 looking towards the termination of forming col 318, respectively. The knife 312, as seen in FIG. 12D, is positioned at the "C" index, while the terminal portion of the col 318 is approximately one rod 30 radius behind the "A" index. Referring to FIG. 12E, the viewer sees the mender head in cross section at the adhesive port 314. Contiguous with the port is the glue or adhesive supply channel 315, represented here in its orthogonal placement within the mender head. The reader will note that partition 315' divides the vertically rising adhesive supply 315S to 315. The purpose for this partition was described earlier and discussed more fully during the explanation of FIG. 12C. Also, in FIG. 12E, the reader will notice that rod 30S (shown in phantom) is, for all practical purposes, in registry with the outer surface of adhesive port 314. Again, as mentioned earlier, the glue or adhesive is applied directly to the surface of the exposed rod during the mending process. Finally, the reader's attention is called to FIG. 12F where, in this cross section of the latter third of the mender head 310, the forming channel 311 is seen more clearly terminating at the forming col 318. It can be readily deduced that fabric margins, overlying rod 30S and adjacent to the upper and lower portions of channel 311 would be urged about the rod by the smooth transition from the flat portion 311F of channel 311 as seen in FIG. 12D to the completely semi-circular shape seen at col 318 of FIG. 12F.
Having fully explained the apparatus and the general process for producing the preferred embodiment of the instant invention, along with the methods preferred by the inventors for removing flaws from the supplied fabric or material, the instant inventors would now briefly summarize the entire process beginning with the entering of the material into the RIFR 200, subsequent to the flaw detection operation. FIG. 13, is a flow chart which distinctly describes the salient steps in the normal fabrication mode and in the flaw removal mode. Beginning with the closing of the lower clamp, the computer of controller (processor) queries for a completed step and, upon receiving assurance of its complete execution, commands an advance of the material under normal mode condition. Once completed, the processor determines if the machine is in normal mode or flaw cycle and, if in normal, closes the upper clamp and, upon proper completion of that step commands the insertion of the rod. Had a flaw been detected during the query on flaw cycle, a logic joining point would be experienced and the processor would query whether a flaw exists in the next increment Should a flaw exists in the next increment, the sequence regresses to the material advance step and the entire process (from advance) is repeated simultaneously, a signal is generated to set the mender head so that when the stitch activity is performed, the mending process, as described earlier in this disclosure, will be actuated once the processor is signaled that no (additional) flaw exists in the next increment the program sequences to the stitch operation and, upon its successful completion (with mending, if required), opens both clamps and trims the rod ends (as discussed earlier). Upon assurance that the clamp opening has been successfully completed, the machine controller dwells an appropriate amount of time and sequences back to the beginning of this process.
The reader will note that little reference was made during the entire text of this disclosure, to the persons or manufacturer of ordinary skill. This was not without purpose, because the applicants, having long been associated with window treatments and coverings, as well as the manufacture of such goods and the machines for such manufacture, know of no extant device that is capable of placing stiffeners in a continuous run of material in an accurate, parallel spacing, while automatically detecting and removing flawed material without interruption of or penalty in the finished product. It is their intention therefore to secure exclusive rights to the practice of this invention and, more specifically, to the construction and use of the machinery described herein subject only to the appended claims.
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An extensible and collapsible covering (10) for framed openings. A shade, having periodically emplaced elastic rod stiffeners (28), is motivated over parallel tracks (20) by a movable sill (26). During shade manufacture, stiffeners (26) are inserted into shade pockets by a machine (100) which examines the fabric, excises flaws and creates pockets for the envelopment therein of the stiffeners. The process for flaw removal uses a single pass technique that cuts fabric around a stiffener, reforms it and bonds the cut ends so as to capture the stiffener in a pocket formed thereby.
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BACKGROUND INFORMATION
[0001] Different navigation systems are known for the navigation by road users from a current position to a specified destination position. In them, the present position of the road user is usually determined and, based on the traffic resistances on sections of the road network on which the road user is located, as advantageous a route as possible is determined and output for the road user. For the determination of the route, current traffic data, for instance, with respect to a temporary traffic obstacle, may also be processed. The road user usually includes a motor vehicle, particularly a passenger car.
[0002] A determination device for determining the routs may be provided onboard the motor vehicle or at a central location. In the first case, the current traffic data may be transmitted to the road user in a wireless manner, and in the latter case, the acquisition of current traffic data may take place in any desired manner, and transmission between the road user and the central determination device usually takes place in a wireless manner.
[0003] If a traffic interference occurs, the traffic flow in the region of the traffic interference is usually difficult to predict. In particular, the traffic volume in the small and smallest space about the traffic congestion may be affected by the individual decisions of the drivers of the motor vehicles affected by the traffic congestion, it being unknown what information base these drivers have available to them.
SUMMARY
[0004] It is therefore an object of the present invention to provide a method and a device for cooperatively based navigation.
[0005] A method according to the present invention, for navigation by road users in a region of a traffic congestion, includes the steps of determining a group of road users in the area of the traffic congestion, who are users of a predetermined service, the capturing of travel data of the members of the group, the determining of driving maneuvers for the members of the group based on the captured driving data and outputting the driving maneuvers to the associated members of the group. In this context, the driving maneuvers determined are coordinated with one another, in order to reduce the effects of the traffic congestion for the members of the group.
[0006] The users of the predetermined service, who form a virtual group, so to speak, are able to form a real group in the manner described, whose driving maneuvers are coordinated with one another within the meaning of a collective advantage. It is known that the overall usefulness for all members of a group, in the case of group-oriented actions of each individual member is generally greater than in the case of individually based actions of each member. The members of the group may be instructed to solve the problem of the traffic congestion in the best manner possible, for all the members of the group. The average obstruction may thereby be reduced for each member of the group. A positive effect may also be output to road users that are not members of the group. An overall traffic load may thereby be reduced in the area of the traffic congestion.
[0007] In one preferred specific embodiment, the driving maneuvers are determined so that driving speeds of the members of the group are made to approach one another. A repeated accelerating and decelerating of the members of the group, which is able to result in unnecessary energy consumption, may thereby be prevented. In particular, a calming effect may start on all traffic users in the area of the traffic congestion, so that an increased average speed of the road users is able to set in at the lowest deviation from average.
[0008] The driving maneuvers may also be determined so that the distances between the members of the group are reduced to a predetermined maximum distance. Thereby, the group is not able to exceed a predetermined magnitude along a road. It may be simpler, thereby, to coordinate with one another the driving maneuvers of the members of the group. In addition, the road users who are not users of the predetermined service, may be squeezed out in this manner from the really formed group, whereby the real group may be easier to influence.
[0009] Besides the influencing of a driving speed and an acceleration or deceleration of the members of the group, other maneuvers, such as lane change or a turning-off process, perhaps for utilizing an avoidance path or for little group-wise passing, may also be coordinated among the members of the group.
[0010] In one particularly preferred specific embodiment, the predetermined service includes a social network. The social network may be provided particularly for group-based traffic management. A clear additional usefulness may be allocated to users of this network in the manner described. Such a network is known by the name WAZE. Such a network may obtain its data and information, on the basis of which navigation solutions are determined for users, from the users during their utilization of the service,
[0011] The determination of the driving maneuvers may be carried out by a device separate from the road users. In particular, the determination may be made by a central entity or by a central service. The central service may be cloud-based, so that it is immaterial at which specific locality an executional entity is situated. Communication expenditure between the members of the group may be minimized by the central determination. Particularly, for n members, communication between n x n members may be avoided. Thereby, an available bandwidth may be saved and the speed of execution of the method may be increased.
[0012] The driving maneuvers may be determined in such a way that, in the area of a lane narrowing, the members of the group are guided from the affected lane according to the manner of a zipper. The zipper method that is usual in the case of lane narrowing, and whose execution frequently leads to differences of opinion between the road users, may thereby be executed in an improved manner. Traffic flow is able to be speeded up thereby and coordinating difficulties between the road users reduced.
[0013] In one specific embodiment, one of the road users includes a motor vehicle, and the driving maneuvers are output in such a way that the motor vehicle automatically initiates the driving maneuvers. This may take place, in particular, in connection with an existing assistant for supporting the driver. The assistant may include, for example, a speed assistant having optional range spacing or a lane assistant, which are able to intervene actively in the driving behavior of the motor vehicle. The expenditure for implementing the method may be lowered by this integration. In addition, because of the integration with an existing assistant, the acceptance by the driver of the motor vehicle may be increased with respect to the method described.
[0014] In one specific embodiment, it may be determined that the number of members of the group exceeds a predetermined value, and the members may be assigned to subgroups that are independent of one another, the method continuing in each case to be carried out on the subgroups. Consequently, the growth of the number of members to a number that can no longer be handled efficiently is able to be avoided. The groups created may be guided individually through the area of the traffic congestion, whereby a mutually negative effect of the road users is able to be avoided.
[0015] One member of the group, whose driving speed exceeds a predetermined value, may be discharged from the group. By this procedure the entire group may, in the final analysis, be dissolved as soon as the traffic congestion is no longer present.
[0016] A computer program product has program code means for carrying out the method described when it is run on a processing device or is stored on a computer-readable data carrier. Using the computer program product, a navigation device onboard a motor vehicle may be put in a position of carrying out the method described.
[0017] A device for navigation by a road user in the area of a traffic congestion includes a determination device for determining that the road user is a user of a predetermined service, and for the assignment of the road user to a group of such road users, a capturing unit for capturing driving data of the road user, a determination device for determining driving maneuvers coordinated with one another for the members of the group, based on the captured driving data, in order to reduce the effects of the traffic congestion for the members of the group, and an output device for the output of the driving maneuver determined for the road user to the road user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows a device and a system for a cooperatively based navigation.
[0019] FIG. 2 shows a traffic situation for explaining the cooperatively based navigation.
[0020] FIG. 3 shows a flow chart of a method for the cooperatively based navigation.
DETAILED DESCRIPTION
[0021] FIG. 1 shows a system 100 and a device 105 for cooperatively based or group-based navigation.
[0022] Device 105 is applied onboard a motor vehicle 110 . Device 105 includes a processing unit 115 , an interface 120 , a communication unit 125 and a user interface 130 . Processing unit 115 is connected to interface 120 , communication unit 125 and user interface 130 . Interface 120 leads to a control unit 135 of vehicle 110 .
[0023] In one specific embodiment, control unit 135 is equipped to provide, via interface 120 , driving data of motor vehicle 110 , particularly a current position, a speed, an acceleration, a destination or an impending driving maneuver. In this context, control unit 135 may include a navigation system, particularly a satellite navigation system. In one specific embodiment, processing unit 115 and control unit 135 may also be integrated or even be coincident.
[0024] Control unit 135 may be designed to accept commands via interface 120 , and to influence the motion of motor vehicle 110 directly, as a function of the commands. The influencing may particularly relate to a speed, and acceleration or deceleration or a directional steering of motor vehicle 110 . In one specific embodiment, two control units 135 are provided, control unit 135 for providing driving data being executed separately from control unit 135 for picking up commands. In another specific embodiment, processing unit 115 and one of the two control units 135 may be integrated or even be coincident.
[0025] User interface 130 may have any optional, usual elements for interaction with a user, particularly an optical, acoustical or haptic input or output. The user is normally a driver of motor vehicle 110 . Processing unit 115 may be designed to carry out an output via an interface 120 and/or user interface 130 .
[0026] System 100 includes a plurality of motor vehicles 110 , which are each equipped with a device 105 , a communication system 140 for wireless communication with communication units 125 , as well as a central processing unit 145 . Central processing unit 145 may be replaced by a service in a network, especially by a cloud-based service. Although basically any motor vehicles 110 are able to communicate with the central communication system 140 , it is advantageous to utilize actualities of communication system 140 in order to address in common specifically those motor vehicles 110 which are located close to one another. Communication device 140 may include, for instance, a radio cell of a cell-based telephone network, and motor vehicles 110 are able to stay within the radio cell.
[0027] Central communication system 140 together with central processing unit 145 may be designed for exchanging data, particularly driving data, between motor vehicles 110 . In this case, onboard of each individual motor vehicle 110 , using processing unit 115 , a driving maneuvers for guiding motor vehicle 110 may be determined based on the driving data of the other motor vehicles 110 .
[0028] In another specific embodiment, the determinations of the driving maneuvers are carried out centrally for all motor vehicles 110 by processing unit 145 .
[0029] FIG. 2 shows a traffic situation 200 for explaining the cooperatively based navigation, which is able to be carried out using device 105 and system 100 of FIG. 1 . A plurality of motor vehicles 110 is located on a road 205 having two lanes 210 . In this instance, motor vehicles 110 , that are shown shaded, are members of a group 200 . There is a traffic congestion 220 in the upper area of the right lane 210 , where two motor vehicles 110 are unable to be driven after an accident. Motor vehicles 110 of group 215 are receiving information on driving maneuvers, the driving maneuvers being coordinated with one another in such a way that the removal of motor vehicles 110 of group 215 past traffic congestion 220 is collectively improved. For this purpose, the driving maneuvers are coordinated with one another on the basis of driving data of the individual motor vehicles 110 of group 215 . The determination of the driving maneuvers was explained above with reference to FIG. 1 .
[0030] The driving maneuvers may, for instance, be determined so that motor vehicles 110 , which are members of group 215 , travel as directly one behind the other or next to one another. In one specific embodiment, motor vehicles 110 , that travel directly as neighbors, may be regarded in principle as a single, large motor vehicle 110 , which is navigated over road 205 . However, other methods of behavior are possible as well. For example, guiding together the traffic flows of the two lanes 210 in the area of traffic congestion 220 according to the zipper principle may be carried out more easily if the members of group 215 travel as nearly as possible directly next to each other or in front of each other before traffic congestion 220 .
[0031] In order to hold group 215 to as closed as possible, a series of driving maneuvers may be suggested, for example, to a member 110 that is at a distance from the rest of group 215 , for example, as is shown at the bottom, left, which bring this motor vehicle 110 closer to the rest of the group.
[0032] FIG. 3 shows a flow chart of a method 300 for a cooperatively based navigation, as was explained above with respect to FIGS. 1 and 2 . In this context, method 300 may be carried out on a central processing unit 145 or, in a distributed manner, on a plurality of processing units 115 onboard of a plurality of motor vehicles 110 .
[0033] In a first step 305 , positions of motor vehicles 110 , which are members of a group 215 , are determined Group 215 is defined in that its members are located in a predetermined area of a traffic obstruction 220 , and that they, or the drivers driving them are members of a social network, which preferably exists for the exchange of navigation-based data.
[0034] In a following step 310 , group 215 is formed according to the criteria described. If a motor vehicle 110 which, or whose driver, is a user of the social network, is not located close enough to the rest of group 215 , an invitation may be sent to this motor vehicle 110 in a step 315 . The invitation may include one or more driving maneuvers for reaching the rest of group 215 . For the individual motor vehicle 110 , method 300 is no longer continued at this point until the vehicle may be taken up into group 215 .
[0035] For the remaining members of group 215 , the method continues in a step 320 , in which it is determined whether the group has exceeded a predetermined size. In addition, it may be determined whether the number of members of group 215 is exceeding a predetermined value. If the group is too large, it may be subdivided into a plurality of subgroups in a step 325 . Method 300 may then be embodied individually for each subgroup, the individual embodiments of method 300 being able to be carried out independently of one another.
[0036] If there is no reason for subdividing the group, or if the group has already been subdivided, in a step 330 driving data of participating motor vehicle 110 are determined These driving data may already be present in the form of the positions of participating motor vehicles 110 determined in step 305 . However, the driving data include additional information, particularly speeds, accelerations, maximum speeds able to be reached or travel destinations.
[0037] It may optionally be determined in a step 335 , which may also be carried out at a different time, what type of traffic congestion 220 is taking place. Furthermore, in a step 340 , that is also optional, an additional traffic position in the area of traffic congestion 220 may be determined
[0038] Based on the data determined, in a step 345 driving maneuvers coordinated with one another are determined for motor vehicles 110 , which are users of group 215 . Subsequently, the driving maneuvers are output to individual motor vehicles 110 in a step 350 , each motor vehicle 110 preferably receiving only that particular driving maneuver which has been determined for this motor vehicle 110 .
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A method for navigation by road users in the area of a traffic congestion, includes the steps of determining a group of road users in the area of the traffic congestion, who are users of a predetermined service, the capturing of travel data of the members of the group, the determining of driving maneuvers for the members of the group based on the captured driving data and the outputting the driving maneuvers to the associated members of the group. The driving maneuvers are coordinated with one another, in order to reduce the effects of the traffic congestion for the members of the group.
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BACKGROUND OF THE INVENTION
This invention is generally related to the field of Electronic Design Automation as it applies to the design of semiconductor chips and, more generally, to a method for placing cells in a VLSI chip and legalizing the process with a minimal amount of disturbance to the cell placement.
Typical stages in an integrated circuit (i.e., IC's or VLSI chips) design flow include logic synthesis, floorplanning, placement, routing and timing analysis steps. The placement phase of physical design is of paramount importance given the impact of placement solution on design metrics like area, routability and timing. The cell placement problem is among the most fundamental in VLSI physical design and has been extensively researched over the past two decades. In the context of standard cells, the classical wire-length driven formulation can be stated as follows: given a netlist of standard cells, each component is assigned to a row and to an x-position in that row such that no two cells overlap and that the estimated wire length is minimized.
Placement techniques can be broadly classified as:
1) partitioning-based methods as described, e.g., in the article “Min-cut Placement” by M. A. Breuer, published in the Proc. of IEEE Design Automation and Fault-Tolerant Computing, pp. 343–382, October 1977, and in the article “Efficient network flow based min cut balanced partitioning,” H. Yang and D. F. Wong, published in the Proceedings of the IEEE/ACM Int. Conf. Computer - Aided Design, pp. 50–55, 1994. (2) analytical placement methods, as described in the article “Generic Global Placement and Floorplanning,” by H. Eisenmann and F. M. Johannes, published in the Proceedings of IEEE/ACM Design Automation Conference, pp. 269–274, 1998; and (3) annealing-based methods, as described in the article “Efficient and Effective Placement for Very Large Circuits,” by W-J. Sun and C. Sechen, published in the IEEE Transactions on Computer - Aided Design, pp. 349–359, 1995.
Most top-down large-scale placement techniques (like partitioning and analytical methods) divide the placement stage into global and detailed placement phases. The global placement phase assigns cells to global bins in a grid imposed over the layout area, and thereby decides the global ordering of cells. The detailed placement phase determines the exact cell locations through local perturbations to minimize a desired objective function.
Placement legalization specifically involves resolving overlaps in cell placement during the physical design phase. In general, placement legalization is a required step in several placement approaches to arrive at a valid overlap-free placement that satisfies design rule constraints. The input to the legalization phase is an overlapping placement configuration and the desired output is an overlap-free placement with minimal perturbation to cell locations. Overlap-removal techniques can be used within the context of both global and detailed placement algorithms that generate intermediate overlapping cell placement solutions requiring coarse or fine legal assignment.
Placement legalization is also vital in the context of physical synthesis, wherein the logic/netlist is changed to correct timing violations that invariably result in cell overlaps. In this scenario, it is desirable that any given cell does not move a large distance from the current location to find a legal placement slot, thereby minimizing the impact on the final timing results. The strength of the overall approach to correct timing through synthesis and placement transforms depends on the placement legalization technique that can effectively realize the solutions with minimal placement changes. Other physical design applications requiring an Engineering Change Order (ECO) facility from placement tools also benefit from such techniques that legalize the placement.
The method presented in the invention directly addresses such overlap-removal techniques.
Terminology:
Some standard terminology and definitions from literature are presented for clarity of content and to be utilized hereinafter:
Graph: A graph G=(V, E) consists of a set of objects V={ν 1 , ν 2 . . . } called vertices (or nodes), and another set E={e 1 , e 2 . . . }, whose elements are called edges, such that each edge e k is identified with an unordered pair (ν i , ν j ) of vertices. The vertices ν i , ν j associated with edge e k are called the end vertices of e k . The most common representation of a graph is a diagram, in which the vertices are represented as points and each edge as a line segment joining its end vertices.
Details on the use of graphs may be found in the textbook Graph Theory with Applications to Engineering and Computer Science. Narsingh Deo, Prentice - Hall Publications, 1974.
Directed Acyclic Graph (DAG): A directed graph G consists of a set of vertices V={ν 1 , ν 2 . . . }, a set of edges E={e1, e 2 . . . }, and a mapping that maps every edge onto some ordered pair of vertices (v i , v j )].
Shortest Path: In the simplest form, a shortest path is referred to as the path from a given source vertex to a given destination vertex having the least distance (cost).
Depth First Search: As quoted from the aforementioned reference by Narsingh Deo, a depth-first search is a systematic traversal of the edges of a given graph such that every edge is traversed exactly once and each vertex is visited at least once.
Topological Order: The vertices of a directed graph G are said to be in topological order if they are labeled 1, 2, 3, . . . ,n such that every edge in G leads from a smaller numbered vertex to a larger one.
Maximum Flow Problem: Given a network with capacities on edge flows, the maximum flow problem seeks to find a solution to send as much flow as possible between two points in the network while honoring the edge flow capacities. Further details may be found in the textbook “Network Flows: Theory, Algorithms, and Applications”, R. K. Ahuja, T. L. Magnanti, J. B. Orlin, Prentice - Hall Publications, 1993.
Minimum Cost Flow: Given a cost per unit flow on a network edge in addition to edge capacities, the minimum cost flow problem solves for the units of flow to be sent from one point in the network (the source) to one or more points in the network (sink) with minimum cost while honoring the edge flow capacity.
Area Migration: In the context of the present invention, area migration refers to the movement of standard cell area units from one region to another of a VLSI layout.
Manhattan Distance: The distance between two points measured along axes at right angles. In a plane with point p 1 at (x 1 , y 1 ) and point p 2 at (x 2 , y 2 ), the manhattan distance is given by |x 1 −x 2 |+|y 1 −y 2 |.
The need for placement legalization arises in almost all physical design flows. Several legalization approaches have been adopted in prior works that generally suffer from the following drawbacks: (a) typically use local search heuristics that does not have a global placement view; (b) disturb the given placement (order) significantly leading to inferior placement solution; and (c) do not behave well under difficult instances that have several cell overlaps in the same proximity or fail to legalize under these circumstances.
Among the notable overlap removal methods proposed in the prior art is described in U.S. Pat. No. 5,943,243 which proposes a row level legalization approach, wherein cells are reassigned from over-capacitated regions to free-spaces between fixed-blocks. However, their method attempts a cell-by-cell legalization scheme with restricted local search and does not incorporate a global view of free-space contention, thereby, resulting in large movement of some cells to find a legal placement.
In another approach, described in U.S. Pat. No. 5,619,419, an analytical placement algorithm incorporating overlap removal through repulsive forces to spread cells apart is presented. Such a recursive approach to eliminate cell overlaps is often applied in many top-down placement algorithms but do not lend them for a post-placement legalization scheme.
There also exists some reference to overlap-removal techniques found in the literature, notably: modeling a detailed placement algorithm as a transportation problem which is solved using network flow techniques, as described in the article “Accurate net models for placement improvements by network flow methods,” by K. Doll, F. M. Johannes, and G. Sigl, published in the Proc. IEEE/ACM Int. Conf. on Computer - Aided Design, pp. 594–597, 1992. Although this approach maintains non-overlapping placement, it does not explicitly address placement legalization issues since the input placement is assumed to be overlap-free. In addition, the aforementioned approach does not globally explore the available free-space in the layout area for cell placement assignment. A detailed placement algorithm using a network-flow based approach to migrate cells from overpopulated regions to free-space with minimal perturbation is described in “Algorithms for Detailed Placement of Standard Cells,” Jens Vygen, published in the Proc. of Design Automation and Test in Europe (DATE), pp. 321–324, 1998. However, this modeling restricts the flow (movement) of cells to only the vertical direction across rows of regions and does not account for the horizontal movement of cells while satisfying global capacity and demand constraints. A legalization scheme that uses gain-graph model to ripple move cells to an overlap-free position in the context of detailed placement is presented in “Mongrel: Hybrid Techniques for Standard Cell Placement,” S. Hur and J. Lillis, published in the Proc. IEEE/ACM International Conference on Computer - Aided Design, pp. 165–170, 2000. This method is applicable for resolving single-source overlaps caused by individual cell moves during placement refinement but does not handle multiple regions with overlaps simultaneously.
The approaches presented in the prior art either do not directly address the post-placement legalization problem or they fail to capture the global-view of the problem or they do not account for all the degrees of cell movement in the global-view context. The present invention proposes a two-dimensional model of the given placement instance as a global area migration problem where both horizontal and vertical movement of cells (area units) is effectively captured. Furthermore, efficient techniques to move cells to satisfy the desired area migration across regions with minimal perturbation from the given placement are also disclosed. The proposed approach provides a robust solution to legalize cell placement without compromising on the placement quality.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, there is provided a method for resolving overlaps in the cell placement, during the physical design phase of a chip design to preserve the quality of the placement.
It is another object of the invention to provide an efficient method to automatically resolve cell overlaps by capturing a globally-aware two-dimensional area-migration solution followed by local perturbations to the given placement.
It is yet another object of the invention to provide a method for legalizing the given placement with minimal disturbance to the cell placements.
These and other objects of the invention are achieved by an overall flow for the proposed legalization scheme that involves three major phases: (a) solving a global area migration problem, followed by, (b) detailed physical movement of cells, and (c) local relative placement order optimization. The core concept captures a globally-aware solution while making local detailed changes to remove cell overlaps.
The first step attempts to capture the given placement instance as a two-dimensional model reflecting blockages, free-space and placement of movable cells. The goal is to identify the regions of overlap (supply points with excess assignment), regions of free-space (demand points with available space in the layout), and regions with zero-capacity (blockages and fixed objects) along with accurate cost per-unit area (unit cell area) movement in both horizontal and vertical directions. The desired area-migration from over-populated regions to the under-utilized regions to satisfy the capacity demand constraints with minimal overall cost of cell area migration can be represented as a linear programming problem. This instance of the linear program is efficiently solved using network flow techniques. The solution to the global problem represents the effective units of area to be migrated between regions in the layout area with minimal overall movement cost. The second step in the legalization process involves physical movement of cells from each region to its neighboring regions to satisfy the desired amount of area migration determined in the global phase while minimizing the cell movement cost. The cells are assigned a detailed location in the target region as they are physically moved during this phase of legalization. At this point, most cells have been assigned a valid overlap free placement; however, some cells may exist that cannot be legalized based on the current global assignment. To eliminate any existing cell overlaps, the first two steps are iterated until an overlap-free cell assignment is achieved for the entire layout. The third and final step involves local cell reordering to improve placement objectives like weighted linear wirelength.
The invention provides a method for resolving cell placement overlaps in an integrated circuit that includes the steps of: a) determining an initial placement of the cells; b) capturing the placement-view including blockage-space and free-space to define in an image space physical regions of the integrated circuit; c) constructing a network flow model representing the movement of the cells between the physical regions; d) solving the network flow model to determine a desired flow of the cells between the physical regions of the integrated circuit; and e) realizing the best approximation of the desired flow of cells.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and which constitute part of the specification, illustrate presently a preferred embodiment of the invention and, together with the general description given above and the detailed description of the preferred embodiment given below; serve to explain the principles of the invention.
FIG. 1 shows a flow chart for the method for legalizing the placement of cells in a chip according to the present invention.
FIG. 2 illustrates the definition of a placement-aware region.
FIG. 3 illustrates the unit-cell-area movement cost.
FIG. 4 shows the problems associated with a network flow model for a two-dimensional area migration.
FIG. 5 shows a detailed cell movement from region i′.
FIG. 6 illustrates the generalized min-cost flow formulation per region.
FIG. 7 is a pictorial representation of a multi-row-high cell placement.
FIG. 8 shows the augmented graph model for approximate modeling of an m by n cell movement.
FIG. 9 describes the process for placement aware region definition
FIG. 10 illustrates the graph model formulation for the global area migration problem.
FIG. 11 illustrates the graph model for cell selection problem per region
DETAILED DESCRIPTION OF THE INVENTION
The flow chart for the proposed legalization ( FIG. 1 ) describes the steps ( 1 through 8 ) involved in the present invention. Each step in the flow chart is described independently in detail in the following sections:
Step 1 : Modeling Placement-Aware Global 2-D Area Migration Problem
The first step in the proposed legalization scheme represents a given placement instance as a global two-dimensional area migration problem. This involves two parts: (a) placement-aware region definition and (b) flow graph model of the 2-D area migration problem.
(a) Placement-aware region definition involves creating a model of a given placement instance reflecting regions of overlap ( 14 , supply points with excess assignment), regions of free-space ( 17 , demand points with available space in the layout), and regions with zero-capacity ( 10 , blockages and fixed objects), all of which are illustrated in FIG. 2 . Shown therein is a physical representation of the region definition scheme for a given placement. The large blocks ( 10 ) are fixed cells or blockages in the placement image space. The horizontal rows ( 11 ) represent the circuit rows with height h ( 15 ), which is typically fixed in a standard cell based design methodology for ASIC chips. The vertical demarcation lines ( 13 ) represent region boundaries that vertically slice the circuit rows to divide the row width into some reasonable sized regions. The vertical region boundaries ( 13 ) are defined such that they reflect blockages ( 10 ), contiguous free-space ( 17 ) and placement of movable cells ( 12 ), thereby capturing a per-unit area movement cost in both, the horizontal and vertical directions as accurately as possible. Furthermore, such a placement-aware region definition facilitates physically realizable global solutions and avoids unnecessary movement of cells (area) across regions. Each layout area that is formed by the horizontal and asymmetrical vertical grid lines defines a “region” or “bin”. Also, for the present, it is assumed that all multi-row high cells are fixed in location and so, the initial legalization problem involves moving only single-row high cells. FIG. 9 shows the pseudo-code for the scan line based region definition process where the default width of regions is set to W (that is, no contiguous space other than that occupied by blockages and fixed objects having a region width greater than W). The space occupied by fixed objects and blockages in a row are further vertically sliced into regions of equal width (less than or equal to W) to accurately model the cell movement cost over them. The value of W is computed based on the design size and average movable single-row-high cell size in the design.
The first step in the region definition process (step 1 , FIG. 9 ) builds the placement image by assigning cells to rows (y-position) and their given x-position. Large fixed cells and blockages are represented as a collection of single row-high cells. The scanline based method defines the regions on a row-by-row basis (step 2 , FIG. 9 ) by advancing the scanline from the left boundary (step 3 , FIG. 9 ) to the right boundary of the each row. The scanline advances based on a given placement of cells (movable, fixed and blockages) of the row concerned. Therefore, the list of cells in a row sorted by their x-position (step 5 , FIG. 9 ) is sequentially processed (step 6 , FIG. 9 ) to define the region boundaries within a row. The left edge position of each cell (c) is represented by xpos(c), the scanline position by scanline_x and the previous region boundary by last_region_boundary. The sequential loop advances the scanline to either the left edge position of the current cell, xpos(c) (as in step 20 , FIG. 9 ) or to the right edge position of the current cell (as in steps 24 , 28 and 32 , FIG. 9 ). The scanline progresses forward until it hits either a fixed cell in the row or it exceeds the predefined width constraint W. If a fixed cell is encountered, then a region is defined to the left of the fixed cell based on scanline_x and the previous region boundaries (step 13 , FIG. 9 ). The scanline is advanced to the left edge of the fixed cell (steps 14 , 15 , FIG. 9 ). If the width constraint is violated as the scanline advances, then a region is defined based on the previous region boundary and the scanline_x value before the scanline is advanced (steps 9 , 10 , and 17 , 18 , 19 , FIG. 9 ). When scanline coincides with the left edge of a fixed cell, then entire width of the fixed cell is captured as a region and the scanline is advanced forward to the right edge of the fixed cell (steps 23 , 24 , 25 , FIG. 9 ). The scanline is simply advanced by the width of any movable cell that is encountered if the width constraint is not violated (steps 27 , 28 , FIG. 9 ). A region is created between the current feasible position and the previous region boundary whenever width constraint is violated by the position or width of any cell (as in steps 30 , 31 , and 32 , FIG. 9 ). The complexity of the region definition phase is O (n log n), where n is the number of cells in the design.
(b) Flow graph model of the two-dimensional area migration problem is constructed from the above set of regions to define the capacity-demand constraints for the given placement view. It results in a directed graph, wherein nodes are defined by the regions (or bins) and the edges (direction of potential movement of area) are defined between neighboring regions that overlap at least partially in one of horizontal or vertical direction. For each region b, neighboring regions as those which adjoin region b are defined. Each such adjacency (neighboring relation) is represented by a directed edge from region b to its neighbors. So, as a general case, for a pair of neighboring regions (b 1 , b 2 ), there exists a pair of directed edges going from b 1 to b 2 and from b 2 to b 1 .
Referring now to FIG. 3 , there is shown a snapshot of regions that illustrates the analogy of edges between nodes in the flow graph and adjacency (neighboring) relationship in the placement view. The figure shows seven regions (B 1 , B 2 , B 3 , B 4 , B 5 , B 6 and B 7 ) with region boundaries ( 18 ) and placement of movable cells ( 19 ) in each region including some cell overlaps ( 20 ) in region B 1 . The regions adjoining B 1 are represented in the corresponding graph model through edges e 1 (B 1 , B 2 ), e 2 (B 1 , B 3 ), e 3 (B 1 , B 5 ), e 4 (B 1 , B 4 ) and e 5 (B 1 , B 6 ). These edges have attributes similar to the edge cost and edge capacity. The edge cost represents the cost per unit cell area movement along that direction and the edge capacity reflects the maximum allowed cell area flow in that direction. All the edges e (ν i , ν j ) in the graph have a cost K e , which is the cost of moving unit commodity from node (region) ν i to its neighboring node (region) ν j , where the cost K e is defined by
∀ e ( v i , v j ) ∈ E , Cost ( e ) = K e = { Width ( v i ) / 2 , If row ( v i ) = row ( v j ) Height ( v i ) + α * Width ( v i ) / 2 , If row ( v i ) ≠ row ( v j )
and the overlap factor (a) between the two regions ν i and ν j by
α
=
1
-
Overlap
Width
(
v
i
,
v
j
)
Width
(
v
i
)
As previously mentioned, the cost per unit area migration associated with an edge captures the physical disposition of neighboring regions. The capacity of all the edges e (ν i , ν j ) in the graph is set to infinity (i.e., a large integer) to allow unlimited movement of cells in and out of each region to satisfy the global capacity-demand constraints.
FIG. 10 depicts a graph model for the global area migration problem. The regions in the placement image define the set of nodes V in the graph. The neighboring regions relationship is captured by the set of edges E in the graph (step 1, FIG. 10 ). Every edge e that is an element of the set E of edges, has two attributes associated therewith: the capacity of the edge, given by Cap(e), that represents the maximum flow allowed in that direction (step 3 , FIG. 10 ), and the cost of unit flow along the edge direction given by the Cost(e) (step 2 , FIG. 10 ). These attributes are assigned values as described previously. Each node ν that is an element of the set V of nodes, has two attributes associated with it: the capacity of the node ν, given by Cap(ν), represents the capacity of the region corresponding to the node ν (step 5 , FIG. 10 ); and the total size of the cells occupying the region corresponding to the node ν, given by Size(ν) (step 4 , FIG. 10 ).
Consequently, each node ν also has an effective excess/deficit number associated with it, given by b(ν), and is the difference between the Size(ν) and Cap(ν) (step 6 , FIG. 10 ). If b(ν) is positive, then node ν represents a supply node (region with excess assignment). If b(ν) is negative, then node ν represents a demand node (region with deficit or available free space).
Step 2 : Solving the Network Flow Formulation
The above graph is now transformed by introducing a source node s and a sink node t. The transformation involves introducing zero cost edges from source node s to all the supply nodes i (Cost(e si )=0, Cap(e si )=b(i)) and zero cost edges from demand nodes j to sink node t (Cost(e jt )=0, Cap(e jt )=−b(j)), as illustrated in FIG. 4 . The minimum cost global area migration solution is obtained by solving a minimum-cost flow problem on the transformed graph using known network flow techniques. These are known optimal algorithms, as described in the textbook “A faster strongly polynomial minimum cost flow algorithm”, James B. Orlin, Operations Research 41, 1993, having a complexity of O (n log n (m+n log n)), where n is the number of nodes in the graph and m is the number of edges in the graph. The solution obtained from solving this network problem defines the extent of the area migration required between nodes (regions) to reach a capacity satisfying assignment of cells to regions with minimum overall movement cost.
Step 3 : Define Effective Edge Flows
Since the graph consists of two-way directed edges between adjacent nodes (neighboring regions), the effective edge flow is determined by scanning for the total net flow from one node to its neighbor. Following this step, a unique non-negative (greater than or equal to zero) flow direction between a pair of nodes that are adjacent is obtained.
Step 4 : Detailed Movement of Cells
This step involves processing individual regions to physically move cells (cell area) to the neighboring regions based on the desired global area migration solution. The order in which the regions are processed is determined by the topological ordering of the global directed acyclic graph based on the positive effective edge flows. The inventive method for detailed movement of cells from each region involves three parts: (a) the cell selection problem, (b) the physical movement of cells, and (c) updating area migration values.
(a) For each region in the topological order, the aim is to select a set of cells from the current region to be moved to the neighboring regions to satisfy the desired flow amount in the edge while minimizing the total cost of moving cells. For each cell assigned to the current region i′, the original location of the cell is known a priori. The target location in the neighboring region is computed to be the closest point within the new region from the current region boundary. With these two positions known, the cell movement cost is computed as the square of the manhattan distance between the two positions (quadratic movement cost). Therefore, for the region i′, the problem is to determine what cells to move and in which direction (the neighboring region) based on the associated movement costs.
Referring to FIG. 5 , there is shown an example of region i′ having positive flows (area migration) to neighboring regions j 1 ′,j 2 ′,j 3 ′ with corresponding flows of f(i′,j 1 ′), f(i′,j 2 ′) and f(i′, j 3 ′). The inventive cell selection method per region attempts to realize the desired area migration to all the neighboring regions simultaneously to minimize the total cell movement cost. This is modeled as a generalized minimum-cost flow problem as shown in FIG. 11 . The cells in region i′ define the set N 1 and the neighboring regions (to i′) along with region i′ that defines the set N 2 (step 1 , FIG. 11 ). The set of edges E represents all possible combinations of cells-to-regions assignment (step 2 , FIG. 11 ). Let S(N 1 ) represent the total size of cells in the region i′ and Smallest(N 1 ) represent the smallest cell size in the set N 1 . Every edge e that is element of set E of edges have three attributes associated therewith: the capacity of the edge, given by Cap(e), is set to a unit value (one) representing an assignment of the cell to the corresponding region; the multiplier which represents the gain in flow through the edge e; and the cost of assigning the cell to the corresponding region, given by Cost(e) (step 5 , FIG. 11 ). This graph is transformed by introducing a source node s and sink node t. Additional edges are introduced from the source node s to all the nodes/cells in the set N 1 with zero edge cost and unit edge capacity (step 6 , FIG. 11 ). Similar edges are introduced from the nodes/regions in the set N 2 to the sink node t with zero edge cost and the capacity defined by the smallest cell size (Smallest(N 1 )) and the desired flow to the corresponding region in set N 2 (step 7 , FIG. 11 ).
FIG. 6 illustrates the graph model for the previously mentioned formulation. The problem is solved using modified successive shortest path algorithm (a technique to solve minimum-cost flow). Since the cells are of fixed widths (area) and the desired flows (area migration) in each direction is a real number, it is sometimes impossible to match the exact flow desired in each direction. The modified network flow implementation is to accommodate for the fact that sometimes there might exits no feasible solution which satisfies both the node-balance and the flow-bound constraints in the network. In such instances, the solution to violate the flow-bound constraints is allowed to converge towards a minimal total cost assignment with some area (desired flow) violations. The desired flow constraint is relaxed to accommodate instances where the desired flow (area migration) in a given direction is smaller than the smallest cell area in the region (step 7 , FIG. 10 ). The complexity of this phase is O (n 2 S (n,m,nC)), where n is the number of cells in the region, and S (n,m,nC) is the order of time for computing shortest path from source s to sink t in the graph.
Given the possibility of failure to satisfy the desired flow constraints due to discreteness in the cell sizes, an alternative approximation scheme is also presented which primarily selects cells to be moved only based on movement cost. The scheme involves first generating pairs (c i , b j ) representing assignment of cell c i to region b j with Cost (c i , b j ) representing the corresponding movement cost (quadratic movement cost). The number of such pairs is bounded by O (nR), where n is the number of cells in the region and R represents the bound on the number of neighboring regions. R is typically a small number. The next step in the approximation scheme involves sorting these pairs in the increasing order of cost. The complexity of this step is O ((nR) log (nR)). For each pair in the ordered list, the cell is assigned to the corresponding region if assigning the cell area to the region does not violate the desired flow area constraint. If a pair is accepted for assignment, then all the other potential assignments for the given cell are invalidated. This update operation can be performed in O(R) by maintaining suitable data structures on the cells. Therefore, one pass of the sorted sequence assigns cells to regions with minimum individual movement cost while satisfying the desired area flow constraint. However, all the excess area from the active region may not be sent out after the first pass. Therefore, a second pass of the sorted list is performed involving assignment of cells to regions even if they exceed the desired flow constraint. However, in this pass, each region is marked saturated after the very first cell assignment that exceeds the flow constraint. Saturated regions are eliminated from any further cell assignments. At the end of this approximation scheme, cells are assigned to the neighboring regions to satisfy (or exceed) the desired area flow. Note that though the total cell movement cost might be non-optimal with the approximation scheme, the solution tends to favor assignments with minimal individual cell movement costs.
For two horizontally adjacent regions b 1 and b 2 (b 1 to the left of b 2 ), the desired area flow of f(b 1 , b 2 ) can be realized in one of two ways: Either by moving the desired units of cell area from b 1 to b 2 , or by assigning the equivalent region area from b 2 to b 1 . The latter implies shifting the region boundaries by suitable flow amounts, i.e. dynamic region-sizing. For movement of cells between horizontally adjacent regions, dynamic region-sizing is applied to avoid unnecessary cell movement.
While the general approach for selecting cells to be moved, as described above, is based on the quadratic movement cost of cells, other variations in cost model based on timing criticality, wirelength and pin congestion metrics may also be used in this framework.
A method for incorporating timing criticality as a cost metric that is based on assigning a cell-centric cost computed from a static timing analysis on the given netlist. In particular, from the slacks computed at each pin associated with a given cell, the worst pin-slack is used to represent the timing sensitivity (criticality) of the cell. The cells are assigned a cell-centric cost in a given cost range based on linear scaling with the cell corresponding to the worst pin-slack in the design being assigned the maximum cost. The cell-centric cost reflects the timing penalty incurred in moving a given cell from its current location. As noted, this cost may be used in lieu of the quadratic movement cost described in the general framework. Similarly, linear wirelength measure can also be used as a cost metric, by computing the increase in the wirelength incurred by moving a cell from its current location to the target location.
(b) Having selected the cells to be moved to the target region, the cells are physically moved to the most optimistic location, i.e., to the closest point in the destination region from their location in the current region, i′. Only the non-horizontal cell moves are applied at this point. The horizontal cell moves are deferred by dynamic region sizing applied on the adjacent regions in the circuit row based on the desired flow amounts. After moving the excess from the current region i′ to the neighboring regions, the remaining cells may still have overlapping placements either from their initial placement locations or from the overlap that result from cells that moved into the current region i′. The cells currently assigned to region i′ are removed from the layout and sorted in the increasing order of their quadratic movement cost from their original locations. The cells are inserted into the layout in the sorted order at the desired locations with local one-dimensional region-level overlap resolution through ripple-slide operation. The ripple-slide scheme pushes the movable cells to the left or the right in the circuit row to accommodate the incoming cell. The cells that have higher quadratic movement cost are inserted later to minimize their movement within region i′. It is a possible that some cells cannot be placed in a legal non-overlapping slot within the region. Such cells are placed overlapping to be resolved in the next iteration of legalization.
(c) Since there is a possibility of excess cell area movement to the neighboring regions due to discrete cell sizes, the global flow solution is locally updated to maintain the mass balance constraint at each region. The excess assignment is distributed in the out-degree of the neighboring regions, to yet unprocessed regions, based on the ratio of edge costs (least cost edge gets a larger fraction of the area excess). The incoming edges to the current active region are ignored in this operation. This local update resolves the potential capacity violations resulting from previous steps.
Step 5 : Analyze the Capacity Constraint Satisfaction
Since the cell sizes are discrete, the detailed cell movement phase may fail to achieve an overlap-free placement within each region in step 4 . This could leave certain regions with small excess assignments that violate capacity constraints. This is evaluated for all the regions in the network at this point.
Step 6 : Iteration Condition
The global area migration solution is iterated to refine the capacity constraint violation under the following two conditions:
(a) If there exists some capacity constraint violations detected in step 5 , and (b) If the total number of iterations of the global solution already performed does not exceed a specified limit.
Step 7 : Update Network Graph
If step 6 identifies more iterations of global solution to be performed, then the global network graph is updated and the solution process from step 2 is repeated.
Step 8 : Local Placement Re-ordering
At this point, the placement is assumed to be legal without any overlaps. Since the legalization process thus far has realized a minimal movement based legal solution, the local placement order may need to be refined. The local placement reordering step attempts to optimize the wirelength objective while very locally perturbing the placement. This is a constrained placement optimization step that improves the quality of final placement result.
(Extension) Multi-Row-High Cell Movement
The invention also presents various approximation methods to handle movable multi-circuit row high (m by n) cells during the legalization process.
FIG. 7 shows a placement view of an m by n cell (which spans four circuit rows) with corresponding adjoining regions to the left (l 1 , l 2 , l 3 , l 4 , l 5 , and l 6 ), right (r 1 , r 2 , r 3 ,r 4 ,r 5 , and r 6 ), top (t 1 , t 2 ) and bottom (b 1 , b 2 ). The figure illustrates the placement view of a movable m by n cell ( 22 ) with regions ( 21 ) defined by vertical grid ( 23 ) and circuit rows. For simplicity, a uniform vertical grid ( 23 ) is used for illustration; however, in concept an asymmetrical vertical grid could be applied. For the circuit rows across which the m by n cell spans, the edges of the m by n cell define the region boundaries.
In FIG. 8 , the augmented graph model for approximating the m by n slide operation (i.e., to maintain the circuit row level assignment while moving the cell across channels) is presented. The figure only captures the modified m by n cell model in the global graph. Nodes L, M and R jointly represent the m by n cell (horizontal view). The edges between the collection of nodes in N 1 (regions to the left of the m by n cell) and the node L captures the potential movement of cells along the left-edge or across the m by n cell. The cost associated with the edges from region i in the set N 1 to node L, represented by Cost(e iL ), is given a value of Width(i)/2, which is the average width of the corresponding region i. The reverse flow cost for edges from node L to the region i in N 1 is assigned a cost of zero (Cost(e Li )=0 for all i in N 1 ). Similarly edges are defined from collection of node in N 2 (regions to the right of the m by n cell) and the node R captures the potential movement of cells along the right-edge or across the m by n cell. Again the cost associated with the edges from region i in the set N 2 to node R, represented by Cost(e iR ), is given a value of Width(i)/2, which is the average width of the corresponding region i. The reverse flow cost for edges from node R to the region i in N 2 is assigned a cost of zero (Cost(e Ri )=0 for all i in N 2 ). To reflect the penalty of migrating cells across the m by n cell width, the edges from node M to L and from node M to R are used. The cost associated with each of these edges has a value equal to the width of the m by n cell (Cost(e ML )=Cost(e MR )=Width(C), where C represents the m by n cell). The capacity of all the edges representing the m by n cell in the augmented model shown in FIG. 8 is set to infinity (i.e., a large integer value) to allow as much area migration across the m by n cells as desired by the global solution. The m by n slide movement is restricted by assigning a suitable capacity constraint in the edges associated with the augmented graph model in FIG. 8 . The need for the center node M in representing the m by n cell arises to facilitate a similar approximate model for movement of the cell across circuit rows (where nodes T and B would represent the top-edge and bottom-edge of the m by n cell and similar graph with the three nodes T, M and B would be constructed). The error in per-unit area cost model of the approximation scheme for movable m by n cells is proportional to the height (number of circuit row spans) of the m by n cell for a slide operation. Therefore, this approximation is mainly suitable for relatively small movable m by n cells.
The inventive method specifies that the movable m by n cells be first fixed in location. The global area migration problem is solved by using an augmented graph to include modeling of the m by n cells. Intuitively, the augmented graph attempts to capture the effective area units(x) that migrate across the m by n cell width if the given m by n cell were fixed in location (i.e., with rigid region boundaries). The reason for introducing the three nodes L, M, and R to model the m by n cell is as follows: for the model of FIG. 8 , cells are allowed to move to any adjoining region on the same side of the m by n cell (e.g., to the left region) through node L for the same cost if there is free space available in any of those regions. This cost is less than the effective cost involved in migrating x units of area across the m by n cell through nodes L, M, and R. For this instance, a cell migrates across the m by n cell only if all the free space in the adjoining regions on the left side of the m by n cell is already used up. The x units of area suffers from extra movement cost (determined by the width of the m by n cell Width(C)) to traverse across the fixed m by n cell. This non-optimality arises in lieu of fixing a priori the m by n location. Given the global area migration solution, the disclosed method pre-places the m by n cell in a good initial position. That is, if x units of area migrate across the m by n cell from left to right, then the m by n cell is moved to the right by x/m units (m being the height of the m by n cell). Once the m by n cells are pre-placed at a globally good initial position, the legalization of remaining single-circuit-row high (1 by n) cells in the design is completed based on the scheme presented in FIG. 1 .
Whereas the present invention has been described in terms of a preferred embodiment, it will be understood by those skilled in the art that numerous changes and modifications to the algorithm may be introduced without departing from the spirit of the invention, all of which fall within the scope of the appended claims.
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A method for resolving overlaps in the cell placement (placement legalization) during the physical design phase of an integrated chip design is described. This problem arises in several contexts within the physical design automation area including global and detailed placement, physical synthesis, and ECO (Engineering Change Order) mode for timing/design closure The method involves capturing a view of a given placement, solving a global two-dimensional area migration model and locally perturbing the cells to resolve the overlaps with minimal changes to the given placement. The method first captures a two-dimensional view of the placement including blockage-space, free-space and the given location of cells by defining physical regions. The desired global area migration across the physical regions of the placement image is determined such that it satisfies area capacity-demand constraints. The method also provides moving the cells between physical regions along previously computed directions of migration to minimize the movement cost. Also provided is an approximate method to model the movement of multi-row high cells.
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STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for government purposes without the payment of any royalties thereon or therefore.
BACKGROUND OF THE INVENTION
This invention relates to compositions and methods for cleaning and removing oleaginous materials from reinforced fiber composites. The proximity of aircraft landing gear doors and horizontal stabilizers to hydraulic fluid (HF) reservoirs leaves composite parts vulnerable to fluid contamination. As aircraft age, this problem is exacerbated, as damaged reservoirs and lines leak operational fluids into open regions, particularly core cells of composite honeycomb. While the majority of these oleaginous fluids are not inherently damaging to the structural materials, residual fluids interfere with bonded patch repair. Without a consistent method to effectively remove hydraulic fluid contamination to enable reliable bonded repairs, repairing the contaminated parts will not be achievable.
The traditional method to remove hydraulic fluid contamination prior to the application of the bonded composite repair patch involves packing the contaminated area with breather cloth and heating at an elevated temperature under vacuum. The current procedure for removing hydraulic fluids from composite materials is costly and time consuming. Methyl-isobutyl ketone (MIBK) is used to remove hydraulic fluid from most composite materials. MIBK is ineffective in the removal of hydraulic fluid from composite materials; however, it has been used because it does not pose a threat to the workers. Due to the limited number of controlled environments to perform this process while aircraft are deployed, it is necessary to use solvents that are environmentally friendly and present minimum risk to workers.
More specifically, aircraft composite structures often become contaminated by various aircraft maintenance fluids during the course of normal operation. For example, hydraulic fluid contamination can cause composite plasticization, delamination and disbanding from honeycomb core. Additionally, hydraulic fluid contamination must be addressed prior to a bonded repair. The solvent of choice for cleaning composite structures has historically been hexane, which efficiently removes hydraulic fluid contamination without adversely affecting composite properties. However, hexane is a hazardous chemical with a low flash point and must be used in a controlled environment to prevent worker exposure. Therefore, any new cleaner must be environmentally-advantaged, less hazardous, and most importantly, must be effective in removing the hydraulic fluid from the composite materials without affecting their mechanical and thermal properties.
DESCRIPTION OF DRAWINGS
FIG. 1 : Infrared spectra for MIL-PRF-83282 hydraulic fluid and standard hydrocarbon solvent showing the spectral differences in the 1740 cm −1 carbonyl stretch vibration region.
FIG. 2 : Infrared spectra for the residue remaining after the initial, second and third cleaning for one of the solvents (swab method).
Accordingly, it is an object of this invention to provide a non-aqueous fluid composition for cleaning and removing oleaginous materials such as hydraulic fluids from reinforced fiber composites.
It is another object of this invention to provide a method of cleaning and removing oleaginous materials from reinforced graphite fiber composites with a non-aqueous fluid composition characterized as being free of ozone depletion materials, having a low vapor pressure, and a flash point above 140° F.
SUMMARY OF THE INVENTION
This invention is focused on optimizing a mixture of specific organic solvents as a cleaner for removing oleaginous materials such as hydraulic fluids from composites effectively and safely. Several non-aqueous solvent blends have been developed to remove hydraulic fluid from composite materials; these blends are less hazardous and are not regulated as hazardous air pollutant (HAPs). Composite materials were soaked in hydraulic fluid and then rinsed with the developed cleaners to remove the fluid. Infrared (IR) spectroscopy was used to measure the effectiveness of the developed cleaners. The results have shown that the developed cleaner of this invention is more efficient than the control materials. In addition to the cleaning efficiency, the effect on the mechanical properties of the composite materials i.e. reinforced graphite fiber (IM7/977-3) was conducted. The IM7/977-3 composite laminate showed no degradation in flexural and short beam shear strength after a 1-hour soak in the solvent blend of this invention (Form 4.2).
DETAILED DESCRIPTION
This invention was focused on optimizing/blending aliphatic and aromatic solvents to form effective cleaners that are capable of removing oleaginous materials such as hydraulic fluids from composite materials effectively and safely. This effort will lead to increased understanding of the physical and chemical properties of cleaning solvents that are capable of decontaminating composite materials safely and effectively. This invention will benefit the Naval Aviation Enterprise (NAE) by providing a more efficient, cost effective and environmentally acceptable means to clean critical composite weapons system components of oleaginous fluids such as hydraulic fluid. The cost savings will be realized through reduced maintenance costs, complying with the environmental regulations and enhanced mission readiness.
Description and Operation
Although various operational oleaginous fluids intrude into composite skin and honeycomb based structure on aircraft, hydraulic fluid was deemed to be the most significant in affecting the bond-line in bonded repairs and the most persistent in the maintenance environment. Specifically, usage of MIL-PRF-83282 hydraulic fluid was identified as more widespread than of products according to other specifications. To address the removal of hydraulic fluid from a polarity and solvency stand-point, a consideration of the constituents of the fluid was made. Table I lists the composition of a representative hydraulic fluid qualified to MIL-PRF-83282 and includes a description and polarity of the components. Since the hydraulic fluid to be removed consists of both polar and non-polar compounds, a solvent system is unlikely to effectively remove all of the components in the hydraulic fluid. For that reason, a mixture of solvents or solvent blend was used to complete the decontamination of the composite. As a measure of solvency, the Kauri-butanol (Kb) values of the pure solvents were first considered before the down-select.
TABLE I
Description of the components of MIL-PRF-83282 hydraulic fluid
Component
Descriptive/Polarity
Poly-alpha-olefin (PAO)
Synthetic Hydrocarbon/NP
Diisooctyl Adipate
Synthetic Ester/P
Tricresyl Phosphate
Phosphate Ester Antiwear Additive/P
Ethanox 4702
Phenolic Antioxidant/P
Benzotriazole
Corrosion Inhibitor/P
Oil Red 235
Oil Soluble Red Dye
To formulate an effective and environmentally-friendly cleaner, the properties of the optimized cleaner must be defined. The properties of the formulated cleaner of this invention are the following: (1) HAP-free (Hazardous Air Pollutant) and low odor; (2) low vapor pressure; (3) free of Ozone-Depleting Substances (ODS); (3) flash point above 140° F. (60° C.); (4) compatible with metals and non-metals; (5) high cleaning efficiency; and safe to use. Based on these criteria, the initial candidates for use in the solvent blend were identified.
Table 2 lists the control materials, the initial materials considered, and the final, optimum formulation along with the properties considered. It should be noted that all solvents considered are HAP-free and ODS-free, while the last five are VOC-exempt.
Composition of the Cleaner Formulation of this Invention (Form 4.2)
PARTS BY WEIGHT
1)
Isopar L Solvent
49
45 to 55 (48 to 50)
(Isoparaffinic Hydrocarbon)
2)
Exxsol D60 Solvent
49
45 to 55 (48 to 50)
(Dearomatized Hydrocarbons)
3)
D-Limonene (Cyclohexene)
2
1.0 to 3.0 (1.5 to 2.5)
4)
Corrosion Inhibitors
0.0 to 3.0
0.0 to 5.0 (1.0 to 3.0)
0.5 to 1.0
PARTS BY WEIGHT
1) Isopar L Solvent 49 45 to 55 (48 to 50)
(Isoparaffinic Hydrocarbon)
2) Exxsol D60 Solvent 49 45 to 55 (48 to 50)
(Dearomatized Hydrocarbons)
3) D-Limonene (Cyclohexene) 2 1.0 to 3.0 (1.5 to 2.5)
4) Corrosion Inhibitors 0.0 to 3.0 0.0 to 5.0 (1.0 to 3.0) 0.5 to 1.0
The corrosion inhibitor is selected from the group consisting of benzimidazole, benzothiazole, benzoxazole, diphenyltriazole, benzotriazole and tolylazole. The cleaning solvents are selected depending on the chemistry of the fiber composites so that the selected solvents will not adversely affect the mechanical or thermal properties of the composite.
Lab Scale Vacuum Assisted Solvent Cleaning (VASC) Process Development
The premise of the VASC process is that a pathway must exist from the outer surface of sandwich structure, i.e. the composite to the interior core cells for the cells to fill with an oleaginous material such as hydraulic fluid. This conduit could be a small crack, hole, or disband between the core and composite skin. This same pathway potentially can be used to inject the solvent or cleaner of this invention into the cells to dissolve the hydraulic fluid followed by flushing the solvent/hydraulic fluid mixture out of the cell. Submerging a hydraulic fluid contaminated sandwich structure in a vat of solvent would not necessarily result in the cleaner reaching all the cells as air pockets could restrict fluid flow. Specifically, the preferred VASC process comprises the following five general steps:
1. Evacuate the composite (via vacuum bag as an example) to remove air from interior honeycomb core cells (30 inches of Hg).
2. Introduce the solvent of this invention to the composite under the sealed vacuum (5 inches of Hg).
3. Mix the solvent with hydraulic fluid by agitation or rotation of composite.
4. Remove the solvent and hydraulic mixture from composite by vacuuming (25 inches of Hg).
5. Remove the composite part from the vacuum and dry in air at about 200° F. for about 24 hours.
By first placing the fiber composite under vacuum, one removes the entrained air in the cracks and cells. If next, the cleaner is introduced into the system, the vacuum would rapidly be replaced by the cleaner up to the interface with the entrained hydraulic fluid. Agitating the composite causes the cleaner to mix/dissolve with the hydraulic fluid. Finally, a partial vacuum is again applied to the composite to evacuate the solvent/hydraulic fluid mixture out of the core cells.
Description of Setup
To test the proposed cleaning approach, a small scale lab set up was assembled utilizing components and materials typically found in a composite processing or repair shop. Aluminum (Al) foil based bagging film (typically used to vacuum bag composite prepreg) is used to construct a vacuum bag around the 6″×6″ honeycomb test pieces. One side of the Al foil has a thermoplastic film which allows the quick formation of a vacuum seal via a heated iron. Teflon tubing (¼″ diameter) is used to produce input and exit ports on the vacuum bag. Two shut-off valves are connected to the input and exit tubing. The exit tubing is connected to a Ventura vacuum pump. A solvent (cleaner) trap is placed between the vacuum pump and the vacuum bag to collect the solvent mixture rinsed through the test article so it does not reach the pump. A simple beaker is used for the solvent source/reservoir.
Vacuum Assisted Solvent Cleaning Procedure (VASC)
Purpose: To remove hydraulic fluid from 6″×6″ sections cut from H-53 Work Platform.
1. The four side faces of the sections were drilled with a ⅛ th inch drill bit to a depth 1.5 inches, 8 times: two holes evenly spaced on each of the four sides.
2. 6″ by 6″ sections were soaked for two weeks in hydraulic fluid.
3. Weights were taken after the fluid was drained and the panel has dried.
4. A piece of 181 fiberglass was cut so that the section is completely wrapped, with one inch extra hanging over on two opposite sides so that vacuum tubes can later be attached.
5. Air Weave N10FR breather cloth next was wrapped around the fiberglass wrapped section, with one inch overhanging on each side so that the input and exit tubes could be installed.
6. The wrapped door was placed on a sheet of envelope bag film, and double sided sealant tape was placed on the envelope bag film around the perimeter of the section.
7. The input tube was placed on the right, with the tube placed near the drilled holes so that the main vacuum suction was in close proximity. In the same way, the exit tube was placed on the left. These tubes were fastened into place by additional sections of double-sided tape.
8. The rest of the envelope bag film was folded over the wrapped section and pressed against the tape so that a sealed off vessel was created.
9. The vessel was attached to the vacuum and was confirmed to be airtight.
10. The vessel was tilted to facilitate the movement of fluids. The tilt was near 45° with the exit tube elevated.
11. 550 mL of rinse solution was measured into a beaker. The open end of the input tube was placed in the beaker so that the vacuum would no longer pull in air, but would now pull the rinse solution through the apparatus via vacuum. A vacuum of 5 inches of Hg was used. Not all 550 mL of solution was injected into the vacuum bag; just enough to fill the bag. The sample was known to be fully immersed in the solution by the saturation of the Air Weave N10FR breather cloth up to the edge of the vacuum bag/exit port. The exact amounts of solution initially injected into the bag, removed from the bag, and that remained in the bag/section are given in Table 14.
12. Once the vacuum bag was filled with cleaner, the exit valve was partially opened and the input valve was closed so that a partial vacuum was held on the section, yet no fluid was moving. This vacuum state was held for 15 minutes so that the rinse solution could dissolve the hydraulic fluid. The pressure was then increased to 25+inches of Hg. Once the pressure was changed, the input and exit valves were both opened so that the rinse solution could be removed. All of the fluid was allowed to drain out in 10 minutes. The process of draining consisted of closing the input valve for enough time to allow the vacuum to build inside the door and then opening the valve so that the built up vacuum would force the fluid into the collecting flask. Tilting the sample towards the exit valve helped remove excess fluid.
13. The flask was removed from the vacuum apparatus and the collected effluent was poured into a separate container. The volumes collected are given in Table 15.
14. The envelope bag was opened and the sample was removed. The envelope bag reseals for minimal spilling of residual effluent.
15. The collecting flask was rinsed out with rinse solution, so any residual hydraulic fluid would not affect the analysis of the next rinse cycle.
16. Isopropyl Alcohol was used to clean off the ends of the tubes so that they would have a clean surface onto which the sealant tape could adhere for the next rinse cycle.
17. The sample was placed upright on a sheet of Air Weave breather cloth and more cleaner/hydraulic fluid mixture drained.
18. This procedure was repeated four times with hydraulic fluid cleaner and four times using NAVSOLVE.
19. After running the collected hydraulic fluid cleaner through an FTIR, the presence of hydraulic fluid was confirmed, and the concentration of hydraulic fluid was shown to decrease from rinse one to four. Note: On the third and fourth NavSolve rinses, it was suggested that the soak time be increased from 15 minutes to 30 minutes. The vacuum was used to keep the NavSolve moving during soak times on these last two rinses.
TABLE 14
Volume Exchanges Using Hydraulic Fluid Cleaner (VASC)
Amount of rinse
solution taken
Amount of solution
Amount left in the
Test #
into the door
recovered from door
envelope bag
Rinse 1
425 mL
365 mL
60 mL
Rinse 2
490 mL
425 mL
65 mL
Rinse 3
450 mL
385 mL
65 mL
Rinse 4
490 mL
440 mL
50 mL
TABLE 15
Volume Exchanges Using NavSolve (VASC)
Amount of rinse
Amount of solution
solution taken
recovered from the
Amount left in the
Test #
into the door
door
envelope bag
Rinse 1
450 mL
405 mL
45 mL
Rinse 2
450 mL
380 mL
70 mL
Rinse 3
500 mL
460 mL
40 mL
Rinse 4
450 mL
405 mL
45 mL
INGREDIENT RESOURCES
Isopar L. Solvent (Isoparaffinic Hydrocarbons)
Exxonmobil Chemical Company
P.O. Box 3272
Houston, Tex. 77253-3272
Exxsol D60 Solvent (Dearomatized Hydrocarbons)
Exxonmobil Chemical Company
P.O. Box 3272
Houston, Tex. 77253-3272
D-Limonene (Cyclohexene C 10 H 16 ), 1-methyl-4-(1-methylethenyl)
Florida Chemical Company
351 Winter Haven Blvd., NE
Winter Haven, Fla. 33881-9432
Properties of the Hydraulic Fluid Cleaner
The cleaning efficiency test results for the formulation of this invention (Formula 4.2) and the effect of the inventive formulation on the mechanical properties of fiber composites are shown in Table 2.
Cleaning Efficiency
The neat and formulated solvents were screened to be able to meet several initial criteria before being subjected to the more-intensive material compatibility testing. These initial criteria were prioritized because they pertain to assuring the suitability of the cleaner and, the ability to effectively and efficiently decontaminate the surface. The selected solvents and formulations for testing and evaluation which include solvent ingredients (Base series), formulation blends (Form series) and control solvents (Hexane and MIBK) are listed in Table 3.
TABLE 2
Testing results of the new hydraulic fluid cleaner formulation (Form 4.2)
compared to the current cleaners (controls)
New For-
Test
Hexane
MIBK
mulation
TEST
method
(Control)
(Control)
(Form 4.2)
Cleaning Efficiency
Gravimetric
MIL-PRF-
92.2%
98.7%
96.2%
Immersion Cleaning
32295A
(%)
Wipe Cleaning
FT-IR
3 Cycles
5 Cycles
2 Cycles
(Cycle)
Composite
MIL-PRF-
94.8%
97.1%
99.5%
Immersion Cleaning
32295A
(%)
Flash Point (F.)
ASTM D93
−15 F.
57 F.
141 F.
Drying Time at 120 F.
MIL-PRF-
1
1
4
(10 minutes/Cycle
32295A
Residual Surface
Contaminants
Tape Peel Adhesion
ASTM
10.01
11.38
10.48
Test
D3330M02
(lb ft/in)
Compression Lap
ASTM
N/A
N/A
6580 psi
shear Testing,
D3846
sanded panels
(psi)
Material Compatibility
Flexural Strength
ASTM
136.5 ksi
139.7 ksi
136.8 ksi
Testing, three
D790
weeks exposure
(ksi)
Short Beam Shear
ASTM
7.3 ksi
7.6 ksi
7.2 ksi
Strength Testing,
D2344
three weeks
exposure
(ksi)
TABLE 3
Selected Solvents and Blended Formulations for Testing and Evaluation
Condition
Flash Point (° F.)
Hydraulic Fluid
40l
Hexane
−15
MIBK
57
Base 2
144
Form 2.1
NA
Base 3
143
Form 3.1
NA
Form 4.1
NA
Form 4.2
141
The IM7/977-3 structural composite system was chosen for this study as it is the main aerospace grade composite material utilized in both primary and secondary structure on several naval aircraft such as the F/A-18 and F-35. IM7/977-3, the composite is composed of graphite-fiber reinforcements (IM7) in a toughened epoxy-based polymer matrix (977-3). To measure the effectiveness of the developed formulations, three cleaning techniques were used for removing hydraulic fluid from composite materials as described herein.
Method 1—Gravimetric Immersion Cleaning
Previous experience investigating a test method to measure cleaning efficiency of low-VOC and VOC-exempt solvents to remove a number of soils led to the inclusion of a solvent immersion test method in the MIL-PRF-32295A specification. In this method, polished stainless steel coupons (1×2×0.05 inch) are weighed, coated on one sided with 20-25 mg of soil, and re-weighed. Stained coupons are cyclically immersed and withdrawn from a 150-ml beaker containing 100 ml of the solvent at a rate of 20 cycles per minute for 5 minutes. The coupons are flash-dried at 140° F. (60° C.) for 5 minutes to prevent excess soil from being removed by gravity, cooled to room temperature, and re-weighed. Cleaning efficiency is determined gravimetrically as an average of three coupons in the same soil. This method is preferred because it produces reproducible results and allows a number of samples to be averaged to determine cleaning efficiency. Method 1 cleaning efficiency results are presented in Table 4.
TABLE 4
Results of Method 1 Immersion Cleaning Testing
Cleaning Efficiency
Solvent
(%)
St. Dev.
Hexane
92.2
1.8
MIBK
98.7
0.4
Base
97.5
0.4
Base 2
94.4
0.8
Form 2.1
94.2
0.8
Form 2.2
93.4
0.6
Base 3
95.9
0.3
Form 3.1
98.1
0.4
Form 3.2
95.8
0.7
Form 4.1
96.7
0.5
Form 4.2
96.2
0.5
Form 4.3
95.3
0.5
Method 2—Wipe (Swab) Cleaning
The wipe (swab) cleaning procedure for removing hydraulic fluid from composite material was developed by Tillman and Boswell in a previous study. The cleaning efficiency was evaluated based on the number of cotton swab wipe cycles needed to remove the entirety of the fluid contamination from the composite surface. In this method, 6×2×0.037 inch panels of IM7/977-3 are immersed in a beaker containing MIL-Prf-83282 hydraulic fluid for two weeks. Panels are removed, lightly wiped with Tech Wipe tissues, and hang-dried to the perpendicular for 24 hours at ambient temperature. Upon verification of hydraulic fluid presence by visual inspection, panels are cleaned by depositing 0.3 ml of solvent onto a cotton swab, cleaning a 1×1 inch area of the contaminated composite by wiping six times in one direction, and wringing the swab out into a glass vial. The surface is wiped, and the residue is deposited into the vial twice more. Three wipes with the same swab constitute one wash cycle. The solvent wrung-out from the swab is deposited onto a Potassium bromide salt plate and dried at 104° F. (40° C.) at 2 psi for 15 minutes. The salt disc is analyzed via infrared spectroscopy to indicate the presence of the hydraulic fluid residue on the surface. Additional cleaning cycles are performed until the infrared spectra show no hydraulic fluid presence.
FT-IR is the analytical tool of choice to detect trace residual hydraulic fluid. A Nicolet model 550 Magna Ft-IR spectrometer was used with data collection by transmission through the sample deposited on the potassium bromide disc. All FT-IR background and sample spectra were collected using 32 scans with a special resolution of cm −1 . FIG. 1 shows the spectra for the contaminant hydraulic fluid (top) and a representative hydrocarbon solvent. The absorption at 1710-1740 cm −1 range was identified as a differentiator between contaminant and solvent; this peak corresponds to the carbonyl stretching vibration from the dibasic ester in the MIL-PRF-83282 hydraulic fluid. FIG. 2 shows the decrease in peak height for successive cleaning cycles. This cleaning method is preferred because it is a better representation of the actual decontamination scenario, being fluid removal from composite material as opposed to stainless steel. Method 2 cleaning efficiency results are presented in Table 5.
TABLE 5
Results of Method 2 Cleaning Efficiency Testing
Solvent
Trials
Hexane
3
MIBK
5
Base 2
3
Form 2.1
3
Base 3
3
Form 3.1
3
Form 4.1
2
Form 4.2
2
Method 3—Composite Immersion Cleaning
In order to incorporate the benefits of the two existing test methods, the MIL-PRF-32295A cleaning efficiency procedure was modified to use IM7/977-3 composite panels. Other than the panel material, the only difference between this procedure and the MIL-PRF-32295A procedure is that the panels were dried at 248° F. (120° C.) and cooled to ambient immediately before using to ensure that all absorbed moisture had been driven off. Method 3 cleaning efficiency results are presented in Table 6.
TABLE 6
Results of Method 3 Cleaning Efficiency Testing
Cleaning
Efficiency
Solvent
(%)
StDev
Hexane
94.8
0.3
MIBK
97.1
0.3
Base 2
96.9
0.2
Form 2.1
97.1
0.3
Base 3
99.1
0.1
Form 3.1
99.1
0.3
Form 4.1
98.9
0.1
Form 4.2
99.5
0.3
Flash Point
To give indication that the flash points of developed solvents exceeded the NFPA 30 Class III lower limit of 140° F. (60° C.), testing was completed using Procedure B and a manual apparatus. The flash point for the optimized cleaner (formulation 4.2) was measured in accordance with ASTM D93 method and found as 141° F. degree.
Drying Time
Drying times for selected solvents were measured in accordance with MIL-PRF-32295A specification. One gram of solvent placed in an Aluminum weighing dish of 2 inch (5 cm) diameter and 0.6 inch (1.5 cm) depth and heated in an oven at 120° F. (49° C.) in 10-minute increments. After each increment, the dish was removed from the oven, cooled to ambient, weighed and re-placed in the oven. This procedure continued until the weight of the dish returned to its original weight, indicating that the solvent had dried off completely. Results for the drying time study are presented in Table 7.
TABLE 7
Results of Drying Time Testing
Dry
Solvent
Cycles a
Hexane
1
MIBK
1
Base 2
3
Form 2.1
4
Base 3
5
Form 3.1
5
Form 4.1
4
Form 4.2
4
a Dry cycles is defined as the number of 10-minute heating cycles at 120° F. (49° C.) required to evaporate all solvent from the tray
Residual Surface Contaminants
Tape Peel Adhesion Testing
Tape peel adhesion tests were performed in accordance with ASTM D 3330M-02
Method A to determine if the new solvent formulations deposited any residual surface contaminates on composite laminates after cleaning which might degrade bond strength. The performance of the new solvent formulations was compared to several currently utilized solvents (see Table 3). Both unexposed and hydraulic fluid saturated composite specimens were also tested as baseline controls. IM7/977-3 composite specimens were immersed in the cleaning fluids under test for 1 week at room temperature, removed, and dry-wiped once. The average results of these studies for each solvent are shown in Table 8.
TABLE 8
Results of Peel Strength Testing after Condition Exposure
Condition
Peel Strength (lb ft/in)
StDev
No Exposure
10.62
0.77
Hydraulic Fluid
2.50
0.42
Hexane
10.01
0.78
MIBK
11.38
0.19
Base 2
9.74
0.61
Form 2.1
10.04
0.68
Base 3
10.19
0.40
Form 3.1
9.89
0.49
Form 4.1
10.68
0.33
Form 4.2
10.48
0.42
Compression Lap Shear (CLS) Testing
The preliminary Compression Lap Shear results are shown in Table 9. Compared to the baseline IM7/977-3 panels which were not cleaned with Form 4.2, the cleaned panels which were not cleaned with Form 4.2, the cleaned panels showed significantly higher shear strengths. This was the case even for the unsanded sample compared to the baseline sanded specimen. The results indicate that Form 4.2 not only left no contamination residuals that would degrade the bond-line, but also increased the bond strength and decreased the measurement scatter compared to the controls.
TABLE 9
Results for Compression Lap Shear Testing
Condition
Bond Strength (psi)
StDev
Unsanded
6580
300
Sanded
6980
370
Un-Sanded, Cleaned
7467
83
Sanded, Cleaned
7515
73
Material Compatibility
Preliminary flexural strength and short beam shear tests were performed on IM7/977-3 specimens exposed to the new solvent formulations to demonstrate the mixtures do not degrade the mechanical properties of this specific composite material system. The flexural strength test was chosen as this measurement is sensitive to surface ply degradation. The 3-point bending moment during the test induces large in-plane compressive and tensile loads in the outer surfaces of the specimen. As such, the test is sensitive to any surface localized mechanical property knockdowns induced by the composites exposure to hydraulic fluid or cleaners. The short beam shear test was chosen as it is simple method for evaluating resin dominated, bulk property knockdowns in a composite laminate.
Flexural Strength Testing
The flexural strength properties of IM7/977-3 composite after exposure to the new solvent formulations were determined in accordance with ASTM D790. The solvent formulations evaluated are listed in Table 3. The composite test specimens were first conditioned by soaking in MIL-PRF-83282 hydraulic fluid for 1-week and 3-week periods followed by exposure to the test solvents for one hour. A solvent soak of one-hour was chosen as the maximum exposure time the composite would encounter in the field. This time was chosen as the next step in the part cleaning step is vacuum bagging and application of heat which will remove and residual solvent trapped in the composite. Five specimens at each condition were run for ASTM D790. The results of the Flexural Strength Testing are shown in Table 10.
TABLE 10 Results of Flexural Strength Testing Soak No Solvent Hexane MIBK Form 3.1 Form 4.1 Form 4.2 Time ksi S.D. ksi S.D. ksi S.D. ksi S.D. ksi S.D. ksi S.D. None 132.4 9.1 136.7 7.9 137.6 9.3 137.1 5.3 138.4 6.5 138.2 6.1 1 Week 142.2 5.6 143.4 7.4 142.6 4.0 138.1 11.7 141.7 3.9 137.4 5.1 3 Weeks 135.2 6.5 136.5 6.7 139.7 5.8 133.0 7.0 138.9 3.8 136.8 8.4
Short Beam Shear Strength Testing
The short beam shear (SBS) properties of im7/9977-3 composite after exposure to the new solvent formulations were determined in accordance with ASTM D2344 (13). The composite test specimens were conditioned the same as described in Section 2.6.1 above. Ten SBS specimens were tested for each exposure condition. The results of the short beam shear strength testing are shown in Table 11.
TABLE 11
Results of Short Beam Shear Strength Testing
Soak
No Solvent
Hexane
MIBK
Form 3.1
Form 4.1
Form 4.2
Time
ksi
S.D.
ksi
S.D.
ksi
S.D.
ksi
S.D.
ksi
S.D.
ksi
S.D.
None
7.7
0.9
8.3
1.1
7.3
0.5
7.4
0.4
7.6
0.3
7.7
0.8
1 Week
7.3
0.7
7.6
0.6
7.8
0.7
7.1
0.3
7.58
0.7
7.5
0.4
3 Weeks
7.8
0.8
7.3
0.5
7.6
0.5
7.2
0.4
7.5
0.5
7.2
0.3
This research was focused on developing an effective, safe, and environmentally friendly non-aqueous solvent cleaner to remove oleaginous materials such as hydraulic fluid from composite materials. Several formulations were developed from selected aliphatic, aromatic, oxygenated, fluorinated, and silanated solvents to meet the established properties and usage requirements of a “green” cleaning solution. The required properties include the following HAP-free, ODS-free, non-carcinogenic, high solvency, high flash point, low vapor pressure, and compatible with metals and non-metals.
Using multiple techniques, the cleaning efficiency of the optimized formulation (Formulation 4.2) was measured and found to be more effective than the control solvents (hexane and MIBK) currently authorized for use in the Navy maintenance depots. The effects of non-volatile residue on both room and elevated temperature composite-adhesive bonding were evaluated by the adhesive peel and compression lap shear tests. These preliminary results on the IM7/977-3 composite system indicate the lab formulations leave no contamination residue on the composite surface that degrades peel and lap shear strengths. This indicates that, while the formulated solvent dries slower than the two solvents currently in use, it does not present a contamination issue at the bond-line. The fluid sensitivity of the down-selected Form 4.2 formulation on IM7/977-3 mechanical properties was also evaluated. Preliminary flexural strength and short beam shear tests on IM7/977-3 specimens exposed to from 4.2 find no knockdown in these properties.
Future use of the 4.2 cleaner of this invention will permit compliance with current environmental regulations on cleaning solvents and will provide a user-friendly and more efficient cleaning solution for removal of oleaginous materials such as hydraulic fluid contamination from fiber composites. In addition, the solvent of this invention does not adversely affect the mechanical or the thermal properties of the composite and, as the cost to replace a composite part is ten times the cost to repair, the ability to more efficiently remove hydraulic fluid from these components and thus lower the bonded repair scrap rate would have a significant impact on Navy sustainment costs.
While a preferred embodiment of the invention has been described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the invention. The appended claims are therefore intended to cover changes and modifications that fall within the scope of the claimed invention.
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A non-aqueous solvent composition and method for cleaning and removing oleaginous materials such as hydraulic fluids from reinforced-fiber composites characterized as a cleaning composition free of ozone depletion materials, having a low vapor pressure, a flash point above 140° F., and consists essentially of cyclohexenes, isoparaffinic hydrocarbons, dearomatized hydrocarbons and corrosion inhibitors.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to improvements in methods for providing a smooth transition from open-loop step-up of a system frequency to closed-loop phase-locked loop (PLL) control by synchronization of the voltage-controlled oscillator (VCO) when the open-loop frequency is within pull-in range, and to circuits for accomplishing the same.
2. Description of the Prior Art
Although the present invention pertains to voltage controlled oscillator (VCO) synchronization of phase-locked loop (PLL) systems in general, it finds particular application in conjunction with polyphase DC motors, particularly of the brushless, sensorless, three-phase type used for rotating data media, such as are found in computer-related applications, such as hard disc drives, CD ROM drives, floppy disc drives, and the like. In such computer applications, three-phase, brushless, sensorless DC motors are becoming more popular, due to their reliability, low weight, and accuracy.
Brushless DC motors are commonly driven by a speed-controller that utilizes two functional loops: an overall speed-control loop, typically a PLL circuit, and a phase switching loop. A typical prior art motor speed-controller 10 is shown in FIG. 1. The outer speed control loop 13 has a phase comparator 11 that compares a reference frequency, F REF , applied to an input line 14 with a signal developed by a signal processor 20 from the stator windings of a motor 19. The phase difference signal developed by the phase comparator 11 is filtered by a filter 12 to drive switch logic circuitry 15, which in turn drives the motor 19 via appropriate drive circuitry 16. The outer speed control loop 13 ensures that the desired motor speed, set by the reference frequency, F REF , on a line 14, is maintained. The phase switching inner loop 17 generates a timing signal that is sent to the switch logic circuit 15 to time the commutations in the stator coils 21 that drive the motor 19. In order to properly time the commutations in the circuit 19, however, the exact position of the rotor 18 must be determined. In the past, sensors, such as Hall or optical sensors, have been used to determine the position of the rotor. A more recent approach uses back emf information derived from selected ones of the stator coils 21 of the motor 19 to determine the location of the rotor 18. In such approach, as the magnetic rotor 18 passes a "floating" stator coil, it acts as a generator in regard to the coil and impresses an electromotive force or "back emf" on the coil. The back emf signal is processed and routed to the switching logic system to obtain the correct phase-switching. The back emf detection information not only enables the position of the rotor 18 to be determined, but the speed of the motor 21, as well. This motor speed information is fed back to the phase-comparator 11 of the outer speed-control loop 13 to maintain the desired motor operating speed.
The inner phase-switching loop 17 can be implemented in several ways. As mentioned, the clock signal for phase-switching in the inner loop may be provided by filtering the back emf of the motor 19 and extracting timing information with a signal processor 20. This involves determining the "zero-crossing" of the back emf, and using delays to control the timing of the switching.
A more sophisticated approach shown in FIG. 2 is similar to that of U.S. Pat. No. 4,928,043, and uses a phase-locked loop (PLL) 35 to phase-track the back emf, in place of the signal processor 20. The phase-locked loop 35 includes a filter 32 connected to receive a signal derived from the back emf generated by the rotor 18 of the motor 19, to produce an output to a phase comparator 34. The phase comparator 34 compares the back emf signal with a desired phase signal (not shown) and produces an output to a second filter 36 to provide an error voltage to a voltage controlled oscillator (VCO) 38. In this approach, the back emf is used as an input to the PLL 35, and the output of the PLL 35 is fed to the phase-switching logic circuitry 15. In this way, the phase-switching logic circuitry 15 is synchronized to the back emf. This configuration offers better performance, since it reduces "phase-jitter", rapid, uncontrolled rotor movements due to imprecisely-timed phase-switching. The drawback of this approach is that at low motor speeds that occur when the motor 19 is first starting, the back emf signal is not of sufficient magnitude to drive the loop. In addition, as with any PLL loop, "lock" can be established in only a limited range of frequencies, and therefore during most of the start-up phase, the switching frequency is outside (lower than) the "lock"range. Thus, the motor 19 is generally ramped-up to speed open-loop, with the timing signal to the switching logic being provided by an external clock. The desired final operating state is a closed-loop mode in which the clock to the phase-switching is provided by a voltage-controlled oscillator (VCO) 38. What is needed is a way to produce a transition from open-loop operation to closed-loop operation without significant error in the switching timing that makes the loop incapable of locking and which may consequently stall the motor.
SUMMARY OF THE INVENTION
It is, therefore, an object of the invention to provide an improved circuit and method to provide a smooth transition from open-loop step-up of a system frequency to closed-loop PLL operation by synchronization of a VCO to the open-loop frequency when that frequency is within pull-in range.
It is another object of the invention to provide an improved apparatus and method of the type described to be used for starting DC motors, particularly of the brushless, sensorless type that are used for rotating data media, such as are found in computer-related applications, including hard disc drives, CD ROM drives, floppy disc drives, and the like.
It is still another object of the invention to provide an improved apparatus and method of the type described that enables a smooth transition from open-loop motor operation to closed-loop operation without a significant error in the sequence of the switching timing that would make the loop incapable of locking and would stall the motor.
These and other objects, features and advantages of the invention will be apparent to those skilled in the art from the following detailed description of the invention, when read in conjunction with the accompanying drawings and appended claims.
In accordance with a broad aspect of the invention, a circuit is presented for starting a polyphase motor. The circuit includes circuitry for initially applying clock pulses of successively decreasing periods to the motor on startup, and a phase-locked loop including a voltage controlled oscillator having an input connected to re-initiate an output of the voltage controlled oscillator in response to the clock pulses of the source of clock pulses during startup. Means are provided for operating the voltage controlled oscillator to produce an output having a fixed period during startup, and a period comparator compares the period of the clock pulses to the period of the output of the voltage controlled oscillator. Circuitry is provided for switching the output of the voltage controlled oscillator to drive the motor when the period of the clock pulses equals the period of the output of the voltage controlled oscillator. In a preferred embodiment, the entire circuit is implemented as a single integrated-circuit device.
In accordance with another broad aspect of the invention, a circuit is provided for switching the output of a phase-locked loop to provide drive signals to an external load when clock signal of successively decreasing periods reach a predetermined period. The circuit includes an oscillator for generating a signal of initial fixed frequency. A period comparator compares a period of the signal of initial fixed frequency to a period of the clock signal, and the clock signal is connected to continually reset the oscillator until the period comparator indicates that the period of the signal of initial fixed frequency exceeds the period of the clock signal. A first switch circuit switches from the clock signal to said oscillator output as the drive signals when the period comparator indicates that the period of the signal of fixed initial frequency exceeds the period of the clock signal. In one embodiment, a circuit generates a feedback signal having a phase indicating a condition of the external load; for example, the external load can be a polyphase dc motor, and the circuit for generating a feedback signal can be a circuit for generating a signal related to the back emf induced in a floating coil of said motor. In such case, the phase-locked loop can include a phase comparator to compare a phase of the feedback signal with a load condition related signal and a second switch circuit can be provided for switching an output of said phase comparator to control the frequency of said oscillator when said period comparator indicates that the period of said signal of initial fixed frequency exceeds the period of said clock signal.
In accordance with yet another broad aspect of the invention, a method of synchronizing a phase-locked loop to external pulses of successively decreasing period is presented. In accordance to the method, a VCO of the phase-locked loop is operated to generate a plurality of pulses having a reference period. The pulses of the VCO are synchronized to the external pulses until the period of the external pulses are less than the reference period, and when the period of the external pulses becomes equal to the reference period, the phase-locked loop is switched to control the VCO.
The external pulses are directed to an output to drive a load until the period of the external pulses becomes equal to the reference period, and thereafter the output of the VCO of the phase-locked loop is provided. In addition, a status signal is generated in response to a condition of the load, and a phase difference is determined between the status signal and the VCO. The phase-locked loop is then operated in accordance with the phase difference. The status signal can be generated from a signal from a back emf of a floating coil of a polyphase motor that indicates the position of a rotor of the motor, and the signal from a back emf of a floating coil can be used as an input to the phase-locked loop.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated in the accompanying drawings, in which:
FIG. 1 is an electrical block diagram of a typical prior art motor speed control system, incorporating an outer motor speed-control loop and an inner phase-switching loop.
FIG. 2 is an electrical block diagram of a typical prior art motor speed control system, incorporating an outer motor speed-control loop and an inner loop for phase-switching that utilizes a PLL circuit.
FIG. 3 is an electrical block diagram of an inner loop for phase-switching in a motor driving system incorporating a motor starter system incorporating a VCO synchronization system in accordance with a preferred embodiment of the invention. The arrow notations in the switches indicate the change from open-loop mode to closed-loop mode.
FIG. 4 is an electrical schematic diagram of a preferred embodiment of the period comparator shown in FIG. 3.
In the various figures of the drawing, like reference numerals are used to denote like or similar parts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention has many applications, particularly in motor controllers where the initial ramp-up of the motor speed is obtained in an open-loop configuration but the final speed of the motor is controlled by a PLL circuit. As noted previously motor-controllers of the prior art include the general idea of using an overall speed-control loop and an inner phase-switching loop. The prior art also includes the use of filtered back emf as a basis for phase-switching in the inner loop and the use of a PLL in the inner-loop to synchronize the switching clock to the back emf signal. The inner phase-switching loop is the part of the system wherein the subject invention is implemented.
In contrast to the prior art, schematic block diagram of an inner phase-switching loop 40 in which the apparatus and method in accordance with a preferred embodiment of the invention may be incorporated is shown in FIG. 3. Although the switching loop 40 can be constructed of discrete components, preferably the circuit is integrated onto a single semiconductor chip (denoted by the dotted line 41) adapted for connection into an overall motor-starting and speed-control system.
As noted before, this system achieves a smooth transition between the open-loop motor-starting phase and closed-loop control. When the system is started, the open-loop phase begins during which the motor switching clock 64 is supplied by an external clock, EXT CLK, on a line 58 via a switch 60. The EXT CLK signal 61 on the line 58 begins at zero frequency and is gradually increased in a linear fashion to not quickly escape the capture-range of the VCO 52 before it can be locked-onto. This slow ramp-up is also necessary because motors have a limited capability for acceleration. Also, at the beginning, the reference voltage (V REF ) applied to a line 46 is placed on the input to the voltage-controlled oscillator (VCO) 52. V REF is the voltage necessary to set the output of the VCO 52 at the "switch over" frequency preselected by the user to be within the pull-in range of the PLL system. By way of example, the switches 47, 54, and 60 discussed above may be realized by any number of devices including mechanical switching devices and multiplexers implemented on integrated-circuit devices. Similarly, the VCO 52 may be realized by any number of devices, including properly set-up 555-timer integrated-circuits or any of several different analog implementations.
The filter 50 is preferably a proportional integral filter, in order to minimize phase error. Since an integrating filter is used, the integrating capacitor must be maintained discharged so as to know exactly the output voltage. Such a clamping may be effected within the filter itself.
As mentioned previously, the VCO 52 is part of the PLL system 40 and will provide the motor switching clock signal on the line 64 after the switch over point is reached. During the open-loop startup phase of operation, the switch 54 assists in synchronizing the VCO 52 to the EXT CLK signal on the line 58 by routing the EXT CLK signal pulses via line 53 to the SYNC input of the VCO 52 to cause the output of the VCO 52 to restart on each pulse of the EXT CLK signal. The restarting of the VCO 52, for example, can be achieved in a manner similar to the reset function provided on a standard 555 timer chip, and serves to synchronize the output of the VCO 52 with the EXT CLK signal, enabling smooth transition on switch over after startup as described below.
The EXT CLK signal also goes to the switch logic via the switch 60 and to the period comparator 62 so that its period may be compared to the period of the VCO 52 output that was set at the switch over frequency. When the EXT CLK signal to the motor 19 reaches a lower period (i.e., higher frequency) than the VCO 52 output frequency, the switch over will occur. At that point the period comparator 62 will trigger the switch over to closed-loop mode by signaling switch 54 to switch the synchronizing input of the VCO 52 from the EXT CLK signal to a reference potential 56, typically ground, by signaling the switch 48 to switch the input of the VCO 52 from V REF on line 46 to the output of the phase comparator 44, and by switching the output of the phase-switching loop 40 (i.e., input to the switching logic) from the EXT CLK signal to the output of the VCO 52. By switching the SYNC input from the EXT CLK signal to the reference potential, the synchronizing of the VCO 52 to the EXT CLK signal is halted, to enable the VCO 52 to run at the desired final speed. In closed-loop operation, the back 42 emf signal produced by bemf processing 65 onto the line 42 from the motor 19 is compared with the output of the VCO 52 by the phase comparator 44. This speeds up the output of the VCO 52 when a phase difference occurs between the back emf on the line 42 and the VCO 52 output. In this fashion, the PLL loop produces a motor switching clock signal on the line 64 that tracks the back emf signal on the line 42.
Thus, a smooth transition to closed-loop operation is achieved. This phase-switching circuit 40 minimizes "jolt" in the motor 19 because the frequency and phase of the VCO 52 is synchronized to the exterior clock signal on line 58. This is important because if the first pulse from the VCO 52 after the switch over is out of phase or is not frequency synchronized with the preceding EXT CLK pulse then the lock on the motor 19 will be lost.
Thus, demanding phase and frequency requirements are placed on this type of circuit. In other applications, if the VCO is inserted with a phase error, the loop will adjust with time. However, in a motor application if the lock is missed the motor 19 must be slowed down to zero speed and restarted. It will be appreciated that acquiring lock-on may be difficult if a phase error is introduced due to motor inertia and erroneous torque generation. It is therefore desirable to get a correct phase-lock-on the first time, as achieved by the phase-switching circuit 40.
The period comparator 62 may be implemented by any number of "off the shelf" devices, including integrated-circuits that have been specially designed for comparing the period of various signals and that are widely available for such applications. FIG. 4 is a block diagram of one particular embodiment of the period comparator 62 that is shown in FIG. 3. This device utilizes three D-type flip-flops 72, 76, and 78, and waits for two consecutive positive edges of pulses from the EXT CLK 58 to occur before a second positive edge of a VCO 52 pulse occurs to determine whether the frequency of the EXT CL signal has exceeded the VCO 52 output frequency on a line 55. Since the VCO 52 will initially be oscillating faster than the EXT CLK signal the first pulse the period comparator 62 will receive will be from the VCO 52.
Referring to FIG. 4, the output from the VCO 52 will clock the first D flip-flop 72, causing a low state at its Q(bar) output. When a positive edge of an EXT CLK pulse occurs, it resets the first flip-flop 72 while simultaneously clocking the second flip-flop 76. Due to the propagation delay of the first flip-flop 72, the low state that was present at its Q(bar) output will be clocked into the D input of the second flip-flop 76 before the reset of the first flip-flop 72 occurs. Therefore, this low state will be clocked through the second flip-flop 76. Soon thereafter, the Q(bar) output of the first flip-flop 72 changes to a high state, since it was reset. If another positive edge of an EXT CLK pulse occurs before a positive edge of a pulse from the VCO 52 occurs, then the Q(bar) output of the first flip-flop 72 remains high because of the reset. This second EXT CLK pulse will clock a high state to the Q output of the second flip-flop 76. The falling edge of the EXT CLK pulse, inverted by the invertor 80, will clock the high state from the Q output of the second flip-flop 76 through the third flip-flop 78 to its Q output regardless of the state of the VCO output 55.
Thus, the circuit 62 looks for two positive pulse edges from the EXT CLK signal before the completion of a VCO 52 cycle (i.e., two adjacent positive pulse edges), and when this occurs signals the switches 48, 54, and 60 in the circuit 40 to change states as indicated by the arrows in FIG. 3. It will be appreciated that the third flip-flop 78 is not strictly necessary to the determination of when the frequency of the EXT CLK signal exceeds the output frequency of said VCO 52 since the desired output was generated on the Q output of the second flip-flop 76 upon receipt of the second rising edge of the EXT CLK signal. In many implementations the phase-switching circuitry 40 will work without the third flip-flop 78, but in the implementation illustrated, the switch over signal is delayed by the length of the EXT CLK pulse signal to give a slower analog VCO 52 time to begin operation.
Although the invention has been described and illustrated with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the combination and arrangement of parts can be resorted to by those skilled in the art without departing from the spirit and scope of the invention, as hereinafter claimed.
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Synchronization of the output of an internally-driven VCO to an exterior clock signal is obtained by using the exterior clock signal to re-start the VCO at every exterior clock pulse, until the pre-set VCO frequency is reached. At that point, the restarting of the VCO ceases, and the VCO locks onto the internal signal it is designed to track. One application of this circuit is for enabling a smooth transition between open-loop, ramp-up of a polyphase DC motor to closed loop operation. Implementation of the circuit described phase-synchronizes the output of a phase-switching PLL loop, which is tracking the back emf of the motor, to the external clock used for motor ramp-up, so that there is no "jolt" in the motor at the transition from open-loop to closed-loop operation of the motor.
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TECHNICAL FIELD
The present invention relates to a hydraulic brake systems and more particularly relates to traction control systems.
BACKGROUND OF THE INVENTION
A brake system of this type is disclosed in Japanese patent application No. 94-171487. The brake system concerned is an anti-lock brake system which, in contrast to conventional brake systems operating according to the recirculation principle, includes neither a low-pressure accumulator nor outlet valves in the return lines from the wheel brakes to the suction side of the return pump. To produce a dynamic pressure in the wheel brakes, the return lines have only restrictors which produce a pressure gradient between the wheel brakes and the suction side of the return pump. The pressure in the wheel brakes is reduced by closing the inlet valves in the brake branch lines to the wheel brakes so that the pump pressure will not reach the wheel brakes. The braking pressure is decreased because the pressure fluid is permanently discharged from the wheel brakes.
An object of the present invention is to retrofit a brake system of this type for traction slip control by minimum possible additional effort, i.e., the least number of electric lines the minimal additional logic structure for valves.
Thus, the present invention permits a brake system in vehicles with one driven axle to perform traction slip control operations by at most four additional solenoid valves. Only the driven wheels require an outlet valve which permits a sufficient braking pressure increase by the return pump alone. There is no need for a low-pressure accumulator in traction slip control. When three individual two-way/two-position directional control valves are chosen, alternatively, either the change-over valve in the suction line to the return pump or the separating valve in the brake line, or both these valves can be operated hydraulically. Solenoid valves are preferably used as outlet valves in order that an amount of braking pressure can be increased or decreased in the wheel brakes in conformity with requirements. When the change-over valve and the separating valve are united in a combination valve, the combination valve can either be actuated electromagnetically and, thus, necessitate the second actuation logic beside the outlet valve, or it can be configured as a hydraulically operated combination valve, thus obviating the need for further actuation and electric lines.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a brake circuit of a brake system according to the present invention.
FIG. 2 is a hydraulically operated separating valve assembly which can replace the electromagnetically operated separating valve assembly of FIG. 1 .
FIG. 3 is a hydraulically operated change-over valve which is closed in its unpressurized state and may replace the change-over valve in FIG. 1 which is open in its unpressurized state.
FIG. 4 is a combination valve which combines the function of a separating valve and a change-over valve according to FIG. 1 .
FIG. 5 is a hydraulically operated combination valve.
FIG. 6 is an outlet valve combination which can replace the normally closed outlet valve of the FIG. 1 embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The brake system of the FIG. 1 embodiment includes a master cylinder 1 which is connected to a supply reservoir 2 and is operable by a brake pedal 3 . Two brake circuits I and II extend from the master cylinder 1 . The brake circuits I and II are identical in design so that the illustration of brake circuit I is similarly applicable to brake circuit II (not shown). The return pumps of both brake circuits can be driven by one joint motor.
A brake line 4 extends from the master cylinder 1 via two brake circuits 7 and 8 to a wheel brake 5 or 6 , respectively. Inserted into brake line 4 is a separating valve 9 which is configured as a normally open, electromagnetically operated two-way/two-position directional control valve. The brake branch line 7 to the wheel brake 5 branches from the brake line 4 at an intersection 10 between the master cylinder 1 and the separating valve 9 . Brake branch line 8 to the wheel brake 6 branches from an intersection 11 which is positioned at the end of the brake line 4 , i.e., beyond the separating valve 9 as viewed from the master cylinder 1 .
An inlet valve 12 or 13 which is a normally open solenoid valve is respectively inserted into the brake branch lines 7 and 8 . A return line 14 or 15 leads from each of the wheel brakes 5 and 6 to the suction side of a self-priming return pump 16 . Beside the return lines 14 and 15 , the suction side of the return pump 16 is still connected to the brake line 4 between master cylinder 1 and separating valve 9 by way of a suction line 17 . The suction line 17 is closable by a hydraulically operated, normally open two-way/two-position change-over valve 18 . Valve 18 is closed by the prevailing master cylinder pressure.
The pressure side of the return pump 16 is connected to the brake line by way of a pressure line 22 in the intersection 11 .
The return line 14 of the wheel brake 5 does not have a solenoid valve but only a restrictor 19 and a non-return valve 20 which closes in the direction of the wheel brake 5 . An electromagnetically operated, normally closed outlet valve 21 is interposed in the return line 15 of the wheel brake 6 . During anti-lock control operations, the restrictor 19 and the non-return valve 20 provide a sufficient amount of dynamic pressure in the wheel brake 5 . In wheel brake 6 , braking pressure is generated and maintained because the outlet valve 21 is closed.
A non-return valve 23 and a pressure-relief valve 24 are connected in parallel to the separating valve 9 . The non-return valve 23 permits a pressure fluid flow from the master cylinder 1 to the wheel brake 6 , and the pressure-relief valve 24 opens in the presence of an excessive pressure in the brake branch line 8 .
The brake circuit I shown is taken from a brake system with a diagonal brake circuit split-up. This means that traction slip control operations with only one driven axle require active braking intervention into respectively one wheel brake of each brake circuit. In this case, the wheel brake 6 is associated with a driven wheel, and wheel brake 5 is associated with a non-driven wheel. Accordingly, only the wheel brake 6 of the driven wheel is isolated from the master cylinder 1 when the separating valve 9 is closed. Wheel brake 5 of the non-driven wheel remains permanently connected to the master cylinder 1 . However, active braking pressure build-up, (without application of the brake pedal only) by means of the supply pressure of the return pump 16 , is necessary only in the wheel brake 6 . Where the objective is to perform active braking intervention in the wheel brake 5 as well, be it for traction slip control, for yaw torque control, or for any other reason, the brake branch line 7 should be connected to the brake line 4 at the intersection 11 rather than at the intersection 10 . In addition, the return line 14 is provided with a solenoid valve rather than with hydraulically operated components. For example, when the brake system has a front-axle/rear-axle brake circuit allotment and, consequently, the two wheel brakes of the driven wheels are arranged in one joint brake circuit, two outlet valves must be provided in this brake circuit for traction slip control operations. However, this provision obviates the need for outlet valves in the second brake circuit in which traction slip control is not required. In addition, the need for a separating valve is eliminated in the second brake circuit.
According to FIG. 2, the separating valve 9 can be replaced by a separating valve 29 which is hydraulically operated. In this separating valve 29 , the master cylinder pressure acts in the opening direction, and the supply pressure of the return pump 16 acts so as to close the valve. When pressure from the master cylinder 1 and from the return pump 16 is applied, valve 29 remains in its open initial position shown, because the valve is acted upon by a spring in the opening direction. The arrangement of the non-return valve 23 and the pressure-relief valve 24 is identical to the arrangement in FIG. 1 .
The change-over valve 38 of FIG. 3 can be considered as an alternative to the change-over valve 18 of FIG. 1 . Valve 38 is also operated hydraulically, however, closed when unpressurized. The purpose of the control line, which permits the pressure on the suction side of the return pump 16 to act on the change-over valve 38 in the closing direction, is that in the event of a vacuum due to the return pump 16 running, the change-over valve 38 is quasi drawn to its open position. Should braking pressure be built up from the master cylinder 1 in this switch position, pressure in excess of atmospheric pressure will also develop downstream of the change-over valve 38 . This excess pressure will act upon the change-over valve 38 so as to close it. As long as pedal-actuated braking of this type does not cause critical slip values, the pump is disconnected and remains out of operation until brake slip control becomes necessary. Even if the return pump 16 starts to aspirate again, the change-over valve 38 will not open initially as long as a sufficient quantity of pressure fluid is discharged through the return line 14 and, if necessary, through the return line 15 in order to feed the return pump 16 . This is because the pressure will not drop below atmospheric pressure in the suction line 17 during this period so that the compression spring which acts upon the change-over valve 38 retains the change-over valve 38 in its closed initial position.
This version of a change-over valve may be configured in a simple manner as an electromagnetically operated change-over valve with a particularly simple actuation logic because it must only be opened when traction slip control or active braking is necessary. The valve may remain closed in all other situations. In this case, however, additional solenoid valves are required for a brake circuit 3 of this type in combination with the separating valve 9 of FIG. 1 and outlet valve 21 or another electromagnetically operated outlet valve. On the other hand, this may have the advantage that standard solenoid valves of a simple construction can be used. Thus, a variation of this type is appropriate when the expenditure in electric lines is insignificant and a corresponding actuation logic can be taken from other brake systems, for example. However, it is also possible to combine an electromagnetically operated change-over valve with a hydraulic separating valve according to FIG. 2 so that only two additional solenoid valves are used in brake circuit I also in this case.
FIG. 4 shows a combination valve which can be mounted instead of the box 25 in FIG. 1 (shown in dotted lines). The combination valve 45 is a combination made up of the separating valve 9 and an electromagnetically operated, normally closed change-over valve in the suction line 17 . This means that the combination valve 45 in its initial position opens the brake line 4 and separates the suction line 17 from the master cylinder 1 . In an energized switch position, however, the combination valve 45 causes connection of the suction line 1 and the master cylinder 1 and interruption of the brake line 4 .
FIG. 5 shows a combination valve of this type in a hydraulically operated design. The combination valve 55 corresponds to a combination of the separating valve 29 in FIG. 2 and the change-over valve 38 in FIG. 3 . It has the same control line like the change-over valve 38 in FIG. 3 so that its spring-loaded initial position shown, in which the brake line 4 is open, is always maintained as long as a vacuum prevails in the suction line 17 when the master cylinder is not operated. In this version of a combination valve 55 , only one additional solenoid valve per wheel brake of a driven wheel is required, i.e., one outlet valve each, for retrofitting a brake system with traction slip control, exactly as is the case when jointly using the separating valve 29 and the change-over valve 38 .
A solution as shown in the FIG. 6 embodiment is appropriate as an alternative of the outlet valve 21 in the return line 15 . The outlet valve 61 shown in FIG. 6 is also electromagnetically operated, but open in its deenergized initial position. The advantage is that the outlet valve 61 must be closed only for traction slip control operations or any other active braking operations when it is connected in series with a restrictor 19 and a non-return valve 20 , as can be found in the return line 14 of the wheel brake 5 . During anti-lock control operations which are performed when the brake pedal 3 is applied, the hydraulic elements 19 and 20 are sufficient to produce a dynamic pressure in the return line 15 as well as in the return line 14 . The actuation logic of an outlet valve 61 of this type is greatly simplified in comparison with a normally closed outlet valve 21 .
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A system for retrofitting a four-valve ABS system for traction slip control. According to the present invention, only the wheel brakes associated with the driven wheels are furnished with outlet valves apart from the prevailing electromagnetically operated inlet valves. A separating valve is additionally inserted into the brake line, and a self-priming return pump is used which additionally has a suction line to the brake line between the master cylinder and the separating valve. Preferably, the suction line is adapted to be closed by a hydraulic valve. The separating valve may also be replaced by a hydraulically operated valve version. The resulting advantage is that at most four additional solenoid valves are required for the entire brake system in order to realize traction slip control.
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BACKGROUND OF THE INVENTION
[0001] This invention relates in general to vehicle park assist systems and in particular to an improved park assist system and method for parking of such a vehicle.
[0002] Vehicle park assist systems are used to identify a feasible parking space, e.g., a parallel parking space or a garage parking space, and then take over the steering of the vehicle to maneuver the vehicle into the identified space hands free. During operation, the driver still shifts the transmission and operates the gas and brake pedals. Thus, while the steering is done automatically, the driver is still responsible for safe parking of the vehicle.
[0003] One known vehicle park assist system is disclosed in U.S. Pat. No. 7,526,368 to Endo et al. and includes an electronic control unit (ECU) for parking assistance, a back camera connected to the ECU, a touch display connected to the ECU, and an electric power assisted steering (EPS) apparatus connected to the ECU. In operation, the back camera takes an image of an area extending on a rear side of the vehicle and supplies the image information around the rear of the vehicle to the parking assistance ECU. The parking assistance ECU displays a real picture taken by the back camera to the touch display when a shift position of the vehicle is at a reverse position. The touch display is provided with a touch operation part of a pressure sensitive type of a temperature sensitive type which enables operation by the vehicle driver to set a target parking position on the display by displacing the picture of the vehicle taken by the back camera into a parking space frame on the touch display. In the Endo et al. system, after the target parking position is set by the driver via manual manipulation of the vehicle into a parking space frame on the touch display, the parking assistance ECU performs an automatic steering of the EPS along a calculated path to the target parking position.
[0004] In the Endo et al. system, if the guidance of the vehicle to the target parking position is cancelled, a memory of the ECU, which continuously holds the target parking position even after the cancellation condition is established, allows the driver via manual touch operation of the touch display, to reset the target parking position to an absolute position. The absolute position can be the same as the target parking position before guidance was cancelled. Thus, the vehicle can be parked to the original target parking position following cancellation without having to restart the parking process again by the driver having to manually reset the target parking position via the manual manipulation of the vehicle into a parking space frame on the touch display. Unfortunately, this type of system in Endo et al. is camera based in that it requires a back camera and also the system requires a touch display which requires driver input. Thus, it would be desirable to provide a park assist system which did not require a back camera and/or a touch display.
SUMMARY OF THE INVENTION
[0005] This invention relates to an improved park assist system and method for parking of such a vehicle which is a sensor based park assist system that provides the driver the option of resuming the functionality provided by the park assist system after it has been deactivated by the driver. According to one embodiment, a method for parking a vehicle in a target parking spot comprising the steps of: (a) providing a vehicle having a sensing system and a park assist system operatively connected thereto, the sensing system including at least one sensor which provides an input signal to the park assist system; (b) scanning neighboring objects using the sensor to determine if a feasible target parking space is available for parking the vehicle; (c) using a computer of the park assist system to determine whether there is a sufficient slot length in which to park the vehicle in the target parking space and to determine a calculated trajectory path to guide the vehicle into the target parking space, the park assist system alone determining the target parking space and the calculated trajectory path thereto without any driver interaction; (d) starting a parking maneuver wherein the vehicle is started to be guided into the target parking space by the park assist system; (e) following step (d), deactivating the park assist system by a driver/passenger action; (f) at the time of deactivation of step (e), storing the parking information determined above in step (c) by the park assist system; and (g) following step (f), the park assist system requesting a driver command to resume the parking maneuver began in step (d), wherein if the driver selects to resume the parking maneuver the park assist system uses the stored parking information to guide the vehicle into the target parking space.
[0006] According to another embodiment, a method for parking a vehicle in a target parking spot comprising the steps of: (a) providing a vehicle having a sensing system, a park assist system operatively connected to the sensing system, a steering system including a steering wheel, and a powertrain system, the sensing system including at least one sensor which provides an input signal to the park assist system; (b) activating the sensing system to scan neighboring objects to determine if there is a feasible target parking space available for parking of the vehicle; (c) using a computer of the park assist system to determine whether there is a sufficient slot length in which to park the vehicle in the target parking space and to determine a calculated trajectory path to guide the vehicle into the target parking space, the park assist system alone determining the target parking space and the calculated trajectory path thereto without any driver interaction; (d) prompting the driver that a feasible target parking space is available; (e) instructing the driver to stop the vehicle, remove their hands from the steering wheel of the steering system, and engage the powertrain system into reverse; (f) starting a parking maneuver wherein the vehicle is started to be guided into the target parking space by the park assist system; (g) following step (f), deactivating the park assist system by a driver/passenger action; (h) at the time of deactivation of step (g), storing the parking information determined above in step (c) by the park assist system; and (i) following step (h), the park assist system requesting a driver command to resume the parking maneuver began in step (f), wherein if the driver selects to resume the parking maneuver the park assist system uses the stored parking information to guide the vehicle into the target parking space.
[0007] According to yet another embodiment, a park assist system for parking a vehicle in a target parking space comprises: a sensing system including at least one sensor which provides an input signal to the park assist system to determine if a feasible target parking space is available for parking the vehicle; and a park assist system computer which determines whether there is a sufficient slot length in which to park the vehicle in the target parking space and to determine a calculated trajectory path to guide the vehicle into the target parking space, the park assist system alone determining the target parking space and the calculated trajectory path thereto without any driver interaction, the computer having a stored memory that can be retrieved upon deactivation of the park assist system; wherein upon starting a parking maneuver in which the vehicle is started to be guided into the target parking space by the park assist system and the system is deactivated by a driver/passenger action, at the time of deactivation the computer of the park assist system stores the parking information determined above and requests a driver command to resume the parking maneuver which has began and, if the driver selects to resume the parking maneuver the park assist system uses the stored parking information, the park assist system is operative to guide the vehicle into the target parking space.
[0008] Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic diagram of a first embodiment of a path to a target parking space using a park assist system according to the present invention.
[0010] FIG. 2 is a schematic diagram of a portion of the park assist system illustrated in FIG. 1 , showing the associated vehicle used therewith.
[0011] FIG. 3 is a flow chart of an embodiment of a method for parking a vehicle using the park assist system of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] Referring now to FIG. 1 , there is illustrated a schematic diagram of a first embodiment of a path P for parking of a vehicle V to a target parking space or spot T between two parked vehicles V 1 and V 2 , using a park assist system, which will be described in detail below, according to the present invention. In the illustrated embodiment, the vehicle V, schematically shown in FIG. 2 , includes at least the following components or systems: a brake pedal 12 , a gas pedal 14 , a braking system 16 , a steering system 18 , a driveline system 20 , wheels 22 , an electric (EPAS) or electro-hydraulic power assisted steering (EHPAS) system 24 which is part of the steering system 18 , a sensing system 26 , a powertrain system 28 , and a park assist system 30 . However, it must be understood that the vehicle V to be parked may include any other suitable components or systems and that only those components or systems which are necessary for describing and explaining the function and operation of the present invention are illustrated herein. Also, in the illustrated embodiment the target parking space T is shown as being a parallel parking space located between two parked vehicles V 1 and V 1 on the passenger or vehicle right hand side; however, the target parking space T may be any other suitable parking space and is not limited to the parking space shown in the illustrated embodiment.
[0013] In the illustrated embodiment, the sensing system 26 is operatively connected to the park assist system 30 to provide input signal(s) thereto and preferably includes ultrasonic sensors, odometric sensors, and an absolute steering wheel angle sensor. The ultrasonic sensors may be located on a side(s) of a front and/or rear bumpers of the vehicle V. In the illustrated embodiment of FIG. 1 , an ultrasonic sensor, indicated generally at S is illustrated schematically as being located at least on a front passenger or right side bumper of the vehicle V. Alternatively, the number and or the location of the ultrasonic sensors may be other than illustrated if so desired. For example, one or more ultrasonic sensors may be located on the front driver side bumper of the vehicle V (as shown at S 2 in FIG. 1 ), on one or both of the rear bumpers of the vehicle (as shown as S 1 and S 3 in FIG. 1 ), or in any suitable combinations of or desired locations thereof on the vehicle V. Also, the types of sensors may be other than illustrated and described. For example, a relative steering wheel angle sensor may be used instead of the absolute steering wheel angle sensor; others sensors, such as for example, radar, thermal, optical (e.g., Light Detection and Ranging (LIDAR), and laser may be used instead of or in combination with the ultrasonic side sensors; and/or a global positioning system (GPS) may be used instead of the odometric sensors.
[0014] In the illustrated embodiment, the odometric sensors may be located on one or more of the wheels 22 of the vehicle V and/or in the driveline system 20 of the vehicle. The absolute steering wheel angle sensor is located on the steering system 18 of the vehicle and preferably is located on a steering wheel of the steering system 18 . Alternatively, the construction and/or the components of the sensing system 26 of the vehicle V may be other than illustrated and described if so desired.
[0015] In the illustrated embodiment, the vehicle V is parked into the target parking space T using the park assist system 30 of the present invention. To accomplish this, at least one of the ultrasonic sensors is used in conjunction with the odometric sensors and the absolute steering wheel angle sensor to scan neighboring objects and their location relative to the position of the vehicle V as a driver of the vehicle drives by them. In the illustrated embodiment of FIG. 1 , the neighboring objects are illustrated as being the two parked vehicles V 1 and V 2 and an object 32 , such as for example, a curb or a wall. However, one or more of the neighboring objects may be omitted or may be of other kinds or types than that which are illustrated and described.
[0016] The information from the sensors is processed by a computer of the park assist system 30 to determine if a valid path trajectory can be performed to park the vehicle V into the target parking space T. The calculation by the computer of the park assist system 30 not only includes a determination of a slot length 34 depending upon a length 36 of the vehicle V, but also considers if there is sufficient space to maneuver the vehicle V into the target parking space T.
[0017] Referring now to FIG. 3 , there is illustrated a flow chart of an embodiment of a method for parking a vehicle using the park assist system 30 of the present invention. As shown in FIG. 3 , the method of the present invention includes a first step 50 in which the computer of the park assist system 30 determines if there is a feasible target parking space T available for parking of the vehicle V. To accomplish this, the park assist system 30 uses the sensing system 26 . As discussed above, the sensing system 26 determines whether there is a sufficient slot length 34 in which to park the vehicle V.
[0018] Once it is determined that a suitable target parking space T has been identified by the park assist system 30 in step 50 , the park assist system 30 in step 52 prompts the driver via a visual and/or audible interface that a feasible target parking space T is available. Next, in step 54 , the driver is instructed by the park assist system 30 , either visually and/or audibly, to stop in order to accept the assistance to park.
[0019] After the driver has stopped in step 54 , the park assist system 30 in step 56 will ask or prompt the driver to remove their hands from a steering wheel of the steering system 18 and engage/shift the transmission of the powertrain system 28 into reverse. Once the driver has removed their hands from the steering wheel and engaged reverse, the park assist system 30 in step 58 will take over the steering wheel movement and control the EPAS system 24 to execute the calculated steering trajectory based on the relative vehicle position to the neighboring objects, i.e., in FIG. 1 the vehicles V 1 and V 2 and the object 32 .
[0020] Following this, if during step 58 the driver (and/or a passenger) performs an action which is effective to cause a deactivation (or interruption and/or cancellation as described below), of the parking of the vehicle V along the calculated steering trajectory path, then the park assist system 30 will be deactivated in step 60 . The action by the driver (and/or passenger) during step 60 which may be effective to cause the deactivation of the park assist system 30 may be caused, for example, by the driver grabbing the steering wheel (as sensed by a steering wheel torque and/or angle sensor), by the driver and/or a passenger opening a door of the vehicle, or by the driver pressing a button (i.e., activation/deactivation button) of the park assist system 30 during step 58 . Alternatively, there may be other kinds of suitable actions and/or events, either caused by the driver and/or a passenger or caused without any driver and/or passenger action, such as engine stall, that may occur besides those described above that can also be effective to deactivate, interrupt and/or cancel the park assist system 30 during its automatic parking operation in step 58 .
[0021] Upon the deactivation of the park assist system 30 , the computer of the park assist system 30 in step 62 stores and retains in a memory thereof, the location of the vehicle V at the time of deactivation relative to the information it obtained during step 50 (i.e., the neighboring objects and their location) as well as the calculated trajectory path (based on the relative vehicle position to such neighboring objects), that the vehicle V was travelling at the time of deactivation. Preferably, the memory of the computer of the park assist system 30 is a non-volatile type of memory which enables the stored information to remain available even if the vehicle loses power in the case of an engine stall; however, other types of memory may be used if so desired.
[0022] Next, the park assist system 30 in step 64 requests from the driver via preferably via a visual an/or audible command whether the driver desires to resume the parking maneuver of the vehicle along the calculated trajectory path to the target parking space T. If the driver indicates that he/she desires to resume the parking maneuver, in step 66 the park assist system resumes the parking maneuver using the stored information in the computer of the park assist system 30 to guide the vehicle V into the target parking space T. The driver may indicate that they desire to resume the parking maneuver by any suitable means, such as for example, by an audible command or by a mechanical command, such as for example, by pressing a button of the park assist system 30 . During step 66 , the park assist system 30 will prompt the driver when to stop and pull forward and/or backwards as needed until the vehicle V is finally parked in the target parking space T. On the other hand, if the driver does not indicate that he/she desires to resume the parking maneuver in the manner described above and/or rather simply drives away in step 68 , then the park assist system in step 70 after recognizing this will clear the stored parking information from the park assist system 30 that was stored in step 62 .
[0023] One advantage of the embodiment of the present invention is that the park assist system and method of the operation thereof is capable of providing a sensor based park assist system that provides the driver the option of resuming the functionality provided by the park assist system after it has been deactivated by the driver. As a result of this, the park assist system can still park the vehicle in the target parking space using the stored parking information in the computer of the system without making the driver restart the parking operation over again from the beginning. Also, the park assist system of the present invention alone determines the target parking space and the calculated trajectory path thereto without any driver interaction, i.e., the driver does not have to manually position the vehicle in the target parking space on a touch display screen of the park assist system such as in the system disclosed in Endo et al. '368 patent.
[0024] In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been described and illustrated in its preferred embodiments. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.
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A method for parking a vehicle in a parking spot comprises the steps of: providing a vehicle having a sensing system and a park assist system, the sensing system including a sensor which provides an input signal; scanning neighboring objects to determine if a feasible target parking space is available; determining whether there is a sufficient slot length in which to park the vehicle and calculating a trajectory path to guide the vehicle into the space; starting a parking maneuver; deactivating the assist system by a driver/passenger action; storing the parking information determined above; and requesting a driver command to resume the parking maneuver, wherein if the driver selects to resume the parking maneuver the assist system uses the stored parking information to guide the vehicle into the space.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of co-pending application No. 08/243,489 filed May 16, 1994.
This application claims the priority of German Application No. P 44 11 548.2 filed Apr. 2, 1994, which is incorporated herein by reference.
U.S. patent applications Ser. No. 08/416,028 filed Apr. 3, 1995 and 08/416,029 filed Apr. 3, 1995 contain related subject matter.
BACKGROUND OF THE INVENTION
This invention relates to a method and an apparatus for handling coiler cans of elongated horizontal cross section (that is, flat cans) before, during and after filling the cans with sliver by a sliver-producing textile machine such as a drawing frame. The sliver is discharged by a stationarily supported rotary coiler head of the textile machine and is deposited in coils and, during the charging (filling) process, the coiler can is moved back-and-forth parallel to its horizontal length dimension. Before the charging process starts, an empty can is moved, for example, from an empty-can storing device, into an intermediate space between empty cans and full cans and is therefrom advanced to the filling position whereupon the can is filled with sliver in the filling position and the full can is, after completion of the filling process, moved from the filling position into the intermediate space and is further advanced therefrom, for example, to a full-can storing device. A conveyor is provided between the filling position and the intermediate space.
WO Publication No. 91/18135 discloses an arrangement where empty-can and full-can storing devices are arranged separately one behind the other. Between the two can storing devices an intermediate space for a can is provided. The intermediate space is, perpendicularly to the can storing devices, connected with the sliver filling station underneath the coiler head of a drawing frame by means of a throughgoing can moving device (conveyor) including chains and rollers. In operation an empty can is advanced from the empty-can storing device into the intermediate space, then forwarded by the can moving device to the sliver filling station where it is filled with sliver by the coiler head and thereafter the full can is, in the opposite direction and by the same can moving device, returned into the intermediate space and then shifted into the full-can storing device. Such a process is time consuming as concerns the coiler can replacement in the zone of the can storing devices. In particular, difficulties are involved with the perpendicular change of direction of can motion between the can storing devices on the one hand and the can moving device on the other hand. In an attempt to remedy such difficulties, at the transitional zones between the conveyor belts or conveyor chains of the can storing devices and the conveyor chain of the can moving device, filler portions are provided which fill the intermediate space to ensure that the flat cans are prevented from overturning upon transition from the storing device into the zone of the transport chain or upon transition from the zone of the transport chain into the storing device. It is a further disadvantage of the prior art arrangement that it is structurally complex and expensive and, in particular, special structural measures are required for performing the method.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved method and apparatus of the above-outlined type from which the discussed disadvantages are eliminated and which ensures, in particular, a disturbance-free transfer of the coiler cans at high speeds between the can moving device (conveyor) on the one hand and the empty-can and full-can storing devices, on the other hand.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the apparatus for handling flat coiler cans before, during and after the cans are filled with sliver by a sliver producing textile machine, includes an empty-can storing device; a full-can storing device; an intermediate space defined between the empty-can storing device and the full-can storing device; and a sliver filling station for receiving a can to be filled. The sliver filling station includes a can-reciprocating device for moving the can back and forth while sliver is deposited thereinto. The apparatus further includes a conveyor extending between the intermediate space and the sliver filling station for moving a can to be filled into and withdrawing a filled can from the sliver filling station; and a transferring device for transferring a can to be filled from the intermediate space onto the conveyor and for transferring a filled can from the conveyor into the intermediate space.
The transfer of the coiler cans from the conveyor into the can storing device and conversely facilitates the reversal of direction and thus permits a rapid exchange so that an overall high working speed may be achieved which encompasses the can replacement and the filling of the cans by sliver. At the same time, the method according to the invention permits a high production rate of the sliver producing machine (drawing frame). In up-to-date drawing frames operating with sliver delivery speeds of over 1,000 m/min, the rapid filling of the sliver into the cans, combined with the rapid can replacement according to the invention, results in a higher degree of efficiency of the sliver producing machine. The high sliver speed makes possible a rapid charging of the can, and such a high output rate is rendered possible to a large extent by the short-path and rapid can exchange.
The invention has the following additional advantageous features:
The can transferring device may change its location, for example, it may be mounted on the can conveyor (sled) for moving therewith.
The transferring device is arranged in a stationary manner.
The transferring device is associated with one end of the conveyor and the intermediate space in the can storing device.
The transferring device has a reciprocating transfer element such as a push-pull element.
The transfer element is driven.
The empty-can storing device and the full-can storing device form a common structure.
The can storing device has a common transporting device, for example, a conveyor belt for the empty cans and the full cans.
A driving device such as an electric motor is provided for the conveyor of the can storing device.
One end of the can conveyor laterally abuts the can storing device.
Between the can conveyor and the can storing device a narrow clearance is provided.
A vertical overlap exists between the can conveyor and the can storing device.
An electronic control and regulating device, for example, a microcomputer is provided which is connected to the drive motor for the can conveyor.
The control and regulating device is connected to the driving device for the can transferring device.
The control and regulating device is connected to the driving device for the can storing device.
A sensor indicating the fill level of the coiler can is connected to the control and regulating device.
A path sensor, for example, an incremental path sensor indicating the location of the can on the filling path and on the conveying path is connected with the control and regulating device.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1a is a schematic top plan view of a drawing frame, a can filling mechanism as well as a can conveying mechanism and a can storing device.
FIG. 1b a schematic side elevational view of the construction illustrated in FIG. 1a.
FIG. 1c is a schematic side elevational view of the can storing device shown in FIG. 1a.
FIG. 1d is a schematic top plan view of a preferred embodiment of a can transferring device according to the invention.
FIG. 2 is a perspective, partially broken-away view of a can conveyor according to the invention.
FIG. 3 is a sectional front elevational view of the can conveyor shown in FIG. 2.
FIG. 4 is a block diagram of an electronic control and regulating device for operating the can handling apparatus according to the invention.
FIGS. 5a and 5b are diagrams illustrating the displacement speed of a can as a function of its position along the filling path.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1a, there is illustrated therein a drawing frame 1 which may be, for example, an HS 900 model manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany. To the sliver guiding table 2 of the drawing frame 1 eight coiler cans 3 are transported from a non-illustrated carding machine. In operation of the drawing frame 1, eight slivers 5 are withdrawn from cans 3, guided over the sliver guiding table 2, and advanced to a drawing unit 4 of the drawing frame 1. The thickness of the sliver outputted by the drawing frame corresponds to the thickness of the individual inputted slivers. The sliver 6 produced by the drawing frame 1 is deposited by a coiler head 7, which forms part of the drawing frame 1, into a coiler can 8 which, after it is filled, is moved away from under the coiler head 7. The coiler can 8 is a flat can having an elongated, generally rectangular horizontal cross-sectional outline. After the coiler can 8 has been moved away from the coiler head 7, it is advanced via a can storing device 12 and a non-illustrated can transporting vehicle to a non-illustrated further processing unit, such as an open end spinning machine.
FIG. 1b shows the filling station which is arranged under the coiler head 7 and which supports a coiler can 8. The coiler head 7, supported in a non-illustrated frame, deposits the sliver 6 in coils as it rotates about a stationary axis. The sliver 6 is advanced to the coiler head 7 in a conventional manner by two cooperating calender rolls after exiting from the drawing unit 4 of the drawing frame 1. The diameter of the coiler head 7 approximately corresponds to the horizontal width measured between two opposite large vertical sides of the coiler can 8. As seen in FIG. 1a, the coiler can 8 is supported on a sled, carriage or similar component of a can conveyor 10. During the filling process the conveyor sled 9 executes a back-and-forth travel effected by the drive of the conveyor 10 in the direction of arrows A and B. As a result, the can reciprocates underneath the coiler head 7 along a filling path a generally corresponding to the horizontal length of the coiler can and having reversal points (end points) I and II. The can replacement motion extends beyond the filling path a and defines a conveying path b having end points II and III. In FIG. 1b the coiler can 8 is shown in solid lines at the left end of the filling path and it is shown in phantom lines at 8' at the right end of the filling path a. The conveyor 10 is driven by an rpm-regulatable electric motor 11.
Parallel to the longitudinal side of the drawing frame 1 a can storing unit 12 is provided which is formed of an empty-can storing device 12a for the empty cans 8a and a full-can storing device 12b for the full cans 8b. As viewed in the direction of motion indicated by the arrows C and D, between the last empty can 8a and the first full can 8b an intermediate space 12c is provided. The empty cans and full cans 8a and 8b, respectively, are supported on a conveyor belt 13 which is an endless member supported by end rollers 13a and 13b and is circulated by an electric motor 14. Thus, the empty-can storing device 12a, the intermediate space 12c and the full-can storing device 12b may be viewed as respective consecutive stationary zones 12a, 12c and 12b of the conveyor belt 13.
Prior to the filling step an empty coiler can 8a is moved from the empty-can storing device 12a into the intermediate space 12c between the empty-can storing device 12a and the full-can storing device 12b and therefrom the can is advanced to the filling station. After the filling process the full can 8 is moved by the sled 9 of the conveyor 10 from the filling station into the intermediate space 12c from which the can is moved to the full-can storing device 12b. The conveyor 10 is oriented perpendicularly to the can storing unit 12 and thus transports the cans individually to and from the filling station below the coiler head 7. Therefore, on the conveying path b either an empty can 8a is moved from the can storing unit 12 into the filling station or a full can 8b is moved from the filling station into the storing unit 12.
A transferring device 15 is provided to transfer an empty can 8a from the intermediate space 12c to the conveyor 10 and to transfer a full can 8b after the filling process from the conveyor 10 into the intermediate space 12c.
Turning now to FIG. 1c, the empty-can storing device 12a and the full-can storing device 12b form a common can storing unit 12 constituted by a single structural unit. The can storing unit 12 has a common, throughgoing, endless conveyor belt 13 which is supported by end rollers 13a and 13b and which is circulated such that its working (upper) run moves in the direction of the arrow E, whereas its lower (idle or return) run moves in the direction of the arrow F. The conveyor belt 13 has carrier strips 13c which, as may be best observed in FIG. 1a, extend perpendicularly to the conveying direction C, D of the conveyor belt 13 and define individual compartments for accommodating individual coiler cans. The end roller 13b is driven by the electric motor 14. The conveyor belt 13 has a small overall structural height.
Turning to FIG. 1d, there is illustrated therein the can transferring device 15 including a pushing and pulling arm 15a which is displaceable by a pushing and pulling element 15b in the direction of the arrows I and K. The pushing and pulling element 15b is driven by an electric motor 16. It is to be understood that instead of an electric motor a fluid displacement motor may be used as well.
As shown in FIG. 2, the conveyor 10 which operatively couples the intermediate space 12c with the sliver filling station underneath the coiler head 7, has a toothed belt 17 on which a mounting plate 18 is secured for positioning the sled 9 thereon. The stub shaft 19 for driving the non-illustrated end roller for the belt 17 is coupled to the reversible drive motor 11. The belt 17 is guided in a slide strip 20 and a guide 21.
As shown in FIG. 3, the flat can 8, whose horizontal width dimension faces the viewer, is positioned in a longitudinal orientation on the sled 9 which carries at its underside a sliding guide 22 partially circumferentially surrounding a stationary guide rod 23 supported on a carrier block 24. A further guide rod 23' is spaced parallel to the guide rod 23 and is formed as a sliding track for the other side of the sled 9 which is guided by the cooperation between a guide lug 25 travelling with the sled 9 and a guide track 23'' provided laterally in the guide rod 23'.
Turning to FIG. 4, there is provided an electronic control and regulating device, such as a microcomputer 26 to which an input of the electric motor 11 is connected with the interposition of a motor regulator 27. The drive motor 11 is connected with the microcomputer 26 with the interposition of a path sensor 29 which may be, for example, an incremental path sensor. The microcomputer 26 is further connected with a terminal 30, sensors 31 and actuators 32, the motor 16 for the can transferring device 15, the motor 14 for the can storing unit 12 as well as measuring and setting members for the control and regulation of the drawing frame 1.
The path sensor 29 applies signals to the microcomputer 26 representing the momentary position of the can 8 to be filled with sliver. The length of the filling path a on which the can is reciprocated during the filling step has structural characteristics (such as, for example, reversal point I=0 and reversal point II=100) which are stored in the microcomputer 26 according to a particular program. As long as the can is not full, it is reciprocated with a predetermined speed v along the filling path a between the two end points I and II. As soon as the maximum fill is reached which is determined by a fill level sensor 31, the can 8 is moved beyond the terminal point II towards the terminal point III along the conveying path b. Therefrom the can is laterally advanced and a new empty can 8a is brought to point III where the can is contacted and moved into the zone of the filling path a. Thereafter, a new filling process may start.
The speed v with which the can 8 is reciprocated between the end points I and II of the charging path a is variable and may be stored in the microcomputer 26 and may be applied thereby to the motor regulator 27 dependent on requirements. In particular, shortly before reaching the end points, the conveyor 10 may be braked according to a programmed course. Upon reaching a point of reversal, the direction of motion is reversed and the can is accelerated according to a programmable function as shown, for example, in FIGS. 5a and 5b. For example, the electric motor 11 may be constantly accelerated or decelerated. It may be expedient to equalize the overlap of the sliver coils at the points of reversal by the acceleration or deceleration. The speed v with which the can 8 is moved on the filling path a during the filling process is dependent from the output speed of the fiber processing machine (drawing frame) 1 and is electronically directly synchronized therewith.
The speed with which the can 8 is moved on the conveying path b may be adapted to the can filling process.
The invention also encompasses an embodiment where the device 10 directly displaces the can 8 which is moved on a conveyor apparatus, such as a roller track.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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An apparatus for handling flat coiler cans before, during and after filling the cans with sliver by a sliver producing textile machine. The apparatus includes an empty-can storing device; a full-can storing device; an intermediate space defined between the empty-can storing device and the full-can storing device; and a sliver filling station for receiving a can to be filled. The sliver filling station includes a can-reciprocating device for moving the can back and forth while sliver is deposited thereinto. The apparatus further includes a conveyor extending between the intermediate space and the sliver filling station for moving a can to be filled into and withdrawing a filled can from the sliver filling station; and a transferring device for transferring a can to be filled from the intermediate space onto the conveyor and for transferring a filled can from the conveyor into the intermediate space.
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[0001] This application is the U.S. national phase of International Application No. PCT/CN32013/087987 filed on 27 Nov. 2013 which designated the U.S. and claims priority to Chinese Application Nos. 201310482695.7 filed on 16 Oct. 2013, the entire contents of each of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention belongs to the field of biotechnology, and it relates to the use of N-acetylneuraminic acid aldolase (Nal), particularly relates to the use of Nal from Corynebacterium glutamicum ATCC 13032 in producing N-acetylneuraminic acid (Neu5Ac) by using N-acetylmannosamine (ManNAc) and pyruvic acid as the substrates.
BACKGROUND OF THE INVENTION
[0003] N-acetylneuraminic acid (N-acetyl-D-neuraminic acid, Neu5Ac) is an important milk powder additive, which can improve immunity of infants [1], meanwhile it can be used as a precursor for synthesizing anti-influenza A/B type virus drugs [2]. Synthesizing Neu5Ac by using ManNAc and pyruvic acid as the substrates under catalysis by Nal is the currently most primary synthesis route for Neu5Ac. Nal has been used in industrial synthesis of Neu5Ac [3-5], and synthesis of Neu5Ac from ManNAc and pyruvic acid under catalysis by Nal is a reversible reaction. Nal is widely distributed in the nature, and it is found in bacteria and mammals [6]. Many pathogenic bacteria, after invasion into human body, decompose human Neu5Ac by Nal as their carbon source and nitrogen source [6], thus currently there are a great number of reports on Nal from pathogenic bacteria. Besides Nal derived from pathogenic bacteria, there is also Nal found from food safe (generally regarded as safe, GRAS) strains, such as Lactobacillus plantarum WCFS1 [7] and Taphylococcus carnosus TM300 [8]. Because the substrate pyruvic acid is cheap [9] and Nals have relatively high temperature stability [10], it has been widely applied in the synthesis of Neu5Ac. However, currently all of Nal have a common defect: in a reversible catalytic synthesis reaction of Neu5Ac, the Nal is more prone to decompose Neu5Ac [7, 8, 11-14].
[0004] To obtain Nal of high activity and to resolve the issue of the chemical equilibrium of Nal being prone to decomposing Neu5Ac, this patent cloned and expressed N-acetylneuraminic acid aldolase (CgNal) from food safe strain Corynebacterium glutamicum ATCC 13032 [15]. It belongs to one of Nal family, comprising 312 amino acids, and its accession number in Genbank is NP — 601846, its amino acid sequence is shown in SEQ ID NO: 2. The gene encoding this protein comprises 939 bp bases, its accession number in the Genbank is NC — 003450.3, and its gene sequence is shown in SEQ ID NO:1. Reports on using CgNal in Neu5Ac synthesis has not been found until now.
SUMMARY OF THE INVENTION
[0005] The technical issue to be resolved by the present invention is to provide use of N-acetylneuraminic acid aldolase (Nal) in catalytic synthesis of N-acetylneuraminic acid (Neu5Ac) from N-acetylmannosamine (ManNAc) and pyruvic acid.
[0006] To resolve the above-described technical issue, a technical solution adopted by the present invention is as follow:
[0007] Use of N-acetylneuraminic acid aldolase (Nal) with an amino acid sequence as shown in SEQ ID NO: 2 in catalytic synthesis of N-acetylneuraminic acid (Neu5Ac) from N-acetylmannosamine (ManNAc) and pyruvic acid.
[0008] A specific method is synthesizing N-acetylneuraminic acid by using N-acetylneuraminic acid aldolase with the amino acid sequence as shown in SEQ ID NO: 2 as a catalyst, and using N-acetylmantosamine and pyruvic acid as substrates.
[0009] A more specific method is to express a recombinant strain comprising a gene sequence as shown in SEQ ID NO: 1, and a crude N-acetylneuraminic acid aldolase after lysis or a pure N-acetylneuraminic acid aldolase obtained by further nickel column purification is reacted with N-acetylmannosamine and pyruvic acid in a buffer, to obtain N-acetylneuraminic acid.
[0010] Wherein, said recombinant strain comprising the gene sequence as shown in SEQ ID NO: 1 is established by the following method: the gene of N-acetylneuraminic acid aldolase Nal is amplified by using Corynebacterium glutamicum ATCC13032 genome as a template and ligated to a pET-28a vector, then the recombinant plasmid is transformed into E. coli Rosetta (DE3). Wherein, the method to express the recombinant strain comprising the gene sequence as showing in SEQ ID NO: 1 is: when the recombinant strain is incubated to OD 600 =0.4 to 0.8, IPTG of final concentration 0.2 to 1.0 mmol·L −1 is added at 15 to 37° C., and induced at 150 to 220 rpm for 4 to 12 hours. The preferred method is: when the recombinant strain is incubated to OD 600 of 0.6, IPTG of final concentration 0.2 mmol·L −1 is added at 30° C., and induced at 220 rpm for 10 hours. Wherein, the condition of the nickel column purification is: a mixed protein is eluted with a 20 mmol·L −1 imidazole solution, and the pure enzyme is eluted with a 500 mmol·L −1 imidazole solution.
[0011] Wherein, the reaction ratio of N-acetylneuraminic acid aldolase with N-acetylglucosamine and pyruvic acid is: 0.36 to 300 U·mL −1 crude enzyme or pure enzyme is reacted with 100 to 1000 mmol·L −1 N-acetylmannosamine and 100 to 2000 mmol·L −1 pyruvic acid.
[0012] Wherein, said buffer is 20 to 200 mmol·L −1 Tris-HCl buffer of pH7 to 8.8 or 20 to 200 mmol·L −1 glycine-NaOH buffer of pH 9.0 to 9.5, preferably Tris-HCl buffer of pH 7 to 8.5, most preferably Tris-HCl buffer of pH 7.5 or Tris-HCl buffer of pH 8.5.
[0013] Wherein, the reaction condition in the buffer is: the temperature being 25 to 60° C., and reaction time being 0.1 to 12 hours; preferably, the temperature being 35 to 45° C., and reaction time being 0.15 to 0.5 hours; most preferably, the temperature being 40° C., and reaction time being 0.15 to 0.5 hours.
[0014] The inventors, based on modern bioinformatics principle and in combination with molecular biotechnology, cloned the gene of N-acetylneuraminic acid aldolase from Corynebacterium glutamicum ATCC13032 by the method of genetic engineering and expressed it in Escherichia coli , and it was found be able to catalyze and synthesize Neu5Ac from ManNAc and pyruvate. Beneficial effects: the present invention firstly used the N-acetylneuraminic acid aldolase with the amino acid sequence as shown in SEQ ID NO: 2 in catalytic synthesis of Neu5Ac from ManNAc and pyruvate, and obtained very good effects, its enzyme activity was up to 12 U/mg. Because this reaction is a reversible reaction, compared with other Nals, the chemical equilibrium of this aldolase is more prone to a direction of N-acetylneuraminic acid synthesis i.e., sialic acid synthesis, meanwhile the expression effect of the enzyme is very good, no inclusion body is formed, and the expression amount of N-acetylneuraminic acid aldolase is large, being 5 folds of expression amount of aldolase gene derived from Escherichia coli , meanwhile Corynebacterium glutamicum is a food safe bacteria.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a graph of establishing the N-acetylneuraminic acid aldolase gene.
[0016] FIG. 2 is a graph of a sodium dodecyl sulfate polyacrylamide gel electrophoresis (SDS-PAGE) after expression of CgNal (from Corynebacterium glutamicum ATCC13032) and EcNal (from Escherichia coli ). Wherein, 1 is CgNal crude enzyme, 2 is CgNal pure enzyme, 3 is EcNal crude enzyme, 4 is EcNal pure enzyme, and 5 is Marker.
[0017] FIG. 3 is effect of pH on CgNal enzyme activity.
[0018] FIG. 4 is effect of temperature on CgNal enzyme activity.
[0019] FIG. 5 is change of the enzyme activity of CgNal during the warm water bath.
[0020] FIG. 6 is effects of metal ion and surfactant at pH 7.5 on CgNal enzyme activity
[0021] FIG. 7 is effects of metal ion and surfactant at pH 8.5 on CgNal enzyme activity.
[0022] FIG. 8 is change of product concentration during synthesis of Neu5Ac using CgNal as the catalyst.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0023] The present invention can be better understood based on the following examples. However, one skilled in the field will easily understand that the specific material ratio described in the examples, process conditions and their results are used to illustrate the present invention only and should not be used to limit the invention described in detail in the claims.
Example 1
Establishing the Recombinant E. coli Rosseta (pET28a-CgNal)
1. Obtaining N-Acetylneuraminic Acid Aldolase Gene:
[0024] The genome of Corynebacterium glutamicum ATCC 13032 was extracted, then PCR was carried out by using the extracted genome as the template.
[0025] The primer adding enzyme digestion site used in expression vector was established, the sequence of the primer was as follow:
[0000]
An upstream primer (CgNal-sense comprising BamH I)
is:
(SEQ ID NO: 3)
5′-GACAGCAAATGGGTCGCGGATCCATGGCTTCCGCAACTTTCACC
G-3′
A downstream primer (CgNal-anti comprising Hind
III) is:
(SEQ ID NO: 4)
5′-TGCTCGAGTGCGGCCGCAAGCTTTTAAGCGGTGTACAGGAATTCAT
C-3′
[0026] All the primers were synthesized by Suzhou GENEWIZ Corporation.
PCR Conditions for Gene:
[0027] Cycle 30 times according to the following parameters: denaturation at 98° C. for 10 seconds, annealing and extension at 68° C. for 1 minute, finally extension at 72° C. for 10 minutes.
[0000] 2. Transforming the Recombinant E. coli Rosseta (DE3):
[0028] The pET-28a vector (pET-28a, purchased from Novagen (Merck China)) was digested by BamH I and Hind III respectively, after conforming that the vectors were completely linearized, the target fragment of PCR and the linearized expression vector were extracted respectively, then with one-step clone kit (ClonExpress), 10 μL of linking product pET-28a-CgNal was added into 100 μL of Rosetta (DE3) competent cells, and placed on ice for 30 minutes, heat shocked at 42° C. for 90 seconds, placed on ice for 5 minutes. A pre-heated 0.9 mL of LB medium was added. Centrifuged at 200 rpm at 37° C. for 1 hour. A 200 μL of bacteria solution was added onto a LB plate containing 100 μg/mL kanamycin and chloramphenicol respectively, incubated at 37° C. overnight for 12 to 16 hours. The graph of establishment is seen in FIG. 1 .
Example 2
Obtaining the Aldolase CgNal
1. Expression of N-Acetylneuraminic Acid Aldolase CgNal.
[0029] The recombinant strain E. coli Rosseta (pET-28a-CgNal) was picked up into a LB liquid medium containing antibiotics, incubated under vibration at 37° C. overnight. Then, inoculated to a fresh culture solution in a 1 (v/v) % inoculation amount, when incubated to OD 600 of about 0.6 at 37° C., IPTG was added to a final concentration of 0.2 mmol·L −1 , centrifuged at 200 rpm at 30° C., induced expression for 10 hours, then centrifuged (4° C., 10000 rpm, 10 minutes).
2. Purifying N-Acetylneuraminic Acid Aldolase CgNal.
[0030] The collected bacterial sludge was re-suspended in a 100 mmol·L −1 Tris-HCl (PH 7.5) buffer, and the cells were ultrasonically lysed (power 300W, sonicated for 3 seconds, interrupted for 5 seconds, totally 5 minutes), centrifuged (4° C., 12000 rpm, 15 minutes), and supernatant was removed.
[0031] The collected enzyme supernatant was added to a Ni-NTA column (Ni-NTA His Bind Resin, Novagen), and incubated on ice for 30 minutes. After the supernatant flowed through the column, the mixed protein was washed away with a 100 mmol·L −1 Tris-HCl (pH 7.5) containing 20 mmol·L −1 imidazole. Then, the target protein CgNal was eluted down with a 100 mmol·L −1 Tris-HCl (pH 7.5) containing 500 mmol·L −1 imidazole. Use aldolase EcNal from Escherichia coli as a control, and the purity and expression level of CgNal were detected by SDS-PAGE, which was shown in FIG. 2 . The protein concentration of the purified CgNal was determined by Bradford method.
Example 3
Study on the Enzymatic Properties of the Aldolase CgNal
1. Detecting Method for CgNal Enzyme Activities
[0032] The enzyme activities of CgNal were divided into the enzyme activity of Neu5Ac synthesis reaction and the enzyme activity of Neu5Ac decomposition reaction. The enzyme activity on Neu5Ac synthesis reaction was defined as the enzyme amount required for synthesizing 1 μmol Neu5Ac per minute, and the enzyme activity on Neu5Ac decomposition reaction was defined as the enzyme amount required for decomposing 1 μmol Neu5Ac per minute, the enzyme activity detection solution for Neu5Ac decomposition reaction was 0.1 M pyruvic acid, 0.1 mol·L −1 ManNAc and 0.1 mol·L −1 Tris-HCl (pH 7.5 or 8.5); the enzyme activity detection solution for Neu5Ac decomposition reaction was 100 mmol·L −1 Neu5Ac and 0.1 mol. L −1 Tris-HCl (pH 7.5 or 8.5). The purified Nal was added into 1 ml of enzyme activity detection solution to the final concentration of 30 μg/ml (about 0.36 U/ml). After reaction at 37 V for 20 minutes, the tube was heated in a boiling water for 5 minutes to stop the reaction, centrifuged at 12000 g for 10 minutes, and the sample was filtered with a 0.22 μm filter.
[0033] The substrate and the product were detected with Bio-Rad Aminex 87-H column by using Agilent 1200 HPLC, (5 mmol·L −1 H 2 SO 4 as a mobile phase, flow rate 0.6 ml/min, differential refractive index detector).
2. The Enzyme Activities of CgNal at Different pH Values.
[0034] The following buffer was used in effect of pH on CgNal: 0.1 M Tris-HCl (pH 7 to 8.8) and 0.1 M glycine-NaOH buffer (pH 9.0 to 9.5). The enzyme activity was detected in the enzyme activity detection solutions of different pHs, in order to detect the effect of pH on the enzyme activity. The detection results showed that the activity of CgNal on Neu5Ac decomposition reaction between pH 7.5 and 8.4 was much higher than the activity on Neu5Ac synthesis reaction; when the pH was between 8.6 and 8.8, the decomposition activity of Neu5Ac was close to Neu5Ac synthesis activity ( FIG. 3 ).
3. Effect of the Temperature on the CgNal
[0035] The enzyme activities of both directions of the aldolase CgNal were detected by using a temperature gradient at pH 7.5 (25° C. to 60° C.), in order to find the optimum reaction temperature. At pH 7.5, the optimum temperature for CgNal was 40° C., the optimum temperature for decomposition and synthesis reaction of Neu5Ac were identical. At pH 8.5, the optimum temperature of Neu5Ac synthesis direction was 40° C., and the optimum temperature of Neu5Ac decomposition direction was 45° C. ( FIG. 4 ). The CgNal was suspended in a 0.1 M Tris-HCl (pH 8.5) buffer, then placed in a warm water bath at 37° C. for 48 hours, and the change of enzyme activities was detected during the warm water bath, in order to determine the stability of CgNal. Within 10 hours prior to the warm water bath, Neu5Ac synthesis activity of CgNal showed a rising trend, after 36 hours of warm water bath it can still maintain about 80% of starting activity ( FIG. 5 ).
4. Effects of Metal Ions and Surfactant on the CgNal Activity
[0036] To an enzyme activity detection solution of CgNal, 5 mM of CaCl 2 , NaCl, BaCl 2 , FeCl 3 , KCl, ZnCl 2 , CoCl 2 , MgCl 2 , NH 4 Cl, NiSO 4 , EDTA, CTAB and SDS were added, and a sample without adding any metal ion and surfactant was used as a control. The enzyme activities of CgNal at both pH 7.5 and pH 8.5 were detected. The enzyme activity of CgNal at pH 8.5 was much higher than the enzyme activity of CgNal at pH 7.5, and the effects of metal ions on CgNal under different pH conditions were quite different. At pH 7.5, ZnCl 2 , CoCl 2 , NiSO 4 , CTAB and SDS all promoted reaction of CgNal in the synthesizing Neu5Ac direction, meanwhile they also inhibited the reaction in the decomposing Neu5Ac direction ( FIG. 6 ). Whereas the metal ions at pH 8.5 had no significant activation effect on CgNal. ZnCl 2 , CTAB and SDS promoted the superiority of Neu5Ac synthesis over Neu5Ac decomposition, but overall decreased the enzyme activity ( FIG. 7 ). Therefore, at suitable pH value and under effect of metal ions and surfactant, the rate of CgNal in Neu5Ac synthesis direction was greater than the rate in Neu5Ac decomposition direction.
5. Determining the Enzyme Reaction Kinetic Constants for CgNal
[0037] The enzymatic reaction kinetic constants of CgNal at pH 7.5 and pH 8.5 on the substrates ManNAc, Neu5Ac and pyruvic acid were determined at different concentration of substrates. When the kinetic constant on pyruvic acid was determined, the fixed ManNAc concentration was 100 mM, and the pyruvic acid concentration varied between 1 and 100 mM. When the kinetic constant on ManNAc was determined, the fixed pyruvic acid concentration was 100 mM, and the concentration of ManNAc varied between 1 and 400 mM. When the kinetic constant on Neu5Ac was determined, the concentration of Neu5Ac varied between 1 and 200 mM. The kinetic constants of CgNal on Neu5Ac, ManNAc and pyruvic acid at pH 7.5 and pH 8.5 were as shown in Table 1. When the pH value was increased from 7.5 to 8.5, the Km and Vmax values of the substrate were greatly increased.
[0000]
TABLE 1
Kinetic constants of CgNal
Neu5Ac
ManNAc
pyruvic acid
Km
Vmax
Km
Vmax
Km
Vmax
pH
(mM)
(U/mg)
(mM)
(U/mg)
(mM)
(U/mg)
7.5
33.5
16.74
53.3
10.2
14.7
10.98
8.5
87.7
79.6
92.1
73.2
72.4
76.64
Example 4
Catalytic Synthesis of Neu5Ac by Using CgNal as the Catalyst
[0038] In a 20 ml of reaction system, the reaction solution was 50 mM Tris-HCl (pH 7.5 and pH 8.5) comprising 0.8 mol·L −1 ManNAc and 2 mol·L −1 pyruvic acid. Under the same conditions, 1 mL of inducer purified CgNal (180 U/mL) and EcNal (64 U/mL) were respectively added into the reaction solution. The catalytic condition was 37° C., 200 rpm for 12 hours. pH was respectively maintain to 7.5 and 8.5, During the reaction, the solution was sampled and the contents of ManNAc, pyruvic acid and Neu5Ac were detected. The catalysis results showed that the yield of CgNal was much higher than the yield of ECNal, and CgNal synthesized the highest amount of 185 g/L Neu5Ac within 12 hours. Within 6 hours prior to catalysis, the yield at pH 8.5 were significantly higher than the yield at pH 7.5, then in terms of catalysis results of EcNal and CgNal, the yield at pH 8.5 was very close to the yield at pH 7.5 ( FIG. 8 ).
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[0000]
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4. Hu, S., et al., Coupled bioconversion for preparation of N - acetyl - D - neuraminic acid using immobilized N - acetyl - D - glucosamine -2- epimerase and N - acetyl - D - neuraminic acid lyase . Appl Microbiol Biotechnol, 2010. 85(5): p. 1383-91.
5. Tabata, K., et al., Production of N - acetyl - neuraminic acid by coupling bacteria expressing N - acetyl - glucosamine 2- epimerase and N - acetyl - neuraminic acid synthetase . Enzyme and Microbial Technology, 2002. 30(3): p. 327-333.
6. North, R. A., et al., Cloning, expression, purification, crystallization and preliminary X - ray diffraction studies of N - acetylneuraminate lyase from methicillin - resistant Staphylococcus aureus . Acta Crystallographica Section F, 2013. 69(3): p. 306-312.
7. Sanchez-Carron, G., et al., Molecular characterization of a novel N - acetylneuraminate lyase from Lactobacillus plantarum WCFS 1. Applied and Environmental Microbiology, 2011. 77(Compendex): p. 2471-2478.
8. García García, M. I., et al., Characterization of a Novel N - Acetylneuraminate Lyase from Staphylococcus carnosus TM 300 and Its Application to N - Acetylneuraminic Acid Production . Journal of Agricultural and Food Chemistry, 2012. 60(30): p. 7450-7456.
9. Ishikawa, M. and S. Koizumi, Microbial production of N - acetylneuraminic acid by genetically engineered Escherichia coli . Carbohydrate Research, 2010. 345(Compendex): p. 2605-2609.
10. Yamamoto, K., et al., Serratia liquefaciensas a New Host Superior for Overproduction and Purification Using the N - Acetylneuraminate Lyase Gene of Escherichia coli . Analytical Biochemistry, 1997. 246(2): p. 171-175.
11. Krüger, D., R. Schauer, and C. Traving, Characterization and mutagenesis of the recombinant N - acetylneuraminate lyase from Clostridium perfringens . European Journal of Biochemistry, 2001. 268(13): p. 3831-3839.
12. Uchida, Y., Y. Tsukada, and T. Sugimori, Purification and properties of N - acetylneuraminate lyase from Escherichia coli . J Biochem, 1984. 96(2): p. 507-22.
13. Schauer, R. and M. Wember, Isolation and characterization of sialate lyase from pig kidney . Biol Chem Hoppe Seyler, 1996. 377(5): p. 293-9.
14. Li, Y., et al., Pasteurella multocida sialic acid aldolase: A promising biocatalyst . Applied Microbiology and Biotechnology, 2008. 79(Compendex): p. 963-970.
15. Zahoor ul Hassan, A., S. Lindner, and V. F. Wendisch, Metabolic engineering of Corynebacterium glutamicum aimed at alternative carbon sources and new products.
16. Sun, W., et al., Construction and expression of a polycistronic plasmid encoding N - acetylglucosamine 2- epimerase and N - acetylneuraminic acid lyase simultaneously for production of N - acetylneuraminic acid . Bioresource Technology, 2013. 130(0): p. 23-29.
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It discloses a use of N-acetylneuraminic acid aldolase with an amino acid sequence as shown in SEQ ID NO: 2 in catalytic synthesis of N-acetylneuraminic acid. The preparation of N-acetylneuraminic acid is to use the N-acetylneuraminic acid aldolase with the amino acid sequence as shown in SEQ ID NO: 2 as a catalyst, and N-acetylmannosamine and pyruvic acid as substrates.
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FIELD OF INVENTION
The present invention relates to diverter type valves and more particularly to a diverter valve assembly designed for use in liquid chromatography.
BACKGROUND OF THE INVENTION
Only about 15% of the known compounds lend themselves to analysis by gas chromatography owing to insufficient volatility or thermal instability. Liquid column chromatography, on the other hand, does not have these limitations. The interchange or combination of solvents can provide special selectivity effects that are absent when the mobile phase is a gas. Ionic compounds, labile naturally occurring compounds, polymers, and high molecular weight polyfunctional compounds are conveniently analyzed by liquid chromatography. While liquid flow in traditional liquid chromatography was achieved by gravity, modern liquid column chromatography uses high pressure pumps with relatively short narrow-bore columns containing small particles of packing.
One of the most important parts in a liquid chromatography setup is the solvent delivery system. Such a system must be able to precisely deliver a solvent (or a mixture of different solvents) over a relatively broad flow range. Sampling valves are essential components of this solvent delivery system, allowing the sample to be reproducibly introduced into the column without significant interruption of the flow. Sampling valves are also used for connecting and disconnecting the chromatography column to the process piping (e.g., for flushing purposes).
An exemplary prior art liquid chromatography valve setup is schematically depicted in FIGS. 1A-1D. FIG. 1A shows a valve assembly 10 comprising valves 12a, 12b, 14a, 14b, 16a, and 16b. Liquid enters the system from the entrance process piping 20 and can be directed through the valve assembly 10 by controlling the afore-mentioned valves as will be later explained. The system gives the user the flexibility to have the product fluid flow through a chromatography column (not shown) in a forward (FIG. 1B) or reverse (FIG. 1C) direction, or the product fluid can be made to completely bypass the column (FIG. 1D). Liquid leaves the valve assembly through the exit process piping 22.
Fluid can flow through the prior art valve assembly 10 depicted in FIG. 1A in any one of the three directions depicted in FIGS. 1B-1D. The fluid flow is represented by arrows 25 in these figures. In FIG. 1B, which represents the forward product flow through the column, valve 14a is opened allowing the fluid to flow from the process piping into the valve assembly 10. Valve 16a is also opened allowing the fluid to flow into the chromatography column (not shown). The fluid returns from the chromatography column passing through valve 16b and reentering the valve assembly. The fluid leaves the valve assembly passing through valve 14b on its path back to the process piping. Valves 12a and 12b remain closed during this process. According to the reverse process flow depicted in FIG. 1C, fluid entering the valve assembly 10 from the process piping can flow through valves 12a and 16b into the column, returning from the column through valve 16a, and exiting the valve assembly through valve 12a back through the process piping. Valves 14a and 14b remain closed during this process. The column may be bypassed altogether according to the process flow depicted in FIG. 1D, where the liquid entering into the valve assembly from the process piping encounters opened valves 12a, 14a, 12b and 14b, exiting the valve assembly without entering the chromatography column which remains inaccessible by closing valves 16a and 16b.
Prior art liquid chromatography valve assemblies like the one described above are typically fabricated using either six independent valves or two two-way diverter valves with two independent valves, connected either by sanitary tri-clams or welded to tee fittings. The problem encountered with these systems, which is especially prevalent in those using the tee fittings, is the existence of dead-legs. Dead-legs are areas of liquid that have become trapped in the valve assembly when the flow of liquid in a particular branch of the system is halted. In dead-legs, fluid can stagnate causing contaminants to accumulate or micro-organisms to grow. This presents a serious problem in liquid chromatography where such contaminants can adversely affect the results of a particular analysis. Hence the need for a diverter type valve assembly in which all flow compartments are shared and fully flushed when a flow through valve is opened clearly exists.
Diverter valves are not particularly new, and, in fact, the prior art includes many examples of different types of these valves. An example of such a valve is described in U.S. Pat. No. 5,273,075 to R. A. Skaer entitled DIVERTER VALVE. The valve described in this patent comprises a diaphragm type valve with a single inlet port and two outlet ports, and is set up such that the flow of fluids can be directed from the inlet port to one or the other outlet ports. The valve operates by closing a diaphragm against an edge or weir of a partition with the valve housing which prohibits fluid flow to the one port while accommodating flow to the other port. This specific diverter valve is made for use with systems that require only a single inlet port and no more than two outlet ports, and hence, such a valve system would not accommodate the intricate plumbing necessary to operate a liquid chromatography system. Moreover, the valve assembly described above requires specialized components, including a specific housing that itself is the subject of a U.S. patent (U.S. Pat. No. 5,427,150 to Skaer et al. Entitled HOUSING FOR A DIVERTER VALVE).
The problem with most prior art diverter valve assemblies revolves around the fact that they are not manufactured out of a single block of material. These valve assemblies are therefore relatively expensive to manufacture, and are, in general, difficult to clean in place due to the dead-legs present when tee fittings are used in them. When these valves are fully assembled, they also take up a large volume in space requiring more installation volume. Since it is the object of most bio technology and pharmaceutical firms to minimize dead-legs and to make process piping and valve assemblies as compact as possible, a new valve assembly which ameliorates these difficulties is sorely needed.
It is therefore an object of the present invention to provide a compact unitarily formed diverter type valve system for use in liquid chromatography in which dead-legs between the valves are eliminated and in which the installation space needed for the system is minimized.
SUMMARY OF THE INVENTION
A unitarily formed diverter valve assembly for use in liquid chromatography. The valve assembly is configured so as to direct the flow of fluid coming from an inlet port through the valve body where it can then be reversibly directed into and out of a chromatography column. On returning from the column, the fluid reenters the valve assembly where it is directed to an outlet port in order to exit the system. The valve assembly can also be configured so as to bypass the column altogether. The smooth and tortuous network of passageways in the valve body, in combination with the placement and operation of the diverter valves, substantially eliminates dead-legs from the system.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed understanding of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings wherein:
FIGS. 1A-1D are schematic views of a prior art chromatography valve assembly showing possible product flow directions;
FIG. 2 is a perspective view of the instant invention valve assembly;
FIG. 3A is a top view of the valve assembly of the instant invention without the manual bonnets;
FIG. 3B is an enlarged cross-sectional view through line A--A of FIG. 3A;
FIG. 3C is an enlarged side elevational view of the instant invention valve assembly without the manual bonnets;
FIG. 3D is an enlarged side elevational view of the instant invention valve assembly rotated approximately 45° from the view depicted in FIG. 3C; and
FIGS. 4A-4C are schematic views of the instant invention valve assembly showing possible product flow directions.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 2, there is shown a perspective view of the instant invention chromatography valve assembly 30. The valve assembly 30 comprises a unitarily formed valve body 32, which may be cast or machined from iron, bronze, stainless steel or aluminum, or may be molded from a suitable plastic or plastic composite material. The outer body 32 is generally that of an octahedral pyramid having a octagonal base 34, a square top surface 36, and a combination of triangular 35 and distorted hexagonal 48 side faces. The top square surface 36 is planar and mounted thereon is the first of five manual bonnet assemblies 38,39,40,41,42 for manually controlling the operation of the underlying valves. The operation of manual bonnets in diverter valve assemblies is well known to those skilled in the art, and is explained, for example, in afore-described U.S. Pat. No. 5,273,075, the specification of which is incorporated herein by reference. It should be noted that although manual bonnet assemblies are shown, other means such as pneumatic or electrical actuators may be mounted on the outer valve body in order to control the valves, thereby eliminating the need for the manual bonnets. The manual bonnets as shown are affixed to the valve body via plates 44, each plate having four suitable screw-type fasteners 46. Extending downwardly and outwardly from each edge of the top square surface 36 of the valve body 32 is a distorted hexagonal side face 48, each side face being planar and having a manual bonnet mounted thereon. These side faces are angled at approximately 30° with respect to the octagonal base of the valve body. The reason for the particular angled mounting of the additional four bonnet assemblies 39,40,41,42 has to do with valve drainage concerns, and will also be explained in detail later.
Still referring to FIG. 2, inlet/outlet ports 50, 52, 54, 56 are located on the triangular side faces 35 of the valve body 32, each port being located between two manual bonnet assemblies. The triangular faces 35 rise perpendicularly from the octagonal base of the valve body, and each triangular face is located approximately 90° from the other. The ports may be threaded, flanged, or left smooth for welding, depending on the desired coupling to the process piping.
Referring now to FIG. 3A, there is shown a top view of the valve assembly, minus the manual bonnets and with a partial cross-sectional view of the underlying channel network drawn in with broken lines. As can be seen in this figure, ports 50, 52, 54 and 56 are arranged at angles of approximately 90° with respect to each other on opposing ends of the octagonal base section of the valve assembly. Each port opens into a chamber in the valve assembly 30--port 50 opening into chamber 60, port 52 opening into chamber 62, port 54 opening into chamber 64, and port 56 opening into chamber 66. Fluid entering any of the ports encounters a chamber and channels leading to three diverter valves. Fluid entering port 50, for example, encounters chamber 60 and channels leading to diverter valves 70, 76 and 78. The smooth and tortuous network of passageways that lead through the valve assembly connect the ports with the chambers and valves in a such a way that the valve assembly is fully drainable as will be later explained. The flow of the fluid is controlled by the diverter valves 70,72,74,76,78 and may be adjusted to permit specific flow directions which, in combination with the smooth and tortuous passageways, eliminate dead-legs from the system.
Referring now to FIG. 3B, there is shown an enlarged cross-sectional view of the valve assembly through line A--A of FIG. 3A. As can be seen in the figure, port 50 opens into chamber 60. A passageway 55 leading to diverter valve 76 can also be seen in this figure. Chamber 60 is connected to chamber 64 via diverter valve 78. The passageway that connects these two chambers is inclined, rising sharply before encountering diverter valve 78 and then falling sharply after encountering the valve. The angle of inclination 63 measured from either side of the diverter valve 78 is approximately 30°. In chamber 64, a passageway 65 leading to diverter valve 74 can be seen. Finally in this figure, port 54 can be seen as opening into chamber 64.
Referring now to FIG. 3C, there is shown an enlarged side elevational view of the instant invention valve assembly 30. This particular side elevational view is directed down port 50 which is disposed on triangular surface 35. As explained above, port 50 opens into chamber 60 which is connected by channels to diverter valves 70, 76 and 78. In this figure, diverter valves 70 and 76 can be seen on opposite sides of port 50, being disposed beneath the afore-described distorted hexagonal side faces 48. These diverter valves, as well as diverter valves 72 and 74 (not shown in this figure), are machined in the position of their drain angle which is approximately 30° as measured from the octagonal base of the valve assembly. This arrangement, coupled with the fact that valve 78 (as seen in FIG. 3B) is at a high point in the valve assembly, allows the valve assembly 30 to be fully and easily drainable. Ports 56 and 52 are also clearly visible in this figure.
Referring now to FIG. 3D, there is shown an enlarged side elevational view of the valve assembly 30 rotated approximately 45° from the view depicted in FIG. 3C. The diverter valve 70 comprises a valve body having a substantially flat, distorted hexagonal side face 48 and a centrally positioned opening 71 which is bisected by a weir 73. Looking directly into diverter valve 70, one surface 75a of the valve body is curved to form a channel connected to port 52, while the other surface 75b is curved to form a channel connected to port 50. The smooth unobstructed chamber 77 and channel through this valve (not shown) permit flow of fluids which, for example, may enter port 50, pass through chamber 60, go across valve 70, pass into chamber 62, and exit port 52. The holes 80a, 80b, 80c and 80d in side face 48 are for locating mounting bolts or suitable fasteners therethrough. It should be understood that the components described for diverter valve 70 are repeated for each of the other four diverter valves in the valve assembly.
Possible fluid flow paths in the valve assembly of the instant invention are depicted in FIGS. 4A-4C. In the preferred embodiment described below, port 50 is connected to an inlet process piping system (not shown) and functions as an inlet port. Port 54 is connected to an outlet process piping system (not shown) and functions as an outlet port. Ports 52 and 56 are connected to a chromatography column (not shown) and function as either inlet or outlet ports to this column depending on the direction of fluid flow. The flow in these figures is represented by arrows 100.
Referring now to FIG. 4A, fluid, containing the product or products to be analyzed, flows from the process piping in a forward direction through port 50, into chamber 60, across valve 76, into chamber 66, and out port 56 to a chromatography column. The fluid returns from the chromatography column entering the valve assembly through port 52, into chamber 62, across valve 72, into chamber 64, and out of the assembly to the outlet process piping through port 54. Since chambers 60, 62, 64 and 66 are common to two valves respectively (72 and 76), the fluid being piped through each port (50, 52, 54, 56) will flush and sweep through the chamber preventing stagnation and the opportunity for contaminants or particulates to accumulate and/or growth of microorganisms to develop.
Referring now to FIG. 4B, there is shown the product flow through the chromatography valve assembly in a reverse direction with respect to the flow depicted in FIG. 4A. Product here flows from the inlet process piping into the valve assembly 30 via port 50, into chamber 60, across valve 70, into chamber 62, and out port 52 into a chromatography column. Product returns from the chromatography column entering the valve assembly 30 through port 56, into chamber 66, across valve 74, into chamber 64, and out to the outlet process piping through port 54. As in the case where the fluid is flowing in a forward direction, chambers 60, 62, 64 and 66 are common to two valves respectively (this time 70 and 74), and the fluid being piped through each port (50, 52, 54, 56) will flush and sweep through the chamber preventing stagnation and the opportunity for contaminants or particulates to accumulate and/or growth of microorganisms to develop.
The chromatography column may be bypassed altogether as is depicted in FIG. 4C. According to this process flow, liquid enters the valve assembly 30 through port 50 and passes into chamber 60. The fluid then crosses valve 78 and passes into chamber 64. From chamber 64 the fluid exits the valve assembly 30 through port 54. During the column bypassing process, valves 70, 72, 74 and 76 remain closed, and fluid remaining in chambers 62 and 66 (as well as in the column) remains undisturbed in the process.
The valve assembly 30 described herein is simple and easy to use, and represents an improvement over prior art diverter valve assemblies. The device is machined out of one block of material, and all flow compartments are shared and fully flushed when a flow through valve is opened, thereby eliminating dead-legs. The main body of the valve assembly (not including any manual bonnets) has an overall diameter of less than 4 inches with a height of less than 11/2 inches and internal piping diameters on the order of 1/2 inch, all of which make the instant device much more compact than the five or six independent valve assemblies of the prior art, thereby minimizing installation space. The afore-mentioned dimensions also make the valve assembly 30 easy to hold and assemble to a liquid chromatography system. In addition, the 1/2 inch diameter of the internal network of passageways and inlet/outlet ports is compatible with common liquid chromatography tubing dimensions. It should be understood, however, that the valve assembly and representative passageways can be manufactured in any size required. While the valve assembly 30 described herein is especially suited for use in liquid chromatography, it should also be understood that the device can be adapted for other uses as desired. It should further be understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications to the embodiments utilizing functionally equivalent elements to those described herein. Any and all such variations or modifications as well as others which may become apparent to those skilled in the art, are intended to be included within the scope of the invention as defined by the appended claims.
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A unitarily formed diverter valve assembly for use in liquid chromatography. The valve assembly comprises a plurality of inlet and outlet ports, diverter valve systems, chambers, and a tortuous network of passageways all of which are arranged to accommodate the flow of fluids in a liquid chromatography system. The valve assembly is configured so as to direct the flow of fluid coming from an inlet port through the valve body where it can then be reversibly directed into or out of a chromatography column. On returning from the column, the fluid reenters the valve assembly where it is directed to an outlet port in order to exit the system. The valve assembly can also be configured so as to bypass the column altogether. Since the entire valve assembly is machined out of a single block of material having smooth liquid passageways, and since all flow compartments are shared and fully flushed when a flow-through valve is opened, dead-legs are virtually eliminated from the system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] This invention relates to a method of increasing the strength of a paper mat of fibers produced in a papermaking process. Paper mat comprises water and solids and is commonly 4 to 8% water. The solid portion of the paper mat includes fibers (typically cellulose based fibers) and can also include filler. Increasing the strength of the paper mat would allow one to increase the proportion of the solids that is filler content. This is desirable because it reduces raw materials costs, reduces energy needed in the papermaking process, and increases the optical properties of the paper. Prior Art discloses paper mat having a solid portion of between 10% and 40% filler. The Prior Art however also discloses that increasing the filler content coincides with a loss in strength in the resulting paper.
[0004] Fillers are mineral particles that are added to paper mat during the papermaking process to enhance the resulting paper's opacity and light reflecting properties. Some examples of fillers are described in U.S. Pat. No. 7,211,608. Fillers include inorganic and organic particle or pigments used to increase the opacity or brightness, reduce the porosity, or reduce the cost of the paper or paperboard sheet. Some examples of fillers include one or more of: kaolin clay, talc, titanium dioxide, alumina trihydrate, barium sulfate, magnesium hydroxide, pigments such as calcium carbonate, and the like. Previous attempts to increase the filler content in paper without losing paper strength are described in British Patent GB 2016498, and U.S. Pat. Nos. 4,710,270, 4,181,567, 2,037,525, 7,211,608, and 6,190,663.
[0005] Calcium carbonate filler comes in two forms, GCC (ground calcium carbonate) and PCC (precipitated calcium carbonate). GCC is naturally occurring calcium carbonate rock and PCC is synthetically produced calcium carbonate. Because it has a greater specific surface area, PCC has greater light scattering abilities and provides better optical properties to the resulting paper. For the same reason however, PCC filled paper mat produces paper which is weaker than GCC filled paper.
[0006] Paper strength is a function of the number and the strength of the bonds formed between interweaved fibers of the paper mat. Filler particles with greater surface area are more likely to become engaged to those fibers and interfere with the number and strength of those bonds. Because of its greater surface area, PCC filler interferes with those bonds more than GCC.
[0007] As a result, papermakers are forced to make an undesirable tradeoff. They must either choose to select a paper with superior strength but inferior optical properties or they must select a paper with superior optical properties but inferior strength. Thus there is a clear need for a method of papermaking that facilitates a greater amount of filler in the paper, a paper that has a high opacity, and a filled paper that has a high degree of strength.
BRIEF SUMMARY OF THE INVENTION
[0008] At least one embodiment of the invention is directed towards a method of papermaking having an increased filler content that does not coincide with a loss in strength in the resulting paper. The method comprises the steps of: providing a blend of filler particles, at least one strength additive, and cellulose fiber stock; treating the filler particles with a composition of matter; combining the filler particles with the cellulose fiber stock; and forming a paper mat by removing some of the water from the combination. At least 10% of the filler particles are the precipitated form of calcium carbonate (PCC) and at least 10% of the filler particles are the ground form of calcium carbonate (GCC). The cellulose fiber stock comprises a plurality of cellulose fibers and water. The composition of matter inhibits the strength additive from adhering to the filler particles. In at least one embodiment, the cellulose fiber stock and the filler particles are combined to form a furnish and subsequently the filler particles are treated with the composition of matter.
[0009] At least one embodiment of the invention is directed towards a method in which the blend of filler particles further comprises one item selected from the list consisting of: calcium carbonate, organic pigment, inorganic pigment, clay, talc, titanium dioxide, alumina trihydrate, barium sulfate, magnesium hydroxide, and any combination thereof.
[0010] At least one embodiment of the invention is directed towards a method in which the composition of matter is an AcAm/DADMAC copolymer. At least one embodiment of the invention is directed towards a method in which the strength additive is glyoxylated Acrylamide/DADMAC copolymer. At least one embodiment of the invention is directed towards a method in which the strength additive and the composition of matter carry the same charge.
[0011] At least one embodiment of the invention is directed towards a method in which the calcium carbonate is in one form selected from the list consisting of: dry calcium carbonate, dispersed slurry calcium carbonate, chalk, and any combination thereof. At least a portion of the calcium carbonate can be in a dispersed slurry calcium carbonate form, the dispersed slurry calcium carbonate further comprising at least one item selected from: polyacrylic acid polymer dispersants, sodium polyphosphate dispersants, Kaolin clay slurry, and any combination thereof. The blend of filler particles can be 50% GCC and 50% PCC. The composition of matter can be a coagulant and can be selected from the list consisting of: inorganic coagulants, organic coagulants, condensation polymerization coagulants, and any combination thereof. The coagulant can have a molecular weight range of between 200 and 1,000,000.
[0012] At least one embodiment of the invention is directed towards a method in which the composition of matter is a coagulant selected from the list consisting of alum, sodium aluminate, polyaluminum chlorides, aluminum chlorohydroxide, aluminum hydroxide chloride, polyaluminum hydroxychloride, sulfated polyaluminum chlorides, polyaluminum silica sulfate, ferric sulfate, ferric chloride, epichlorohydrin-dimethylamine (EPI-DMA), EPI-DMA ammonia crosslinked polymers, polymers of ethylene dichloride and ammonia, condensation polymers of multifunctional diethylenetriamine, condensation polymers of multifunctional tetraethylenepentamine, condensation polymers of multifunctional hexamethylenediamine condensation polymers of multifunctional ethylenedichloride, melamine polymers, formaldehyde resin polymers, cationically charged vinyl addition polymers, and any combination thereof.
[0013] At least one embodiment of the invention is directed towards a method in which the ratio of strength additive relative to the solid portion of the paper mat can be 0.3 to 5 kg of additive per ton of paper mat. At least some of the GCC particles can be treated with the composition of matter. At least one embodiment of the invention is directed towards a method in which none of the PCC particles are treated with the composition of matter. The strength additive can be a cationic starch. The filler particles can have a mass which is up to 50% of the combined mass of the solid portion of the paper mat. The strength additive and the composition of matter can carry the same charge.
[0014] At least one embodiment of the invention is directed to a composition of matter for use in a papermaking process. The composition of matter comprises: cellulose, filler particles, a strength additive, and a coating surrounding at least some of the filler particles. The coating is constructed and arranged to prevent the strength additive from adhering to the filler particles. In at least one embodiment, at least some of the filler particles are calcium carbonate. In at least one embodiment, the filler particles are GCC, PCC, or a combination of the two. In at least one embodiment, the filler particles comprise at least 10% PCC and 10% GCC.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
[0016] FIG. 1 is a graph showing the improved strength of paper made according to the invention.
[0017] FIG. 2 is a second graph showing the improved strength of paper made according to the invention.
[0018] FIG. 3 is a graph showing the Scott Bond strengths of paper blends made according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] In at least one embodiment of the invention is a method of making paper which is strong, has a high filler content, has a high PCC content, and has superior optical properties. In at least one embodiment of the invention the method of papermaking comprises the steps of: creating a filler blend of PCC and GCC in which PCC comprises at least 10% by mass of the filler and GCC comprises at least 10% of the filler mass, pre-treating at least some of the filler particles with a coating that decreases the adhesion between a strength additive and the filler particles, and adding both the filler blend and the strength additive to the paper mat.
[0020] It has been known for some time that adding strength additives to paper mat increases the strength of the resulting paper. Some examples of strength additives are described in U.S. Pat. No. 4,605,702. Some examples of strength additives are cationic starches, which adhere to the cellulose fibers and tightly bind them together.
[0021] Unfortunately it is not practical to add large amounts of strength additives to compensate for the weakness that results from using large amounts of filler in paper mat. One reason is because strength additives are expensive and using large amounts of additives would result in production costs that are commercially non-viable. In addition, adding too much strength additive negatively affects the process of papermaking and inhibits the operability of various forms of papermaking equipment. As an example, in the context of cationic starch strength additives, the cationic starch retards the drainage and dewatering process, which drastically slows down the papermaking process.
[0022] Furthermore cellulose fibers can only adsorb a limited amount of strength additive. This imposes a limit on how much additive and therefore how much filler can be used. One reason why this is so is because strength additive tend to neutralize the anionic fiber/filler charges and when these charges are too neutralized further adsorption of strength additives is inhibited.
[0023] Unfortunately, adding filler to the paper mat also reduces the effectiveness of the strength additive. The strength additive has a tendency to coat the filler particles. The more filler particles present, the more strength additive coats the filler particles, and therefore there is less strength additive available to bind the cellulose fibers together. Because there is a maximum amount of strength additive that can be added, more filler has always meant less effective strength additive. This effect is more acute with PCC than GCC because PCC's higher surface area becomes more coated with strength additive than GCC.
[0024] In at least one embodiment of the invention at least some of the filler particles are pre-treated with a composition of matter to at least partially prevent the adherence of strength additive to the filler particles. The pre-treatment contemplates entirely coating some or all of one or more filler particles with the composition of matter. In the alternative, the pre-treatment contemplates applying the composition of matter to only a portion of one or more of the filler particles, or completely coating some filler particles and applying the composition of matter to only a portion of some other particles. In at least one embodiment the pre-treatment is performed with at least some of the compositions of matter described in U.S. Pat. No. 5,221,435 and in particular the cationic charge-biasing species described therein. In at least one embodiment the pre-treatment is performed with a diallyl-N,N-disubstituted ammonium halide-acrylamide copolymer described in U.S. Pat. No. 6,592,718.
[0025] While pre-treating filler particles is known in the art, prior art methods of pre-treating filler particles are not directed towards affecting the adhesion of the strength additive to the filler particles. In fact, many prior art pre-treatments increase the adhesion of the strength additive to the filler particles. For example, U.S. Pat. No. 7,211,608 describes a method of pre-treating filler particles with hydrophobic polymers. This pre-treatment however does nothing to the adhesion between the strength additive and the filler particles and merely repels water to counterbalance an excess of water absorbed by the strength additive. In contrast, the invention decreases the interactions between the strength additive and the filler particles and results in an unexpectedly huge increase in paper strength. This can best be appreciated by reference to FIG. 1 .
[0026] FIG. 1 plots tensile strength of a given paper versus the percentage of filler relative to the total solid portion of the paper mat used to produce the given paper. As shown in FIG. 1 , the relationship between increasing filler content and decreasing paper strength is a linear relationship. This is because the reduced effectiveness of the strength additive is directly proportional to the increase in strength additive trapped against the filler particles. FIG. 1 also shows that for any given proportion of prior art filler to paper mat, if the filler is pure PCC it will often have a lower strength than if it is partially GCC. FIG. 1 also illustrates the unexpectedly high strength that paper made according to the inventive method possesses. In FIG. 1 , a sample of paper mat containing 32% by mass of filler which was 50% PCC and 50% GCC pre-treated with a strength additive-repelling coagulant produced a paper with a greater strength than that produced by a paper mat having only 20% pure GCC filler. This result is doubly unexpected because: a) a PCC containing filler is producing a greater strength paper than pure GCC filler does, and b) the more than 12% increase in allowable filler is extremely large. The high paper strength is a result of the GCC content reducing the interference between cellulose fiber bonds and the pre-treatment allowing the strength additive to achieve or come close to achieving the maximum paper strength.
[0027] At least some of the fillers encompassed by this invention are well known and commercially available. They include any inorganic or organic particle or pigment used to increase the opacity or brightness, reduce the porosity, or reduce the cost of the paper or paperboard sheet. The most common fillers are calcium carbonate and clay. However, talc, titanium dioxide, alumina trihydrate, barium sulfate, and magnesium hydroxide are also suitable fillers. Calcium carbonate includes ground calcium carbonate (GCC) in a dry or dispersed slurry form, chalk, precipitated calcium carbonate (PCC) of any morphology, and precipitated calcium carbonate in a dispersed slurry form. The dispersed slurry forms of GCC or PCC are typically produced using polyacrylic acid polymer dispersants or sodium polyphosphate dispersants. Each of these dispersants imparts a significant anionic charge to the calcium carbonate particles. Kaolin clay slurries also are dispersed using polyacrylic acid polymers or sodium polyphosphate.
[0028] In at least one embodiment, the treating composition of matter is any one of or combination of the compositions of matter described in U.S. Pat. No. 6,592,718. In particular, any of the AcAm/DADMAC copolymer compositions described in detail therein are suitable as the treating composition of matter. An example of an AcAm/DADMAC copolymer composition is product# Nalco-7527 from Nalco Company of Naperville, Ill. (hereinafter referred to as 7527).
[0029] The treating composition of matter can be a coagulant. The coagulants encompassed in this invention are well known and commercially available. They may be inorganic or organic. Representative inorganic coagulants include alum, sodium aluminate, polyaluminum chlorides or PACs (which are also known as aluminum chlorohydroxide, aluminum hydroxide chloride, and polyaluminum hydroxychloride), sulfated polyaluminum chlorides, polyaluminum silica sulfate, ferric sulfate, ferric chloride, and the like and blends thereof.
[0030] Some organic coagulants suitable as a treating composition of matter are formed by condensation polymerization. Examples of polymers of this type include epichlorohydrin-dimethylamine (EPI-DMA), and EPI-DMA ammonia crosslinked polymers.
[0031] Additional coagulants suitable as a treating composition of matter include polymers of ethylene dichloride and ammonia, or ethylene dichloride and dimethylamine, with or without the addition of ammonia, condensation polymers of multifunctional amines such as diethylenetriamine, tetraethylenepentamine, hexamethylenediamine and the like with ethylenedichloride and polymers made by condensation reactions such as melamine formaldehyde resins.
[0032] Additional coagulants suitable as a treating composition of matter include cationically charged vinyl addition polymers such as polymers, copolymers, and terpolymers of (meth)acrylamide, diallyl-N,N-disubstituted ammonium halide, dimethylaminoethyl methacrylate and its quaternary ammonium salts, dimethylaminoethyl acrylate and its quaternary ammonium salts, methacrylamidopropyltrimethylammonium chloride, diallylmethyl(beta-propionamido)ammonium chloride, (beta-methacryloyloxyethyl)trimethyl ammonium methylsulfate, quaternized polyvinyllactam, vinylamine, and acrylamide or methacrylamide that has been reacted to produce the Mannich or quaternary Mannich derivatives. Preferable quaternary ammonium salts may be produced using methyl chloride, dimethyl sulfate, or benzyl chloride. The terpolymers may include anionic monomers such as acrylic acid or 2-acrylamido 2-methylpropane sulfonic acid as long as the overall charge on the polymer is cationic. The molecular weights of these polymers, both vinyl addition and condensation, range from as low as several hundred to as high as several million. Preferably, the molecular weight range should be from about 20,000 to about 1,000,000. In at least one embodiment, the pre-treatment is preformed by a combination of one, some, or all of any of the compositions of matter described as suitable compositions of matter for pre-treating the filler particles.
[0033] In at least one embodiment, the strength additive carries the same charge as the composition of matter suitable for treating the filler particles. When the two carry the same charge, the filler additive is less likely to adsorb strength additives on its surface. In at least one embodiment, the strength additive is cationic starch. Strength additives encompassed by the invention include any one of the compositions of matter described in U.S. Pat. No. 4,605,702 and US Patent Application 2005/0161181 A1 and in particular the various glyoxylated Acrylamide/DADMAC copolymer compositions described therein. An example of a glyoxylated Acrylamide/DADMAC copolymer composition is product# Nalco 64170 (made by Nalco Company, Naperville, Ill.)
[0034] In at least one embodiment, the fillers used are PCC, GCC, and/or kaolin clay. In at least one embodiment, the fillers used are PCC, GCC, and/or kaolin clay with polyacrylic acid polymer dispersants or their blends. The ratio of strength additive relative to solid paper mat can be 3 kg of additive per ton of paper mat.
[0035] The foregoing may be better understood by reference to the following example, which is presented for purposes of illustration and is not intended to limit the scope of the invention.
Example 1
1(i) Filler Pre-Treatment
[0036] A blend of filler particles was obtained from a paper mill. The blend was a mixture of 50% PCC and 50% GCC. The PCC was un-dispersed Albacar HO (manufactured by Specialty Mineral of Bethlehem, Pa.), and the GCC (also manufactured by Specialty Mineral of Bethlehem, Pa.) was chemically dispersed. For purposes of this application, the definition of the term “un-dispersed” is distributed through a fluid without the aid of a chemical dispersant. For purposes of this application, the definition of the term “chemically dispersed” is distributed through a fluid with the aid of a chemical dispersant.
[0037] The filler blend was diluted to 18% solid content with tap water. 200 mL of the diluted filler blend was placed in a 500 mL glass beaker. Stirring was conducted for at least 30 seconds prior to the addition of coagulant. The stirrer was a EUROSTAR Digital overhead mixer with a R1342, 50 mm, four-blade propeller (both from IKA Works, Inc., Wilmington, N.C.). A coagulant solution was slowly added after the initial 30 seconds of mixing under stirring with 800 rpm. The coagulant solution used was 7527. The dose of coagulant was 1 kg/ton based on dry filler weight. Stirring continued at 800 rpm until all the coagulant was added. Then the stirring speed increased to 1500 rpm for one minute.
1(ii) Use of Filler
[0038] A thick stock of cellulose fibers was obtained from a paper mill. The stock was cooled and then diluted with clarified white water to a consistency of approximately 0.7%. The cellulose fibers were 60% hardwood bleached kraft pulp (HBKP), 20% softwood bleached kraft pulp (SBKP), and 20% bleached chemi-thermo mechanical pulp (BCTMP). Samples of various filler compositions indicated in FIG. 1 were added. Strength additive 64170 was also added. The tensile strength of paper made with each sample was then measured and plotted in FIG. 1 .
[0039] Strength analysis of the samples revealed the following: Replacement of pure PCC with 50% PCC and 50% GCC consistently allows for an approximately 3% increase in filler content without any loss of paper strength. However, the combination of a 50% PCC and 50% GCC filler with pretreatment of the GCC particles with the strength additive 64170 and repelling coagulant 7527 resulted in an allowance of an astounding 12% increase in filler content with no loss in paper strength. As a result, it is clear that the steps of the inventive method allow for more filler to be used in papermaking, more PCC to be used in papermaking, while improving the optical properties of the resulting paper.
Example 2
[0040] The cellulose mixture and filler were provided as in Example 1. The filler was treated as in Example 1. 3 kg/ton strength additive 64170 was added to three samples, one containing 100% PCC, one containing 50% PCC-50% GCC, and one containing 50% PCC-50% GCC with the GCC pre-treated with 7527. The resulting paper samples were analyzed and results were shown in FIG. 2 , which plots tensile strength of a given paper versus the percentage of filler relative to the total solid portion of the paper mat used to produce the given paper.
[0041] When 3 kg/ton additive 64170 was added with 100% PCC, only 3% filler content could be increased without strength loss. At around 34% filler content, strength improved 12%. When 100% PCC was switched to 50% PCC-50% GCC, strength increased and it could allow a 3.5% filler content increase without losing sheet strength. When 3 kg/ton additive 64170 was added, about another 2.5% filler content could be increased without sacrificing sheet strength. At 35% filler content, sheet strength improved 14% with the addition of 3 kg/ton 64170. Compared with 50% PCC-50% GCC, 7527 pre-treated 50% PCC-50% GCC could increase 2% filler without losing strength. When add 3 kg/ton N-64170 to the furnish with pre-treated 50% PCC-50% GCC, the filler content could be increased by 4% without losing sheet strength compared with pre-treated 50% PCC-50% GCC only. At 36% filler content, addition of 3 kg/ton N-64170 increased the strength 19%. This experiment demonstrated that with the same amount of strength additive 64170, the efficiency of improving sheet strength was increased significantly by pre-treating the filler.
Example 3
[0042] A machine trial was run in which a papermaking machine made 108 gsm coated base paper with machine speed of 1360 m/min. A composition was provided whose cellulose fibers were 40% Bleached Chemi-Thermo-Mechanical Pulp (BCTMP), 40% HBKP 40%, SBKP 20%. The furnish also contained a filler blend which was 70% PCC and 30% GCC. During the trial, all the wet end additives including retention aids, sizing agents, and cationic starches were kept constant. The resulting paper strength was measured using a Scott Bond tester.
[0043] FIG. 3 shows the resulting Scott Bond strengths of paper blends that included 8 blends that have various amounts of 7527 and 64170. When no 7527 and no 64170 were added, the strength was 0.92 kg cm. When 2.5 kg/ton of 64170 was added, the strength increased to 1.14 kg cm, a 24% strength improvement. Upon the further addition of 0.5 kg/ton of 7527 however the strength increased from 1.14 kg cm to 1.30 kg cm a further 14% improvement. This trial demonstrated that with addition of a small amount of coagulant, the efficiency of 64170 is greatly improved.
[0044] A person of ordinary skill in the art will recognize that all of the previously described methods are also applicable to paper mat comprising other non-cellulose based fibrous materials, paper mats comprising a mixture of cellulose based and non-cellulose based fibrous materials, and/or synthetic fibrous based materials.
[0045] Changes can be made in the composition, operation, and arrangement of the method of the invention described herein without departing from the concept and scope of the invention as defined in the claims. While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. Furthermore, the invention encompasses any possible combination of some or all of the various embodiments described herein. All patents, patent applications, and other cited materials mentioned anywhere in this application or in any cited patent, cited patent application, or other cited material are hereby incorporated by reference in their entirety.
[0046] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
[0047] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
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The invention provides a method of producing paper with a higher proportion of mineral filler particles than is otherwise be possible without the expected loss in paper strength. The method allows for the use of the greater amount of filler particles by coating at least some of the filler particles with a material that prevents the filler materials form adhering to a strength additive. The strength additive holds the cellulose fibers together tightly and is not wasted on the filler particles. The method is particularly effective when the filler particles are a PCC-GCC blend and when the GCC particles are coated with the adherence preventing coating.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. provisional application No. 61/468,092 filed Mar. 28, 2011, the contents of which are herein incorporated by reference.
TECHNICAL FIELD
[0002] The invention generally relates to the processing of information stored in large databases, and more particularly to the processing of such information in an environment that is dynamically changing over time, including the model used with respect of the information stored in the database.
BACKGROUND
[0003] In today's ever more competitive environment of providing subscribers with offers, and in particular the subscribers of telephony services, there is a need to effectively track the offers provided to the users to ensure that the users receive the promised benefits, as well as to remove a benefit if a user has not met the criteria. In addition it is necessary to continuously monitor the user's behavior on the system and address issues that may lead to the user's defection to another provider. In such systems a large number of transactions take place at any given point in time and it is desirable to be able to provide a response in as close as possible to real-time.
[0004] The systems are supported by relatively large database structures that are capable of handling the significant load thereon in general and in particular in peak hours. The offers to a subscriber are typically kept in the database and continuously monitored. There are many offers per subscriber, each offer having different terms and conditions that are to be met. For example, a subscriber may be required to perform a “top-up” at least five times a week of five US$ each time to qualify for a certain benefit, but may also have another offer of a “top-up” of at least ten US$ on each Monday and Thursday of the week. Another type of offer may be consumption of at least 150 minutes of calling time in a given period to receive a quantity of free minutes in another time period. Furthermore, all the offers can exist simultaneously and may enter and exit the billing system's database at any independent point in time which is not necessarily synchronized.
[0005] Typically, the solution to keep and monitor many offers per subscriber is to map into a relational database using a plurality of tables respective of the offers and states of the subscribers in all the offerings, so that when the processing of each takes place the user can enjoy the benefit. As noted above, an offer can be quite complex and may even be hierarchical and there are many structures that can occur. The subscriber may have the same structure for different offerings. For example, buy two ringtones and get one free as well as buy four games and get two free of some games. The structures are the same but the offerings are different and both need to be kept with respect of the subscriber having two different instances. This requires using and maintaining numerous databases' tables and there is a need to perform a join between the many tables, which is a daunting task as the number of offerings and number of subscribers increase. It is especially critical because of the need to respond in close to real-time when handling the case of an event that needs to respond synchronously to the subscriber.
[0006] In such systems that handle a large number of offerings to subscribers a large number of objects must be stored to and retrieved from a database in any given point in time. Once stored through a serialization method, retrieval requires deserialization that has a significant overhead. The serialization method converts a data structure or an object state into a storable format. Such a format may be a file, a database table, a packet, or other means that cause the data to be serialized. Then when the data is to be reconstructed, a deserialization process takes place to reconstruct the original data structure or object. The overhead results from the time needed for instantiation, the time necessary for the detection of changes in the binary, i.e., a dirty check, as well as the impact of garbage collection that is typically required and grows significantly as the number of objects grow.
[0007] It would be therefore advantageous to provide a solution that overcomes the deficiencies of the prior art.
SUMMARY
[0008] Certain embodiments disclosed herein include a computerized method for binary persistence in a system providing offerings to subscribers of a service provider. The method comprises receiving a plurality of objects respective of offerings made to a subscriber of a service provider; serializing the plurality of objects beginning at an origin to generate a binary record; and storing the binary record in a binary field of an entry in a database, the entry being respective of the subscriber, wherein retrieval of the offerings made to the subscriber requires merely extraction of the binary record from the binary field and performing at least a partial deserialization thereon.
[0009] Certain embodiments disclosed herein also include a computerized method for efficient retrieval of offerings from a system providing offerings to subscribers of a service provider. The method comprises maintaining a binary representation respective of a plurality of offerings made to a subscriber of a service provider; upon receiving a request to retrieve one or more offerings of the plurality of offerings made to the subscriber, extracting of a binary record that includes the a binary representation; and performing at least a partial deserialization of the binary record.
[0010] Certain embodiments disclosed herein also include an apparatus for binary persistence in a system providing offerings to subscribers of a service provider. The apparatus comprises a database comprising at least an entry corresponding to a subscriber of the service provider, the entry having a binary field; and a processor connected to the database for processing a plurality of objects respective of offerings made to the subscriber of the service provider, serializing the plurality of objects beginning at an origin to generate a binary record, and storing the binary record in the binary field of the entry in the database; wherein retrieval of the offerings made to the subscribers requires merely the extraction of the binary record from the binary field and performing at least a partial deserialization thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings.
[0012] FIG. 1 is a flowchart depicting the storage of objects respective of offerings made to a subscriber in accordance with an embodiment of the invention.
[0013] FIG. 2 is a flowchart depicting the deserialization process in accordance with an embodiment of the invention.
[0014] FIG. 3 is a flowchart depicting the compression process of the content directed to a binary field in accordance with an embodiment of the invention.
[0015] FIG. 4 is a flowchart depicting the access to a binary field in accordance with an embodiment of the invention.
[0016] FIG. 5 is a flowchart depicting the update of a binary field in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0017] The embodiments disclosed herein are only examples of the many possible advantageous uses and implementations of the innovative teachings presented herein. In general, statements made in the specification of the present application do not necessarily limit any of the various claimed inventions. Moreover, some statements may apply to some inventive features but not to others. In general, unless otherwise indicated, singular elements may be in plural and vice versa with no loss of generality. In the drawings, like numerals refer to like parts through several views.
[0018] In a billing or offerings system requiring the processing of events there is a need to use information regarding a subscriber as well as a join of a plurality of other entities to understand the offerings given to the subscriber by a service provider. It should be noted that while offerings are described herein in greater detail, the teachings with respect of the offerings should not be viewed as limiting the scope of the invention. The service provider may be for example, a cellular carrier, a cable company, an Internet service provider, and the like. As a result, there is a need to perform many read/write operations on the database that stores the various offerings associated with each subscriber, which slows the overall response. An approach that enables the extraction of one record from the database and at most one record being updated is used. The record allows storage and retrieval of data by a unique identifier without knowledge of the application of the data. The one record contains a binary large object of the database and contains all the objects needed for the processing. The format is adapted to enable evolution of the system's dynamic model where offerings continuously change over relatively short periods of time.
[0019] In accordance with certain embodiments disclosed herein, instead of creating multiple tables as used in the prior art, the information about all the offerings, including all of the variations thereof, is kept as a large binary container, a form of a compound binary format (CBF), that is kept in a single record of the subscribers table. This solves the need to read multiple tables every time there is an event that relates to a subscriber. In fact, only a single row is read where one or more columns of the row is the binary of the offerings that contains all that is needed for handling the offerings for a particular subscriber.
[0020] The binary container maintains a plurality of objects, for example Java objects, that are then executed. It should be understood that a container allows its clients, which are the likes of offerings, benefits, etc., to store arbitrary subscriber-related data, without specific knowledge of its content. That is, a client is an entity that can use data in the binary container. A client can be, for example, offers that are defined by a user of the system and that can access the data container for information. The data supply by the clients includes a unique identifier, which is kept consistent between requests, so that each client can retrieve its corresponding data by the use of this unique identifier. The entire graph of objects containing multiple objects (hundreds, thousands or tens of thousands), organized as a tree having an origin, are mapped to a single or multiple columns in the subscriber's table in a binary form.
[0021] The binary form is generated using a serialization process provided according to one embodiment of the invention and described in more detail herein below. The disclosed serialization process would improve the retrieval of the objects and the cost associated in fetching, instantiating, dirty-checking and garbage-collecting objects. In a typical application, this structure significantly reduces access time to the subscriber's information from hundreds of milliseconds to a few milliseconds.
[0022] FIG. 1 depicts an exemplary and non-limiting flowchart 100 of the storage of objects respective of offerings made to a subscriber in accordance with an embodiment of the invention. In S 110 , the plurality of objects related to the offerings made to a subscriber are collected for the purpose of preparation of the binary container. In S 120 , a binary representation of the objects is generated through a serialization process that is described in more detail herein below. The binary representation is a flat map in which clients deposit elements that have a back-pointer to their client (or sub-component thereof) using a unique identifier. In S 130 , the binary representation is stored in a record of a row in the database that is respective of the subscriber. This allows at retrieval time access to all the objects respective of the subscriber's offering in a single access to the database thereby overcoming some of the deficiencies of the prior art solutions. Optionally, in S 140 it is checked whether additional subscribers are to be added to the database in the same manner, and if so execution continues with S 110 ; otherwise, execution terminates.
[0023] Prior art solutions assume that the classes created by the programmer are static and do not change during the operation of the system. This prevents the use of a standard serialization that cannot work in an ever changing model as required in accordance with the principles of the invention, as classes may change. The serialization/deserialization processes (or serializer/deserializer) in accordance with the embodiments disclosed herein can operate in an ever changing model environment of the solution.
[0024] For example, and without limitation, the model according to one embodiment changes dynamically and a class that may have three properties A, B and C at one point is serialized in that manner. At a later time, the model may change to have four properties, A, B, C, and D which can also be serialized. The challenge is to deserialize correctly so that the earlier object is deserialized with the interface elements A, B, and C while the later object is deserialized with A, B, C and D. The deserializer recognizes the attempt to deserialize an earlier version and provides an adaptor to handle the earlier version appropriately. In another example, the change of the interface elements may be for interface element C to be a string instead of a number. The deserializer recognizes that there was a change in the model and an appropriate utility supplied for the conversion is used to adapt the previously stored binary to the current operating model. It should be noted that this functionality is made possible by means of an external description of the model and a corresponding management version identifier at the instance level.
[0025] FIG. 2 shows an exemplary and non-limiting flowchart 200 of the deserialization process in accordance with one embodiment. In S 210 , a request is received to access a binary object (representation), where a binary object is an object within a binary record, in a row respective of a subscriber. In S 220 , it is checked if the model version of the stored binary object is the current model version, and if so execution continues with S 230 where deserialization is performed using either standard deserialization, or otherwise an on-demand deserialization as explained in more detail herein below; otherwise, execution continues with S 235 where the objects that have changed in the newer model are handled by deserializing converters to enable the handling of the older version. One or more converters are provided to handle objects of an older model that are required due to changes made in the newer model. Execution then continues with S 240 where the deserialized objects are returned, or otherwise stored in memory for execution purposes. In S 250 , it is checked whether additional requests are to be handled, and if so execution continues with S 210 ; otherwise, execution terminates. It should be further noted that this allows online upgrade support as there is always a way to handle objects of an older model in newer versions of the system.
[0026] Typically, a binary record is limited in the size that it can store. For example, Oracle® limits the size of the binary record stored in line to be no more than 4 KB and if a larger size is to be stored then the database program essentially directs the data to a different storage location. While transparent to the user of the database, such behavior leads to a significantly reduced performance as the consequence of the redirection and the size of the larger binary record. The impact on retrieval and storage time can be such that a 10× to 20× performance degradation may be observed. Therefore, in accordance with an embodiment of the invention, prior to storage of the binary data, the size of the record is checked and if it is above a predetermined threshold, for example 4 KB, a compression is applied on the binary data.
[0027] The compression may be performed using commonly available compression schemes, such as but not limited to Zip®, thus more data can be stored in the record. Typically, a record of 26 KB can be compressed into a 4 KB for storage in the binary field. Of course, when such a compression takes place it is necessary to decompress the binary record prior to the handling of the binary data. For example, and without limitation, in FIG. 2 , a step can be added between S 210 and S 220 that checks if the content of the binary field was compressed, and if so, uncompresses that content to generate the binary field.
[0028] While in a typical system a 26 KB binary data should be ample, it is foreseeable that larger sizes may be needed. In such a case, at least another binary field may be used for splitting the data between the two records in the same line (entry) associated with the subscriber. This way the solution can store larger binary representation of objects, while maintaining the solution's advantage of one read and one write at the most with respect to access information of a respective subscriber. The binary representation typically starts with a Boolean marker, denoting whether the rest of the data is compressed.
[0029] FIG. 3 depicts an exemplary and non-limiting flowchart S 130 for storing a binary record directed to a binary field when compression is needed. In S 130 - 10 , a binary record is received for storage in the binary field. In S 130 - 20 , the size of the binary record is checked, and if it exceeds a threshold value execution continues with S 130 - 30 ; otherwise, execution continues with S 130 - 40 . The threshold value is a parameter of the database in which the binary record should be stored. In S 130 - 30 , the binary record is compressed using for example, and without limitation, a standard compression algorithm such as Zip®. In S 130 - 40 , the binary record is stored in the binary field of the appropriate entry associated with the subscriber.
[0030] The binary representation in the binary field, as noted above, contains at all times all the offerings made with respect to a subscriber along with their respective state. Therefore, such a binary content will tend to grow over time as more offerings are added with respect to a subscriber. However, some of the offerings expire over time. In accordance with one embodiment, when an event takes place that results in change in the binary of a subscriber, a cleaning process takes place.
[0031] In one embodiment, the cleaning process removes from the binary content the offerings that are no longer relevant. Doing it in this manner is advantageous over cleaning processes that take place as batch programs that require significant resources and handle each and every record whether necessary or not. Handling the binary content when it is actually being processed for other reasons, allows for continuous cleaning processes and maintaining the size of the binary content under constant control.
[0032] In an embodiment, the binary representation stored in the binary field for the user has a structure that is particularly useful for efficient serialization and deserialization of the binary content respective of a user. The binary representation has in fact three sections, a header section, a map section, and a binary section. The header section contains general information about the binary representation such as compression, version, header size, number of entries and the like. The map section has a list of an identification, or key, which is unique to each client and the offset of the binary section that contains the objects for that specific client. For example, for ID=123, the offset maybe ‘0’ meaning that it starts at address ‘0’ of the binary section, and for ID=456 the offset maybe ‘60’ meaning that it starts at address ‘60’ of the binary section.
[0033] The binary section itself contains the binary representation as described in greater detail hereinabove. When a certain offer needs to read a section of the data according to a given key, first the map section is checked, and if no match is found then there is no need to perform any kind of deserialization. If a match is found, then only the necessary portion needs to be deserialized thereby avoiding the need to deserialize and activate multiple objects that will not ever be used in the processing of the event. Overall the performance of the offerings system is significantly improved by avoiding such unnecessary deserializtion or confining the deserialization to only those portions that are needed for the specific processing. This further prevents the need to perform significant garbage cleaning of objects that were instantiated but never used.
[0034] FIG. 4 shows an exemplary and non-limiting flowchart 400 depicting the access to a binary record in accordance with one embodiment. In S 410 , there is a request to access a binary field by a specific event. In S 420 , it is checked whether the unique identification of the offer appears in the map section of the binary content, and if so execution continues with S 430 ; otherwise, deserialization terminates. In S 430 an offset is extracted from the map respective of the event, the offset being the location from which the deserialization is to begin. In S 440 , deserialization from the offset point begins, for example, according to the deserialization process discussed with respect of FIG. 2 hereinabove, after which execution terminates.
[0035] Once the offset is open it is necessary to know if there is a need to replace the binary representation due to a change done as part of the execution. In prior art solutions, the entire binary would have to undergo comparison with the value read from the DB and then be serialized from the beginning. However, as in accordance with the invention as discussed hereinabove, only the portions of the binary representation that were deserialized are necessary to check for changes, and only those that were changed need to undergo serialization. The entire binary representation is recomposed from the newly serialized binary parts and the parts that were not deserialized. The advantage is that in most cases the checking is limited to a very small portion of the entire binary content, and even if changes are found, not the entire binary needs to be serialized but only the portions found to be changed as well as an update of the map.
[0036] FIG. 5 depicts an exemplary and non-limiting flowchart 500 of the update of a binary field in accordance with one embodiment. In S 510 , the objects that were previously deserialized as explained hereinabove are serialized. As mentioned above, a serialization process converts a data structure or an object state into a storable format.
[0037] In S 520 each newly serialized object is checked with the corresponding binary previously extracted. In S 530 , it is checked if all are equal, and if so execution terminates; otherwise, execution continues with S 540 where serialized objects found to be different from the originating binaries replace the originating binaries, and the map is updated with the new corresponding offset value. In S 550 , the new binary record is saved in the binary field of the line (or entry) corresponding to the subscriber. As noted above the use of this method significantly reduces the overhead related to the serialization of the binary into the binary field by restricting the operations to only accessed objects rather than the entire content.
[0038] In one embodiment, it is desirable to minimize the size of the binary content. For that purpose, unique identifications for the model elements are represented by their hash signature instead of a full textual identification. The hash code requires only four bytes, thus saving a considerable amount of space. Using the hash code instead of a separately generated index ensures consistency over time and resilience to model evolution. An additional mechanism is used to prevent collisions of hash codes. In yet another embodiment, each string object is assigned a numeric index on a per-serialization basis, and consecutive appearances of the same string are represented by this index only, saving the need to repeat string objects in the same binary object.
[0039] The various embodiments disclosed herein can be implemented as hardware, firmware, software, or any combination thereof. Moreover, the software is preferably implemented as an application program tangibly embodied on a program storage unit or computer readable medium consisting of parts, or of certain devices and/or a combination of devices. The application program may be uploaded to, and executed by, a machine comprising any suitable architecture. Preferably, the machine is implemented on a computer platform having hardware such as one or more central processing units (“CPUs”), a memory, and input/output interfaces. The computer platform may also include an operating system and microinstruction code. The various processes and functions described herein may be either part of the microinstruction code or part of the application program, or any combination thereof, which may be executed by a CPU, whether or not such computer or processor is explicitly shown. In addition, various other peripheral units may be connected to the computer platform such as an additional data storage unit and a printing unit. Furthermore, a non-transitory computer readable medium is any computer readable medium except for a transitory propagating signal.
[0040] A database may comprise a single database or a plurality of databases that may be further distributed and communicatively connected by means of, for example and without limitation, a network. Such a network may be a local area network (LAN), a wide area network (WAN), a metro area network (MAN), the Internet, the worldwide web (WWW), and other wired and wireless networks.
[0041] All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the principles of the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.
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A computerized method and system for binary persistence in a system providing offerings to subscribers of a service provider are provided. The method includes receiving a plurality of objects respective of offerings made to a subscriber of a service provider; serializing the plurality of objects beginning at an origin to generate a binary record; and storing the binary record in a binary field of an entry in a database, the entry being respective of the subscriber, wherein retrieval of the offerings made to the subscriber requires merely extraction of the binary record from the binary field and performing at least a partial deserialization thereon.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority under 35 U.S.C. §119(e) to a prior co-pending provisional patent application Ser. No. 60/224,149, filed Aug. 10, 2000.
FIELD OF THE INVENTION
This invention relates to electrical connectors, and more particularly, to an improved modular connector for use in data communications and/or telephony.
BACKGROUND OF THE INVENTION
Modular connectors, such as the popular RJ 45 connector, are well known in the communications art. FIGS. 1A and 1B show a typical male modular connector 12 , known as the “plug”, and typical female modular connector 14 , known as the “jack”. The plug 12 and the jack 14 connectors mate for communicating signals between the external circuit 16 , in this instance a printed circuit board, and the external circuit 18 , in this instance a computer. The pins 20 of the jack 14 electrically connect to the printed circuit board, and the cable 22 electrically connects the plug 12 to the computer.
FIG. 1B shows a perspective view of the plug connector 12 and a partially cut away view of the jack connector 14 . The plug connector 12 includes a body 24 , and disposed with the body 24 are a plurality of conductors 28 that include blade-type contacts 30 . The jack connector 14 can include the body 32 , which in turn can include a housing 34 and a lead frame 36 . The plurality of conductors 38 is disposed with the body 32 , and each of the conductors of the plurality include a contacting portion for contacting the contacts 30 of the plug connector 12 when the plug connector 12 is mated with the jack connector 14 . The reference numeral 40 indicates generally the row of contact portions of the plurality of connectors 38 . The lead frame 36 of the body 32 can be included with the body 32 to space and support the plurality of conductors 38 such that contact portions thereof properly electrically connect with the contacts 30 of the plurality of conductors 28 of the plug connector 12 , when the connections are mated.
Although the plug 12 and jack 14 above are each shown with eight conductors, one example of a modular connector, which can use only four conductors, is the ubiquitous telephone jack present in almost every home. Typically, however, the plug 12 and jack 14 will each include eight conductors, as shown in FIG. 1B, yielding four data conductor pairs.
The general mechanical design of the modular plug and jack connectors shown FIGS. 1A and 1B was determined at a time when the connectors were to be used almost exclusively for the transmission of relatively low frequency signals, such as analog telephone signals. At the present time, however, modular connectors are used at higher and higher frequencies, such as in computer networks. Unfortunately, at these higher frequencies, cross talk between data pairs of conductors becomes increasingly problematic. It is considered that certain aspects of the mechanical design of the typical modular connector contribute to causing the undesired cross talk.
For example, the conductors 28 of the plug connector 12 are very close and run parallel to each other, such that data conductors that should ideally be electromagnetically isolated from one another actually do interact. Cross talk can be categorized as capacitive, wherein the electric field of conductor of one data pair induces a voltage in a conductor of a different data pair, and inductive, wherein the magnetic field of a conductor of one data pair induces a current in a conductor of a different data pair.
The cross talk in modular connections is often further categorized as near-end cross talk, or NEXT, and far-end cross talk, or FEXT. NEXT refers to cross talk that appears as an unwanted signal in one data pair at, for example, the end 42 of plug connector 12 , and is responsive to a signal also entering the end 42 of the plug on another data pair. Such cross talk can be launched onto the external circuit to which the plug connector 12 is electrically connected, such as the computer in FIG. 1 A. Similarly, FEXT refers to cross talk that travels through the plug-jack mated pair. For example, for a desired signal entering the end 42 of the plug connector 12 on one data pair, FEXT refers to an undesired signal appearing at the pins 20 and on a different pair of conductors.
Cross talk becomes progressively worse as the frequency of the electrical signals increases. Cross talk standards are promulgated from time to time. Each new standard is typically stricter than the last, such as by increasing the frequency range and/or lowering the amount of allowable cross talk. For example, the Category 5 standard now in use specifies NEXT up to approximately 100 MHz. The Category 5 standard does not address FEXT. The new Category 6 standard specifies cross talk up to a frequency of 250 MHz. Furthermore, the Category 6 standard specifies limits for both NEXT and FEXT.
Because of the large installed base of older modular connectors, and the need for new connector designs to be backwardly compatible with such older connectors installed in the field, the mechanical arrangement of modular connectors is now standard and subject to little change. Accordingly, design choices can be limited, and the focus is on compensating for the cross talk introduced in the connectors. For example, designers have attempted to meet the Category 5 standard by introducing compensating electronic elements into the external circuits to which the plug and jack are connected, or into the jack and/or plug connectors. These elements typically compensate for the cross talk induced in the plug. For example, the conductors of a jack connector can be arranged to introduce inductive cross talk that cancels cross talk introduced in the plug. Also, it is known to provide capacitors on the external circuit 16 , such as the printed circuit board of FIG. 1B, to which the output of the jack connector is electrically connected to compensate for cross talk introduced by the plug connector. While such techniques have been useful at lower frequencies, they are not entirely satisfactory, even in the upper frequency range of Category 5 . The Category 6 specification significantly exceeds the 100 MHz limit of Category 5 to 250 MHz.
There is an additional complication. Designers are wary to attack the problem of cross talk in the Category 6 frequency range by attacking the source, that is by reducing the cross talk introduced in the plug connector, even apart from the general consideration that much of the mechanical design is fixed. This is because many Category 5 jacks in use meet the Category 5 specification by compensating for a known amount of cross talk in the plug. Remove that cross talk, and the “solution”, that is, the compensation in the Category 5 jack, or in the external circuitry associated with the jack, simply becomes the “problem”, and introduces cross talk when such a jack is mated with a newer plug that introduces less cross talk or that includes it own compensation.
Reducing the cross talk in modular connectors, particularly at higher frequencies, such as above the 100 MHz upper limit of the Category 5 specification, can be problematic.
Accordingly, it is an object of the present invention to address one or more of the foregoing disadvantages and drawbacks of the prior art.
It is another object of the present invention to provide an improved modular connector, such as a modular connector having improved cross talk performance.
SUMMARY OF THE INVENTION
In one aspect, the invention provides an improved modular connector such as a jack connector, for mating with another modular connector, such as a plug connector, for electrical connection therewith. The modular connector includes a body and a plurality of conductors disposed with the body. Each of the conductors extends from a first portion to a second end and has a contact portion therebetween, and the contact portions can be substantially parallel and arranged in a row for electrical connection with a row of contacts of the other connector when mated with the modular connector of the invention. The first portions are for connection with an external circuit for communication of signals between the contacts and the external circuit, and are electrically spaced from the contact portions. A capacitive element is disposed with the modular connector and is in electrical communication with a first pair of the conductors, where the electrical communication is established nearer electrically to the contact portions of the conductors than the first portions are to the contact portions.
Preferably, the electrical communication is established at less than about 5 degrees of phase of the contact portions at a selected frequency, such as the highest frequency at which cross talk is to reduced. More preferably, the electrical communication is established at less than about 3 degrees of phase of the contact portions. The selected frequency can be 200 MHz, or alternatively, 250 MHz.
In another aspect of the invention, there is provided a modular connector, such as a jack connector, for mating with a second modular connector of the opposite sex, such as a plug connector, where the second modular connector introduces cross talk having, a predetermined inductive component and a predetermined capacitive component. The modular connector includes a body and a plurality of conductors disposed with the body. Each of the conductors extends from a first portion to a second end and has a contact portion therebetween. The contact portions are substantially parallel and arranged in a row for electrical connection with a row of contacts of the second connector when the modular connector is mated with the second connector. The first portions are for connection with an external circuit for communication of signals between the contacts and the external circuit. Disposed with the connector are a capacitive element and an inductive element. The capacitive and inductive elements are in electrical communication with a first pair of the conductors. The capacitive element provides a capacitive compensation selected to address substantially only the capacitive component of the cross talk, and the inductive element provides an inductive coupling selected to address substantially only the inductive component of the cross talk. Apportioning the compensation in this manner can advantageously help reduce both NEXT and FEXT.
In yet a further aspect of the invention, there is provided a modular connector, such as a jack connector, for mating with a second modular connector of the opposite sex, such as a plug connector, for electrical connection therewith, and where the second modular connector introduces a undesirable cross talk. The modular connector of the invention includes a body and a plurality of conductors disposed with the body, where each of the conductors extends from a first portion to a second end and has a contact portion therebetween. The contact portions are substantially parallel and arranged in a row for electrical connection with a row of contacts of the second connector when the modular connector is mated with the second connector, and the first portions are for connection with an external circuit for communication of signals between the contacts and the external circuit. A capacitive element and an inductive element are both disposed with the connector. The capacitive and inductive elements are in electrical communication with a first pair of the conductors, and the inductive element is not interposed electrically between the capacitive element and the contact portions of the first pair of conductors.
The invention can also include methods than can be practiced in accordance with the teachings herein. For example, in yet an additional feature of the invention, there is provided a method of compensating for cross talk that occurs when a first modular connector mates with a second modular connector that includes a plurality of data pairs and that introduces cross talk between the data pairs. The method includes the following steps:
1) providing the first connector, where first connector includes a plurality of data pairs of conductors, each of the conductors having a contact portion for electrically contacting with a conductor of the other connector when the connectors are mated. Each of the conductors of the first connector extends from a first portion to a second end, with the contact portion being located between the first portion and the second end. The first portions are for connection with an external circuit for communication of signals between the contact portions and the external circuit, and have a predetermined electrical spacing from the contact portions; and
2) disposing a capacitive element with the first connector and in electrical communication with a first pair of the conductors, the pair not being a data pair, and the electrical communication being established nearer electrically to the contact portions of first pair of conductors than the first portions of the first pair of conductors are to the contact portions of the first pair of conductors.
In another aspect of the invention, there is provided a method for compensating for cross talk using a first modular connector when the first modular conductor is mated with a second modular connector that includes a plurality if pairs of data conductors and that introduces cross talk, having a predetermined capacitive component and a predetermined inductive component, between the data pairs. The method can include the steps of:
1) providing a capacitive element that provides a capacitive coupling selected to address substantially only the capacitive component of the cross talk;
2) providing an inductive element that provides an inductive coupling selected to address substantially only the inductive component of the cross talk; and
3) disposing the capacitive and inductive elements with the connector such that each is in electrical communication with a first pair of the conductors, the first pair being other than one of the data pairs.
In yet a further additional feature of the invention, the invention provides a method of compensating for cross talk in modular connector having a plurality of data conductor pairs, where each conductor has a contact portion for contacting; a conductor of the other connector when the connectors are mated. The method can include the steps of:
1) providing a capacitive element;
2) providing an inductive element; and
3) disposing the capacitive and inductive elements with the first connector such that each is in electrical communication with a first pair of the conductors, and such that the inductive element is not interposed electrically between the capacitive element and the contact portions of the conductors of the first pair.
Other features of the invention will be apparent from the present disclosure, including the following Brief Description of The Drawings and Detailed Description Of the Preferred Embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the invention, reference is made to the following Detailed Description Of The Preferred Embodiments, and the accompanying drawings, in which:
FIG. 1A is a perspective view of plug and jack connectors known in the art;
FIG. 1B is a perspective view of a plug connector and a perspective, partially cut away view of a jack connector, both known in the art, and showing additional detail of the conductors disposed with the connectors;
FIG. 2 is an electrical schematic illustrating an electrical model of mated jack and plug connectors, and in particular of the coupling that is understood to contribute to near end cross talk, or NEXT, and far end cross talk, or FEXT;
FIG. 3 is an electrical schematic illustrating an electrical model of the a mated plug and jack, where the jack connector includes compensation according to the invention for reducing NEXT and FEXT;
FIG. 4A is a plot of NEXT versus frequency, showing the Category 6 limit and the performance of a mated jack and plug connector where a capacitive element is used to compensate for the both the inductive and capacitive components of the cross talk;
FIG. 4B is a plot of NEXT versus frequency, showing the Category 6 limit and the performance of a mated jack and plug connector where an inductive element is used to compensate for the both the inductive and capacitive components of the cross talk;
FIG. 5A is a plot of FEXT versus frequency, showing the Category 6 limit and the FEXT produced by the mated connector pair having the NEXT shown in FIG. 4A;
FIG. 5B is a plot of FEXT versus frequency, showing the Category 6 limit and the FEXT produced by the mated connector pair having the NEXT shown in FIG. 4B;
FIG. 6A is a plot of NEXT versus frequency, showing the category 6 limit as well as the performance of a mated jack and plug connectors where the jack includes compensation according to the invention;
FIG. 6B is a plot of FEXT versus frequency, showing the Category 6 specification and the FEXT of a mated jack and plug compensated according to the invention and having the NEXT of FIG. 6A;
FIG. 7A is a front perspective view of a jack connector according to the invention, showing the plurality of conductors and the printed circuit board that includes capacitive elements;
FIG. 7B is a rear perspective view of the jack connector of FIG. 7A;
FIG. 8A is a top view of the printed circuit board of the jack connector of FIGS. 7A and 7B;
FIG. 8B is a bottom view of the printed circuit of the jack connector of FIGS. 7A and 7B;
FIG. 9 is a perspective view of the inner and straddle pairs of conductors of the jack connector of FIGS. 7A and 7B;
FIG. 10A is a front perspective view of all eight conductors of the jack connector of FIGS. 7A and 7B; and
FIG. 10B is a rear perspective view of the all eight conductors of the jack connector of FIGS. 7A and 7B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the invention, the following discussion is provided in furtherance of an understanding of the creation and reduction of cross talk.
In FIG. 1B, each of the plurality of conductors 28 and 38 of the plug 12 and jack 14 , respectively, includes eight conductors. These conductors can be considered as being numbered from 1 to 8, as shown in FIG. 1 B. Conductors 4 and 5 can define a one data pair, known in the art as the “inner” pair, and indicated by reference numeral 58 , and the conductors either side of the inner pair 58 can define another signal pair, typically known in the art as the “straddle” pair, and indicated by reference numeral 60 . In telephony, one conductor of a given pair can be designated the “tip” conductor and the other conductor the “ring” conductor.
FIG. 2 is a schematic illustration of an electrical model of a plug connector mated to a jack connector. The electrical model of FIG. 2 illustrates the mechanism by which near end cross talk, or NEXT, and far end cross talk, or FEXT, is thought to be generated.
Consider an information signal generated by the generator 62 and being transmitted by the inner pair 58 of conductors. The signal impressed on the inner pair 58 by the voltage generator 62 appears as a signal across the output load 64 of an external circuit connected to the jack 14 . Undesirable inductive coupling between the conductors of the inner pair 58 and the outer pair 60 , represented by the transformers 68 A and 68 B, introduces cross talk onto the straddle pair 60 . Similar inductive coupling can take place, as represented by transformers 68 C and 68 D, in the jack connector. In addition, due to undesirable capacitive coupling between the inner pair 58 and the outer pair 60 in the plug where such capacitive coupling is represented by capacitors 70 A and 70 B, additional cross talk is introduced to the straddle pair 60 from the inner pair 58 . Such capacitive coupling can also occur in the jack connector, as represented by capacitors 70 C and 70 D. Thus, for the signal 62 impressed upon the inner pair 60 , a NEXT signal 72 appears across the load 74 of the external circuit to which the plug is connected, and a FEXT signal 78 appears across the load 80 of the external circuit to which the jack 14 is connected. The NEXT signal 72 and the FEXT signal 80 are the undesired signals which are addressed by the present invention.
The transformers 68 A- 68 D model inductive coupling, which occurs when current in one conductor creates a magnetic field that induces a current in a second conductor. The induced current generates voltages across the resistors 74 and 80 at the near end and the far end of the conductor pair. Note however, that the voltage at the far end, such as the voltage across the resistor 80 , is 180 degrees out of phase with the voltage generated the near end 72 , such as the voltage across the resistor 74 .
The capacitors 70 A- 70 D model cross talk due to capacitive coupling. Capacitive coupling refers to a voltage on one conductor creating an electric field that couples to another conductor, inducing a voltage on the other conductor. This capacitively coupled cross talk is equal at both the near end 72 and the far end 78 . That is, the same voltage, in terms of magnitude and phase, appears across resistors 74 and 80 .
The total induced voltage (cross talk) at the near end 72 is the sum of the inductive and capacitive induced voltages while at the far end 78 the cross talk is the difference between the two voltages. This can be represented by the equations:
NEXT=XT c +XT i
FEXT=XT c −XT i
where XT c is the cross talk voltage due to capacitive coupling and XT I is the cross talk voltage due to inductive coupling.
Typically, when modular connectors are mated, and there is no compensation for cross talk, the capacitive and inductive induced voltages are of the same order of magnitude so the NEXT is quite poor (due to the summation) while the FEXT is quite good (difference between two nearly equal signals). Older communications cabling standards (up to Category 5 ) specified NEXT because of the significant impact on attenuated signals being received at the near end, and as typical protocols of the time used only one signal path in each direction, FEXT was not important.
Cross talk can be reduced by creating compensating cross talk to cancel the undesired cross talk. FIG. 3 is an electrical schematic illustrating an electrical model of a mated plug-jack pair, where the jack connector includes compensation according to the invention for reducing cross talk at the near and far ends of the mated pair of connectors. Capacitive elements Cl and C 2 , indicated by reference numbers 102 A and 102 B, respectively, introduce a capacitive compensation voltage. Inductive elements 104 A and 104 B introduce an inductive compensation voltage. Note that the inductive and capacitive elements are connected across the inner conductor pair 58 and the straddle pair 60 so as to induce the compensation signals to cancel the cross talk.
For later reference below, please note that reference numeral 106 in FIG. 3 indicates the phase plane where connection is made to an external circuit such as would physically correspond to the pins 20 of the jack connector 14 of FIG. 1B; reference numeral 108 is the phase plane of the electrical connection between the jack and plug connectors such as would correspond to the contacting portions 40 shown in FIG. 1B; reference numeral 110 indicates the phase plane where the capacitive elements 102 A and 102 B establish electrical communication with the conductors to which they are connected; and reference numeral 112 indicates the phase plane of the inductive elements 104 A and 104 B. Thus, the pins 20 are electrically spaced from the phase plane 108 such as by the electrical distance 114 ; the inductive elements are electrically separated from the phase plane 108 by the electrical distance 118 ; and the capacitive elements are electrically spaced from the phase plane 108 of the contacts by the electrical distance 116 .
For a simple transmission line, electrical distances are usually specified in degrees of phase, and increase linearly with frequency with a slope depending on the physical length of the transmission line that causes the electrical separation.
Known in the prior art are designs that employ either capacitive or inductive compensation coupling within the body of the jack, and designs which employ both capacitive and inductive compensation coupling, with the capacitive compensation on the external circuit, such as the printed circuit board of FIG. 1 A.
It is simplest to use inductive compensation to address both capacitive and inductive cross talk, or to use capacitive compensation to address both capacitive and inductive cross talk. This is because compensation is basically introducing a second voltage to cancel an undesired voltage, and because the capacitive cross talk acts as a parallel capacitor and inductive cross talk act as a series transformer. Prior art designs focus on this simple approach. However, prior art designs could actually make FEXT worse, and did not necessarily optimally reduce NEXT, as is shown below.
According to the invention, however, it is possible to improve the reduction of NEXT and to also simultaneously reduce FEXT.
In this approach, capacitive and inductive compensation are both preferably employed, with the capacitive compensation and amount of inductive compensation each properly selected. Various cases are discussed below.
Case 1: Capacitive only compensation:
It is possible to address NEXT with capacitive compensation only, as discussed above. The capacitive compensation can be selected to be equal to and out of phase with NEXT:
COMP c =−NEXT=−XT c −XT i
NEXT NEW =NEXT+COMP c
NEXT NEW =XT c +XT i −XT c −XT i =0
where COMP c is the capacitively coupled compensation voltage.
Unfortunately, the FEXT suffers:
FEXT NEW =FEXT+COMP c
FEXT NEW =XT c −XT i −XT c −XT i =− 2 XT i
The NEXT is theoretically zero, but the FEXT is sacrificed!Nevertheless approach is understood to be used in at least one Category 5 prior art jack design.
Case 2: Inductive compensation:
Inductive compensation can also be used to alone address NEXT, as is also discussed above. Ideally, inductive compensation is set equal to and out of phase with NEXT:
COMP i =−NEXT=−XT c −XT i
NEXT NEW =NEXT+COMP i
NEXT NEW =XT c +XT i −XT c −XT i =0
where COMP c is the capacitively coupled compensation voltage.
But, since inductive signals are out of phase at opposite ends:
FEXT NEW =FEXT−COMP i
FEXT NEW =XT c −XT i +XT c +XT i =2XT c
Again NEXT is good but FEXT is sacrificed. Nevertheless the foregoing approach is understood to be used in at least one known Category 5 jack, which device is of course different than the device referred to in case I.
Case 3: Inductive AND capacitive compensation:
According to the invention, it is possible to reduce NEXT, while simultaneously reducing FEXT. Furthermore, NEXT performance can be improved over the prior art. Consider applying both capacitive and inductive compensation, with the inductive compensation and capacitive compensation selected as below:
COMP c =−XT c
COMP i =−XT i
NEXT NEW =NEXT+COMP c+COMP i
NEXT NEW =XT c +XT i −XT c −XT i =0
and:
FEXT NEW =FEXT+COMP c −COMP i
FEXT NEW =XT c −XT i −XT c +XT i =0
Thus, when capacitive and inductive compensation are both used, and, furthermore, the capacitive compensation is selected to address substantially only the capacitive cross talk (that is to provide a voltage to cancel the cross talk due to capacitive coupling) and the inductive compensation selected to address substantially only the inductive cross talk (that is, to provide a voltage that cancels the cross talk voltage due to inductive coupling) both NEXT and FEXT are ideally zero. Note than one of NEXT and FEXT can be ideally zero even when, for example, the capacitive compensation is selected to compensate ⅓ of the capacitive and inductive cross talk voltages and the inductive compensation is selected to cancel the other ⅔ of the capacitive and inductive cross talk. However, the other of the NEXT and FEXT is understood to suffer and be other than zero, even ideally.
Modeling using the SPICE™ program using models for actual jack and plug connectors confirms the above analysis. For example, FIG. 4A is a plot of NEXT versus frequency for a capacitive compensation design, that is, for a design where a capacitive element is selected to compensate for cross talk voltages, without reference to whether the cross talk is inductive or capacitive. The vertical axis of FIG. 4A is in decibels and the horizontal axis is a log plot in MHz. The curve 120 represents the Category 6 standard for NEXT, which can extend to a frequency of 250 MHz. The curve 124 represents the cross talk when the aforementioned capacitive compensation is applied, where the capacitive compensation includes a capacitor on the external circuit to which jack connected is connected, as is known in the art. The curves 120 and 124 intersect at the point 126 , and as indicated by the vertical line 128 , the Category 6 specification is exceeded at a frequency less than 100 MHz. As indicated by reference numeral 130 , the Category 6 standard can be exceeded by approximately 10 dB at a frequency of 250 MHz.
FIG. 4B is a plot of NEXT versus frequency for an inductive compensation design, that is, for a design where inductive compensation is selected to compensate for cross talk voltages, again without reference to whether the cross talk is inductive or capacitive. The vertical axis of FIG. 4A is in decibels and the horizontal axis is a log plot in MHz. The curve 120 again represents the Category 6 standard for NEXT, which can extend to a frequency of 250 MHz. The curve 134 represents the cross talk when the aforementioned inductive compensation is applied in the jack connector. The curves 120 and 134 intersect at the point 136 , and as indicated by the vertical line 138 , the Category 6 specification is again exceeded at a frequency less than 100 MHz. As indicated by reference numeral 140 , the Category 6 standard can be exceeded by approximately 10 dB at a frequency of 250 MHz.
FIGS. 5A and 5B are plots of the FEXT for the designs of FIGS. 4A and 4B respectively. Curve 144 is the Category 6 FEXT specification for FEXT; curve 146 is the FEXT of the capacitive compensation design whose NEXT is plotted as curve 124 in FIG. 4A, and curve 148 FIG. 5B is the FEXT produced by the inductive compensation design having the NEXT plotted as curve 134 in FIG. 4 B. The FEXT for both designs exceeds the Category 6 specification throughout the frequency range plotted.
FIG. 6A is a plot of NEXT versus frequency, where curve 120 represents the Category 6 specification for NEXT. Curve 152 represents NEXT where the inductive compensation is provided to address the inductive cross talk and capacitive compensation is provided to address the capacitive cross talk. The inductive compensation is disposed with the jack connector, and capacitive compensation applied at the external circuit to which the jack 14 is electrically connected, which can correspond to electrically applying the capacitive compensation at the phase plane 106 in FIG. 3 .
Note that the NEXT is considerably improved over the NEXT of FIGS. 4A and 4B, in that the curve 152 crosses the category 6 curve 120 at nearly 100 MHz. (When comparing FIGS. 4A and 4B with FIG. 6A, remember that the MHz scale is logarithmic). Significantly, FEXT is reduced. FIG. 6A is a plot of FEXT versus frequency, where curve 170 is the Category 6 specification, and curve 172 is the FEXT corresponding to curve 152 in FIG. 6 A. The FEXT is below the Category 6 specification for all frequencies plotted, typically meeting the Category 6 specification by approximately 20 dB. Extrapolating by eye, FEXT likely remains below the Category 6 specification for frequencies well in excess of 250 MHz.
However, curve 152 does not meet the Category 6 specification. It is not entirely below curve 120 . Curve 152 crosses curve 120 at the point 154 , shown in FIG. 6 A.
Further analysis and design was performed. Such analysis is typically an iterative process that involves modification, analysis, such as with the SPICE analysis program, and further modification based on the results of the prior analysis. One hopes this iterative process converges on an acceptable overall design after a finite number of iterations. Modifications to designs are usually made based on the experience, intuition of the designer.
Curve 160 represents the results of such additional design work, and is a plot of the NEXT versus frequency where the Category 6 specification is met up to and including 250 MHz. Returning to FIG. 6B, which is a plot of FEXT versus frequency, curve 170 is the FEXT produced also represents the FEXT corresponding to 160 in FIG. 6 A. Thus, according to the invention, cross talk can be reduced in connectors, including reducing both FEXT and NEXT.
Curve 160 represents moving the capacitive element such that it is electrically nearer to the contact portions of the appropriate connectors. One approach is to dispose the capacitive element with the jack connector. Preferably, the inductive element is not interposed electrically in between the capacitive element and the contacting portions and the capacitive element.
It is considered that the increase in performance represented by curve 152 and 160 can be understood as due to an undesirable phase shift occurring in the conductors of the connector, which phase shift detrimentally interferes with the application of the capacitive compensation. Moving the capacitive element nearer to the contacting portions reduces the effect of such phase shift.
Conductors that are sufficiently proximate to one another can act as a transmission line, which transmission line can be modeled by a series inductance per unit length along the transmission line and a parallel capacitance per unit length along the transmission line, and are further characterized by a characteristic impedance and a phase constant, which can often be calculated form the capacitance and inductance per unit length. One can determine the electrical phase shift introduced by a physical length of transmission line, given the frequency and the phase constant of the transmission line. The phase shift increases with frequency. Transmission line theory usually considers infinitely long, uniform structures, such as two parallel wires spaced by a fixed distance and surrounded by a single, uniform substance (e.g., air) having a single dielectric constant. For these structures, the capacitance per unit length, inductance per unit length, impedance and phase constant. Adding bends and turns to the conductors, as well some different dielectric materials around the wires, such as air and plastic, and the analysis quickly becomes complicated.
More complicated structures, such as the geometrically complex conductors of a typical modular connector, which can typically have bends, and include various dielectrics at varying distances from the conductors, are not necessarily amenable to any straightforward analysis. The frequency at which such a structure may exhibit transmission line behavior, and the nature of the behavior, is not readily apparent, especially to those of ordinary skill in the art of modular connectors. According to the invention, it is now known that the conductors of a modular connector can introduce a phase shift that must be accounted for when introducing capacitive compensation for cross talk.
Accordingly, in one embodiment of the invention, substantially only capacitive cross talk is addressed by a capacitive compensation, and substantially only inductive cross talk is addressed by inductive compensation. In another embodiment, providing capacitive compensation includes providing a capacitive element that is electrically applied as near as possible to the contact portions of the appropriate conductors, i.e., as near as possible to the phase plane 108 in FIG. 3 . Typically, applying the capacitive compensation electrically near the contacting portions means that the capacitive element is physically located as near as possible to the contacting portion of the appropriate conductors as well.
Furthermore, inductive compensation, if present, is not electrically interposed between the capacitive element and the contacting portions of the conductors. Introducing selective inductive compensation can involve increasing the inductive coupling, for a selected length, between selected conductors, and/or decreasing the inductive coupling between other conductors as is described in more detail below. It is considered that inductive compensation, such as is provided by the inductive element described above, when introduced electrically between the capacitive element and the contacting portions, can also contribute phase shift that lessens the effectiveness of capacitive compensation. Accordingly, in one aspect of the invention, the capacitive compensation is applied such that the inductive compensation is not electrically located between capacitive compensation and the contacting portions of the appropriate conductors. Thus, it is preferable to avoid electrically interposing the inductive elements 104 A and 104 B between the capacitive elements 102 B and 102 A, such as would occur if the capacitive elements 102 A and 102 B were to be electrically located at the phase plane 106 in FIG. 3 .
Preferably, to ensure that cross talk is reduced over a selected frequency range having an upper limit frequency, the phase shift between the contacting portions of the appropriate conductor and the capacitive element is less than about five (5) degrees over the frequency range, and more particularly, is less than about five (5) degrees at the upper frequency limit; more preferably, the phase shift is less than about four (4) degrees over the frequency range, and more particularly, is less than about four (4) degrees at the upper frequency limit; most preferably, the phase shift is less than about three (3) degrees over the frequency range, and more particularly, is less than about three (3) degrees at the upper frequency limit.
Preferably, the capacitive element provides a capacitance in the range of about 0.3 pf to about 0.7 pf; more preferably, the capacitance is in the range of about 0.4 pf to about 0.6 pf, and most preferably, the capacitance is about 0.5 pf.
The term “capacitive element”, as used herein, refers to an electronic component that provides a capacitive impedance. Similarly, the term “inductive element”, as used herein, refers to an element that provides an inductive impedance. For example, a capacitive element can provide an impedance having a negative imaginary part, whereas an inductor can provide an impedance having a positive imaginary part. The sign of the imaginary part of the impedance is indicative of the phase of the relationship between the voltage across an element to the current in the element. One example of capacitive element is a discrete capacitor. Other examples include a pair of wires, such as a twisted pair of wires; planar capacitors disposed on a printed circuit board or other substrate and that use the substrate material as the dielectric between the planar conductive regions; and interdigitated capacitors disposed with a substrate, such as by depositing metal on a printed circuit board. Capacitive elements can also be formed by depositing metal on the body, such as on the lead frame, of the modular connector, or by arranging sections of the conductor such that the electric fields of one conductor can couple to another conductor to store appropriate charge thereon, hence inducing a voltage on the other conductor. A suitable length of a transmission line can also provide a capacitive impedance, and hence is another example of a capacitive element. According to the invention it is disclosed that the electrical spacing between a capacitive element and the contract portions is preferably as small as possible. The capacitive element need not necessarily be of a particular type to realize the benefits of the invention.
Also, as understood by one of ordinary skill, in light of the disclosure herein, “electrical communication” can be established between an electrical element and a conductor without actual physical connection; for example, the capacitive elements can be capacitively coupled to the conductors with which they electrically communicate.
FIGS. 7A and 7B are front and rear perspective views, respectively, of one embodiment of a jack connector in accordance with the invention. The lead frame 36 can include a rectangular base 200 defining a plurality of slots 204 A- 204 H for guiding and/or supporting the plurality of conductors 38 . The base 200 includes an upper platform 210 , and a back 214 that extends vertically from the rear of the upper platform 210 and which includes a ridge 216 including dividers 218 . The slots 204 A- 204 H can open to the platform 210 , and conductors of the plurality of conductors 38 emerge from slots and extend, a various angles to the plane of the platform 210 , to the ridge 216 . The ridge 216 supports the upper ends of the plurality of conductors 38 , with the dividers 218 separating individual conductors of the plurality of conductors 38 .
The lead frame 36 mounts a substrate 220 , e.g., printed circuit board, which in turn includes compensating capacitive elements (not shown) for electrical communication with selected conductors of the plurality of conductors 38 . The back 214 of the lead frame 36 can include tabs 226 and shoulders 228 for confining the printed circuit board 220 therebetween. The lead frame 36 , plurality of conductors 38 , and printed circuit board 220 thus provide a compact arrangement wherein capacitive elements can be located electrically nearer to the contact portion, indicated generally by reference numeral 40 , of the plurality of conductors 38 .
Those conductors of the plurality of conductors that are to electrically communicate with one of the capacitive elements of the printed circuit board can include generally u-shaped upper portions (not readily visible in FIGS. 7 A and 7 B), which wrap, at least partially, for electrical communication with the capacitive elements of the printed circuit board 220 .
FIGS. 8A are top and bottom views, respectively, of the printed circuit board 220 of the jack connector shown in FIGS. 7A and 7B, illustrating the capacitors C 1 and C 2 of FIG. 3 .
Capacitor C 1 , which corresponds to the capacitive element 102 A in FIG. 3, includes upper planar conductive area 226 A and lower planar conducive area 226 B. The capacitor C 2 , which corresponds to the capacitive element 102 B in FIG. 3, includes upper planar conductive region 228 A and lower planar conductive region 228 B. Conductive paths 230 A and 230 B extend from the conductive planar areas 226 A and 226 B, respectively, toward the upper edge of the printed circuit board 220 , for electrical connection to an appropriate u-shaped portion of one of the conductors of the plurality of conductors 38 . With reference to FIG. 8B, conductive paths 232 A and 232 B connect the conductive planar areas 226 B and 228 B, respectively, to the conductive via holes 238 A and 238 B, respectively. As shown in FIG. 8A, the conductive paths 240 A and 240 B connect with the via holes 238 A and 238 B, respectively, and lead to the edge of the printed circuit board 220 so as to make electrical connection with appropriate u-shaped portions of conductors of the plurality of conductors when the printed circuit board is received by the lead frame 36 .
The conductive areas and/or paths can be formed by conductive metals deposited on the printed circuit board 220 . One method of defining the conductive areas and/or paths is to deposit a suitable metal, such as by sputtering, evaporation, etc., over a surface of the printed circuit board 220 and to then use photolithographic techniques to etch away undesired metal, thereby leaving the desired conductive areas and/or paths. Alternatively or additionally, metal can be selectively deposited on the printed circuit board 220 to form conductive areas and/or paths.
Note that the printed circuit board 220 can optionally include other capacitors for providing compensation. Planar conductive area 260 A forms a one optional capacitor with planar conductor area 260 B. Planar conductor 260 B is electrically connected to via hole 268 A, which in turn is electrically connected to conductive path 270 A in FIG. 8 A. Conductive path 270 A extends to the edge of the printed circuit board 220 for connection with an appropriate u-shaped portion of one of the plurality of conductors 28 . Similarly, conductive area 264 A forms another optional capacitor with conductive area 264 B, which capacitor is in electrical communication with via hole 268 B, which in turn is connected to conductive path 270 B. Conductive path 270 B runs to the upper edge of the printed circuit board 220 for appropriate connection with a unshaped portion of one of the plurality of conductors 28 . Note also that the conductive planar regions 260 A and 264 A are electrically connected respectively with the conductive regions 226 A and 228 A as indicated by reference numerals 260 C and 262 C. These optional capacitors are further discussed below.
FIG. 9 shows the inner conductor pair 58 and straddle conductor pair 60 shown in FIGS. 7A and 7B. The inner pair 58 includes conductors 304 and 305 , and the straddle pair 60 includes conductors 303 and 306 . Each of the four conductors shown in FIG. 9 includes a contact portion, which contact portions include the sections of each conductor in between the two lines indicated by reference numeral 40 . The contact portions are arranged in a row for electrical connection with the electrical contacts of a plug connector when mated with the jack connector of the present invention. Note that in FIG. 9 the conductor 303 is next to the conductor 304 , the conductor 304 is next to the conductor 305 , and the conductor 305 is next to the conductor 306 . Thus the four conductors 303 - 306 are also arranged in a row. Each of the conductors includes a pin portion (e.g., 303 A, 304 A, 305 A and 306 A) for connection with an external circuit, such as the circuit board 16 A shown in FIG. 9, for communication of signals between the contacts of the plug connector and the external circuit board 16 A. Solder joints 313 can connect the conductors to the external circuit board 16 A.
Note that the conductor 303 includes a section 303 C that is parallel to the section 305 C of the conductor 305 , and the conductor 304 includes a section 304 C that is parallel to the section 306 C of the conductor 306 , and that the sections 303 C and 305 C are not parallel to the sections 304 C and 306 C. Thus, the sections 303 C and 305 C are selectively inductively coupled, and the sections 304 C and 306 C are selectively inductive coupled. The sections 304 C and 306 C form a inductive element, such as the inductive element 104 A in FIG. 3, that is arranged to provide a selected inductive coupling between the conductors 304 and 306 . Similarly, the section 303 C and 305 C form a second inductive element, such as the inductive element 104 B in FIG. 3, that is arranged to provide second selected inductive coupling between conductors 303 and 305 . However, inductive coupling between the sections 303 C and 304 C, between the sections 304 C and 305 C, and between the sections 305 C and 306 C is reduced, as these pairs of sections are not parallel. The inductive coupling of a particular pair of section can be responsive to the length of the sections, the spacing therebetween, and the degree to which the section are co-oriented. It two sections are parallel, coupling is enhanced; if they are perpendicular, coupling is reduced. As shown in FIG. 9, sections 303 C, 304 C, 305 C and 306 C are arranged in a row. This row of conductor pairs are so shaped as to provide nonparallel or skewed conductor sections within each conductor pair.
Note also that conductor 303 includes another section 303 D; the conductor 304 includes another section 304 D, the conductor 305 includes another section 305 D, and the conductor 306 includes another section 306 D. Furthermore, the “D” section of each conductor forms a continuous length with the “C” section of that conductor. Note also that the sections 303 C and 303 D form a continuous straight length of the conductor 303 , and the sections 305 C and 305 D form a continues straight length of the conductor 305 . Preferably, the sections 303 D- 306 D are coplanar and the sections 303 C and 305 C lie in the plane 328 of the sections 303 D- 306 D. Furthermore, the sections 303 C and 305 C are preferably parallel and coplanar with the sections 303 D- 306 D. Typically, the contact portions 40 are all substantially parallel and lie in the plane 328 .
Note that the “A” sections of the conductors shown in FIG. 9, that is, sections 303 A- 306 A, are preferably also arranged, in conjunction with the “C” sections, to provide inductive coupling between the conductors 303 - 306 to help compensate for inductive cross talk. The shape of the conductors 303 - 306 can be analyzed and optimized using the SPICE™ circuit analysis program.
Typically, the center-to-center spacing indicated by reference numeral 315 is approximately 0.080″, and the center to center spacing of adjacent conductors is approximately 0.040″.
Note the plane 328 includes a front 332 , which is toward, or faces, the plug connector when mated with the jack connector that includes the lead frame 36 of FIGS. 7A and 7B, such that the plug connector will lie substantially on the front side of the plane 328 . The contact portions 40 also include front faces, of which the front face 334 is representative.
Reference numeral 340 indicates a plane parallel to the plane of the circuit board 220 when disposed with the lead frame 36 . Note that the circuit board 220 lies behind the plane 328 , and that the plane 340 of the circuit board defines an acute angle 344 with the plane of the circuit board 220 . Thus the circuit board tucks behind the back 214 of the lead frame 36 for providing a compact jack connector that provides for electrical communication between compensation capacitors and the conductors, where electrical communication can be established electrically nearer to the contact portions than when the capacitors are connected at the “A” sections of the conductors.
FIG. 10 shows a preferred embodiment of the conductors of the jack when more than four conductors are present in the jack. Note that the geometric arrangement shown in FIG. 9 is not simply repeated. In arriving at the design of FIG. 10, the configuration of appropriate sections of the inner pair 58 of conductors and of appropriate sections of the straddle pair 60 was selected to provide a desired inductive coupling for canceling NEXT and FEXT. However, analysis then revealed undesirable cross talk between the straddle pair and the first outer pair of conductors ( 301 and 302 ) and between the straddle pair and the second pair of outer conductors ( 307 and 308 ). Design changes were made to appropriate sections of the outer pair, and analysis performed, in an iterative process, until this cross talk was sufficiently reduced. However, further analysis then revealed undesirable cross talk between the one or both of the outer pairs of connectors and the inner pair 58 . Accordingly, the outer pairs were modified, and analysis performed, and eventually the structure shown in FIG. 10 was found to be satisfactory, in that cross talk between the pairs of conductors was reduced.
With reference to FIGS. 10A and 10B, note that the section 307 C is oriented in a selected direction, which direction is not parallel to the “C” sections of the adjacent conductors 308 and 306 or to the next conductor 305 . As can be observed from FIGS. 10A and 10B, preferably section 307 C is not parallel to any of the other “C” sections of the conductors 301 to 308 . In a preferred embodiment, section 307 C is anti-parallel to section 305 C and section 303 C. That is, the section 307 C is oriented transversely to a plane defined by sections 303 C and 305 C.
As can also be seen from FIGS. 10A and 10B, section 301 C is parallel and coplanar with sections 302 C and 305 C, and section 302 C is parallel to sections 304 C and section 306 C. However, the geometric pattern of the “C” sections of conductors 303 , 304 , 305 , and 306 is not exactly repeated as section 302 C is physically longer than sections 304 C and 306 C. Based on the iterative analysis above using the SPICE™ program, the above-described geometry symmetries were found to reduce the aforementioned problems of cross talk between the conductors 301 to 308 .
Referring back to FIGS. 8A and 8B which includes optional capacitors disposed with the printed circuit board 222 , a first capacitor is formed by planar conductive region 260 A and planar conductive region 260 B, and a second optional capacitor is formed by planar conductive region 264 A and planar conductive region 264 B. Viewing FIGS. 8A and 8B in conjunction with FIGS. 10A and 10B, the first optional capacitor is in electrical communication with conductor 306 and conductor 308 and the second optional capacitor is in electrical communication with conductor 301 and conductor 303 . Thus, the capacitors C 1 and C 2 are defined by conductive traces 226 A, 226 B and 228 A, 228 B that are electrically provided between or interdigitated relative to the paired conductors in the circuit board or substrate. Capacitive elements disposed as described above have been found to be useful in further reducing unwanted noise generated between data pairs of the plurality of conductors 28 . The use of the optional capacitive elements with the conductor structure shown in FIG. 9 is exemplary, and is discussed in part to indicate the conductors with which the optional capacitors can electrically communicate.
It will thus be seen that the invention efficiently obtains the objects set forth above, among those made apparent from the foregoing description. Because certain changes in the above constructions can be made without departing from the scope of the invention, it is intended that all matter contained in the above description and accompanying drawings be interpreted as illustrative and not in a limiting sense. For example, preferably a connector in accordance with the invention includes both capacitive and inductive elements for compensating for capacitive and inductive cross talk. However, the methods and apparatus disclosed herein can be useful in a connector that uses substantially inductive compensation or substantially capacitive compensation to address cross talk.
It is also to be understood that the following claims are intended to cover generic and specific features of the invention described herein and all statements of the scope of the invention which as a matter of language might be said to fall therebetween.
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A modular connector has a body defining an opening to receive a telephone type jack. The conductors are arranged in pairs so that adjacent conductors of non-pairs create capacitive and inductive cross talk. The conductors are non-parallel in-part to provide inductive coupling that reduces cross talk. The free ends of the conductors are connected to capacitive layers of a substrate located behind the contact portions to reduce capacitive cross talk.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 61/069,200 filed Mar. 13, 2008.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
REFERENCE TO A “COMPUTER LISTING APPENDIX SUBMITTED ON A COMPACT DISC”
Not Applicable.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates generally to an apparatus and a process for synthesizing diamond, preferably single crystal diamond (SCD) by Microwave Plasma Assisted Chemical Vapor Deposition (MPCVD).
(2) Description of the Related Art
Microwave Cavity Plasma Reactors (MCPR) designs are typically able to achieve relatively high deposition rates and deposition uniformity. MCPR's have been applied to many different diamond synthesis applications. (See e.g., Zhang, J., Experimental development of microwave cavity plasma reactors for large area and high rate diamond film deposition ; Kuo, K. P., Microwave assisted plasma CVD of diamond films using thermal - like plasma discharges , Ph.D. Thesis, Michigan State University, East Lansing: 1997; Ulczynski, M. J., Thesis, Michigan State University, East Lansing: 1999; Huang, W. S., Microwave plasma - assisted chemical vapor deposition of ultra - nanocrystalline diamond films , Ph.D. Thesis, Michigan State University, East Lansing: 2004; Khatami, S., Controlled synthesis of diamond films using a microwave discharge ( non equilibrium plasma ), Ph.D. Thesis, Michigan State University, East Lansing: 1997; Kahler, U., Microwave plasma diamond film growth , M.Sc. Thesis, Universitaet Gesamthochschule Wuppertal and Michigan State University, East Lansing and Wuppertal: 1997) 40-44] and U.S. Pat. Nos. 4,507,588, 5,311,103.) A cross sectional view of this reactor is shown in FIG. 1 .
According to FIG. 1 , a microwave plasma reactor creates a hemisphere-shaped plasma in close contact with the substrate and thus allows the coating of a large substrate surface. For example, using 2.45 GHz excitation, diamond films can uniformly be deposited over three to four inch diameter (80 cm 2 ) substrates, and when excited with 915 MHz the substrate deposition diameter can be scaled to over eight inches and deposition areas can exceed 320 cm 2 . Additionally this reactor concept is also operationally versatile. It can be adjusted to deposit diamond over a wide range of experimental conditions; i.e. it can deposit diamond on a variety of substrates, at pressures of 0.5-200 Torr, with variable power levels of (i) 500 W-6 kW at 2.45 GHz and (ii) 3 kW-20 kW at 915 MHz.
FIG. 1 shows a cross sectional view of a typical microwave cavity plasma reactor configured for operation in the “thermally floating substrate” mode. As shown, the cavity applicator sidewall ( 1 ) is made of a cylindrical brass tube. This brass tube forms the outer conducting shell of the cavity applicator and is electrically shorted to a water-cooled baseplate assembly ( 2 - 4 ) and a water-cooled ( 21 ) sliding short ( 8 ) via finger stock ( 9 ). Thus the cylindrical volume bounded by the sliding short, the cavity applicator sidewall and the substrate holder/baseplate form the cavity applicator electromagnetic excitation region. Continuous wave (CW) microwave power, typically at 2.45 GHz, is coupled into the cylindrical cavity applicator through a mechanically tunable coaxial excitation probe ( 11 ). This probe is the center conductor of the coaxial waveguide ( 10 ), which, as shown in FIG. 1 , is attached to the center of the sliding short ( 8 ). The movement of the sliding short changes the applicator length, L s , while the variation of the coaxial probe ( 10 ) position adjusts the depth of penetration of the coaxial excitation probe, L p , inside the cavity applicator. Both L s and L p can be independently varied up and down along the longitudinal axis of the applicator and both are adjusted: (i) to select the desired electromagnetic mode (primarily achieved by adjusting the length, L s ) and then (ii) couple microwave energy into the desired electromagnetic mode (primarily a probe depth adjustment) and (iii) to optimally match (achieved by iteratively but slightly adjusting both the probe and the short) the reactor to the input microwave system.
Transverse magnetic TM013 electromagnetic mode is used to establish the plasma discharge and is excited inside the cavity applicator by applying 2.45 GHz microwave power and length and probe tuning of the applicator to ignition conditions. For example, for an applicator with an inner diameter of 17.8 cm, the sliding short and probe lengths are adjusted to about L s =21.7 cm and L p =3.2 cm respectively. When approximately 20-50 W of microwave energy is coupled into the applicator and the reactor pressure is reduced to approximately 1-10 Torr, a discharge can be ignited inside the quartz dome. Then as the reactor system and discharge are brought up to the desired steady-state diamond deposition pressure, power and flow rate conditions, the applicator length, L s , and the probe depth, L p , are iteratively adjusted to reduce the reflected power and to achieve the desired process results such as deposition uniformity. It has been determined experimentally that the discharge loaded TM013 mode produces an axi-symmetric ellipsoid-like discharge, which is in good contact with the substrate.
The baseplate assembly consists of a water-cooled ( 22 ) and air-cooled ( 19 ) baseplate ( 2 ), an annular input gas feed plate ( 3 ) and a gas distribution plate ( 4 ). A quartz dome ( 5 ) with an inside diameter of 12.5 cm is sealed by an O-ring ( 20 ) in contact with the baseplate assembly. The thermally floating substrate holder cross section shown in FIG. 1 includes a flow pattern regulator ( 15 ), a metal tube ( 16 ), a quartz tube ( 17 ) and a holder-baseplate ( 6 ). The premixed input gases are fed into the gas inlet ( 23 ) in the baseplate assembly. The substrate ( 7 ) is placed on top of a molybdenum substrate holder ( 15 ), which is supported by the quartz tube ( 17 ). Quartz tubes of different heights may be used to change the position of the substrate with respect to the plasma to optimize (i.e. improve the uniformity, increase deposition rates, etc.) the film deposition process. The molybdenum holder ( 15 ), shown in greater detail in FIG. 2 , also serves as a gas flow pattern regulator.
According to FIG. 2 ( a - b ), a cylindrical metal tube ( 16 ) is placed concentrically inside the quartz tube. This metal tube prevents a discharge from forming underneath the substrate by reducing the electric field underneath the substrate. The metal tube ( 16 ) and the quartz tube ( 17 ) are placed on the holder baseplate ( 6 ). This holder baseplate has a 3 cm diameter hole cut in its center that allows the gases ( 24 ) to exit out of the reactor and then are pumped out of the vacuum system. The baseplate assembly ( 2 - 4 ), i.e. in particular the annular input gas feed plate ( 3 ), and the gas distribution plate ( 4 ), introduce an uniform ring of input gases that flow into the low pressure region inside the quartz dome. The TM013 electromagnetic fields are also focused into this region and ignite and sustain the microwave discharge ( 12 ) over the substrate ( 7 ). Air-cooling of the reactor is carried out by forcing air (or nitrogen gas) into the reactor through inlets ( 14 ) and ( 18 ), onto the dome and the interior cavity walls and then out through the screened window ( 13 ), and the optical access ports ( 19 ).
The thermally floating substrate holder configuration shown in FIG. 2 ( a - b ) utilizes a flow pattern regulator. The objective of this regulator is to spatially control the gas flows within the quartz dome to produce a flat, uniform, disk-shaped discharge hovering over and above and in good contact with the substrate. It consists of a specially designed molybdenum substrate plate ( 15 ) with a series of holes located around its outer circumference. This holder was developed to increase the uniformity of the film deposition by changing the gas flow patterns within the reactor and especially within the discharge. The gas flows circulating within the quartz dome are directed by the flow pattern regulator to flow around and through the discharge and thereby alter the shape and position of the discharge.
Screened windows ( 13 ) are cut into the cavity wall for viewing the discharge. These windows were also used for substrate temperature measurement. A topside substrate temperature measurement can be performed by focusing the pyrometer through the window onto the substrate. When the spot size of the pyrometer is reduced to 2 mm, temperature uniformity can be measured over two to three inch diameter silicon substrates (See e.g., Kuo, K. P., An experimental study of high pressure synthesis of diamond films using a microwave cavity plasma reactor ; Kuo, K. P., Microwave assisted plasma CVD of diamond films using thermal - like plasma discharges ; S. S. Zuo, M. K. Yaran, T. A. Grotjohn, D. K. Reinhard, and J. Asmussen, “ Investigation of diamond deposition uniformity and quality for freestanding film and substrate applications”, Diamond and Related Materials, 17, 300-305, 2008.) Other process measurements, such as quartz dome temperature and plasma optical emission measurements also can be preformed through these screened windows.
As discussed in U.S. Pat. No. 5,311,103, several features of the Microwave Cavity Plasma Reactor are responsible for its operational versatility including: (i) independently adjustable (tunable end plate) sliding short, (ii) coupling probe, and (iii) an axially adjustable stage that supports the substrate. The sliding short and coupling probe adjustments allow the reactor to excite the discharge with the desired electromagnetic mode and also to achieve a microwave power match over a large operational (pressure and power) regime. These two adjustments together with the independent adjustment of the substrate position also enable the positioning of the discharge above and in contact with the substrate. A hemispherical or disk shaped plasma is formed over the substrate and thereby creates the conditions for large area uniform deposition and also allows a degree of substrate temperature control. In addition to smooth substrates like silicon wafers irregular shaped and multiple substrates such as inserts and tool bits can be coated.
The versatility of this reactor concept also includes the ability to specifically engineer the substrate holder configuration to a specific deposition task. Given a specific CVD deposition/synthesis application the substrate holder configuration is redesigned and modified to achieve the goals of the application. For example, when operating in the higher pressures regime (80-200 Torr) a cooling stage is added. (See e.g., FIG. 3 .) Thus in this higher pressure operating regime the substrate temperature can be controlled (lowered) to be within the desirable substrate temperature diamond deposition regime; i.e. between 500-1400° C. Other examples of specially engineered substrate holders include: (i) examples given in U.S. Pat. Nos. 4,507,588, 5,311,103, 5,571,577, and 5,645,645; and the substrate assemblies designed for depositing polycrystalline diamond films on (ii) glass (See e.g. Ulczynski, M. J., Thesis, Michigan State University, East Lansing: 1999; and Ulczynski, M. J., et al., Ultra - High Nucleation Density for Diamond Film Growth at 470 and 900 C, in Advances in New Diamond Science and Technology , S. Saito, et al., Editors. 1994 , Scientific Publishing Division of MVC : Tokyo); (iii) round tools as shown in FIG. 4 ; (iv) carbon fibers as shown in FIG. 5 ; (v) ring seals as shown in FIG. 6 ( a - b ); and the synthesis of (vi) ultrananocrystalline diamond film deposition. (See e.g., Huang, W. S., Microwave plasma - assisted chemical vapor deposition of ultra - nanocrystalline diamond films , Ph.D. Thesis, Michigan State University, East Lansing: 2004; Huang, W. S., et al., Synthesis of thick, uniform, smooth ultrananocrystalline diamond films by microwave plasma - assisted chemical vapor deposition. Diamond and Related Materials, 2006. 15(2-3): p. 341-344; Tran, D. T, Synthesis of thin and thick ultra - nanocrystalline diamond films by microwave plasma CVD , M.Sc. Thesis, Michigan State University, East Lansing: 2005; and Tran, D. T, et al., New Diamond and Frontier Carbon Technology, 2006, to be published.) In each of these example deposition applications a special substrate holder configuration was designed and was inserted into the reactor.
As previously described, when the operating pressure is increased to above about 90 Torr the substrate temperature can exceed the temperature that is allowed for diamond deposition. The substrate must then be cooled. Hence the substrate holder configuration shown in FIG. 1 must be changed from the thermally floating configuration to the cooled configuration shown in FIG. 3 and in greater detail in FIG. 7 .
The water-cooled substrate holder configuration consists of a cylindrical, metallic, water-cooled stage attached to the holder-baseplate ( 7 ). As shown in FIG. 3 and FIG. 7 cooling water flows into ( 8 ) and out ( 9 ) of this stage keeping the stage at a low temperature. The molybdenum flow pattern regulator is placed on top of and is in good thermal contact with the cooling stage. A set of molybdenum insulation disks (d) are inserted between the flow pattern regulator and the substrate ( 10 or a) and thereby enable the variation of the substrate temperature. Gas flow patterns are similar to the gas flows shown in FIG. 2 ( a - b ) for the thermally floating configuration. Thus the quartz tube ( 17 ) serves the same purpose for both configurations; i.e. it helps direct the gases to flow through and around the discharge, through the gas flow regulator and then exit the reactor into the vacuum system. Additional substrate temperature control is achieved by placing several disk shaped molybdenum inserts (see (d) in FIG. 7 ) between the substrate and the substrate cooling stage. For example, at a constant operating pressure substrate temperature variation is achieved by varying the number and thicknesses of the molybdenum disks that are placed between the substrate and the water-cooled stage. It is noted here that as the number and thicknesses of the molybdenum inserts are changed the substrate position and the sliding short positions also may have to be varied slightly in order to achieve the optimum substrate temperature and deposition uniformity. Additionally, it was determined that by varying the pressure, substrate temperatures, and input gas mixtures, i.e. CH 4 /H 2 and N 2 /H 2 ratios, the growth α-parameters varies, thereby adjusting the horizontal and vertical growth ratio on each diamond crystal (Jes Asmussen and D. K. Reinhard, Diamond Films Handbook, Marcel Dekker, pp. 252, 2002). Thus process optimization becomes an iterative process where the sliding short, the coupling probe, the substrate position and the substrate configuration, i.e. the number and thicknesses of the molybdenum inserts, are all adjusted for optimum deposition conditions.
Initially the microwave cavity reactor was experimentally evaluated in a variety of diamond synthesis applications over a low-pressure regime of 20-80 Torr. Using the thermally floating configuration uniform deposition was achieved over three and four-inch (80 cm 2 ) substrates with linear, polycrystalline diamond deposition rates as high as 0.7 micron per hour. Discharge power densities were as high as 10 W/cm 3 . Although large area uniform deposition was achieved the low linear deposition rates were similar to the earlier experimental results, which employed the tubular reactor.
In an effort to increase the deposition rates the microwave cavity reactor was experimentally evaluated over a higher-pressure 80-160 Torr regime. In this pressure regime the microwave discharge becomes a high power density discharge. As pressure increases the discharge size decreases and the absorbed power density increases to 30-45 W/cm 3 . A thermal like discharge is created and neutral gas temperatures are 2500 K to over 3000 K. As described above and shown in FIG. 3 , a water cooled substrate holder stage is added to enable the adjustment of the substrate temperate within the diamond deposition regime. Under these conditions, thick, two-inch diameter, uniform (better than 15%) diamond films were synthesized. For example, two-inch diameter polycrystalline disks with uniformities of 10% and with thicknesses greater than 600 microns were grown. Recently, high quality, uniform (+/−5%) polycrystalline diamond deposition over three inch diameter silicon substrates was examined. When operating in the higher-pressure regime (100-160 Torr) uniform deposition rates were as high as 4.5-7 microns per hour. These rates are eight to ten times higher than the rates at lower pressure operation. If uniformity is not a concern, i.e. if high rate deposition over smaller areas is desired then deposition rates of over 10 microns per hour are possible. Accordingly, these experiments demonstrated that by increasing the operating pressure to 100-200 Torr a high power density microwave discharge is created. This discharge produces very high radical densities, such as atomic hydrogen and carbon radicals, which are important for rapid diamond synthesis. The densities of these radical species increase with increasing pressure.
The MPCR and the associated high pressure microwave discharge can be controlled to produce high quality, uniform, thick polycrystalline films over two and three inch substrates. These experiments demonstrated that the high-pressure operation together with the associated high power density microwave discharge and the high radical species densities causes a substantial increase in polycrystalline diamond deposition rates. These results may suggest suitable commercial potential for microwave CVD diamond synthesis.
Controlled and uniform, high pressure (100-200 Torr), microwave plasma assisted CVD polycrystalline diamond synthesis was achieved by introducing a number of innovations: (i) cooling the substrate holder; (ii) the introduction of molybdenum holder inserts and the associated shaping and holding of the substrate; (iii) the reduction of the spot size for the substrate temperature measurement to about 2 mm and then during the deposition process the in-situ, online monitoring and the controlling of the substrate temperature uniformity (to less than 50 K); (iv) the adjustment of the spatial neutral gas flows within the reactor and through the discharge to improve deposition uniformity; and (v) the positioning and the controlling of the shape of the discharge so that it becomes a hemisphere-shaped plasma that hovers over and is in good contact with the substrate.
A typical process cycle includes several steps: (i) discharge ignition; (ii) pre-deposition plasma surface treatments; (iii) adjustment of the operating conditions to the desired process conditions, i.e. pressure, gas flow rates, substrate temperature and temperature uniformity, etc.; (iv) steady-state operation; (v) post-deposition plasma surface treatments; and (vi) process shut down. Discharge ignition is achieved by first adjusting the cavity applicator sliding short to a length position so that the empty cavity TM013 mode (or any TM01n) electromagnetic mode is excited within the cavity and then also by adjusting the probe depth to enable the coupling of microwave energy into the cavity applicator. For a typical 17.8 cm diameter cavity applicator the initial sliding short length for TM013 mode excitation is about 21.6 cm and the initial coupling probe depth is approximately 3.2 cm. The discharge is ignited by adjusting the pressure to about 1-20 Torr (depending on the filling gas), and then by increasing the incident microwave power and finally by coupling this power, via the adjustment of the probe and sliding short, into the applicator. After discharge ignition, the cavity applicator may have to be further adjusted by tuning the sliding short and the coupling probe so that the incident microwave energy is matched (coupled) into the cavity applicator. Once the microwave discharge is created the operating pressure is increased to the desired process conditions, which are typically between 100-200 Torr, 1.5-5 kW, and 100-800 sccm, for high-pressure operation. While increasing the pressure from a few Torr to over 100 Torr, the sliding short, coupling probe and the substrate position are adjusted to place and keep the discharge over and in good contact with the substrate. After the desired pressure and gas flow rates are reached, the probe, sliding short and the substrate position are further adjusted to achieve temperature uniformity over the substrate. Additionally the coupling probe and sliding short are tuned to achieve a suitable microwave power match while still achieving substrate temperature deposition uniformity. Thus the three independent adjustments, i.e. sliding short, coupling probe and substrate position, enable the placement of the discharge over and in contact with the substrate there by enabling uniform substrate deposition temperature and deposition uniformity.
Other microwave reactor and process technologies have been developed to produce polycrystalline diamond at high-pressure conditions. Research groups such as Element Six, Osaka University in Japan [52], Fraunhofer IAF, Freiburg, Germany [53], and the Institute of Applied Physics at Nizhniy Novgorod, Russia [54] have developed microwave assisted CVD technologies that can produce thick (1-4 mm) high quality polycrystalline windows (one to four inch diameter) for mm-wave and optical applications. (See e.g., Kobashi, K, R & D of diamond films in the Frontier Carbon Technology Project and related topics. Diamond and Related Materials, 2003. 12(3-7): p. 233-240; Funer, M., C. Wild, and P. Koidl, Novel microwave plasma reactor for diamond synthesis. Appl. Phys. Lett., 1998. 72(10): p. 1149-1151; and Vikharev, A. L., et al., Diamond films grown by millimeter wave plasma - assisted CVD reactor. Diamond and Related Materials, 2006. 15(4-8); p. 502-507.)
Recently CVD diamond synthesis for high quality, high rate homoepitaxial growth of single-crystal diamond was demonstrated. (See e.g., Yan, C. S., et al., Very high growth rate chemical vapor deposition of single - crystal diamond. Proc. Natl. Acad. Sci., 2002. 99: p. 12523-12525.) Using a microwave plasma CVD process, a MPCR (a modified Wavemat design), and synthetic high pressure high-temperature (HPHT) diamond substrates, single-crystal diamond at rates from 30-150 microns per hour were synthesized. These deposition rates were larger than the rates previously observed for polycrystalline diamond synthesis and the single-crystal diamond product was superior to the CVD synthesized polycrystalline diamond product. Thus the research results stimulated worldwide research in single crystal diamond synthesis. (See e.g., U.S. Pat. Nos. 6,858,078; 7,115,241; 6,582,513 6,858,080; 7,122,837; and 7,128,974.) While these patents generally discuss to the possibility of growing single crystal diamond using microwave plasma-assisted CVD, they do not elaborate, teach or discuss an actual or operable apparatus. Accordingly, a need still exists for effective single crystal diamond growth using microwave plasma-assisted CVD.
OBJECTS
Therefore, it is an object of the present invention to provide an improved system and process for growing single crystal diamond using microwave plasma and in particular to grow multiple diamond samples simultaneously.
SUMMARY OF THE INVENTION
The present invention relates to a process for growing diamond in microwave plasma, which comprises: providing a substrate holder as a first disc for growing the diamond with at least a first recess around a longitudinal axis of the holder for holding a growth substrate, wherein the holder defines a second recess positioned around the longitudinal axis of the holder and extending a predetermined distance above the first recess forming a growth volume space, wherein a recess extending means is provided in the plasma for extending the distance of the second recess above the first recess along the longitudinal axis thereby increasing the growth volume space as the substrate grows in thickness; placing the substrate in the first recess; placing the holder in the plasma reactor so that the plasma can contact the holder and substrate in the growth volume space; generating a plasma in the reactor comprising methane, hydrogen and optionally nitrogen in an amount and at a temperature and pressure which deposits the diamond on the substrate to provide a first thickness of diamond; extending the distance of the second recess above the substrate and increasing the growth volume space with the recess extending means and depositing a second thickness of diamond; and stopping the diamond growth in the reactor and opening the reactor to provide the substrate with at least the first and second thicknesses of diamond. The holder can be fabricated from molybdenum. In further embodiments the substrate is a member selected from the group consisting of diamond and silicon. In still further embodiments, the diamond growth on the substrate forms polycrystalline diamond. Further still, the diamond growth was boron doped by adding diborane (B 2 H 6 ) into the reactor thereby producing boron doped diamond (BDD). Further still, the substrate is a diamond chip and the diamond growth is single crystal diamond (SCD). In still further embodiments, a plurality of first and second recesses defined on the first disc spaced apart with respect to each other defining parallel longitudinal axis into the plasma, each of the plurality of first and second recess is adapted to hold a substrate for simultaneous multiple diamond growth. Further still, the diamond chips in each of the plurality of recesses can be individually adjusted in height relative to a top surface of the substrate holder by placing an insert defining an optionally different thickness with respect to any other insert underneath each substrate such that the temperature of each chip can be adjusted to a suitable value for deposition. In yet an even further embodiment, each substrate is grown into a thickness range position such that a top portion of the substrate is located from just below to just above the top surface of the second recess. In still a further embodiment, the temperature at each of the plurality of recesses is controlled by adjusting the plasma, a cooling means, or the substrate height into the plasma or combinations thereof to create temperature uniformity among each of the plurality of substrates. In yet a further embodiment, the methane, hydrogen and optionally nitrogen of the plasma are introduced into the reactor as a feedgas further adding diborane (B 2 H 6 ) in the feedgas in a quantity of up to 100 parts per million (ppm). In yet a further embodiment, the feedgas comprises nitrogen in a quantity of up to 1000 ppm. In still a further embodiment, the methane is provided between 3-15% of the feedgas and the reactor is operating at a pressure between 14-160 Torr, 2-3 kW and using a 2.45 GHz microwave reactor. Further still, the reactor operates under a microwave frequency selected from the group consisting of a 2.45 GHz reactor and a 915 MHz reactor.
The present invention further provides for a process for single crystal diamond (SCD) growth in microwave plasma, which comprises: providing a substrate holder as a first disc for growing the SCD with at least a first recess around a longitudinal axis of the holder for holding a SCD chip as a growth substrate, wherein the holder defines a second recess positioned around the longitudinal axis of the holder and extending a predetermined distance above the first recess and the substrate, wherein a recess extending means is provided in the plasma for extending the distance of the second recess above the first recess as the substrate grows in thickness; placing the SCD chip in the first recess; placing the holder in the plasma reactor so that the plasma can contact the holder and chip in the first and second recesses around the axis; generating a plasma in the reactor comprising methane, hydrogen and optionally nitrogen in an amount and at a temperature and pressure which deposits the SCD on the diamond chip to provide a first thickness of SCD; extending the distance of the second recess above the substrate with the recess extending means and depositing a second thickness of the SCD; and stopping the SCD growth in the reactor and opening the reactor to provide the SCD chip with at least the first and second thicknesses of the SCD.
The present invention further provides for a process for single crystal diamond (SCD) growth in a microwave plasma reactor, which comprises: (a) providing a substrate holder as a first disc for growing the SCD with at least a first recess around a longitudinal axis of the holder for holding a SCD chip as a substrate, the holder defines a second recess positioned around the longitudinal axis of the holder and extending above the first recess; (b) placing the SCD chip in the first recess; (c) placing the holder in the plasma reactor so that the plasma can contact the holder in the first recess and the second recess around the longitudinal axis; (d) generating a plasma in the reactor from a flow rate of gas comprising methane, hydrogen and optionally nitrogen in an amount and at a temperature and pressure which deposits the SCD on the diamond chip to provide a first thickness of SCD; (e) stopping the SCD growth in the reactor; (f) placing a second disc on the first disc with an opening defining a third recess above and around the longitudinal axis of the first disc; (g) closing the reactor and starting growth of a second section of the SCD over the first section of the SCD to provide a second thickness of SCD over the first thickness of SCD; and (h) stopping the SCD growth in the reactor and opening the reactor to provide the SCD with the first and second thicknesses of SCD. The substrate holder can be fabricated from molybdenum. In further embodiments, the second recess defines a larger cross sectional area than that of the first recess taken perpendicular to the longitudinal axis of the holder. Still further, steps (b) to (h) are repeated for growing one or more additional thicknesses of the SCD. Further still, a plurality of first and second recesses defined on the first disc spaced apart with respect to each other defining parallel longitudinal axis into the plasma, each of the plurality of first and second recess is adapted to hold a diamond chip. Still further, the flow rate of gas is between 100 and 1200 sccm of hydrogen, methane and optionally nitrogen having a molar ratio of methane to hydrogen of 3-15% and nitrogen to hydrogen of 0-10%. Further still, the recesses define a square geometry around the longitudinal axis. Further still, a side of the first disc opposite the plasma is shimmed to provide approximately the same height of an exposed surface of the diamond in the plasma at the start of each growth run. In still further embodiments, the holder is mounted on a cooler means providing a stage so as to maintain a temperature of the holder between about 850 and 1,300° C. wherein the plasma is at a pressure between about 100 and 200 Torr. Further still, the temperature is adjusted by either moving a sliding short within the reactor chamber or moving the position of the substrate holder. Still further, the diamond chip is a substrate defining a square geometry cross section of sides from 1 mm to over 1 cm. In still further embodiments, an initial cleaning of the diamond chip, reactor and substrate holder prior to step (a) and then additional cleanings in between stopping and restarting. Still further, adjustment of the plasma delivery adjusts the a parameter and thereby adjusts the horizontal and vertical growth characteristics of the SCD. Further still, each recess comprises side walls and the SCD is spaced apart from the side walls a specified distance. Still further, the specified distance the SCD is spaced apart from the side walls is from 0.1 mm to 2.0 mm.
The present invention further provides a process for single crystal diamond (SCD) growth in a microwave plasma reactor, which comprises: (a) providing a molybdenum holder as a first disc for growing the SCD with at least a first recess around a longitudinal axis of the holder for holding a SCD chip as a substrate, the first disc being mounted on a movable stage; (b) a second disc defining a second recess positioned around the longitudinal axis of the holder and above the first recess mounted on a stationary element; (c) placing the SCD chip in the first recess; (d) placing the holder in the plasma reactor so that the plasma can contact the holder in the first recess and the second recess around the longitudinal axis; (e) generating a plasma in the reactor comprising methane, hydrogen and optionally nitrogen in an amount and at a temperature and pressure which deposits the SCD on the diamond chip to provide a first thickness of SCD; (f) lowering the first disc within the chamber by the movable stage operable to longitudinally raise or lower the first disc holding the growing SCD such that the second disc remains stationary with respect to the first disc thereby increasing the growth area for the SCD between the first and second disc; (g) continuing growth of a second section of the SCD over the first section of the SCD to provide a second thickness of SCD over the first thickness of SCD; and (h) stopping the SCD growth in the reactor and opening the reactor to provide the SCD with the first and second thicknesses of SCD. In further embodiments, the second disc defining the second recess defines a cross sectional area larger than that of the first recess. Further still, steps (e) to (g) are repeated for growing one or more additional thicknesses of the SCD before stopping the reactor in step (h). Still further, a plurality of first recesses defined on the first disc spaced apart with respect to each other defining parallel longitudinal axis into the plasma, each of the plurality of first recess is adapted to hold a diamond chip.
The present invention provides a microwave cavity plasma reactor (MCPR) for growing diamond which comprises: a substrate holder as a first disc having at least a first cavity defining a first and second recess around a longitudinal axis of the holder for holding a growth substrate, wherein the second recess extends a predetermined distance above the first recess forming a growth volume space; a reactor chamber enclosing the holder coupled to a microwave delivery means and a fluid inlet stream for generating a plasma in the reactor chamber, the plasma is comprised of methane, hydrogen and optionally nitrogen; a quartz dome for facilitating formation of a plasma discharge over the substrate; a recess extending means for extending the distance of the second recess above the substrate along the longitudinal axis thereby increasing the growth volume space; wherein the reactor is operable to grow diamond on the substrate as a first and second thickness by contacting the substrate with the plasma in the growth volume space. In further embodiments, the first disc is fabricated from molybdenum. Further still, a second disc having an opening defining a third recess positioned on the second disc for growing diamond as the second thickness on the first thickness. Still further, a cross section of the second recess taken perpendicular to the longitudinal axis is larger than that of the first disc. Further still, the substrate is a diamond chip and the diamond growth is characterized as single crystal diamond (SCD). In still further embodiments, the microwave generating means is characterized by a microwave frequency selected from the group consisting of 2.45 GHz and 915 MHz. Further still, the first disc comprises a plurality of cavities each defining a first and second recess around a longitudinal axis parallel to that of the at least a first cavity. Still further, the reactor is operable to grow a plurality of diamonds on a plurality of substrates in each of the plurality of cavities. In still further embodiments, a cooling stage for maintaining the holder at a predetermined temperature. Further still, the predetermined temperature is between 850 and 1300° C. and a predetermined pressure in the quartz dome is between 100-200 Torr. Still further, the recess extending means is a movable stage adapted to increase the growth volume space during a reaction.
BRIEF DESCRIPTION OF THE DRAWINGS
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
FIG. 1 illustrates a microwave cavity plasma reactor in thermally floating substrate holder configuration;
FIG. 2 a illustrates a top view of the substrate holder of FIG. 1 ;
FIG. 2 b illustrates a thermally floating substrate holder setup;
FIG. 3 illustrates a cross sectional view of a high-pressure MCPR system shown operating with a cooling stage configuration;
FIG. 4 illustrates a cross sectional view of a particular configuration for diamond film coating on eighteen and thirty six WC-6% Co round tools;
FIG. 5 illustrates a cross sectional view of a microwave plasma jet reactor for diamond thin film coating on carbon fibers;
FIG. 6 a illustrates a top view of a seal substrate holder
FIG. 6 b illustrates a seal coating substrate holder setup;
FIG. 7 illustrates a substrate holder setup used in high-pressure MCPR for diamond film deposition: (a) 2″ Si wafer, (b) 2″ Mo substrate holder, (c) Mo ring, (d) Mo discs, (e) Mo gas flow regulator, (f) water cooling stage;
FIG. 8 illustrates a multiple single crystal diamond substrate MCPR configuration;
FIG. 9 illustrates a reactor scaling with microwave frequency (left 2.45 GHz, right 915 MHz);
FIG. 10 illustrates an exemplary holder structure design;
FIG. 11 illustrates the holder structure of FIG. 10 showing a cooling stage and positioning ring;
FIG. 12 illustrates a holder structure for multiple samples on a raised disc;
FIG. 13 illustrates a further embodiment of a holder structure with a recessed holder and blank discs;
FIG. 14 illustrates an isometric view of an exemplary holder design with a plurality of recess positions;
FIG. 14A schematically illustrates SCD growth in a first recess on a Si substrate;
FIG. 14B schematically illustrates SCD growth in a first recess on a diamond chip substrate for an X mm thickness;
FIG. 14C schematically illustrates SCD growth in a first recess on a diamond chip substrate for a Y mm thickness;
FIG. 14D schematically illustrates SCD growth in a first recess on a diamond chip substrate for an Z mm thickness;
FIG. 14E schematically illustrates SCD growth in a first recess on a diamond chip substrate for an W mm thickness;
FIG. 15 illustrates an isometric view of the exemplary holder design of FIG. 13 with a plurality of recesses and several discs;
FIG. 16 schematically illustrates an order of diamond growth process;
FIG. 17 illustrates a Molybdenum holder structure for new SCD samples (diamond chips);
FIG. 18 illustrates a Molybdenum holder structure for previously grown SCD samples (i.e. additional depositions to FIG. 17 );
FIG. 19 illustrates a Molybdenum holder structure for previously grown SCD samples (i.e. additional depositions to FIG. 18 );
FIG. 20 illustrates a Molybdenum holder structure for previously grown SCD samples (i.e. additional depositions to FIG. 19 );
FIG. 21 illustrates a top schematic view of a first disc having a plurality of recesses with 4 samples positioned on a 4″ substrate holder;
FIG. 22 shows photographs of Samples SCD#DK001 and SCD#DK002 illustrating the Influence of nitrogen on the SCD growth;
FIG. 23 shows photographs of Samples SCD#DK003 and SCD#DK004 illustrating the repeatability of SCD growth;
FIG. 24 shows photographs of Samples SCD#DK005 and SCD#DK006 illustrating that more nitrogen decreases defects on SCD;
FIG. 25 illustrates a surface of Si wafer (R=8 ohms) (1500×) and surface of Si wafer (R=8 ohms) (5000×);
FIG. 26 illustrates boron-doped diamond coated on single crystal substrate;
FIG. 27 illustrates an exemplary movable stage embodiment of a holder and reactor configuration for multiple SCD growth;
FIG. 28A shows photographs of a 70 seed growth run of 42 hours using an optical microscope on the top surfaces of the samples;
FIG. 28B shows photographs of the 70 seed growth run of 42 hours from FIG. 28A with a light delivered from the bottom of the substrates;
FIG. 28C shows an array of total thickness (microns)(top number) and growth rate (microns/hour) (bottom number) corresponding to the samples from FIG. 28A ;
FIG. 28D shows an array of deposition temperature (top number) and growth rate (microns/hour) (bottom number) corresponding to the samples from FIG. 28A ; and
FIG. 29 shows variation of room temperature electrical conductivity of boron-doped single crystal diamond layers with nitrogen content in a plasma feed gas.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present disclosure provides for diamond synthesis on crystal substrates. Particularly, the present disclosure provides for exemplary process methods and associated Chemical Vapor Deposition (CVD) deposition machine technology that is able to rapidly synthesize single crystal diamond at a low, commercially attractive cost. Furthermore, the present disclosure provides for single crystal diamond (SCD) synthesis on a substrate, particularly on an SCD substrate. An SCD substrate can be an SCD seed or an SCD chip. An SCD chip can be characterized as any piece of single crystal diamond including but not limited to industrial diamond, high temperature and high pressure synthesized diamond, gem stone diamond and/or natural diamond. An SCD chip can be formed or utilized in any geometric shape and size. Moreover, an SCD diamond can define a geometry cut on any diamond surface plane.
In an exemplary embodiment, microwave plasma assisted CVD single crystal diamond synthesis can be improved by addressing the following objectives: (i) control the quality of the synthesized single crystal diamond (both during a run and from run to run), (ii) achieve high growth rates while still synthesizing high quality single crystal diamond material, (iii) develop technologies and processes that enable the synthesis of multiple single crystal substrates, and (iv) scale up the process further to simultaneously synthesize multiple (>100) substrates, i.e. develop and process test large area 915 MHz reactor technology and associated processes.
In a particular exemplary embodiment, a water-cooled, high pressure, 2.45 GHz MCPR (see FIG. 3 ) is employed to further include a substrate holder configuration to accommodate multiple high-pressure high-temperature (HPHT) grown diamond substrate seeds. Using 2.45 GHz excitation and existing 17.8 cm diameter MCPRs, an advantageous substrate holder configuration was designed and developed that was associated with processes that enable the controlled deposition of one to many single crystal substrates per process run. Additionally processes, holders, etc. that were developed using the 2.45 GHz MCPR had to be scalable to operate in the much larger eighteen inch diameter, 915 MHz MCPR reactor. Accordingly, in an exemplary embodiment a uniform, large area deposition area that enables uniform, controlled, single crystal deposition simultaneously over many substrates was achieved. In certain embodiments related to the present disclosure, deposition rate per substrate may be sacrificed in order to achieve a uniform controlled deposition over many substrates.
The present disclosure is described and illustrated with reference to the following particular exemplary embodiments by way of examples:
Example I
A. MCPR Loaded with Multiple Diamond Substrates
A cross sectional view of an exemplary MCPR loaded with multiple diamond substrates is shown in FIG. 8 . As shown the substrate holder configuration is water-cooled and employs a molybdenum disk set similar to those described in FIG. 7 . The molybdenum disk set and substrate holder itself ( 10 ) are designed to accommodate either one or multiple diamond substrates. Reactor tuning and plasma control, and efficient creating, maintaining, and positioning of a hemispherical discharge over the substrates are carried out according to previously described procedures. In an exemplary embodiment, when using 2.45 GHz excitation, the substrate holders can accommodate up to as many as 10-20 diamond substrates for one run. The exact shape/configuration of the substrate holder and the disk set varies as the deposition processes develops versus process time and even the method/geometry of positioning and holding the diamond substrates changes versus process time. This was achieved in-situ using suitable reactor technology, i.e. adjusting the variable sliding short and probe, variable substrate holder positioning and variable input power. Reactor configuration and its many design and process variations are discussed in further detail hereinbelow. In all experimental runs, the plasma size is adjusted to cover a large area, i.e. up to 4 inch diameters in the 2.45 GHz system and up to 6 to 8 inch diameters in 915 MHz systems. While most experiments were performed using the water cooled configuration of FIG. 8 , the thermally floating configuration of FIG. 2 could also be employed for single crystal diamond growth.
B. Reactor Scaling
In an exemplary embodiment, an exemplary MCPR, associated substrate holders and the process itself can be scaled to much larger deposition areas by dropping the excitation frequency to 915 MHz and scaling up the MCPR size to 460 mm diameter with an associated discharge size of 330 mm diameter. This reactor and discharge scaling are shown in FIG. 9 . The process scaling allows the substrate holder configuration to be enlarged to accommodate many single crystal diamond substrates. FIG. 21 illustrates an exemplary 915 MHz substrate holder ( 10 ) configuration that is able to simultaneously process over one hundred diamond substrates.
C. Single Crystal Work on 2.45 GHz Reactor
A first set of experiments determined growth rates of 10 microns per hour at a pressure of 160 Torr and a process gas composition of 7% Methane and 93% of Hydrogen. Addition of 400 ppm Nitrogen to the process gas composition increased the growth rate to 30 microns per hour. Analysis of the process data and the sample properties from numerous runs showed that the sample temperature has a substantial effect on the quality of the surface of the sample. A polycrystalline frame that grew during the experiments, which were run at around and above 1300° C., was not detected for those which were run at around 1100° C. In addition, the experiments which were run below 1050° C. have resulted with samples completely grown with a polycrystalline film. Therefore, it is desirable that experiments are run at around 1100-1250° C.
Additional experiments were conducted with changing Methane percentages. During these runs pressure was kept relatively steady at about 160 Torr and Nitrogen percentage at 400 ppm. Methane percentages were varied between 7 to 14% and achieved 30 to 45 microns/hour growth rate, respectively. However, having a higher Methane ratio resulted in limited lifetime of quartz domes. Some of the runs were stopped after only 5 hours due to carbon deposition on the dome. These domes were either cleaned with hydrofluoric acid solution and reused, or they were discarded as waste. After these runs, it is concluded that 7-10% Methane ratio provided suitable results.
Pressure is increased from 160 Torr to 180 Torr and the Methane ratio was reduced down to 8.5 percent in order to increase the life of quartz domes and to execute longer runs. Since the increase in pressure reduces a plasma ball's size, it was considered that keeping the plasma ball away from the quartz dome walls will increase the overall life of the quartz dome. Moreover, lowering the Methane ratio will help reduce the likelihood of carbon deposition on the dome walls. Additionally, increasing the pressure also increases the growth rate of diamond.
Nine experiments were conducted at the 180 Torr pressure and 8.5% methane ratio composition. These experiments showed that the average growth rate increased to 40 to 45 micron/hour. Additionally, the life of the quartz domes improved substantially. However, all the samples from these runs ended up with an impurity/imperfection on the grown film. Based on runs executed, a process window was established for repeatable growth of single crystal diamond that consists of 160 Torr, 9% methane, 400 ppm nitrogen and a substrate temperature of 1100° C. The set of deposition conditions gives of growth rate of 35-40 microns/hr. Sample growth up to a total thickness of 4.75 mm has been achieved.
D Growth Process
Single crystal diamond samples are often received with dirt and residue from a supplier. These samples are typically first run through an acidic and ultrasonic cleaning procedure to remove the dirt and residue that are present on the sample surface. In an exemplary embodiment, acidic cleaning can be achieved by any of the following exemplary technique:
1. Add sample into a solution of Nitric Acid (20 mL)+Sulfuric Acid (20 mL) in a beaker and then heat the solution to boiling temperature by placing the beaker; for example, on a basic heater (set to 10 or max) for approximately 15 minutes (there is no temperature measurement on the heater or in the beaker, the acidic solution needs to be at boiling temperature); then rinse sample in DI water; 2. Add sample to Hydrochloric Acid (30 mL) in a beaker and heat on a heater (set to 10 or max) for 10 minutes (there is no temperature measurement on the heater or in the beaker, the acidic solution needs to be at boiling temperature); then rinse sample in DI water; and 3. Add sample to Ammonium Hydroxide (30 mL) in a beaker and heat on a heater (set to 10 or max) for 10 minutes (there is no temperature measurement on the heater or in the beaker, the solution needs to be at boiling temperature; then rinse sample in DI water.
Ultrasonic cleaning can be achieved according to the following exemplary techniques:
1. Place sample in an ultrasonic bath with Acetone (30 mL) in a beaker for 15 minutes; and 2. Place sample in an ultrasonic bath with Methanol (30 mL) in beaker for 15 minutes.
Final rinsing and drying is generally desirable by rinsing the sample with DI water and then drying. In an exemplary embodiment, drying is accomplished by blowing nitrogen on the sample to remove water. The sample can then be placed in a clean and new Petri dish if desired.
E. Substrate Holder Preparation
In an exemplary embodiment a Molybdenum substrate holder and associated mechanical parts of an exemplary chamber are cleaned before every deposition process according to the following suitable cleaning procedure:
1. Sand Blasting—The Molybdenum (Mo) pieces that go into the chamber are sand blasted (cleanliness of the Multiple Sample Holder (MSH) ensures and promotes desirable product achievability; if MSH is not sufficiently clean, localized polycrystalline diamond growth will likely start and adversely affect the plasma); 2. Ultrasonic cleaning of all Mo pieces (with water or a solvent); 3. Rinsing and nitrogen blowing; and 4. Drying the Mo pieces in a dryer at about 80° C. for about 20 minutes.
F. Substrate Loading and a Two Principle Substrate Holder Design
In an exemplary embodiment, a single crystal diamond sample is loaded into a chamber. FIG. 10 shows a detailed setup of an exemplary system according to the present disclosure. Typically the system is comprised of a stainless steel cooling stage, a quartz tube, stainless steel positioning rings, Molybdenum holders and a diamond sample.
In an exemplary process, the quartz tube is attached onto the cooling stage. The positioning rings are attached to the base plate. The positioning rings are available in various thicknesses. In an exemplary embodiment, positioning rings are available in thicknesses of 7, 4, 2 and 1 mm. With reference to FIGS. 10-13 , the Mo pieces are mounted on top of the cooling stage. In an exemplary embodiment, the Mo pieces are positioned relative to the cooling stage in the following order: a four inch holder; inserts ( FIG. 13 shows two inserts); a centering ring; a multiple sample holder (MSH). In a particular embodiment, a 2 inch raise disc (See FIG. 12 ) is used defining a plurality of recesses. In an exemplary embodiment, the recess dimension size is 6×6×1 mm for new samples and a recess dimension size of 6×6×2 mm is suitable for grown samples.
In further embodiment (See FIG. 13 ), blank disks of various thicknesses are employed. Exemplary blank discs can be 1, 2 or 4 mm in thickness. The embodiment as illustrated in FIG. 13 further comprises a recessed holder and frame discs of various thicknesses. Exemplary frame discs can be 1, 2 or 4 mm in thickness. Typically, thickness of the discs depends on the condition of the sample, e.g. new sample, grown one time, grown two times, etc.
Single crystal diamond (SCD) Substrate set up can be achieved according to the following exemplary process:
1. Load a clean SCD substrate using clean tweezers into a designated recess;
2. Load the Mo pieces onto the cooling stage;
3. Load the stage onto the base plate;
4. Install the door of the chamber; and
5. Start pump down process.
G. System Start-Up
In an exemplary embodiment, the mechanical and electrical components of the system are turned on prior to the process start. In a further embodiment, the system is pumped down over night (i.e., more than 12 hours) to ensure that all the air inside the chamber is evacuated and there is no leak and residual gas left inside the chamber. Accordingly, in an exemplary embodiment, it is suitable to employ the following procedural steps:
1. Turn on chiller;
2. Turn on microwave power supply;
3. Turn on rectangular waveguide cooling fan (small blower);
4. Pump down over night;
5. Adjust short position to 20.8 cm;
6. Adjust probe position to 3.9 cm.
H(1). Deposition Process (Start Up)
In a particular embodiment, In-situ (H 2 ) cleaning is performed. The first in-situ process step is plasma cleaning of the sample with Hydrogen etching. This process cleans up the sample surface and removes the defects and impurities that were not removed during the chemical cleaning process. This cleaning is achieved according to the following exemplary steps
1. Turn on applicator purge;
2. Turn on main gas valve;
3. Turn on H 2 valve;
4. Input 500 sccm for H 2 flow;
5. Input 10 Torr for Pressure;
6. At 5 Torr Turn on Microwave (MW) power;
7. Set MW power to 0.5 kW;
8. If it fires OK, set 950 sccm for H 2 flow;
9, Set 160 Torr for Pressure;
10. After about 10 minutes, turn on external fans;
11. Adjust power accordingly, increase forward power as the pressure increases, keep the reflected power below 0.4 kW as the forward power increases.
12. After it reaches 160 Torr, set 400 sccm for H 2 flow;
13. Turn on all interlocks; and
14. Run system for about 3 hours for new samples, for 0.5 to 1 hour for previously grown samples.
H(2). Diamond Deposition
Diamond deposition is accomplished in an exemplary embodiment according to the following steps:
1. Open CH 4 and N 2 /H 2 valves;
2. Set 10 sccm for CH 4 flow;
3. Every half minute increase CH 4 flow by 10 sccm up to 40 sccm (can be changed depending on the experiment);
4. Set 8 sccm for N 2 /H 2 flow;
5. Run as long as necessary or desired;
6. Gas purities:
CH 4 : 99.999% H 2 : 99.9995% N 2 /H 2 : 2% N 2 , Balance H 2 .
H(3) Deposition Process (Shut Down)
Process shut down can be achieved according to the following exemplary steps with particular attention to safety:
1. Turn off all interlocks;
2. Turn off MW power;
3. Turn off gas valves;
4. Set 0 sccm for all gas flow;
5. Set 0 Torr for pressure (pressure brought down to 0 at once);
6. Cool down for 3 hours; and
7. Open the chamber.
I. Process for SCD Deposition for Multiple Runs
A diamond deposition process is typically interrupted or stopped as a result of various circumstances including but not limited to: high temperature of the sample, coating on the quartz dome, and localized polycrystalline growth on the Mo holders. Despite breaks in an exemplary overall growth process, a deposition process according to the present disclosure can be continued on the same sample using appropriate ex-situ and in-situ (e.g. chemical and hydrogen cleaning) processes in combination with suitable substrate holder design.
FIG. 14 illustrates an exemplary isometric view of a particular holder design that is used during deposition experiments. This holder defines a plurality of recesses of various depths. A particular recess is chosen based on the thickness of the sample (e.g. new, previously grown once or previously grown twice, etc).
Referring to FIGS. 14A, 14B, 14C, 14D, and 14E , an exemplary process for deposition in the plurality of recesses of various thicknesses is schematically shown. FIG. 14A illustrates a first deposition in a first particular recess of a Si wafer substrate, 0.45 mm thick cut to a 4×4 mm dimension. In an additional embodiment, as shown in FIG. 14B , a Si wafer substrate is not used. Alternatively, a deeper recess can be chosen as shown in FIGS. 14C-14E . The recess chosen should depend on the desired growth thickness as schematically depicted in the FIGS. Accordingly, recess # 2 (desired thickness of Y mm) is deeper than recess # 1 (desired thickness of X mm), recess # 3 (desired thickness of Z mm) is deeper than recess # 2 and recess # 4 (desired thickness of W mm) is deeper than recess # 3 .
J. Process for SCD Samples for Multiple Runs with Additional Embodiment (FIG. 13 )
A diamond deposition process is typically interrupted or stopped as a result of various circumstances including but not limited to: high temperature of the sample, coating on the quartz dome, and localized polycrystalline growth on the Mo holders. Again, despite breaks in an exemplary overall growth process, a deposition process according to the present disclosure can be continued on the same sample using appropriate ex-situ and in-situ (e.g. chemical and hydrogen cleaning) processes in combination with suitable substrate holder design.
Multiple SCD samples can be grown simultaneously according to a particular exemplary design holder. Moreover, recess depth can be adjusted by adding multiple frame discs on top of each other. FIG. 15 Illustrates an isometric view of an exemplary multiple SCD growth holder design that is suitable for deposition experiments having a plurality of discs.
FIG. 16 shows an exemplary order of diamond growth process with a particular holder design. As the sample grows and the process is stopped, the Mo holder structure is adjusted according to desired outcome. For example, more discs are added during stoppage to increase sample growth thickness. Cleaning can also be achieved during the stoppages. In an exemplary growth process, some of the blank discs will be removed from the bottom and framed discs will be added on top depending on the total thickness of the SCD sample.
FIGS. 17-20 illustrate exemplary embodiments of adding additional discs during multiple depositions of a particular sample. FIG. 17 represents a first deposition disc embodiment for a new SCD sample. FIG. 18 illustrates an embodiment of FIG. 17 further comprising additional discs to allow for additional growth of a previously grown SCD sample or samples. Each recess can grow a separate and distinct SCD sample. Depending on the desired thickness of a particular sample, a third deposition can be achieved as shown in FIG. 19 by stacking additional discs to the embodiment shown in FIG. 18 . FIG. 20 is an even further extension of adding more discs to the embodiment of FIG. 19 . Thus, FIG. 18 represents growth of a sample to an X mm thickness (second deposition); FIG. 19 to a Y mm thickness (third deposition); and FIG. 20 to a Z mm thickness (fourth and n*th deposition).
K. Single Crystal Diamond Using 915 MHz
Initially a 915 MHz microwave delivery system was evaluated by demonstrating diamond growth on multiple samples operating with no nitrogen added to the growth chemistry. As seen in Table 1 below, the 915 MHz system showed repeatable deposition rates for multiple crystals placed at different locations (i.e., different recesses). The deposition rate was 6-7 microns per hour. This rate is comparable to results obtained from, a 2.45 GHz system for no nitrogen conditions.
TABLE 1
First Experiment
Second Experiment
Growth Rate (microns
Growth Rate (microns
Sample ID Number
per hr)
per hr)
81
6.53
7.76
82
5.38
5.65
83
6.12
6.20
84
6.80
6.47
Average Growth Rate
6.208
6.520
Operating Conditions: 1130° C., 130 Torr, 7% CH 4 , 0% N 2
Referring to FIG. 21 , in an exemplary SCD holder apparatus, a multi-seed deposition was performed. FIG. 21 schematically illustrates an exemplary embodiment of an apparatus defining a plurality of recesses filled in four different positions with SCD samples or seeds. In an exemplary embodiment, a 4″ substrate is employed. Improving growth rate using a nitrogen/hydrogen mixture procedure was investigated. This procedure was similar to that used from the 2.45 MHz system for purposes of verifiability. Accordingly, adding 175 ppm nitrogen effectively increased the growth rate up to 16 microns per hour for sample SCD#DK002 as shown in FIG. 22 .
Increasing nitrogen flow rate proved to increase growth rate. Changing nitrogen flow rate from 175 ppm to 300 ppm provided a growth rate of 20.3 microns per hr as shown in FIG. 23 . Repeatability was tested by running a shorter experiment, which provided a growth rate of 18.39 microns per hour. Although the recorded value is lower, growth duration will influence the calculated growth rate by replacing the material lost during etching. The longer the growth period the less significant the etched material enters into the calculation. Additionally decreasing the number of defects also was achieved. As shown in FIG. 23 , sample SCD#DK003 and SCD#DK004 are examples of the repeatability of the process according to the present disclosure.
Following the growth rate experiments another multi-seed deposition was conducted with samples SCD#DK005 and SCD#DK006 as shown in FIG. 24 . The growth rates were similar to the previous depositions of FIG. 23 ( FIG. 24 shows growth rate of 19.54 and 17.88 microns per hour), however, decreased defects were maintained during the multi-seed run as shown in FIG. 24 . These experiments were conducted at a pressure of 130 Torr, which is less than the 160 Torr used in the 2.45 GHz system. This lower pressure may be attributable to be a major reason for the lower growth rates (˜20 microns/hr) as compared to the 35-40 microns per hour in the 2.45 GHz system. Higher pressures will be more readily utilized with the installation of the nitrogen generator system, which will provide greater safety in the operation of the 915 MHz system.
In an exemplary embodiment, the present disclosure provides for an apparatus and process for growth of single crystal diamond on diamond substrate. Growth of single crystal diamond in microwave plasma-assisted CVD at pressures of 100-200 Torr is sustainable through proper management of process operating conditions including: substrate temperature; plasma/gas chemistry; substrate preparation (cleaning); and plasma/gas flow rates. A different set of operating conditions for these parameters will result in favorable outputs depending on the different single crystal diamond variations that can be grown and are desirable. Variations in SCD's that can be grown include and can depend from the amount of nitrogen in the gas feed, boron in the gas feed, and methane in the feed gas. Moreover, these feed gas variations produce diamond of different quality including color, growth rate, electrical and optical properties. In a particular embodiment, improved quality of diamond synthesis is attributable to establishing a growth environment with appropriate substrate temperature, plasma species, plasma/gas flow rates and their uniformity across the diamond substrate.
In an exemplary embodiment, the present disclosure provides for an apparatus and process adapted to allow for subsequent sustaining of particularly desirable conditions for diamond deposition. The following exemplary techniques are suitable to achieve and maintain desirable substrate temperature:
a. Using a multilayer molybdenum substrate holder structure that sits on a cooler and inserting or removing layers in this holder structure thereby establishing and/or maintaining desired temperature;
b. Positioning the plasma with respect to the substrate by raising and lowering the substrate cooler/holders and by raising and lowering a top sliding short;
c. Adjusting the input power to change/optimize the substrate temperature;
d. Positioning the diamond substrate in a holder structure such that a top surface of the diamond is within a specific range of the top surface of the molybdenum holder that the diamond is held in—a typical range is from 0.5 mm below the top surface of the molybdenum to 1.0 mm above the top surface of the molybdenum;
e. Placing a separate insert into a recess of the molybdenum holder such that the diamond sits on the placed insert instead of directly on the molybdenum thereby discretely adjusting the vertical position of the diamond substrate and adjusting the thermal connection between the diamond and the molybdenum;
f. Verifying that the correct temperature can be obtained before a deposition run is started by running a hydrogen plasma without in carbon source—the temperature of the substrate during this pre-run check indicates or is predictive of the temperature to be expected during a deposition run;
g. Running the deposition only when the substrate temperature is maintained within a specific range since the deposition temperature often changes during a run as the diamond grows and extends further above the molybdenum substrate holder—once a specific temperature range is exceeded, the run is stopped and the diamond is reconfigured in the substrate holder to obtain the correct substrate temperature alternatively the power, substrate position and/or top sliding short can be adjusted to maintain a specific temperature range;
h. Utilization of appropriate laterally sized recesses in the molybdenum to control the temperature and gas flow around the diamond substrate; and/or
In a further exemplary embodiment, the present disclosure provides for deposition of diamond on multiple seed crystals simultaneously. Depositing single crystal diamond on multiple crystals simultaneously is accomplished by utilizing apparatus and process conditions that 1) provide a plasma discharge of sufficient uniformity and size to deposit diamond over a large area at high rates, and 2) provide the capability to operated with all diamond seeds within a specific substrate temperature range. The following exemplary techniques are suitable for achieving and/or facilitating SCD deposition on multiple crystals:
a. The substrate holder can be designed with variable controlled thermal connection to the substrate cooler that varies versus radial position;
b. Since each substrate is relatively small, they can be placed in a substrate holder that varies in either thickness or recess depth to achieve relative uniform temperature for all the crystals;
c. A process can be defined where the temperature of each seed crystal is determined before a run begins by running with just a hydrogen plasma interacting with the multiple seed crystals—a pyrometer can be used to map the temperature of each seed crystal—the process can then be stopped and the position of each seed crystal adjusted by either moving it to recesses of different depth or placing thin inserts under selected seeds to adjust their temperature;
d. extending the run time between starting and stopping of the process by maintaining the top of the diamond within a certain distance of the top of the molybdenum which is achievable by placing the seed crystals close enough together that the plasma interacts with just diamond surfaces spaced just a few mm apart—this reduces polycrystalline diamond growing on molybdenum which requires the process to be stopped often to clean the molybdenum (Note: This configuration starts to look like depositing on a large continuous wafer surface); and/or
e. Using a holder configuration defining a plurality of recesses to deposit on multiple seeds at the same time.
High rate synthesis of high quality single crystal diamond (SCD) is achievable through adjustment of environmental factors inside the reactor. Particular diamond deposition variables suitable for adjustment include: (1) reactor pressure, (2) input microwave power, (3) substrate temperature, (4) radical deposition species concentrations, and (5) the geometric position of local substrate top surface and top edges with respect to the plasma and the substrate surface. In an exemplary embodiment, experimentally determined “high rate, high quality diamond deposition” can occur within (1) 100-200 Torr and particularly within 120-180 Torr, (2) a substrate temperature between 1050-1200° C., (3) input gas flow rate of 100-1200 sccm, and (4) a methane to hydrogen concentration of 3-15%. In a further exemplary embodiment, deposition results were observed at pressures of 160-180 Torr, 6-10% methane, and substrate temperatures of 1100-1200° C. According to the experiments, input power and cavity tuning were adjusted to create a microwave discharge hovering over and in contact with and covering the substrates. Typically the absorbed input microwave power was within the range of 2-3 kW. The addition of a small amount (5-500 ppm) of nitrogen gas improved growth rates and with the addition of only very small concentrations of nitrogen (5-50 ppm) the diamond quality also improved.
The experiments also demonstrated that the single crystal diamond substrate can be positioned appropriately within the microwave discharge. For example, placing the HTHP SCD substrate directly on top of a flat Mo holder where the top, edges and sides were exposed to the plasma did initially deposit SCD diamond, but as deposition progressed polycrystalline diamond formed on the sides and also produced a polycrystalline rim around the substrate. As growth continued substrate deposition hot spots were formed either on the substrate top edges or on the substrate holder itself producing undesirable runaway polycrystalline growth over the entire substrate. In order to reduce the polycrystalline growth around the rim and also to control runaway growth the local deposition environment surrounding the substrate top surface was controlled.
Local control is achieved by placing the substrate within a recess or “well” that is defined or cut into the Mo holder. When the substrate was placed within this recess the substrate sides, edges and the top surface were no longer exposed to the intense microwave plasma and were also possibly shielded from any microwave fields that may be concentrated on the hot edges of the substrate. When the top of the substrate surface was located in the recess, as is shown in FIG. 16 (first run), SCD growth was achieved without any significant formation of a polycrystalline rim/border. As shown the substrate surface is located a short distance below the top surface of the substrate holder, and also the top edge of the substrate was also located a short distance from the adjacent edge of the substrate recess. If the spacing between the edges and the surface was either too large or too small, quality SCD growth was not achieved. Under particular desired geometric conditions, as shown with respect to FIGS. 14A-14E diamond growth with minimal polycrystalline rim formation is achievable.
In a particular exemplary embodiment according to the present disclosure, as diamond was added (i.e., deposited) to a particular substrate via CVD process, the substrate grew slightly horizontally but especially in height. The substrate increased in size and it eventually grew out of the recess and into the microwave plasma. The growing substrate assumed a position within the plasma similar to that of a single crystal placed on top of a smooth Mo plate. The substrate again had to be placed within a larger recess or cavity in order to achieve high quality diamond growth. Accordingly, the present disclosure provides for synthesis of large multi-carat stones grown on a multi-substrate frame with a multi-step process.
An additional variable related to improvement of SCD growth is a substrate/recess variable. In order to achieve high quality, thick SCD growth the substrate surface and edges must be positioned appropriately within a recess in the substrate. As the SCD grows upward and horizontally the substrate recess must also be enlarged (both in depth and width) to maintain an appropriate spatial relationship between the substrate and the substrate holder. An appropriate spatial relationship between the top of the substrate surface and edges and the adjacent substrate holder interior surface and edges is achieved by maintaining the correct distance between the substrate and the substrate holder and the plasma. Accordingly, in an exemplary embodiment, the special relationship can be adjusted and controlled by: (1) maintaining diffusion/flows of plasma and the radical species onto the SCD surface; (2) shielding the SCD substrate from the hot plasma species and the impressed microwave electromagnetic fields; and (3) placing the substrate into an environment that is thermally uniform, i.e. the substrate surface, edges and the surrounding Mo holder surfaces and edges are at locally uniform temperatures, thereby creating conditions that are conducive for uniform SCD diamond synthesis over the entire substrate.
A process for growing diamond according to the present disclosure can be scaled up to multiple substrates using a 915 MHz reactor. Simultaneous deposition over many substrates was demonstrated by way of the following example.
Example II
Synthesis over seventy substrates was achieved according to the process described herein. Referring to FIGS. 28A-28D , SCD was achieved for seventy seeds over a 42.5 hour run time. Only one deposition was studied for this example although additional depositions are possible by the process described hereinabove. The deposition took place over 38 hours. The difference in run time and deposition time is attributable to general preparation time and cleaning of sample, reactor chamber and associated components. After the 42.4 hour run, photos were taken via an optical microscope. FIG. 28A represents photos of top surfaces of each of the 70 samples. Light was delivered to the samples such that the optical microscope in the photos of FIG. 28A was focused on the top surfaces of the substrates having diamond deposited thereon. FIG. 28B illustrates the samples shown in FIG. 28A with the light being delivered from underneath the substrate. In this example, each sample typically expressed a generally yellow, brown or orange like color. The color is dependent upon the quantity of Nitrogen introduced into the deposition and is not necessarily a reflection of desired product, indeed this experiment was intended to illustrate the growth characteristics of Multi-Substrate deposition.
The SCD run was performed using a 915 MHz reactor under the following parameters: H 2 flow rate of 600 sccm; CH 4 flow rate of 42 sccm; H 2 /N 2 mixture flow rate of 9 sccm (150 ppm of N 2 ); 125 Torr, and 11.5 kW. FIGS. 28C and 28D represents an array of numbers corresponding to each sample from FIGS. 28A and 28B . Each box shown in FIGS. 28C and 28D corresponds to the sample in the same relative position from the previous FIGS. 28A and 28B . Each box of FIGS. 28C and 28D show a top and bottom number. In both FIGS. 28C and 28D , the bottom number represents the linear growth rate of the corresponding substrate in microns/hour. The top number in FIG. 28C represents the total thickness achieved over the 38 hour deposition. The top number in FIG. 28D represents the deposition temperature measured at each sample. The temperature was intended to be maintained uniformly across all of the substrates.
Results from the experiment demonstrate relatively high quality SCD synthesis on each substrate with little or no polycrystalline rim formation. Spots in the center of the substrates may have originated from either the laser scribed number on the bottom surface (non deposited surface) or from the substrate surface after the initial etch step. FIG. 28D shows experimentally measured deposition temperatures and linear growth rates on each substrate respectively. The temperature distribution and the synthesis growth rates are relatively uniform over a 4-5 inch diameter deposition area. For example, the linear growth rates varied across the four and one half inch diameter substrate holder surface from about 14 microns/hr. to 20 microns/hr. Additional deposition process steps were performed with either silicon inserts placed under each substrate, or with additional frames added. These experiments resulted in the synthesis of high quality larger SCD substrates. In order to improve deposition uniformity individual substrate positions were moved around from run to run; i.e. individual substrates were moved from the center to the outer diameter position and vise versa as each new process step was carried out.
The present disclosure provides for a multi-substrate and multi-step CVD synthesis process that deposits a diamond atomic layer by layer onto a diamond substrate. As the substrate thickness increases the substrate gradually grows higher and also grows horizontally, and most importantly the substrate top surface grows upward and eventually extends deeper into the plasma. Since the edges of the substrate also grow horizontally, the substrate edges move closer to the substrate side wall within the recess. The growth then alters the substrate Mo holder geometry which in turn changes the substrate temperature, alters the gas flows around and onto the substrate and varies the radical species diffusing onto the substrate. As the substrate gradually becomes larger the substrate becomes thicker with a larger cross sectional surface area and then since the substrate holder geometry changes the experimental growth conditions are no longer appropriate (i.e. no longer within the “deposition window”) for synthesis of high quality diamond. Thus the process is stopped and the reactor is opened and the substrate and Mo holders are unloaded. An additional frame is placed on top of the substrate holder and then growth is resumed. Then the deposition process is restarted. It is desirable to perform cleaning of the reactor chamber, holder, substrate and associated components according to the cleaning mechanisms described hereinabove.
In an exemplary embodiment, an additional frame is added defining a relatively larger recess or cavity and positioned above the first recess. A top surface of the additional frame is defined above the diamond substrate top surface and associated edges with respect (a) to the plasma and (b) to the substrate holder edges. This allows the substrate to be located in a suitable single crystal growth environment. Diamond synthesis continues until the substrate thickness increases such that it again protrudes from the holder and extends slightly into the microwave plasma. It is experimentally observed that as the substrate grows and moves into the discharge the deposition conditions change (for example substrate temperature and the number of deposition species that are impinging on the substrate are changed) and the resulting synthesized diamond properties are also changed; i.e. deposition conditions are no longer desirable. Accordingly, the process is stopped once the diamond has protruded above the top surface of the additional frame, another frame is added and the deposition process is resumed and carried out within the “deposition window”. These steps can be repeated several times depending on the desired size of the final diamond substrate.
Example III
The present disclosure provides for a process for SCD synthesis using a movable stage. A multiple recess holder reactor configuration and the associated process consists of several start and stop process steps. However, it may be burdensome to start and stop the process many times, since it adds to the total process time and adds handling and other process complexities to the complete process. For example, special substrate handling concerns must be taken between runs to minimize process contamination. Thus it is desirable to employ a method of continuously adjusting the substrate position in situ and there by keeping the deposition conditions on the substrate within the experimental variable window that enables optimum, high quality, new diamond synthesis. In an exemplary embodiment, the present disclosure provides for a reactor with a movable stage operable to reduce process steps and thus simplifying the entire process.
In an exemplary movable stage substrate holder configuration, a basic applicator design is used that is similar to the basic microwave cavity plasma reactor design with an alteration to allow the substrate holder/cooling stage to be varied axially as diamond synthesis proceeds. In an exemplary embodiment, the axial position variation is relatively small, typically about 2-10 mm. The movable substrate cooling stage allows the substrate to be repositioned during growth and thus the substrate position with respect to the discharge and the Mo holder walls can be continuously adjusted during the diamond growth process. This repositioning allows the substrate top surface and the associated edges to be adjusted to be in a desired location to keep deposition variables within a desired deposition window.
In an exemplary embodiment, addition of a movable stage modifies the basic reactor design by changing the substrate holder/cooling stage configuration. The modified substrate holder configuration with a movable cooling stage is shown in FIG. 27 . According to FIG. 27 , a movable stage reactor comprises: (a) a water cooled stage 6 , 8 and 9 ; (b) a fixed bottom base plate ( 7 ); (c) a quartz tube 17 ; (d) a Mo insulation disk set 19 ; (e) one or more single crystal substrates 33 ; (f) sliding microwave “finger stock” contacts 40 ; (g) a Mo flow pattern regulator 16 and substrate frame; and (h) a top Mo disk set piece 41 with substrate holder wells to fix the locations of the diamond substrates. The fixed bottom plate, the quartz tube, the single crystal substrates, and the Mo insulation disks have the same roles as in the fixed substrate holder configurations described in 1.0 and 2.0. The cooling stage assembly is modified so that it can move several millimeters up and down axially. This motion can be controlled by the linear motion of a support rod 42 through a vacuum feed-through or by the linear motion a fixed length shaft surrounded length adjustable cylindrical bellow wall assembly.
In an exemplary embodiment, the sliding finger stock contacts 40 allow the cooling stage to move axially without breaking the electrical microwave contact. Deposition holes are added to the flow pattern regulator 16 to provide the diamond substrates open access to the plasma radical species. The top Mo disk piece 41 is similar to the substrate holder disk piece, i.e. it positions the substrates into precisely located recess holes. It can also be modified as shown in FIG. 27 to allow a sliding, telescoping Mo contact with the Mo flow pattern regulator. The dimensions of the adjustable substrate deposition aperture are adjusted empirically to provide high quality diamond synthesis.
During each experimental run each substrate temperature is continuously monitored via a pyrometer measurement, and all substrates are visually inspected by the operator during the experimental run. Then as the diamond grows the stage is adjusted (moved up or down) manually or by computer control to adjust the substrate growth environment to be located within the appropriate deposition window.
Example IV
In an exemplary embodiment, the present disclosure provides for deposition of thick boron-doped homoepitaxial single crystal diamond by microwave plasma chemical vapor deposition. Deposition of boron-doped homoepitaxial single crystal diamond can be accomplished using a microwave plasma-assisted chemical vapor deposition system. Experiments were performed to investigate capabilities of depositing high-quality boron-doped single crystal diamond and establish relationships between deposition conditions and diamond growth rate, quality and electrical conductivity. Studies were done growing 25 μm thick B-doped layers, with boron content varying from 0.02 ppm to 20 ppm in the pressure range of 135-140 Torr. (See e.g., E. Bustarret, E. Gheeraert, K. Watanabe, Phys. Stat. Sol . ( a ) 199 (1) (2003) 9.) Previous experiments have grown boron doped diamond using diborane levels of 5-50 ppm diborane in a feedgas of hydrogen and methane (4-6%). (R. Ramamurti, M. Becker, T. Schuelke, T. Grotjohn, D. Reinhard, G. Swain, and J. Asmussen, “ Boron doped diamond deposited by microwave plasma - assisted CVD at low and high pressures”, Diamond and Related Materials, 17, 481-485, 2008, and R. Ramamurti, T. A. Grotjohn, D. K. Reinhard and J. Asmussen, “ Synthesis of boron - doped homoepitaxial single crystal diamond by microwave plasma chemical vapor deposition,” Diamond and Related Materials, 17, 1320-1323, 2008.) Accordingly, in an exemplary embodiment, boron can be incorporated substitutionally and B/C concentration measures in the diamond layer from 80 to 700 ppm for feedgas ratios in the plasma discharge of 5 to 50 ppm diborane, respectively. The experimental conditions utilized included pressures of 140-160 Torr and substrate temperatures of 900-1200° C. The room temperature electrical conductivity for the diamond deposited under these conditions ranged from 0.1 to 30 (ohm-cm) −1 . Diamond was deposited with growth rates of 2 to 11 μm/hr. Boron doped films grown on Silicon wafers are shown in FIG. 25 . In an exemplary embodiment, a single crystal seed holder and seeds were mounted in a diborane system and coated with single crystal diamond as illustrated with respect to FIG. 26 .
It was observed that incorporation of higher amounts of boron in diamond deposition leads to a degradation of crystalline quality. (See e.g., Bustarret, E. Gheeraert, K. Watanabe, Phys. Stat Sol . ( a ) 199 (1) (2003) 9. Teraji, H. Wada, M. Yamamoto, K. Arima, and T. Ito, Diamond Relat. Mater. 15 (2006) 602.) Hence, doping with low boron content is needed for some boron doped diamond applications. As such, this study examined using boron content in the feedgas at concentrations of 10 ppm or less.
A particular objective was to alter the critical deposition parameters developed for deposition with high boron concentrations of 5-50 ppm in order to grow high quality boron doped SCD layers up to 2000 μm thick with lower boron content (10 ppm or less in the feedgas). In an exemplary embodiment, in order to grow such layers with minimum defects parameters such as methane concentration, substrate temperature and concentration of nitrogen in the feedgas were adjusted, observed and controlled to a suitable extent. For example, the effect of nitrogen in the feedgas on the electrical properties of the B-doped diamond layers was measured and the results are shown in FIG. 29 . Specifically, FIG. 29 shows the variation of electrical conductivity with nitrogen content in the plasma. Type Ib HPHT diamond seeds as substrates were used to study growing diamond with varying amounts of diborane in a methane-hydrogen gas mixture. The deposition system utilized a 2.45 GHz microwave plasma-assisted CVD system operating at 140-160 Torr, 2-3 kW, 4-6% methane, 1-10 ppm diborane in the feedgas, and 0-500 ppm nitrogen in the feedgas. As one example, a low defect boron doped SCD layer 2000 μm thick was realized with 1 ppm diborane and 0 ppm nitrogen.
Example V
Thermal management of the process is desirable to achieve suitable substrate growth. In an exemplary embodiment, the process is thermally managed by appropriate design/adjustment of the molybdenum substrate holder. Local thermal management can be characterized as controlling the local environment of the substrate for an individual substrate or the local environment of each substrate for multiple substrate deposition. Macroscopic thermal management is typically related to managing environment and species characteristics by maintaining uniformity across a substrate holder and the growth volume space (i.e., reactor cavity). Macroscopic thermal management is utilized to create a uniform deposition environment over an entire deposition area covering all of the substrates. The local substrate area may involve areas of less than 1-2 cm2 while multiple substrate deposition may involve larger areas that may range from 10 cm2 to areas greater than 100 cm2. The local environment is controlled by adjusting the local deposition volume space while the process uniformity of the larger deposition area is controlled by adjusting the plasma position, plasma size/volume and the substrate holder set geometry.
In a particular embodiment, the substrate holder can be designed and adjusted to express a desired temperature adjustment or profile across the entire substrate. Molybdenum plates can be stacked one upon the other forming a multilayer stack of relatively thin molybdenum plates. The thin plates are then placed directly on a water cooling stage for desired thermal control. Thus, the temperature of the substrate can be adjusted to be within a desired temperature profile range for a given operating pressure by adding or subtracting molybdenum plates. (See e.g., FIG. 7 .) Accordingly, if the pressure is increased, for example from 140 to 180 Torr, the discharge gas temperature will increase and thus the substrate should be cooled more in order to keep the substrate within the deposition range. This additional cooling is achieved by removing one or more of the molybdenum plates. If the pressure is decreased from 140 Torr to 100 Torr then one or more molybdenum plates can be added to adjust the substrate temperature to be within the deposition range.
In a further embodiment, local substrate temperature can be adjusted by varying the operating pressure. Substrate temperature is measured on the substrate surface or the diamond seed/chip surface growing into the plasma. If the pressure is adjusted, then the input power and possibly the cavity tuning may also be adjusted to ensure that the plasma discharge is in contact with and covers the substrates. Temperature can further be adjusted while operating at a constant pressure by adjusting the sliding short or by varying the input power. Substrate temperature, input power, plasma size, and pressure are nonlinearly related—i.e. a change in one variable results in variation of the others. In a multiple substrate embodiment, substrate temperature can be adjusted by placing an insert directly underneath each substrate thereby effectively adjusting the relative height of each substrate. Exemplary inserts can be made from molybdenum, silicon and characterized as insert wafers or shims. The present disclosure provides for a multiple diamond deposition process operable to grow diamond in an environment of temperature uniformity. By maintaining the substrate within the growth volume space and thus within deposition volume space, the substrate temperature remains relatively uniform thus avoiding thermal runaway on the substrate edges. In a further embodiment, the diamond substrate chip can be physically clamped or brazed to the cooling stage or molybdenum holder to further manage and control the thermal parameters of each substrate.
In an exemplary embodiment, it is desirable for the microwave discharge to hover over and be in contact with each substrate. The positioning (or moving) of the discharge is done by varying the axial position of the (1) substrate holder configuration, and/or (2) the sliding short. For a single SCD substrate deposition, input power is adjusted to produce a discharge size that entirely covers the substrate producing a thermally and reactive species deposition environment over the entire single substrate. This provides for uniform deposition over the substrate. In a multiple substrate embodiment, the discharge must be increased to create a relatively larger area, positioned such that thermally homogeneous discharge is achievable to uniformly cover each substrate. The input microwave power can be increased to cover each substrate. Thus deposition over one substrate requires much less input power than the power required for a multiple substrate deposition process. However the input gas mixtures and substrate temperatures are similar.
While the present invention is described herein with reference to illustrated embodiments, it should be understood that the invention is not limited hereto. Those having ordinary skill in the art and access to the teachings herein will recognize additional modifications and embodiments within the scope thereof. Accordingly, such modifications and/or embodiments are considered to be included within the scope of the present invention.
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The present invention relates to a microwave plasma deposition process and apparatus for producing diamond, preferably as single crystal diamond (SCD). The process and apparatus enables the production of multiple layers of the diamond by the use of an extending device to increase the length and the volume of a recess in a holder containing a SCD substrate as layers of diamond are deposited. The diamond is used for abrasives, cutting tools, gems, electronic substrates, heat sinks, electrochemical electrodes, windows for high power radiation and electron beams, and detectors.
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FIELD OF THE INVENTION
[0001] The field of the invention is that of article carriers supported by an animate bearer, such as a human being.
BACKGROUND OF THE INVENTION
[0002] Human beings have long carried articles by attaching them to belts worn around the waist or hips. Such objects have included canteens, weapons, food carriers, and the like. In modern times, for example, photographers may carry cameras, lens systems such as telephoto lens systems, and other photographic gear in pouches or carriers suspended from a belt worn about the waist or hips.
[0003] An article to be carried by a belt may be permanently or releaseably attached to a definite position on the belt. Alternatively, the article may be attached to the belt by a sleeve or the like so that the article may be moved along the belt as needed in order to access the article or to wear it in the most comfortable position. A belt carrier system that provides for both types of attachment at the choice of the wearer is needed.
[0004] U.S. Pat. No. 5,881,933 to Rogers, entitled “Track Member System” discloses a system for carrying containers suspended from a track member which may be attached to a body encircling belt or attached to clothing which includes a pair of protruding tracks substantially parallel and from which the containers for holding articles are suspended by clips on the containers which are attachable to the tracks anywhere along the lengths thereof or positionable lengthwise on the tracks by sliding thereon at tapered ends of the tracks. This system includes a clamp in the form of a planar wedge for locking the container in place on the tracks to prevent the container from sliding along the tracks to an undesired position and inhibiting forceful unintended removal of the clip and container from the tracks without removal of the clamp. The track member system of Rogers is complicated and expensive to make because its construction requires the provision of two parallel and protruding members and a rigid clip attached to a carrier that is specifically shaped to receive the parallel members and thereby hold the carrier on the belt. The security of the attachment of the clip to the carrier depends on how well the clip encloses the members so that failure of that enclosure will cause detachment of the carrier from the belt. In addition, the planar wedge clamp is complicated and requires the provision of additional components.
[0005] What is needed for is an improved carrier system that provides for attaching articles to a belt that provides for the articles to be releaseably attached at a fixed position on the belt or, in the alternative, to be in a slideable relation to the belt.
SUMMARY OF THE INVENTION
[0006] The invention is a system comprising an elongated planar member or belt to be worn by an animate bearer such as a human being having an outside surface facing away from the bearer's body and an inside surface facing toward the body of the bearer, at least one loop or pocket attached to the outside surface of the belt, and at least one carrier for an object comprising a sleeve having a first end attached to a body of the carrier and a second end detachably attached to the body of the carrier, the first end and the second end of the sleeve being spaced apart at their respective places of attachment to the body of the carrier so that the second end of the sleeve can be folded over the belt and attached to the body of the carrier, and further comprising a tab of stiff material having a first end attached to the carrier at or near the junction of the first end of the sleeve to the carrier and a second end remaining unattached, the tab having an axis generally aligned with the sleeve, the second of the tab being capable of being inserted through one of the loops of the belt when the sleeve is folded over the belt for attachment of the carrier to the belt and thereby fixing the carrier with respect to the belt so that the carrier substantially may not be slid along the belt whereas if the tab is not inserted into a loop when the sleeve is folded over the belt the carrier is not substantially fixed with respect to the belt and therefore may be slid along the belt.
OBJECTS OF THE INVENTION
[0007] It is an object and advantage of the present invention to provide to provide an improved system for carrying equipment on the wearer. Another object and advantage is to provide a system for carrying equipment on the wearer that will positively attach the equipment to a member supported by the wearer so that the equipment will not become accidentally detached.
[0008] Another object and advantage is to provide a system that will positively attach equipment to the wearer that will permit the equipment to be moved with respect to the member worn by the wearer while the equipment is supported by that member but alternatively, at the option of the wearer, to permit the equipment to be carried in a fixed relationship to the member.
[0009] Another object and advantage is to provide a system for carrying equipment on a wearer that is simple and inexpensive to manufacture.
DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a preferred embodiment of the carrier system according to the invention shown being worn by a person;
[0011] FIG. 2 is a front side view of a portion of the preferred embodiment of the carrier system according to the invention shown in FIG. 1 ;
[0012] FIG. 3 is a back side view of the portion of the carrier system according to the invention shown in FIG. 2 ;
[0013] FIG. 4 is a partial sectional view of the portion of the carrier system according to the invention shown in FIG. 2 ;
[0014] FIG. 5 is a perspective view from the right of the portion of the carrier system according to the invention shown in FIG. 2 demonstrating how the tab attached to a carrier for articles is inserted in a loop attached to the belt so as to prevent the carrier for objects from sliding with respect to the belt;
[0015] FIG. 6 is a perspective view from the right of a portion of the carrier system according to the invention shown in FIG. 2 demonstrating how the tab of the carrier for objects is not inserted into a loop attached to the belt so as to allow the carrier for articles to slide with respect to the belt;
[0016] FIG. 7 is a perspective view from below of a portion of the carrier system according to the invention shown in FIG. 2 demonstrating how the tab of the carrier for articles is inserted into a loop attached to the belt so as to prevent the carrier for articles from sliding with respect to the belt; and
[0017] FIG. 8 is a perspective view of the tab shown as a separate component and not attached to the carrier for articles.
REFERENCE NUMERALS IN THE DRAWINGS
[0000]
1 carrier system
2 person
10 belt
11 buckle
12 fabric tube
13 foam interior
14 outside surface of belt
16 inside surface of belt
20 webbing
22 bar tack
24 loop
30 carrier for objects
32 zipper
34 body of carrier
40 sleeve
42 first end of sleeve
44 second end of sleeve
46 loop strip
48 hook strip
60 tab
62 first end of tab
64 second end of tab
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] Referring now to the drawings, an animate bearer (in this case a person) 2 wearing a preferred embodiment of a carrier system according to the invention 1 is shown in FIG. 1 . The carrier system 1 is comprised of a belt 10 attached to a carrier for articles 30 .
[0041] The belt 10 is shaped in the form of an elongated planar member having an outside surface 14 facing away from the bearer's body and an inside surface 16 (not shown in FIG. 1 ; see FIG. 3 ) facing toward the body of the bearer. The belt 10 is shown in cross-section in FIG. 4 and preferably comprises a fabric tube 12 surrounding a foam interior 13 . The foam interior 13 is preferably made of EVA (Ethylene Vinyl Acetate) foam.
[0042] The specific structure and materials of the belt 10 , however, are not important to this invention. The belt 10 could be made without the foam interior 13 or could be made of leather or other materials known to the art to which this invention pertains. The belt 10 is secured around the body of the wearer 2 by a buckle 11 . The buckle shown in FIG. 1 comprises two mating and detachable pieces formed from a thermoplastic of a kind well known to the art. Such buckles are sold under the FASTEX, DURAFLEX, and other brands. The specific structure and materials of the buckle 11 are not important to this invention. The buckle 11 could have any number of designs and be made of different materials known to the art as long as it is suitable to be a buckle for a belt.
[0043] The carrier for articles 30 comprises a body 34 and a sleeve 40 . The carrier for articles 30 shown in the drawings is a pouch of a known kind in the photography field having an interior main compartment (not shown) with a top opening secured by a zipper 32 . The carrier 30 shown in the drawings is designed to hold photographic articles such as a lens system and the like. The structure and form of the body of the carrier for articles 30 is not important to the invention. All that is necessary is that the carrier for articles 30 be suitable for carrying an article or articles that a wearer may wish to carry. The system of the invention could be used with virtually any carrier for articles, such as a holster for a handgun or a canteen.
[0044] Webbing 20 is sewn by regularly spaced bar tacks 22 to the outside surface 14 of the belt 10 . The spacing of the bar tacks 22 causes the webbing 20 to form loops (or bottomless pockets) 24 spaced along and above the outside surface 14 of the belt 10 . Webbing made of nylon or polyester is preferred.
[0045] At least one or more loops 24 must be provided on the outside surface 14 of the belt 10 for cooperation with the tab 60 attached to the carrier for articles 30 (see FIGS. 5 and 7 and the discussion below). The specific structure and materials of the loops 24 are not important as long as at least one loop 24 capable of cooperating with a tab 60 is provided.
[0046] The carrier for articles 30 is provided with a sleeve 40 made of fabric. The sleeve 40 has a first end 42 sewn or otherwise attached to the carrier for articles 30 , as is best seen in FIGS. 3 , 5 , 6 , and 7 . A second end 44 of the sleeve 40 detachably connects to a location on the carrier for articles 30 that is spaced from the attachment of the first end 42 so that the sleeve 40 forms a loop sized to enclose the belt 10 as shown in FIGS. 1-4 . In the preferred embodiment of the invention shown in the drawings the means for attaching the second end 44 of the sleeve 40 to the carrier for articles 30 is by provision of mating hook and loop strips 46 and 48 sewn onto to the carrier for articles 30 and adjacent the second end 44 of the sleeve 40 , respectively. Although hook and loop strips are preferred, other means of detachable connection such as snaps and the like are suitable for use in this invention.
[0047] The means of attachment of the second end 44 of the sleeve 40 to the body 34 of the carrier for articles 30 is illustrated best in FIGS. 4-7 . The mating hook and loop strips 46 and 48 may be separated in order to rotate the second end 44 of the sleeve 40 away from the carrier for articles 30 as shown in FIGS. 5-7 so that the carrier for articles 30 can be attached or detached from the belt 10 .
[0048] The specific structure and materials of the sleeve 40 is not important as long as the sleeve 40 can be detachably secured at one of its ends to the carrier 30 .
[0049] As may be seen in FIGS. 5-7 , a tab 60 is attached to the carrier 30 by being sewn at a first end 62 between the carrier 30 and the first end 42 of the sleeve 40 . The tab 60 is preferably made of a thin and stiff material such as polyethylene (PE) board that may be sewn through. The second end 64 of the tab 60 is not sewn or otherwise permanently attached to anything so that it may be inserted through one of the loops 22 as shown in FIGS. 5 and 7 .
[0050] The tab 60 lies between the carrier for articles 30 and the sleeve 40 when the second end 44 of the sleeve 40 is attached to the carrier for articles 30 and thus will not be observed when the carrier for articles 30 is in that condition and is viewed from front and back as shown in FIGS. 2 and 3 . The tab 60 will be easily observable when the second end 44 of the sleeve 40 is detached from the carrier for articles 30 as shown in FIGS. 5-7 . The preferred tongue-like structure of the tab 60 is shown in FIG. 8 . The first end 62 of the tab 60 is broadened in the form of the cross-bar of a “T” to provide a broader space for sewing in the attachment of that end to the carrier for articles 30 . This will help prevent rotation of the second end 64 of the tab 60 from side to side along the plane of the tab and will anchor the tab 60 more securely to the carrier 30 because of the greater length of the stitch line.
[0051] The second end 64 of the tab 60 is rounded to facilitate insertion of the second end 64 through one of the loops 22 as shown in FIGS. 5 and 7 . The tab 60 being preferably made of a stiff but flexible material such as the PE board mentioned in order facilitates the insertion of the second end 64 through one of the loops 22 . Preferably the tab 60 is long enough that the second end 64 will be in contact with the hook and loop strips 46 and 48 when the second end 44 of the sleeve 40 is attached to the body 34 of the carrier for articles 30 but will not extend below or beyond the sleeve 40 . This positioning and length of the tab 60 is indicated in FIGS. 5-7 . It has been found that the configuration is preferred in order to further prevent twisting or rotation of the tab 60 with respect to its attachment to the body 34 of the carrier for articles 30 when the carrier for articles 30 is subjected to forces that would tend to twist the carrier for articles 30 with respect to the belt 10 because the second or free end 64 of the tab 60 is anchored with respect to the body 34 of the carrier for articles 30 by being trapped between the hook and loop strips 46 and 48 .
[0052] The carrier for articles 30 may be attached to the belt 10 in one or another of two modes. FIGS. 5 and 7 show a first mode of attachment in which the carrier for articles 30 will be fixed with respect to the belt 10 because the tab 60 is inserted through one of the loops 22 when the sleeve 40 is wrapped around the belt 10 . In this mode the carrier for articles 30 cannot slide or move along the belt and therefore will remain in the same position with respect to the body of the bearer as long as the belt 10 itself remains in the same relative position with respect to the body of the bearer. This is the mode to use if the bearer has found a preferred position for the carrier for articles 30 or simply wishes for the carrier for articles 30 to not shift while the bearer is moving.
[0053] The other or second mode of attachment is shown in FIG. 6 . In this mode the tab 60 is not inserted through one of the loops 22 when the sleeve 40 is wrapped around the belt 10 . In this mode the carrier for articles 30 can slide or move along the belt. The bearer can slide or move the carrier for articles 30 on the belt as needed for use and/or comfort. This is the mode to use if the bearer wishes to adjust the position of the carrier for articles 30 without removing the carrier for articles 30 from the belt 10 . The bearer, for example, may want to bear the carrier for articles 30 in one position on the belt for reasons of comfort or convenience when moving, sitting or standing but would like to quickly move the carrier for articles 30 to a position for more ready access to the articles contained in the carrier.
[0054] While the invention has been described in conjunction with the preferred embodiment, it will be understood that it is not intended to limit the invention to this embodiment. On the contrary, the invention is intended to cover alternatives, modifications and equivalents that may be included within the spirit and scope of the invention as defined by the appended claims.
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A system for carrying articles on a user's belt, comprising a belt ( 10 ) having multiple loops ( 22 ) on its outside surface and an article carrier ( 1 ) having a sleeve ( 40 ) sewn to the body of the carrier at a first end ( 42 ) and detachably connected to the body of the carrier at a second end ( 44 ). A stiff tab ( 60 ) is sewn at one end thereof into the sewn connection of the body of the carrier to the sleeve. The other end of the tab ( 64 ) is unattached and overlapped by the sleeve when the sleeve is wrapped around the belt for supporting the carrier from the belt. The carrier can be moved along the belt and placed in different positions unless the free end of the tab is inserted through a loop on the belt in which case the carrier will be fixed in position with respect to the belt.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an air bag apparatus which is attached to a steering wheel.
2. Description of the Related Art
Recently, a vehicle operator's seat is equipped with, in general, an air bag apparatus serving as a passive safety auxiliary device (SRS: supplemental restraint system). FIG. 11 illustrates the structure of such vehicle operator's seat SRS air bag. The entire air bag apparatus is integrally assembled to a steering wheel 14 which is secured to the distal end portion of a steering main shaft 12 in a steering column 10.
As a result, in the steering wheel 14, a boss portion 18 of the steering wheel 14 is connected to a serration portion 16 at the distal end of the steering main shaft 12. Further, the boss portion 18 is connected to a conical inclined surface of the steering main shaft 12 so that the boss portion 18 is not inserted in the axial direction thereof. The boss portion 18 is secured by a bolt 20 so that the boss portion 18 is not removed from the end portion of the steering main shaft 12. An air bag apparatus main body 26 is provided within a concave space surrounded by the boss portion 18, a spoke portion 22, and a wheel portion 24 of the steering wheel 14. The air bag apparatus main body 26 is covered by a steering wheel pad 28 and a lower cover 30.
In the air bag apparatus main body 26, as gas is rapidly injected from an inflator 34 into a bag body 32 so as to inflate the bag body 32, the steering wheel pad 28 is broken away and the bag body 32 is unfolded in a predetermined state. When large acceleration is applied to a vehicle, an ignition device of the inflator 34 is energized due to the designation of a central control unit which has detected the acceleration, such that gas generating agent is combusted, a large amount of gas is generated, and the bag body 32 is unfolded. In the air bag apparatus main body 26 which performs electrical ignition and control in this way, it is necessary to connect electrically the air bag apparatus main body 26 and the central control unit disposed at the vehicle body side. As a result, an unillustrated roll connector is disposed at a rotating portion between a steering column 10, which is fixed to the vehicle body, and the steering wheel 14, which is rotated with respect to the steering column 10. The central control unit and the inflator 34 are electrically connected via the roll connector so that the inflator 34 is energized highly reliably.
When the air bag apparatus main body 26 is attached to the steering wheel 14 in this way, it is necessary to have a large space for attaching the large roll connector at the rotating portion between the steering column 10 and the steering wheel 14. Therefore, the portion at which the roll connector is disposed is increased, and since the expensive roll connector is used, the product becomes expensive.
Moreover, there is need to increase the concave space surrounded by the boss portion 18, the spoke portion 22, and the wheel portion 24 of the steering wheel 14 so as to accommodate the bag body 32 and the inflator 34 simultaneously. Accordingly, the design of entire steering wheel 14 is restricted. Further, because the bag body 32 and the heavily-weighted inflator 34 are integrally attached to the steering wheel 14, the mass of the rotating portion of the steering wheel 14 increases. Thus, it is difficult to design the steering wheel 14 for improving the vibration characteristics thereof at the time of running of the vehicle.
SUMMARY OF THE INVENTION
With the aforementioned in view, an object of the present invention is to reduce the number of parts of an air bag apparatus disposed at a steering wheel in a case in which the air bag apparatus is provided at the steering wheel.
An air bag apparatus relating to a first aspect of the present invention, comprising: an inflator portion for supplying pressured gas which is attached to a vehicle body side; a bag portion which is attached to a steering wheel side; and connecting means which introduces gas from the inflator portion to the bag portion in a state in which the inflator portion and the bag portion are relatively rotatable.
Due to the aforementioned structure, when the steering wheel is rotated for steerage, the bag portion and a part of the connecting portion which introduces gas from the inflator portion to the bag portion are rotated integrally along with the steering wheel. The inflator portion is fixed to the vehicle body side.
An air bag apparatus relating to a second aspect of the present invention, comprising: an inflator portion which is fixedly disposed at a vehicle body around a steering shaft of a steering column; a bag portion which is attached to a steering wheel and which rotates along with the steering wheel; and a connecting portion which is provided with a rotational connecting member and a gas passage portion, the rotational connecting member being rotatably attached to at least one of the inflator portion and the bag portion so as to keep air tightness, the gas passage portion being connected to an opening of the rotational connecting member such that the gas can be flowed between the inflator portion and the bag portion in a relatively rotatable state, and which introduces gas generated at the inflator portion to the bag portion so as to inflate and unfold a bag.
Due to the aforementioned structure, even if the steering wheel is rotated, the gas which has been generated at the inflator portion is introduced to the bag portion through the opening of the connecting member, which rotates so as to keep the air tightness, and the gas passage portion. The bag portion can be inflated and unfolded by the gas.
In the present invention, if the connecting portion is formed so as to introduce the gas from the inflator portion to the bag portion through an interval between spokes of the steering wheel, the inflator portion and the bag portion can be easily connected.
Further, in the present invention, the inflator portion may have an annular opening portion which opens in the annular shape around an axis of the steering shaft, and the rotational connecting member is rotatably attached to the annular opening portion. The connecting portion can be easily rotated along with the steering wheel.
Moreover, in the present invention, the rotational connecting member may be attached to the inflator portion, the gas passage portion may include a first pipe-shaped body and a second pipe-shaped body, the first pipe-shaped body is connected to an opening of the rotational connecting member and provided in the axial direction of the steering shaft, and the second pipe-shaped body is provided at the bag portion in the axial direction of the steering shaft and is provided so as to be able to fit with the first pipe-shaped body. As the steering wheel is attached to the steering shaft in a state in which the bag portion is provided at the steering wheel, the inflator portion and the bag portion can be easily connected so as to keep air tightness.
In this case, the gas passage portion may include a pipe-shaped body which is provided at the bag portion and which is provided so as to be able to fit with the opening of the rotational connecting member. The gas passage portion may include a pipe-shaped body which is connected to an opening of the rotational connecting member and which is provided so as to be able to fit with an opening provided at the bag portion.
Furthermore, in the present invention, the inflator portion may include a case which has an outer pipe-shaped portion, a first presser portion, an inner pipe-shaped portion, and a second presser portion, the first presser portion is plate annular-shaped and is formed from the outer pipe-shaped portion toward the center, the inner pipe-shaped portion is formed within the outer pipe-shaped portion, and the second presser portion is flat annular-shaped and is formed outwardly from the inner pipe-shaped portion, and the annular-shaped opening portion can be formed between the first presser portion and the second presser portion.
In this case, the first presser portion may be formed by a large-diameter ring nut which is fit with a screw groove on an outer circumferential surface of the outer pipe-shaped portion, and the second presser portion may be formed by a small-diameter ring nut which is fit with a screw groove on an inner circumferential surface of the inner pipe-shaped portion. The outer pipe-shaped portion and the inner pipe-shaped portion may be connected by a flat annular-shaped bottom plate having connecting portions, and the connecting portions are stood upright at both edges of the bottom plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an essential portion which, cut along a steering axis, shows a state in which an air bag apparatus relating to a present embodiment is attached to a steering column of a steering wheel.
FIG. 2 is a schematic exploded perspective view which shows a state in which the air bag apparatus relating to the present embodiment is decomposed into an inflator portion and a bag portion.
FIG. 3 is an exploded perspective view of an essential portion which shows the bag portion of the air bag apparatus relating to the present embodiment.
FIG. 4 is an enlarged cross-sectional view of an essential portion, taken along line IV--IV in FIG. 3.
FIG. 5 is an exploded perspective view of an essential portion which shows the inflator portion of the air bag apparatus relating to the present embodiment.
FIG. 6 is an enlarged cross-sectional view of an essential portion which, cut along the steering axis, shows connecting portion between the inflator portion and the bag portion in the air bag apparatus relating to the present embodiment.
FIG. 7 is an enlarged cross-sectional view of an essential portion which corresponds to FIG. 6 and which shows the other structural example of connecting portion between the inflator portion and the bag portion in the air bag apparatus relating to the present embodiment.
FIG. 8 is an enlarged cross-sectional view of an essential portion which corresponds to FIG. 6 and which shows the other structural example of connecting portion between the inflator portion and the bag portion in the air bag apparatus relating to the present embodiment.
FIG. 9 is an enlarged cross-sectional view of an essential portion which corresponds to FIG. 6 and which shows the other structural example of connecting portion between the inflator portion and the bag portion in the air bag apparatus relating to the present embodiment.
FIG. 10 is an enlarged cross-sectional view of an essential portion which corresponds to FIG. 6 and which shows the other structural example of connecting portion between the inflator portion and the bag portion in the air bag apparatus relating to the present embodiment.
FIG. 11 is a cross-sectional view of an essential portion which shows a conventional air bag apparatus attached to a steering wheel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a cross-sectional view of an air bag apparatus relating to a present embodiment. As shown in FIG. 1, in this air bag apparatus 50, an inflator portion 54 is disposed at a steering column 52 side, i.e., a vehicle body, and a bag portion 58 is disposed at the steering wheel 56 side.
As shown in FIGS. 1 and 2, the inflator portion 54, which is a device for blowing air, gas and the like, is disposed at the periphery of the distal end portion of a steering main shaft 60 disposed at the central portion of the steering column 52 and is fixed to the vehicle body. In the steering column 52, a lever combination switch portion 62, in which a turn signal switch, a head lamp switch, and the like are combined, is disposed at a position which is adjacent to the inflator portion 54.
As shown in FIGS. 5 and 6, the inflator portion 54 includes a case 64, an inflator 66 for generating gas, and a plate 68 serving as a rotational connecting member. The case 64 is made of a metal so that the case 64 can bear the high pressure and high temperature of gas upon generation thereof. The case 64 is formed as a ring-shaped strong container whose one side planar portion is opened. Further, the inner diameter of a hole portion provided at the center of the case 64 is so large that the boss 71 of the steering wheel 56 can be inserted freely.
A ring-shaped inflator 66, which is smaller than the case 64, is accommodated within the case 64. The inflator 66 is formed by a housing at which a plurality of holes 66A for gas generating agent, ignition agent, filter, and gas injection is formed.
A plate 68 is rotatably attached to the opening portion of the case 64, in which the inflator 66 is accommodated. In the plate 68, gas passage portions 72 are integrally connected to openings of the plate 68 at a plurality of predetermined places of a ring-shaped metal plate member 70. (Because the steering wheel 56 is formed with three spokes in the present embodiment, there are three predetermined places. However, in case of four spokes, there are four predetermined places. The number of places is determined in accordance with the number of intervals between the spokes). Each of the gas passage portions 72 is formed at the ring-shaped plate member 70 so that a pipe-shaped body integrally extends from the periphery of an opening at which a substantially arc-shaped ellipse is punched. After the plate 68 is inserted through the opening of the case 64, an outer side opening circumferential portion 64A of the case 64 is bent at a right angle toward the center and a central hole side opening circumferential portion 64B thereof is bent at a right angle outwardly. Accordingly, the plate 68 is coaxially rotatable with respect to the case 64 and the plate 68 is attached to the case 64 so that the plate 68 is not removed from the opening portion of the case 64. Further, even if there is a small amount of gas leakage, air tightness is maintained so that gas for expanding the bag body 32 is not escaped. Also, as occasion demands, a packing for air tightness is provided between the plate 68 and the outer side opening circumferential portion 64A, the central hole side opening circumferential portion 64B.
As shown in FIG. 1, the inflator portion 54 structured in this way is fixed to a flange portion 52B. The flange portion 52B is formed as a plane which intersects at a right angle with the axis of the steering shaft 60 in an axially-supporting pipe-shaped body 52A, of the steering shaft 60, which forms the steering column 52. An unillustrated portion of the axially-supporting pipe-shaped body 52A is fixed to the vehicle body. Further, in the inflator portion 54, a lead wire connecting portion 74, which energizes an ignition device built in the inflator 66, is fixed to a through-hole (unillustrated) punched at the case 64. The lead wire connecting portion 74 to be fixed and the unillustrated central control unit are connected by a lead wire 76.
As shown in FIG. 3, a bag portion 58 disposed at the steering wheel 56 side in the air bag apparatus is mainly formed by a bag 78 serving as a bag body, a retainer 80, and a bag holder 82. The bag 78 is folded in the shape of a small rectangular parallelopiped so that a circular opening 84 of the bag body, which inflates in the shape of a compressed sphere, is placed on the bottom surface of the bag 78 as shown in FIG. 3. The retainer 80, which is made of a metal and formed as a strong member, is mounted to the circular opening 84 portion. The retainer 80 is disc-shaped so that the periphery of the circular flat plate is bent at a right angle with respect to a circular plane. In addition, a gas introduction passage portion 86 is integrally formed at a plurality of predetermined places (three places in the present embodiment) of the retainer 80 so as to correspond to the gas passage portions 72 of the plate 68 in the aforementioned inflator portion 54. In each of the gas introduction passage portions 86, a pipe-shaped body extends integrally from the periphery of the opening in which a substantially arc-shaped ellipse is punched at the retainer 80, and each of the distal end portions of the gas introduction passage portions 86 is inserted through and fit with the outer side of the corresponding pipe-shaped gas passage portion 72.
The bag 78 and the retainer 80 are accommodated within the bag holder 82. The bag holder 82 is formed in the shape of a rectangular boxed body in which one side portion at the occupant side is opened. A through-hole 94, which is a substantially arc-shaped ellipse and through which each of the gas introduction passage portions 86 of the retainer 80 is inserted, is penetrated through the bottom surface portion of the bag holder 82.
A through-hole 88 is punched at predetermined three places of the disc-shaped portion of the retainer 80. As shown in FIG. 4, a bolt 92 is inserted through the through-hole 88 and fixed at the retainer 80 in the direction which is the same as the protruding direction of the gas introduction passage portion 86. The retainer 80 is inserted into the bag 78 through the circular opening 84 thereof, and each of the bolts 92 is inserted through a through-hole 90 which is formed near the opening 84 of the bag 78. Further, as shown in FIGS. 1 and 3, the retainer 80 attached to the bag 78 is accommodated within the box of the bag holder 82, and each of the gas introduction passage portions 86 penetrates through the corresponding through-hole 94. Moreover, each of the bolts 92 is inserted through a through-hole 95 which is punched at the bottom surface of the bag holder 82 so as to correspond to each of the through-holes 88 of the retainer 80. A nut 96 is fit with the bolt 92, and the bag 78, the retainer 80, and the bag holder 82 are integrally secured. The bag portion 58 shown in FIG. 2 is thereby formed.
The bag portion 58 is disposed between the boss 71 of the steering wheel 56 and a pat cover 98. A spoke core 100 is disposed at a portion between the adjacent gas introduction passage portions 86 of the retainer 80.
As can be seen in FIGS. 1, 2 and 6, the bag portion 58 is integrally assembled to the inflator portion 54. Namely, the outer peripheral portion of each of the gas passage portions 72 of the inflator portion 54 is inserted and fit so as to slidingly abut the inner peripheral portion of each of the corresponding gas introduction passage portions 86 of the bag portion 58. The inflator portion 54 and the bag portion 58 are assembled so that the respective gas passage portions 72 communicate with the gas introduction passage portions 86 within the air bag apparatus and the bag holder 82 is mounted to the steering wheel 56.
As shown in FIGS. 1 and 2, the steering main shaft 60 of the steering column 52 and the boss 71 of the steering wheel 56 are secured. For securing, a conical inclined surface portion 102, a serration portion 104, and a removal preventing groove portion 106 are provided at the distal end portion of the steering main shaft 60.
Correspondingly, in the boss 71 portion, a conical inclined surface hole portion 110, a serration hole portion 112, and a removal preventing screw securing portion 114 are provided at a hole portion 108 for securing a main shaft.
Then, the distal end portion of the steering main shaft 60 is inserted through the hole portion 108 for securing a main shaft, and the conical inclined surface portion 102 is fit with the conical inclined surface hole portion 110 so that the steering wheel 56 does not enter any further than the root side of the steering main shaft 60. The serration portion 104 is fit with the serration hole portion 112 such that the serration portion 104 and the serration hole portion 112 do not rotate relatively around the shafts thereof. The body portion of a screw 114A, which is screwed to and inserted into the removal preventing screw securing portion 114, is interposed so as to intersect the removal preventing groove portion 106. The steering wheel 56 is supported so as to be not removed from the steering main shaft 60. Accordingly, the steering wheel 56 is integrally mounted to the steering main shaft 60. The mounting operation can be effected by putting a tool from the transverse side of the steering column 52 and rotating the screw 1 14A. Further, as the other means of connecting the steering main shaft 60 and the steering wheel 56, it is possible that a shaft member extends from the portion which corresponds to the boss 71 of the steering wheel 56 to the position which has passed the inflator portion 54, and the distal end of the shaft member is secured by the distal end of the steering main shaft 60 which is formed shorter than the one shown in FIG. 1.
Next, instead of an example in which the gas passage portion 72 and the gas introduction passage portion 86 serve as means of connecting the inflator portion 54 and the bag portion 86 in the aforementioned embodiment, variant examples will be explained with reference to FIGS. 7 and 8. In a first variant example shown in FIG. 7, only openings 118, at which a substantially arc-shaped ellipse is punched, are provided at three predetermined places of an annular flat plate of a plate 116 in an inflator portion 54. Gas introduction passage portions 86 of a retainer 80 in a bag portion 58 are extended and the distal end portions of the gas introduction passage portions 86 are fit with the openings 118 of the plate 116. The connecting portion is thereby formed.
Moreover, in a second variant example shown in FIG. 8, an opening 122, at which a substantially arc-shaped ellipse is punched, is provided at each of three predetermined places of the circular disc-shaped portion of a retainer 120 in a bag portion 58. Gas passage portions 72 of a plate 68 in an inflator portion 54 are extended and the distal end portions of the gas passage portions 72 are fit with the openings 122 of the retainer 120. The connecting portion is thereby formed.
Next, the other structural example of the case 64 in the inflator portion 54 will be explained with reference to FIGS. 9 and 10. In the third variant example shown in FIG. 9, a screw groove is formed at the outer circumferential surface portion of a large-diameter circumferential opening portion in which one side plane surface portion of the case 64 is opened. Further, a screw groove is formed at the inner circumferential surface portion of a small-diameter circumferential opening portion which forms a central hole portion.
A large-diameter ring nut 124 is fit with a screw groove of the large-diameter circumferential opening portion of the case 64. In the large-diameter ring nut 124, a screw groove is formed at the inner side of a pipe-shaped portion 124A and a plate annular-shaped presser portion 124B, which is bent from the pipe-shaped portion 124A at a right angle in the central direction of the nut 124, is formed. The large-diameter ring nut 124 is fit with the screw groove of the large-diameter circumferential opening portion of the case 64 and the presser portion 124B slidably supports the planar outer circumferential portion of a ring-shaped plate member 70 of a plate 68.
In addition, a small-diameter ring nut 126 is fit with a screw groove of the small-diameter circumferential opening portion of the case 64. In the small-diameter ring nut 126, the screw groove is formed at the outer side of a pipe-shaped portion 126A and a plate annular-shaped presser portion 126B, which is bent from the pipe-shaped portion 126A at a right angle outwardly in the radial direction of the nut 124, is formed.
The small-diameter ring nut 126 is fit with the screw groove of the small diameter circumferential opening portion of the case 64 and the presser portion 126B slidably supports the planar inner circumferential portion of the ring-shaped plate member 70 of the plate 68. As a result, the plate 68 is rotatably supported at the case 64 by the large-diameter ring nut 124 and the small-diameter ring nut 126.
Further, in a fourth variant example shown in FIG. 10, a case 64 is formed with a bottom plate portion 128, an outer circumferential pipe-shaped portion 130, and an inner circumferential pipe-shaped portion 132. The bottom plate portion 128 is plate-ring shaped, and each of the inner circumferential portion and the outer circumferential portion thereof is bent at a right angle in the same direction. Moreover, the outer circumferential pipe-shaped portion 130 is formed in a pipe shape which has an inner diameter in which the outer circumferential pipe-shaped portion 130 is fit with an outer circumferential surface 128A of the bottom plate portion 128. The free end circumferential opening portion of the outer circumferential pipe-shaped portion 130 is formed with a support receiving portion 130A, whose circumferential opening portion is bent at a right angle toward the center.
Furthermore, the inner circumferential pipe-shaped portion 132 is formed in a pipe shape which has an outer diameter in which the inner circumferential pipe-shaped portion 132 is fit with an inner circumferential surface 128B of the bottom plate portion 128. The free end circumferential opening portion of the inner circumferential pipe-shaped portion 132 is formed with a support receiving portion 132A, whose circumferential opening portion is bent at a right angle outwardly in the radial direction.
A pipe-shaped opening portion of the outer circumferential pipe-shaped portion 130, at which the support receiving portion 130A is not provided, is fit with the outer circumferential surface 128A of the bottom plate portion 128. The pipe-shaped opening portion and the outer circumferential surface 128A are screwed through penetrating through-holes and secured by a nut, or alternatively, secured by a rivet 133. The outer circumferential pipe-shaped portion 130 and the bottom plate portion 128 are thereby integrated. Further, a pipe-shaped opening portion of the inner circumferential pipe-shaped portion 132, at which the support receiving portion 132A is not provided, is fit with the inner circumferential surface 128B of the bottom plate portion 128. The pipe-shaped opening portion and the inner circumferential surface 128B are screwed through penetrating through-holes and secured by a nut, or alternatively, secured by the rivet 133. The inner circumferential pipe-shaped portion 132 and the bottom plate portion 128 are thereby integrated. As a result, the case 64 whose cross-sectional configuration is formed in the inverted U-shape as shown in FIG. 10 is formed.
Next, the operation of an air bag apparatus relating to the aforementioned embodiment will be explained. In the air bag apparatus, the inflator portion 54 is fixed to the steering column 52, and the bag portion 58 is fixed to the steering wheel 56. As a result, when the steering wheel 56 is rotated due to steerage, the bag portion 58 and the plate 68 portion integrally rotate along with the steering wheel 56. At this time, the plate 68 rotates at the circular opening portion of the case 64. A ball bearing, a low friction plate member, or the like which serves as a member for reducing frictional resistance may be used at a slide portion.
Next, when large acceleration (rapid deceleration) is applied to a vehicle, ignition current is flowed to the ignition device within the inflator 66 through the lead wire 76 and the lead wire connecting portion 74 due to the designation of the central control unit. The gas generating agent within the inflator 66 is thereby ignited. Then, the gas, which has been generated due to the combustion of the gas generating agent in the inflator 66, is rapidly filled within the bag 78 through the gas passage portion 72 and the gas introduction passage portion 86. As the bag 78 is inflated, the pat cover 98 is broken away and the air bag is unfolded on the steering wheel 56.
Further, in the present embodiment, because the inflator portion 54 is fixed and attached to the steering column 52, the lead wire connecting portion 74 of the inflator portion 54 and the central control unit are directly connected by the lead wire 76, and a roll connector is not used therein. Moreover, if the inflator portion 54 is disposed at the position at which a roll connector is provided conventionally, the steering column 52 can be formed without increasing the size thereof.
Moreover, it suffices that only the bag portion 58 is provided at the concave space area which is surrounded by the boss 71 and the spoke core 100 in the steering wheel 56 and the inflator portion 54 can be omitted from the area. Accordingly, a space for the components of the air bag apparatus which occupy the concave space of the steering wheel 56 can be made small, and the degrees of freedom in designing the entire steering wheel 56 can be improved. In addition, since the degrees of freedom in size and shape of the bag portion 58 increase, the degrees of freedom in folding the bag 78 increase, and the way of folding can be changed so that the bag 78 unfolds more preferably. Furthermore, vibration characteristics can be improved due to reduction of the mass of the steering wheel portion.
Additionally, if the steering wheel 56 is designed so that the surface of the pat cover 98, which covers the bag portion 58, is closer to the boss 71 side than a ring portion 56A, the space between the ring portion 56A and the pat cover 98 is increased. Thus, a vehicle operator can see meters, which are provided at the instrument panel portion within the vehicle, through the space. Consequently, visibility to the meters can be improved.
The air bag apparatus may not be operated electrically. Further, the inflator may be attached to the fixed position other than that of the steering column. The gas passage portion 72 serving as a gas passage portion may not be penetrated through the spokes. For example, the spokes themselves may be penetrated, or alternatively, the large-diameter boss may be penetrated. The inflator may be the gas filling type.
Because the present invention is structured as described above, a superior effect is achieved in that the number of parts of the air bag apparatus attached to the steering wheel can be reduced.
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An bag apparatus wherein an inflator portion is disposed at a steering column side, a bag portion is disposed at a steering wheel side and in a state in which the inflator portion and the bag portion are relatively rotatable by connecting means, gas which has been generated at the inflator portion is introduced to the bag portion side, and superior effects are achieved in that a space for providing the air bag apparatus at the steering wheel is reduced so as to improve the designing abilities, the mass of the air bag apparatus is decreased so as to improve the vibration characteristics, and a roll connector for transmitting a control signal is not required.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present invention claims priority from, and incorporates by reference the entire disclosure of, Japanese Patent Application No. 2011-173675, filed on Aug. 9, 2011.
TECHNICAL FIELD
[0002] The present invention relates to an extrusion press which is used for extrusion of aluminum alloy or another metal, more particularly relates to a short stroke type extrusion press which shortens the machine length to save space and relates to an extrusion press which is designed for multiple functions and shortens the idle time.
BACKGROUND ART
[0003] In general, when extruding an material to be extruded (billet) made of a metal material, for example, aluminum or an alloy material of the same etc., by an extrusion press, a stem is attached to a front end of a main ram which is driven by a hydraulic pressure cylinder. The material to be extruded (billet) is placed in a container by a placement means in a state where the container is pushed against a die. In addition, by further advancing the main ram by driving the hydraulic cylinder, the material to be extruded (billet) is extruded by the stem. Therefore, a shaped product is extruded from the outlet part of the die.
[0004] FIG. 2 shows the configuration of a conventional short stroke type extrusion press which shortens the machine length so as to save space. Reference numeral 1 of FIG. 2 indicates an end platen, 2 a die slide which is provided with a die 9 for extrusion of a product, 3 a container holder which holds a container 14 which stores a material to be extruded (billet) 12 , 4 a main cylinder housing, 5 a main cylinder, 6 a main ram, 7 a main crosshead which is integrally attached to the front end of the main ram 6 , and 10 side cylinders which are used for movement of the main crosshead 13 and are provided at the right-left horizontal outside surface part of the main cylinder 5 .
[0005] At the front end of the main crosshead 7 , a stem slider 11 is attached slidably in the horizontal direction perpendicular to the advancing/retracting direction of the main crosshead 7 , that is, the axial direction. At one end of the stem slider, an extrusion stem 13 which extends to the end platen side is attached. This extrusion stem 13 can move by a not shown stem slide cylinder between the press center and a standby position of the extrusion stem which is offset from the center position.
[0006] The material to be extruded (billet) 12 is supplied by a not shown extruded material (billet) supplying means to the space which was formed by movement of the extrusion stem and is stored in the container by an extruded material (billet) pushing means.
[0007] In the container 14 , first ends of container cylinder rods 15 are attached to the container holder 3 . The other ends of these container cylinder rods 15 are connected to container cylinders 16 which are provided at the top-bottom vertical outside surface part of the main cylinder 5 . Due to the supply of hydraulic fluid to the container cylinders 16 , the container 14 can be moved between the die 9 and the extrusion stem 13 (see PLT 1).
[0008] The container cylinders 16 operate in an advancing/retracting operation where they advance to abut against the die 9 so that the end face of the container 14 at the extrusion stem side and the extrusion stem 13 move to form a clearance so as to obtain a space for supplying the material to be extruded (billet) 12 , an advancing/retracting operation in an air exhaust process in which compressed air which remains inside the container 14 after upset is exhausted, a strip operation of a container 14 which strips discard after the extrusion process ends during which the container 14 retracts to secure a clearance for a shear blade 28 to move up and down between an end face of the container 14 at the die side and the die 9 , and an operation where when the die 9 is to be replaced, the container 14 retracts to secure a clearance for a die slide operation between the end face of the container 14 at the die side and the die 9 in which the die slide 2 can horizontally move. Further, it also operates in equal pressure extrusion control which renders constant the container sealing force which would otherwise fall along with the progress in the extrusion process.
[0009] In this regard, in the above conventional extrusion press, the container cylinders 16 are configured attached to the main cylinder housing 4 in this way, so there is the problem that, due to interference with other parts at the extrusion press and other mechanisms and other factors, increasing a container strip force is accompanied with difficulties in design strength and structure.
[0010] Further, since the above operations are performed by the container cylinders 16 , there is the problem that a large amount of hydraulic fluid is supplied, useless energy is consumed, and the energy efficiency is poor.
CITATIONS LIST
Patent Literature
[0011] PLT 1: Japanese Patent Publication No. H8-206727A
SUMMARY OF INVENTION
Technical Problem
[0012] The present invention is made to solve the above problem and has as its object to provide a short stroke type extrusion press which increases the container strip force, improves the energy efficiency, shortens the machine length, and saves space.
Solution to Problem
[0013] To achieve the above object, an extrusion press as set forth in a first aspect of the present invention is an extrusion press comprising a moving means which advances and retracts an extrusion stem in an extrusion axial direction and a moving means which advances and retracts a container in the extrusion axial direction, characterized in that a container pushing means which enables at least four different types of movement operations in a direction in which the container separates from the die alone or in cooperation with the container moving means is provided at an end platen which is arranged facing the main cylinder housing.
[0014] The extrusion press as set forth in a second aspect of the present invention provides the invention as set forth in the first aspect characterized in that the four types of movement operations are an air exhaust operation which exhausts compressed air in the container which has been formed in an upset process, an equal pressure extrusion operation which renders a container sealing force which acts on the container constant during an extrusion process, a discard strip operation which strips discard of the billet after the end of the extrusion operation from the inside of the container, and a die opening operation which provides a clearance between an abutting end face of the die and end face of the container when replacing the die after the end of an extrusion cycle.
[0015] The extrusion press as set forth in a third aspect of the present invention provides the invention as set forth in the first aspect characterized in that the container pushing means is configured by a plurality of hydraulic cylinders which are smaller in diameter than the container moving means.
Advantageous Effects of Invention
[0016] According to the present invention, hydraulic cylinders which assist movement of the container when making the container move in the retracting direction are provided at the end platen, so, without impairing the strength of the main cylinder housing, the design is simplified and the container strip force for the discard strip operation can be increased.
[0017] Further, the container pushing means is configured using hydraulic cylinders which are smaller in diameter than the container moving means, so when making the container retract, supply of a small amount of hydraulic fluid is sufficient, the required drive force can be slashed, and the energy efficiency can be improved.
[0018] The present invention will become more clearly understood from the attached drawings and the explanation of preferred embodiments of the present invention.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a longitudinal cross-sectional view of an extrusion press which explains an embodiment of the present invention.
[0020] FIG. 2 is a longitudinal cross-sectional view of a conventional extrusion press.
DESCRIPTION OF EMBODIMENTS
[0021] Below, the present invention will be explained in detail based on FIG. 1 . FIG. 1 shows an embodiment of an extrusion press of the present invention, where 1 indicates an end platen, 2 a die slide which is provided with a die 9 for product extrusion, 3 a container holder which holds a container 14 which stores material to be extruded (billet) 12 , 4 a main cylinder housing, 5 a main cylinder, 6 a main ram, 7 a main crosshead which is integrally attached to a front end of the main ram 6 , and 10 side cylinders which are used for movement of the main crosshead 13 and are provided at the left-right horizontal outside surface part of the main cylinder 5 .
[0022] At the front end part of the main crosshead 7 , a stem slider 11 is attached to be slidable in a vertical or horizontal direction perpendicular to the advancing/retracting direction of the main crosshead 7 , that is, the axial direction. At one end of the stem slider 11 , an extrusion stem 13 is attached extending to the end platen side. This extrusion stem 13 can be moved by a not shown stem slide cylinder between a press center and an extrusion stem standby position offset from the center position.
[0023] The material to be extruded (billet) 12 is placed on the front end part of a not shown extruded material (billet) supplying means, is supplied to a space which is formed by movement of the extrusion stem, and is stored in a container 14 by a pushing means of a material to be extruded (billet) 12 which is provided at the front end of a not shown extruded material (billet) supplying means.
[0024] In the container 14 , first ends of container cylinder rods 15 are attached to the container holder 3 . The other ends of these container cylinder rods 15 are connected to container cylinders 16 which are provided at the top-bottom vertical outside surface part of the main cylinder 5 . Due to the supply of hydraulic fluid to the container cylinders 16 , the container 14 can be moved between the die 9 and the extrusion stem 13 .
[0025] Reference numeral 21 is a container pushing means which is mainly comprised of assist cylinders 22 and assist cylinder rods 23 . The assist cylinders 22 are attached at the end platen 1 symmetrically with the axial direction of the extrusion press to be able to push the container 14 in the direction of the extrusion stem 13 . Reference numeral 18 shows seats for the assist cylinder rods 23 which are provided extending to the container holder 3 . Further, the extrusion press is provided with a not shown position detecting means for detecting the amount of movement of the container holder 3 . Due to the assist cylinders 22 , the container holder 3 is controlled to a predetermined amount of movement. This enables adjustment of the amount of opening of the container holder 3 .
[0026] Reference numeral 27 indicates a main shear device adapted to cut away the not shown discard of the material to be extruded (billet) 12 by moving a shear blade 28 down into the clearance between the die 9 and the container 14 , after the material to be extruded (billet) 14 finishes being extruded, then the extrusion stem 13 retracts by the operation of the side cylinders 10 , and then the container 14 retracts by the operations of the container cylinders 16 and assist cylinders 22 .
[0027] In the discard strip operation, the extrusion stem 13 holds its position, only the container holder 3 is opened by a predetermined amount, then the container holder 3 and the extrusion stem 13 are simultaneously retracted.
[0028] The assist cylinders 22 are configured in a pair facing the outer edges of the die at a slant as explained above, but four assist cylinders 22 may also be provided to push the container 14 .
[0029] The action of the container pushing means 21 in the extrusion press which is configured in this way will be explained.
[0030] For the air exhaust operation, at the start of the extrusion process, the material to be extruded (billet) 12 which is made slightly smaller in diameter than the inside diameter of the container is stored in the container 14 , then the material to be extruded (billet) 12 is pushed by the extrusion stem 13 against the die 9 inside of the container 14 for so-called upset, the material to be extruded (billet) 12 is crushed and the air between the container 14 and the material to be extruded (billet) 12 is compressed. To release this compressed air, hydraulic fluid is supplied to the head side of the assist cylinders 22 to retract the container holder 3 and the extrusion stem 13 is retracted to draw out the compressed air from the clearance between the die 9 and container 14 . At this time, the container holder 3 and the container cylinder rods 15 are pushed by the assist cylinder rods 23 and retracted. The compressed air is released, then the container cylinders 16 and the side cylinders 10 are used to again advance the container 13 and the extrusion stem 13 to start the extrusion process.
[0031] In the extrusion process, the material to be extruded (billet) 12 in the container 14 gradually becomes shorter in length, so at the time of start of the extrusion process and the time of end of the extrusion process, usually the former is larger in force of extrusion action. That is, even if the extrusion resistance of the die 9 is constant, the frictional resistance of the container 14 and the material to be extruded (billet) 12 becomes smaller as the material to be extruded (billet) 12 is reduced in length, so overall force of the extrusion action ends up falling. This fall in the force of the extrusion action causes a reduction in the container sealing force on the die 9 and causes deformation of the shape of the die 9 and a change in the dimensions and shape of the product.
[0032] This equal pressure extrusion operation supplies hydraulic fluid to the head sides of the assist cylinders 22 (and rod side of container cylinder) when there is a change in the dimensions and shape of the extruded product in this way, pushes the container holder 3 in a direction opposite to the extrusion to reduce the container sealing force which excessively acts on the die 9 from the time of extrusion start to the middle of the extrusion process, and controls the container sealing force which acts on the die 9 during the extrusion process so as to become constant from the time of extrusion start to the time of extrusion end.
[0033] Due to the discard strip operation, after the end of the extrusion process, after the material to be extruded (billet) 12 finishes being extruded, the side cylinders 10 are operated to make the extrusion stem 13 retract while hydraulic fluid is supplied to the container cylinders 16 and the assist cylinders 22 at the head side so that the container 14 is also retracted to pull out discard from the container 14 . Further, the shear blade 28 is made to descend in the clearance formed between the die 9 and the container 14 to cut the discard. After cutting the discard, the shear blade 28 is made to rise.
[0034] When the discard is pulled out from the container 14 (discard strip operation), the moving means of the assist cylinders 22 and container cylinders 16 are used.
[0035] In the case of the die opening operation, the die is made to move horizontally along with the die slide 2 when changing the shape of the product or when the die 9 becomes worn and is replaced. At this time, hydraulic fluid is supplied to the head sides of the assist cylinders 22 to retract the container housing 3 and thereby secure a clearance between the die 9 and the container 14 .
[0036] In the above four operations, in each case, hydraulic fluid is supplied to the head sides of the assist cylinders 22 to retract the container holder 3 . Further, the rods of the assist cylinders 22 may be pulled back by the method of supplying hydraulic fluid to the rod sides of the assist cylinders 22 , the method of being pushed back by the advancing container cylinders 16 through the container holder 3 , etc.
[0037] The container strip force in the present invention is the working force which pulls out the discard from the container.
[0038] The strokes of the assist cylinders 22 are adjusted by control based on the amount of detection of a not shown position detecting means which detects the amount of movement of the container holder 3 , but, for example, it is also possible to provide a stroke adjustment mechanism which enables mechanical control of the strokes at the assist cylinders 22 and perform control by adjustment to predetermined strokes for each operation.
[0039] As explained above, in the extrusion press of the present invention, the end platen is provided with a plurality of assist cylinders which assist the retraction operation of the container (movement to extrusion stem side) and which are smaller in diameter than the container cylinders and smaller in output.
[0040] For this reason, in the air exhaust operation and die opening operation which are smaller in load of movement of the container, it is possible to reduce the amount of supply of hydraulic fluid required for retracting the container and possible to save energy and shorten the operating time.
[0041] Further, at the time of the equal pressure extrusion and discard strip operation which are large in load of movement of the container, the container cylinders and assist cylinders cooperate in output, so design is facilitated and the container strip force can be increased without impairing the strength of the main cylinder housing.
[0042] The present invention was explained by reference to a specific embodiment selected for the purpose of explanation, but it will be clear to a person skilled in the art that a large number of modifications are possible without departing from the basic idea and scope of the present invention.
REFERENCE SIGNS LIST
[0043] 1 end platen
[0044] 2 die slide
[0045] 3 container holder
[0046] 4 main cylinder housing
[0047] 5 main cylinder
[0048] 6 main ram
[0049] 7 main crosshead
[0050] 9 die
[0051] 10 side cylinder
[0052] 11 stem slider
[0053] 12 material to be extruded (billet)
[0054] 13 extrusion stem
[0055] 14 container
[0056] 15 container cylinder rod
[0057] 16 container cylinder
[0058] 21 container pushing means
[0059] 22 assist cylinder
[0060] 23 assist cylinder rod
[0061] 27 shear device
[0062] 28 shear blade
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Provided is a short stroke type extrusion press which is capable of increasing a container strip force, improving energy efficiency, and saving space by reducing apparatus length. A main cylinder housing ( 4 ) of the extrusion press comprises a transfer medium ( 10 ) which advances or retreats an extrusion stem ( 13 ) in an extrusion axis direction, and a transfer medium ( 16 ) which advances or retreats a container ( 14 ) in the extrusion axis direction. A container pushing medium ( 21 ) is disposed at an end platen ( 1 ) disposed opposite the main cylinder housing ( 4 ) and makes it possible for at least four different transfer motions to be carried out independently or in collaboration with the container transfer medium in the direction in which the container ( 14 ) separates from a die ( 9 ).
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CROSS-REFERENCED RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/399,700, filed Mar. 6, 2009, which is a continuation of International Patent Application No. PCT/CH2007/000414 filed Aug. 22, 2007, which claims priority to German Patent Application No. DE 10 2006 042 233.3 filed Sep. 6, 2006, the entire contents of both of which are incorporated herein by reference.
BACKGROUND
[0002] The invention relates to devices for injecting, delivering, infusing, dispensing or administering a substance, and to methods of making and using such devices. More particularly, it relates to a needle guard device which is releasably attached to or can be attached to an injection device. The injection device may be used to administer medicaments, for example insulin, and for self-administration, i.e. by patients who administer the relevant medicament themselves. The injection device may be configured for repeated use and to allow the dose of product to be administered to be set or selected. More particularly, the injection device may be an injection device of the type used to treat diabetes or otherwise.
[0003] To prevent the risk of infections, needle guard devices have been developed which enable an injection device to be used only once. A needle guard device of this type is known from patent specification WO 01/91837 A1, for example. The injection needle extends through the needle holder and is fixedly secured by the needle holder. It has an injection portion extending beyond the needle holder in the distal direction and a connecting portion extending beyond the needle holder in the proximal direction.
SUMMARY
[0004] One object of the present invention is to provide needle guard devices that increase the level of safety which can be achieved by using such devices and to prevent injury due to piercing.
[0005] In one embodiment, the present invention comprises a needle guard which can be releasably attached to an injection device. In one embodiment, the needle guard comprises an injection needle and a needle holder holding the injection needle, from which the needle projects by a needle injection portion in the distal (front or forward) direction and from which the needle projects by a needle connecting portion in the proximal (rear) direction. The needle guard also has a distal needle guard for the needle injection portion which is connected to the needle holder so that it can move. The injection needle may extend through the needle holder and is fixedly secured by the needle holder. Alternatively, the needle injection portion and the needle connecting portion may also be separate needles, which are retained by the needle holder and connected to one another to establish a fluid flow. However, the needle holder may also incorporate the two needle portions in a single piece.
[0006] When administering the substance or product to be administered, the needle injection portion pierces the skin and/or tissue lying subcutaneously underneath. When a membrane is attached, providing a tight seal at a distal outlet of a reservoir filled with the product to be administered, the needle connecting portion pierces it. The distal needle guard is able to move in the distal direction relative to the needle holder from a released position as far as a guard position, such as by spring force. When the needle guard assumes the released position, the injection needle sits or rests with its needle injection portion beyond the needle guard in the distal direction. In the guard position, on the other hand, the needle guard overlaps the needle injection portion as far as and including a distal (forward or injection end) end of the injection needle. In the initial state prior to using the device for the first time, the needle guard may assume a distal initial position from which it can be moved into the released position.
[0007] In some embodiments, the distal needle guard is locked in the guard position so that it can not be moved into the released position again. The lock may be established automatically when the needle guard has reached the guard position, having moved in the distal direction. Apart from self-locking needle guard devices of this type, however, the present invention also generally relates to needle guard devices with a displaceable distal needle guard which does not lock after an injection. In such designs, the needle guard is primarily used to block the view to remove the fear of the injection needle for a user administering the product himself.
[0008] As provided herein, in some embodiments, the needle guard device comprises a proximal needle guard, which is displaceably connected to the needle holder. The proximal needle guard can be moved in the proximal direction out of a released position as far as a guard position. In the released position, the needle connecting portion extends beyond the proximal needle guard in the proximal direction. In the guard position, the proximal needle guard overlaps the needle connecting portion up to and including the proximal end of the injection needle. The needle guard device also has a lock mechanism for the proximal needle guard. As soon as the proximal needle guard has reached the guard position, having moved in the proximal direction, it is automatically locked by the lock mechanism so that it is no longer able to move back into the released position. Although needle guard devices with a distal guard are already known from the prior art, for example, from patent specification WO 01/91837 A1 mentioned above, as recognized herein, the needle connecting portion can also cause piercing injuries after the respective needle guard device has been used and the embodiments disclosed herein eliminate this risk via the other needle guard which automatically locks in a guard position after the needle guard device in accordance with the present invention has been used, i.e. as the injection device is removed or after it has been removed.
[0009] In some embodiments, the needle guard device has a fixing mechanism configured as a fixing sleeve to provide a releasable connection to the injection device. The fixing mechanism may co-operate with fixing means associated with or disposed externally on the injection pen. It may be a threaded or bayonet sleeve or a snap-fit, catch-fit or clip-on sleeve, for example. In such designs, the fixing device surrounds the needle connecting portion in a manner conventionally used for needle guard devices. However, the known fixing devices are usually so large in terms of their diameter that the user can easily reach the needle tip of the needle connecting portion with the finger and injure himself. The distal needle guard provided herein, however, is disposed closer to the needle connecting portion than with other fixing mechanisms, and the distance measured transversely to the needle connecting portion is short, such that the user does not come into contact with the proximal needle tip if he touches the proximal end of the proximal needle guard. As a result, the manufacturer also has greater freedom in terms of the design of the fixing mechanism because it offers an additional protective function compared with the other sleeve-shaped, fixing mechanisms, but in this case protecting against piercing injuries can be obtained by the proximal needle guard.
[0010] In some embodiments, a needle guard device in accordance with the present invention has a spring element, which biases the proximal needle guard in the proximal direction by a spring force. The spring element may be supported directly on the proximal needle guard but may also act on the needle guard via one or more intermediate elements. In such designs, when the needle guard device is removed from the injection device, the needle guard is moved into the guard position by spring force. In other variants, the same spring element also acts in the distal direction on the distal needle guard directly or via one or more intermediate elements. In further embodiments, the spring element is supported at one end on the distal needle guard and at the oppositely lying end on the proximal needle guard. Depending on its function, the spring element may be a compression spring, such as a helical spring. In alternative embodiments, the proximal needle guard is not moved into the guard position by spring force, but by a retaining mechanism comprising a retaining holder on the proximal needle guard and a retaining holder on the injection device or product reservoir, which automatically move into a retaining engagement when the needle guard device and injection device are connected, which causes the proximal needle guard to be moved from the released position into the guard position when the needle guard device is released. Once the proximal needle guard has assumed its guard position, the retaining engagement automatically releases when the needle guard device is substantially or completely detached from the injection device.
[0011] In some embodiments, the lock mechanism comprises at least two locking elements, a first locking element formed on the needle holder or, in the situation where the parts are separate, connected to the needle holder, and a second locking element formed on the proximal needle guard or, in the situation where the parts are separate, connected to the needle guard. At least one of the locking elements may be able to move transversely to the longitudinal direction of the injection needle against a resistant or rebounding spring force. The relevant locking element itself may be inflexible, i.e. rigid, and in such embodiments is biased by the rebounding spring force by a separate spring element. However, the relevant locking element may be elastic and may form an elastic bending beam. The rebounding spring force may be used to move the locking element into the locked engagement with the other locking element. The locked engagement may be achieved by an elastic snapping movement. In alternative embodiments, however, the lock mechanism may be provided in the form of only rigid locking elements, i.e. they are not flexible. This being the case, however, the locking elements may need to be moved into the locked engagement when the proximal needle guard moves into the guard position. In such embodiments, the lock mechanism may have one or more slide guides, by which the locking elements are forcibly guided relative to one another into the locked engagement.
[0012] In some embodiments, the second locking element formed on the proximal needle guard or connected to the needle guard may be guided outwardly from the needle guard and co-operate with the first locking element by gripping the needle guard device, but the proximal needle guard may extend through the needle holder in the distal or in the proximal direction, at least in the guard position.
[0013] In one embodiment, the proximal needle guard assumes a proximal (rearward) initial position prior to using the needle guard device, from which it is moved into the released position as the needle guard device is connected to the injection device. In a second embodiment, the proximal needle guard is already in the released position in the state in which the needle guard device is sold. In both embodiments, the needle guard device comprises an unlocking element. In the first embodiment, the unlocking element co-operates with the at least one locking element, which can be displaced transversely to the longitudinal direction of the injection device so that the locked engagement can be established during the movement out of the proximal initial position into the released position because the unlocking element is engaged with the transversely moving locking element, which may also include the situation in which it is engaged with the first and the second locking element in order to prevent the locked engagement. During the course of the injection, such as during piercing by the needle injection portion or as the needle injection portion is being pulled out of or has been pulled out of the tissue, the engagement between the unlocking element and locking element is automatically released so that the locking elements are able to move into the locked engagement when the needle guard device is detached from the injection device. In the second embodiment, during piercing by the injection needle, the unlocking element is moved out of an unlocking position, in which it prevents the proximal needle guard from moving in the proximal direction, into a neutral position in which it permits such a movement and hence a movement into the guard position. The unlocking element of the second embodiment may be rotatable and connectable to the needle holder so as to be rotatable about the injection needle.
[0014] The unlocking elements of both embodiments may be coupled with the distal needle guard or may be automatically coupled with the distal needle guard during piercing or as the injection needle is being pulled out of the tissue. In such designs, the distal needle guard causes the unlocking element to move out of the unlocking position into the neutral position via the coupling. The coupling may be a driving engagement by which the distal needle guard drives the unlocking element with it as far as the neutral position as it moves in the distal direction, i.e. during removal from the tissue. Alternatively, the slide guide may form the coupling, in which case the slide guide converts the piercing movement or the movement of extracting the distal needle guard into the movement of the unlocking element out of the unlocking position into the neutral position. As a result, the slide guide enables a linear piercing movement or extraction movement of the distal needle guard to be converted into a rotating movement of the unlocking element, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a view onto a distal end face of an example of a needle guard device according to a first embodiment in accordance with the present invention;
[0016] FIG. 2 shows the needle guard device in a longitudinal section A-A;
[0017] FIG. 3 shows the needle guard device in a longitudinal section B-B;
[0018] FIG. 4 shows the needle guard device in a longitudinal section C-C;
[0019] FIG. 5 illustrates components of the needle guard device aligned along a longitudinal axis of the needle guard device;
[0020] FIGS. 6A-D show a fixing and guide mechanism of the needle guard device at a front view, along longitudinal sections A-A and B-B and a perspective view along a longitudinal axis of the fixing guide mechanism;
[0021] FIG. 7 shows a distal needle guard of the needle guard device;
[0022] FIG. 8 shows an unlocking element of the needle guard device;
[0023] FIG. 9 is a perspective diagram showing a needle holder of the needle guard device;
[0024] FIG. 10 shows the needle holder in longitudinal section;
[0025] FIG. 11 is a perspective diagram showing a proximal needle guard of the needle guard device;
[0026] FIG. 12 shows the proximal needle guard in longitudinal section;
[0027] FIG. 13 shows an embodiment of a lock mechanism of the needle guard device, with the proximal needle guard in a proximal initial position;
[0028] FIG. 14 shows the lock mechanism, with the proximal needle guard in a releasing position;
[0029] FIG. 15 shows the lock mechanism, with the proximal needle guard in a guard position;
[0030] FIG. 16 is a diagram on a larger scale showing the lock mechanism, with the proximal needle guard in two different positions;
[0031] FIG. 17 shows components of a needle guard device based on a second embodiment in accordance with the present invention;
[0032] FIG. 18 shows the distal needle guard of the second embodiment;
[0033] FIG. 19 is a perspective diagram showing a needle holder of the second embodiment;
[0034] FIG. 20 shows the needle holder of the second embodiment in longitudinal section;
[0035] FIG. 21 is a perspective diagram showing an unlocking element of the second embodiment;
[0036] FIG. 22 is a plan view in the distal direction showing the unlocking element of the second embodiment;
[0037] FIG. 23 shows a proximal needle guard of the second embodiment;
[0038] FIG. 24 shows a lock mechanism of the second embodiment in an initial state prior to an injection;
[0039] FIG. 25 shows the lock mechanism of the second embodiment in an end state after an injection;
[0040] FIG. 26 shows the needle guard device of the second embodiment in the initial state;
[0041] FIG. 27 shows the needle guard device of the second embodiment in a state during an injection; and
[0042] FIG. 28 shows the needle guard device of the second embodiment in the end state.
DETAILED DESCRIPTION
[0043] With regard to fastening, mounting, attaching or connecting components of the present invention, unless specifically described as otherwise, conventional mechanical fasteners and methods may be used. Other appropriate fastening or attachment methods include adhesives, welding and soldering, the latter particularly with regard to the electrical system of the invention, if any. In embodiments with electrical features or components, suitable electrical components and circuitry, wires, wireless components, chips, boards, microprocessors, inputs, outputs, displays, control components, etc. may be used. Generally, unless otherwise indicated, the materials for making the invention and/or its components may be selected from appropriate materials such as metal, metallic alloys, ceramics, plastics, etc. Generally, unless otherwise indicated, relative positional or orientational terms (e.g., upwardly, downwardly, above, below, etc.) are intended to be descriptive, not limiting.
[0044] FIG. 1 is a plan view onto a distal end face illustrating a needle guard device based on a first embodiment of the present invention. Three longitudinal planes are indicated, A-A, B-B and C-C.
[0045] FIG. 2 is a view in longitudinal section A-A indicated in FIG. 1 , showing the needle guard device based on the first embodiment. FIG. 3 is a view of the needle guard in longitudinal section B-B and FIG. 4 illustrates longitudinal section C-C.
[0046] FIGS. 1 to 4 illustrate the needle guard device in an initial state, which it assumes or is in prior to being used for the first time. In this state, the needle guard device may be supplied to the user in a suitable sterile packaging, not illustrated. The needle guard device comprises an injection needle 1 in the form a straight, hollow cannula and a needle holder 2 , which fixedly retains the injection needle 1 in a middle needle portion so that the injection needle 1 is not able to move axially, i.e. in the longitudinal direction L, and is also not able to rotate. The needle holder 2 has a base 9 and a retaining region 10 , which projects centrally out from the base 9 and holds the injection needle 1 . The injection needle 1 extends through the retaining region 10 of the needle holder 2 . It projects beyond the retaining region 10 by an injection portion 1 a in the distal direction and by a connecting portion 1 b in the proximal direction.
[0047] The needle holder 2 is inserted in a sleeve-shaped fixing and guide mechanism and secured so that it is not able to move. The needle holder 2 divides the fixing and guide mechanism into a proximal fixing portion 3 and a distal guide portion 4 . The needle injection portion 1 a extends beyond the guide portion 4 in the distal direction by a length suitable for administering subcutaneous injections. The fixing portion 3 constitutes a fixing mechanism to provide a releasable attachment to a distal end of an injection device. The fixing mechanism may have one or more catch elements to provide a catch connection to the injection device. Alternatively, the fixing mechanism of the needle guard device may also have a screw thread or a bayonet fitting. The fixing portion 3 surrounds the needle connecting portion 1 b and extends beyond it in the proximal direction. The guide portion 4 acts as a non-rotatable, axial guide for a distal needle guard 5 , which in the initial state assumes a distal initial position relative to the needle holder 2 in which it extends beyond the guide portion 4 and distal tip of the injection needle 1 . The distal needle guard 5 is a sleeve-shaped body extending circumferentially around the injection portion 1 a and simultaneously also acts as a visual guard so that the user is not able to see the injection portion 1 a . The distal needle guard 5 is biased by a spring element 6 by spring force acting in the distal direction. In the distal initial position, the distal needle guard 5 is retained against the force of the spring element 6 relative to the guide portion 4 by an unlocking element 8 .
[0048] FIGS. 5 to 8 illustrate how the distal needle guard 5 co-operates with the unlocking element 8 and the guide portion 4 . In FIG. 5 , the components of the needle guard device are aligned one after the other along its central longitudinal axis L in the order in which they are assembled. The injection needle 1 is shown released from the needle holder 2 but may already be fixedly connected to the needle holder 2 at the time of assembly.
[0049] FIGS. 6A-D shows the fixing and guide mechanism (which may be thought of as comprising elements 3 , 4 ) from a front view ( FIG. 6A ), two longitudinal sections A-A ( FIG. 6B ) and B-B ( FIG. 6C ) and a perspective view ( FIG. 4D ). The fixing and guide mechanism has two recesses 4 a in its guide portion 4 at the distal end in an internal face extending circumferentially about the longitudinal axis L. At their proximal end, the recesses 4 a merge into the internal face via a steep shoulder. The two shoulders each form a translation stop 4 c pointing in the distal direction. Disposed to the side of the recesses 4 a are respective axially extending guides 4 b to ensure that the distal needle guard 5 is guided in a straight line. Two other recesses 4 d are provided at the distal end of the guide portion 4 in the same internal face, which are offset from the recesses 4 a on the circumference of the internal face by 90° in each case. The recesses 4 d each merge into the internal face via a steep shoulder at their distal end. The two shoulders each form a translation stop 4 e pointing in the proximal direction.
[0050] FIG. 7 shows the distal needle guard 5 . The distal needle guard 5 has axial guides 5 b , which co-operate with the guides 4 b of the guide portion 4 and with them guide the distal needle guard 5 linearly but prevent it from rotating. Disposed at the proximal end of the distal needle guard 5 , two orifices O are provided in its casing, offset from one another in the circumferential direction by 180°. A projection 5 c projects respectively in the proximal direction into the orifices O, which axially lengthens the casing of the distal needle guard 5 in the respective orifice. The internal faces of the projections 5 b are outwardly inclined in the proximal direction towards free ends of the projections 5 b and, in the embodiment illustrated as an example, each has a constant inclination. They each form a ramp in co-operation with the unlocking element 8 . The distal needle guard 5 has two locking element elements 5 a on its proximal end offset from one another in the circumferential direction by 180°, which are provided in the form of resilient lugs in the embodiment illustrated as an example. The locking elements 5 a are outwardly inclined in the proximal direction. Finally, two locating elements 5 d in the form of outwardly projecting cams are provided on the external circumference of the distal needle guard 5 , likewise at its proximal end offset from one another by 180° in the circumferential direction.
[0051] FIG. 8 illustrates an embodiment of the unlocking element 8 . The unlocking element 8 has an annular base 22 at its proximal end. Projecting out from the base 22 in the distal direction are two fingers 23 , each of which has a projection 24 extending outwardly from its distal end. When the needle guard device is in the initial state, the projections 24 extend through the orifices of the distal needle guard 5 , as illustrated in FIG. 4 , and hold the distal needle guard 5 in its distal initial position against the spring force of the spring element 6 due to the spring element 6 pushing the outer ends of the projections 24 into abutment with contact surfaces of the guide portion 4 . Like the projections 5 c of the distal needle guard 5 , the projections 24 are inclined to form a ramp shape and their inclination is adapted to that of the projections 5 c.
[0052] As may be seen from FIGS. 2 to 4 , not only does the needle guard device have the distal needle guard 5 , it also has a proximal needle guard 7 for the connecting portion 1 b of the injection needle 1 . The unlocking element 8 co-operates with both the distal needle guard 5 and the proximal needle guard 7 . In co-operation with the distal needle guard 5 , it fulfils the described locking function. In co-operation with the proximal needle guard 7 , it fulfils an unlocking function because in its initial position illustrated in FIGS. 2 to 4 , it prevents a movement of the proximal needle guard 7 in the distal direction from being blocked. To enable co-operation with the proximal needle guard 7 , two axially extending recesses formed as an axially extending track 25 are provided in the internal face of the base 22 of the unlocking element 8 offset from one another in the circumferential direction by 180°, in which the proximal needle guard 7 locates in its initial position.
[0053] FIGS. 9 and 10 illustrate the needle holder 2 and FIGS. 11 and 12 illustrate the proximal needle guard 7 . The proximal needle guard 7 has an annular base 14 at its proximal end and locking elements 15 projecting out from the base 14 in the distal direction. The locking elements 15 are finger-shaped or rod-shaped. In the embodiment illustrated as an example, these are two locking elements which project out from a distal end face of the base 14 and are offset from one another by 180° in the circumferential direction about the longitudinal axis L so that they enclose the needle connecting portion 1 b between them when the proximal needle guard 7 is in the proximal initial position. The base 14 has a central passage P for the needle connecting portion 1 b.
[0054] Disposed in a distal portion of the proximal needle guard 7 , the locking elements 15 have several projections, each extending outwards from the locking elements, in this example three projections 16 , 17 and 18 . The locking elements 15 also each have a support 21 for the spring element 6 . The supports 21 are formed by projections extending radially inwardly toward one another at the distal ends of the locking elements 15 . The spring element 6 is supported on the proximal needle guard 7 in the proximal direction by means of the supports 21 , in other words is clamped or held between the distal needle guard 5 and the proximal needle guard 7 .
[0055] In the assembled state, the base 14 of the proximal needle guard 7 is disposed proximally of the base 9 of the needle holder 2 and the rod-shaped or finger-shaped locking elements 15 extend in the distal direction through two passages 11 formed in the base 9 of the needle holder 2 . In the proximal initial position, the distal projections 16 absorb the force of the spring element 6 . To this end, the projections 16 respectively form a stop pointing in the proximal direction which is pushed by the spring element 6 against a complementary stop 13 ( FIG. 10 ) of the needle holder 2 , which is formed by the base 9 of the needle holder 2 in the embodiment illustrated as an example. The projection 17 acts as another stop 20 pointing in the proximal direction. The projection 18 acts as yet another stop 19 but pointing in the distal direction.
[0056] FIGS. 13 , 14 and 15 illustrate the different positions which the proximal needle guard 7 assumes relative to the needle holder 2 when the needle guard device is connected to the injection device and when detached from the injection device again after an injection. In FIG. 13 , the proximal needle guard 7 has assumed its proximal initial position. It can be moved from the initial position against the force of the spring element 6 relative to the needle holder 2 and to the unlocking element 8 disposed in an unlocking position as far as a releasing position illustrated in FIG. 14 , in which the needle connecting portion 1 b extends beyond the proximal needle guard 7 in the proximal direction. In FIG. 15 , the proximal needle guard 7 has assumed a guard position in which it is locked relative to the needle holder 2 so that it can not be moved out of the guard position back into the releasing position. To produce the lock, the needle holder 2 and the proximal needle guard 7 form a lock mechanism with locking elements in a locked engagement, namely on the two locking elements 15 of the proximal needle guard 7 and the base 9 of the needle holder 2 acting as a locking element. A result, the proximal needle guard 7 can be moved into the releasing position once only, namely by a force expended on the proximal needle guard 7 in the distal direction, and automatically moves due to the spring force of the spring element 6 , as the external force decreases, back in the proximal direction as far as the locked guard position. In the guard position, it extends beyond the distal tip of the needle connecting portion 1 b in the distal direction and thus protects the user against injuries caused by piercing. In the embodiment illustrated as an example, a particularly reliable guarding action is provided due to the annular base 14 of the proximal needle guard 7 , the central passage of which is so narrow that the connecting needle is able to fit through the passage when attached to the injection device but the user cannot reach the distal needle tip through the passage.
[0057] FIG. 16 illustrates two states of the components which co-operate to move the proximal needle guard 7 . In the left-hand half of FIG. 16 , the proximal needle guard 7 has assumed the distal initial position and in the right-hand half, the locked guard position. The left-hand half corresponds to the state illustrated in FIGS. 2 to 4 and FIG. 13 and the right-hand half of FIG. 16 corresponds to the state illustrated in FIG. 15 .
[0058] In the initial position, the projections 16 hold the proximal needle guard 7 on the needle holder 2 . The projections 17 taper in an arrow shape in the distal direction whilst the projections 18 taper in an arrow shape in the proximal direction. The stops 19 and 20 of the projections 17 and 18 are disposed axially facing one another. When the needle guard device is attached to an injection device by the fixing portion 3 , for example is screwed on or clipped on, the proximal needle guard 7 moves into contact with the distal end of the injection device and is pushed in the distal direction against the force of the spring element 6 during the attachment operation. During this movement, the projections 17 slide by their arrow-shaped distal faces through the passages 11 of the needle holder 2 so that the locking elements 15 are bent elastically inward. As soon as the projections 17 have moved through the passages 11 , they move into contact with the axial guide tracks 25 of the unlocking element 8 . The locking elements 15 thus remain in the bent state, for which purpose the passages 11 offer a way of axially extending the guide tracks 25 . The projections 17 extend farther outward than the following projections 18 which now move into the region of the passages 11 . The extra distance of the projections 17 measured transversely to the longitudinal axis L is long enough for the projections 20 in contact with the guide tracks 25 to hold the locking elements 15 far enough away from the outer edge of the passages 11 to enable the projections 18 to be moved in the distal direction, likewise through the passages 11 . Once the projections 18 have also moved through the passages 11 , the proximal needle guard 7 moves farther in the distal direction due to the contact with the injection device until the proximal needle guard 7 assumes the releasing position illustrated in FIG. 14 , once the connection to the injection device is established. At the same time as the injection device is attached, the needle connecting portion 1 b pierces a sealing membrane on a distal end of a medicament reservoir and thus establishes a flow connection between the medicament reservoir and the proximal tip of the needle injection portion 1 a.
[0059] When the needle guard device is detached from the injection device and pressure on the proximal needle guard 7 is thus released, the spring element 6 pushes the proximal needle guard 7 in the proximal direction. The proximal projections 18 firstly move into contact with the base 9 forming the locking element of the needle holder 2 so that the locking elements 15 are bent elastically inward again and the passages 11 are able to move in the proximal direction. As illustrated in FIG. 16 , the guide track 25 of the unlocking element 8 may be sufficiently long in the axial direction to enable the projections 18 extending radially outward the farthest to pass the unlocking element 8 during the movement of the proximal needle guard 7 into the guard position. Alternatively, if the guide tracks 25 are short, as is the case with the exemplary unlocking element illustrated in FIGS. 8-15 , the projections 18 are rounded at their outer ends or may be inclined, as in the embodiment illustrated as an example in FIG. 16 and also in FIGS. 12 and 14 . In the end state after use illustrated in the right-hand half of FIG. 16 , the projections 18 with their respective stop 19 in co-operation with the base or locking element 9 prevent the proximal needle guard 7 from being able to move in the distal direction again relative to the needle holder 2 .
[0060] According to some embodiments, the needle guard device may be used as follows. The user attaches the needle guard device in the initial state illustrated in FIGS. 2 to 4 to an injection device by connecting the fixing portion 3 to the distal end of the injection device. During the connection process, the injection device pushes in the distal direction against the proximal needle guard 7 , causing the latter to move into the releasing position illustrated in FIG. 14 . At the same time, the injection needle 1 pierces the sealing membrane of the medicament reservoir in the region of its connecting portion 1 b and establishes the flow connection to the proximal needle tip. When the needle guard device is attached to the injection device, the spring element 6 pushes the proximal needle guard 7 loosely against a point on the distal end of the injection device, for example against a terminal edge of the device or medicament reservoir. The distal needle guard 5 extends with its locking element 5 a ( FIG. 7 ) into the guide portion 4 so that the locking elements 5 a are not able to fulfil any locking function in this state and the distal needle guard 5 is able to move freely against the force of the spring element 6 in the proximal direction.
[0061] For the actual injection, the user then places the injection device on the desired injection point on the skin by the distal end, which is now formed by the distal needle guard 5 , and moves the injection device in the distal direction relative to the distal needle guard 5 . The distal needle guard 5 moves under the pressing force and against the force of the spring element 6 in the proximal direction deeper into the guide portion 4 . Simultaneously at the start of this movement, the ramp-shaped projections 5 c of the distal needle guard 5 ( FIG. 7 ) slide across the adapted ramp-shaped projections 24 of the unlocking element 8 ( FIG. 8 ) so that its fingers 23 are elastically bent in the direction towards the central longitudinal axis L. During the remaining movement of the distal needle guard 5 in the proximal direction, the projections 24 slide in the axial direction across the internal face of the distal needle guard 5 . During this sliding movement, the fingers 23 of the unlocking element 8 are constantly bent elastically inwardly and push against the internal face of the distal needle guard 5 with an elastic force. The distal needle guard 5 moves completely into the guide portion 4 so that the injection needle 1 penetrates the skin and the subcutaneous tissue by its entire injection portion 1 a extending out from the guide portion 4 . Full insertion of the distal needle guard 5 in the guide portion 4 may make the needle injection portion 1 a as short as possible, but is not necessary.
[0062] After administering the medicament, the user moves the injection device away from the injection point so that the distal needle guard 5 moves back in the distal direction under the effect of the spring element 6 . Since the unlocking element 8 is connected to the distal needle guard 5 due to a non-positive connection via the projections 24 and the elastically bent fingers 23 , the distal needle guard 5 drives the unlocking element 8 with it as it moves in the distal direction so that the unlocking element 8 is lifted from the base 9 of the needle holder 2 and is moved relative to the proximal needle guard 7 into a neutral position. Since the projections 24 no longer extend through the distal needle guard 5 , the distal needle guard 5 moves beyond the distal initial position relative to the guide portion 4 in the distal direction. As soon as the locking elements 5 a of the distal needle guard 5 have passed the stops 4 c of the guide portion 4 ( FIG. 6 ), they snap outward into the recesses 4 a and lock the distal needle guard 5 in a distal guard position, preventing a movement back in the proximal direction. The locating elements 5 d move into the recesses 4 d and co-operate with the stops 4 e to hold the distal needle guard 5 on the guide portion 4 . Instead of the unlocking element 8 holding the projections 24 on the distal needle guard 5 by only a non-positive connection (e.g., frictional contact), the engagement could also be based on a positive connection, in which case the unlocking element 8 would latch with the distal needle guard 5 by the projections 24 . However, it the connection may be established early via the described non-positive connection.
[0063] To administer another injection, the user releases the needle guard device from the injection device with the distal needle guard 5 locked in its guard position. During the releasing process, the needle holder 2 moves in the distal direction relative to the injection device. The proximal needle guard 7 moves in the proximal direction relative to the needle holder 2 under the effect of the spring element 6 . As soon as the projections 18 of the proximal needle guard 7 have passed the passages 11 in the base 9 , i.e. the passages 11 of the locking element of the needle holder 2 , the locking elements 15 of the proximal needle guard 7 snap elastically outward. In this state illustrated in the right-hand half of FIG. 16 , the stops 20 of the big projections 17 hold the proximal needle guard 7 on the needle holder 2 against the force of the spring element 6 and the stops 19 of the proximal projections co-operating with the complementary stops 12 of the needle holder 2 prevent the proximal needle guard 7 from being able to move in the distal direction again. The two stops 19 and 20 clamp the base 9 of the needle holder 2 in a close fit between them, and the clearance is ideally just enough to ensure that the short snapping or pivoting movement of the locking elements 15 is not prevented. However, the play may be greater, provided allowance is made for the proximal needle guard 7 to move axially. Such an ability to move should not be so great that the distal tip of the injection needle 1 is able to project out from the proximal needle guard 7 .
[0064] FIG. 17 shows a needle guard device based on a second embodiment with its components aligned longitudinally along a central longitudinal axis L in the order in which they are assembled. The needle guard device again comprises an injection needle 1 which is held by a needle holder 2 , as was the case with the embodiment illustrated as a first example, a fixing and guide mechanism 3 , 4 for attaching the needle guard device to the distal end of an injection device and providing an axial guide for a distal needle guard 5 as well as a spring element 6 . As regards the way in which these components co-operate, the needle guard device of this embodiment corresponds to the embodiment illustrated as a first example. The fixing and guide mechanism is substantially similar to that described in connection with the first embodiment. The needle guard device also has a distal needle guard 27 and an unlocking element 30 , which differ in terms of function from the same components 7 and 8 of the first embodiment, due to the way in which they co-operate with the other components.
[0065] FIG. 18 illustrates the distal needle guard 5 ′ of the second embodiment. The distal needle guard 5 ′ of the second embodiment is missing the two orifices with the projections 5 c but otherwise corresponds to the distal needle guard 5 of the first embodiment except that there is a smaller geometric deviation in the case of the locating elements 5 d ′. The locating elements 5 d ′ each have an inclination with respect to the longitudinal axis L on a side pointing in the circumferential direction about the longitudinal axis L so that the respective locating element 5 a ′ forms a ramp at the relevant side.
[0066] FIGS. 19 and 20 illustrate the needle holder 2 ′ of the second embodiment. The needle holder 2 ′ again has a base 9 ′ and a central retaining region 10 ′ for an injection needle 1 to be arranged in base 9 ′. As with the first embodiment, the base 9 ′ is provided with two passages 11 ′ through which the needle guard 27 can move in the proximal direction into its guard position and which also serve as a means of locking the needle guard 27 in the guard position. Projecting outward from the base 9 ′ in the distal direction adjacent to the retaining region 10 ′ are two projections 26 a offset from one another by 180° in the circumferential direction about the longitudinal axis L, each of which is inclined on one side to form a ramp. Facing the ramp-shaped, inclined sides of the projections 26 a , a respective projection 26 b also extends out from the base 9 ′ in the distal direction. The plane of the section illustrated in FIG. 20 extends through the longitudinal axis L and through the gaps between each one of the projections 26 a and the projection 26 b facing the respective ramp.
[0067] FIG. 21 is a perspective view illustrating the unlocking element 30 . FIG. 22 is a plan view showing a bottom face of the unlocking element 30 , i.e. a view in the distal direction. The unlocking element 30 is of a hollow cylindrical design. Two recesses 31 are provided in the casing of the unlocking element 30 offset from one another by 180° in the circumferential direction, which extend through the casing and form a guide track 32 inclined on one side in the circumferential direction for one of the locating elements 5 d ′ of the distal needle guard 5 ′. A respective projection 33 extends out from a distal edge of the unlocking element 30 into the respective recess 31 . The two recesses 31 are circumferentially framed by the casing of the unlocking element 30 and a recess 35 is provided respectively on the internal face of the casing distally in front of the guide tracks 32 which extends from the distal end of the unlocking element 30 continuously into the respective recess 31 . When the needle guard device is being assembled, the unlocking element 30 with its two recesses 35 is moved across the locating elements 5 d ′ of the distal needle guard 5 ′ so that the locating elements 5 d ′ move into the respective co-operating recess 31 . By turning the unlocking element 30 , likewise during the course of assembly, the locating elements 5 d ′ are then moved in the circumferential direction behind the respective projection 33 into the circumferential region 34 so that the locating elements 5 d ′ locate behind the distal edge of the unlocking element 30 in its circumferential regions 34 and hold the distal needle guard 5 ′ on the guide portion 4 against the force of the spring element 6 as a result. The unlocking element 30 is able to move in the distal direction so that it abuts with the guide portion 4 but is not able to move backward and forward between this abutting position and the base 9 ′ of the needle holder 2 ′, nor is it able to rotate relative to the needle holder 2 ′ about the longitudinal axis L.
[0068] The unlocking element 30 has an annular base 36 projecting radially inwardly on its bottom face at the proximal end of its casing and locating elements 37 projecting out from the base 36 in the proximal direction, in total two locating elements 37 , which are offset from one another by 180° in the circumferential direction. Two passages 38 for the proximal needle guard 27 are provided in the base 36 , offset from one another by 180° in the circumferential direction.
[0069] FIG. 23 illustrates the proximal needle guard 27 . The needle guard 27 has an annular base at a distal end and flexible legs or fingers projecting elastically out from the base in the direction towards the longitudinal axis L, which constitute the locking elements 28 of the needle guard 27 . A projection 29 is respectively formed on the external face of the locking elements 28 . The projections 29 taper in an arrow shape in the proximal direction and, as was the case with the projections 17 of the first embodiment, respectively form a stop of the needle guard 27 pointing in the distal direction. In this respect, reference may be made to the explanation given in connection with the first embodiment.
[0070] FIG. 24 illustrates the components of the lock mechanism of the second embodiment which co-operate to lock the needle guard 27 , with the needle guard 27 assuming a distal initial position which simultaneously also corresponds to the releasing position of the needle guard 27 . In the second embodiment, when the needle guard 27 is in the initial position, it already is completely behind the connecting portion 1 b of the injection needle 1 in the distal direction. It is also behind the base 9 ′ of the needle holder 2 ′, i.e. the spring element 6 pushes the needle guard 27 towards the base 9 ′ in the proximal direction in the initial position. The locking elements 28 extend through the passages 38 of the unlocking element 30 ( FIG. 22 ). When the needle guard device is in the initial state, the passages 38 and the passages 11 of the needle holder 2 ′ are offset from one another in the circumferential direction. The locating elements 37 of the unlocking element 30 axially face the ramp-shaped sides of the projections 26 a of the needle holder 2 ′. The spring element 6 holds the unlocking element 30 in the illustrated distal initial position illustrated in FIG. 24 via the distal needle guard 5 ′ because the distal needle guard 5 ′ locates behind the unlocking element 30 in the circumferential regions 34 by its locating elements 5 d ′ and pulls it into the distal initial position, thereby moving it into abutment against the guide portion 4 . This initial state is also illustrated in FIG. 26 .
[0071] FIG. 25 illustrates the components of the lock mechanism in the end state after the needle guard device has been used and with the needle guard 27 disposed in its proximal guard position. FIG. 28 illustrates the needle guard device as a whole, likewise in its end state.
[0072] A description will be given below of how the needle guard device of the second embodiment works with reference to FIGS. 26 to 28 but also with reference to the other drawings of FIGS. 17 to 25 , particularly FIGS. 24 and 25 .
[0073] The needle guard device is connected to the injection device in the initial state illustrated in FIGS. 24 and 26 , for example screwed to it or clipped onto it. As this happens, the needle connecting portion 1 b pierces the sealing membrane of the medicament reservoir. A movement of the needle guard 27 does not yet take place during the fitting process.
[0074] The user then pierces the skin through to the subcutaneous tissue at the desired injection point with the injection needle 1 . As this happens, the distal needle guard 5 ′ moves in the proximal direction relative to the needle holder 2 ′ so that, conversely, the needle injection portion 1 a projects forward. FIG. 27 illustrates the needle guard device in the piercing state whilst the medicament is being administered.
[0075] As the distal needle guard 5 ′ moves in the proximal direction, the locating elements 5 d ′ move along the respective associated guide track 32 of the unlocking element 30 . The inclination of the guide track 32 is selected so that there is no or practically no inhibiting effect. As a result of this guide engagement, the unlocking element 30 is rotated out of its angular position illustrated in FIG. 24 , the unlocking position, into the angular position (neutral position) illustrated in FIG. 25 . The rotating movement is superimposed by an axial translating movement during which the locating elements 37 of the unlocking element 30 slide on the ramp-shaped side of the respective co-operating projection 26 a . The translating and rotating movement is restricted by an abutting contact of the locating elements 37 and the projections 26 b . The unlocking element 30 drives the needle guard 27 with it during the rotating movement because the locking elements 28 extend through the passages 38 . As soon as the unlocking element 30 has reached its neutral position illustrated in FIG. 25 , the passages 38 of the unlocking element 30 ( FIG. 22 ) overlap the passages 11 ′ of the needle holder 2 ′ ( FIGS. 19 and 20 ) to the degree that the locking elements 28 of the needle guard 27 are able to pass through the passages 11 ′ due to the force of the spring element 6 . The locking elements 28 are pushed by the spring element 6 against a point on the distal end of the injection device, for example a distal point of the device itself or the medicament reservoir. Once they have moved into the passages 11 of the needle holder 2 , the locking elements 28 prevent the unlocking element 30 from being able to turn back into its unlocking position ( FIG. 24 ).
[0076] When the injection needle 1 has been pulled out of the tissue and pressure has thus been relieved on the distal needle guard 5 ′, the spring element 6 moves the distal needle guard 5 in the distal direction. The position of the two projections 33 in the circumferential direction relative to the respective facing guide track 32 is selected so that the locating elements 5 d are able to move into the recesses 35 as the distal needle guard 5 moves in the distal direction, thereby causing the distal needle guard 5 ′ to be finally released by the unlocking element 30 , and the locking elements 5 a ′ are able to move into the recesses 4 a of the guide portion 4 ( FIG. 6 ), as was the case with the first embodiment, and lock the distal needle guard 5 ′ in its distal guard position to prevent it from moving in the proximal direction due to the lock engagement with the stops 4 c . As with the first embodiment, the locating elements 5 d co-operate with the stops 4 e ( FIG. 6 ) to ensure that the distal needle guard 5 ′ can not be completely extracted from the guide portion 4 in the distal direction.
[0077] The needle guard device is released from the injection device with the distal needle guard 5 ′ locked. The proximal needle guard 27 moves in the proximal direction relative to the needle holder 2 ′ into the guard position illustrated in FIG. 25 and FIG. 26 under the effect of the spring element 6 . In the guard position, the locking elements 28 extend beyond the tip of the needle connecting portion 1 b in the proximal direction. The needle guard 27 is locked by a lock engagement between its projections 29 and the base 9 ′ of the needle holder 2 ′ to prevent a movement back in the distal direction. The needle guard 27 is supported by its annular base on the base 9 ′ of the needle holder 2 ′ in the proximal direction.
[0078] Embodiments of the present invention, including preferred embodiments, have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms and steps disclosed. The embodiments were chosen and described to provide the best illustration of the principles of the invention and the practical application thereof, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are 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 they are fairly, legally, and equitably entitled.
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A needle protection device detachably fixed to an injection appliance includes a needle, a needle holder from which a needle injection section of the needle projects distally and a needle connection section of the needle projects proximally, a distal needle protection element connected to the needle holder movable in the distal direction from a release position to a protection position and arranged behind the needle injection section in the release position and overlapping the needle injection section and distal end of the injection needle in the protection position, a proximal needle protection element connected to the needle holder movable from a release position and arranged behind the needle connection section into a protection position and overlapping the needle connection section and proximal end of the injection needle, and a blocking device which blocks movement of the proximal needle protection element from the protection position into the release position.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a method for determining the stability of two dimensional polygonal scenes and, more particularly, to a kinematics based method for determining the stability of two dimensional polygonal scenes which designates each scene in a sequence of scenes as either stable or unstable.
2. Prior Art
Methods are known in the art for determining the stability of a collection of blocks. These methods differ from the one presented here in that these prior methods use an approach based on dynamics whereas the method presented herein is based on kinematics.
Kinematics is a branch of mechanics which deals with the motion of a physical system without reference to the forces which act on that system and without reference to the precise velocities and accelerations of the components of that system. A kinematic model takes the form of a set of constraints which specify the allowed combinations of positions of system components. The allowed motions follow from the possible transitions between allowed positions.
In contrast, dynamics is a branch of mechanics which deals with the motion of a physical system under the influence of forces applied to the components of that system. A dynamic model takes the form of a set of constraints which specify the relation between the positions of system components and the forces on those components. The motions follow by relating forces on system components to accelerations of those components and, in turn, to velocities and positions of those components.
Methods are also known in the art for determining the stability of a collection of line segments and circles. These methods differ from the one presented here in that they are based on a naive physical theory rather than on kinematics. Yet other methods are known in the art for determining the stability of a collection of line segments and circles. While these methods are based on kinematics, they have some fundamental flaws which lead them to produce incorrect results. Lastly, still another method is known in the art for determining the stability of a collection of rectangles. This method differs from the one presented herein in that it is based on a heuristic that does not always work.
SUMMARY OF THE INVENTION
Therefore it is an object of the present invention to provide a method for determining stability of two dimensional polygonal scenes which overcomes the problems of the prior art.
Accordingly, a method for determining the stability of a two dimensional polygonal scene is provided. Each polygon in the scene includes data representing a set L of line segments comprised of individual line segments l. The method determines whether the line segments are stable under an interpretation I. I is a quintuple (g, ⇄ i , ⇄ j , ⇄ θ , ) and g is a property of line segments while ⇄ i , ⇄ j , ⇄ θ , and are relations between pairs of line segments. The method comprises the steps of: initializing a set Z of constraints to an empty set; for each l contained in L, if g(l), instantiating [{dot over (c)}(l)=0] and [{dot over (θ)}(l)=0] and adding them to Z; for each l i , l j contained in L, if l i ⇄ i l j , instantiating [{dot over (ρ)}(I(l i , l j ), l i )=0] between l i and l j and adding it to Z; for each l i , l j contained in L, if l i ⇄ j l j , instantiating [{dot over (ρ)}(I(l i , l j ), l j )=0] between l i and l j and adding it to Z; for each l i , l j contained in L, if l i ⇄ θ l j , instantiating [{dot over (θ)}(l i )={dot over (θ)}(l j )] between l i and l j and adding it to Z; for each l i , l j contained in L, if l i l j , instantiating [{dot over (ρ)}(l i )·σ≦{dot over (l)} j (ρ(p(l i ),l j ))·σ] between l i and l j and adding it to Z; instantiating [{dot over (E)}=−1] between all l of L and adding it to Z; and determining the stability of the scene based upon whether Z has a feasible solution.
Also provided are a computer program product and program storage device for carrying out the method of the present invention and for storing a set of instructions to carry out the method of the present invention, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the methods of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 is a schematic diagram depicting various support relations of blocks A, B, C, D, E, and F shown in the Figure.
FIGS. 2 ( a ) and 2 ( b ) are schematic diagrams of the same scene but with different ground relationships and therefore different stability interpretation.
FIG. 3 ( a ) is a schematic diagram representing a block F resting on two blocks G and H that are rigidly attached to a grounded table top.
FIG. 3 ( b ) is a schematic diagram representing an attachment relation between a hand I and a block J.
FIGS. 4 ( a ), 4 ( b ) are schematic diagrams representing a rigid joint, a revolute joint, and a prismatic joint, respectively.
FIGS. 5 ( a ), 5 ( b ), 5 ( c ), and 5 ( d ) are schematic diagrams which define differing attachment relations and therefore different stability interpretations.
FIGS. 6 ( a ) and 6 ( b ) are schematic diagrams depicting different depth interpretations effecting differing stability judgments on similar scenes.
FIGS. 7 ( a ), 7 ( b ), 7 ( c ), and 7 ( d ) are sets of sequential frames of four movies which were analyzed by a machine vision system utilizing the stability determination method of the present invention.
FIG. 8 is a schematic flow diagram depicting one embodiment of the stability determination method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Although this invention is applicable to numerous and various types of scenes, it has been found particularly useful in the environment of scenes generated by placing polygons around objects in a video frame. Therefore, without limiting the applicability of the invention to scenes generated by placing polygons around objects in a video frame, the invention will be described in such an environment.
For the purposes of this direction, a scene is defined as a set of polygons having a relationship to one another. Each polygon is represented by a number of line segments, each line segment having two endpoints. Preferably, the scenes are generated by taking a video sequence as input and outputting a sequence of scenes, one scene for each video input frame. Each scene consists of a collection of convex polygons placed around the objects in the corresponding image.
Referring now to FIG. 1, there is illustrated a scene 100 having a polygons A-F in various positions in relation to a table top 102 . If one were to look at the scene 100 in FIG. 1, he or she would say that polygon A is supported by the table top 102 , and hence will not fall, while polygon B is unsupported, and hence will fall. Humans have the ability to make stability judgments. The method of the present invention presents a way that such judgments can be made artificially, such as by a computer (not shown).
In FIG. 1, polygon A is supported by virtue of the fact that it is above and in contact with the table top 102 . This alone is not sufficient to guarantee stability, for polygon C is also above and in contact with the table top 102 yet is not stable because it can rotate either clockwise or counterclockwise. An object may require more than one source of support. For example, in FIG. 1, polygons D and E are not stable, because they can slide off their pedestals, while F is stable. Thus determining the stability of a scene requires analyzing the degrees of freedom of motion of the polygons in the scene and showing that no polygon can move under the force of gravity.
So far, the only notion used to explain the stability of a scene is surface-to-surface contact. However, this is insufficient. In FIG. 1, the table top 102 supports polygons A and F and prevents them from falling. But what supports the table top 102 and prevents it from falling? To account for the stability of the table top, one needs to ascribe to it the distinguished property of being grounded, i.e. of being inherently supported and not requiring any further source of support. This property is indicated by the ground symbol 202 attached to the table top 102 in FIG. 2 ( a ). In doing so, one analyzes a scene under an interpretation. Some aspects of a scene are visible. For example, the positions, orientations, shapes, and sizes of the polygons in the scene. Other aspects of a scene are invisible and subject to interpretation. For example, which polygons are grounded. This leads to the possibility of multiple interpretations of a scene, some of which are stable and some of which are not. For example, if the table top 102 is grounded and polygon A is not, as in FIG. 2 ( a ), the scene is stable, while if polygon A is grounded while the table top 102 is not, as in FIG. 2 ( b ), the scene is not stable.
In actuality, polygon F in FIG. 1 is also unstable. Because, in the absence of friction, the two polygons G and H that support polygon F can slide sideways along axis X—X. To explain the stability of polygon F, one can hypothesize the polygons G and H are attached to the table top 102 , as shown in FIG. 3 ( a ). Likewise, suppose that FIG. 3 ( b ) depicts a hand I grasping a block J. To explain the stability of polygon J, one must hypothesize that polygon J is attached to polygon I, even if polygon I is grounded. These attachment relations are indicated by small solid circles in FIGS. 3 ( a ) and 3 ( b ).
There are a wide variety of different kinds of attachment relations. Each kind of attachment relation imposes different constraints on the relative motion of the attached polygons. In this patent disclosure, three kinds of attachment relations are considered, namely rigid joints, revolute joints, and prismatic joints. Rigid joints, indicated by small solid circles, constrain the relative rotation and translation of the attached objects. FIG. 4 ( a ) depicts a rigid joint 402 , hand I grasping block J. Revolute joints 404 , indicated by small unfilled circles, constrain the relative translation of the attached polygons but allow one polygon to rotate relative to the other about the revolute joint 404 . FIG. 4 ( b ) depicts a revolute joint 404 between a washing machine cover 406 and its base 408 . Prismatic joints 410 , indicated by small solid circles with small thick lines along one of the joined edges, constrain the relative rotation of the two attached polygons but allow one polygon to translate relative to the other along the direction of the small thick line. FIG. 4 ( c ) depicts a prismatic joint 410 between a drawer 412 and its cabinet 414 .
Attachment relations, like the grounded property, are subject to interpretation. And just as is the case for the grounded property, different interpretations of the same scene that specify different attachment relations will lead to different stability judgments. FIGS. 5 ( a )- 5 ( d ) show four different interpretations of the same scene 500 . The interpretations of scene 500 shown in FIGS. 5 ( b ) and 5 ( c ) are stable, because polygons K and L cannot move under the force of gravity, while the interpretations in FIGS. 5 ( a ) and 5 ( d ) are not stable, because polygon L is free to rotate clockwise in FIG. 5 ( a ) about revolute joint 404 and polygon L is free to translate vertically in FIG. 5 ( d ) along prismatic joint 410 .
The world is three dimensional while images are 2D projections of the 3D world. When you see a scene 600 , like that in FIGS. 6 ( a ) and 6 ( b ), it is unclear whether polygon A is in front of, on, or behind the table 102 . Like the grounded property and attachment relations, different interpretations of the relative depth of polygons will lead to different stability judgments. If polygon A is on the table 102 , as shown in FIG. 6 ( a ), then the scene 600 is stable. If polygon A is in front of or behind the table 102 , as shown in FIG. 6 ( b ), then the scene 600 is not stable. For purposes of this disclosure, it is assumed that each polygon lies on a plane that is parallel to the image plane. Any two polygons are said to either be on the same layer or on different layers. Two polygons are depicted as being on the same layer by giving them the same layer index (FIG. 6 ( a ) shows both polygon A and the table 102 as having the same layer index 0 ). Two polygons are depicted as being on different layers by giving them different layer indices (FIG. 6 ( b ) shows polygon A at layer index 1 and the table 102 at layer index 0 ). Two polygons can be in contact only if they are on the same layer. Thus one polygon can support another polygon by contact only if they are on the same layer.
The methods of the present invention use an algorithm STABLE (P, I) for determining the stability of a polygonal scene under an interpretation. The input to this method consists of a scene having a set P of polygons and an interpretation I. The output is a designation of Stable or Unstable indicating whether or not the scene is stable.
The primary application that is currently being considered for the methods of the present invention is visual event perception. In this application, a video camera is connected to a computer system and the computer system recognizes simple actions performed by a human in front of the video camera. For example, the human can pick up or put down blocks. The counter system takes the video input, digitizes it, segments each frame of the video input into the participant objects and tracks those objects over time. A scene is generated for each frame by placing polygons around the human's hand and other objects in the scene. The computer then generates all possible interpretations for each scene, checks the stability of each interpretation for each scene and constructs a preferred set of stable interpretations for each scene. With a sequence of such preferred stable interpretations, a pick up event can be recognized by detecting a state change where the object being picked up starts out being supported by being in contact with the table and is subsequently supported by being attached to the hand. Likewise, a put down event can be recognized by detecting the reverse state change. The approaches to visual event classification of the prior art use motion profiles rather than changes in support, contact, and attachment relations.
A prototype implementation has been constructed for the methods of the present invention. FIGS. 7 ( a )- 7 ( d ) show the results of processing four short movies with this implementation, the movies illustrated in FIGS. 7 ( a )- 7 ( d ) are referred to generally by reference numerals 700 , 720 , 740 , and 760 , respectively. Each Figure shows a subset of the frames from a single movie. From FIGS. 7 ( a ) to 7 ( d ), the movies 700 , 720 , 740 , and 760 have 29, 34, 16, and 16 frames, respectively, of which six frames are shown. Each movies was processed by a segmentation procedure to place convex polygons around the colored and moving objects in each frame. A tracking procedure computed the correspondence between the polygons in each frame and those in the adjacent frames. Such segmentation and tracking procedures are well known in the art and can be automatically or manually carried out by software. A model reconstruction procedure was used to construct a preferred stable interpretation of each frame. This model reconstruction procedure used the stability determination methods of the present invention. Each frame is shown with the results of segmentation and model reconstruction superimposed on the original video image.
Referring to movie 700 illustrated in FIG. 7 ( a ), notice that the method of the present invention determines that the lower block 702 and the hand 704 are grounded for the entire movie 700 , that the upper block 706 is supported by being on the same layer as the lower block 702 for frames 2 , 4 , and 8 , and that the upper block 706 is supported by being rigidly attached to the hand 704 for frames 20 , 22 , and 24 . Referring to movie 720 illustrated in FIG. 7 ( b ), notice that the method of the present invention determines that the lower block 722 and the hand 724 are grounded for the entire movie 720 , that the upper block 726 is supported by being rigidly attached to the hand 724 for frames 5 and 10 , and that the upper block 726 is supported by being on the same layer as the lower block 722 for frames 21 , 24 , 26 , and 29 . Referring to movie 740 illustrated in FIG. 7 ( c ), notice that the method of the present invention determines that the lower block 742 and the hand 744 are grounded for the entire movie 740 and that the upper block 746 is supported for the entire movie 740 by being on the same layer as the lower block 742 . Referring to movie 760 illustrated in FIG. 7 ( d ), notice that the method of the present invention determines that the lower block 762 and the hand 764 are grounded for the entire movie 760 and that the upper block 766 is supported for the entire movie 760 by being rigidly attached to the hand 764 .
The prototype implementation was given the following lexicon when processing the movies 700 , 720 , 740 , and 760 of FIGS. 7 ( a )- 7 ( d ): PICKUP ( x , y ) [ SUPPORTED ( x ) SUPPORTED ( y ) ( ATTACHED ( x , y ) ; ATTACHED ( x , y ) ) ] PUTDOWN ( x , y ) [ SUPPORTED ( x ) SUPPORTED ( y ) ( ATTACHED ( x , y ) ; ATTACHED ( x , y ) ) ]
Essentially, these define pick up and put down as events where the agent (hand) is not supported throughout the event, the patient (block) is supported throughout the event, and the agent grasps or releases the patient, respectively. The methods of the present invention correctly recognize the movie 700 in FIG. 7 ( a ) as depicting a pick up event and the movie 720 in FIG. 7 ( b ) as depicting a put down event. More importantly, the methods of the present invention correctly recognize that the remaining two movies 740 , 760 of FIGS. 7 ( c ) and 7 ( d ) do not depict any of the defined event types.
Note that systems of the prior art that classify events based on motion profiles will often mistakenly classify these last two movies 740 , 760 as either pick up or put down events because they have similar motion profiles.
An algorithm used in the methods of the present invention to make a determination of stability for a given score will now be described. The algorithm, named STABLE (P, I), that determines whether a set P of polygons is stable under an interpretation I is determined by reducing the problem to determining whether a set L of line segments is stable under an interpretation I. Thus, the algorithm STABLE (P, I) is defined from STABLE (L, I) simply by considering each polygon to be a set of rigidly joined line segments on the same layer.
The line segments in a scene have fixed positions and orientations. The coordinates of a point p are denoted as x(p) and y(p). The endpoints of a line segment l are denoted as p(l) and q(l). The length of a line segment l is denoted as ||l||. The position of a line segment is denoted as the position of its midpoint c. The orientation θ(l) of a line segment l is denoted as the angle of the vector from p(l) to q(l). The quantities p(l), q(l), ||l||, c(l), and θ(l) are all fixed in a given scene. And p(l) and q(l) are related to ||l||, c(l), and θ(l) as follows: c ( l ) = p ( l ) + q ( l ) 2 l = ( q ( l ) - p ( l ) ) · ( q ( l ) - p ( l ) ) θ ( l ) = tan - 1 y ( q ( l ) ) - y ( p ( l ) ) x ( q ( l ) ) - x ( p ( l ) ) x ( p ( l ) ) = x ( c ( l ) ) - 1 2 l cos θ ( l ) y ( p ( l ) ) = y ( c ( l ) ) - 1 2 l sin θ ( l ) x ( q ( l ) ) = x ( c ( l ) ) + 1 2 l cos θ ( l ) y ( q ( l ) ) = y ( c ( l ) ) + 1 2 l sin θ ( l )
An interpretation I is a quintuple <g, ⇄ i , ⇄ j , ⇄ θ , >, g is a property of line segments while ⇄ i , ⇄ j , ⇄ θ , and 's are relations between pairs of line segments. The assertion g(l) indicated that line segment l is grounded. The assertion l i ⇄ i l j indicates that the position of the intersection of l i and l j is fixed along l i . The assertion l i ⇄ j l j indicates that the position of the intersection of l i and l j is fixed along l j . The assertion l i ⇄ θ l j indicates that the angle between l i and l j is fixed. Collectively, ⇄ i , ⇄ j , and ⇄ θ describe the attachment relations.
IF l i ⇄ i l j Λl i ⇄ j l j Λl i ⇄ θ l j , then l i and l j are joined by a rigid joint 402 . If l i ⇄ i l j Λl i ⇄ j l j Λl i not ⇄ θ l j , then l i and l j are joined by a revolute joint 404 . If l i not ⇄ i l j Λl i ⇄ j l j Λl i ⇄ θ l j , then l i and l j are joined by a prismatic joint 410 that allows l j to slide along l i . IF l i ⇄ i l j Λl i not ⇄ j l j Λl i ⇄ θ l j , then l i and l j are joined by a prismatic joint 410 that allows l i to slide along l j . If l i not ⇄ i l j Λl i not ⇄ j l j Λl i not ⇄ θ l j , then l i and l j are not joined. Finally, the assertion l i l j indicates that l i and l j are on the same layer.
An interpretation is admissible if the following conditions hold:
For all l i and l j , if l i ⇄ i l j , l i ⇄ j l j , or l i l j , then l i intersects l j .
For all l i and l j , l i ⇄ i l j if l j ⇄ j l i .
⇄ θ is symmetric.
For all l i and l j , if l i l j , then l i and l j do not overlap. Two line segments overlap if they intersect in a non-collinear fashion and the point of intersection is not an endpoint of either line segment.
is symmetric and transitive. Only admissible interpretations are considered.
Let us postulate an unknown instantaneous motion for each line segment l in a scene. This can be represented by associating a linear and angular velocity with each line segment l. Such velocities are denoted with the variables {dot over (c)}(l) and {dot over (θ)}(l). It is assumed that there is no motion in depth so the relation does not change. If the scene contains n line segments, then there will be 3n scalar variables, because {dot over (c)} has x and y components. Assuming that the line segments are rigid, i.e. that instantaneous motion does not lead to a change in their length, one can relate {dot over (p)}(l) and {dot over (q)}(l), the instantaneous velocities of the endpoints, to {dot over (c)}(l) and {dot over (θ)}(l), using the chain rule as follows: p . ( l ) = ∂ p ( l ) ∂ x ( c ( l ) ) x ( c . ( l ) ) + ∂ p ( l ) ∂ y ( c ( l ) ) y ( c . ( l ) ) + ∂ p ( l ) ∂ θ ( l ) θ . ( l ) q . ( l ) = ∂ q ( l ) ∂ x ( c ( l ) ) x ( c . ( l ) ) + ∂ q ( l ) ∂ y ( c ( l ) ) y ( c . ( l ) ) + ∂ q ( l ) ∂ θ ( l ) θ . ( l )
where each of {dot over (p)}(l) and {dot over (q)}(l) are linear in {dot over (c)}(l) and {dot over (θ)}(l).
Each of the components of an admissible interpretation of a scene can be viewed as imposing constraints on the instantaneous motions of the line segments in that scene. The simplest case is the g property. If g(l), then
{dot over (c)}(l)=0 (1)
and
{dot over (θ)}(l)=0 (2)
Note that equations (1) and (2) are linear in {dot over (c)}(l) and {dot over (θ)}(l).
Let us now consider the l i ⇄ i l j and l i ⇄ j l j relations and the constraint that they impose on the motions of l i and l j . First, the intersection of the l i and l j is denoted as I(l i ,l j ). If we let A = ( y ( p ( l i ) ) - y ( q ( l i ) ) x ( q ( l i ) ) - x ( p ( l i ) ) y ( p ( l j ) ) - y ( q ( l j ) ) x ( q ( l j ) ) - x ( p ( l j ) ) ) b = ( y ( p ( l i ) ) ( x ( q ( l i ) ) - x ( p ( l i ) ) ) + x ( p ( l i ) ) ( y ( p ( l i ) ) - y ( q ( l i ) ) ) y ( p ( l j ) ) ( x ( q ( l j ) ) - x ( p ( l j ) ) ) + x ( p ( l j ) ) ( y ( p ( l j ) ) - y ( q ( l j ) ) ) )
then I(l i ,l j )=A −1 b.
Next, let us denote by ρ(p,l), where p is a point on l, the fraction of the distance where p lies between p(l) and q(l). ρ ( p , 1 ) = ( p - p ( l ) ) · ( p - p ( l ) ) l
Recall that I(l i , l j ) is the intersection of l i and l j . Thus ρ(I(l i , i j ), l i ) is the fraction of the distance of that intersection point along l i . Next, let us compute {dot over (ρ)}(I(l i , l j ), l i ), which is the change in ρ(I(l i , l j ), l i ). Let α be the vector containing the elements x(p(l i )), y(p(l i )), x(q(l i )), y(q(l i )), x(p(l j )), y(p(l j )), x(q(l j )), and y(q(l j )), let β be the vector containing the elements x(c(l i )), y(c(l i )), θ(l i ), x(c(l j )), y(c(l j )), and θ(l j ), let γ be the vector where Y k = ∂ ρ ( I ( l i , l j ) , l i ) ∂ α k ,
and let D be the matrix where D kl =aα k/ aβ l . {dot over (ρ)}(I(l i , l j ), l i ) can be computed by the chain rule as follows:
{dot over (ρ)}(I(l i ,l j ),l i )=γ T D{dot over (⇄)}
Note that {dot over (ρ)}(I(l i , l j ), l i ) is linear in {dot over (c)}(l i ), {dot over (θ)}(l i ), {dot over (c)}(l j ), and {dot over (θ)}(l j ) because all of the partial derivatives are constant.
Similarly, ρ(I(l i , l j ), l j ) is the fraction of the distance of the intersection of l i and l j along l j . Next, let us compute {dot over (ρ)}(I(l i , l j ), l j ), which is the change in ρ(I(l i , l j ), l j ). Let α be the vector containing the elements x(p(l i )), y(p(l i )), x(q(l i )), y(q(l i )), x(p(l j )), y(p(l j )), x(q(l j ), and y(q(l j )), let β be the vector containing the elements x(c(l i )), y(c(l i )), θ(l i ), x(c(l j )), y(c(l j ), and θ(l j ), let γ be the vector where Y k = ∂ ρ ( I ( l i , l j ) , l j ) ∂ α k
and let D be the matrix where D kl =aα k /aβ l , {dot over (ρ)}(I(l i , l j ), l j ) can be computed by the chain rule as follows:
{dot over (ρ)}(I(l i ,l j ),l j =γ T D{dot over (β)}
Note the {dot over (ρ)}(I(l i , l j ), l j ) is linear in {dot over (c)}(l i ), {dot over (θ)}(l i ), {dot over (c)}(l j ), and {dot over (θ)}(l j ) because all of the partial derivatives are constant.
The ⇄ i constraint can then be formulated as follows: if l i ⇄ i l j , then
{dot over (ρ)}(I(l i , l j ), l i )=0 (3)
And the ⇄ j constraint can then be formulated as follows: if l i ⇄ j l j , then
{dot over (ρ)}(I(l i , l j ), l j )=0 (4)
Again, note that equations (3) and (4) are linear in {dot over (c)}(l i ), {dot over (θ)}(l j ), and {dot over (θ)}(l j ).
Let us now consider the l i ⇄ θ l j relation and the constraint that it imposes on the motions of l i and l j . If l i ⇄ θ l j , then
{dot over (θ)}(l i )={dot over (θ)}(l j ) (5)
Again, note that equation (5) is linear in {dot over (θ)}(l i ) and {dot over (θ)}(l j ).
The same-layer relation l i l j imposes the constraint that the motion of l i and l j must not lead to an instantaneous penetration of one by the other. An instantaneous penetration can occur only when the endpoint of one line segment touches the other line segment. Without loss of generality, let us assume that p(l i ) touches l j . Let {overscore (p)} a denote a vector of the same magnitude as p rotated counterclockwise 90°.
{overscore ((x,y))}=(−y,x)
Let σ be a vector that is normal to l j , in the direction towards l i .
σ=−{overscore ([q(l j )−p(l j ))}·(q(l i )−p(l i ))]{overscore (q(l j )−p(l j ))}
If 0≦ρ≦1, let us denote by l(ρ) the point that is the fraction ρ of the distance between p(l) and q(l).
l(ρ)=p(l)+ρ(q(l)−p(l))
And let us denote by {dot over (l)}(ρ) the velocity of the point that is the fraction ρ of the distance between p(l) and q(l) as l moves. Let α be the vector containing the elements x(p(l)), y(p(l)), x(q(l)), and y(q(l)), let β be the vector containing the elements x(c(l)), y(c(l)), and θ(l), let γ be the vector where γ k =al(ρ)/aα k , and let D be the matrix where D kl =aα k /aβ l .
Again, by the chain rule:
{dot over (l)}(ρ)=γ T D{dot over (β)}
Again, not that {dot over (l)}(ρ) is linear in {dot over (c)}(l) and {dot over (θ)}(l) because all of the partial derivatives are constant.
An instantaneous penetration can occur only when the velocity of p(l i ) in the direction of σ is less than the velocity of the point of contact in the same direction. The velocity of p(l i ) is {dot over (ρ)}(l i ) and the velocity of the point of contact is {dot over (l)} j (ρ(p(l i , l j )). Thus if l i l j and p(l i ) touches l j , then
{dot over (p)}(l i )·σ≦{dot over (l)} j (ρ(p(l i ),l j ))·σ (6)
Again, note that inequality (6) is linear in {dot over (c)}(l i ), {dot over (θ)}(l i ), {dot over (c)}(l j ), and {dot over (θ)}(l j ).
We now wish to determine the stability of a scene under an admissible interpretation. A scene is unstable if there is an assignment of linear and angular velocities to the line segments in the scene that satisfies the above constraints and decreases the potential energy of the scene. The potential energy of a scene is the sum of potential energies of the line segments in that scene. The potential energy of a line segment l is proportional to its mass times y(c(l)). We can take the mass of a line segment to be proportional to its length. So the potential energy E can be taken as Σ lεL ||l||y(c(l)).
The potential energy can decrease if {dot over (ε)}<0. By scale invariance, if E can be less then zero, then it can be equal to any value less than zero, in particular −1. Thus a scene is unstable under an admissible interpretation is the constraint
{dot over (E)}=−1 (7)
is consistent with the above constraints. Note that E is linear in all of the {dot over (c)}(l) values. Thus the stability of a scene under an admissible interpretation can be determined by a reduction to linear programming.
This leads to the following algorithm STABLE (L,I) for determining whether a set L of line segments is stable under an interpretation I where I=<g, ⇄ i , ⇄ j , ⇄ θ , >.
In summary, the method of the present invention for determining the stability of a scene can be summarized by reference to the flowchart of FIG. 8 :
At step 800 : Initialize the set Z of constraints to the empty set;
At step 802 : For each element l contained in L, if g(l), instantiate equations {dot over (c)}(l)=0 and {dot over (θ)}(l)=0, and then add them to Z;
At step 803 : For each l i , l j ε L, if l i ⇄ i l j , instantiate the equation {dot over (ρ)}(I(l i , l j ), l i )=0 between l i and l j and add it to Z;
At step 804 : For each l i , l j ε L, if l i ⇄ j l j , instantiate the equation {dot over (ρ)}(I(l i , l j ), l j )=0 between l i and l j and add it to Z;
At step 805 : For each l i , l j ε L, if l i ⇄ θ l j , instantiate the equation {dot over (θ)}(l i )={dot over (θ)}(l j ) between l i and l j and add it to Z;
At step 806 : For each l i , l j ε L, if l i l j , instantiate the equation {dot over (p)}(l i )·σ≦{dot over (l)} j (ρ(p(l i ),l j ))·σ between l i and l j and add it to Z;
At step 807 : Instantiate the equation {dot over (E)}=−1 between all l ε L and add it to Z; and
At step 808 : Pass Z to a linear programming solver as understood by one skilled in the art.
At step 810 a test is done to determine if Z has a feasible solution. The method outputs a designation indicating Unstable if there is a feasible solution (step 810 a ); otherwise the method outputs a designation indicating Stable (step 810 b ). These designations can take on any number of forms. Preferably, a binary logical value in which case 1 indicates a stable scene and a logical value of 0 indicates an unstable scene (or vice versa).
It will be apparent to those skilled in the art that the methods of the present invention disclosed herein may be embodied and performed completely by software contained in an appropriate storage medium for controlling a computer.
While there has been shown and described what is considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact forms described and illustrated, but should be constructed to cover all modifications that may fall within the scope of the appended claims.
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A method for determining the stability of a two dimensional polygonal scene. Each polygon in the scene includes data representing a set L of line segments comprised of individual line segments l. The method determines whether the line segments are stable under an interpretation I. I is a quintuple (g, ⇄ i , ⇄ j , ⇄ θ , ) and g is a property of line segments while ⇄ i , ⇄ j , ⇄ θ , and are relations between pairs of line segments. The method includes the steps of: initializing a set Z of constraints and to an empty set; for each l contained in L, if g(l), instantiating [{dot over (c)}(l)=0] and [{dot over (θ)}(l)=0] and adding them to Z; for each l i , l j contained in L, if l i ⇄ i l j instantiating [{dot over (ρ)}(I(l i , l j ), l j )=0] between l i and l j and adding it to Z; for each l i , l j contained in L, if l i ⇄ j l j instantiating [{dot over (ρ)}(I(l i , l j ), l j )= 0 ] between l i and l j and adding it to Z; for each l i , l j contained in L, if l i ⇄ θ l j , instantiating [{dot over (θ)}(l i )={dot over (θ)}(l j )] between l i and l j and adding it to Z; for each l j , l j contained in L, if l i l j instantiating [{dot over (ρ)}(l i )·σ≦{dot over (l)} j (ρ(p(l i ),l j ))·σ] between l i and l j and adding it to Z; instantiating [{dot over (E)}=−1] between all l of L and adding it to Z; and determining the stability of the scene based upon whether Z has a feasible solution. Also provided are a program storage device and computer program product for carrying out the method of the present invention.
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This is a continuation of application Ser. No. 06/819,761, filed Jan. 21, 1986 which is a continuation-in-part of application Ser. No. 06/809,954 filed Dec. 20, 1985 which was a continuation-in-part of application Ser. No. 06/698,050 filed Feb. 4, 1985 all abandoned.
BACKGROUND OF THE INVENTION
A. Field of the Invention
The present invention relates to novel hindered amides and more particularly relates to multicycloalkyl and azamulticycloalkyl amides which are 5-lipoxygenase inhibitors and are useful as anti-inflammatory and anti-allergy agents.
It is well recognized that arachidonic acid and its analogs, unsaturated fatty acids, are the precursors of prostaglandins, thromboxanes, the 5-, 11-, 12- and 15-hydroxyeicosatetraenoic acids (HETEs, DIHETEs, TRIHETEs) and hydroperoxyeicosatetraenoic acids (HPETEs) and the leukotrienes, all of which have profound physiological effects. The leukotrienes, which are produced via the 5-lipoxygenase pathway, are the major contributors to the onset of the symptoms of asthma, and mediators for immediate hypersensitivity reactions and inflammation.
Leukotrienes are found in inflammatory exudates and are involved in the process of cellular invasion during inflammation. The term "leukotrienes" is used as a generic term to describe a class of substances, such as slow-reacting substance (SRS) which is an important mediator in asthma and other immediate hypersensitivity reactions. Immunologically generated SRS is usually referred to as slow-reacting substance of anaphylaxis (SRS-A). SRS-A consists of leukotrienes (LT) known as A 4 , B 4 , C 4 , D 4 , D 5 and E 4 . LTC 4 is at least 100 times more potent than histamine in causing long lasting bronchoconstricting effects. The leukotrienes also increase vascular permeability and cause decreased cardiac output and impaired ventricular contraction. LTB 4 may be an important mediator of inflammation in inflammatory bowel disease.
Chemotaxis is a reaction by which the direction of migration of cells is determined by substances in their environment. It is one of the major processes bringing leukocytes from the blood to an inflammatory site. Whether the inflammation is caused by an infectious agent, allergic challenge, or other pro-inflammatory stimuli. LTB 4 is not only chemotactic for neutrophils and monocytes, but is also highly active in stimulating eosinophil locomotion. The infiltration of eosinophils is one of the histologic features of a variety of allergic reactions.
With the exception of benoxaprofen, which has 5-lipoxygenase inhibition activity, aspirin and the other non-steroidal anti-inflammatory agents (NSAIDs) such as indomethacin, ibuprofen, fenoprofen, and the like, inhibit the synthesis of prostaglandins via the cyclooxygenase pathway of arachidonic acid. These prostaglandin synthetase inhibitors generally exhibit anti-inflammatory, anti-pyretic and analgesic activity, and are widely used in the treatment of arthritis. The non-steroidal anti-inflammatory agents can lead to the formation of additional pro-inflammatory derivatives of arachidonic acid produced through the 5-lipoxygenase pathway which play a role in immediate hypersensitivity reactions and also have pronounced pro-inflammatory effects. Administration of the NSAIDs alone can produce allergic reactions including bronchospastic reactivity; skin rashes; syndrome of abdominal pain, fever, chills, nausea and vomiting, and anaphylaxis. For this reason, aspirin and the other non-steroidal anti-inflammatory agents (NSAIDs) are generally contraindicated for patients suffering from asthma or who have previously exhibited allergic sensitivity to aspirin or other NSAIDs.
Prior to the recognition of the arachidonic acid cascade and the significance and interaction of the 5-lipoxygenase and other arachidonic acid cascade conversion products in allergic reactions and inflammation, the search for effective therapeutic agents was based primarily on those agents which treated the symptoms of allergy and inflammation. There has since been effort to develop new drugs which selectively block the formation of the mediators of these conditions, and the present invention provides multicycloalkyl and azamulticycloalkyl amides which are metabolically stable inhibitors of the 5-lipoxygenase pathway and are useful in the treatment of asthma and other allergy and hypersensitivity reactions, and many types of inflammation.
To date, benoxaprofen has been the only commercial anti-inflammatory agent which has 5-lipoxygenase inhibition activity. Prior to its withdrawal from the market because of untoward side effects, benoxaprofen was considered to represent a significant advance in the treatment of crippling arthritis and psoriasis. Thus, there remains a longstanding need for agents which block the mechanisms responsible for inflammation and allergic reactions, and which can be safely employed to treat, for example, arthritis, asthma, psoriasis and other dermatoses, allergic reactions and other 5-lipoxygenase mediated conditions. A need also exists for agents which can be administered with the inhibitors of other lipoxygenase enzymes, e.g. cyclooxygenase, to mitigate their side effects and support their desirable medicinal properties.
See Bengt Samuelson, "Leukotrienes: Mediators of Immediate Hypersensitivity Reactions and Inflammation", Science, Vol. 220, pp. 568-575 (May 1983); Michael K. Bach, "Inhibitors of Leukotriene Synthesis and Action", The Leukotrienes, Chemistry and Biology, pp 163-194 (Academic Press, Inc., 1984); C. W. Lee et al., "Human Biology and Immunoreactivity of Leukotrienes", Advances in Inflammation Research, Volume 6, pp 219-225 (Raven Press, New York, 1984); Editorial, "Leukotrienes and other Lipoxygenase Products in the Pathegonesis and Therapy of Psoriasis and Dermatoses", Arch. Dermatol., Vol. 119, pp 541-547 (July, 1983); Robert A. Lewis et al., "A Review of Recent Contributions on Biologically Active Products of Arachidonate Conversion", Int. J. Immunopharmac., Vol. 4, No. 2, pp 85-90 (1982); Michael K. Bach, Biochemical Pharmacology, Vol. 23, No. 4, pp 515-521 (1984); E. L. Becker, Chemotactic Factors of Inflammation, pp 223-225 (Eliver Science Publishers B.V., Amsterdam, 1983); P. Sharon and W. F. Stenson, Gastroenterology, Vol. 84, 454 (1984); and M. W. Musch, et al., Science, Vol. 217, 1255 (1982).
The present invention provides compounds which block the 5-lipoxygenase pathway of the arachidonic acid cascade, block the formation of the leukotrienes therefore responsible for the allergy and inflammation, and hence and represent a new class of therapeutic agents which are useful in the treatment of allergic and hypersensitivity reactions and inflammation, alone, or in combination with other oxygenase inhibitors such as the non-steroidal anti-inflammatory agents (cyclooxygenase inhibitors).
B. Prior Art
Wagner et al. U.S. Pat. No. 4,029,812, and related U.S. Pat. Nos. 4,076,841 and 4,078,084, which issued from divisional applications of the -812 application all assigned to The Dow Chemical Company, disclose 2-(3,5-di-tert-butyl-4-hydroxyphenyl)thiocarboxylic acids, esters and simple amides which are hypolipidemics and are useful in reducing plasma lipid levels, especially cholesterol and triglyceride levels.
The Wagner et al. and related compounds have also been reported in the literature as plasticizers and pesticides. See for Example, Khim. Tekhnol. 20(4), 568-574 (1977); Pestic. Biochem. Physiol. 1979, 12(1), 23-30. Chem. Abs. 90(19):151802x is of interest.
SUMMARY
The compounds of this invention are sterically hindered multicyclic amides represented by the formula ##STR3## wherein: R 1 and R 2 are the same or different members of the group consisting of halo, phenyl, substituted phenyl and a ##STR4## group wherein n, m and p are independently an integer of from 1 to 8 provided that n+m+p is equal to or less than 10; X is thio, sulfinyl or sulfonyl; Alk is straight or branched chain lower alkylene, and R 3 is selected from the group consisting of a bicycloalkylamino, tricycloalkylamino, azabicycloalkyl, azatricycloalkyl, azabicycloalkylamino, azatricycloalkylamino or dicycloalkylamino.
The compounds of the present invention are useful in the treatment of allergy and hypersensitivity reactions and inflammation. The compounds are particularly useful in the treatment of arthritis and other inflammatory joint disease, asthma, proliferative skin disease such as psoriasis, and the like, alone or in combination with one or more cyclooxygenase inhibitors.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The compounds of the present invention are generally administered in oral or parenteral dosages of from 0.1 to 100 mg/kg, preferably 0.5 to 50 mg/kg daily, preferably in divided dosages, to patients suffering from allergic or hypersensitivity reactions or inflammation, and are preferably applied topically to patients suffering from proliferative skin disease such as psoriasis. The compounds may be administered as the sole therapeutic agent, or in combination with other agents such as cyclooxygenase inhibitors, particularly in patients who exhibit pro-inflammatory or allergic response to, for example, conventional non-steroidal anti-inflammatory agents. Parenteral, e.g., intravenous, administration is preferable if a rapid response is desired, as, for example, in some cases of asthma.
Generally speaking, synthesis of the compounds of this invention is accomplished by displacement of the halogen or tosylate on a halo or tosyl substituted aliphatic acyl multicyclic or azamulticyclic amide by a thiol in the presence of a base. Addition of a thiol to the double bond of a suitable alkenyl acyl amide is also a useful synthetic route. Alternatively, the displacement via reaction with a thiol and base can be carried out on a tosyl or halo substituted aliphatic carboxylic acid or ester which is then converted into the amide via reaction of the corresponding acid chloride with the desired multicyclic amine. An ester is preferably hydrolized to the corresponding acid before conversion to the acid chloride by, for example, oxalyl chloride. The sulfones and sulfoxides are readily prepared by oxidation of the sulfides with, for example, m-chloroperbenzoic acid or sodium metaperiodate.
Suitable amines include, but are not limited to, N-tricyclo[3.3.1.1 3 ,7 ]dec-1-yl amine; N-[6,6-dimethylbicyclo[3,1,1]hept-2-yl amine; N-endo-bicyclo[2,2,1]hept-2-yl amine; N-tricyclo [3.3.1.1 3 ,7 ]dec-2-yl amine; N,N-dicyclohexylamine, 3-azabicyclo[3.2.2]nonane; N-[1-azabicyclo[2,2,2]octa-3-yl amine; 3-azabicyclo[3.3.2] nonane; 4-azatricyclo[4.4.0.0 3 ,8 ]decane; 4-azatricyclo [4.3.1.1 3 ,8 ]undecane; 11-azabicyclo[4.4.1]undecane; 3-amino-9-azabicyclo[3.3.1]nonane; 2-aminobicyclo[2.2.1]heptane; 2-amino-1,7,7-trimethylbicyclo[2.2.1]heptane; 1-amino-2-azatricyclo[3.3.1.1 3 ,7 ]decane; and the like. The above lipophilic hindered amines are C-bridged cycloalkylamines and C-bridged azacycloalkylamines.
The term "lower alkyl", as used herein, refers to straight or branched chain lower alkyl groups having from 1 to 6 carbon atoms, inclusive, i.e., methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, tert-butyl, n-pentyl, 2-methylbutyl, 2,2-dimethylbutyl, n-hexyl, and the like.
The term "lower alkylene", as used herein, refers to straight or branched chain lower alkylene groups having from 1 to 6 carbon atoms, i.e., methylene, ethylene, n-propylene, iso-propylene, n-butylene, sec-butylene, 1,1-dimethylethylene, n-pentylene, 2-methylbutylene, 2,2-dimethylpropylene, n-hexylene and the like.
The group represented by X is preferably thio or sulfinyl and most preferably thio.
Preferred radicals represented by the group of the formula ##STR5## include tertiary alkyl moieties wherein n and m are preferably 1 or 2 and most preferred radical is represented by the group wherein n, m and p are 1, namely t-butyl.
The term "halo", as used herein, included chloro, bromo, fluoro and iodo.
The term "lower alkoxy" refers to alkoxy groups having from 1 to 6 straight or branched chain carbon atoms, i.e., methoxy, ethoxy, n-propoxy, tert-butoxy, etc.
The term "substituted phenyl" refers to phenyl having one or more substituents selected from the group consisting of amino, halo, hydroxy, lower alkyl, lower alkylaminoalkyl, lower dialkylaminoalkyl, trifluoromethyl, lower alkoxy, and the like for R 1 and R 2 .
The selective activity of the compounds of this invention was first determined using the following assays.
Test A- An in vitro inhibition of soybean 15-lipoxygenase assay is employed to check the specificity of selected 5-lipoxygenase inhibitors. The oxygen-uptake during the oxidation of arachidonic acid to 15-HPETE by soybean lipoxygenase is measured in the presence and absence of inhibitors, using nordihydroguaiaretic acid (NDGA) as a reference standard. Compounds which inhibit at 100 μM are tested further to determine the IC 50 values. "IC" stands for "inhibitory concentration".
Test B- Determination of anti-inflammatory, anti-allergy activity: in vitro inhibition of 5-lipoxygenase. The 100,000 ×g supernatant fraction bf Rat Basophilic Leukemia Cell Homogenate (RBL-1) serves as a 5-lipoxygenase enzyme source. The enzyme is incubated with [1- 14 C]-arachidonic acid and Ca ++ in the presence and absence of test compound. The product of 5-lipoxygenase, 5-hydroxyeicosatetraenoic acid (5-HETE), is separated by thin-layer chromatography and measured by radioactivity. A compound inhibiting 5-HETE synthesis by 30% or more is considered active at that concentration. Initial screening doses are 1×10 -4 M. When the compound inhibits more than 50% of 5-HETE synthesis at 10 -4 M, that compound is tested at multiple dose levels to determine the IC 50 value.
Test C- Inhibition of slow reacting substance (SRS) biosynthesis in cells. SRS synthesis by Rat Basophilic Leukemia Cell (RBL-1) cells is induced by incubation of cells with ionophore A23187 alone and in combination with the test compound. The SRS released into the culture media is measured by high pressure liquid chromatography, scintillation counting or bioassay. In the bioassay procedure, the percent inhibition of SRS production is estimated by determining the doses of treated and control media needed in the tissue bath to produce equivalent contractions of segments of isolated guinea pig ileum. A compound that inhibits SRS biosynthesis by 50% or more is considered active at that concentration if an equivalent amount of the compound does not antagonize ileum contraction by SRS directly. If the compound directly inhibits the smooth muscle contractions, it will be considered inactive as an SRS biosynthesis inhibitor. Initial screening doses of test compounds are 1×10 -4 M and 1×10 -5 M.
Test-D- In vitro inhibition of human platelet 12-lipoxygenase. A 40,000 ×g supernatant of platelet lysate is incubated with [1- 14 C]-labeled arachidonic acid in the presence and absence of test compound. The conversion product, 12-hydroxyeicosatetraenoic acid (12-HETE), is quantitated after isolation by thin-layer chromatography. Compounds, initially screened at 100 μM concentration, which inhibit the synthesis of 12-HETE by 30% or more, are considered active. IC 50 values are determined for active compounds.
Test E- In vitro inhibition of sheep seminal vesicle microsome cyclooxygenase. Arachidonic acid cyclooxygenase reaction rates, in the presence or absence of test compounds, are determined by monitoring oxygen uptake. Compounds which inhibit at 10 -4 M are tested further to determine IC 50 values.
The following examples further illustrate the present invention.
EXAMPLE 1
Preparation of 3,5-bis(1,1-dimethylethyl)-4-hydroxyphenylthiocyanate ##STR6##
To a three-necked, round bottom 5 L flask, equipped with a mechanical stirrer, gas inlet, thermometer and gas inlet, thermometer and gas outlet, was added 2,6-di-tert-butylphenol (474 g, 2.30 mole), ammonium thiocyanate (76.12 g, 4.83 mole) and methanol (1200ml). The reaction mixture was stirred and cooled to 0° C. in an ice/salt bath. Maintaining the temperature at 0° to 10° C., chlorine gas was slowly bubbled through the mixture for about 1 hour whereupon the reaction mixture was a heterogeneous yellow color. Ammonia was then bubbled through the reaction for about 11/2 hours, maintaining the reaction mixture at a temperature of between 0° to 10° C. The reaction was stirred for an additional hour at 0° C., poured into 2 L of cold distilled water and refrigerated overnight. The aqueous phase was decanted and the solid taken up in methanol, precipitated from water, filtered and dried for 2 days over phosphorous pentoxide. The resulting gummy yellow solid was recrystallized from pentane and dried in vacuo to yield the product as a white powder, m.p. 61.5°-63° C. Analysis calc. for C 15 H 21 NSO: Theory: C, 68.40; H, 8.03; N, 5.32; S, 12.17. Found: C, 68.85; H, 8.05; N, 5.29; S, 12.12.
EXAMPLE 2
Preparation of 2,6-bis(1,1-dimthylethyl)-4-mercaptophenol ##STR7## 3,5-bis(1,1-Dimethylethyl)-4-hydroxyphenyl thiocyanate (55 g, 0.209 mold) was dissolved in acetone (200 ml) under an argon atmosphere. Water (7.6 g, 0.42 mole) was added and the reaction cooled to 0° C. Triethylphosphine (24.7 g, 0.209 mole) was added dropwise over a period of 1 hour and the reaction was then allows to warm to room temperature with stirring. The solution was concentrated, solvents removed, and the resulting oil chromatographed on silica. The fractions containing the thiol were combined, the solvents removed to yield a white powder which was recrystallized from methanol/water and dried to yield 43.3 g of the desired product. NMR confirmed the identity of the product.
EXAMPLE 3
Preparation of N,N-dicyclohexyl-2-propenamide ##STR8##
A solution of dicyclohexylamine (19.92 ml, 0.10 mole) and triethylamine (27.88 ml, 0.20 mole) in ethyl ether (100 ml) was cooled to 0° C. A solution of acryloyl chloride (7.93 ml, 0.1 mole) in ethyl ether (20 ml) was added and the solution was stirred for 12 hours, filtered and concentrated to obtain the product as a solid which was dried in vacuo. The stucture was confirmed by NMR.
EXAMPLE 4
Preparation of 3-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio]-N,N-dicyclohexylpropanamide ##STR9##
The title compound of Example 3 (1.9 g, 0.008 mole), 2,6-bis(1,1-dimethylethyl)-4-mercaptophenol(2 g, 0.008 mole) and triethylamine (0.5 ml) were stirred in methanol (25 ml) for about 12 hours. The solvent was removed in vacuo on a rotary evaporator, the crude material purified by chromatography on silica and recrystallized from hexane, m.p. ca. 168.5°-172° C. Analysis calc. for C 29 H 47 O 2 NS(473.76): Calc.: C, 73.52; H, 10.00; N, 2.96; S, 6.77. Found: C, 73.43; H, 10.24; N, 2.91; S, 6.91.
EXAMPLE 5
Preparation of N-tricyclo[3.3.1.1 3 ,7 ]dec-1-yl-2-propenamide ##STR10##
A solution of acryloyl chloride (4.05 ml, 0.05 mole) in ethyl ether (25 ml) was added to a cold (+5° C.) soltuion of 1-adamantaneamine (7.65 g, 0.05 mole) and triethylamine (15.3 ml, 0.11 mole) in ethyl ether (300 ml) and the solution stirred for 72 hours at room temperature. The solvent was removed on a rotary evaporator. The residue was dissoled in ethyl acetate (100 ml), washed with 10 percent hydrochloric acid (100 ml) and water (50 ml), dried over sodium sulfate, filtered and the solvent removed in vacuo leaving an oily solid which was crystallized from methanol-ethyl acetate-hexane. The structure was confirmed by NMR.
EXAMPLE 6
Preparation of 3-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio]-N-tricyclo[3.3.1.1.sup.3,7 ]dec-1-ylpropanamide ##STR11##
Following the method of Example 4, 2,6-bis(1,1-dimethylethyl)-4-mercaptophenol (1.19 g, 0.005 mole), the title compound of Example 5 (1.03 g, 0.005 mole) and triethylamine (0.5 ml) were stirred in methanol (100 ml) for 12 hours at room temperature under argon. The solvent and triethylamine were removed on a rotary evaporator and the product purified by chromatography on silica, recrystallized from ethyl aceate/hexane, filtered and dried in vacuo, m.p. ca.172.5°-173.5° C. Analysis calc. for C 27 H 41 NO 2 S(443 69): Calc.: C, 73.09; H, 9.31; N, 3.16; S, 7.23. Found: C, 73.03; H, 9.18; N, 3.08; S, 7.30.
EXAMPLE 7
Preparation of N-(6,6-dimethylbicyclo[3.1.1]hept-2-yl)-2-propenamide ##STR12##
Following the procedure of Example 3, a solution of acryloyl chloride (4.05 ml, 0.05 mole) in ethyl ether (50 ml) was added dropwise to a cold 5° C. mixture of triethylamine (15.3 ml, 0.11 mole) and norpinylamine (6.96 ;g, 0.05 mole) in ethyl ether (400 ml). The reaction was allowed to warm to room temperature and stirred for 72 hours. The light tan solid was filtered and washed well with ethyl ether. The solvent and triethylamine were removed, leaving the title product as an oily solid. The sturcture was confirmed by NMR. Analysis calc. for C 12 H 19 NO(193.28): Calc.: C, 74.57; H, 9,91; N, 7.24. Found: C, 74.28; H, 9.65; N, 7.15.
EXAMPLE 8
Preparation of 3-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio]-N-(6,6-dimethylbicyclo[3.1.1]hept-2-yl)propanamide ##STR13##
Following the method of Example 4, 2,6-(bis-1,1-dimethylethyl)-4-mercaptophenol (1.19 g, 0.005 mole), N-(6,6-dimethylbicyclo[3.1.1]hept-2-yl)-2-propenamide (0.96 g, 0.005 mole)and triethylamine (0.5 ml) were stirred in methylene chloride (75 ml) for 1 hours. Additional thiol (1 g) was Triethylphosphine (0.5 ml) was added and the solution stirred for 72 hours. The solvent and phosphine were removed on a rotary evaporator and the product purified by chromatography on silica and recrystallized from ethyl acetate/hexane, m.p. 152.5°-154° C. Analysis calc. for C 26 H 41 NO 2 S(431.68): Calc.: C, 72.34; H, 9.55; N, 3.24; S, 7.43. Found: C, 72.54; H, 9.53; N, 3.20; S, 7.58.
EXAMPLE 9
Preparation of N-endo-bicyclo[2.2.1]hept-2-yl-2-propenamide ##STR14##
Following the method of Example 7, a solution of acryloyl chloride (2 ml, 0.025 mole) in ethyl ether was added to a mixture of endo-2-aminonorbornane (3.67 g, 0.025 mole) and triethylamine (15.3 ml) in methylene chloride (250 ml) and ethyl ether (250 ml) at 0°-5° C. over a 30 minute period. The solution was allowed to warm to room temperature and stirred for 72 hours. The solvents were evaporated on a rotary evaporator, fresh methylene chloride (400 ml) added and the solution refluxed for 3 hours. The solvents were removed on a rotary evaporator and the residue taken up in ethyl ether (500 ml), stirred for 1 hour, and the solid filtered and washed with ethyl ether. Removal of the solvent left the title product as an oil. The structure was confirmed by NMR.
EXAMPLE 10
Preparation of N-endo-bicyclo[2.2.1]hept-2-yl-3-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio]propanamide ##STR15##
Following the method of Example 4, the title compound of Example 9 (0.87 g. 0.005 mole). 2,6-(bis-1,1-dimethylethyl)-4-mercaptophenol (1.19 g, 0.005 mole), triethylamine (0.5 ml) and triethylphosphine (0.5 ml)were stirred in methylene chloride (75 ml) for 12 hours. The solvent was removed on a rotary evaporator and the product purified by chromatography on silica, recrystallized from ethyl acetate/hexane, and dried, m.p. 128°-131° C. Analysis calc. for C 24 H 37 NO 2 (403.62): Calc.: C, 71.42; H, 9.24; N, 3.47; S, 7.94. Found: C, 71.69; H, 9.15; N, 3.46; S, 8.12.
EXAMPLE 11
Preparation of N-tricyclo[3.3.1.1 3 ,7 ]dec-2-yl-2- propenamide ##STR16##
A solution of acryloyl chloride (4.52 g, 0.05 mole) in ethyl ether (20 ml) was added dropwise to a stirring mixture of 2-adamantylamine hydrochloride (9.35 g, 0.05 mole) and triethylamine (30.65 ml) in methylene chloride (200 ml) and ethyl ether (200 ml) over a 30 minute period. The solution was stirred for 12 hours, the solid filtered and washed with ethyl ether and the filtrate stripped to an oily material which was taken up in ethyl acetate and hexane and allowed to stand overnight. The solid was filtered, the filtrate concentrated and chilled and the product as an orange solid filtered and dried. The structure was confirmed by NMR.
EXAMPLE 12
Preparation of 3-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio]-N-tricyclo[3.3.1.1.sup.3,7 ]dec-2-yl propanamide ##STR17##
Following the procedure of Example 4, triethylamine (0.5 ml) was added to a solution of 2,6-bis(1,1-dimethylethyl)-4-mercaptophenol (1.19 g, 0.005 mole) and the N-tricyclo[3.3.1.1 3 ,7 ]dec-2-yl-2-propenamide (1.02 g, 0.005 mole) in methanol (100 ml) and the solution stirred ar room temperature for 12 hours. The solvent and triethylamine were removed on a rotary evaporator and the product purified by chromatography on silica, recrystallized from ethyl acetate/ethyl ether/hexane and dried, m.p. ca. 155.5°-156° C. Analysis calc. for C 27 H 41 NO 2 S(443.69): Calc.: C, 73.09; H, 9.31; N, 3.16; S, 7.35. Found: C, 73.18; H, 9.23; N, 3.09; S, 7.21.
EXAMPLE 13
Preparation of 3-(1-oxo-2-propenyl)-3-azabicyclo[3.2.2]- nonane ##STR18##
A solution of acryloyl chloride (4.05 ml, 0.05 mole) in 50 ml of ethyl ether was added with stirring to a cold mixture of 3-azabicyclo[3.2.2]nonane (6.26 g, 0.05 mole) and triethylamine (15.3 ml, 0.11 mole) in 250 ml of ethyl ether. The ice bath was removed and the reaction was allowed to warm to room temperature and stirred for 72 hours. The resulting white material was filtered and washed well with ethyl ether and ethyl acetate. The solvent was removed on a rotary evaporator and the residue taken up in ethyl ether, hexane added and the solution chilled. The remaining small amount of insoluble material was filtered and the solvent evaporated, leaving the product as an oil. The structure was confirmed by NMR.
EXAMPLE 14
Preparation of [3-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio]-1-oxopropyl]-3-azabicyclo[3.2.2]nonane ##STR19## 2,6-bis(1,1-Dimethylethyl)-4-mercaptophenol (1.19 g, 0.005 mole), 3-(1-oxo-2-propenyl)-3-azabicyclo[3.2.2]nonane (900 mg, 0.005 mole) and triethylamine (1.25 ml) were combined following the procedure of Example 4 and stirred in methanol (50 ml) under an argon atmosphere for 72 hours. The product was purified by chromatography on silica and recrystallized from ethyl acetate and hexane, m.p. ca. 110.5°-112° C. Analysis calc. for C 25 H 39 NO 2 S(417.65): Calc.: C, 71.90; H, 9.41; N, 3.35; S, 7.68. Found: C, 71.94; H, 9.27: N, 3.31; S, 7.88.
EXAMPLE 15
Preparation of 4-[[3,5-bis(1,1-dimethylethyl)-4-hydroxy phenyl]thio]butanoic acid ##STR20##
Potassium hydroxide flakes (2.52g, 0.045 mole) were added to a clear solution of 2,6-bis(1,1-dimethylethyl)-4-mercaptophenol (3.57 g. 0.0165 mole) and ethyl-4-bromo-butyrate (3.23 g, 0.0165 mole) in acetone (10 ml). Water (20 ml) was added and the solution stirred for 1.5 hours, the solvent removed on a rotary evaporator and water (50 ml) added, and the mixture was extracted with ethyl ether (3×75 ml). The aqueous layer was acidified with concentrated hydrochloric acid, extraced with ethyl ether (2×50 ml), the combined organic extracts were washed with water (50 ml), dried over sodium sulfate, filtered and the solvents removed, leaving an oil, which was purified by chromatography on silica, recrystallized from ethyl ether/Skellysolve B, filtered and the product dried in vacuo at room temperature for 12 hours, m.p. ca. 112°-113.5° C.
Analysis calc. for C 18 H 28 O 3 S(324.48): Calc.: C, 66.63; H, 8.70; S, 9.88. Found: C, 66.71; H, 8.74; S, 9.57.
EXAMPLE 16
Preparation of 4-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio-N- tricyclo[3.3.1.1 3 ,7 ]dec-1-yl butanamide ##STR21##
The title compound of Example 19 is dissolved in benzene and the solution cooled to about 5° C. in an ice bath. A solution of oxalyl chloride in benzene is added dropwise over a period of about 5 minutes. The ice bath is removed and the solution is allowed to warm to room temperature and is stirred for about 5 hours. The benzene is evaporated and fresh benzene is added. Triethylamine an 1-adamantaneamine are added to the solution and stirred overnight. The benzene is evaporated on a rotary evaporator and the product is purified by chromatography on silica.
EXAMPLE 17
Preparation of N-1-Azabicyclo[2.2.2]oct-3-yl-2-chloroacetamide, monohydrochloride ##STR22##
Potassium hydroxide (10 g) was added to a solution of 3aminoquinuclidine dihydrochloride (10.45 g, 0.052 mole) in water (80 ml) saturated with sodium chloride. After stirring for 30 minutes, methylene chloride (75 ml) was added and the layers separated. The aqueous layer was washed with methylene chloride (2×75 ml), and the extracts combined with the methylene chloride layer above; dried over sodium sulfate, filtered, and the volume reduced to 100 ml. A solution of chloroacetyl chloride (3.11 g, 0.0273 mole) in methylene chloride (25 ml) was added dropwise and the mixture stirred overnight. The solvent was removed on a rotary evaporator. The residue was recrystallized from methanol-ethyl acetate to give a white solid (4.7 g), m.p. ca. 189°-195° C. The structure was confirmed by NMR.
EXAMPLE 18
Preparation of N-1-Azabicyclo[2.2.2]oct-3-yl-2-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio]acetamide, monohydrochloride ##STR23##
The title compound was prepared by dissolving the product of Example 17 (2.0 g, 0.0084 mole) and 2,6-bis (1,1-dimethylethyl)-4-mercaptophenol (1.99 g, 0.0084 mole) in acetonitrile (25 ml). Triethylamine (5 ml) was added to the mixture and the mixture stirred at room temperature for 12 hours then refluxed for 72 hours. The hot mixture was filtered and the solvent removed on a rotary evaporator. The residue was triturated with hexane and dissolved in hot ethyl acetate and allowed to cool. After filtering, the solvent was removed by a rotary evaporator and the residue recrystallized from ethyl acetate-methanol-ethyl ether to give a tan solid. The structure was confirmed by mass spectroscopy M + 404.
EXAMPLES 19-24
By sutstituting the appropriate amide, e.g., N,N-dicyclohexyl-2-butenamide for the amide of Example 4, the following compounds are obtained:
Example 19: 3-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenylthio]-N,N-dicyclohexylbutanamide.
Example 20: 2-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio-N,N-dicyclohexylacetamide.
Example 21: 2-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio-N-tricyclo[3.3.1.1.sup.3,7 ]dec-1-yl hexanamide.
Example 22: 4-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio]-N-(6,6-dimethylbicyclo[3.1.1]hept-2-yl)2,2-dimethylbutanamide.
Example 23: N-endo-bicyclo[2.2.1]hept-2-yl-2-[[3,5-bis (1,1-dimethylethyl)-4-hydroxypheny]thio]ethanamide.
Example 24: 3-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]thio]-N-tricyclo[3.3.1.1.sup.3,7 ]dec-2-yl)hexanamide.
EXAMPLE 25
Preparation of 3,5-dichloro-4-hydroxyphenyl thiocyanate ##STR24##
2,6-Dichlorophenol (100 g, 0.613 mole) and ammonium thiocyanate (102.73 g 1.350 mole) were mixed in methanol and the solution cooled to 0° C. Chlorine gas was bubbled through the reaction, maintaining the temperature below 10° C. The solution turned a pale yellow color. The reaction was stirred for a total of 3 hours until acidic at which time ammonia gas was bubbled through the reaction mixture and the solution stirred for an addtional three hours 0° to 10° C. The reaction was poured into iced distilled water, and filtered, yielding approximately 20 g of yellow solid which was dried overnight in vacuo. The filtrate was extracted with ethyl ether and the extract dried over magnesium sulfate and solvent removed in vacuo to yield approximately 100 g of crude product. Following purification by silica chromatography, the material was taken up in 1 liter of toluene, charcoal added, filtered and recrystallized from hexane to yield 55.03 g of product as yellow solid, m.p. ca. 94.5°-97° C. The structure was confirmed by NMR.
EXAMPLE 26
Preparation of 3,5-dichloro-4-mercaptophenol ##STR25##
The title compound of Example 25 (55.03 g, 0.25 mole) was dissolved in 300 ml of acetone. Water 9 ml, 0.50 mole) was added and the solution cooled to 0° C. Triethyl phosphine (36.9 ml, 0.250 mole) was added dropwise over a period of 65 minutes, maintaining the temperature, stirred for 11/2 hours, solvent was removed and the product purified by chromatography on silica and recrystallized from hexane to yield the title compound. Analysis calc. for C 6 H 4 OCl 2 S: Calc.: C, 36.94; H, 2.07; Cl, 36.35; S, 16.44. Found: C, 36.96; H, 2.06; Cl, 36.31; S, 16.56.
EXAMPLES 27-30
By replacing 2,6-bis(dimethylethyl)-4-mercaptophenol with an appropriate dihalothiol such as 3,5-dichloro-4-mercaptophenol in the preceding Examples, the corresponding dihalo amides are obtained:
Example 27: 3-[[3,5-dichloro-4-hydroxyphenyl]thio]-N-tricyclo[3.3.1.1 3 ,7 ]dec-1-yl propanamide.
Example 28: N-endo-bicyclo[2.2.1]hept-2-yl-3-[(3,5-dichloro-4-hydroxyphenyl)thio]propanamide.
Example 29: 3-[[3,5-dichloro-4-hydroxyphenyl]thio]-N-tricyclo[3.3.1.1 3 ,7 ]dec-2-yl propanamide.
Example 30: [3-[(3,5-dichloro-4-hydroxypheny)thio]-1-oxopropyl]-3-azabicyclo[3.2.2]nonane.
EXAMPLE 31
Preparation of 2'-hydroxy1,1':3',1"-terphenyl]-5'-yl thiocyanate ##STR26##
2,6-Diphenylphenol (100.0 g, 0.406 mole) and ammonium thiocyanate (76.99 g, 0.893 mole) were suspended in methanol (150 ml) in a three-necked round bottom flask equipped with magnetic stirrer, thermometer and gas inlet tube. The reaction mixture was cooled to -5° C. in an acetone/ice bath and chlorine gas bubbled through the solution for three hours. Maintaining the temperature below 10° C., ammonia gas was bubbled through the reaction for 2 hours. The contents of the flask were then poured into iced distilled water (250 ml) and allowed to stand for 12 hours in the refrigerator. After filtering, the solid was dried in vacuo at 45° C. for 12 hours. The title compound was purified by chromatography on silica and recrystallized from hexane, m.p. about 104°-106.5° C.
Analysis calc. for C 19 H 13 OSN(303.39): Calc.: C, 75.22; H, 4.32; N, 4.62; S, 10.57. Found: C, 75.12; H, 4.49; N, 4.65; S, 10.41.
EXAMPLE 32
Preparation of 5'-mercapto[1,1':3',1"terphenyl]-2'-ol ##STR27##
The title compound of Example 31 (32.2 g, 0.106 mole) was dissolved in acetone (150 ml) and water (1.9 ml), stirred and cooled to -5° C. Triethylphosphine (15.7 ml, 0.106 mole) was added dropwise over a period of 40 minutes. The raction was stirred at 0° for 1 hour and then at room temperature for 2 hours. The solvent was evaporated and the product isolated by chromatography on silica.
Analysis calc. for C 18 H 14 OS(278.31): Calc.: C, 77.67; H, 5.07; S, 11.52. Found: C, 77.80; H, 5.19; S, 11.68.
EXAMPLES 33-38
By replacing 2,6-bis(1,1-dimethylethyl)-4-mercaptophenol in Examples 4, 6, 8, 10, 12, 14, 16, 18, and 19-24 with the product of Example 32, the corresponding 3,5-diphenyl products are obtained:
Example 33: 3-[(2'-hydroxy[1,1':3',1"-terphenyl]-5'-yl) thio]-N,N-dicyclohexylpropanamide.
Example 34: 3-[(2'-hydroxy[1,1':3',1"-terphenyl]-5'-yl) thio]-N-tricyclo3.3.1.1 3 ,7 ]dec-1-yl propanamide.
Example 35: 3-(2'-hydroxy[1,1':3',1"terphenyl]-5'-yl) thio]-N-(6,6-dimethylbicyclo [3.1.1]hept-2-yl)propanamide.
Example 36: N-endo-bicyclo[2.2.1]hept-2-yl-4-[(2'-hydroxy [1,1':3',1"-terphenyl]5'-yl)thio]butanamide.
Example 37: 3-(2'-hydroxy[1,1':3',1"-terphenyl]-5"-yl) thio]-N-tricyclo[3.3.1.1 3 ,7 ]dec-2-yl propanamide.
Example 38: [3-[(2'-hydroxy[1,1':3',1"-terphenyl]-5'-yl) thio]-1-oxopropyl]-3-azabicyclo-[3.2.2]nonane.
The active agents of this invention can be administered to animals, including humans, as pure compounds. However, it is advisable to first combine one or more of the active compounds with one or more suitable pharmaceutically acceptable carriers or diluents to attain a satisfactory size to dosage relationship and thereby obtain a pharmaceutical composition.
Pharmaceutical carriers which are liquid or solid can be employed. Solid carriers such as starch, sugars, talc and the like can be used to form powders which may be used for direct administration or to fill gelatin capsules. Suitable lubricants such as magnesium stearate, stearic acid, as well as binders and disintegrating agents may be included to form tablets. Additionally, flavoring and sweetening agents may be added.
Unit dosage forms such as tablets and capsules can contain any suitable, predetermined, therapeutically effective amount of one or more active agents and a pharmaceutically acceptable carrier or diluent. Generally speaking, solid oral unit dosage forms of a compound of this invention will contain from 1.75 to 750 mg per tablet of drug.
The compounds of this invention exhibit both oral and parenteral activity and accordingly can be formulated in dosage forms for either oral or parenteral administration.
Solid oral dosage forms include capsules, tablets, pills, powders, granules and the like.
Liquid dosage forms for oral administration include emulsions, suspensions, solutions, syrups and the like containing diluents commonly used in the art such as water. Besides inert diluents, such preparations can also include adjuvants such as wetting agents, emulsifying and suspending agents, and sweetening, flavoring and perfuming agents.
Preparations for parenteral administration include sterile aqueous or non-aqueous solutions. Examples of nonaqueous solvents or vehicles are propylene glycol, polyethylene glycol, vegetable oils such as olive oil and injectable organic esters such as ethyl oleate. The parenteral preparations are sterilized by conventional methods.
The compounds of this invention may also be formulated for topical or transdermal application using carriers which are well known in the art, as well as in aerosols or sprays for nasal administration.
The amount of active ingredient administered may be varied; however, it is necessary that the amount of active ingredient be such that a suitable dosage is given. The selected dosage depends upon the desired therapeutic effect, the route of administration and the duration of treatment. Generally speaking, oral dosages of from 0.1 to 100 mg/kg, and preferably from 0.5 to 50 mg/kg of body weight daily are administered to patients in need of such treatment, preferably in divided dosages, e.g. three to four times daily. In the case of acute allergic or hypersensitivity reactions, it is generally preferable to administer the initial dosage via the parenteral route, e.g. intravenous, and continue parenteral administration until the patient is stabilized, and can be maintained, if necessary on oral dosing.
In the case of psoriasis and other skin conditions, it is preferred to apply a topical preparation of a compound of this invention to the affected areas three or four times daily.
In treating asthma and arthritis with a compound of this invention, the compounds may be administered either on a chronic basis, or as symptoms appear. However, in the case of arthritis and other inflammatory conditions which can lead to deterioration of joints and malformations, it is generally preferable to administer the active agent on a chronic basis.
When the compounds of this invention are co-administered with one or more cyclooxygenase inhibitors, they may conveniently be administered in a unit dosage form or may be administered separately. When the patient is allergic or hypersensitive to the cycloxygenase inhibitor, it is preferred to initiate therapy with a compound of this invention prior to administration of the cyclooxygenase inhibitor.
A typical tablet of this invention can have the following composition:
______________________________________Ingredient Mg/tablet______________________________________Active ingredient 100Starch, U.S.P. 57Lactose, U.S.P. 73Talc, U.S.P. 9Stearic acid 12______________________________________
It will be understood by those skilled in the art that the above examples are illustrative, not exhaustive, and that modifications may be made without departing from the spirit of the invention and the scope of the claims.
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The compounds of this invention are bicyclic, tricyclic, azabicyclic and azatricyclic amides represented by the formula: ##STR1## wherein: R 1 and R 2 are the same or different members of the group consisting of halo, phenyl, substituted phenyl and a ##STR2## group wherein n, m and p are independently an integer of from 1 to 8 provided that n+m+p is equal to or less than 10; X is thio, sulfinyl or sulfonyl; Alk is straight or branched chain lower alkylene; R 3 is selected from the group consisting of a bicycloalkylamino, tricycloalkylamino, azabicycloalkyl, azatricycloalkyl, azabicycloalkylamino, azatricycloalkylamino or dicycloalkylamino. The compounds are useful as anti-inflammatory and anti-allergy agents.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims benefit of U.S. Provisional Application No. 60/680,877 filed May 13, 2005, the entire disclosure of which is hereby incorporated by reference herein for all purposes.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates in general to methods and circuits for sensing and correcting skew between the two signals in a differential lane.
2. Description of Related Art
In high-speed digital applications it is common to use differential inputs and outputs to interconnect integrated circuits at the next higher level of integration (e.g. circuit board or multi-chip module). The reason for this is that differential signaling offers relative immunity to noise and drift that would otherwise have negative impact on the signal integrity of the lane carrying the high-speed information.
It is, however, known that this relative immunity to noise and drift can be compromised by skew. The reason for this is that when the skew between the differential signals is sufficiently large, the receiving stage may switch as a result of the transition of (substantially) one line of the differential pair. In such a case, the drift and noise canceling features of differential signaling are nearly eliminated.
U.S. Pat. Nos. 6,812,777 and 6,963,237 issued Nov. 2, 2004 and Nov. 8, 2005, respectively, to Tamura et al describe a method and circuits for controlling the differential skew of an output circuit. This method is illustrated in his FIGS. 19 and 20 , included here as FIGS. 1 and 2 , by example. Tamura adjusts the duty cycle of the output signals to eliminate the differential skew. Tamura, however, assumes that the differential skew arises as a consequence of problems in the driver circuit or the output circuit that is the subject of the patent. Tamura's invention does not deal with skew introduced by interconnect between the output circuit he has de-skewed and the input circuit of another, remote, integrated circuit.
U.S. Pat. No. 6,686,779 issued Feb. 3, 2004 to Takefumi Yoshikawa describes a method for controlling the differential skew of an output circuit. Yoshikawa uses independently programmable pull down capability for the true and complement versions of the differential output, thereby providing an ability to de-skew the output circuit. Yoshikawa, however, assumes that the differential skew arises as a consequence of problems in the driver circuit or the output circuit that is the subject of the patent. Yoshikawa's invention does not deal with skew introduced by interconnect between the output circuit he has de-skewed and the input circuit of another, remote, integrated circuit.
U.S. Pat. No. 6,909,980 issued Jun. 21, 2005 to Chenjing Fernando describes a method for deciding how an article of test equipment, e.g. an oscilloscope, should adjust the timing of input differential signals to obtain optimal skew values in an eye diagram. Fernando uses independently programmable “paired independent skew circuits” for the true and complement versions of a differential input, thereby providing an ability to de-skew the signal circuit. Fernando, however, assumes that the differential skew arises as a consequence of problems in the interconnection to the test equipment and that is the subject of the patent. Fernando's invention does not deal with skew introduced by interconnect between a source and the input circuit of another, remote, integrated circuit that is not a part of the test equipment that is the subject of his invention.
In contrast to the prior art cited in the patents by Tamura et al, Yoshikawa, and Fernando, the invention described here is a method for sensing skew at the receiving end of a differential signaling lane and automatically eliminating it independently of whether it was caused by problems in the driver IC, the interconnect, or the receiver input impedance.
The circuit driving the transmitter differential signals out of a transmitter IC may introduce skew because of asymmetric driving capability or other defects such as asymmetric loading of the output or of the input of the driver. But for the most part, skew is introduced by differences in the length, or effective length, of interconnects. In the construction of media for interconnecting integrated circuits there are a variety of opportunities for inadvertently introducing skew. If a pair of differential lines have to be routed between a transmitter and a receiver, it can at times be very difficult to ensure that the two lines have the same effective length because of length differences or differences in bends and corners in the two transmission paths, because the lines may have to be run in different layers of interconnect or may have spatial variations in dielectric constant, and because of non-homogeneous transmission media like glass fiber based laminates. A secondary, though still significant, source of skew is the difference in the impedance and/or frequency response of the two paths in a differential lane. Such differences can arise because of the differences in parasitics loading the paths caused by proximity of components, vias, and co-planar grounds, among others.
SUMMARY OF THE INVENTION
A differential signal comprises a pair of complementary signals conveyed by a pair of lines of a differential lane, and when a differential lane forwards a differential signal from its transmitting end to its receiving end, edges of the complementary signals should preferably arrive concurrently at the receiving end. However, when a pair of lines have dissimilar path delays, the differential signal will be skewed at the receiving end in that edges of the complementary signals will not arrive concurrently at the receiving end. When a differential lane is terminated at its receiving end by a differential termination, any skew in the differential signal will produce signal reflections that affect the magnitudes, relative timing of edges, and the polarity of the complementary signals as viewed at the transmitting end in a manner indicating the nature of the skew at the receiving end.
The invention relates to a method or apparatus for reducing skew in the receiving end of a differential lane. In accordance with the invention, a skew correction system is incorporated into a transmitter supplying a differential signal as input to a differential lane. With a differential termination at the receiving end of the differential lane, the skew correction system monitors the differential signal at transmitting end to determine how, if at all, it is influenced by returning signal reflections, and based on the nature of the determined influence, adjusts the relative timing of complementary edges of the differential signal departing the transmitter so as to reduce skew at the receiving end of the differential lane.
The claims appended to this specification particularly point out and distinctly claim the subject matter of the invention. However those skilled in the art will best understand both the organization and method of operation of what the applicant(s) consider to be the best mode(s) of practicing the invention, together with further advantages and objects of the invention, by reading the remaining portions of the specification in view of the accompanying drawing(s) wherein like reference characters refer to like elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are block and schematic diagrams illustrating a prior art method for controlling differential skew.
FIG. 3 is a block diagram illustrating the differential skew correction method of this invention.
FIG. 4 is a block diagram illustrating details of the skew sensor and skew adjuster of FIG. 3 .
FIG. 5 is a timing diagram illustrating appearance of skewed differential signals at the driver of FIG. 3 .
FIG. 6 is a timing diagram illustrating the appearance of the skewed differential signals at the receiver of FIG. 3 .
FIG. 7 is a timing diagram illustrating the received signal.
FIG. 8 is a timing diagram illustrating the effect of a differential equalizer on the received signal.
FIG. 9 is a timing diagram illustrating the received signal.
FIG. 10 is a timing diagram illustrating the effect of two single ended equalizers on the received signal.
FIG. 11 is a timing diagram illustrating a de-skewed received signal.
FIG. 12 is a timing diagram illustrating the effect of a differential equalizer on the received signal.
FIG. 13 is a block diagram illustrating the response of a matched single ended transmission line.
FIG. 14 is a timing diagram illustrating the response of matched differential transmission lines.
FIG. 15 is a timing diagram illustrating the voltage on the lines resulting from skewed inputs.
FIG. 16 is a timing diagram illustrating the reflections on the lines after the signals have both arrived.
FIG. 17 is a timing diagram illustrating the reflections just before they arrive back at the driver.
FIG. 18 is a schematic diagram illustrating an ordinary differential driver stage.
FIG. 19 is a schematic diagram illustrating a differential driver stage for use with the skew corrector.
FIG. 20 is a block diagram illustrating details of a preferred skew sensor of FIG. 19 .
FIG. 21 is a block diagram illustrating a circuit for calibrating of the skew adjuster.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 3 depicts a transmitter IC 44 for transmitting a differential signal to a receiver IC 60 via a differential lane formed by a pair of lines 20 and 21 . The receiver ends of the lines 20 and 21 are connected to a termination 26 , and a differential input circuit 62 of receiver IC 60 . Complementary edges of the differential signal on lines 20 and 21 ideally should arrive concurrently at receiver 60 , but due to differences in lines 20 or 21 , the complimentary edges can arrive at different times. When the timing of the differential signal arriving at receiver 60 exhibits such skew, termination 26 reflects the signal edges back toward transmitter 44 .
Transmitter IC 44 includes a skew correction system 46 in accordance with the invention that monitors the signal reflections returning to transmitter 44 to detect any skew in the differential signal input to receiver IC 60 and adjusts the relative timing of the complementary signal edges as they depart transmitter IC 44 to eliminate the detected reflections, thereby minimizing skew at the receiver end of the differential lane.
Skew correction system 46 includes a skew adjuster 52 receiving and adjustably delaying complementary edges of a differential signal from a pulse generator 16 to supply a differential signal to a pair of drivers 42 and 43 for buffering the signal onto lines 20 and 21 through a pair of reverse terminations 22 and 23 . A skew sensor 50 detects which of lines 20 and 21 conveys a reflection that increases the magnitude of the signal on that line thereby indicating that skew at the receiving end of the differential lane makes that line appear shorter than the other line. Skew sensor 50 therefore signals skew adjuster 52 to retard the input of that line and/or advance the input of the other line in order to eliminate the reflection.
Because there are limits to the detectability of narrow pulses in signals which are created by relatively small amounts of skew, skew adjuster 52 may be calibrated and the measurements of the limits of detectable skew on both sides of the zero skew point are noted. The noted measurements may then be averaged to yield the setting required for zero skew. Calibration establishes the relationship between the control signal latched in the counters and the variable delay in the respective channel. This calibration can be accomplished in many ways, but preferentially as shown in FIG. 21 by selecting the feedback inputs of multiplexers 98 and 99 , causing the delay lines 62 and 63 to oscillate in a closed loop at a frequency equal to 1/(2*TD), where TD is the time delay of the delay line. In this manner, the time delay for each control code supplied on lines 86 and 87 , through multiplexers 82 and 83 respectively, on both delay lines can be easily determined by observing the output frequency from buffers 42 and 43 , respectively, for each such supplied code.
FIG. 4 is an example implementation of skew sensor 50 and skew adjuster 52 . Drivers 42 and 43 drive the inputs of lines 20 and 21 through back terminating resistors 22 and 23 , respectively. Buffers 2 and 3 are used to generate a static voltage equal to the high and low levels of the outputs from drivers 42 and 43 , respectively. The resistor networks connected to the outputs of 2 and 3 cause these buffers to have the same load impedance as 42 and 43 , but they are computed to generate a voltage at the midpoints of each of the two resistor pairs that is mid-way between the normal driven levels on lines 20 and 21 and the level that exists when there is a reflection on these lines as a result of skew. Schmidt comparators, 72 and 73 , sense any reflections that increase the voltage magnitude to threshold levels 1.25 times the magnitude of the transmitted voltage level at the inputs of lines 20 and 21 . The up/down counters are crafted to count only once for each pulse edge originally transmitted down lines 20 and 21 . The first such circuit of 72 or 73 to respond to a reflection will switch and cause the up/down counters to advance or retard their counts by one, changing the delay of the programmable delays in such a way as to reduce the reflection duration, thereby reducing the skew which caused the reflection. (Note that the up/down counters are preset to mid-range at initialization.) The sequence of operations is repeated with the emission of the next differential pulse signal from the pulse generator 16 . The sequence continues to repeat until the detectable limit of skew is reached.
FIG. 5 illustrates skewed differential signals as they emerge from transmitter 44 of FIG. 3 . As the length of the differential paths 20 and 21 grow the rise times at the receiving side of the paths also grow, as illustrated in FIG. 6 , because of high frequency skin effect and dielectric losses. Thereby the skew between the differential paths may become a much smaller and seemingly insignificant part of the signal's rise time. Under these conditions one might deduce that the skew was no longer a problem. However, it has become customary in many applications to use receiver equalization on differential signals in an attempt to restore the rise time and pulse width of the received signal and thereby improve the signal to noise ratio and the resulting bit error rate. In FIG. 8 , when such equalization is applied, the rise time does recover to a limited extent. In fact, it is found that the functionality of a differential equalizer (one that works on the difference between the two signals in a differential lane) is degraded by skew, so that it can not equalize the lane as well as two single ended equalizers, as shown in FIG. 10 . But in using two single ended equalizers, the equalizers restore high grade signals that have significant skew between them, which is undesirable, as described above. In FIG. 11 , the received signal is de-skewed. In FIG. 12 , the de-skewed signal is equalized by a differential equalizer, creating a high quality signal with no skew. This invention solves the skew problems described in this paragraph.
FIG. 13 depicts the response of a matched transmission line, 20 , to a unit step input supplied by pulse generator 18 . Since the line is matched at the input and output by source termination 22 and load termination 24 respectively, the response consists of a voltage wave 30 , of amplitude 0.5 that propagates from the input to the output, without any reflections.
FIG. 14 depicts the response of a matched differential transmission lane (consisting of two transmission lines, 20 and 21 , or a differential two conductor transmission line—e.g. parallel wire line) to differential unit step inputs supplied by generators 18 and 19 , which together constitute a differential pulse generator, 16 . Since the lines are matched at the input, by source terminations 22 and 23 , and output, by load terminations 24 and 25 , the response consists of voltage waves 30 and 31 , of amplitude +/−0.5, respectively, that propagate from the input to the output, without any reflections. Note here that the far end termination 26 , consists of two series resistors 24 and 25 , of value Zo, but since the lines and signals are balanced, there is a virtual ground at the junction of the two resistors, and the circuit behaves as if each of the resistors were connected from their respective lines to ground.
FIG. 15 depicts the response of a matched differential transmission lane, consisting of transmission lines 20 and 21 , to differential unit step inputs supplied by differential pulse generator 16 , which have become skewed. The signals are depicted just as the first signal 30 , reaches the far end of the line.
FIG. 16 depicts the response of a matched differential transmission lane to differential unit step inputs, which have somehow become skewed. The signals are depicted just as the second signal reaches the far end of the line. What has occurred is that the signal that arrived first saw a termination of 3Zo to ground because of the physical 2Zo termination resistance and the Zo of the other transmission line—which has zero volts on it at this time. This led to a reflection voltage coefficient of:
Kr= ( Zt−Zo )/( Zt+Zo )=(3 Zo−Zo )/(3 Zo+Zo )=0.5
This reflection 26 , travels back towards the input of the line. Simultaneous with the reflection on transmission line 20 , which increases the voltage on line 20 , a signal is created on transmission line 21 by the termination current in line 20 . This reflection, 28 , is the same size as the reflected signal in line 20 , but it reduces the magnitude of the voltage on line 21 , rather than increasing it—as is the case with line 20 . At time T 2 plus deltaT, line 21 finally receives the input step, the virtual ground occurs at the junction of the two terminating resistors 24 , and further reflections from the receiving end of the line are terminated.
FIG. 17 depicts the progress of the reflected waves, 26 and 28 , towards the transmitting end of lines 20 and 21 , where they will be sensed by the skew sensor 50 in the transmitter 44 .
The logic circuits in the main signal path of FIG. 4 are shown as single ended, for simplicity, however for best signal integrity they should all be implemented as differential. FIG. 18 shows a common output driver for differential applications, including back terminations 22 and 23 . The preferred differential implementation 42 , is shown in FIG. 19 . Note that the circuit of FIG. 18 works well when the two inputs have identical timing. In the present instance, however, the inputs will generally have markedly different timing because they are being adjusted to compensate for skew.
The circuit of FIG. 19 works well for this situation and has the additional advantage that the total power supply current is constant, irrespective of timing.
The system is shown using a unit step input. After the reflection and skew correction action appropriate to a step input, the counters are frozen or disabled, the step is reset to zero, and after a short settling time (to allow for reflections that occur during the reset) the counters are re-enabled and a new step can be issued. By repetitive action, the skew at the receiver is thereby eliminated. Those of skill in the art will appreciate that a variety of other means could be used to implement the sequencing of the skew correction, and other types of signals could be used—other than a step. For example, rather than sensing the magnitude of the reflections, skew sensor 50 could observe the polarities of the reflections or could observe an order of arrival of reflection edges and determine how to adjust skew adjuster 52 to minimize skew based on either of those observations.
Clearly, skew sensor 50 of FIG. 4 must sense a combination of the sequence of receipt of the reflections and the magnitude of reflections—otherwise, the receipt of two reflections in rapid sequence would confuse it. An example of an alternative skew sensor is shown in FIG. 20 . Here skew sensor 50 uses detected and filtered versions of the reflected signals to activate the up/down counter controls. Detector diode 86 is coupled to line 20 by coupling capacitor 78 and the resistor (100Z0) connected from capacitor 78 to node 99 , which is set at the common mode voltage of the logic signals on the lines 20 and 21 . The positive edge of the step emitted from driver 22 charges capacitor 92 to the equivalent of the output voltage level on line 20 just after the step transition. A subsequent positive reflection from the differential termination between lines 20 and 21 will charge capacitor 92 to a higher voltage than is created by network created by the two resistors marked 1.25Z0, 0.75Z0, and diode 96 . (Note that diode 96 compensates for the voltage drop created by diode 86 when it detects a reflected signal. Diode 97 has the same function respecting diode 87 .) This will cause comparator 72 to switch, forcing the U/D line at its output to the U mode, thereby increasing the delay in delay line 62 and reducing the skew at the receiver. Similar circuitry containing diode 87 capacitor 79 , and 93 and a resistor diode network, similar to the one associated with line 20 , monitors line 21 . However, on line 21 only negative reflections can activate the D/U line of delay line 63 because of the polarity of the diodes involved. This means that comparator 73 can only switch if line 21 carries the signal that arrives at the differential termination before that of line 20 . The switching action of this comparator will result in an increase in the delay setting of delay line 63 thereby reducing the skew at the receiver end of lines 20 and 21 .
The system described above can be used off-line, but it is also capable of being used on-line to correct for dynamic changes in skew caused by temperature drifts and power supply variation. One of many ways this can be done is through short interrupts of the normal flow of data, during which the skew correction is activated as described above.
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A skew correction system incorporated into a transmitter forwarding a differential signal on a differential lane monitors returning signal reflections when the receiving end of the differential lane is appropriately terminated. Based on an analysis of the reflections, the skew correction system adjusts the relative timing of complementary edges of the differential signal departing the transmitter so as to substantially eliminate skew at the receiving end of the differential lane.
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FIELD OF THE INVENTION
This invention relates to tubes for medical applications, and more particularly relates to centrifuge tubes having decreased deformation and leakage in use.
BACKGROUND OF THE INVENTION
Tubes for medical applications have traditionally been made of glass. Glass is advantageous because of its clarity, recycleability and freedom from any morphological changes, but suffers from the severe disadvantage of breakability. In recent years, plastic has come to the fore as a replacement for glass in fabrication of medical tubes. Plastic provides the advantages of lower breakage than glass, less weight in shipment and easier disposal by incineration.
For small medical tubes (10 ml or less), polystyrene (PS) has conventionally been the plastic of choice because of its ease of injection molding and high clarity. It does, however, shatter easily due to inherent brittleness, a disadvantage which is magnified when fabricated into tubes of larger capacity. For this reason, larger tubes have conventionally been made of styrene-butadiene copolymer (S-Bu), styrene-butadiene-styrene terpolymer (S-Bu-S), and crosslinked blends of S-Bu and S-Bu-S or other elastomers. Such compositions are disclosed in U.S. Pat. No. 4,371,663 and in U.S. Pat. No. 5,248,729.
While improved polystyrene compositions have been disclosed, there is yet a need in the art for still better compositions combining the excellent clarity of polystyrene with the toughness of styrene-butadiene elastomers. This invention is directed to fulfulling this need.
SUMMARY OF THE INVENTION
A tube is injection molded of a blend of PS having a melt flow index of 7-11 g/10 min and S-Bu having a melt flow index of 10-12 g/10 min. The PS present in the blend may be between 25 and 35, preferably 28-32, most preferably 29.5-30.5 weight percent of the total polymer. The tube may be of any shape, preferably a conventional round bottom tube, most preferably a conventional centrifuge tube. Tubes of blends within the recited limits of polystyrene have improved performance, particularly diminished leakage or plastic deformation, compared to otherwise identical tubes of 100% S-Bu.
The tube may be sterilized with radiation, and may be provided with a hermetically sealed closure.
Another aspect of the invention is an assembly including the tube and an appropriate closure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are perspective views of typical round bottom and centrifuge tubes respectively in accordance with the invention; and
FIGS. 3 a and 3 b are perspective views of suitable closures.
DETAILED DESCRIPTION
While this invention is satisfied by embodiments in many different forms, there will herein be described in detail embodiments of the invention with the understanding that the present disclosure is to be considered as exemplary of the principles of the invention and is not intended to limit the invention to the embodiments illustrated and described. The scope of the invention will be measured by the appended claims and their equivalents.
The present invention is directed to a particular composition providing articles of superior strength, non-brittleness, rigidity and clarity when injection molded. While the composition may be used for fabrication of any medical article for which the above properties are advantageous, it is particularly well suited for tubes, and the invention will be described in detail below for the preferred centrifuge tube of the invention.
The composition of the invention includes two resins which, when blended within the specified range, may be injection molded into the tube of the invention.
The first component of the blend is a general purpose PS having a melt flow rate of 7-11 gm/10 min when measured in accordance with ASTM D 1238. This commercially available material is standard in the art for injection molding of small tubes, and is available from BASF under the trade name POLYSTYROL® 147F.
The second component of the composition is a high clarity S-Bu rubber block copolymer having a melt flow rate of 10-12 gm/10 min when tested according to ASTM 1238. A suitable product is available from BASF under the tradename STYROLUX® 684D.
The two components may be blended in a ratio of 25-35 preferably 28-32, most preferably 29.5-30.5% by weight of the PS.
The blend may be conventionally injection molded into the tube of the invention. While tubes of any size are contemplated in the invention, preferred tubes are standard 50 ml centrifuge tubes.
After molding, the tube may be sterilized using gamma or electron beam radiation. Any dose of radiation up to a maximum of 23 Kgy may be used.
In another aspect of the invention, an assembly includes the tube of the invention and a hermetically sealed closure for the tube.
Adverting now to the drawings, FIGS. 1 and 2 illustrate a test tube and a centrifuge tube respectively of the invention. In FIG. 1 , test tube 10 has a closed bottom wall portion 12 and a side wall portion 14 continuous therewith. Side wall portion 14 has a top edge 16 and defines an open top end 18 . In FIG. 2 , centrifuge tube 20 has closed bottom wall portion 22 , side wall portion 24 continuous therewith and top edge 26 defining open top end 28 .
FIGS. 3 a and 3 b illustrate conventional screw cap and snap cap type closures 30 for open ends 18 and 28 of the tubes of FIGS. 1 and 2 . Closures 30 include an upper portion 32 having a top 34 . Upper portion 32 has a lower lip 36 which extends over top edges 16 and 26 of the tubes when the closure is in the tube. Closures 30 also include an internal portion 38 which forms a hermetic interference fit with the inside wall surface of the tubes.
It is understood that other closure designs may be used wherein the tubes may or may not have molded threads for receiving a conventional plug type cap.
In accordance with the invention, tubes molded from the disclosed blend of PS and S-Bu have been found to have unexpectedly improved strength and resistance to deformation as measured by diminished craze (Example 2) and leakage through either the cap area or the gate location. Data in support thereof is tabulated in the following experimental section.
Experimental
Fifty ml centrifuge tubes were injection molded from blends of S-Bu having a melt flow index of 10-12 g/10 min and 25, 30 and 35% by weight of general purpose PS having a melt flow index of 7-11 g/10 min. Testing was performed as follows:
a) after 30 min at room temperature b) after 21 days at 60° C. (accelerated aging simulating shelf life) c) after sterilizing with 23 KGy radiation d) for evidence of craze (defined below)
In the tables below, n is the number of tubes in the particular test, and the 0% PS column provides comparative data against tubes of the prior art made of 100% S-Bu.
EXAMPLE 1
Vacuum Leak Testing
A dark red aqueous solution was prepared by dissolving 20 g of conventional food coloring in 1000 ml water. Tubes to be tested were filled to just below the top with the red dye solution and an appropriate cap applied. Each tube was wrapped with a piece of white absorbent paper and the paper slid upward until in contact with the closure, and then affixed with tape. The tubes were placed closure-down in a vacuum chamber (Precision Theca) and the pressure in the chamber was maintained at 10 mm Hg for 5 min. A second group of tubes was aged for 21 days at 60° C. The tubes were removed and the absorbent paper examined carefully for any trace of leakage of the red dye. Any tube showing leakage was scored as failure.
% failure (n = 50)
Composition
Non aged
Aged
0% PS
0
12
25% PS
0
nt
30% PS
0
6
35% PS
0
nt
nt—not tested
EXAMPLE 2
Centrifuge Testing
The red dye solution from Example 1 was added to tubes to be tested, the tubes were hermetically closed and placed in the centrifuge (IEC Centra). The tubes were spun for 11 min at 3200 rpm (2000RCF) and removed from the centrifuge. Each tube was inspected carefully for the presence of red dye leakage, and the gate stubs were placed on clean white absorbent paper. Any trace of red on the paper was indicative of leakage and the tube was scored as a failure.
A second group of tubes was sterilized with 23 Kgy radiation.
When tested according to this procedure, the following results were obtained wherein leakage during centrifugation is generally associated with plastic deformation or craze resulting from the spinning.
A-Effect of Percentage of PS Blended with S-Bu
0% PS
25% PS
30% PS
35% PS
rpm
RCF
n
failed
n
failed
n
failed
n
failed
3500
2350
50
2
12
0
48
1
nt
4000
3075
12
0
24
2
24
1
12
2
5500
5800
24
1
nt
48
5
12
10
6500
8130
12
2
12
0
11
0
nt
7000
9430
20
3
48
2
36
1
nt
It is evident from this experiment that the failure rate is high for the 35% PS blend whereas the 25 and 30% PS blends are comparable to pure S-Bu. It is concluded from this experiment that 35% is the high end of suitable compositions.
B-Effect of Sterilizing dose (23 Kgy) of Radiation
0% PS
30% PS
rpm
RCF
n
failed
n
failed
4000
3075
12
1
12
0
5000
4800
12
2
12
1
6000
6925
12
6
12
1
This experiment shows that radiation sterilization is more detrimental to the pure S-Bu tube than it is to the preferred 30/70 PS-S-Bu tube of the invention.
C-Effect of Aging
0% PS
30% PS
rpm
RCF
n
failed
n
failed
3500
2350
12
4
12
0
4000
3075
12
7
12
7
5500
5800
12
8
12
10
This experiment shows that the preferred 30% blend of the invention has improved stability compared to pure S-Bu after aging when tested at the lower rpm conventionally used for centrifugation, but has about the same failure rate at higher rpm.
EXAMPLE 3
Craze Testing
Craze is an art term for internal stress lines which occur during centrifugation, generally due to plastic deformation, and may be accompanied by color change and opacity. The following craze scale was used:
0—no craze 1—few marks (less than ¼″) 2—repetitive marks (less than 1″) 3—many marks (greater than 1″) 4—some deformation, no interference 5—bulging, interference with removal from holder 6—excessive bulging
When tested for craze under the centrifugation conditions set forth in Example 2, the following results were obtained:
CRAZE RATING
RCF
0%
25%
30%
35%
3075
2
2.5
2
2
5800
3.5
3.5
3.5
4
8130
4
4
4
nt
9430
4
4
4
nt
Examination of the data in this table shows craze to increase at higher RCF and PS percentage.
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A tube, preferably a centrifuge tube, molded of a blend of 25-35 weight percent of polystyrene and 75-65 weight percent of styrene-butadiene rubber block copolymer has improved performance compared to a tube of pure copolymer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/365,074, filed Feb. 2, 2012, pending, which is a continuation of U.S. patent application Ser. No. 11/637,333, filed Dec. 12, 2006, now U.S. Pat. No. 8,141,665, issued Mar. 27, 2012, which claims the benefit of U.S. Provisional Application No. 60/750,647, filed Dec. 14, 2005, the disclosure of each of which application is hereby incorporated herein, in its entirety, by this reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to rotary, earth boring drag bits for drilling subterranean formations, as well as to the operation of such bits. More specifically, the present invention relates to modifying the designs of bits to include bearing elements for effectively reducing the exposure of cutting elements, or cutters, on the crowns of the bits by a readily predictable amount, as well as for optimizing performance of bits in the context of controlling cutter loading or depth-of-cut.
[0004] 2. State of the Art
[0005] Bits that carry polycrystalline diamond compact (PDC) cutting elements, or cutters, have proven very effective in achieving high rates of penetration (ROP) in drilling subterranean formations exhibiting low to medium compressive strengths. A PDC cutter typically includes a disc-shaped diamond “table” formed on and bonded under high-pressure and high-temperature conditions to a supporting substrate, which may be formed from cemented tungsten carbide (WC), although other cutter configurations and substrate materials are known in the art. Recent improvements in the design of hydraulic flow regimes about the face of bits, cutter design, and drilling fluid formulation have reduced prior, notable tendencies of such bits to “ball” by increasing the volume of formation material that may be cut before exceeding the ability of the bit and its associated drilling fluid flow to clear the formation cuttings from the face of the bit.
[0006] The body of a rotary, earth boring drag bit may be fabricated by machining a mold cavity in a block of graphite or another material and introducing inserts and cutter displacements into the machined cavities of the mold. The surfaces of the mold cavity define regions on the surface of the drill bit, while the cutter displacements and other inserts may define recesses on the face of the bit body and internal cavities within the bit body. Once any inserts and displacements have been positioned within the mold cavity, a particulate material, such as tungsten carbide, may be introduced into the cavity of the mold. Thereafter, an infiltrant, or binder, material may be introduced into the cavity to secure the particles to one another. The cutter displacements and other inserts may be removed from the bit body following the infiltration process, after which other elements, such as the cutters and hydraulic nozzles, may be assembled with and secured to the bit body.
[0007] The relationship of torque-on-bit (TOB) to weight-on-bit (WOB) may be employed as an indicator of aggressivity for cutters, with the TOB-to-WOB ratio corresponding to the aggressiveness with which a cutter is exposed or oriented relative to the crown of a bit or the cone of the crown. When cutters are placed in cavities that have been formed with standard cutter displacements, they may be exposed an aggressive enough distance that a phenomenon that has been referred to in the art as “overloading” may occur, even when a low WOB is applied to the drill string to which the bit is mounted. The occurrence of this phenomenon is more likely with more aggressive exposure or orientation of the cutters. Overloading is particularly significant in low compressive strength formations where a relatively great depth-of-cut (DOC) may be achieved at an extremely low WOB. Overloading may also be caused or exacerbated by drill string bounce, in which the elasticity of the drill string causes erratic, or inconsistent, application of WOB to the drill bit. Moreover, when bits with cutters that are carried by cavities are operated at excessively high DOC, more formation cuttings may be generated than can be consistently cleared from the bit face and directed back up the borehole annulus via junk slots on the face of the bit, which may lead to bit balling.
[0008] Another problem that may be caused when cutters located on the crown of a rotary, earth boring drill bit are overexposed may occur while drilling from a zone or stratum of higher formation compressive strength to a “softer” zone of lower compressive strength. As the bit drills from the harder formation into the softer formation without changing the applied WOB, or before a directional driller can change the WOB, the penetration of the PDC cutters and, thus, the resulting torque-on-bit (TOB) increases almost instantaneously and by a substantial magnitude. The abruptly higher torque may, in turn, cause damage to the cutters and/or the bit body. In directional drilling, such a change causes the tool face orientation (TFO) of the directional (measurement-while-drilling, or MWD, or a steering tool) assembly to fluctuate, making it more difficult for the directional driller to follow the planned directional path for the bit. Thus, it may be necessary for the directional driller to back off the bit from the bottom of the borehole to reset or reorient the tool face, which may take a considerable amount of time (e.g., up to an hour). In addition, a downhole motor, such as drilling fluid-driven Moineau-type motors commonly employed in directional drilling operations, in combination with a steerable bottomhole assembly, may completely stall under a sudden torque increase, possibly damaging the motor. That is, the bit may stop rotating, thereby stopping the drilling operation and necessitating that the bit be backed off from the borehole bottom to re-establish drilling fluid flow and motor output. Such interruptions in the drilling of a well can be time consuming and quite costly, especially in the offshore drilling environment.
[0009] So-called “wear knots” have been deployed behind cutters on the faces of rotary, earth boring drag bits in an attempt to provide enhanced stability in some formations, notably interbedded soft, medium and hard rock. Drill bits drilling such formations easily become laterally unstable due to the wide and constant variation of resultant forces acting on a bit due to engagement of such formations with the cutters. Wear knots comprise structures in the form of bearing elements projecting from the bit face. Conventionally, wear knots rotationally trail some of the cutters at substantially the same radial locations as the cutters, usually at positions from the nose of the bit extending down the shoulder, to locations that are proximate to the gage. A conventional wear knot may comprise an elongated segment having an arcuate (e.g., half-hemispherical, part-ellipsoidal, etc.) leading end, taken in the direction of bit rotation. A wear knot projects from the bit face a lesser distance than the projection, or exposure, of its associated cutter and typically has a width less than that of a rotationally leading, associated cutter and, consequently, than a groove that has been cut into a formation by that cutter. One notable deviation from such design approach is disclosed in U.S. Pat. No. 5,090,492, wherein so-called “stabilizing projections” rotationally trail certain PDC cutters on the bit face and are sized in relation to their associated cutters to purportedly snugly enter and move along the groove cut by the associated leading cutter in frictional, but purportedly non-cutting, relationship to the side walls of the groove.
[0010] The presence of bearing elements in the form of wear knots, while well-intentioned in terms of enhancing rotary drag bit stability, often fall short in practice due to deficiencies in the abilities of bit manufacturers to accurately position and orient the wear knots. Notably, rather than riding completely within a groove cut by an associated, rotationally leading cutter or portions thereof, conventional wear knot designs and placements may contact the uncut rock at the walls of the groove in which they travel, which may excite, rather than reduce, lateral vibration of the bit. Additionally, the areas of the bearing surfaces of the wear knots (i.e., the surface area of a portion of a wear knot that contacts the formation being drilled rotationally behind a cutter at a given DOC) are often difficult to calculate because of the typically half-hemispherical or part-ellipsoidal shapes thereof. Furthermore, the sizes and shapes of wear knots that are foiiiied from hardfacing and that are applied by hand are often not consistent from one wear knot to another. If the bearing surfaces of wear knots on opposite sides of a bit are not almost exactly the same, the bit could be subjected to uneven forces that might result in vibration, uneven wear, or, possibly, cutter or bit failure.
[0011] Several patents that have been assigned to Baker Hughes Incorporated address some issues related to DOC, wear knots, and the like. Included among these patents are U.S. Pat. No. 6,200,514; U.S. Pat. No. 6,209,420; U.S. Pat. No. 6,298,930; U.S. Pat. No. 6,659,199; U.S. Pat. No. 6,779,613; and U.S. Pat. No. 6,935,441, the disclosures of each of which are hereby incorporated herein, in their entireties, by this reference.
[0012] While some of the foregoing patents recognize the desirability to limit cutter penetration, or DOC, or otherwise limit forces applied to a borehole surface, the disclosed approaches do not provide a method or apparatus for controlling DOC in a manner that is easily and inexpensively adaptable across various product lines and applications.
BRIEF SUMMARY OF THE INVENTION
[0013] The present invention includes bearing elements for rotary, earth boring drag bits, bits that include bearing elements behind cutters on the crowns thereof, methods for designing and fabricating the bearing elements and bits, and drilling methods that employ the bearing elements to effectively reduce DOC.
[0014] A bearing element that incorporates teachings of the present invention limits the DOC or the effective extent to which PDC cutters, or other types of cutters or cutting elements (which are collectively referred to hereinafter as “cutters”) are exposed on the face of a rotary, earth boring drag bit. A bearing element might be located proximate to an associated cutter, which may, among other locations, be set in the crown, or nose, region of the bit, including, without limitation, within the cone of the crown and on the face of the crown. A bearing element may have a substantially uniform thickness across substantially an entire area thereof. The thickness, or height, of the bearing element, which is the distance the bearing element protrudes from a face of the bit (e.g., a blade on which the bearing element is located) may correspond directly to an effective decrease in the exposure, or standoff, and hence, the DOC of one or more adjacent cutters. A bearing element may be configured to distribute a load attributable to WOB over a sufficient surface area on the bit face, blades or other bit body structure contacting the formation face at the borehole bottom (e.g., at least about 30% of the blade surfaces at the crown of the bit) so that the applied WOB might not exceed, or is approximately less than, the compressive strength of the formation. As a result, the bit does not substantially indent, or fail, the formation rock. As the DOC is reduced by the bearing element, the bearing element may also limit the unit volume of formation material (rock) removed by the cutters per each rotation of the bit to prevent one or more of over-cutting the formation material, balling the bit, and damage to the cutters. If the bit is employed in a directional drilling operation, the likelihood of tool face loss or motor stalling may also be reduced by the presence of a bearing element of the present invention behind cutters on the crown of the bit.
[0015] A method for fabricating a bit is also within the scope of the present invention. Such a method may account for the compressive strength of a specific formation to be drilled, as noted above, and include the formation of one or more bearing elements at locations that will provide a bit or its cutters with one or more desired properties.
[0016] While a variety of techniques may be used to fabricate a bearing element or a bit with a bearing element, such a method may include fabricating a mold for forming the bit. The mold is formed by milling a cavity that includes a crown-forming region with smaller cavities, or recesses, that are configured to receive standard preforms, or displacements. Other inserts may also be placed within the mold cavity. The mold cavity is milled in such a way that slots, or grooves, are formed in the crown-forming region (e.g., in the cone thereof or elsewhere within the crown-forming region) in communication with trailing ends of the smaller, displacement-receiving cavities. These slots may have substantially uniform depths across substantially the entire areas thereof. Each slot defines the location of a bearing element to be formed on the crown of a bit and has a depth that corresponds to the distance the amount of cutter exposure at an adjacent region of the crown is to be effectively reduced to effectively control the DOC that each adjacent cutter may achieve. An area of the slot may be sufficient to support the anticipated axial load, or WOB, to prevent the cutters from digging into the formation beyond their intended DOC or so that the compressive strength of the expected formation to be drilled is not exceeded. Together, the mold cavity, the displacements, and any other inserts within the mold cavity define the body of a bit. Once a mold cavity has been formed and includes desired features, and cutter displacements and any other inserts have been positioned therein, a bit body may be formed, as known in the art (e.g., by introducing particulate material and infiltrant into the mold cavity). The displacements may then be removed from the bit body, leaving pockets that are configured to receive the cutters, which are subsequently assembled with and secured to the bit body.
[0017] According to another aspect, the present invention includes methods for drilling subterranean formations, which methods include using bits with bearing pads that effectively reduce the exposures of cutters on the crowns or in the cones of the bits.
[0018] Methods for designing bearing elements include selecting a formation to be drilled, calculating a desired DOC and the strength of the formation, and calculating the height or thickness of a bearing element that will limit the DOC and the unit force applied to the formation.
[0019] Other features and advantages of the present invention will become apparent to those of ordinary skill in the art through consideration of the ensuing description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0020] FIG. 1 is a perspective view of an example of a rotary earth boring drag bit that includes bearing pads that incorporate teachings of the present invention, with the bit in an inverted orientation relative to its orientation when drilling into a formation;
[0021] FIG. 2 is a schematic representation of a crown-forming surface of a mold for forming a rotary earth boring drag bit, the mold including milled cavities, or recesses for receiving preforms for cutters of the earth boring drag bit;
[0022] FIG. 3 is a schematic representation of the crown-forming surface of the mold shown in FIG. 2 with preforms, or inserts, for cutters installed in the milled cavities;
[0023] FIG. 4 is a schematic representation of the crown-forming surface of the mold with milled slots located at the trailing edges of at least some of the milled cavities for receiving the preforms or inserts;
[0024] FIG. 5 is a schematic representation of the crown-forming surface of the mold of FIG. 4 with preforms, or inserts, in the milled cavities;
[0025] FIG. 6 is a perspective view of a crown-forming surface of a mold including the features depicted in FIG. 4 ;
[0026] FIG. 7 is a close-up view of the milled cavities and milled slots of the portion of the bit illustrated in FIG. 6 ;
[0027] FIG. 8 is a schematic representation of a crown of a rotary earth boring drag bit that illustrates the relationship between DOC, crown profile, and cutter profile;
[0028] FIG. 9 is a close-up rear perspective view of a portion of a blade of a rotary earth boring drag bit that is located within a cone of the crown of the bit and that includes cutters and a bearing element located adjacent to a trailing edge of at least some of the cutters on the cone portion of the blade to effectively reduce an exposure of each adjacent cutter; and
[0029] FIG. 10 is a close-up front perspective view of the portion of the rotary earth boring drag bit shown in FIG. 9 .
DETAILED DESCRIPTION
[0030] FIG. 1 of the drawings depicts a rotary drag bit 10 that includes a plurality of cutters 24 (e.g., PDC cutters) bonded by their substrates (diamond tables and substrates not shown separately for clarity), as by brazing, into pockets 22 (see also FIG. 2 ) in blades 18 , as is known in the art with respect to the fabrication of so-called impregnated matrix, or, more simply, “matrix,” type bits. Such bits include a mass of particulate material (e.g., a metal powder, such as tungsten carbide) infiltrated with a molten, subsequently hardenable binder (e.g., a copper-based alloy). It should be understood, however, that the present invention is not limited to matrix-type bits, and that steel body bits and bits of other manufacture may also be configured according to the present invention. The exterior shape of a diametrical cross section of the bit taken along the longitudinal axis 40 , or axis of rotation, of bit 10 defines what may be termed the “bit profile” or “crown profile.” See also FIG. 8 . The end of drag bit 10 may include a shank 14 secured to the “matrix” bit body. Shank 14 may be threaded with an API pin connection 16 , as known in the art, to facilitate the attachment of drill bit 10 to a drill string (not shown).
[0031] Internal fluid passages of bit 10 lead from a tubular shank at the upper, or trailing end, of bit 10 to a plenum extending into the bit body, to nozzle orifices 38 . Nozzles 36 that are secured in nozzle orifices 38 provide fluid courses 30 , which lie between blades 18 , with drilling fluid. Fluid courses 30 extend to junk slots 32 , which extend upwardly along the sides of bit 10 , between blades 18 . Formation cuttings are swept away from cutters 24 by drilling fluid expelled by nozzles 36 , which moves generally radially outward through fluid courses 30 , then upward through junk slots 32 to an annulus between the drill string (not shown) from which bit 10 is suspended, and on up to the surface, out of the well.
[0032] A plurality of bearing elements 42 may reside on the portions of blades 18 located at a crown, or nose, of bit 10 . By way of non-limiting example, bearing elements 42 may be at least partially located on portions of blades 18 that are located within the cone of the crown of bit 10 . Bearing element 42 , which may be of any size, shape, and/or thickness that best suits the need of a particular application, may lie substantially along the same radius from axis 40 as one or more other bearing elements 42 . The bearing element 42 or surfaces may provide sufficient surface area to withstand the axial or longitudinal WOB without exceeding the compressive strength of the formation being drilled, so that the rock does not unduly indent or fail and the penetration of PDC cutters 24 into the rock is substantially controlled.
[0033] As an example, the total bearing area of the bearing element 42 of an 8.5-inch-diameter bit configured as shown in FIG. 1 may be about 12 square inches. If, for example, the unconfined compressive strength of a relatively soft formation to be drilled by bit 10 is 2,000 pounds per square inch (psi), then at least about 24,000 lbs. WOB may be applied to the formation without failing or indenting it. Such WOB is far in excess of the WOB that may normally be applied to a bit in such formations (e.g., as little as 1,000 to 3,000 lbs., up to about 5,000 lbs., etc.) without incurring bit balling from excessive DOC and the consequent cuttings volume which overwhelms the bit's ability to hydraulically clear the cuttings. In harder formations, with, for example, 20,000 to 40,000 psi compressive strengths, the collective surface area of the bearing elements of the bit may be significantly reduced while still accommodating substantial WOB applied to keep the bit firmly on the borehole bottom. When older, less sophisticated drill rigs are employed or during directional drilling, both circumstances that render it difficult to control WOB with any substantial precision, the ability to overload WOB without adverse consequences further distinguishes the superior performance of a bit that includes one or more bearing elements 42 according to the present invention. It should be noted that the use of an unconfined compressive strength of formation rock provides a significant margin for calculation of the required bearing area of bearing element 42 for a bit, as the in situ, confined, compressive strength of a subterranean formation being drilled is substantially higher. Thus, if desired, confined compressive strength values of selected formations may be employed in designing a bearing element with a total bearing area, as well as the total bearing area of a bit, to yield a smaller required bearing area, but which still advisedly provides for an adequate “margin” of excess bearing area in recognition of variations in continued compressive strengths of the formation to preclude substantial indentation and failure of the formation downhole.
[0034] In addition to serving as a bearing surface, the thicknesses or heights of bearing elements 42 , or the distance they protrude from the surfaces of the blades 18 , may determine the extent of the DOC, or the effective amount the exposure of cutters 24 is reduced vis-à-vis a formation to be drilled. By way of example only, each bearing element 42 may be configured to a certain height related to the desired DOC of its associated cutter or cutters 24 . That is, as the height of bearing element 42 increases relative to the surface of blade 18 , the DOC of its associated cutter or cutters 24 decreases. For example, a cutter 24 might have a nominal diameter of 0.75 inch that, when brazed into a pocket 22 in blade 18 may, without an adjacent bearing element 42 , have a nominal DOC of 0.375 inch. By including a bearing element 42 , the DOC of the 0.75-inch-diameter PDC cutter 24 might be reduced to as little as zero (0) inches. Of course, the DOC may be selected within a variety of ranges that depend upon the height of bearing element 42 , or the distance that bearing element 42 protrudes from a surface of the crown of bit 10 . Thus, bearing elements 42 eliminate the need to alter the depth of the cutter displacement-receiving cavities formed in a mold for the bit body, which permits the use of existing, standard displacements. Thus, the DOC of cutters 24 at the crown of a bit 10 and, hence, the aggressiveness of bit 10 , may be quickly modified to the requirements of a particular formation without resorting to a redesign of the blade geometry or profile, which normally takes significant time and money to achieve.
[0035] A bit of the present invention may be fabricated by any suitable, known technique. For example, a bit may be formed through the use of a mold. The displacements and other inserts may be placed at precise locations within a cavity of the mold to ensure the proper placement of cutting elements, nozzles, junk slots, etc., in a bit body formed with the mold. Therefore, the cutter displacement-receiving cavities machined into the crown-forming region of a mold may have sufficient depths to support and hold displacements in position as particulate material and infiltrant are introduced into the mold cavity.
[0036] FIG. 2 is a representation of bit mold 46 from the perspective of one looking directly into a cavity 45 of mold 46 . Mold 46 may be thought of as the negative of the bit (e.g., bit 10 ) to be formed therewith. The portion of mold 46 that is shown in FIG. 2 is a crown-forming region of the cavity 45 thereof. Small cavities 22 ′ are shown that have been milled to hold the displacements for subsequently forming pockets within which the cutting elements that are to be located in the cone of the bit face are eventually inserted and secured. FIG. 3 is a representation of mold 46 from the same point of view, only, in this instance, displacements 44 have been inserted into small cavities 22 ′. As shown in FIGS. 4 through 7 , slots, or grooves 48 , 48 ′, which subsequently form bearing elements 42 ( FIG. 1 ), may be formed in mold 46 , e.g., by milling the same into the surface of the cavity 45 of mold 46 . Grooves 48 , 48 ′ and small cavities 22 ′ may be formed, by way of non-limiting example, by hand milling or by a multi-axis (e.g., five- or seven-axis), milling machine under control of a computer. For example only, among other factors, the size, shape, area, and depth of each groove 48 , 48 ′ may be selected to achieve a desired DOC (i.e., aggressiveness) and bearing element area for a given application or formation as aforementioned.
[0037] Each groove 48 , 48 ′ has a substantially uniform depth across substantially an entire area thereof, regardless of the contour of the surface within which groove 48 , 48 ′ is formed. Each groove 48 , 48 ′ may, for example, have a width that is slightly greater than the widths of small cavities 22 ′ in the mold 46 and, further, extend somewhat between adjacent small cavities 22 ′. Such configurations may provide greater bearing surface areas and may support a higher applied WOB than would otherwise be possible if the drill bit 10 lacked such features. Alternatively, each groove 48 , 48 ′ may have a width somewhat less than the widths of small cavities 22 ′, in this instance about two-thirds (⅔) the total widths of small cavities 22 ′. In addition, grooves 48 , 48 ′ may not extend substantially between adjacent small cavities 22 ′. As a result, a groove 48 , 48 ′ with either of these features, or a combination thereof, would form a bearing element 42 that has a smaller surface area and, thus, that could support a relatively smaller applied WOB than a bearing element 42 with a greater surface area.
[0038] Mold 46 may include one groove 48 , 48 ′, or a plurality of grooves 48 , 48 ′. If mold 46 includes a plurality of grooves 48 , 48 ′, the individual grooves 48 , 48 ′ may have the same dimensions as one another, or the individual grooves 48 , 48 ′ may have at least one dimension that differs from a corresponding dimension of another groove 48 , 48 ′. For example, a mold 46 may include a first groove 48 with the larger dimension and surface area noted above, while another groove 48 ′ may include smaller dimensions, as noted above. In addition, the depths of grooves 48 , 48 ′ may be the same, or differ from one groove 48 to another groove 48 ′. Furthermore, while mold 46 is depicted as including slots 48 , 48 ′ at particular locations merely for the sake of illustration, grooves 48 , 48 ′ may be formed elsewhere within mold 46 without departing from the scope of the present invention.
[0039] FIG. 5 shows mold 46 of FIG. 4 after displacements 44 have been installed in small cavities 22 ′, with the associated examples of grooves 48 and 48 ′. Once displacements 44 have been installed within small cavities 22 ′, bit 10 may be formed with mold 46 by any suitable process known in the art, including the introduction of a particulate material and the introduction of a binding agent, or binder or infiltrant, within cavity 45 of mold 46 .
[0040] FIG. 8 illustrates a profile view 56 of an exemplary bit 10 designed in accordance with teachings of the present invention. The crown profile 52 is the line that traces the profile of blades 18 from axis 40 to the gage radius 12 , as also seen in FIG. 1 . The cutter profile 54 traces the edges of cutters 24 as the bit is rotated around axis 40 and cutters 24 pass through the plane that corresponds to the page on which FIG. 8 appears. The distance between crown profile 52 and cutter profile 54 is the nominal depth-of-cut (DOC), labeled D, absent the bearing element 42 . However, the bearing element 42 , as formed from slot or groove 48 of mold 46 , as discussed above, may modify the DOC of cutters 24 . In this instance, bearing element 42 extends beyond crown profile 52 a set distance H, and the DOC of cutters 24 is the distance between bearing element 42 and cutter profile 54 , indicated by D′.
[0041] Of course, other techniques may be used to form a bit with one or more bearing elements. For example, a bit body or a portion thereof may be machined from a solid blank; formed by programmed material consolidation (e.g., “layered manufacturing,” etc.) and infiltration processes, such as those disclosed in U.S. Pat. Nos. 6,581,671, 6,209,420, 6,089,123, 6,073,518, 5,957,006, 5,839,329, 5,544,550, 5,433,280, which have each been assigned to Baker Hughes Incorporated, the disclosures of each of which are hereby incorporated herein, in their entireties, by this reference; or by any other suitable bit fabrication process.
[0042] A bit 10 embodying teachings of the present invention is shown in FIGS. 9 and 10 . FIG. 9 provides a close-up view of a bearing element 42 of a bit 10 . Cutters 24 are also visible in FIG. 9 . Similar features are visible in FIG. 10 . Bearing element 42 is visible from a different angle, as are cutters 24 . The bearing element 42 extends laterally between laterally adjacent cutters 24 and abuts each of the laterally adjacent cutters 24 along a rotationally trailing end and at least a portion of opposing sides of each of the cutters 24 .
[0043] With returned reference to FIGS. 1 and 8 - 10 , a method for drilling a subterranean formation includes engaging a formation with at least one cutter 24 , the exposure of which is limited by at least one bearing element 42 , which may also limit the DOC of each cutter 24 . One or more cutters 24 having DOCs limited by one or more bearing elements 42 may be positioned on a formation-facing surface of at least one portion, or region, of at least one blade 18 to render a cutter 24 spacing and cutter profile 54 exposure that will enable the bit 10 to engage the formation within a wide range of WOB without generating an excessive amount of TOB, even at elevated WOBs, for the instant ROP that the bit 10 is providing. That is, as aforementioned, the torque is related directly to the WOB applied. Using a bit 10 with bearing elements 42 that will limit the DOC by a predetermined, readily predictable amount and, hence, limit the torque applied to drill bit 10 , decreases the likelihood that the torque might cause the downhole motor to stall or the tool face to undesirably change. Drilling may be conducted primarily with cutters 24 , which have DOCs limited by one or more bearing elements 42 , engaging a relatively hard formation within a selected range of WOB. Upon encountering a softer formation and/or upon applying an increased amount of WOB to bit 10 , at least one bearing element 42 located proximate to at least one associated cutter 24 limits the DOC of the associated cutter 24 while allowing bit 10 to ride against the formation on bearing element 42 , regardless of the WOB being applied to bit 10 and without generating an unacceptably high, potentially bit-damaging TOB for the current ROP.
[0044] Although the foregoing description contains many specifics and examples, these should not be construed as limiting the scope of the present invention, but merely as providing illustrations of some of the presently preferred embodiments. Similarly, other embodiments of the invention may be devised which do not depart from the spirit or scope of the present invention. The scope of this invention is, therefore, indicated and limited only by the appended claims and their legal equivalents, rather than by the foregoing description. All additions, deletions and modifications to the invention as disclosed herein and which fall within the meaning of the claims are to be embraced within their scope.
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A bearing element for a rotary, earth boring drag bit effectively reduces an exposure of at least one adjacent cutting element by a readily predictable amount, as well as a depth-of-cut (DOC) of the cutter. The bearing element has a substantially uniform thickness across substantially an entire area thereof. The bearing element also limits the amount of unit force applied to a formation so that the formation does not fail. The bearing element may prevent damage to cutters associated therewith, as well as possibly limit problems associated with bit balling, motor stalling and related drilling difficulties. Bits including the bearing elements, molds for forming the bearing elements and portions of bodies of bits that carry the bearing elements, methods for designing and fabricating the bearing elements and bits including the same, and methods for drilling subterranean formations are also disclosed.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a process for the synthesis of 3-phenoxy-1-azetidinecarboxamides, particularly 3-(3-trifluoromethylphenoxy)-1-azetidine-carboxamide, in which an appropriately substituted 3-phenoxyazetidine is fused with urea. The compounds prepared by the process of this invention are useful as anticonvulsants.
2. Information Disclosure Statement
Anticonvulsant 3-phenoxy-1-azetidinecarboxamides as shown in Formula I: ##STR2## where n is 1-3, R is H, and X is selected from hydrogen, fluorine, loweralkyl, loweralkoxy, trifluoromethyl, acetyl or aminocarbonyl are disclosed in U.S. Pat. No. 4,571,393. U.S. Pat. No. 4,956,359 further discloses 3-phenoxy-1-azetidinecarboxamides of Formula I in which X, among other things, is chlorine, bromine or iodine and R is H or methyl. The methods of preparation of Formula I carboxamides as disclosed hereinabove involve reaction of a Formula II intermediate where n, X and R ##STR3## are as defined under Formula I below with either nitrourea or phosgene/ammonium hydroxide. The reaction with nitrourea involves heating a Formula II compound with nitrourea in an appropriate organic solvent such as ethanol. Nitrourea is relatively expensive, somewhat unstable, and potentially explosive and thus is not the reagent of choice for a large scale reaction. The synthetic procedure involving phosgene requires formation of a 3-phenoxyazetidine-1-carbonyl chloride from a Formula II intermediate followed by reaction of the carbamoyl chloride with ammonium hydroxide. Both phosgene and ammonium hydroxide are toxic and formation of the carbamoyl chloride requires the use of an anhydrous aprotic solvent. The Formula II intermediate is prepared from the N-protected intermediate having the structure shown as Formula III: ##STR4## where n, X and R are as defined under Formula I below and Y is methyl or phenyl by catalytic hydrogenolysis in the presence of an appropriate hydrogenation catalyst to remove the --CHYC 6 H 5 group. An alternative procedure for preparing the 3-phenoxyazetidine-1-carbonyl chloride is to react a Formula III compound with phosgene, which N-dealkylates the Formula III compound, giving the corresponding carbamoyl chloride and the chlorinated by-product, ClCHYC 6 H 5 which is a lachrymator and skin and lung irritant. The above synthetic procedures are given in the U.S. patent cited hereinabove and in U.S. Pat. Nos. 4,954,189 and 4,379,151.
Reactions of urea with primary alkylamines to obtain monosubstituted ureas which may be further reacted to give symmetrical dialkylureas, alkylbiurets and dialkylbiurets appear in the literature. T. L. Davis and H. W. Underwood, Jr., J. Amer. Chem. Soc. 44, 2596-2597 (1922) report that no reaction occurs between urea and diphenylamine or N-ethylaniline and that with dibutyl and diamylamines or their hydrochlorides, the formation of a by-product, ammonium chloride, indicated that reaction had taken place, although the products were exceedingly difficult to separate. T. L. Davis and K. C. Blanchard, J. Amer. Chem. Soc. 45, 1817 (1923), report that when an aqueous solution of urea and N-methylaniline hydrochloride or N-ethylaniline hydrochloride was refluxed, the corresponding unsymmetrical ureas were produced in poor yields. J. C. Erikson, J. Amer. Chem. Soc. 76, 3977-8 (1954) reported the synthesis of 1,1-dioctadecylurea from dioctadecylamine and urea heated together at 160°-165° C. for 5 hours.
SUMMARY OF THE INVENTION
This invention concerns a process for the preparation of a compound having the formula: ##STR5## wherein n is 1 to 3, X is selected from hydrogen, halogen, trifluoromethyl, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, acetyl and aminocarbonyl; and R is H or methyl. When n is two or three, the values of X may be the same or different.
The present process obviates the hazards and higher expense associated with nitro-urea or phosgene and comprises heating together a sufficient amount of inexpensive urea and a Formula II compound at a temperature sufficient to drive the reaction to completion. The reaction mixture then is extracted with an organic solvent and/or water to remove any organic impurities and/or unreacted water-soluble urea to obtain the Formula I compound. The reaction proceeds well at temperatures below 150° C. and gives the product in good yield. If the Formula II compound is prepared by catalytic hydrogenolysis to remove the protecting group (i.e., diphenylmethyl or α-methylbenzyl), it is not necessary to remove the diphenylmethane or ethylbenzene formed as the present process provides a method for facile removal of these organic by-products.
DETAILED DESCRIPTION OF THE INVENTION
The process of the invention is summarized in the following reaction scheme: ##STR6##
In the process of this invention the amount of urea used is from one to ten molar equivalents with respect to the amount of Formula II compound. Preferably the amount of urea used is from one to about two molar equivalents and more preferably, about 1.5 molar equivalents. In general, the urea is added to the Formula II compound at from about 60° C. to about 90° C. The reaction temperature is then raised to a temperature of from about 130° C. to about 150° C. for a period of from 0.5 to 5 hours. When the reaction is complete, the melt is allowed to cool to a lower temperature, ideally from about 80° C. to about 100° C. As noted above, as a "melt" is used, this portion of the process is run in the absence of any solvent.
If diphenylmethane or ethylbenzene is present as a result of the Formula II compound being prepared from 1-(diphenylmethyl or α-methylbenzyl)-3-phenoxyazetidine by catalytic hydrogenolysis to remove the diphenylmethyl or α-methylbenzyl protecting group, the melt is triturated with an organic solvent having a boiling range of from about 80° C. to about 120° C. such as benzene, toluene or petroleum ethers (boiling range 80°-110° C.) or mixtures thereof and the liquid and solid phases separated by conventional means such as filtration or centrifugation. The liquid phase contains the diphenylmethane or ethylbenzene and the solid residue consists of the Formula I compound and unreacted urea, if any.
The solid residue, or melt if diphenylmethane or ethylbenzene is absent, is triturated with water to dissolve any excess urea and the solid Formula I compound is separated from the aqueous urea solution by conventional means, and dried. Further purification is achieved by conventional purification techniques such as recrystallization or chromatography.
The following procedures are illustrative of the process of this invention and are not to be construed as limiting this disclosure in any way.
Urea Fusion Process for the Preparation of 3-(3-Trifluoromethylphenoxy)-1-azetidinecarboxamide
Procedure 1
A 30 gallon glass-lined reactor was charged with a solution containing equal parts of 3-(3-trifluoromethylphenoxy)azetidine and diphenylmethane in methanol as obtained from the catalytic hydrogenolysis of 78.32 moles of 1-diphenylmethyl-3-(3-trifluoromethylphenoxy)azetidine. The methanol was distilled off at a pressure of 150 mm Hg until the reactor temperature reached 65° C. The reactor was flushed with nitrogen and charged with 117.4 moles of urea. Heating was continued to approximately 135° C. and held at 135° C. until thin layer chromatographic analysis showed the azetidine derivative to be consumed. When the reaction was complete the mixture was cooled to approximately 80° C. A 30 gallon receiver equipped with an agitator was charged with 80 L of petroleum ether (80°-110° C. boiling range) and the contents of the reactor drained into the receiver with the agitator at high speed. The mixture was slowly cooled to 50° C. and held at that temperature for 5-6 hours. The resulting slurry was then pumped onto a vacuum filter and the filter cake compressed under a rubber dam for 4-5 hours to remove as much solvent as possible.
The filter cake was dried in a vacuum oven at a maximum of 40° C. and the solid then milled to pass through a 100 mesh screen. the receiver was charged with 75 L of water and with agitation charged with the milled solid. After agitating for 4-5 hours, the slurry was pumped onto the vacuum filter. The filter cake was transferred to a vacuum oven and the product dried at 45°-50° C. to obtain 16.45 kg (80%) of the title compound, mp 150°-151.5° C.
Procedure 2
A stirred mixture containing equimolar amounts of 3-(3-trifluoromethylphenoxy)azetidine and diphenylmethane (9.265 kg, 24.1 moles of each) obtained by catalytic hydrogenolysis (Pd/C) was heated to 90° C. under a nitrogen purge while urea (1.445 kg, 24.1 moles) was added. Heating was continued to 137° C. and additional urea (1.445 kg, 24.1 moles) was added portionwise. After 10 minutes at 137° C., nuclear magnetic resonance (nmr) and thin layer chromatographic (tlc) analysis showed the reaction to be only 25% completed. After another 30 minutes, nmr and tlc analysis showed only a trace of starting material. After another 30 minutes, the mixture was cooled to 120° C. Toluene (6 liters) was added and the mixture heated to reflux. The heat was removed and the toluene slurry transferred to a 30 gal glass lined jacketed tank and stirred. The reactor was washed with an additional 3 L of toluene and the wash added to the slurry in the tank. The contents of the tank were chilled by circulating cold (0° C.) ethylene glycol solution in the jacket and heavy crystallization occurred. Petroleum ether (18.6 liters, boiling range 80°-110° C.) was slowly added to the mixture and after 1 hour, stirring was stopped and the mixture allowed to stand overnight. Stirring was then resumed and the slurry pumped onto a 30 gal ceramic filter. The solid was dried under vacuum (product covered with rubber dam) for 2 hours, washed with 3 liters of 1:2 toluene-petroleum ether, and dried under vacuum for another hour. The solid was divided into trays and dried in an oven at 110° F. to obtain 6.17 kg of solid (product and excess urea). The solid was stirred in 24 liters of water for 3 hours and the solid collected by vacuum filtration and dried under a rubber dam for 2 hours. The wet solid was dissolved in 13 liters of hot absolute ethanol, the solution filtered, and 12 liters of warm water (60° C.) added to the filtrate. Seed crystals were added and the solution was chilled in a refrigerator overnight. The recrystallized solid was collected, the cake rinsed with 25% ethanol-75% water, and dried under vacuum at 100° F. for 18 hours to obtain 3.4 kg. The solid was then stirred with 8 liters of isopropyl ether for 2.5 hours, filtered, and the white solid dried at 125° F. overnight to obtain 3.21 kg (61%), of the title compound, mp 151°-152° C.
Analysis: Calculated for C 11 H 11 N 2 O 2 F 3 : C, 50.77; H, 4.26; N, 10.76. Found: C, 50.81; H, 4.28; N, 10.74.
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This invention relates to an improved process for the preparation of 3-phenoxy-1-azetidinecarboxamides of Formula I which are useful ##STR1## in the treatment of epileptic seizures. Under Formula I, n is 1 to 3, X is H, halogen, trifluoromethyl, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, acetyl, or aminocarbonyl, and R is H or methyl. This process involves heating a 3-phenoxyazetidine with urea to obtain the Formula I compound. Urea is inexpensive and easily removed by washing the solid Formula I product with water.
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BACKGROUND OF THE INVENTION
Thermoplastic copolyester elastomers in which the polyester is modified with long rubbery segments have long been known in the art and are used in the preparation of molded and extruded articles. Such resins can be used alone or in conjunction with fillers or other resins to provide materials having a variety of properties. It is well known, however, that materials of this general type are subject to thermal degradation. U.S. Pat. Nos. 3,023,192, 3,651,014, 3,766,146, 3,784,520 and 3,763,109 are among prior patents describing elastomers of this type.
Unstabilized elastomers of the type described above exhibit poor processing behavior and unacceptable performance, especially at elevated temperatures. While a number of antioxidant stabilizers are available for use in polymers, many are unsuitable for use in copolyester elastomers of the type mentioned above because of the severe time-temperature conditions involved in the manufacture and/or use of such elastomers. When used in elastomers of this type, most available stabilizers either inhibit polymer formation or result in production of a non-white colored product. Additionally most available stabilizers do not provide adequate long term retention of desirable mechanical and thermal properties. U.S. Pat. Nos. 4,355,155 and 4,405,749 describe elastomer of the general type described above but which is modified to provide improved thermal stability together with a desirable white color.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide thermoplastic copolyester elastomers of the general type described above, but with improved thermal stability, particularly at elevated use temperatures. In accordance with the invention, a thermoplastic elastomer composition is provided which consists essentially of:
(a) segmented thermoplastic copolyester elastomer consisting essentially of a multiplicity of recurring long chain ester units and short chain ester units joined head to tail through ester linkages, said long chain units being represented by the formula ##STR1## and said short chain units being represented by the formula ##STR2## where G is a divalent radical remaining after the removal of the terminal hydroxyl groups from a difunctional polyether glycol having a number average molecular weight in the range from about 400 to about 6,000, R is a hydrocarbon radical remaining after removal of the carboxyl groups from terephthalic acid or isophthalic acid, and D is a divalent radical remaining after removal of hydroxyl groups from 1,4-butanediol or 1,4-butenediol; provided, said short chain units amount to between about 30% and about 85% by weight of the copolyester;
(b) between about 0.1 and about 25% by weight of said copolyester of polyvinylpyrrolidone;
(c) between about 0.05 and about 5% by weight of said copolyester of cyanoguanidine or guanidine stabilizer of the formula ##STR3## where n is an integer between 2 and about 20; (d) between about 0.1 and about 5% by weight of said copolyester of diphenylamine derivative of the formula ##STR4## where R and R 1 are methyl or phenyl; and (e) between about 0.05 and about 3% by weight of said copolyester of phosphorus compound of the formula ##STR5## where R represents an alkyl radical having from 6 to about 22 carbon atoms or a hydrocarbon radical of the structure ##STR6## where t represents a tertiary butyl radical.
In preferred embodiments of the invention, at least about 80% of the R groups of formulas I and II are hydrocarbon radicals remaining after removal of carboxyl groups from terephthalic acid, between about 10 and about 40%, more usually between about 20 and about 30%, of the D groups of Formula II represent divalent radicals remaining after removal of hydroxyl groups from 1,4-butenediol and short chain units amount to between about 40% and about 65% by weight of the copolyester.
DETAILED DESCRIPTION OF THE INVENTION
The long chain ester units of the product of the invention are the reaction product of a long chain glycol with terephthalic acid or isophthalic acid. The long chain glycols are poly(alkylene oxide) glycols having terminal (or as nearly terminal as possible) hydroxyl groups and hydroxyl numbers between about 18 and about 280 as determined in accordance with ASTM test method E-222. Corresponding number average molecular weights are between about 400 and about 6,000. Number average molecular weight for a particular glycol may be calculated by dividing the hydroxyl number into 112,200. Glycols used in the invention preferably have a number average molecular weight between about 400 and about 6,000 as carbon to oxygen ratio of between about 2.0 to 1 and about 4.3 to 1. Representative long chain glycols available for use in making product of the invention include poly(ethylene oxide) glycol, poly(1,2- and 1,3-propylene oxide) glycol, and poly(tetramethylene oxide) glycol. Poly(tetramethylene oxide) glycol is a particularly preferred glycol for long chain ester units of the invention.
Short chain units of product of the invention may be made by reacting 1,4-butanediol, 1,4-butenediol or a mixture thereof with terephthalic acid or isophthalic acid. In preferred embodiments 1,4-butenediol is used in amounts between about 10 and about 40%, more usually between about 20 and about 30%, based on the total of 1,4-butanediol and 1,4-butenediol. In making both the long chain and short chain units of product of the invention, the use of terephthalic acid is generally preferred with the use of between about 1 and about 20% isophthalic acid based on the total of terephthalic acid and isophthalic acid used being preferred when product of lower flexural modulus is desired.
The terms "terephthalic acid" and "isophthalic acid" as used herein are intended to include the condensation polymerization equivalent of such acids, i.e. their esters or ester-forming derivatives such as acid chlorides and anhydrides, or other derivatives which behave substantially like such acids in a polymerization reaction with a glycol. Dimethyl terephthalate and dimethyl isophthalate are for instance suitable starting materials for elastomers of the invention.
Copolyester elastomer for use in the invention can be made by conventional ester interchange reaction. A preferred procedure involves heating the dimethyl ester of terephthalic acid or of a mixture of terephthalic and isophthalic acids with a long chain glycol and a molar excess of a mixture of butanediol and butenediol in the presence of a catalyst at 150°-260° C. followed by distilling off of methanol formed by the interchange. Heating is continued until methanol evolution is complete. Depending upon temperature, catalyst and glycol excess, the polymerization is complete within a few minutes to a few hours. This procedure results in the preparation of a low molecular weight pre-polymer which can be carried to a desired high molecular weight copolyester by distillation of the excess of short chain diol in a conventional polycondensation reaction. Additional ester interchange occurs during this distillation to increase the molecular weight and to randomize the arrangement of the copolyester units. Best results are usually obtained if this final distillation or polycondensation is run at less than 1 mm pressure and 220°-255° C. for less than 2 hours in the presence of antioxidants. Most practical polymerization techniques rely upon ester interchange to complete the polymerization reaction. In order to avoid excessive hold time at high temperatures with possible irreversible thermal degradation, it is advantageous to employ a catalyst for ester interchange reactions. While a wide variety of catalysts can be used, organic titanates such as tetrabutyl or tetraisoproply titanate used alone or in combination with magnesium or calcium acetates are preferred. Complex titanates, such as derived from alkali or alkaline earth metal alkoxides and titanate esters are also very effective. Inorganic titanates, such as lanthanum titanate, calcium acetate/antimony trioxide mixtures and lithium and magnesium alkoxides are representative of other catalysts which can be used.
Prepolymers for product of the invention can also be prepared by a number of alternate esterification or ester interchange processes. For example, the long chain glycol can be reacted with a high or low molecular weight short chain ester homopolymer or copolymer in the presence of catalyst until randomization occurs. The short chain ester homopolymer or copolymer can be prepared by ester interchange from either the dimethyl esters and low molecular weight diols, as above, or from the free acids with the diol acetates. Alternatively, the short chain ester copolymer can be prepared by direct esterification from appropriate acids, anhydrides or acid chlorides, for example, with diols or by other processes such as reaction of the acids with cyclic ethers or carbonates. Obviously the prepolymer might also be prepared by running these processes in the presence of the long chain glycol.
Ester interchange polymerizations are generally run in the melt without added solvent, but inert solvents can be used to facilitate removal of volatile components from the mass at low temperatures. This technique is especially valuable during prepolymer preparation, for example, by direct esterification. However, certain low molecular weight diols, for example, butanediol in terphenyl, are conveniently removed during high polymerization by azeotropic distillation. Other special polymerization techniques, for example, interfacial polymerization of bisphenol with bisacylhalides and bisacylhalide capped linear diols, may prove useful for preparation of specific polymers. Both batch and continuous methods can be used for any stage of copolyester polymer preparation. Polycondensation of prepolymer can also be accomplished in the solid phase by heating finely divided solid prepolymer in a vacuum or in a stream of inert gas to remove liberated low molecular weight diol. This method has the advantage of reducing degradation because it must be used at temperatures below the softening point of the prepolymer. The major disadvantage is the long time required to reach a given degree of polymerization.
Molecular weight of elastomer used in product of the invention may vary widely depending upon end use requirements. For elastomer used in product of the invention melt flow rate (MFR) is usually used as an indication of molecular weight. The actual molecular weight of the elastomer is not usually determined. For typical uses of product of the invention such as extrusion or molding operations elastomer used frequently has an MFR between about 0.1 and about 50 grams/10 minutes (220° C., 2160 g) as determined in accordance with ASTM test method D-1238 although elastomer of greater MFR such as up to about 350 or more may be produced if desired.
Elastomer composition of the invention contains between about 0.1 and about 25 weight percent (wt %) polyvinylpyrrolidone (PVP) based on copolyester, preferably between about 0.5 and about 15 wt % on the same basis. While molecular weight of PVP used in the invention is not critical as long as the PVP does not produce discrete particles in the blend, use of PVP having a K value not exceeding about 30 is preferred. PVP having a K value between about 0.5 and about 20 is especially preferred. K values mentioned herein are as determined by the Fikentscher equation (Kline, G. M., "Polyvinylpyrrolidone", Modern Plastics, November, 1945).
Elastomer of the invention also contains between about 0.05 and about 5 wt % based on polyester of cyanoguanidine (CNG) ##STR7## or of guanidine stabilizer of the formula ##STR8## where n is an integer between 2 and about 20, preferably 5 or 6. Use of this type of stabilizer improves long term thermal stability of the elastomer. Use of cyanoguanidine or stabilizer of Formula III in which n is 6, i.e. 1,6 Hexamethylene-bis-dicyandiamide (HMBD) is especially preferred.
Elastomer composition of the invention also includes between about 0.1 and about 5% by weight of said copolyester of diphenylamine derivative of the formula ##STR9## where R and R 1 are methyl or phenyl and between about 0.05 and about 3% by weight of said copolyester of phosphorus compound of the formula ##STR10## where R represents an alkyl radical having from 6 to about 22 carbon atoms or a hydrocarbon radical of the structure ##STR11## where t represents a tertiary butyl radical. Addition of these ingredients provides further unexpected improvement in thermal stability of elastomer of the invention.
Phosphorous compounds suitable for use in the invention include for instance
distearyl pentaerythritol diphosphite
dioctyl pentaerythritol diphosphite
diisodecyl pentaerythritol diphosphite
dimyristyl pentaerythritol diphosphite
bis(2,4 di-t-butyl phenyl) pentaerythritol diphosphite
Use of distearyl pentaerythritol diphosphite or bis(2,4 di-t-butyl phenyl) pentaerythritol diphosphite is preferred.
Small amounts of antioxidant stabilizer, such as between about 0.1 and about 5 wt % based on copolyester, are preferably included with the ingredients used in making copolyester for use in the invention. It is preferred that at least this small amount of antioxidant be present during polymerization of the copolyester in order to prevent excessive oxidation. Antioxidant consisting of 3,4-di-tert-butyl-4-hydroxyhydrocinnamic acid triester with 1,3,5-tris(2-hydroxy ethyl-s-triazine-2,4,6-(1H, 3H, 5H) trione is preferred but other suitable stabilizers may be used.
Compositions of the invention may include additional conventional ingredients such as UV absorbers, e.g. benzophenones or benzotriazoles. The properties of these compositions can also be modified by incorporation of various conventional inorganic fillers such as carbon black, silica gel, alumina, clays and chopped fiberglass. In general, these additives have the effect of increasing the modulus of the material at various elongations. Compounds having a range of hardness values can be obtained by blending hard and soft copolyesters of the invention. The copolyesters can also be compounded with other resins such as polyvinyl chloride or polybutylene terephthalate. Suitable flame retardant additives may also be used.
As mentioned above, at least small amounts of antioxidant are preferably used during polymerization of copolyester of the invention. Other essential and optional ingredients of compositions of the invention are preferably added by blending with previously polymerized copolyester. All such ingredients or portions thereof may, however, be present during polymerization of the copolyester so long as the polymerization reaction is not interfered with. Blending with copolyester may be carried out in any suitable manner such as in conventional mixing equipment with extrusion compounding being preferred.
Elastomers of the invention exhibit superior retention of mechanical properties, especially tensile strength, and improved brittleness characteristics at elevated temperatures. Such elastomers are especially suited for use in molding various articles such as tires, hoses, drive belts, gears, etc. Such elastomers can be made in grades of low melt flow rate. This permits faster molding cycle times and allows the manufacture of blow molding grades of elastomers of the invention.
Both cyanoguanidine (CNG) and guanidine stabilizers of formula III are quite effective for stabilizing elastomer of the type used in the invention. CNG will, however, plate out onto extrusion processing equipment. This results in extruded parts which have dull surfaces. Guanidine stabilizers of formula III tend to bloom, resulting in dull, greasy appearing surfaces on finished products. Use of PVP along with CNG or stabilizer of formula III in compositions of the invention substantially eliminates such plate-out or blooming and resulting dull surfaces on extruded products. Stability of elastomers of this type containing PVP or PVP plus guanidine is further improved by the use of diphenylamine and phosphorous stabilizer as described herein.
EXAMPLES
The following examples are intended to illustrate the invention without limiting the scope thereof.
In the examples presented herein, the following terms have the meanings given below.
DMT--dimethyl terephthalate
B 1 D--1,4-butanediol
B 2 D--1,4-butenediol
Poly(THF)--poly(tetramethylene oxide) glycol of number average molecular weight 1,000
TPT--tetra isopropyl titanate
Goodrite 3125--trade name for 3,5-di-tertbutyl-4-hydroxyhydrocinnamic acid triester with 1,3,5-tris-(2-hydroxyethyl)-s-triazine-2,4,6-(1H, 3H, 5H) trione
Naugard 445--trade name for α,α- dimethylbenzyl diphenyl amine (formula IV)
GT--weight percent of short chain ester units of formula II in elastomer of the invention
HMBD--1,6 Hexamethylene-bis-dicyandiamide
PVP--K-15 polyvinylpyrrolidone
CNG--cyanoguanidine
Weston 618--trade name for distearyl pentaerythritol diphosphite
Elastomer used in making the elastomer compositions referred to in the examples is commercially available elastomer (GAF Gaflex 555) having a melt flow rate of about 12 grams per 10 minutes (220° C., 2160 g) and a GT of 62. 25% of the D groups of formula II are derived from 1,4-butenediol with the remaining 75% being derived from 1,4-butanediol. This elastomer is made from the following ingredients:
______________________________________Ingredient Mols Grams______________________________________DMT 6.13 1189B.sub.1 D 4.98 448B.sub.2 D 2.34 206Poly (THF) 0.65 650Goodrite 3125 35TPT 1.3______________________________________
EXAMPLE 1
The elastomer described immediately above was pelleted and tumble blended with various additional ingredients as indicated in Table I below to form elastomer compositions. Each blend was then extruded into sheets using a one inch extruder equipped with a mixing screw and operated at a temperature of 200° C. ASTM D-412 test specimens were then made of each composition by die cutting. Test specimens were placed in a hot air convection oven at 145° C. and were tested initially and after two weeks in accordance with ASTM D-412. Percent elongation for each composition is reported in Table I below.
TABLE I______________________________________ % retention of Additional Amount elongation afterComposition Ingredients (wt %) 2 weeks (145° C.)______________________________________A none (control) 11.5B PVP 4.0 48 CNG 0.35 Naugard 445 1.5 Weston 618 0.5C PVP 1.5 100 CNG 0.35 Naugard 445 1.5 Weston 618 0.5______________________________________
EXAMPLE 2
The elastomer described above may be pelleted and tumble blended with various additional ingredients as indicated in Table I below to form elastomer compositions of the invention.
Such compositions may then be extruded or molded to form desired end products.
TABLE II______________________________________ Amount (wt % basedComposition Additional Ingredients on resin)______________________________________A 1,3 trimethylene-bis-dicyandiamide 1 Distearyl pentaerythritol 3 diphosphite Naugard 445 4 PVP 1B 1,10 decylmethylene-bis- 2.5 dicyandiamide bis(2,4 di-t-butyl phenyl) 2.0 pentaerythritol diphosphite Naugard 445 0.5 PVP 5.0C 1,16 hexadecylmethylene-bis- 4.5 dicyandiamide Dioctyl pentaerythritol diphosphite 1.5 methylphenyl benzyl 1.5 diphenyl amine PVP 10.0D 1,5 pentamethylene-bis- 0.5 dicyandiamide Naugard 445 1.5 Diisodecyl pentaerythritol 0.5 diphosphite PVP 15.0E HMBD 0.35 Naugard 445 1.5 Distearyl pentaerythritol 0.05 diphosphite PVP 20.0F HMBD 3.0 Naugard 445 3.0 Dimyristyl pentaerythritol 2.5 diphosphite PVP 25.0______________________________________
EXAMPLE 3
Elastomer compositions may also be formulated which are similar to those mentioned above but which use elastomers in which R groups of Formulas I and II are hydrocarbon radicals remaining after removal of carboxyl groups from terephthalic acid, D groups of formula II are divalent radicals remaining after removal of carboxyl groups from 1,4-butanediol and G of formula I is a divalent radical remaining after removal of terminal hydroxyl groups from poly(tetramethylene oxide) glycol. Such elastomers are available for example from E. I. duPont de Nemours and Company in several GT grades under the tradename Hytrel.
While the invention has been described above with respect to preferred embodiments thereof, it will be understood by those skilled the art that various changes and modifications may be made without departing from the spirit or scope of the invention.
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Segmented thermoplastic copolyester elastomers containing recurring polymeric long chain ester units derived from phthalic acids and long chain glycols and short chain ester units derived from phthalic acids and 1,4-butanediol or 1,4-butenediol. The elastomers also contain polyvinylpyrrolidone and preferably also contain guanidine stabilizer, phosphorus stabilizer and diphenylamine.
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This application claims priority to Taiwan Patent Application No. 101208199 filed on May 2, 2012.
BACKGROUND OF THE INVENTION
The present invention generally relates to a lock and the application thereof and, more particularly, to a lock capable of converting a horizontal axial rotation into a vertical displacement and the application thereof.
Electronic apparatus and storage devices in market are provided with a lock on the housing thereof to prevent access of components resided in the housing from people without authorization for security purpose. However, such lock currently available in market has disadvantages such as a large number of movable elements, a complex structure and a high cost.
It may therefore be desirable by one skilled in the art to provide a lock that allows a user to easily lock and unlock an object such as a cover plate of a housing with a simple, compact structure and low cost of.
BRIEF SUMMARY OF THE INVENTION
To achieve the aforesaid objective, examples of the present invention may provide a lock mounted to a base. The base has an inner surface and an outer surface. The lock comprises a lock plate and a motion module. The motion module has a curved surface facing the lock plate. The curved surface comprises a first surface and a second surface. A main feature of the present invention is that the lock has a close status and a far status. The lock plate abuts against the first surface and has a first distance from the base when the lock is in the close status, and abuts against the second surface and has a second distance, which is greater than the first distance, from the base when the lock is in the far status.
For example, the lock disclosed above comprises a fixed portion, a movable portion and an abutting portion in practical applications. The fixed portion is fixed to the inner surface of the base. The movable portion extends outwards from the fixed portion and can be elastically deformed under the action of an external force. The through-hole portion is formed in the movable portion and through the lock plate, and has a sidewall. The abutting portion extends in a normal direction from the sidewall and abuts against the curved surface of the lock to adjust a relative distance between the lock plate and the base. Furthermore, the fixed portion, the movable portion, the through-hole portion and the abutting portion are all selectively formed integrally with the lock plate (ONE PIECE FORMED).
The motion module further has an extending portion that extends vertically towards the base and extends through the through-hole portion to be pivotally connected with the through-hole portion. The base comprises a through-hole, and the motion module comprises an interfacing part having a head portion and a tail portion. The tail portion is fixed to an end of the extending portion and penetrates through the base to be pivotally connected with the base, and the head portion abuts against the outer surface of the base. Both the head portion and the extending portion have a cross-sectional area greater than that of the tail portion. Meanwhile, the motion module has two blocking surfaces, and the two blocking surfaces are disposed on the first surface and the second surface respectively and extend in a normal direction from the first surface and the second surface respectively to limit a rotation angle of the abutting portion.
Besides, an angle of smaller than 6° is included between the base and an extending direction of the movable portion of the lock plate. The motion module has a back surface facing away from the lock plate, and a vertical distance between the back surface and the base in the close status is the same as that in the far status. It is worth noting that, the lock of the present invention can be used in an electronic device or a computer housing.
According to the above descriptions, some examples of the present invention may provide a novel lock that allows the user to easily lock and unlock an object such as a cover plate of a housing effectively in a limited space. As compared to the prior art, the lock of the present invention has a simple structure, a low manufacturing cost and a small volume. Thereby, the long-lasting problem with the prior art is solved.
Some examples of the present invention may provide a lock applied to a base of an electronic device, the base has an inner surface and an outer surface, the lock comprises a lock plate comprising: a fixed portion; and a movable portion; and a motion module having a curved surface facing the lock plate, the curved surface comprising a first surface and a second surface.
Some examples of the present invention may provide a lock applied to a base of a computer housing, the base having an inner surface and an outer surface, the lock comprises a lock plate comprising: a fixed portion fixed to the inner surface of the base; a movable portion extending outwards from the fixed portion; a through-hole portion formed in the movable portion and through the lock plate, and the through-hole portion having a sidewall; and an abutting portion extending in an normal direction from the sidewall and abutting against the curved surface of the lock to adjust a relative distance between the lock plate and the base; and a motion module having a curved surface facing the lock plate, the curved surface comprising a first surface and a second surface, the motion module comprising: an extending portion extending vertically towards the base and extending through the through-hole portion; an interfacing part having a head portion and a tail portion, the tail portion is fixed to an end of the extending portion and penetrates through the base to be pivotally connected with the base, and the head portion abuts against the outer surface of the base, wherein both the head portion and the extending portion have a cross-sectional area greater than that of the tail portion; two blocking surfaces disposed on the first surface and the second surface respectively and extending in a normal direction from the first surface and the second surface respectively to limit a rotation angle of the abutting portion; and a back surface facing away from the lock plate.
Additional features and advantages of the present invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The features and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings examples which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
In the drawings:
FIG. 1A is an assembly diagram of elements of a lock in accordance with an embodiment of the present invention;
FIG. 1B is a partially cross-sectional front view of the lock in a close status in accordance with an embodiment of the present invention;
FIG. 1C is a partially cross-sectional back view of the lock in a far status in accordance with an embodiment of the present invention;
FIG. 2 is a schematic perspective view of a lock plate in accordance with an embodiment of the present invention;
FIG. 3 is a schematic perspective view of a motion module in accordance with an embodiment of the present invention;
FIG. 4A is a partially cross-sectional front view of a lock in a close status in accordance with another embodiment of the present invention; and
FIG. 4B is a partially cross-sectional back view of the lock in a close status in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the present examples of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
Hereinbelow, the aforesaid subject matter will be further described. The present invention relates to a lock that allows for locking and unlocking in a limited space. However, it shall be appreciated that, unless otherwise defined, all scientific and technical terms used in this specification shall have the same meanings as generally known by those skilled in the art. Additionally, what described in this specification is only some of various embodiments of the present invention, and any methods or devices similar to or equivalent to what described herein may be used in practical implementations of the present invention.
The wording “above or below” a numeric value as set forth herein shall be interpreted to include the numeric value itself. It shall be appreciated that, the wording “the present invention” and similar wordings used in this specification are all intended to mean the lock of the present invention. Furthermore, the sequence of steps of methods or flow processes used to execute disclosed functions in this specification shall not be limited to what described in this specification, but may be adjusted freely depending on the user's needs unless otherwise specified. Moreover, unless otherwise specified, the scale, sizes, relative positions and shapes of individual elements shown in the figures are all similar to what shall be in practical applications and this shall also be a basis for subsequent supplement or amendment of the specification. Considering that elements described in different embodiments of this specification have similar properties, like designations and reference numerals represent like elements throughout the attached drawings. Further, it shall be noted that, structural parts such as devices, modules and units set forth in this specification shall not be limited to hardware implementations independent of each other, but may also be integrated into a single unit.
Now, the lock of the present invention will be described. Referring to FIG. 1A through FIG. 1C together, FIG. 1A is an assembly diagram of a lock in accordance with an embodiment of the present invention, FIG. 1B is a partially cross-sectional front view of the lock in a close status S 1 in accordance with an embodiment of the present invention, and FIG. 1C is a partially cross-sectional back view of the lock in a far status S 2 in accordance with an embodiment of the present invention. Additionally, FIG. 1C has been turned over horizontally in order to distinguish FIG. 1B and FIG. 1C from each other. As can be seen, the lock 1 of the present invention is disposed on a base B to lock the base B to an external latching element L so that a relative position of the base B is maintained. The aforesaid base B generally refers to any object or a surface thereof on which the lock 1 of the present invention can be disposed. In this embodiment, the base B is a cover plate of a computer housing, but it is not limited thereto. The term “base B” may also refer to an electronic device, a door sheet, or any other object or a surface thereof that conforms to the aforesaid definition. The base B has an inner surface B 1 and an outer surface B 2 . The inner surface B 1 is defined as a surface of the base B that faces a lock plate 10 , and the outer surface B 2 is defined as the other surface of the base B that is opposite to the inner surface. Further, as can be known from the figures, the lock 1 of the present invention generally comprises the lock plate 10 and a motion module 20 . Taking FIG. 1A and FIG. 1B as an example, in the present invention, the lock plate 10 is sandwiched between the motion module 20 and the base B and, through axial rotation of the motion module 20 , the lock plate 10 is driven to abut against a surface of the motion module 20 so that the lock plate 10 is elastically deformed correspondingly in compliance with thickness variations of the surface of the motion module 20 . The lock 1 of the present invention has a close status S 1 and a far status S 2 depending on different relative positions of the lock plate 10 with respect to the base B. Simply speaking, the lock plate 10 is closer to the base B when the lock 1 is in the close status S 1 , and is farther from the base B when the lock 1 is in the far status S 2 . Thereby, the lock 1 of the present invention allows for locking and unlocking.
After having generally described the operation mode of the present invention, structures of the lock plate 10 and the motion module 20 will be described respectively now. Referring to FIG. 2 , there is shown a schematic perspective view of a lock plate of a lock in accordance with an embodiment of the present invention. The lock plate 10 refers to an element of the lock 1 that is used to mate with or abut against an external latching element L so that the base B and the lock 1 can be locked to each other. Furthermore, the lock plate 10 of the present invention generally has a fixed portion 11 , a movable portion 12 and a lock opening 13 .
The fixed portion 11 is disposed at an end of the lock plate 10 to fix the lock plate 10 to the surface of the base B. Taking FIG. 2 as an example, the fixed portion 11 is disposed on the lock plate 10 and comprises a large protrusion, a recess and a small protrusion so that the fixed portion 11 can be embedded into a corresponding structure of the base B. It shall be noted that, the large protrusion, the recess and the small protrusion illustrated herein are only provided as an example and are used to prevent wrong assembly by the user. However, the fixed portion 11 of the present invention is not limited to what described above, and any part or structure that is located on the surface of the lock plate 10 and used to connect the lock plate 10 to the surface of the base B can be considered as the fixed portion 11 of the lock plate 10 . Furthermore, the means for connection between the fixed portion 11 and the base B is not limited to the protrusions and the recess disclosed above, and the fixed portion 11 and the base B may also be fixed to each other through adhesion, soldering, snap-fitting and so on.
The movable portion 12 of the lock plate 10 is adjacent to the fixed portion 11 of the lock plate 10 , and extends outwards from the fixed portion 11 . The movable portion 12 can be elastically deformed under the action of a force to adjust a vertical position of the locking opening 13 . Furthermore, as depicted, an angle A is included between an extending direction of the movable portion 12 and a surface on which the fixed portion 11 is disposed. Taking the design of FIG. 2 as an example, the angle is approximately 6°, but it is not merely limited thereto. Rather, the angle may be changed or adjusted correspondingly depending on such factors as the size of the lock plate 10 , the position of the fixed portion 11 and the shape of the motion module 20 , and is preferably smaller than 20°. On the other hand, the surface of the movable portion 12 is formed with a through-hole portion 14 which has a sidewall 15 , and the through-hole portion 14 is used for inserting the motion module 20 therethrough. The sidewall 15 further has a protrusion for use as an abutting portion 16 . The abutting portion 16 extends from the sidewall 15 in a normal direction T of the sidewall 15 . The abutting portion 16 is used to abut against the curved surface 23 of the lock 1 so as to adjust a relative distance between the movable portion 12 of the lock plate 10 and the base B according to the shape of the curved surface 23 .
The lock opening 13 extends outwards from the movable portion 12 , and is used to interlock with or abut with an external latching element L for purpose of locking the base B.
Generally speaking, the fixed portion 11 of the lock plate 10 is fixed to the base, and the lock opening 13 can be elastically deformed correspondingly in compliance with the varying height of the movable portion 12 so that the lock 1 is switched between a locking status and an unlocking status. Incidentally, the fixed portion 11 , the movable portion 12 , the through-hole portion 14 and the abutting portion 16 may be (but not limited to) integrally formed with the lock plate 10 (ONE PIECE FORMED).
Referring next to FIG. 3 , there is shown a schematic perspective view of the motion module 20 of the lock 1 in accordance with an embodiment of the present invention. In the present invention, the motion module 20 generally refers to any object capable of controlling a vertical distance between the lock plate 10 and the base B so that the lock 1 can be switched between the locking status and the unlocking status by controlling the position of the lock plate 10 , or a combination of such objects. For example, in the design depicted in FIG. 3 , the motion module 20 has a main body 21 and an interfacing part 22 . The motion module 20 is disposed on the surface of the lock plate 10 and is adapted to apply a force to the lock plate 10 in a direction towards the base B. The motion module 20 has a curved surface 23 facing the lock plate 10 , and the curved surface 23 comprises a first surface 23 A and a second surface 23 B. As can be seen, the first surface 23 A and the second surface 23 B are disposed at two ends of the curved surface 23 respectively and have a different height or thickness from each other. Additionally, the motion module 20 has two blocking surfaces 24 , which are disposed on the first surface 23 A and the second surface 23 B respectively and extend outwards in a normal direction from the first surface 23 A and the second surface 23 B respectively to limit a rotation angle of the abutting portion 16 . Besides, the motion module 20 has an extending portion 25 , which extends vertically towards the base B and is formed with a hollow hole portion 26 for another element to be inserted therein. Meanwhile, the motion module 20 further comprises an interfacing part 22 corresponding to the hollow hole portion 26 . The interfacing part 22 has a head portion 221 and a tail portion 222 . The tail portion 222 is fixed to an end of the extending portion 25 and extends through the hole of the base B to be pivotally connected with the base B, and the head portion 221 abuts against the outer surface of the base B. To achieve the aforesaid effect, the hole of the base B must have a horizontal cross-section area smaller than that of the head portion 221 and the extending portion 25 . Meanwhile, the tail portion 222 is connected into the hollow hole portion 26 through a conventional means so as to move along with the motion module 20 . For example, as shown in this figure, the hollow hole portion 26 and the interfacing portion are fixed with respect to each other by an adhesive or a thread structure. Furthermore, the outer surface of the head portion 221 is formed with a recess so that an unlocking tool can be inserted therein to rotate the interfacing part 22 . However, the present invention is not limited to the form of a recess, and the recess may also be replaced by a manually operated screw or other tool-free designs depending on the design requirements. Additionally, the reference plane of the aforesaid horizontal cross-sectional area is parallel to the base B.
Next, how the lock of the present invention is used and relationships among individual elements will be further described. Referring back to FIG. 1B and FIG. 1C , the motion module 20 is disposed on the other surface of the lock plate 10 opposite to the base B and is connected to the base B via an extending portion 25 that extends through the base B. After being fixed to the base B, the motion module 20 can only rotate axially and the position thereof or the maximum distance between the motion module 20 and the base B becomes invariable. Meanwhile, the abutting portion 16 of the lock plate 10 will abut against any position of the curved surface 23 of the motion module 20 .
Furthermore, the lock 1 has a close status S 1 and a far status S 2 in use. When the lock 1 is in the close status S 1 , the abutting portion 16 of the lock plate 10 abuts against the first surface 23 A and has a first distance D 1 from the base B; and when the lock 1 is in the far status S 2 , the abutting portion 16 of the locking plate 10 abuts against the second surface 23 B and has a second distance D 2 from the base B. It shall be appreciated that, switching between the first surface 23 A and the second surface 23 B of the motion module 20 has no influence on the position of the motion module 20 relative to the base B. It shall be emphasized again that, the motion module 20 can only rotate axially with respect to the base B but cannot perform other axial movements, so the distance between a back surface 27 of the motion module 20 and the base is invariable. Incidentally, the first distance D 1 and the second distance D 2 are defined as respective minimum vertical distances between the abutting portion 16 of the lock plate 10 and the base B. Simply speaking, the close status S 1 refers to a status in which the lock plate 10 is closer to the base B, while the far status S 2 refers to a status in which the lock plate 10 is farther from the base B.
Referring to FIG. 1A again, as can be seen, the motion module 20 has a back surface 27 , which is defined as a surface of the motion module 20 opposite to the curved surface 23 . When the lock 1 is disposed in the close status S 1 and the far status S 2 , the vertical distance between the back surface 27 and the base B remains unchanged and is not affected by variations of the distance between the lock plate 10 and the base B.
More specifically, when the first surface 23 A at a higher level abuts against the abutting portion 16 of the lock plate 10 , the lock plate 10 is pressed to be elastically deformed towards the base B to move closer to the base B, as shown in FIG. 1B . On the other hand, when the second surface 23 B at a lower level abuts against the abutting portion 16 of the lock plate 10 , the lock plate 10 is elastically deformed, with the fixed portion 11 being as a fulcrum, in a direction opposite to the base B to move away from the base B, as shown in FIG. 1C . Through the aforesaid operations and through use of an external latching element L, the lock 1 of the present invention can be switched between the locking status and the unlocking status. It shall be appreciated that, switching between the first surface 23 A and the second surface 23 B of the motion module 20 is accomplished through the horizontal axial rotation of the motion module 20 itself, and the vertical distance between the back surface 27 of the motion module 20 and the base B is not affected by variations of the distance between the lock plate 10 and the base B.
It shall also be emphasized that, any module that has a curved surface 23 for the abutting portion 16 to abut against and that can utilize the curved surface 23 to adjust the relative vertical position between the lock plate 10 and the base B can be considered as the motion module 20 of the present invention. For example, besides the design depicted in FIG. 1A , the motion module 20 may also be disposed between the lock plate 10 and the base B with the curved surface 23 thereof facing the lock plate 20 to accomplish the aforesaid movements as shown in FIG. 4A and FIG. 4B . In the latter case, the motion module 20 may selectively comprise a reset element 28 (e.g., a spring or a reed) for applying a force to the lock plate 10 in a direction towards or opposite to the base B. However, the motion module 20 is not limited to having the aforesaid reset element 28 , but may also be reset by virtue of elasticity of the lock plate 10 itself. Furthermore, because FIG. 4A and FIG. 4B correspond to FIG. 1B and FIG. 1C respectively, reference may be made to the above descriptions for design of individual elements and no further description will be made herein again. This design is different from the design depicted in FIG. 1A in that, the blocking surfaces 24 are omitted, so a user may lock and unlock the lock in a clockwise or counterclockwise direction and the rotation direction of the motion module during the locking and unlocking operations is not limited. Moreover, the lock of the present invention may also be adjusted to operate reversely, i.e., the locking and unlocking operations are accomplished by having motion module move together with the external latching element and sandwiching the lock plate therebetween.
According to the above descriptions, the present invention provides a novel lock that allows the user to easily lock and unlock an object such as a cover plate of a housing effectively in a limited space. As compared to the prior art, the lock of the present invention has a simple structure, a low manufacturing cost and a small volume. Thereby, the long-lasting problem with the prior art is solved.
The detailed descriptions of the preferred embodiments of the present invention are provided to disclose the features and spirits of the present invention more clearly but not to limit the scope of the present invention thereto. Rather, it is intended to cover various modifications and equivalent arrangements into the scope claimed in the present invention. Accordingly, the scope claimed in the present invention shall be interpreted in the broadest sense to cover all possible modifications and equivalent arrangements.
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The present invention discloses a lock and the application thereof. The lock is applied on a base having an inner surface and an outer surface. The lock comprises a locking plate and a motion module. The motion module has a curved surface facing the locking plate. The curved surface has a first surface and a second surface. A main feature of the present invention is that the lock has a close status and a far status. The locking plate contacts with the first surface and has a first distance from the base in the close status, and contacts with the second surface of the base and has a second distance, which is greater than the first distance, from the base in the far status. The invention has the advantages of low cost and simplicity, and solves the long lasting problem of the prior arts.
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TECHNICAL FIELD
[0001] The present invention relates to an interconnected cell porous body and a manufacturing method for the interconnected cell porous body.
BACKGROUND ART
[0002] Porous bodies are solids containing many pores. The structure in which these pores are connected to each other is called interconnected cell structure. Porous bodies having the interconnected cell structure often have a property of absorbing liquid.
[0003] For example, polyurethane foams having the interconnected cell structure have been used widely as cleaning sponges for tableware, because of their favorable water-absorbing efficiency. In addition, polyurethane foams and phenol foams having the interconnected cell structure have been used as flower-arrangement holders. Interconnected cell porous bodies are used in this application because of their water-absorbing efficiency and such a product has a function to keep flowers fresh for an extended period of time. Alternatively, in the field of agriculture, interconnected-cell porous bodies obtained by bonding rock wools are being used as a medium for use for example in nutriculture. An interconnected-cell porous body used in this application has functions to hold firmly the root of plants to be cultivated and supply nutrient-containing water to the plants by absorbing it by itself.
[0004] As described above, interconnected-cell porous bodies are very useful. In addition, among the interconnected-cell porous bodies for use as flower-arrangement holders and media for example for plant nutriculture, those that are made of a biodegradable resin are easily decomposed in the environment and thus have an advantage that they can be disposed easily after use and thus, they are highly useful.
[0005] Patent Document 1 discloses, as such a biodegradable porous body, a porous polylactic acid material of a polymer containing lactic acid as a principal component and having interconnected pores of an average pore size of 1 to 30 μm. The porous body is prepared by dissolving a polymer containing lactic acid as a principal component and a copolymer of a water-soluble polyalkylene ether and lactic acid in a solvent, drying the solution to solid matter, and removing the copolymer by elution with another liquid. However, this production method is very complicated in procedure and has a problem that it easily leads to increase in cost. Although a film-shaped product can be prepared easily the production method also has problems that the interconnected structure can change easily during drying and it is difficult to obtain products with relatively larger thickness.
[0006] Alternatively, Patent Document 2 discloses an interconnected-cell body containing as a principal component a biodegradable plastic that is manufactured by blending, extruding, and expanding a mixture of a biodegradable resin, an expanding agent, an inorganic filler and others, and a flower-arrangement holder produced from the same. However, it is difficult to obtain a favorable interconnected cell structure only by molding a biodegradable plastic together with an expanding agent or the like. In addition, the extrusion expanding method has limitation in the shape of the molding obtained and does not always permit molding into a desired shape.
[0007] Yet alternatively, Patent Document 3 discloses use of a foam of an aliphatic polyester such as a polylactic acid resin as a flower-arrangement holder. However, the aliphatic polyester resin foam does not have a pore structure suitable for water absorption, although it is an interconnected cell foam, and thus absorbs water slowly and shows insufficient water-absorbing efficiency.
[0008] Patent Document 4 discloses a production method of preparing a foam by pressurizing expandable particles having a polymer coat in a mold, thus performing heating without use of steam, and describes that pulverized particles obtained from the foam by recycling were used as the expandable particles. However, Patent Document 4 uses preliminary expanded particles of an expandable polyolefin or styrene polymer as expandable particles and there is no description on biodegradable polymers in the Patent Document 4. Patent Document 4 also does not contain any description on pulverized particles Obtained from the foam. Patent Document 4 further does not contain any description on foams having an interconnected cell structure.
CITATION LIST
Patent Literature
[0009] Patent Document 1: JP-A No. 2006-306983
[0010] Patent Document 2: JP-A No. 2000-217683
[0011] Patent Document 3: WO2009/119325
[0012] Patent Document 4: JP-A No. 2009-506149
SUMMARY OF INVENTION
Technical Problem
[0013] An object of the present invention is to provide a porous body having an interconnected cell structure that can absorb water, and being made of a biodegradable resin, which can be disposed easily after use because it is degradable in the environment, and a production method thereof.
[0014] Another object of the invention is to provide a method of producing an interconnected cell porous body made of such a biodegradable resin, permitting production of large-sized moldings uniform in the thermal bonding state both in the internal and external regions thereof, easily and at high productivity in a short period of time.
[0015] Yet another object of the present invention is to provide a water-absorbing material that absorbs water and is biodegradable.
Solution to Problem
[0016] After intensive studies to achieve the objects above, the inventors have found that a porous body of a resin composition containing polylactic acid resin as a principal component, in which micropore walls manufactured by bonding of powdery fragments obtained by pulverization of the foam thereof forms an interconnected cell structure, has a favorable interconnected cell structure and shows excellent water-absorbing efficiency. The inventors have also found that the porous body above shows extremely favorable water-absorbing efficiency when it contains a certain amount of a surfactant. The inventors also found that it is possible to obtain a large-sized molding made of a powder of a resin composition containing a polylactic acid resin as a principal component, in which the powdery fragments are thermally bonded to each other uniformly, by heating the interconnected cell porous body during molding in an atmosphere containing steam at a temperature of 60 and 140° C. and a relative humidity 20% or more. The present invention was made based on these findings.
[0017] The present invention provides an interconnected cell porous body comprising a resin composition containing a polylactic acid resin as a principal component, wherein: the micropore walls formed by mutual bonding of powdery fragments obtained by pulverization of a foam of the resin composition form an interconnected cell structure of the porous body; the apparent density of the interconnected cell porous body is 0.01 g/cm 3 or more and 0.2 g/cm 3 or less; the 10% compressive stress of the interconnected cell porous body is 0.02 MPa or more and 0.3 MPa or less; and the compression recovery rate of the interconnected cell porous body is 95% or less.
[0018] In an embodiment, the powdery fragments are bonded to each other by thermal bonding.
[0019] In an embodiment, the powder has a bulk density of 0.001 g/cm 3 or more and 0.1 g/cm 3 or less.
[0020] In an embodiment, the powder has an average diameter of 100/μm or more and 2,000 μm or less.
[0021] In an embodiment, the foam of the resin composition is hydrolyzed.
[0022] In an embodiment, the interconnected cell porous body contains a surfactant.
[0023] The present invention also relates to a method of producing an interconnected cell porous body including a resin composition containing a polylactic acid resin as a principal component, wherein the porous body has an apparent density of 0.01 g/cm 3 or more and 0.2 g/cm 3 or less, a 10% compressive stress of 0.02 MPa or more and 0.3 MPa or less and a compression recovery rate of 95% or less.
[0024] Provided is a method of producing an interconnected cell porous body characterized by containing steps (1) to (3):
(1) a foam-preparing step of preparing a foam by expanding a resin composition containing a polylactic acid resin as a principal component, (2) a powder-preparing step of preparing a powder by pulverization of the foam, and (3) a porous body-preparing step of preparing a porous body having an interconnected cell structure by molding the powder into a particular shape, bonding the powdery fragments of the foam to each other and thus forming micropore walls.
[0028] In an embodiment, the thermal bonding is performed by heating.
[0029] In an embodiment, the heating is performed under an atmosphere containing steam at a temperature of 60 to 140° C. and a relative humidity of 20% or more.
[0030] In another embodiment, the heating is performed under an atmosphere at a relative humidity of 60 to 100%.
[0031] In an embodiment, the powder has a bulk density of 0.001 g/cm 3 or more and 0.1 g/cm 3 or less.
[0032] In an embodiment, the powder has an average diameter of 100 μm or more and 2,000 μm or less.
[0033] In an embodiment, the foam is hydrolyzed after the foam-preparing step and before the powder-preparing step.
[0034] In an embodiment, the interconnected cell porous body contains a surfactant that is added in the foam-preparing step or in the porous body-preparing step.
[0035] The present invention also provides a water-absorbing material including the interconnected cell porous body of the present invention or an interconnected cell porous body manufactured by the production method of the present invention.
Advantageous Effects of Invention
[0036] The interconnected cell porous body of the present invention is manufactured by a simple method of molding a powder prepared by pulverization of a foam. The interconnected cell porous body of the present invention shows water-absorbing efficiency because the micropore walls formed by mutual bonding of the powdery fragments obtained by pulverization of the foam of the resin composition form an interconnected cell structure that is uniform over the entire region of the porous body. In addition, the interconnected cell porous body of the present invention shows relative low stress to compressive deformation and relative low recovery rate after compression. For that reason, the interconnected cell porous body of the present invention can be used as a flower-arrangement holder or a medium for nutriculture of plants very favorably. In addition, the interconnected cell porous body of the present invention, which comprises a biodegradable resin composition containing a polylactic acid resin as a principal component and is degradable in the environment, can be disposed easily after use.
[0037] The interconnected cell porous body of the present invention shows higher water-absorbing efficiency when it contains a surfactant and can be used favorably as a flower-arrangement holder or a medium for plants.
[0038] It is possible by the method of producing an interconnected cell porous body of the present invention to produce, easily and at high productivity, a large-sized interconnected cell porous body including the powder of a polylactic acid resin, in which the powdery fragments are thermally bonded to each other uniformly.
[0039] The water-absorbing material of the present invention, which has an interconnected cell structure and is superior in water absorbing efficiency, can be used favorably as a flower-arrangement holder or a medium for plants. Further, the water-absorbing material of the present invention, which comprises a biodegradable resin composition containing a polylactic acid resin as a principal component and is degradable in the environment, can be disposed easily after use.
BRIEF DESCRIPTION OF DRAWINGS
[0040] FIG. 1 is a micrograph of the cross section of an interconnected cell porous body obtained by molding a powder obtained by pulverization of a polylactic acid resin foam.
[0041] FIG. 2 is a micrograph of a powder obtained by pulverization of a polylactic acid resin foam.
[0042] FIG. 3 is a micrograph of the cross section of a polylactic acid resin foam (particles) before pulverization.
DESCRIPTION OF EMBODIMENTS
[0043] The interconnected cell porous body of the present invention comprises a resin composition containing a polylactic acid resin as its principal component, in which micropore wails formed by mutual binding of the powdery fragments (see FIG. 2 ), which are obtained by pulverization of the resin composition foam (see FIG. 3 ), form an interconnected cell structure (see, for example, FIG. 1 ).
[0044] The interconnected cell porous body of the present invention contains, as the base resin, a resin composition containing a polylactic acid resin as its principal component. The polylactic acid resin is a resin containing polylactic acid in an amount of 50 wt % or more. The polylactic acid resin has advantages such as thermoplasticity and relatively favorable processability. In addition, the polylactic acid resin, which shows favorable biodegradability, has an advantage that there is no particular treatment required before disposal after used as a flower-arrangement holder or as an agricultural horticultural material such as a medium for plant nutriculture.
[0045] A polylactic acid resin mainly containing a polylactic acid ha ring a lactic acid component isomer ratio of 5% or more, preferably 8% or more, is favorable, because the resin is substantially amorphous and it is possible to easily obtain a low-density foam because of its favorable expandability and moldability.
[0046] The polylactic acid resin for use in the present invention is not particularly limited, and a commercially available polylactic acid may be use as it is. For preparation of a lower-density (higher-expansion-ratio) foam, a polylactic acid resin having a melt viscosity increased by addition of a crosslinking agent may be used. In particular, the crosslinking agent for use is preferably an isocyanate compound, which can increase the melt viscosity of polylactic acid efficiently. The polyisocyanate compound may be an aromatic or aliphatic polyisocyanate. Examples of the aromatic polyisocyanates include polyisocyanate compounds having tolylene, diphenylmethane, naphthylene or triphenylmethane as the skeleton. Alternatively, examples of the alicyclic polyisocyanates include polyisocyanate compounds having isophorone or hydrogenated diphenylmethane as the skeleton. Yet alternatively, examples of the aliphatic polyisocyanates include polyisocyanate compounds having hexamethylene or lysine as the skeleton. Although any one of these polyisocyanates may be used, tolylene- or diphenylmethane-based polyisocyanates are used favorably, and diphenylmethane-based polyisocyanates are used particularly favorably from the points of flexibility in use, handleability and others.
[0047] In the present invention, a biodegradable resin other than the polylactic acid resin may be also used. Examples of the biodegradable resins include aliphatic polyester resins including hydroxy acid polycondensates such as poly(3-hydroxybutyrate), poly(3-hydroxybutyrate-co-valerate), and poly(3-hydroxybutyrate-co-hexanoate); lactone-based ring-opening polymerization polymers such as polycaprolactone; resins mainly containing a polycondensate from an aliphatic polyvalent alcohol and an aliphatic polyvalent carboxylic acid, such as polybutylene succinate, polybutylene adipate, polybutylene succinate adipate, and poly(butylene adipate/terephthalate), and synthetic polymers such as polyvinylalcohol, polyethylene glycol and polyvinylpyrrolidone; proteins such as gelatin, collagen, zein, and fibroin; cellulose derivatives such as cellulose, acetylcellulose, methylcellulose, hydroxypropylcellulose, chitin, and chitosan. The biodegradable resins may be used alone or in combination of two or more in the polylactic acid resin.
[0048] The resin composition for use in the present invention may contain a resin other than biodegradable resin in an amount of less than 10 wt %, if the advantageous effects of the present invention are not hindered. Typical examples thereof include polyethylene resins, polypropylene resins, polystyrene resins, polyamide resins, polyether resins, acrylic resins, vinyl resins, and aromatic polyester resins. These polymers may be used alone or in combination of two or more in the polylactic acid resin.
[0049] The melt flow rate of the polylactic acid resin of the present invention is not particularly limited, but it is likely possible to obtain low-density product easily by adjusting the melt flow rate (hereinafter, referred to simply as “MFR”) of the polylactic acid resin constituting the foam in the range of 0.001 to 10 g/10 minute.
[0050] The MFR of the polylactic acid resin is a value determined in accordance with JIS K7210 at 190° C. and 2.16 kg.
[0051] The powder for use in the present invention is powdery fragments of the foam of the resin composition containing the polylactic acid resin as a principal component, which can be obtained by pulverization of the foam. The pulverization of the foam can be carried out easily by using any known technology. Typical favorable examples include methods of using a pulverizer such as jet mill, cutter mill, ball mill, spiral mill, hammer mill, or oscillator. A method of separating only sufficiently pulverized powder by screening the product discharged from the pulverizer may be used in combination. For prevention of thermal fusion of the base resin during pulverization, it is favorably possible to use a method of cooling the foam or the pulverizer.
[0052] The powdery fragments obtained by pulverization of the foam have a fine structure containing flaky regions derived from the cell walls of the original foam (see, for example, FIG. 2 ). The powder also has low bulk density. It is possible in this way to make the interconnected cell porous body lighter and the internal pore rate larger and thus to make the water absorption per volume significantly larger.
[0053] In order to prepare the powder having a fine structure described above, it is preferable to control the average pore diameter of the foam before pulverization (see, for example, FIG. 3 ) in the range of 100 μm or more and 1,000 μm or less, more preferably 150 μm or more and 700 μm or less. When the average pore diameter of the foam is less than 100 μm, the powder may contain independent pores, leading to reduced water-absorbing efficiency. Alternatively, when it is more than 1,000 μm, the powder may have increased bulk density.
[0054] The average diameter of the powder may vary depending on the properties of the desired porous body, but is preferably 100 μm or more and 2,000 μm or less. When the average diameter of the powder is less than 100 μm, the powder may have increased bulk density. Alternatively, when the average diameter of the powder is more than 2,000 μm, the powder may contain independent pores, leading to reduced water-absorbing efficiency. The average diameter, as used in the present invention, means a diameter at an integrated percentage of 50% in the particle size distribution by weight of dry screened particles, as determined by the dry sieving test method specified in JIS K0069. Specifically, the integrated percentage (%) of the particles screened in the test, which is performed by using the standard screens specified in JIS Z8801-1, is plotted against the opening of each screen and the respective points are bonded with a straight line, and the value of the opening at an integration percentage of 50% in the graph is used as the average diameter.
[0055] The bulk density of the powder seems to be dependent on the density of the foam supplied to the pulverization processing and the shape of the powder, and generally, lower apparent density of the foam and also larger aspect ratio of the powdery fragments leads to smaller bulk density.
[0056] The bulk density of the powder is preferably 0.001 g/cm 3 or more and 0.1 g/cm 3 or less, more preferably 0.002 g/cm 3 or more and 0.05 g/cm 3 or less.
[0057] The bulk density of the powder is determined in accordance with JIS K6911 and can be calculated from the Formula (1) below.
[0000] Bulk density of powder (g/cm 3 )=[Mass of graduated cylinder containing sample (g)−mass of graduated cylinder (g)]/[Volume of graduated cylinder (cm 3 )] (1)
[0058] The powder for use in the present invention may be hydrolyzed for adjustment of the hardness. Especially, when the interconnected cell porous body obtained in the present invention is used as a flower-arrangement holder or a medium for plants, the hydrolysis treatment makes the interconnected cell porous body brittler, allowing adjustment of the hardness thereof to a degree suitable for its application.
[0059] If the powder is to be hydrolyzed, the hydrolysis is preferably carried out before pulverization. An example of favorable hydrolysis condition is high temperature and high humidity (specifically, a temperature of 40° C. or higher and 140° C. or lower, preferably 60° C. or higher and 100° C. or lower, and a relative humidity of 60% RH more, more preferably 80% RH or more), and the treatment period is generally 3 hours or more and 48 hours or less, although it depends on the kind of the base resin constituting the foam before treatment. For reduction of the hydrolysis period, the hydrolysis may be performed by using an alkali vapor containing a trace amount of alkali components.
[0060] The means for performing the hydrolysis treatment is not particularly limited, but it is for example a method of using a batchwise heat-treatment oven having a temperature- and a moisture-conditioning function of controlling the atmosphere in the chamber at a relative humidity by using steam or alkali vapor.
[0061] The apparent density of the interconnected cell porous body of the present invention is preferably 0.01 g/cm 3 or more and 0.2 g/cm 3 or less, more preferably 0.02 g/cm 3 or more and 0.1 g/cm 3 or less, from the points of light weight, water-absorbing efficiency, and favorable mechanical strength.
[0062] The apparent density of the interconnected cell porous body is a value obtained by cutting the porous body into cubes of 3 cm×3 cm×3 cm, weighing one of the cubes, and calculating from the following Formula (2):
[0000] Apparent density (g/cm 3 )=[Weight of cube (g)]/[27 (cm 3 )] (2)
[0063] The interconnected cell porous body of the present invention shows relative low stress in response to compressive deformation. Specifically, the 10% compressive stress of the interconnected cell porous body of the present invention is 0.02 MPa or more and 0.3 MPa or less, and preferably 0.03 MPa or more and 0.25 MPa or less.
[0064] The 10% compressive stress is determined in accordance with JIS K7220.
[0065] The interconnected cell porous body of the present invention shows relative low recovery rate after compression. Specifically, the interconnected cell porous body of the present invention has a recovery rate of 95% or less, when it is compressed by 10% and then recovered.
[0066] The recovery rate is a value calculated from the thickness of the porous body after the porous body (length 4 cm×width 4 cm×thickness 2.5 cm) is pressed by 10% (to 90% of the original thickness) under load by a press at normal temperature for 1 minutes and, then after removal of the load, recovered as it is left still at normal temperature for 1 day (i.e., post-recovery thickness), in accordance with the following Formula (3):
[0000] Recovery rate (%)=[Post-recovery thickness (mm)/Original thickness (mm)]×100 (3)
[0067] The interconnected cell porous body of the present invention can be prepared by bonding powdery fragments obtained by pulverization of the foam to each other. The bonding of powdery fragments means that the powdery fragments are bonded to each other locally. The method of bonding the powdery fragments to each other is not particularly limited but, in a favorable embodiment, the powdery fragments are bonded to each other as they are fused under heat.
[0068] A typical production method for the interconnected cell porous body of the present invention includes,
(1) a foam-preparing step of preparing a foam by expanding a resin composition containing a polylactic acid resin as a principal component, (2) a powder-preparing step of preparing a powder by pulverization of the foam, and (3) a porous body-preparing step of preparing a porous body having an interconnected cell structure by molding the powder into a particular shape, bonding powdery fragments of the foam to each other, and thus forming micropore walls.
[0072] In the step (1), a foam is prepared by using the resin composition described above containing a polylactic acid resin as a principal component. Any known method may be used favorably as the method for preparing the foam. Examples thereof include the extrusion foaming method described in JP-A No. 2005-162804, the bead method described in JP-A No. 2004-149649.
[0073] Then in step (2), a powder is prepared by pulverization of the foam. The pulverization method was already described.
[0074] Further in step (3), a porous body having an interconnected cell structure is prepared by forming micropore walls by bonding the powdery fragments of the foam to each other. The bonding method is not particularly limited, but bonding by thermal bonding is preferable, and thermal bonding under heat is more preferable.
[0075] Typical examples of preparing a porous body by bonding the powdery fragments of the form to each other under heat include a method of placing the powder in a mold, heating the powder at a temperature allowing softening and thermally bonding of the powder but not allowing fusion, and treating the powder at the temperature for a particular time, a method of thermally bonding the powder by feeding the powder gradually onto a hot plate adjusted to a temperature allowing softening and thermal bonding but not allowing fusion of the powder.
[0076] The temperature then may vary, for example, depending on the kind of the base resin constituting the powder and the shape and size of the desired porous body but it is preferably 80° C. or higher and 200° C. or lower, in the case where the powder is not heated under an atmosphere containing steam, as will be described below. A temperature of lower than 80° C. may result in insufficient thermal bonding, possibly prohibiting production of a sufficiently solidified interconnected cell porous body. Alternatively, a temperature of higher than 200° C. may result in excessive increase of the density of the porous body, giving an interconnected cell porous body inferior in water-absorbing efficiency.
[0077] The heat-treatment period may also vary depending on the kind of the base resin constituting the powder, the shape and size of the desired interconnected cell porous body the treatment temperature, processing method and others, but it is preferably 10 minutes or more and 24 hours or less, if the heat treatment is carried out in an atmosphere containing steam. A heat-treatment period of shorter than 10 minutes may result in insufficient progress of the thermal bonding of the powder, prohibiting production of a sufficiently solidified interconnected cell porous body. For example, when a relatively large porous body for example a block-shaped interconnected cell porous body with a size of 11 cm×23 cm×8 cm, which is a general size for use as a flower-arrangement holder, is prepared, the heat-treatment period may become longer. Alternatively, when the heat-treatment period exceeds 24 hours, the interconnected cell porous body obtained may shrink and have increased density over time.
[0078] Further, in the method of thermally bonding the powdery fragments of the foam to each other under heat, it is preferable to perform heating in an atmosphere containing steam at a temperature of 60 to 140° C. and a relative humidity of 20% or more. It is possible by the production method to perform thermal bonding of the powdery fragments to each other efficiently. Although the reasons for the effect is not necessarily clear, it is probably because the steam, which has relative large heat capacity, increases the efficiency of heat transfer to the powder and, as the polylactic acid resin has relative high steam permeability, the steam penetrates into the pores of the powder relatively easily, allowing efficient heating of the internal region of the powder.
[0079] The lowest allowable temperature f the atmosphere containing steam is preferably 60° C. or higher, and more preferably 70° C. or higher. When the lowest allowable temperature of the atmosphere containing steam is less than 60° C., the time needed for mutual thermal bonding of the powder may be elongated, resulting in insufficient thermal bonding.
[0080] Alternatively, the highest allowable temperature of the atmosphere containing steam is preferably 140° C. or lower, and more preferably 120° C. or lower. When the highest allowable temperature of the atmosphere containing steam is more than 140° C., shrinkage associated with thermal bonding may be amplified.
[0081] The most favorable example of the atmosphere containing steam is an atmosphere of a mixture of steam and air at a particular temperature under normal pressure. An atmosphere only of steam at a particular temperature under normal pressure may also be favorably in the present invention. For adjustment of the atmosphere temperature, an atmosphere of a mixture of steam and air or only of steam at a particular temperature under increased pressure or under reduced pressure can also be used favorably. When pressurized atmosphere is used, the pressure may be determined properly depending on the desired temperature and steam/air ratio, but it is normally in the range from normal pressure to 0.3 MPa as absolute pressure, and when reduced-pressure atmosphere is used, the pressure is normally in the range from 0.04 MPa to normal pressure as absolute pressure.
[0082] The atmosphere containing steam above may contain a vapor component other than steam and air in a small amount for acceleration of the thermal bonding of the powder, and typical examples thereof include lower alcohols such as methanol and ethanol; lower ethers such as dimethylether and diethylether; and lower ketones such as acetone and methylethylketone. Normally, the content of the vapor component other than steam and air is 10% or less by weight.
[0083] The specific method of achieving the atmosphere containing steam above is not particularly limited, and a typical example that is favorable from the viewpoint of powder molding is a method of using a batchwise heat-treatment oven having a temperature- and humidity-controlling function. Another favorable typical example is a method of preparing a particular atmosphere in a continuous oven having a function of transporting the powder by blowing a mixture of steam and air into the oven. In such a case, a method of controlling the condition of the atmosphere in the oven for example by adjusting the amount of the mixture blown in, in accordance with the observed temperature of the oven is also used favorably.
[0084] Particularly preferably, among the atmospheres containing steam for use in the present invention described above, the atmosphere is substantially at normal pressure and has a relative humidity of 60 to 100% for easier preservation of the atmospheric condition. When the atmosphere's relative humidity is less than 60%, the treatment period needed for mutual thermal bonding of the powdery fragments obtained by pulverization of the foam may be elongated.
[0085] The condition of the atmosphere containing steam needed for the heat treatment of the present invention has been described. The period of the heat treatment may vary significantly depending on the kind of the base substrate used, the condition of the atmosphere, and the size of the desired interconnected cell porous body and can be determined properly, but it is approximately 2 minutes to 3 hours. For example, the treatment period needed for folding a block-shaped interconnected cell porous body having a size of 11 cm×23 cm×8 cm, which is a general size for flower-arrangement holders, is in the range from approximately 2 to 40 minutes.
[0086] A specific method of producing an interconnected cell porous body preferably used is, for example, a method of placing a powder or a mixture of a powder and any other components described below in a mold haying a desired size and heat-treating it, as it is placed in the mold. The shape of the mold then is not particularly limited, but it is preferable that the mold has an opening allowing penetration of steam at least in part of it, because steam can penetrate into the powder more efficiently. Specifically, a mold having an opening on the top face or a mold having many small holes permitting sufficient flow of steam may be used.
[0087] Although the method of filling the powder in a mold and the filling state of the powder are not particularly limited in the present invention, the filling density of the powder during molding is preferably uniform so that the resulting molding has a uniform density over the entire region. Thus for that purpose, a method of packing the powder partially or entirely in a mold and tapping the mold or a method of packing the powder partially or entirely in a mold and vibrating the mold for uniformization of the filling density is used favorably in the present invention.
[0088] Another typical favorable method of molding an interconnected cell porous body is a method of preparing a preliminary molding by molding a powder or a mixture of a powder and any other components described below, either in a mold or continuously under slight compression, and heat-treating the preliminary molding.
[0089] Thus, it is possible by the production method of the present invention to obtain an interconnected cell porous body and mold it into a shape suitable for its application, such as block or sheet.
[0090] The interconnected cell porous body of the present invention may contain various additives as additional components, if the advantageous effects of the present invention are not hindered. Typical examples of the additives include surfactants; pigments; dyes; inorganic materials such as talc, calcium carbonate, borax, zinc borate, aluminum hydroxide, and calcium stearate; flame retardants; antistatic agents; weathering agents; fillers; anti-fogging agents; antibacterial agents; lubricants; nutrients and the like. These additives can be added, for example, by mixing with the powder during heated molding or by mixing previously with the base resin constituting the powder.
[0091] In the present invention, especially when the interconnected cell porous body is used in applications demanding water absorption such as a flower-arrangement holder and a medium for plants, addition of a surfactant is effective for expression of more favorable water-absorbing efficiency.
[0092] The content of the surfactant in the present invention is 0.1 wt % or more and 30 wt % or less, and preferably 2 wt % or more and 20 wt % or less, with respect to 100 wt % of the total weight of the interconnected cell porous body. A surfactant content of less than 0.1 wt % may not be effective to make the interconnected cell porous body show improved water-absorbing efficiency, while a surfactant content of more than 30 wt % may lead to reduction of the strength of the porous body after water absorption.
[0093] Any one of anionic, cationic, amphoteric, and nonionic surfactants may be used favorably as the surfactant for use in the present invention, but an anionic or nonionic surfactant is preferable, from the points of relative stability and cost.
[0094] Typical examples of the surfactants favorably used in the present invention include anionic surfactants such as fatty acid sodium salts, fatty acid potassium salts, sodium alkylbenzenesulfonates, potassium alkylbenzenesulfonates, sodium higher alcohol sulfates, potassium higher alcohol sulfates, alkylether sulfate ester sodium salts, alkylether sulfate ester potassium salts, α-sulfofatty acid esters, sodium α-olefinsulfonates, potassium α-olefinsulfonates, sodium monoalkylsulfates, potassium monoalkylsulfates, and sodium monoalkylphosphates; cationic surfactants such as alkyltrimethylammonium chlorides, dialkyldimethylammonium chlorides, and alkylbenzyldimethylammonium chloride; a amphoteric surfactants such as alkylcarboxybetaines; nonionic surfactants such as polyoxyethylene alkylethers, polyoxyethylene alkylphenol ethers, alkyl glucosides, polyoxyethylene fatty acid esters, sucrose fatty acid esters, sorbitan fatty acid esters, polyoxyethylene sorbitan fatty acid esters, fatty acid diethanolamides, and alkyl monoglyceryl ethers; and the like. These surfactants may be used alone or in combination of two or more.
[0095] The method of adding the surfactant is not particularly limited, but typical favorable examples thereof include a method of mixing a surfactant with the powder and making the powder bonded to each other before preparation of the interconnected cell porous body, a method of mixing a surfactant previously with the base resin constituting the powder.
[0096] The rate of interconnected cells in the interconnected cell porous body of the present invention is preferably 60% or more and less than 100%, more preferably 80% or more and less than 100%. When the interconnected-cell rate is less than 60%, the interconnected cell porous body may not have sufficient water-absorbing property, a characteristic property thereof.
[0097] The water absorption (water absorbed by 1 g of porous body) by the interconnected cell porous body of the present invention is preferably 5 to 100 g/g, and more preferably 10 to 100 g/g. When the water absorption less than 5 g/g, the porous body may show performance insufficient for use as a flower-arrangement holder or a medium for plants.
[0098] It is easy to make the interconnected cell porous body of the present invention lower in density and have uniform interconnected cells and thus to make the porous body have a structure allowing expression of favorable liquid-absorbing efficiency (see, for example, FIG. 1 ). It is also possible, by adding a particular amount of a surfactant to the interconnected cell porous body having the structure described above, to make the resulting porous body show extremely favorable water-absorbing efficiency. Therefore, the interconnected cell porous body of the present invention can be used as a water-absorbing material.
[0099] The water-absorbing material above is a material that permits penetration of water therein when in contact with water under normal temperature and pressure, and holds the water in the state after water has penetrated. The water-absorbing material of the present invention is a material characteristic in that it absorbs water on the basis of physical phenomenon such as so-called capillary phenomenon, thus has favorably weak water-holding power after water absorption and can release the water for example in response to absorption of water by the root of plant. Specifically, it can be applied for example as a flower-arrangement holder, a medium for plants, a soil conditioner and can be used favorably in these fields.
EXAMPLES
[0100] Hereinafter, the present invention will be described in more detail with reference to typical examples, but it should be understood that the present invention is not limited to these examples.
[0101] The apparent density, 10% compressive stress, recovery rate, interconnected-cell rate, water absorption, liquid-absorbing rate, internal thermal bonding state of the porous body obtained in each of the Examples and the Comparative Example were evaluated in accordance with the following criteria.
Apparent Density
[0102] A porous body obtained was cut into cubes of 3 cm×3 cm×3 cm, the weight of it was measured and the apparent density thereof was calculated from the following Formula (2):
[0000] Apparent density (g/cm 3 )=[Weight of cube (g)]/[27 (cm 3 )] (2)
10% Compressive Stress
[0103] The 10% compressive stress was determined in accordance with JIS K7220.
Recovery Rate
[0104] A porous body (length 4 cm×width 4 cm×thickness 2.5 cm) was kept compressed by 10% (to 90% of original thickness) for 1 minute under load of a press at normal temperature. After removal of the load, it was left still at normal temperature for 1 day, and the thickness of the porous body (i.e., thickness after recovery) was determined. The recovery rate was calculated from the following Formula (3):
[0000] Recovery rate (%)=[Thickness after recovery (mm)/Original thickness (mm)]×100 (3)
Interconnected-Cell Rate
[0105] A porous body obtained was cut into samples of 1 cm×1 cm×1 cm and the volume of the foam was measured by using an air pycnometer (air-comparative hydrometer Type 1000, manufactured by TOKYO SCIENCE CO., LTD.) The interconnected-cell rate was calculated from the following Formula (4):
[0000] Interconnected-cell rate (%)={1−[Volume of foam, as determined by using air pycnometer (cm 3 )/1 (cm 3 )]}×100 (4)
Water Absorption
[0106] A porous body obtained was cut into cubes of 3 cm×3 cm×3 cm; tap water was placed in a 1 L beaker to a depth of 10 cm; and, after stabilization of the liquid surface, the cube obtained was placed still on the liquid surface with its bottom face in contact with water. The cube of the porous body sediments gradually by absorbing the aqueous solution; the cube was withdrawn 5 minutes after its placement on the liquid surface, and the water absorption was determined from the weight change of the cube between before and after water absorption; and calculated from the following Formula (5);
[0000] Water absorption (g/g)=[Water absorbed (g)]/[Weight of cube before water absorption (g)] (5)
Liquid-Absorbing Rate
[0107] A porous body obtained was cut into cubes of 5 cm×5 cm×5 cm and the weight of the cube was determined. Aqueous 1 wt % sodium α-olefinsulfonate solution was placed in a 1 L beaker to a depth of 10 cm; and, after stabilization of the liquid surface, the cube obtained was placed still on the liquid surface with its bottom face in contact with the solution. The cube of the porous body sediments gradually by absorbing the aqueous solution; and the time needed for the top face of the cube to reach the liquid surface was determined by visual observation.
[0108] The cube immediately after immersion was withdrawn; the liquid absorbed was determined from the weight change of the cube between before and after liquid absorption; and the liquid absorption was calculated from the following Formula (6):
[0000] Liquid absorption (g/g)=[Liquid absorbed (g)]/[Weight of cube before liquid absorption (g)] (6)
[0109] When the top face of the cube did not reach the liquid surface by sedimentation, the test was terminated after 10 minutes and the liquid absorption was calculated from the Formula (6).
Internal Thermal Bonding State
[0110] A porous body obtained was cut with a cutter knife in the direction perpendicular to the longest side (crosswise direction) and along the face at the central position of the longest side, and the thermal bonding state of the powder in the central region of the cut surface was evaluated in accordance with the following criteria.
[0111] A: Thermal bonding is sufficient and the porous body retains its shape when it is pressed with finger.
[0112] B: Thermal bonding is insufficient and the porous body retains its shape when it is pressed with finger, although there is some powder exfoliated.
[0113] C: There is no thermal bonding and the porous body does not retain its shape when it is pressed with finger, as the powder is exfoliated.
Example 1
Preparation of Expanded Particles
[0114] 100 wt parts of a polylactic acid resin having a D isomer rate of 10% and a melt flow rate of 3.7 g/10 minute and 2.0 wt parts of a polyisocyanate compound (MR-200, manufactured by NIPPON POLYURETHANE INDUSTRY CO., LTD.) were melt-extruded in a biaxial extruder (TEM35B, manufactured by TOSHIBA MACHINE CO., LTD.) at a cylinder temperature of 185° C. and cut in water by using a underwater cutter, to give bead-shaped polylactic acid resin particles of approximately 1 mmφ (approximately 1.5 mg).
[0115] 100 wt parts of the polylactic acid resin particle obtained, 100 wt parts of water, 12 wt parts of deodorized butane (n-butane/isobutane, weight ratio: 7/3) as an expanding agent, 10 wt parts of sodium chloride, and 0.3 wt part of polyoxyethylene oleylether as a dispersion aid were placed in an autoclave and held at 84° C. for 90 minutes. The mixture was cooled sufficiently and then withdrawn and dried, to give polylactic acid resin expandable particles. The polylactic acid resin expandable particles obtained had an expanding agent content of 5.5%.
[0116] The polylactic acid resin expandable particles obtained were supplied into a preliminary foaming machine (BHP300, manufactured by DAISEN CO., LTD.) and held under a vapor at 90° C. for 40 to 60 seconds, to give expanded polylactic acid resin particles. The expanded polylactic acid resin particles obtained were dried in air, and thermal bonding particles were fractionated by using screens. The expanded polylactic acid resin particles thus fractionated had a bulk density of 0.025 g/cm 3 and an average pore diameter of 500 μm.
Preparation of Powder
[0117] The expanded particles obtained was pulverized in a cutter mill and filtered through a screen having an opening of 800 μm, to give a powder. The powder had a bulk density of 0.031 g/cm 3 .
Preparation of Interconnected Cell Porous Body
[0118] 10 wt parts of sodium α-olefinsulfonate powder (LIPOLAN (registered trademark) PJ-400, manufactured by LION CORPORATION) as a surfactant was added to 100 wt parts of the powder obtained and the mixture was mixed thoroughly. The mixture was placed in an aluminum mold (internal size: 5 cm×5 cm×5 cm) and heat-treated in a hot air drier at 120° C. for 10 hours, to give an interconnected cell porous body.
Example 2
[0119] An interconnected cell porous body was prepared in a manner similar to Example 1, except that the amount of the sodium α-olefinsulfonate powder (LIPOLAN PJ-400), manufactured by LION CORPORATION) used in Example 1 was changed from 10 wt parts to 2 wt parts.
Example 3
[0120] An interconnected cell porous body was prepared in a manner similar to Example 1, except that the amount of the sodium α-olefinsulfonate powder (LIPOLAN PJ-400, manufactured by LION CORPORATION) used in Example 1 was changed from 10 parts to 25 wt parts.
Example 4
[0121] An interconnected cell porous body was prepared in a manner similar to Example 1, except that the amount of the sodium α-olefinsulfonate powder (LIPOLAN PJ-400, manufactured by LION CORPORATION) used in Example 1 was changed from 10 wt parts to 0.2 wt part.
Example 5
[0122] An interconnected cell porous body was prepared in a manner similar to Example 1, except that the sodium α-olefinsulfonate powder (LIPOLAN PJ-400, manufactured by LION CORPORATION) used in Example 1 was not used.
Example 6
Preparation of Expanded Particles
[0123] Polylactic acid resin expandable particles were obtained in a manner similar to Example 1, except that the amount of deodorized butane as a expanding agent used in Example 1 was changed from 12 wt parts to 4 wt parts. The polylactic acid resin expandable particles obtained had an expanding agent content of 2.5%. The particles were treated in a manner similar to Example 1, to give expanded polylactic acid resin particles. The expanded polylactic acid resin particles obtained were dried in air; the thermal bonding particles were fractionated by using screens; and the fractionated expanded polylactic acid resin particles had a bulk density of 0.08 g/cm 3 and an average pore diameter of 300 μm.
Preparation of Powder
[0124] The expanded particles obtained were pulverized in a cutter mill and filtered through a screen having an opening of 800 μm, to give a powder. The powder had a bulk density of 0.06 g/cm 3 .
Preparation of Interconnected Cell Porous Body
[0125] 10 wt parts of α-olefinsulfonate powder (LIPOLAN PJ-400, manufactured by LION CORPORATION) as a surfactant sodium was added to 100 wt parts of the powder obtained and the mixture was mixed thoroughly. The mixture was placed in an aluminum mold (internal size: 5 cm×5 cm×5 cm) and heat-treated in a hot air drier at 120° C. for 10 hours, to give an interconnected cell porous body.
Example 7
Preparation of Powder
[0126] The expanded polylactic acid resin particles obtained in Example 1 was left still for hydrolysis in a thermohygrostat (programmed temperature/humidity-controlled machine HPAV-120-40, manufactured by ISUZU SEISAKUSHO CO., LTD.) at a temperature of 80° C. and a relative humidity of 95% for 15 hours. The expanded particles were pulverized in a cutter mill and filtered through a screen having an opening of 800 μm, to give a powder. The powder had a bulk density of 0.033 g/cm 3 .
Preparation of Interconnected Cell Porous Body
[0127] 10 wt parts of sodium α-olefinsulfonate powder (LIPOLAN PJ-400, manufactured by LION CORPORATION) as a surfactant was added to 100 wt parts of the powder obtained and the mixture was mixed thoroughly The mixture was placed in an aluminum mold (internal size: 5 cm×5 cm×5 cm) and heat-treated in a hot air drier at 120° C. for 10 hours, to give an interconnected cell porous body.
[0128] The interconnected cell porous body after the hydrolysis treatment showed favorable brittleness and allowed smooth insertion of flowers and thus showed properties favorable for use as a flower-arrangement holder.
Comparative Example 1
[0129] Polylactic acid resin expandable particles were obtained in a manner similar to Example 1, except that the amount of deodorized butane as a expanding agent used in Example 1 was changed from 12 wt parts to 2 wt parts. The polylactic acid resin expandable particles obtained had an expanding agent content of 1.0%. The particles were treated in a manner similar to Example 1, to give expanded polylactic acid resin particles. The expanded polylactic acid resin particles obtained were dried in air; the thermal bonding particles were fractionated by using screens; and the fractionated expanded polylactic acid resin particles had a bulk density of 0.29 g/cm 3 and an average pore diameter of 100 μm.
[0130] Subsequently the expanded particles obtained were pulverized in a cutter mill and filtered through a screen having an opening of 800 μm, to give a powder. The powder obtained had a bulk density of 0.28 g/cm 3 . 10 wt parts of sodium α-olefinsulfonate powder (LIPOLAN PJ-400, manufactured by LION CORPORATION) as a surfactant was added to 100 wt parts of the powder obtained and the mixture was mixed thoroughly. The mixture was placed in an aluminum mold (internal size: 5 cm×5 cm×5 cm) and heat-treated in a hot air drier at 120° C. for 10 hours, to give an interconnected cell porous body.
Comparative Example 2
[0131] An in-mold foamed molding was prepared by using the polylactic acid-based expanded particles obtained Example 1 under the following condition. Specifically, a mold of 300×400×25 mm in size was installed in a foaming machine (BHP-300, manufactured by DAISEN CO., LTD.), and the polylactic acid-based expanded particles were filled therein at a compressibility of 0% and treated at a steam pressure of 0.1 MPa(G) for 10 to 20 seconds, to give a in-mold foamed polylactic acid resin molding.
[0132] The in-mold foamed molding obtained was hydrolyzed under the condition of a temperature of 80° C. and a relative humidity of 100% for 12 hours and additionally pressurized under a nitrogen pressure of 0.3 MPa for 4 hours, to give an interconnected cell porous body.
Comparative Example 3
[0133] An in-mold foamed polylactic acid resin molding obtained in a manner similar to Comparative Example 2 was roughly pulverized in a coarse pulverizer (Quick Mill, screen: 8 mmφ, manufactured by SEISHIN ENTERPRISE CO., LTD.), to give a powder having an average external diameter of 5.6 mm and a bulk density of 0.038 g/cm 3 . The powder obtained was placed in an aluminum mold (internal size: 5 cm×5 cm×5 cm) and heat-treated in a hot air drier at 120° C. for 10 hours, to give a molding.
[0134] Evaluation results for the porous bodies (moldings) obtained in Examples 1 to 7 and Comparative Examples 1 to 3 are summarized in Table 1.
[0000]
TABLE 1
Exam-
Exam-
Exam-
Exam-
Comparative
Comparative
Comparative
ple 1
ple 2
Example 3
ple 4
Example 5
ple 6
Example 7
Example 1
Example 2
Example 3
Powder bulk density (g/cm 3 )
0.031
0.031
0.031
0.031
0.031
0.06
0.033
0.28
—
0.038
Amount of surfactant in
10
2
25
0.2
0
10
10
10
0
0
100 wt parts of powder
(wt part)
Porous
Apparent density
0.039
0.041
0.068
0.04
0.033
0.11
0.038
0.33
0.023
0.047
body
(g/cm 3 )
10% Compressive
0.14
0.15
0.12
0.15
0.15
0.17
0.03
1.2
—
0.26
stress (MPa)
Recovery rate (%)
91.3
91.5
91.1
91.4
91.6
92.1
90.1
96.6
—
95.6
Interconnected-cell
98
99
99
99
98
97
99
87
96
41
rate (%)
Water absorption
25
23
13
23
0.16
8.3
25
2.5
0.10
0.06
(g/g)
Liquid-
Period
—
—
—
—
36 sec
—
—
—
10 min*
—
absorbing
Liquid
—
—
—
—
28.8
—
—
—
0.12
—
rate
absorption
(g/g)
*Water was not completely absorbed
[0135] The results shown in Table 1 indicate that porous bodies obtained in Examples having low density and high interconnected-cell rate and interconnected-cell porous bodies additionally containing a surfactant show high water absorption. As shown in Example 7, it was confirmed that interconnected-cell porous bodies containing the powder obtained from a hydrolyzed foam can be used favorably as a flower-arrangement holder.
[0136] On the other hand, the high-density porous body of Comparative Example 1 has high recovery rate after compressed and shows low water absorption. In addition, the molding of Comparative Example 2 obtained by hydrolysis and pressurization of a molding of conventional expanded polylactic acid resin particles has high interconnected-cell rate, but the pore structure is resistant to penetration of liquid and the liquid absorption thereof is unsatisfactory. In the case of the molding of Comparative Example 3, the powder is insufficiently fine and the particles of the powder after pulverization still contain independent pores that were originally present in the foam before pulverization. For that reason, the molding of Comparative Example 3 has low interconnected-cell rate and the liquid absorption thereof is unsatisfactory.
Example 8
Preparation of Expanded Particles and Powder
[0137] A powder having a bulk density of 0.031 g/cm 3 was prepared in a manner similar to Example 1.
Preparation of Interconnected Cell Porous Body
[0138] 3 wt parts of sodium α-olefinsulfonate powder (LIPOLAN PJ-400, manufactured by LION CORPORATION) as a surfactant was added to 100 wt parts of the powder obtained and the mixture was mixed thoroughly The mixture obtained was placed in a rectangular paper mold (internal size: length 11 cm×width 23 cm×height 8 cm) with open top face, as it is filled therein. The mold containing the mixture was placed in a batchwise heat-treatment oven having temperature- and humidity-controlling functions (programmed temperature/humidity-controlled machine HPAV-120-40, manufactured by ISUZU SEISAKUSHO CO., LTD.) and heat-treated in the heat-treatment oven described above under an atmosphere of normal pressure, 90° C. and 95% RH, which was achieved by controlling the temperature in the oven constant and keeping the humidity therein constant by supplying a desirable amount of steam into the oven as needed, for 10 minutes, to give an interconnected cell porous body.
Example 9
[0139] An interconnected cell porous body was prepared in a manner similar to Example 8, except that the heat treatment atmosphere used in the [Preparation of interconnected cell porous body] was changed to normal pressure, 90° C. and 70% RH.
Example 10
[0140] An interconnected cell porous body was prepared in a manner similar to Example 8, except that the heat treatment atmosphere used in the [Preparation of interconnected cell porous body] was changed to normal pressure, 70° C. and 70% RH.
Example 11
Preparation of Expanded Particles and Powder
[0141] A powder having a bulk density of 0.06 g/cm 3 was prepared in a manner similar to Example 6.
Preparation of Interconnected Cell Porous Body
[0142] 3 wt parts of sodium α-olefinsulfonate powder (LIPOLAN PJ-400, manufactured by LION CORPORATION) as a surfactant was added to 100 wt parts of the powder obtained and the mixture was mixed thoroughly. The mixture obtained was placed in a rectangular paper mold (internal size: length 11 cm×width 23 cm×height 8 cm) with open top face, as it is filled therein. The mold containing the mixture was placed in a batchwise heat-treatment oven having temperature- and humidity-controlling functions (programmed temperature/humidity-controlled machine HPAV-120-40, manufactured by ISUZU SEISAKUSHO CO., LTD.) and heat-treated in the heat-treatment oven described above under an atmosphere of normal pressure, 90° C. and 95% RH for 10 minutes, to give an interconnected cell porous body.
Example 12
[0143] An interconnected cell porous body was prepared in a manner similar to Example 8, except that the heat treatment atmosphere used in the [Preparation of interconnected cell porous body] was changed to normal pressure, 90° C. and 50% RH.
Example 13
Preparation of Expanded Particle
[0144] The expanded polylactic acid resin particles obtained in Example 1 were left still for 18 hours for hydrolysis in a batchwise heat-treatment oven having temperature- and humidity-controlling functions (programmed temperature/humidity-controlled machine HPAV-120-40, manufactured by ISUZU SEISAKUSHO CO., LTD.) adjusted to a temperature of 80° C. and a relative humidity of 95%.
Preparation of Powder
[0145] The expanded particles obtained were pulverized in a cutter mill and filtered through a screen having an opening of 800 μm, to give a powder. The powder had a bulk density of 0.041 g/cm 3 .
Preparation of Interconnected Cell Porous Body
[0146] 3 wt parts of sodium α-olefinsulfonate powder (LIPOLAN PJ-400, manufactured by LION CORPORATION) as a surfactant was added to 100 wt parts of the powder obtained and the mixture was mixed thoroughly. The mixture obtained was placed in a rectangular paper mold (internal size: length 11 cm×width 23 cm×height 8 cm) with open top face, as it is filled therein. The mold containing the mixture was placed in a batchwise heat-treatment oven having temperature- and humidity-controlling functions (programmed temperature/humidity-controlled machine HPAV-120-40, manufactured by ISUZU SEISAKUSHO CO., LTD.) and heat-treated in the heat-treatment oven described above under an atmosphere of normal pressure, 90° C. and 95% RH for 10 minutes, to give an interconnected cell porous body.
[0147] Evaluation results for the interconnected-cell porous bodies obtained in Examples 8 to 13 above are summarized in Table 2.
[0000]
TABLE 2
Example 8
Example 9
Example 10
Example 11
Example 12
Example 13
Powder
Bulk density (g/cm 3 )
0.031
0.031
0.031
0.06
0.031
0.041
Hydrolysis treatment
no
no
no
no
no
yes
Heat-treatment
Temperature (° C.)
90
90
70
90
90
90
atmosphere
Relative humidity (RH %)
95
70
70
95
50
95
Heat-treatment period
10 min
10 min
10 min
10 min
10 min
10 min
Porous body
Internal thermal bonding state
A
A
A
A
B
A
Apparent density (g/cm 3 )
0.037
0.035
0.034
0.052
0.038
0.038
10% Compressive stress (MPa)
0.15
0.14
0.14
0.16
0.12
0.03
Recovery rate (%)
91.4
91.2
91.1
91.4
91.8
90.2
Interconnected-cell rate (%)
98
99
99
96
98
99
Water absorption (g/g)
26
26
26
14
25
18
Comparative Example 4
[0148] An interconnected cell porous body was prepared in a manner similar to Example 8, except that the heat treatment atmosphere used in the [Preparation of interconnected cell porous body] was changed to normal pressure, 50° C. and 95% RH, but only unsuccessfully. No internally thermal-bonded interconnected-cell body was obtained and thus no evaluation was made.
Comparative Example 5
[0149] An interconnected cell porous body was prepared in a manner similar to Example 8, except that the heat treatment machine used in the [Preparation of interconnected cell porous body] was changed to a hot air drier (forced-convection constant-temperature drier, SOFW-600, manufactured by AS ONE CORPORATION) and the heat treatment atmosphere was changed to normal pressure and 120° C. (without moisture control), but only unsuccessfully. No internally thermal-bonded interconnected-cell body was obtained and thus, no evaluation was made.
Example 14
[0150] An interconnected cell porous body was prepared in a manner similar to Example 8, except that the heat treatment machine used in the [Preparation of interconnected cell porous body] was changed to a hot air drier (forced-convection constant-temperature drier, SOFW-600, manufactured by AS ONE CORPORATION) and the heat treatment atmosphere was change to normal pressure and 120° C. (without moisture control) and the treatment period to 24 hours.
Comparative Example 6
[0151] An interconnected cell porous body was prepared in a manner similar to Example 8, except that the heat treatment atmosphere used in the [Preparation of interconnected cell porous body] was changed to normal pressure, 90° C. and 15% RH, but only unsuccessfully. No internally thermal-bonded interconnected-cell body was obtained and thus no evaluation was made.
Reference Example 1
[0152] An interconnected cell porous body was prepared in a manner similar to Example 8, except that the heat treatment atmosphere used in the [Preparation of interconnected cell porous body] was changed to normal pressure, 50° C. and 95% RH and the paper mold was changed to a rectangular paper mold (internal size: length 5 cm×width 5 cm×height 2 cm) with open top face.
Reference Example 2
[0153] An interconnected cell porous body was prepared in a manner similar to Example 8, except that the heat treatment machine used in the [Preparation of interconnected cell porous body] was changed to a hot air drier (forced-convection constant-temperature drier, SOFW 600, manufactured by AS ONE CORPORATION) and the heat treatment atmosphere was changed to normal pressure and 120° C. (without moisture control) and the paper mold to rectangular paper mold (internal size: length 5 cm×width 5 cm×height 2 cm) with open top face.
[0154] Evaluation results for the moldings (porous bodies) obtained in Comparative Examples 4 to 6, Example 14, and Reference Examples 1 and 2 are summarized in Table 3.
[0000]
TABLE 3
Comparative
Comparative
Comparative
Reference
Reference
Example 4
Example 5
Example 14
Example 6
Example 1
Example 2
Powder
Bulk density (g/cm 3 )
0.031
0.031
0.031
0.031
0.031
0.031
Hydrolysis treatment
no
no
no
no
no
no
Heat-treatment
Temperature (° C.)
50
120
120
90
50
120
atmosphere
Relative humidity (RH %)
95
Without
Without
15
95
Without
moisture control
moisture control
moisture control
Heat-treatment period
10 min
10 min
24 hr
10 min
10 min
10 min
Porous body
Internal thermal bonding state
C
C
A
C
A
A
Apparent density (g/cm 3 )
—
—
0.041
—
0.039
0.051
10% Compressive stress (MPa)
—
—
0.26
—
—
—
Recovery rate (%)
—
—
92.2
—
—
—
Interconnected-cell rate (%)
—
—
98
—
95
97
Water absorption (g/g)
—
—
25
—
22
18
It was not possible to prepare an internally thermal-bonded interconnected-cell body in Comparative Examples 4, 5, and 7 and thus no evaluation was made.
[0155] As obvious from the results shown in Tables 2 and 3, it is possible under the production condition of the present invention, in particular under the production condition of heating the foam-pulverized powder under an atmosphere containing steam at a temperature of 60 to 140° C. and a relative humidity of 20% or more, to obtain an interconnected cell porous body in a favorable thermally bonded state even inside, because thermal bonding of the power progresses in a shorter time even when a relatively large mold is used. In contrast, in Comparative Example 4 where the heating temperature is lower, no sufficient thermally bonded state is obtained when a relatively large mold is used. In addition, the results of Comparative Examples 5 and 6 and Example 14 show that it is not possible when a relative large mold is used to obtain a sufficient thermal-bonded state under relative low humidity condition or it takes a very long period for obtaining a sufficient thermal-bonded state. As obvious from Reference Examples 1 and 2, when a relatively small mold is used, a favorable interconnected cell porous body in a favorable thermal bonding state even inside can be obtained, even if the temperature and the relative humidity are lower.
[0156] As shown in Examples, interconnected cell porous bodies containing a surfactant show favorable water-absorbing efficiency that is required for use as a flower-arrangement holder or a medium for plants.
INDUSTRIAL APPLICABILITY
[0157] The interconnected cell porous body and the water-absorbing material of the present invention can be used favorably as a flower-arrangement holder or a medium for nutriculture of plants. In addition, the interconnected cell porous body and the water-absorbing material of the present invention, which contains a biodegradable resin composition as a principal component, demands no special treatment during disposal after use and can be post-processed easily.
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Disclosed is a water absorbent material and an interconnected cell porous body which can be optimally used as a flower arranging pedestal and a plant culture medium. The interconnected cell porous body is formed from a resin composition with a polylactic acid-based resin as the main component. The pore walls, formed by joining together the crushed powder fragments formed by crushing the foam of the aforementioned resin composition, form the interconnected cell structure of the aforementioned porous body. The apparent density greater of the interconnected cell porous body is than or equal to 0.01 g/cm3 and a less than or equal to 0.2 g/cm3; the 10% compression stress is greater than or equal to 0.02 MPa and less than or equal to 0.3 MPa; and the compression recovery rate is less than or equal to 95%. The water absorbent material comprises the interconnected cell porous body.
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FIELD OF THE INVENTION
This invention relates to apparatus for driving chains. More particularly, this invention relates to the elimination of the "chordal" action present in prior art chain drive systems as applied to conveyor drives.
BACKGROUND OF THE INVENTION
The operation of chain type conveyor drives is frequently characterized by irregular chain movement called chordal action. Chordal action manifests itself in the form of cyclical velocity variations of the conveyor. In conventional conveyor drives this cyclical velocity variation can be as much as 5-8% of the average velocity of the conveyor. While such variation may be tolerated in certain manufacturing processes where a smooth, continuous drive is not required; i.e., crusher feed conveyors at a quarry, more sophisticated processes; i.e., lamination processes, require the steady, even movement or progress of the manufactured good. Any variation in the speed of the conveyor, even comparatively minor, can seriously effect the integral quality of the finished product.
Of course not all types of conveyors suffer from this problem. Endless belt conveyors, which are driven by a smooth drum at either end of the curved turn arounds, do not have the requisite physical characteristics which allow chordal action to occur unless, of course, the driving drum is itself driven by a chain drive system that creates chordal action. These belt type conveyors, however, have limited use in some manufacturing processes and other problems are associated with their drive systems.
Conventional chain conveyor drive systems, on the other hand, use some form of toothed drive mechanism which engages the conveyor. The toothed drive can be in the form of either a large sprocket, usually at one end of the conveyor, which directly engages a drive chain attached to the moving portion of the conveyor, or a cat drive system which engages the conveyor at some midpoint location between the ends. In both systems, the former perhaps more than the later, chordal action is present. In the large sprocket system the chordal action effect is easily described as follows: Each successive link pin of the conveyor drive chain engages the drive sprocket at a radius point below the point of tangency between the conveyor drive sprocket and the conveyor drive chain. The velocity of the drive chain therefore increases as the link pin is pulled or raised upwardly to the point of tangency. This occurs because the perpendicular vector component of the velocity imparted by the drive sprocket to the link pin goes to zero while the vector component of velocity parallel to the direction of conveyor travel is maximized. This cyclical increase in the parallel or horizontal vector will cause a jump in conveyor movement.
Use of a cat drive system for conveyors will reduce but not eliminate chordal action. In such a cat drive, protruding teeth are mounted on a smaller chain, directly driven through reduction gearing by an electric motor, with those teeth engaging the conveyor drive pins, which protrude from the under side of the conveyor, so that the conveyor is moved along. At the point of disengagement, the tooth on the smaller chain is pulled away from the conveyor drive pins as it wraps around its own drive sprocket.
Since the cat drive is itself a miniature chain drive system, chordal action is inherent in its operation. Although chordal action is reduced, as compared to a large sprocket drive, it is nonetheless present and uneven motion is imparted thereby to the driven conveyor. Again, a steady, even, conveyor velocity is not achieved.
Many methods of eliminating chordal action in chain drives have been tried: Larger drive sprockets with greater numbers of smaller dimensioned teeth; offset drive sprockets which halve the action, for an otherwise equal amount of driving teeth; scrupulously machined sprockets with precision alignment, etc. None of these methods, however, has succeeded.
The present invention eliminates the cyclical velocity variations of chain drives by ridding the drive system of the physical characteristics of conventional chain drives which cause the chordal action.
SUMMARY OF THE INVENTION
The present invention eliminates chordal action by modifying the drive assembly concept for a main conveyor drive chain. The driving relation between the drive sprocket and the driven chain is arranged such that positive engagement begins to occur at a point where the chain and sprocket are tangentially related.
The driven conveyor chain, which includes link pins, is supported on each side of a centrally positioned drive sprocket. The conveyor support in particular, is arranged so that the outer sides of the conveyor are supported on precisely fixed support rails which have curved end portions that extend parallel to the pitch circle of the central drive sprocket. The central drive sprocket is machined and aligned such that the link pins of the conveyor drive chain first contact the drive sprocket at the point of tangency between the path followed by the centers of the conveyor chain link pins and the pitch circle of the drive sprocket. The drive sprocket is designed with appropriately shaped notches to both receive the link pins at this point of tangency and to maintain the position of the link pins at a constant radius from the center of the drive sprocket as they are pulled through the driving arc of 180° while in engagement with the drive sprocket.
The chain link support rails are also constructed to maintain the link pins away from the pitch circle of the drive sprocket until the link pins and the pitch circle of the sprocket are tangentially related. Thus, since the link pins and the drive sprocket do not come into driving relation until the only element of sprocket velocity imparted to the link pin is along a path which is colinear to the path of travel of the link pin, there can be no chordal action.
Other objects, features, and characteristics of the present invention, as well as the methods and operation and functions of the related elements of the structure, and to the combination of parts and economies of manufacture, will become apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a laminator which uses the present invention chain drive apparatus.
FIG. 2A is a partial cross-sectional end view of a conveyor chain drive apparatus embodying the present invention along line 2A--2A of FIG. 1;
FIG. 2B is a partial cross-sectional view of the lower conveyor taken along line 2B--2B of FIG. 1;
FIG. 3 is a side elevational view along section 3--3 of FIG. 2.
FIG. 4 is an enlarged view of a conveyor slat link pin used with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a schematic of a laminator machine using the present invention conveyor drive. The laminator comprises a conveyor assembly 10 having upper and lower conveyor slat assemblies 20 and 20a, respectively. The conveyor slats extend across the entire width of the conveyor with a plurality of such slats being pivotally connected together, side by side, to form an endless conveyor slat assembly. The upper and lower conveyor slat assemblies 20 and 20a ride on and are supported by wheeled followers 28, as shown in FIGS. 1, 2A and 2B, which are positioned outboard of the center and in turn operate along and are supported by support rails 54, 54a, and 58. The upper conveyor employs a pair of continuous outboard support rails 54. The lower conveyor has a pair of outboard support rails comprised of a first portion in the form of rail segment 54a, that extends along the upper portion of the lower conveyor 20a as well as about each end, together with a pair of lower support rail segments 58 that span the distance between the end points of rail segments 54a. The upper and lower conveyors require different support rails because of their intended unction. Upper conveyor 20 is urged downwardly against the laminated product 2 by hydraulic actuator 4. Since the hydraulic actuator 4 pushes from above the support rail 54, wheeled followers 28 must ride beneath the support rail 54 in order to be acted on by hydraulic actuator 4. Conversely, the bottom conveyor 20a has the hydraulic actuators 4 associated with the discontinuous upper support rail 54a whereas lower support rail 58 merely acts as a return support for the returning slats of the lower conveyor.
Additionally, both upper and lower conveyor slat assemblies 20 and 20a respectively have a center support rail segment 56, 56a associated therewith for supporting the center wheeled followers 22c. Thus, each conveyor 20 and 20a has a center support rail segment to support the center portions of the conveyor slats adjacent the product 2.
The support rails 54, 54a, 56, 56a, and 58 are conventionally supported by and attached to frame assembly 50. Since laminator conveyors generally accommodate laminated products of varying thicknesses, the conveyor slat assemblies 20 and 20c and their associated support rails are conventionally mounted on surrounding frame assembly 50 so as to accommodate limited vertical adjustment.
FIG. 2A illustrates an end view of the driven end of conveyor 20. As shown, the conveyor assembly 10 comprises the following major subassemblies: conveyor slat assembly 20; drive assembly 30; sprocket 40; and frame assembly 50.
Conveyor slat assembly 20 is comprised of plurality of slat members 21 each of which is supported by a center wheeled follower support assembly 22 and outboard wheeled follower support assemblies 24. The support assemblies 22 and 24 are mounted of the underside of the slat members 21 and provide rolling support against the underlying support rails. To this end, wheeled followers 22c and 28 ride along and are supported by their associated support rails. Wheeled follower support assemblies 24 are comprised of an extended bracket portion 24a with an axle 26 inserted therethrough which engages and allows rotation of wheeled follower 28. Center wheeled follower support assembly 22 comprises an extended bracket portion 22a with axle 22b inserted therethrough which engages and allows rotation of wheeled follower 22c.
As previously noted, each of the support rails 54, 54a, and 56 are attached so as to be vertically adjustable relative to frame assembly 50 to accommodate differently sized laminated products between the upper and lower conveyors. Frame assembly 50 provides general support for the conveyor system and is itself of conventional design and is, therefore, shown merely as an attachment surface in FIGS. 2A and 2B.
The slat members that together form conveyor slat assembly 20 are engaged and driven by sprocket 40. Sprocket 40 is in turn driven by driving assembly 30 comprised of a motor 32 which is drivingly connected to drive shaft 34 which in turn is connected in any convenient fashion to sprocket mounting assembly 38 which in turn drivingly supports sprocket 40. Drive shaft 34 rotates in and is supported by suitable roller bearings, generally indicated at 36.
Detail B in the right side of FIG. 2B illustrates the bottom conveyor 20a return support rail segment 58. A lower conveyor wheeled follower 28a is supported along the top portion of the lower conveyor 20a by support rail segment 54a. Rail segment 54a has curved end portions which provide continuous support for wheeled follower 28a as the conveyor is engaged by sprocket 40. As a lower conveyor slat approaches the bottom of the curved end portion of rail segment 54a wheeled follower 28a rolls onto lower support rail segment 58 and is thus continuously supported by either rail segment 54a or 58, throughout. Hence, where support rails 54 for the upper conveyor 20 are continuous, the support rail segments 54a and 58 for the lower conveyor 20a are discontinuous. Wheeled follower 28 rides along support rail segments 54a as slat 21 contacts product 2 and through the driving arc. After the lower conveyor has been acted on by its associated drive sprocket, wheeled follower 28a rides above, and is supported by, return support rail segment 58.
As previously noted, the upper and lower conveyors 20 and 20a each have an associated center support rail segment 56 or 56a. Since the drive pins/wheeled follower 22c only require support when the associated slat 21 is in contact with laminated product 2, upper conveyor 20 may only have a center support rail 56a along its bottom side. Likewise, bottom conveyor 20a may only have a center support rail 56 along its top side.
FIG. 3 is a side view of drive sprocket 40 as its drives conveyor assembly 20. The view is taken along line 3--3 of FIG. 2A. FIG. 3 illustrates the relationships which are critical to the successful construction of the present invention. Rail 54 is shown as continuing around the end of the conveyor by a pair of dotted lines behind sprocket 40 in FIG. 3. The outer or working surface of rail 54, engaged by wheeled followers 28 and along which they move, corresponds to the outermost of that pair of dotted lines. Thus, as shown in FIG. 3, wheeled followers 28 remain in engagement with the working surface of rail 54 as sprocket 40 drives the conveyor. Similarly, center support rail 56 has a working surface engaged by wheeled followers 22c and along which they move. Rail 56 stops adjacent sprocket 40 and wheeled followers 22c are, in turn, engaged by sprocket 40, particularly within notches 42 as explained below.
This outermost dotted line is also characterized by radius 78 and because it passes tangentially past the bottom of notches 42 it constitutes the root circle 70 of sprocket 40.
The center or center line of wheeled followers 22c, those operating along the middle or center rail 56, follow path 74. This path could be called a pitch line along the portion lying parallel to and adjacent rail 56. Path 74 also continues around the curved end of the conveyor and is referenced by the pitch radius 76. The curved portion of path 74 also corresponds to the pitch circle of sprocket 40. Particularly, the following geometric relationships must be observed: the pitch circle (the pitch circle being the effective drive imparting diametric size of a circular drive member) of drive sprocket 40 must not cross path 74 followed by drive pins 22c. Instead, the path 74 must become tangent to pitch circle at point of engagement 72. Point 72 represents the location at which drive pin wheeled follower 22c and drive sprocket 40 may first come into positive engagement. Thus, because wheeled followers 22c engage the bottom of notches 42, this initial positive engagement between sprocket 40 and wheeled followers 22c occurs at a point of tangency between the working surface of the support rail and the root circle 70 of sprocket 40. By eliminating the possibility of premature contact between the drive pin wheeled follower 22c and the drive sprocket 40 such a tangential relationship between path 74 and drive pins wheeled followers 22c eliminates the possibility that drive sprocket 40 could impart cordal action, to conveyor assembly 20. Since the only driving action imparted by sprocket 40 to drive pin wheeled follower 22c is in a direction colinear to the path of travel 74, cordal action is a physical impossibility.
The support rails 54, 56, and 54a collectively support their associated wheeled followers not only along parallel paths but on a substantially common horizontal plane. When the center support rail 56 terminates just ahead of drive sprocket 40, as shown at 57 in FIG. 3, the side support rails 54 and 54a must continue to support, through slat 21, the center drive pins/wheeled follower 22c along path 74. It is essential that drive pin/wheeled follower 22c not engage drive sprocket 40 until the point of tangency 72 is reached. Hence, the outboard support rails 54 and 54a need not be aligned at the same level as center rail 56, but they must, in combination with slat member 21 (or other connecting structure), maintain drive pin/wheeled follower 22c along tangential path 74. That is, the spatial relationship between pitch radius 76 and radius 78 of the side support rails must be a constant. As long as the side support rails are able, through the associated slat structure, to maintain the tangential relationship between the pitch circle and path 74 up to the point of positive engagement 72, they may be arranged in any relative but parallel alignment.
Drive sprocket 40 has machined notches 42 located thereon so as to align with and drivingly engage wheeled follower 22c. In order to achieve a non-contacting relationship between the sprocket 40 and wheeled follower 22c until the point of tangency 72 is reached, the leading machined tooth 44 and the trailing machined tooth 46 must be precisely shaped. The leading tooth 44 is curved to travel beneath the drive pin immediately prior to engagement, similarly the trailing tooth 46 is curved to travel above a drive pin immediately following engagement.
Also shown in FIG. 3, in phantom lines, is the previously discussed relationship between discontinous rail segments 54a and 58. As shown, rail segment 54a follows a path similar to the path of upper rail member 54, except that member 54a terminates just as support member 58 begins. Thus, a given wheeled follower associated with lower conveyor 20a is continuously supported either by an upper discontinuous rail member 54a or by a lower discontinuous rail member 58.
FIG. 4 illustrates how adjacent conveyor assemblies 20 are connected. Extended bracket portions 22a from adjacent slat assemblies overlap and share a common drivepin/wheeled follower axle 22b. Thus, axle member 22b acts as a link pin between conveyor assemblies. The entire conveyor assembly may be considered as a chain wherein the links are conveyor assemblies and the link pins are wheeled follower axles. In this manner, it is easily seen that the present invention can equally apply to non-conveyor oriented chain assemblies.
The general notion of link pin supported chain drive, as disclosed herein with regard to a chain driven conveyor apparatus, can be applied in any situation where precision chain drive operation, i.e., cordal action free, is required. Such instances may include, but are not limited to, any situation where a chain drive would be useful over other forms of endless drive systems. Such applications of cordal action free chain drive need not be heavy industrial situations, two such examples would be: record player turntable drives and tape drives for audio or visual playing/recording machines. As such, the choice of materials for the various components of drive systems can include a wide range, depending on the particular application as well as any anticipated stress and wear.
The instant conveyor chain drive system is composed largely of steel, with hardened steel being used at locations where wear is expected. Such locations would include the sprocket 40, and the drive pins/wheeled followers. The presently disclosed conveyor system is, of course, a heavy industrial application of the present cordal action free drive apparatus. Lighter duty applications might use a combination of materials, such as resinous plastics (both reinforced and unreinforced), or lighter metal alloys.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications or equivalent arrangements included within the spirit and scope of the appended claims.
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A chain driving system wherein positive engagement between the driving element and the chain begins to occur only when the pitch circle of the driving element and the path of the centers of the chain link pins tangentially intersect. Such a positive engagement relationship eliminates the chordal action usually associated with chain drive systems.
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CROSS-REFERENCE TO RELATED APPLICATIONS
(Not Applicable)
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
(Not Applicable)
BACKGROUND OF THE INVENTION
The present invention relates generally to aerial targets, and more particularly to an improved aerial target decoy which simulates an exhaust of a jet engine through use of an infrared augmenter device having a silicon window.
The use of aerial targets to enhance military weapons training is well known. As shown in FIG. 1, aircraft typically tow these aerial targets so that they duplicate battle targets (e.g., enemy aircraft). By providing a scenario which closely resembles a real-life battle situation, target-striking weapons such as anti-aircraft missiles can be launched thereagainst so as to optimize their use and operation.
Certain types of aerial targets utilized in the military weapons training are adapted for more sophisticated weaponry such as heat-seeking missiles. These types are not only designed to provide visual indications of the targets' locations, but further emit infrared thermal; signatures. In this respect, military weaponry such as heat-seeking missiles can trace and follow the thermal signatures to strike and destroy those targets that emit them. By incorporating these types of aerial targets into the military weapons training, the operation and use of heat-seeking weaponry can be significantly improved in preparation for real-life situations.
Traditionally, gas or liquid fuel powered aerial targets have been used to achieve this purpose. These fuel-burning targets typically operate to heat a mesh or to create an external flame which radiates sufficient thermal signature. However, because such targets require fuel tanks, plumbing, valves and an ignition source, they are complicated and expensive. They also are limited in altitude and airspeed of operation. A further disadvantage is that their infrared emission is primarily directed aft. Thus, they are poorly suited in training pilots to attack an enemy heading toward them.
One known solution to this problem is the use of aerial targets manufactured by Global Target Systems Limited of Challock, Great Britain. Generally, a typical aerial target from Global comprises an enclosed housing which places a heater unit therein to selectively emit thermal signatures through its window. Although its targets are believed to be proven effective for their intended purpose, they are extremely expensive to manufacture. Simply put, these targets are too impractical as to cost to serve as one-time target designations.
Perhaps the greatest cost factor in manufacturing Global's aerial targets is the use of zinc-sulphide windows in their targets. In particular, Global's use of zinc-sulphide windows is due to the fact that they allow frequencies of infrared to radiate therethrough which can be readily detected by heat-seeking weaponry. However, these windows are extremely costly, not to mention that they are often difficult to obtain and/or fabricate. This becomes a tremendous factor when considering that aerial targets, by their inherent nature, are manufactured to be used for one-time target practice.
In view of the above-described shortcomings of conventional aerial targets, there exists a need in the art for an aerial target which can be economically manufactured. More specifically, there exists a need for an aerial target adapted for heat-seeking weaponry which generates and emits the required infrared thermal signature therefor, while being mass-producible with mitigated costs.
BRIEF SUMMARY OF THE INVENTION
The present invention specifically addresses and alleviates the above-referenced deficiencies associated with the use of aerial targets of the prior art. More particularly, the present invention is an improved aerial target which simulates an exhaust of a jet engine through use of an infrared augmenter device having a silicon window. This specific augmenter of the present invention is designed to continuously output the required infrared thermal signature in the forward direction as it is advantageously insensitive to mounting orientation. In addition, it is advantageously insensitive to airspeed and altitude. More importantly, however, the present invention's aerial target decoy uses a silicon window to radiate detectable infrared frequencies therethrough, which is significantly cheaper and more easily obtainable than the conventional windows performing the same.
In accordance with a preferred embodiment of the present invention, there is provided an unpowered aerial target for emitting an infrared thermal signature in a specific waveband range (about 3 to 5 microns) when being towed by an aircraft. The present invention features an infrared augmenter device which is engaged to the forward end of a fuselage. However, because the present augmenter device is adapted to consistently emit thermal signature through its window, it would be recognized that the augmenter can be placed any desired location defined on the fuselage.
In the preferred embodiment of the present invention, the silicon window may be incorporated into the infrared augmenter device in any sensible fashion, whether it be via conventional or creative means. Preferably, however, the silicon window is mounted in the front end of the augmenter device by an O-ring that acts like a snap-ring. This manner of attachment is further preferred as it helps prevent outside dust and moisture from entering within the device.
In operation, an aircraft may tow the present invention's aerial target by connecting elongated tow line to the target. By doing so, the target becomes airborne but should be far enough from the aircraft (about 2 miles) so that any incoming missiles do not inadvertently harm the aircraft. When airborne, the infrared augmenter device is operative to electrically generate high-intensity heat (about 1,400°F.) therewithin whereat its silicon window allows continuous emission of required infrared signatures of approximately 40 watts per steradian in the 3-5 micron waveband. In this respect, military weaponry such as heat-seeking missiles can be launched to trace these signatures for the purpose of striking and destroying the aerial target that emits them.
BRIEF DESCRIPTION OF THE DRAWINGS
These as well as other features of the present invention will become more apparent upon reference to the drawings wherein:
FIG. 1 is a side view of an aircraft towing a prior art aerial target (not drawn to scale) when conducting a military weapons training;
FIG. 2 is a perspective view of an aerial target utilized for emitting infrared thermal signatures constructed in accordance with a preferred embodiment of the present invention;
FIG. 3 is a perspective view of an infrared augmenter device featured in the aerial target of FIG. 2 and comprising a silicon window which is mounted therein;
FIG. 4 is a cross-sectional view of the infrared augmenter device of FIG. 3 and illustrating its internally disposed heating elements; and
FIG. 5 is a cross-sectional view of the infrared augmenter device of FIG. 3 and illustrating layers of insulation which are strategically arranged therein.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the present invention only, and not for purposes of limiting the same, FIG. 2 perspectively illustrates an infrared augmenter device 10 constructed in accordance with a preferred embodiment of the present invention. As indicated above, the infrared augmenter device 10 is adapted to emit an infrared thermal signature 12 in the forward direction 14 . Those of ordinary skill in the art will recognize that the augmenter device 10 may be formed to have a variety of shapes, configurations, geometries and sizes other than for that shown in the provided figures.
As shown in FIG. 3, the infrared augmenter device 10 is enclosed in a housing 16 . Although the housing 16 is shaped in a cylindrical configuration, such depiction is exemplary in nature and should not be limited thereto. The housing 16 may be fabricated from any material, but is preferably fabricated from a metallic material, and even more preferably aluminum.
Referring more particularly to FIGS. 4 and 5 ,there is provided a plurality of heating elements 24 that are disposed within the internal compartment 22 of the housing 16 . It would be known to a person of ordinary skill in the art that the number of heating elements 24 may vary. For example, there could be only one heating element 24 , or more than three. Rather, it is the concept of generating heat 26 within the internal compartment 22 that should be appreciated. In the preferred embodiment, however, three heating elements 24 should be used for optimization.
The three heating elements 24 are concentrically disposed within the internal compartment 22 of the housing 16 (best shown in FIG. 5 ). Although each of the heating elements 24 may be characterized by various shapes and configurations, the ones of the present invention each generally has an a circular configuration. These heating elements 24 further include electrical input terminals 28 which extend and protrude through the back end 20 of the housing 16 (as shown in FIG. 4 ). In this regard, the back end 20 is preferably a metallic backplate, and more particularly an aluminum backplate, which provides sufficient clearance holes 30 for the input terminals 28 to extend therethrough.
Referring now to FIGS. 2 and 4, the electrical input terminals 28 are in communication with an electrical power source 31 for supplying power thereto. More specifically, the heating elements 24 can be connected in parallel to the power source 31 . These elements 24 can be sized for 28 VDC, or can be designed in a manner as to be adapted for any type of power. The power source may be located within the fuselage 34 . In the alternative, the requisite electricity may be drawn from an outside power source such as from an aircraft 50 for example through an electrical cable which is elongated within the connecting tow line 52 . Moreover, there is further provided an insulating plate 36 disposed between the back end 20 and the forward end 32 to which the electrical input terminals 28 are mounted.
Referring more particularly to FIGS. 3 and 4, the infrared augmenter device 10 comprises a window 38 which is preferably fabricated from silicon. It is expressly stated herein that the use of a silicon window to radiate detectable infrared signature 12 is both advantageous and imperative to the present invention as it is significantly cheaper, sufficiently rugged and more easily obtainable than the conventional windows (e.g., zinc-sulphide windows) performing the same.
Preferably, the silicon window 38 is mounted within an opening 42 of the housing's front end 18 by an O-ring that acts like a snap-ring and further simultaneously mitigating outside dust and moisture from entering within the device 10 . However, it will be recognized by those of ordinary skill in the art that there are other methods of mounting the silicon window 38 within the housing 16 .
The silicon window 38 is preferably an anti-reflective window. In this respect, the silicon window is coated with an anti-reflective material. Moreover, as shown in FIGS. 4 and 5, there may further comprise insulation layers 48 which are selectively positioned within the internal compartment 22 of the housing 16 in a manner as to expo se the silicon window 38 to the generated heat 26 . Of course, these insulation layers 48 protect the housing 16 from heat 26 and further reduce heat losses in operation.
In operation, an aircraft 50 is utilized to tow the present invention's aerial target 40 by connecting an elongated tow line 52 thereto. However, it should be recognized by those of ordinary skill in the art that the present target 40 may be adapted for use with a variety of other vehicular structures (e.g., tanks, jeeps, gunboats, manned and unmanned fixed-wing aircraft and helicopters, etc.)
In particular, one end of the tow line 52 is connected to the aircraft 50 while the other end is connected to the fuselage 34 . By doing so, the decoy 40 becomes airborne but it should be emphasized that the decoy 40 should be sufficiently distanced from the aircraft 50 (about 2 miles)i so that any incoming missiles do not inadvertently harm the aircraft 50 .
When the present decoy 40 is airborne, the heating elements 24 are operative to electrically generate high-intensity heat 26 (about 1,4000° F.) within the internal compartment 22 . These heating elements 24 produce radiant heat 26 which is radiated through the silicon window 38 whereat the silicon window 38 allows continuous emission of required infrared signatures 12 . These signatures 12 are approximately 40 watts per steradian in the 3-5 micron waveband which are selected frequencies associated with infrared engines. In this respect, military weaponry such as heat-seeking missiles can be launched to trace these signatures 12 for the purpose of striking and destroying the aerial target 40 .
Additional modifications and improvements of the present invention may also be apparent to those of ordinary skill in the art. Thus, the particular combination of parts described and illustrated herein is intended to represent only certain embodiments of the present invention, and is not intended to serve as limitations of alternative devices within the spirit and scope of the invention.
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There is provided an electrically powered augmenter device that has a silicon window. The silicon window emits the infrared radiation from the augmenter in a specific waveband, to attract heat seeking missles. Moreover, the augmenter may be mounted on the fuselage of an unpowered aerial towed target or other airborne vehicle.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to prefabricated folding structures, or more particularly to prefabricated residential dwellings comprised of a prefabricated floor, wall and roof members that fold inwardly upon itself to produce a compact partially collapsed folded structure, which is easily transportable, and then unfold outwardly for quick and easy on-site installation.
[0003] 2. Description of the Related Art
[0004] The vast majority of structures, particularly residential houses, are completely constructed on-site. In the various sequential construction stages required materials and labor are brought to the site. A foundation is laid and the shell of the house is framed. Thereafter, exterior walls, roofing, and floors are installed using plywood sheets, followed by the installation of exterior siding and roof shingles. Windows, heating, electrical and plumbing systems are installed by heating contractors, electricians and plumbers. Insulation is added followed by installation of all the interior walls and floors. Thereafter, appliances are positioned and connected to the electrical and plumbing systems. Interior finishing work such as painting, wall-papering, and interior trim follow. While on-site construction, is the predominant form of house construction, such entail considerable labor costs. It would be desirable to reduce construction costs by taking advantage of the economies of scale available with factory prefabricated housing.
[0005] Prefabricated building structures are well known and the majority of these comprise pre-cast or pre-assembled panel structures which are transported to an erection site and assembled. Although many of the component parts of the buildings are pre-fabricated, the erection time can be fairly lengthy and inclement weather conditions can further slow down the erection time as well as expose building materials to the elements. Often, the pre-assembled parts are difficult to transport, heavy to manipulate and often require the use of large cranes for assembly. Prior alternatives involve prefabricating various portions of a house at a central facility or plant, transporting these portions to a building site and then performing the remaining assembly work on-site. It was believed that by prefabricating a significant portion of a house, sufficient cost savings would occur so that the purchase price of the installed prefabricated house would be less than that of a similarly sized conventionally constructed house. However, the installation cost of prefabricated prior art structures was found to be substantial and, when added to the cost of manufacture and delivery, caused the total cost of any of these prefabricated structures to exceed that of conventional construction. Many of the prefabricated or other type-home or building structures are constructed for permanent installation/and cannot be easily dismantled and reassembled on another site. A still further disadvantage of prefabricated structures is that often these are not very structurally sound and can become damaged if exposed to tornadoes or hurricane force winds. Some of these are also not well insulated or resistant to insect infestation such as by termites. Still further prefabricated building structures require expensive foundations made of concrete thereby increasing the cost of the prefabricated structure. U.S. Pat. No. 6,253,521 shows a steel-framed building construction. A number of prefabricated sections are assembled on a construction site, however, such is not foldable. U.S. Pat. No. 5,950,373 shows a transportable structure kit. All of the parts for a disassembled housing structure are placed in a transportable container for subsequent assembly. U.S. Pat. No. 6,295,766 shows a multistory, modular building structure which may be mounted on a trailer, however such is not indicated to be foldable. U.S. Pat. No. 5,960,593 shows a transportable and collapsible building, however, such is for temporary use as a bar, or the like, for example at sporting functions. Such is not habitable. This invention improvers on U.S. Pat. Nos. 4,545,171; 4,660,332 and 3,348,344, all of which are incorporated herein by reference, which show prefabricated folding structures suitable for residential housing, however, the frameworks thereof are made of hardwood materials which are subject to termite infestation and can become damaged if exposed to hurricane force winds. U.S. Pat. No. 5,890,341 shows a modular, structure, but does not mention steel framing. U.S. Pat. No. 6,434,895 shows a foldable, trailerable building which is useful as a field office, however, no plumbing or electrical capability is mentioned and such would not be suitable as a residential dwelling.
[0006] It has now been found that a permanent, pre-fabricated, modular, building may be formed from interlocking rooms using interlocking, pivoting metal channel beams which are resistant to insect infestation and hurricane force winds. The structure has a number of rooms having pivotably floor, roof and wall sections which fold upon one another and thereby form a compact folded structure, and which when unfolded, deploy to form a habitable structure.
SUMMARY OF THE INVENTION
[0007] The invention provides a prefabricated folding structure comprising:
[0008] a generally rectangular central core comprising a plurality of core walls, a core floor section connected to and extending between the core walls at a base of the core walls, and a core roof section connected to and over the core walls and over the core floor section; each of said core walls, core floor section and core roof section comprising a plurality of spaced metal channel beams having at least one flat side;
[0009] a plurality of folding rooms attached to the central core; each folding room comprising a plurality of room wall members, a folding room floor section removably attached to and extending between the room walls at a base of the room walls and a folding a room roof section removably attached to and extending over the room wall members and extending over the room floor section; each of the room wall members, the room floor section and the room roof section comprising a plurality of spaced metal channel beams having at least one flat side;
[0010] at least one said room floor section being pivotedly connected at one end thereof to said core floor section; at least said one room roof section being pivotedly connected at one end thereof to said core roof section; said room wall members being removably attached to said room floor section and said room roof section; each room roof section being pivotedly connected to the core roof section on the same side of the central core as each room floor section is connected to the core floor section;
[0011] wherein each folding room floor section and each folding room roof section may be alternately detached from its room wall members and pivoted inwardly toward said central core and positioned in close proximity to and substantially parallel to a corresponding core wall and thereby form a compact folded structure, or pivoted outwardly away from said central core to define a room adjacent to said central core when attached to its room wall members.
[0012] The invention also provides a multistory prefabricated folding structure comprising:
[0013] a generally rectangular central core comprising a plurality of core walls, a core floor section connected to and extending between the core walls at a base of the core walls, and a core roof section connected to and over the core walls and over the core floor section; each of said core walls, core floor section and core roof section comprising a plurality of spaced metal channel beams having at least one flat side;
[0014] a plurality of folding rooms attached to the central core; each folding room comprising a plurality of room wall members, a folding room floor section removably attached to and extending between the room walls at a base of the room walls and a folding a room roof section removably attached to and extending over the room wall members and extending over the room floor section; each of the room wall members, the room floor section and the room roof section comprising a plurality of spaced metal channel beams having at least one flat side;
[0015] at least one said room floor section being pivotedly connected at one end thereof to said core floor section; at least said one room roof section being pivotedly connected at one end thereof to said core roof section; said room wall members being removably attached to said room floor section and said room roof section; each room roof section being pivotedly connected to the core roof section on the same side of the central core as each room floor section is connected to the core floor section;
[0016] a sub-core attached under the central core, said sub-core comprising a generally rectangular central sub-core comprising a plurality of sub-core walls, a sub-core floor section connected to and extending between the sub-core walls at a base of the sub-core walls, each of said sub-core walls and the sub-core floor section comprising a plurality of spaced metal channel beams having at least one flat side;
[0017] a plurality of folding sub-rooms, one folding sub-room attached under one of the folding rooms and also attached to the central sub-core; each folding sub-room comprising a plurality of sub-room wall members, and a folding sub-room floor section removably attached to and extending between the sub-room walls at a base of the sub-room walls; each of the sub-room wall members and the sub-room floor section comprising a plurality of spaced metal channel beams having at least one flat side;
[0018] at least one said sub-room floor section being pivotedly connected at one end thereof to said sub-core floor section; said sub-room wall members being removably attached to said sub-room floor section;
[0019] wherein each folding room floor section and each folding room roof section may be alternately detached from its room wall members and pivoted inwardly toward said central core or central sub-core and positioned in close proximity to and substantially parallel to a corresponding core wall or sub-core wall and thereby form a compact folded structure, or pivoted outwardly away from said central core to define a room adjacent to said central core when attached to its room wall members;
[0020] wherein each folding sub-room floor section may be alternately detached from its sub-room wall members and pivoted inwardly toward said central sub-core and positioned in close proximity to and substantially parallel to a corresponding sub-core wall and thereby form a compact folded structure, or pivoted outwardly away from said central sub-core to define a room adjacent to said central sub-core when attached to its sub-room wall members.
[0021] The invention further provides a three-story prefabricated folding structure comprising:
[0022] a generally rectangular central core comprising a plurality of core walls, a core floor section connected to and extending between the core walls at a base of the core walls, and a core roof section connected to and over the core walls and over the core floor section; each of said core walls, core floor section and core roof section comprising a plurality of spaced metal channel beams having at least one flat side;
[0023] a plurality of folding rooms attached to the central core; each folding room comprising a plurality of room wall members, a folding room floor section removably attached to and extending between the room walls at a base of the room walls and a folding a room roof section removably attached to and extending over the room wall members and extending over the room floor section; each of the room wall members, the room floor section and the room roof section comprising a plurality of spaced metal channel beams having at least one flat side;
[0024] at least one said room floor section being pivotedly connected at one end thereof to said core floor section; at least said one room roof section being pivotedly connected at one end thereof to said core roof section; said room wall members being removably attached to said room floor section and said room roof section; each room roof section being pivotedly connected to the core roof section on the same side of the central core as each room floor section is connected to the core floor section;
[0025] a sub-core attached under the central core, said sub-core comprising a generally rectangular central sub-core comprising a plurality of sub-core walls, a sub-core floor section connected to and extending between the sub-core walls at a base of the sub-core walls, each of said sub-core walls and the sub-core floor section comprising a plurality of spaced metal channel beams having at least one flat side;
[0026] a plurality of folding sub-rooms, one folding sub-room attached under one of the folding rooms and also attached to the central sub-core; each folding sub-room comprising a plurality of sub-room wall members, and a folding sub-room floor section removably attached to and extending between the sub-room walls at a base of the sub-room walls; each of the sub-room wall members and the sub-room floor section comprising a plurality of spaced metal channel beams having at least one flat side;
[0027] at least one said sub-room floor section being pivotedly connected at one end thereof to said sub-core floor section; said sub-room wall members being removably attached to said sub-room floor section;
[0028] wherein each folding room floor section and each folding room roof section may be alternately detached from its room wall members and pivoted inwardly toward said central core or central sub-core and positioned in close proximity to and substantially parallel to a corresponding core wall or sub-core wall and thereby form a compact folded structure, or pivoted outwardly away from said central core to define a room adjacent to said central core when attached to its room wall members;
[0029] wherein each folding sub-room floor section may be alternately detached from its sub-room wall members and pivoted inwardly toward said central sub-core and positioned in close proximity to and substantially parallel to a corresponding sub-core wall and thereby form a compact folded structure, or pivoted outwardly away from said central sub-core to define a room adjacent to said central sub-core when attached to its sub-room wall members;
[0030] a second sub-core attached under the sub-core, said second sub-core comprising a generally rectangular central second sub-core comprising a plurality of second sub-core walls, a second sub-core floor section connected to and extending between the second sub-core walls at a base of the second sub-core walls, each of said second sub-core walls and the second sub-core floor section comprising a plurality of spaced metal channel beams having at least one flat side; a plurality of folding second sub-rooms, one folding second sub-room attached under one of the folding sub-rooms and also attached to the central second sub-core; each folding second sub-room comprising a plurality of second sub-room wall members, and a folding second sub-room floor section removably attached to and extending between the second sub-room walls at a base of the second sub-room walls; each of the second sub-room wall members and the second sub-room floor section comprising a plurality of spaced metal channel beams having at least one flat side;
[0031] at least one said second sub-room floor section being pivotedly connected at one end thereof to said second sub-core floor section; said second sub-room wall members being removably attached to said second sub-room floor section;
[0032] wherein each folding room floor section and each folding room roof section may be alternately detached from its room wall members and pivoted inwardly toward said central core or central sub-core and positioned in close proximity to and substantially parallel to a corresponding core wall or sub-core wall and thereby form a compact folded structure, or pivoted outwardly away from said central core to define a room adjacent to said central core when attached to its room wall members;
[0033] wherein each folding sub-room floor section may be alternately detached from its sub-room wall members and pivoted inwardly toward said central sub-core and positioned in close proximity to and substantially parallel to a corresponding sub-core wall and thereby form a compact folded structure, or pivoted outwardly away from said central sub-core to define a room adjacent to said central sub-core when attached to its sub-room wall members;
[0034] wherein each folding second sub-room floor section may be alternately detached from its second sub-room wall members and pivoted inwardly toward said central second sub-core and positioned in close proximity to and substantially parallel to a corresponding second sub-core wall and thereby form a compact folded structure, or pivoted outwardly away from said central second sub-core to define a room adjacent to said central second sub-core when attached to its second sub-room wall members.
[0035] The invention also provides a process for forming a prefabricated folding structure comprising:
[0036] I. providing a trailer which comprises a rectangular framework, which framework is disposed on at least four wheels, an upper edge of the rectangular framework comprising a channel around a periphery of the framework;
[0037] II. forming a habitable structure on the trailer by erecting a generally rectangular central core comprising a plurality of core walls, a lowermost portion of each of the core walls being positioned within the channel of the trailer framework, a core floor section connected to and extending between the core walls at a base of the core walls, and a core roof section connected to and over the core walls and over the core floor section; each of said core walls, core floor section and core roof section comprising a plurality of spaced metal channel beams having at least one flat side;
[0038] attaching a plurality of folding rooms to the central core; each folding room comprising a plurality of room wall members, a folding room floor section removably attached to and extending between the room walls at a base of the room walls and a folding a room roof section removably attached to and extending over the room wall members and extending over the room floor section; each of the room wall members, the room floor section and the room roof section comprising a plurality of spaced metal channel beams having at least one flat side;
[0039] pivotedly connecting at least one said room floor section at one end thereof to said core floor section; at least said one room roof section being pivotedly connected at one end thereof to said core roof section; said room wall members being removably attached to said room floor section and said room roof section; each room roof section being pivotedly connected to the core roof section on the same side of the central core as each room floor section is connected to the core floor section;
[0040] wherein each folding room floor section and each folding room roof section may be alternately detached from its room wall members and pivoted inwardly toward said central core and positioned in close proximity to and substantially parallel to a corresponding core wall and thereby form a compact folded structure, or pivoted outwardly away from said central core to define a room adjacent to said central core when attached to its room wall members.
[0041] Thus the invention provides sturdy, habitable low-cost prefabricated structures which are not only economical to manufacture but are also easy and inexpensive to install on-site, to thereby provide significant cost savings over a similarly sized conventionally constructed structure. All the necessary systems, such as wiring, plumbing and heating, and appliances in the structure during prefabrication.
[0042] Thus the need for heavy machinery during installation of the structure as well as the labor and effort required for installation are minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] [0043]FIG. 1 is a perspective view of the outside of the inventive prefabricated folding structure shown in a completely folded shipping configuration.
[0044] [0044]FIG. 2 is a cross-sectional view of applicant's prefabricated folding structure, depicting the pivotal movement of the folding roof sections.
[0045] [0045]FIG. 3 is a cross-sectional view of the prefabricated folding structure, depicting the pivotal movement of folding floor members.
[0046] [0046]FIG. 4 is a plan elevational view of the interior of the prefabricated folding structure, depicting the movement of exterior side walls 91 , 92 , 93 and 94 during erection.
[0047] [0047]FIG. 5 is an exterior perspective view of the prefabricated structure shown completely unfolded and installed on-site.
[0048] [0048]FIG. 6 is a cross-sectional view of an alternate embodiment of a single story prefabricated structure, shown completely unfolded.
[0049] [0049]FIG. 7 is a cross-sectional view of a multi (two) story prefabricated house shown completely unfolded.
[0050] [0050]FIGS. 8A and 8B show beams have a generally U-shaped or C-shaped cross-section.
[0051] [0051]FIG. 9 illustrates an interlocking of rafter beams wherein adjacent beams have their edge flanges cut away and one beam rests on the other prior to bolting together.
[0052] [0052]FIG. 10 illustrates an interlocking of a stud to a beam wherein a notch is cut into a bolt edge flange, a stud is positioned within the notch and rests on the opposite bolt flange prior to the stud and beam being bolted together.
[0053] [0053]FIG. 11 illustrates a trailer having a channeled framework on which a habitable structure according to the invention may be built.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0054] The present invention is applicable to a wide variety of structures of different weight, size, shape and materials for a variety of diverse uses. The invention pertains to single story as well as multiple story prefabricated residential dwellings constructed from interlocking rooms.
[0055] [0055]FIG. 1 shows an exterior perspective view of a single-story prefabricated folding house constructed in accordance with the invention and folded into a shipping configuration. As shown, the house contains a generally rectangularly shaped prefabricated central core 5 , of which only exterior core wall 21 is shown. Positioned substantially parallel to and alongside this core wall, are the front and rear walls and pivoting floor sections.
[0056] On the sides of the core, exterior side walls 71 , 72 having corners 3 , are adjacent to pivoting floor section 61 at floor joist 611 . Each of these joists in the pivoting floor sections are-pivotedly connected at an end, via pivots 2 , to a respective one of the floor joists, e.g. joist 411 , which joists together comprise the floor of the central core 5 . The floor of the central core is comprised of a plurality of beams, positioned substantially perpendicular to the walls of the central core, at least one beam oriented parallel to the walls of the central core connected to each of the plurality of beams, and acceptable decking material attached to and substantially covering the beams.
[0057] Preferably, these beams are made of steel, and the decking material can be plywood or fiberboard. The preferred material comprises steel studs enclosing polystyrene foam panels or sections, such as are available commercially from ThermaSteel Corporation of Radford, Va. Panels, such as 4 foot by 8 foot panels may be formed by setting steel studs in a forming jig and then filling the cavity with expanded polystyrene. The polystyrene protects the steel and greatly adds to the thermal insulation value of the structure. In a particularly advantageous embodiment, the decking comprises a subflooring of plywood or the like, followed by a final floor covering of hardwood planking, carpeting, tile or linoleum, depending upon the use for that particular section of the house.
[0058] The beams of the central core floor 41 (FIG. 2), are C-shaped or U-shaped metal joists, which are preferably steel. All the joists comprising these floor members are arranged in an approximate 16″ center-to-center spacing and are staggered such that an end of each floor joist in each pivoting floor member lies adjacent to an end of a corresponding floor joist in the central core. During prefabrication, both subflooring, of illustratively ⅝″ thick plywood, and final floor covering, of illustratively ¼″ hardwood planking, are attached over all the joists comprising each of these floor members with exception of an area above pivots 2 between each pivoting floor section and the core floor. Affixed atop the central core is a ceiling member upon which is positioned a plurality of prefabricated roof trusses, of which only truss 31 is shown. When a folding structure is used as a single story dwelling or the top floor of a multiple story dwelling, these trusses provide support for the folding roof which is comprised of lower folding roof sections 51 and 52 and upper folding roof sections 50 and 53 . Each lower roof section is pivotedly connected at one of its ends to both an end of a respective upper folding roof section and to an end of each truss. In the shipping configuration as shown, the lower folding roof sections are pivotedly oriented downward to lie alongside the pivoting floor section, and the upper folding roof sections are pivotedly oriented downward to lie against each of the trusses. These folding roof sections preferably comprise a plurality of rafters positioned substantially perpendicular to the walls of the core, at least one rafter positioned perpendicular to the plurality of rafters for connection thereto, a sheathing material connected to and substantially covering the rafters and moisture barrier means attached to the sheathing. The moisture barrier is preferably builder felt, and a building exterior, such aluminum siding, PVC siding, shingles, cedar shakes, bricks, etc., is placed upon the moisture barrier and sheathing materials. Since the weight of the folding structure is primarily supported by the walls of the central core, relatively little weight is borne by any of the wall, and pivoting floor and pivoting roof members. Consequently, these pivoting members can be made light in weight. Not only does this advantageously eliminate the need to use a reinforced foundation, but, in addition, this advantageously minimizes the effort required to pivotally move these members into proper position during installation of the structure. Thus, once the structure is properly positioned on its foundation, only a minimum amount of labor and no heavy machinery is needed to unfold the structure and complete the installation. These factors, coupled with the use of only inexpensive standard building materials and extensive prefabrication, advantageously permit substantial cost savings to be achieved over the cost of both prior art prefabricated structures and conventional construction. The use of pivoting floor, pivoting roof and movable walls, which fold and unfold, reduces the height and width of the folded home to specifically 11 feet 4 inches and 13 feet 8 inches, respectively. Advantageously, this greatly lowers the center of gravity of the folded home. Consequently, this ensures that the house is not susceptible to being tipped over during shipment. Hence, the house can be easily and safely transported on a flatbed truck to a suitable building site. In a preferred embodiment of the invention, the entire building is constructed on a wheeled trailer, which is may be used to drive the partially built structure from assembly station to assembly station, and ultimately to the final installation site.
[0059] Once a suitable site has been appropriately excavated, a concrete foundation is laid. This foundation is provided with four points for supporting the folding structure. Two supports are located just below and outside of the core walls, and each of the two other supports is located under one of the pivoting floor sections. Thus, the two supports for the core hold the weight of the structure while the pivoting floor supports maintain the floor in the correct orientation and position i.e., parallel to and level with the core floor. A plate (not shown), which may be comprised of a pair of studs laid one atop another, is affixed all around the top surface of this foundation. These studs and the foundation are configured and arranged so as to facilitate the unfolding of the structure. Preferably, the core walls each comprise a plurality of steel studs and at least two plate members connected respectively to the top and bottom of the plurality of studs. Since these core walls are located within the folded structure, they are provided with gypsum board after the necessary piping, plumbing, and electrical components have been installed. An advantageous stud is a steel, although aluminum, or other metals could be used, if desired. Thereafter, the folded house shown in FIG. 1 is positioned on top of the plate and unfolded in a manner discussed below.
[0060] [0060]FIG. 2 depicts a cross-sectional view of the prefabricated folding house of FIG. 1. FIGS. 1 and 2 show that the folding house is comprised of a rectangularly shaped central core 5 , a plurality of detachable and movable exterior wall members 71 and 72 , pivoting floor sections 61 and 62 ; folding upper and lower roof section 50 and 53 , and 51 and 52 , respectively; and pivoting ceiling members 81 and 82 , a plurality of prefabricated roof trusses of which only truss 31 is shown and ridge beam 56 . Central core 5 is comprised of interior core walls 22 , 23 , 24 , 26 , 27 and 28 , movable and detachable side walls 91 , 92 , 93 and 94 , and exterior core walls 21 and 25 all secured, both core floor 41 and ceiling member 40 as shown in FIGS. 2 , 3 and 4 . The central core is completely prefabricated and contains all piping, plumbing, and electrical control means (i.e.—circuit breaker box, etc.) for connection to external sources of supply (i.e. water, gas, electricity, etc.). Also, all necessary systems for the entire structure, e.g. heating, plumbing and electrical, and all the required appliances and plumbing fixtures are installed in the central core during prefabrication. Furthermore, any outlets that are to be located in any of the pivoting members, particularly the walls, are installed while the structure is being prefabricated.
[0061] As shown in FIG. 4, the core contains the kitchen including all its appliances; the bathroom—including the necessary plumbing fixtures, including a bathroom sink, tub/shower and toilet; and a closet with folding doors containing the hot water heater, washer and dryer. Each pivoting exterior wall (front wall 71 , rear wall 72 and side walls 91 , 92 , 93 and 94 ) is completely assembled during pre-fabrication. These walls would be constructed in the same manner as the core walls. One difference, however, is that these walls would each have one side facing the exterior of the building. These faces would then be covered with a sheathing, moisture barrier, and finally, the desired exterior facade.
[0062] Each wall is specifically fabricated from steel studs which are approximately spaced 16″ apart on a center-to-center basis. During prefabrication, windows are installed at predetermined locations into these walls, and the exterior surface of each folding wall; i.e., that surface which faces the outside environment, is covered with standard ½″ plywood sheathing material over which a moisture barrier along with the desired siding material, e.g. aluminum siding, PVC siding, asbestos shingle or other siding material, is applied. In addition, electrical outlet boxes are affixed to various studs in these walls and wired at the factory. To conform with standard building codes, all electrical wiring is placed inside each wall. Thereafter, thermal insulation is installed within each wall and illustratively ½″ gypsum board, (also known as “dry wall” or “sheet rock”) is then installed over the interior surface of each folding exterior wall, with an appropriately located prewired electrical outlet. If polystyrene embedded steel panels are used, such extra insulation may be eliminated. Roof and ceiling supporting structures are provided above the central core. These are located on and are supported by the common walls of the core, and preferably comprise a plurality of prefabricated steel truss assemblies. Each of the prefabricated trusses provide the necessary structural support for the upper and lower folding roof sections whenever they are pivoted into an open, i.e. unfolded, position. While only one truss 31 is shown in the cross-sectional view of FIG. 2, the house is illustratively comprised of a number of separate trusses, each fabricated from rafters and mounted on a 24″ center to center spacing. Any number of trusses can be used, with the particular number being predicated upon the desired spacing between trusses and the size of the structure. The spacing for the trusses (and also for the floor joists, wall studs and ceiling rafters) is often specified by local building codes and/or practice and can thus vary from that specified below. Each truss is pivotedly attached to upper roof sections 50 and 53 , and lower roof sections 51 and 52 of the roof. As shown in FIGS. 2 and 4, a number of structural members, including exterior side and front and rear walls and a pivoting floor member, are positioned during prefabrication substantially parallel to and alongside the interior core walls. These structural members are arranged in two groups of similar members, group 7 being adjacent to interior wall 28 and the other, group 8 , being adjacent to interior wall 22 . In the shipping configuration shown in FIG. 1, the structural members comprising each group are positioned alongside each other and are all substantially parallel to the adjacent interior core wall 22 or 28 . Group 7 is comprised of free-standing partition 105 , exterior side wall 91 , exterior front wall 71 and pivoting floor section 61 , and also, as is apparent from FIG. 4, walls 102 104 and exterior side wall 94 . Group 8 is comprised of similar structural members and free-standing partitions, specifically, exterior side walls 92 and 93 , exterior rear wall 72 , pivoting floor section 62 , interior walls 108 - 112 and free standing partitions 106 and 107 . It should be noted that interior walls are joined together, but are provided with an open area in between for access (i.e., a doorway). The same applies to wall 103 and 104 ; 108 and 110 ; and 109 and 111 .
[0063] In accordance with this feature of the invention, substantial closet space is incorporated into the folding structure through the use of the folding interior walls and free-standing partitions. When the structure is fully folded, these interior walls and partitions are initially positioned to lie alongside various interior side walls comprising the central core. Once the walls and floor members are pivoted into their properly installed positions, an enclosed area is defined around the core. Each pivoting interior wall and each free-standing partition are then pivoted or moved to a pre-determined position within this area in order to define all the rooms arranged about the core and all the closets existing therein.
[0064] Folding the Structure
[0065] The shipping configuration, shown in FIG. 1, is achieved during prefabrication by removing the interior walls and positioning the free-standing partitions against the core walls and positioning the various structural members inwardly about the central core.
[0066] First, free-standing partition 105 is positioned, alongside interior side core wall 28 . This partition is preferably oriented such that its vertical edges are parallel to those of the interior core wall. In a similar fashion, interior walls 101 - 104 are positioned, as shown in FIG. 4, such that each lie alongside interior side core walls 26 and 27 .
[0067] Thereafter, folding ceiling members 81 and 82 are each pivotedly positioned upwardly, as shown in FIG. 2, such that each folding ceiling member, e.g. ceiling member 81 , lies partially within and parallel to a corresponding lower folding roof member, e.g. folding roof member 51 . The rafters in each folding ceiling member are staggered with respect to those in each corresponding lower folding roof member such that when those ceiling members are folded their joints partially interleave with those in each corresponding lower roof folding section.
[0068] Next, as shown in FIG. 4, exterior side walls 91 and 94 are positioned inwardly, about corners 4 , such that these walls lie alongside free-standing partitions 105 and wall 101 , respectively. Then, exterior front wall 71 is positioned downward, such that it lies alongside pivoting floor section 61 .
[0069] Thereafter, pivoting floor section 61 is pivoted upward about pivot 2 located in the left end of core floor 41 , such that exterior front wall 71 , particularly its exterior surface, lies alongside exterior side wall 91 (and 94 not shown). Now, with all the exterior walls positioned inwardly about the core, upper folding roof section 50 and 53 are folded, as shown in FIG. 2, by being pivotedly positioned downward until each abuts against all the trusses, e.g. truss 31 . Lower folding roof sections 51 and 52 are then folded by being pivotedly positioned downward and inwardly such that each lies vertically alongside folded floor members 61 and 62 , respectively. The pivots 2 between folding floor members 61 and 62 and core floor 41 provides a for rotation of the pivoting floor section with respect to the central core floor, means for transferring the load from the pivoting floor section to the central core floor and provides a means for reducing frictional forces during rotation of the pivoting floor section. The pivoting means is preferably bolting means or the like. Specifically, this pivoting assembly may be a ½″ ASTM A307 bolt secured by washers and a nut. Similar pivots are between folding roof sections 51 and 52 and core 5 .
[0070] Unfolding the Structure
[0071] Having summarily described the sequence in which the walls are positioned, and the folding floor and roof members fold inwardly about the central core to form the folded structure shown in FIGS. 1-3, an explanation will now be given as to the manner in which the structural members are sequentially unfolded and interlocked to transform the house from its shipping, i.e., folded, configuration into a fully habitable residential dwelling as shown in FIG. 5.
[0072] The first structural members to be unfolded are the roof sections. As shown in FIG. 2, upper folding roof sections 50 and 53 are pivotedly positioned upward and outward. Ridge beam 56 is preferably a steel beam which runs the entire length of upper folding roof section 53 and abuts against the top edge of folding roof section 50 when both these roof sections are completely unfolded. The rafters that comprise each of these upper roof sections are steel beams located on a 24″ center-to-center spacing, and all the rafters comprising either of the upper roof sections are staggered with respect to those of the other. Once these upper roof sections are completely unfolded into position as shown in FIG. 2, the ridge beam and each rafter comprising folding roof sections 50 and 53 are secured sections in position. It should be noted that all upper roof sections have been fully sheathed and shingled during prefabrication. Next, as shown in FIG. 2, lower roof sections 51 and 52 , each comprised of illustratively steel rafters are pivoted upward and outward into position. These rafters are connected by pivots comprising bolts. Each pivot connecting both the upper and lower roof sections to the trusses, is comprised of a series of ½″ bolts (not shown), each of which runs through a rafter in a lower roof section, an adjacent truss and an adjacent rafter in upper roof section. A temporary support (not shown) is then positioned under the lower end of each of these lower folding roof sections and is adjusted to an appropriate height to temporarily keep each lower roof section in its completely unfolded position. To secure the roof sections in a final position, a properly sized nut which has been threaded onto the end of each bolt is fully tightened. Again all lower roof sections have been fully sheathed and shingled during prefabrication. Once the roof is completely unfolded, folding floor member 61 and 62 are pivoted into position. Specifically, both folding floor members are pivoted downward and away from the central core, thereby forming the entire floor for the dwelling. Thereafter, as shown in FIG. 8, exterior front and rear walls 71 and 72 are set into position. Specifically, each wall is positioned outward until the upper ends of exterior front wall 71 and exterior rear wall 72 abut against all the rafters comprising lower folding roof sections 51 and 52 , respectively. With these exterior front and rear walls secured in place, exterior side walls 91 , 92 , 93 , and 94 , as shown in FIG. 4, are then positioned and secured in place. Specifically, each exterior wall is positioned such that each end wall lies substantially perpendicular to the exterior front or rear walls. Once each exterior side wall is properly positioned, they are bolted to adjacent ceiling rafters and floor joists. At the end walls of the house, the ceiling and lower roof section are pivotally joined. The pivots utilized for this connection comprises means for rotation of the ceiling member with respect to the roof member, and for attaching the ceiling and roof member to the outer wall member. At this juncture, folding ceiling members 81 and 82 are unfolded into position. To accomplish this, folding ceiling members are pivoted downward such that unfolded ceiling member 81 lies on top of unfolded exterior front wall 71 and side walls 91 and 94 ; and unfolded ceiling member 82 lies on top of exterior front wall 72 and side walls 92 and 93 , respectively. Next, exterior front wall 71 is secured to unfolded ceiling member 81 and to lower folding roof section 51 . To further secure the exterior front wall to the lower roof section, a bolt and nut assembly (not shown) preferably ½″ diameter, which has been inserted through a pre-drilled hole and into a corresponding hole in the adjacent lower roof rafter during prefabrication, is tightened. Appropriate size washers may be used with each bolt. Exterior rear wall 72 is secured to lower folding roof section 52 in a substantially identical fashion. Since adequate support for the lower roof members is now provided by all the exterior walls, temporary supports, such as jacks that support these lower roof sections are now removed.
[0073] Once the folding ceiling members have been fully unfolded and secured in position, an enclosed area is defined about this central core. Then, interior walls 101 - 104 and 108 - 112 , and free-standing partitions 105 , 106 , and 107 , are moved into respective positions in this area to define both the rooms arranged about the central core and all the closets contained therein. Specifically, interior walls 103 and 112 are positioned in the same manner as does exterior side wall 92 . Once the interior walls are positioned, then each free-standing partition is appropriately positioned in place. The interior walls and partitions are completely framed and covered with gypsum board during prefabrication. Once in position, each of these interior walls and partitions are secured by bolts, nuts and washers to the floor joists in pivoting floor sections 61 or 2 , and to the rafters in ceiling members 81 and 82 . Specifically these bolts are driven through adjacent rafters in the ceiling and between joists in the folding floor members, and into the top (and bottom) horizontal studs comprising each of these interior walls and partitions. Advantageously, the use of free-standing partitions, which are positioned during on-site installation, to define room sizes and closets, readily permits changing the dimensions of these rooms and closets at any time up to installation without incurring much, if any, expense. While the doors to each of the closets formed by the free-standing partitions, as well as a number of interior room doors, have all been omitted for the sake of clarity from the plan views shown in the drawing, these doors are attached, i.e. pre-hung, to corresponding pivotal walls or free-standing partitions and interior core walls during prefabrication. Advantageously, this further reduces on-site installation time and expense.
[0074] As should be readily apparent, applicant's folding prefabricated house is now completely unfolded. At this stage of installation, the only portion of the dwelling that remains to be enclosed is the attic. To accomplish this, a prefabricated gable end is fixed to the outermost roof rafters and ceiling beams existing at each side of the dwelling. Specifically, each of the two gable ends, of which only gable end 97 is shown in FIG. 5, is triangularly shaped and is comprised of a series of steel studs (not shown) of appropriate length and mounted apart from each other on an approximate 16″ center to center spacing. A layer of sheathing (not shown), preferably ½″ plywood, is installed over these studs during prefabrication at the factory. After the gable ends are installed on-site, appropriate siding material, e.g. aluminum or shingle, is applied to the entire side of the house including the gable ends. Applying this type of siding in the field advantageously minimizes the likelihood that any misalignment between the siding on the gable ends and that on the rest of the exterior side walls will be visible. If, however, cedar shingles are used for siding, then any minor misalignment between the siding attached to the gable ends and that attached to the rest of the exterior side walls is generally not visible. Consequently, this siding material can be applied during prefabrication to both the gable ends and to all the exterior side walls in order to further reduce on-site installation time and cost. The prefabricated gable ends, are temporarily stored in the central core (more specifically by being placed on the floor of the core) while the folded house is being shipped to the building site.
[0075] The last remaining stage of installation, namely interior finishing, can now proceed. Specifically, the edges of any interior surfaces of abutting structural members are appropriately taped, spackled and sanded, in preparation for applying final wall covering, e.g. paint, or wallpaper. Thereafter, subflooring and final hardwood planking or other final flooring materials are installed in the previously unfloored areas of the house, i.e. above pivots 4 . Alternatively, the entire sub-floors and final floor covering can be installed on-site. While this latter approach slightly increases installation cost, it may be necessary, depending upon the final floor covering chosen by the owner, in order to eliminate any visible gaps or joint lines from appearing in the floor. Thereafter, molding and any remaining interior trim is now installed. At this point, the dwelling has been completely constructed and only requires connection to the local utilities, e.g. electricity and sewerage, for it to be completely habitable. An exterior perspective view of the dwelling as it stands completely installed and ready for occupancy is shown in FIG. 5.
[0076] In the illustrative embodiment described herein, heat is provided through electric baseboard. While electric heat is usually relatively expensive to operate, it is the least expensive to install. Consequently, separate electric baseboard units are installed along the interior bottom edge of various interior core walls and various folding walls. However, to minimize heating costs, a separate thermostat is installed in each room during prefabrication. Other types of heating, ventilating, and air conditioning systems, where desired, can be substituted for electric baseboard or added in addition thereto. Any desired system can be substantially shop installed during prefabrication. In addition, the necessary cable or wiring requirements (i.e., electrical, telephone, television, etc.) can be shop installed during prefabrication. Since the weight of a residential dwelling constructed in accordance with the teachings of the present invention is primarily supported by the walls comprising the central core, this advantageously permits all the pivoting structural members to be made relatively light. Consequently, this permits each member to be pivoted into position by a few workers without using any heavy machinery. Furthermore, the minimal weight inherent in the structure eliminates the need to incorporate any columns into the structure or to construct the foundation from reinforced concrete. Consequently, these factors advantageously reduce installation cost.
[0077] The exterior front walls are not limited to being co-planar when fully unfolded. The two walls making up the exterior front wall can be staggered to create a relatively large living room, and also lend a pleasing appearance to the front of the dwelling. In a similar fashion, any of the other walls and/or core walls are also not constrained to entirely lie in a single plane but can instead by comprised of a number of staggered or otherwise non-co-planar sections. Moreover, the pivoting floor and/or ceiling member can also take on many varied non-co-planar geometries to create many diverse and architecturally pleasing layouts. Consequently, a variety of differently shaped structures, including but by no means limited to a simple rectangular layout, can be easily fabricated using the principles of the invention.
[0078] [0078]FIG. 6 illustrates a single story structure which can be provided with a flat roof or used as the first or lower floors of a multi-story structure. The single story structure or the lower floors of the multi-story structure are not provided with folding roofs or roof trusses, but instead have ceiling members 40 a only in the area of the central core. Then, when such structure is to be used as a single story house, ceiling members 81 a , 82 a for the rooms adjacent to the central core are installed.
[0079] These members 81 a , 82 a shown in phantom in FIG. 6 may be pivotally connected to ceiling members 40 a in the same manner as the pivoting floor sections are connected to the core floor. Alternately, these ceiling members 81 a , 82 a may be field installed. In either embodiment, these ceiling members are partially supported at their opposite end by a pivotable wall member. Then, a flat or conventional roof can be constructed upon these ceiling members 40 a , 81 a , 82 a to complete the single story structure. For multi-story, construction, the lower structures are not provided with such ceiling members 81 a , 82 a , since the floors of the adjacent upper structure 61 , 62 become the ceiling members for the lower structure. For multi-story fabrication, it is advantageous to use steel beams 40 a positioned upon the central core and to stagger the position of these beams with respect to the position of the floor joists 40 of the upper structure. Also, these beams extend slightly beyond the width of the central core 5 so as to provide enough area to pivotally connect the folding side and internal wall members. In this construction, the floor joists 40 of the upper structure will be positioned between the steel beams 40 a of the lower structure. Also, the core walls, 22 , 28 are sufficiently sized to support the weight of the upper structure. Then, as mentioned above, the floor members 61 , 62 of the upper structure become the ceiling members of the lower structure.
[0080] Specifically, to construct a two-story residential dwelling as shown in FIG. 7, two folding structures—an upper and a lower of the type described previously, are stacked on top of each other. The main difference between these structures is that the lower structure does not contain a roof and appears substantially as shown in FIG. 6. At the time of on-site installation, the lower structure is first appropriately positioned on the foundation, and is then completely unfolded. All the folding structural members of the lower structure are then secured in position. As shown in FIG. 6, the lower folding structure is provided with 2″×10″ ceiling beams 40 a straddling the central core. As mentioned above these 2″×10″ beams are positioned in a staggered configuration such that they would not be directly under the floor joists of the upper structure. Then, the upper structure, in a completely folded position, is placed above the lower structure and the floor joists of the upper structure are supported by the walls of central core of the lower structure. In this arrangement, the floorjoists of the upper structure 61 , 62 become the ceiling rafters of the lower structure. All the ceiling beams 40 a of the lower structure thus abut against and are attached to the central core floor joists using appropriately sized nailing plates and nails. The remaining folding structural members of the upper structure are unfolded into position and secured as described hereinabove.
[0081] Appropriate openings are provided both in the ceiling of the central core of the lower structure and in the core floor member of the upper structure during their prefabrication in order to accommodate a stair case, which can be installed in the lower structure during its prefabrication. Any necessary banisters and the like are installed during the final interior finishing stage of on-site installation. Unless the two-story dwelling is to be a two family-house, there is little if any need to include any appliances and/or a hot water heater in the upper structure. Thus, the area reserved for the kitchen and closet in the central core can be converted into other usable space, e.g. a den or study. The technique of this invention may be used to form a single family home, a town home, a two story colonial style dwelling, among others.
[0082] As can be readily appreciated by those skilled in the art, multi-story structures in excess of two stories, such as three stories can be easily constructed in a similar manner to that described above. The number of separate folding structures that can be stacked to form the multi-story structure is essentially determined by the weight of each folding structure, and the amount of weight that can be supported by both the foundation and the walls in each folding structure, particularly the lowest in the stack.
[0083] The beams and studs used herein are metal channel beams, preferably steel channel beams having at least one flat side. The beams have a generally U-shaped cross-section with a wide flat side 150 extending to opposite perpendicular edges 152 as shown in FIG. 8A, or C-shaped cross-section with a wide flat side extending to opposite perpendicular edges having perpendicularly inwardly positioned edge flanges 154 as shown in FIG. 8B. Widths may range from about 6 inches to about 12 inches. Edges may have a height of from about 1⅜ inch to about 3½ inches. Edge flanges may range from 0 to 1 inch. Typical material thickness ranges from 18 gauge to 12 gauge, i.e. from about 0.046 inch to about 0.117 inch (about 1.184 mm to about 2.982 mm). Such may be made from galvanized or carbon steel coil or sheets using a Knudson Model KR-612H, available from Knudson Manufacturing, Inc of Broomfield, Colo. In an important embodiment of the invention, the beams and studs of the structure are connected by interlocking them together such as by fitting one beam or stud into a notch in an adjacent beam. FIG. 9 illustrates an interlocking of rafter beams wherein adjacent beams 156 , 158 have their edge flanges cut away and one beam rests on the other prior to bolting together. FIG. 10 illustrates an interlocking of a stud 160 to a beam 162 wherein a notch 164 is cut into an edge flange, a stud 160 is positioned within the notch 164 and rests on the opposite flange prior to the stud and beam being bolted together. In another preferred embodiment, the bolts, especially the bolts which act as pivots are locked into the structural members which they connect by being surrounded by self-tapping screws.
[0084] While the pivoting structural members, i.e. the walls, floors, ceiling and roof members, have been described above as folding and unfolding in a particular sequence, it is readily apparent to those skilled in the art that any or all of these structural members can be readily folded and unfolded in a variety of different sequences. The particular sequence is determined by the desired volume of the folded structure and the particular materials used for the folding members and manner in which these members are constructed.
[0085] [0085]FIG. 11 shows a trailer 202 on which the habitable structure of the invention may be built. The trailer comprises a rectangular framework 204 which is on at least four wheels. An upper edge of the rectangular framework comprising a channel 206 around a periphery of the framework. A habitable structure may be formed on the trailer by erecting a generally rectangular central core section of the previously described building within the channel 206 . A lowermost portion of each of the core walls is positioned within the channel 206 of the trailer framework 204 . The core is then erected on the trailer framework within channel 206 and then the folding rooms are added. This technique allows movement of the partially erected building structure from work station to work station within a suitable factory and then allows hauling of the finished structure to the final destination site, at which point it is lifted out of the trailer.
[0086] While the present invention has been particularly shown and described with reference to preferred embodiments, it will be readily appreciated by those of ordinary skill in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. It is intended that the claims be interpreted to cover the disclosed embodiment, those alternatives which have been discussed above and all equivalents thereto.
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The invention provides prefabricated folding residential dwellings comprised of prefabricated floor, wall and roof members that fold inwardly upon itself to produce a compact partially collapsed folded structure, which is easily transportable, and then unfold outwardly for quick and easy on-site installation.
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RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 61/040,412 filed Mar. 28, 2008, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a web based billing system for Medicare services provided through Care Plan Oversight.
BACKGROUND OF THE INVENTION
[0003] Family physicians spend a lot of time on the phone following up with patients, family and other caregivers to coordinate the care of patients. Unfortunately, most insurance companies' do not reimburse physicians for the amount of time spent in the phone, and physicians are specifically prohibited from billing Medicare patients for phone calls. Medicare considers this pre-visit and post-visit work to be a bundled component of Evaluation and Management (E/M) services. However, there is non-face-to-face service but can be billed for and will be reimbursed by Medicare: namely, Care Plan Oversight (CPO). Physicians often provide the service but do not bill for it because the rules are both complicated and extremely specific. The rules specify which provider can bill the service, which beneficiaries are eligible to receive the service, and which components make up Care Plan Oversight. However, the reimbursement for the service justifies taking some time to learn the rules, document the time spent and bill for the service. Apparently, growing numbers of physicians have been sorting through Care Plan Oversight CPO complexities. The Centers for Medical and Medicaid Services (CMS) have noted a significant increase in the payment to physicians for (CPO), from $15 million in 2000 to $41 million in 2001. As a result billing for CPO is an area that the Department of Health and Human Services Office of the Inspector General (OIG) has announced it will be scrutinizing more carefully this year for evidence of fraud.
SUMMARY OF THE INVENTION
[0004] On-line, web-based, software keeps patient information safe on a secure server. The physician and the office staff have log in ID's with unique password protection. Whenever the physician gets a phone call from the hospice or the homecare agency, and if he or she thinks that it is billable time, the physician can log in and enter the minutes himself or herself. Also when the paperwork is received from these agencies, the physician can write on the paperwork how much time was spent and the staff can enter the minutes spent into the software. At the end of the work, or at the end of the month, the software will calculate which patients are eligible to be billed along with the appropriate diagnosis. The agency name can be displayed on the billing report, and staff does not have to go back and forth to look in each patient's chart. The software saves time for the physician and staff in entering, calculating and billing the time spent i dealing with paper work received from homebound patients. The software is an excellent tool as the data can be entered from any computer. Data is safely stored and available to be viewed anytime. This software helps physicians reduce paperwork and get paid for the time they actually spent taking care of patients. The software will also create an online invoice for the physician's office for a small percentage of the amount billed.
[0005] Other applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
[0007] FIG. 1 is a simplified flow chart illustrating the online web-based software flow;
[0008] FIG. 2 is a screen shot of the sign in screen requesting user name and password;
[0009] FIG. 3 is the welcome screen after successfully logging in;
[0010] FIG. 4 is a screen shot of a patient list with data removed for confidentiality;
[0011] FIG. 5 is a screen shot of blank data fields to be filled in to create a new patient profile;
[0012] FIG. 6 is a screen shot of a pop-up for data entry into a particular patient file;
[0013] FIG. 7 is a screen shot of a billing screen with data removed for confidentiality; and
[0014] FIG. 8 is a screen shot showing billing history with data removed for confidentiality.
DETAILED DESCRIPTION
[0015] If a physician's situation meets all the requirements listed below, the physician is eligible to bill for services: (1) the physician cannot have a significant financial arrangement with the home health agency or hospice that is providing care to the patient; (2) the physician may not be an employee or medical director of the home health care agency or hospice; (3) only one physician per month may bill CPO; (4) neither a physician who is billing for end-stage renal disease services under a capitation arrangement nor a physician who is providing surgical follow-up in the global period may bill for CPO; (5) the physician who bills for the CPO must be the same physician who signed the certification for the home health agency or hospice in the first place; (6) the physician must have had a face-to-face service with the patient within 6 months of billing for the CPO; (7) the physician must have personally provided at least 30 minutes of service in one calendar month; (8) the beneficiary must be receiving Medicare covered home health or hospice services during the period in which CPO is billed; and (9) the beneficiary must require complex or multidisciplinary care modalities requiring ongoing physician involvement in the patient's plan of care.
[0016] The CPT manual defines CPO using six CPT codes, 99374 through 99380. Specifically, 99374 is used for 15 to 29 minutes and 99375 for 30 minutes or more. For services relating to hospice care, 99377 is used for 15 to 29 minutes and 99378 is used for 30 minutes or more. For services relating to nursing facility care, 99379 is used for 15 to 29 minutes and 99380 is used for 30 minutes or more. The physician must check with the various health plans to find out whether the health plan pays for these services; many do not pay for these services. Medicare however uses two HCPCS codes, G0181 and G0182, to define and pay for CPO. The definition of G0181 is “physician supervision of a patient receiving Medicare-coverage services provided by a participating home health agency (patient not present) requiring complex and multi disciplinary care modalities involving regular physician development and/or revision of care plans, review of subsequent reports of patent status, review of laboratory and other studies, communication (including telephone calls with other health care professionals involved in the patient's care, integration of that information into the medical treatment plan and/or adjustment of medical therapy within a calendar month, 30 minutes or more). G0182 describes the same service for a patient in a Medicare-approved hospice. HCPCS code G0181 has 3.28 relative value (RVU's) and G0182 has 3.46 (RVU's). By comparison, a patient visit coded as 99213 has 1.39 (RVU's). These are the national non-geographically adjusted RVU values.
[0017] A physician or non-physician practitioner must personally furnish CPO services. CMS recently clarified that a non-physician practitioner may bill for CPO. CMS defines non-physician practitioner as a nurse practitioner, a clinical nurse specialist or a physician assistant, and requires that the non physician practitioner have a collaborative relationship with the physician who signed the initial hospice or home health agency plan of care. The CPO services must take at least 30 minutes in a calendar month to be billable. The services do not need to be provided on the same day, but the total services over the course of a month must add up to at least 30 minutes. The physician or non-physician practitioner must personally document the date, the time spent and a brief description of the activities provided in the patient's record. The services should be billed to Medicare with a start date of the first of the month and an end date of the month's final day.
[0018] The following list helps sort out the activity a physician or non-physician practitioner can or cannot count toward the Care Plan Oversight time to be billed. A physician or non-physician practitioner can bill for the time spent: (1) reviewing charts, reports and treatment plans; (2) reviewing diagnostic studies if the review is not part an E/M service; (3) talking on the phone with other health care professionals who are not employees of the practice and are involved in the patient's care; (4) conducting team conferences; (5) discussing drug treatment and interactions (not routine prescription renewals) with a pharmacist; (6) coordinating care if physician or non-physician practitioner time is required; and (7) making and implementing changes to the treatment plan. A physician or non-physician practitioner cannot bill for the time spent: (1) renewing prescriptions; (2) talking with fellow employees at the practice; (3) traveling; (4) preparing or submitting claims; (5) talking to the patient's family, even if discussing treatment plan changes; (6) holding informal consults with physician's who are not treating the patient; (7) working on discharge services (99217 for observation care discharge, 99238 or 99239 for hospital discharge); and (8) interpreting test results at an E/M visit. In addition, a physician or non-physician practitioner may not bill for Care Plan Oversight work performed by staff who are neither physicians nor non-physician practitioners (defined by Medicare as a nurse practitioner, a clinical nurse specialist, or a physician assistant who has a collaborative relationship with a physician who signed the initial hospice or home health agency plan of care).
[0019] Patients are eligible to receive CPO services if they require complex treatment, are being cared for by multi disciplinary teams, and are under the care of a Medicare-approved home health agency or hospice. For example, a family physician sees an elderly patient with diabetes who lives alone and has non-healing skin ulcers. The patient is enrolled in and receiving services from a home health agency, and the physician signs the initial plan of care. Over the course of the month, the physician coordinates care with the agency's nursing staff, arranges for treatment at a wound clinic and talks to the treating physician there, reviews multiple lab results not related to an office visit or other E/M service and adjust the patient's medication. The physician spends more time than 30 minutes during the month doing these activities, documents the dates, times and services, and bills G0181.
[0020] Another example is medical care for a patient undergoing chemotherapy for colon cancer. The family physician signs the plan of care, certifying the patient for home health services, and provides an E/M service. During the course of the month, the physician discusses the patient's care with the oncologist, manages the patient's pain, arranges for nutrition services and interacts with the home health agency staff. Over the course of the calendar month, the physician spends more than 30 minutes on these activities and documents the services, dates, and time, then G0181 can be billed.
[0021] Billing for Care Plan Oversight requires the establishment of a monthly routine to ensure payment for services. One manual approach would be to first create a written log of all patients for whom CPO is provided each month. The log list can remind the physician or non-physician practitioner which charts to pull at the end of the month when it is time to submit claims for payment of services provided during that month. Second, a written CPO service log can be kept in each patient's chart and the physician can document the date, total time and a brief description of the services, each time services are provided to that particular patient. The CPO documentation must be signed by the physician or non-physician practitioner. At the end of the month, a staff person can collect the logs from the patient's charts, total the time and bill CPO for those patients that have been provided more than 30 minutes of CPO during the calendar month. Use the start and end dates of the month as the service dates, and put the provider number of the home health agency/hospice on the claim form. Finally, return the logs to the charts for use in future months.
[0022] The challenges for billing for Care Plan Oversight is that there are several thousand charts in a typical primary care practice and most of those charts are stored in a paper format. Most practices that have charts alphabetically lined up in the chart cabinet. When a HCFA 485 form is received from the home care or hospice agency the form is signed and filed in the patient's chart. Subsequent forms from these agencies are also signed and filed. It is difficult to keep tab of minutes spent with the agency staff and insert those minutes in each chart each day. Finally, it is impossible to pull out each patient chart at an end of the month and see if any patient has 30 minutes or more of care provided. Also time spent by the physician office is scattered between the physician, medical assistants, nurse and receptionist. Mostly the physician is the final decision maker to change plan of care. There are several agencies, which send the paperwork to the physician's office, and each agency has their unique way of sending information. Not all the agencies send paperwork in timely fashion. There is not one contact person who enters information in a patient's chart and gets the charts, which have met the requirements to be billed.
[0023] The Care Plan Oversight billing software was created by a physician after trying several years of paper method of collecting data and entering minutes and finally analyzing which patient can be billed. The on-line web based billing software solution solves the difficulties encountered by physicians in dealing with the collection of data, entering minutes, and analyzing which patient's can be billed. The software could also be provided in a standalone or network version, rather than the online web-based version, if desired. The online software keeps the patient information safe on a secure server. The physician and the office staff have log in ID's which are unique password protected. Whenever the physician gets a phone call from the hospice or home care agency, and if he/she thinks it is billable time, the physician can log in and enter the minutes himself or herself. Also, when the paper work is received from these agencies, the physician can write on the paperwork how much time was spent and the staff can enter the minutes spent into the CPO billing software. At the end of the week or the end of the month, the software will calculate which patients are eligible to be billed along with the appropriate diagnosis. Also, the agency name can be displayed on the billing report, and staff does not have to go back and forth to locate each patient's chart. The CPO billing software saves time for the physician and his staff in entering, calculation, and billing the time which was spent on dealing with the paperwork for homebound patients. The CPO billing software is an excellent tool. The online version allows data to be entered from any computer. Data is safely stored and available to be viewed at any time. The CPO billing software helps a physician reduce paperwork and get paid for the time which is actually spent taking care of patients. The CPO billing software can also create an online invoice for the physician office. The online version can be marketed to provide billing services in return for a small percentage of the amount billed.
[0024] Referring now to FIG. 1 , a flowchart illustrates the flow through various pages of the online web based CPO billing software. The standalone or network versions of the software would be similar to that illustrated in FIG. 1 . The online user is first presented with a home page 10 . The home page 10 provides the opportunity to jump to one of the following page options: CPO billing page 12 through link 12 a , Physician Network page 14 through link 14 a , Hospitals page 16 through link 16 a , Buy/Sell Practice page 18 through link 18 a , Billing page 20 through link 20 a , and Contact Us page 22 through link 22 a . If the CPO billing page 12 is selected through link 12 a , the CPO screen 24 is displayed. On the CPO screen 24 , it is determined if the sign-in is for a new user 26 . If the sign-in is for new user, the software branches to registration of the new user 28 . If the sign-in is not by a new user or if a new user has been registered, the software continues to the sign in screen 30 of the online user. Once the online user has signed in on the sign-in page 30 , the software allows access to the secure section 32 . In the secure section 32 , the online user is provided access to select one of the following: (1) patent list page 34 through link 34 a ; (2) patient profile page 36 through link 36 a ; (3) billing report page 38 through link 38 a ; (4) CPO invoice page 40 through link 40 a ; and (5) physician profile page 42 through link 42 a . If the patient list screen 34 is selected through link 34 a , the online user can then select one of the following: (1) add new patient screen 44 through link 44 a ; (2) update patient profile screen 46 through link 46 a ; or (3) delete patient screen 48 through link 48 a . If the update patient profile screen 46 is selected through link 46 a , the add/update CPO time screen 50 for that particular patient is displayed for online user data entry. When in the secure section 32 , if the report screen 38 is selected, the online user can then select the pending billing 52 screen or the billing history 54 screen. When the online user wishes to leave the secure section 32 , the online user selects the sign out and is presented with the sign out page 56 which ends the online user's access to the secure section 32 .
[0025] Referring now to FIG. 2 , the sign-in screen 30 is illustrated with a link 28 a to create a new user profile 28 and with links 12 a , 14 a , 16 a , 18 , 20 a , 22 a to the main headings for CPO billing screen 12 , physician network screen 14 , hospital screen 16 , buy/sell practice screen 18 , billing screen 20 , and contact us screen 22 , respectively.
[0026] After an online user has successfully logged in, FIG. 3 welcome screen to the secure section 32 appears. From this screen as illustrated in FIG. 3 , the user can access the links 34 a , 36 a , 38 a , 40 a , 42 a to the patient list screen 34 , patient profile screen 36 , billing report screen 38 , CPO invoice screen 40 , and physician profile screen 42 , respectively. Each physician has a unique user log-in ID and password to securely log into the CPO billing software from any computer or cell phone which has internet access through the first sign-in screen page 30 . Once the physician logs in, the secure section screen 32 illustrated in FIG. 3 welcomes the logged in online physician user by showing the appropriate practice name. The data stored in the CPO billing software is stored on a secure server and is HIPPA compliant.
[0027] If the patient list screen 34 is selected, the screen can display an entire list of patients which have been entered, and can also display the home care/hospice company's name along with patient's diagnosis. The patient list can be filtered by patient name, if desired. The list can also be filtered by showing all patients, or limiting the list to home care patients, or limiting the list to hospice patients. Each patient is assigned a unique ID or can be searched using the filter. Patient's data can also be retrieved using the home care or hospice filter criteria. If the add new patient screen 44 is selected, a new patient profile data entry screen is displayed as illustrated in FIG. 5 . The appropriate data is entered and the add new patient screen 44 by the online user and once updated, the new patient profile will show on the patient list screen 34 .
[0028] If the update patient profile 46 screen is selected from the patient list screen 34 by selecting an individual patient, the add/update CPO time screen 50 will display as illustrated in FIG. 6 . When the patient is selected, it automatically brings the subsequent CPO 1 and CPO 2 data up in an overlay on the patient list screen 34 . The add/update CPO time screen 50 displays the subsequent two CPO data periods (CPO 1 and CPO 2 ) for home care patients, and if it is a hospice patient six CPO data periods are displayed. Minutes can be added in any row as considered appropriate by the physician or non-physician practitioner. The CPO billing software will automatically save time and when the displayed screen adds up to 30 minutes or more for a particular month, the CPO billing software will generate a billing report for that patient.
[0029] If the billing report screen 38 is selected, the list of pending billables is displayed by patient name. The list can be filtered by patient name. The billing report contains all the patients which are ready to be billed for Care Plan Oversight. The biller can put a check mark in the column after billing and then the patient's name is sent to the billing history report. A physician using an out of office biller can print the report and send it to the biller for billing. The pending billing screen 52 is illustrated in FIG. 7 . The online biller can put a check mark in a column after billing and then the patient name is sent to billing history report screen 54 .
[0030] Referring now to FIG. 8 , the billing history screen 54 keeps a running data list of patients which have been billed, for which kind of CPO and on which date. The billing history also stores which company had offered services to the patient. It makes it easier to contact the company to get data in case of an audit. The billing history also saves the diagnosis codes and displays the diagnosis codes on the screen. The Care Plan Oversight invoice screen will save the data for how many CPO's are billed each month and contains a copy of the invoice.
[0031] The Care Plan Oversight billing software provides an easy use online, web-based system allowing a physician or a non-physician practitioner to keep accurate records regarding Home Plan Oversight services provided to patients. The CPO billing software collects individual patient data, diagnosis, certification, and service provider information. For each patient, the CPO billing software then collects data regarding the amount of time spent by the physician or non-physician practitioner providing billable services to the patient. The physician or non-physician practitioner enters the appropriate amount of time spent on billable services in each patient's data base on an ongoing basis. At the end of each calendar month, the CPO billing software accumulates and calculates the amount of billable time spent by the physician or non-physician practitioner for each particular patient and determines if it meets a threshold of 30 minutes or more for billing purposes for that month. For each patient who has been rendered billable services greater than the minimum threshold, the appropriate data is sent to the pending billing screen list for billing. After billing, a billing history list is generated and maintained for future reference.
[0032] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law
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A system for billing Care Plan Oversight services including storing patient data in a databases; accumulating time for Care Plan Oversight services provided to individual patients in the patient databases; and periodically calculating a total accumulated time for Care Plan Oversight services provided to each patient in a predetermined time period window and if greater than a predetermined threshold, generating a billing statement for that particular patient.
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BACKGROUND
The invention relates to residential load shedding.
A typically U.S. house is wired with the capacity to consume approximately 24 kilowatts (kW) of electrical power from an electrical utility company. However, the typical house consumes a much lower annual average power near approximately 1 kW. In order to consume 24 kW of power, nearly all of the electrical appliances and devices in the house would have to be turned on at the same time.
Conventionally, for purposes of receiving electrical power, the house is connected to a power grid that communicates electricity from one or more electrical power plants (hydroelectric or nuclear power plants, for example). However, in the near future, the house may receive partial or total power from its own fuel cell system.
For purposes of generating power, the fuel cell system includes fuel cells that are electrochemical devices that convert chemical energy produced by reactions directly into electrically energy. For example, one type of fuel cell includes a proton exchange membrane (PEM), a membrane that may permit only protons to pass between an anode and a cathode of the fuel cell. At the anode, diatomic hydrogen (a fuel) is oxidized to produce hydrogen protons that pass through the PEM. The electrons produced by this oxidation travel through circuitry that is external to the fuel cell to form an electrical current. At the cathode, oxygen is reduced and reacts with the hydrogen protons to form water. The anodic and cathodic reactions may be described by the following equations:
H 2 →2H + +2 e −
at the anode of the cell, and
O 2 +4H + +4 e − →2H 2 O
at the cathode of the cell.
Because a single fuel cell typically produces a relatively small voltage (around 1 volt, for example), several serially connected fuel cells may be formed out of an arrangement called a fuel cell stack to produce a higher voltage. The fuel cell stack may include different plates that are stacked one on top of the other in the appropriate order, and each plate may be associated with more than one fuel cell of the stack. The plates may be made from a graphite composite material and include various channels and orifices to, as examples, route the above-described reactants and products through the fuel cell stack. Several PEMs (each one being associated with a particular fuel cell) may be dispersed throughout the stack between the anodes and cathodes of the different fuel cells. The anode and the cathode may each be made out of an electrically conductive gas diffusion material, such as a carbon cloth or paper material, for example.
A fuel cell system typically is sized to efficiently provide a predefined range of output power. In this manner, components of the fuel cell system, such as electrical devices (electrical motors for pumps and blowers, for example) and non-electrical devices (valves, for example), may be sized to produce the predefined range of output power. If the fuel cell system is sized to provide the maximum power (24 kW, for example) that may be consumed by the average house, then the fuel cell system may suffer from inefficiency at the much lower output power that is typically consumed by the house. Additionally, the base cost of such a fuel cell system may be higher due to the system components that are designed to support a larger power output.
SUMMARY
In one embodiment of the invention, a system includes a fuel cell subsystem, switches and a controller. The fuel cell subsystem is adapted to provide power that is capable of being consumed by residential loads, and the fuel cell subsystem is sized to provide power up to a first power threshold that is less than a maximum power threshold that is capable of being consumed by the residential loads. The controller is adapted to determine the power that is consumed by the residential loads and based on the determined power, operate the switches to selectively regulate electrical connections between the residential loads and the fuel cell subsystem to keep the power approximately below the first power threshold.
Advantages and other features of the invention will become apparent from the following description, from the drawing and from the claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of a residential electrical system according to an embodiment of the invention.
FIG. 2 is an illustration of a priority scheme for shedding loads of the electrical system of FIG. 1 according to an embodiment of the invention.
FIG. 3 is an illustration of a priority scheme for connecting loads to the electrical system of FIG. 1 according to an embodiment of the invention.
FIG. 4 is a flow diagram illustrating execution of a routine to shed loads of the electrical system of FIG. 1 according to an embodiment of the invention.
FIG. 5 is a flow diagram illustrating operation of a routine to connect loads to the electrical system of FIG. 1 according to an embodiment of the invention.
FIG. 6 is a power versus time plot.
FIG. 7 is a schematic diagram of a fuel cell system of the electrical system of FIG. 1 according to an embodiment of the invention.
FIG. 8 is a schematic diagram of a well pump system according to an embodiment of the invention.
FIG. 9 is a schematic diagram of a load sense and switch circuit of the electrical system of FIG. 1 according to an embodiment of the invention.
DETAILED DESCRIPTION
Referring to FIG. 1, an embodiment 10 of a residential electrical system in accordance with the invention includes controlled residential loads 16 (controlled residential loads 16 1 , 16 2 . . . 16 N , as examples) and uncontrolled residential loads 18 that receive power from a fuel cell system 12 (of the residential electrical system 10 ). The controlled residential loads 16 may be, as examples, appliances (a refrigerator and/or an electric oven, as examples) and/or other electricity consuming devices. The components of the fuel cell system 12 , such as flow control motors 14 , valves, etc. are sized to produce a maximum output power that is below the maximum power that may be collectively consumed by the residential loads 16 and 18 . To ensure that the fuel cell system 12 is not overloaded, a fuel cell control circuit 15 (of the fuel cell system 12 ) is designed to monitor the output power of the fuel cell system 12 and shed the appropriate controlled loads 16 to regulate the output power.
Unlike the controlled residential loads 16 , the uncontrolled residential loads 18 may not be shed from the electrical system 10 for purposes of reducing the power output of the fuel cell system 12 . Instead, each uncontrolled residential load 18 is coupled to the fuel cell system 12 by wiring of the house that may be disconnected from the fuel cell system 12 only by a standard circuit breaker panel switch (not shown). In this manner, the circuit breaker panel switch may be manually turned off or may automatically turn off if the current through its associated house circuit exceeds a predefined level. Similar to the controlled residential loads 16 , the uncontrolled residential loads 18 may be, as examples, appliances and/or other electricity consuming devices.
A technique of storing electricity, such storing energy in a storage battery 85 (a lead acid battery, for example), may be utilized for extending the peak power output capability of the fuel cell system 12 . This way the maximum peak power output of the fuel cell system 12 is equal to the combined peak outputs of both the battery 85 and the fuel cell system 12 . The battery 85 provides extra power capability for limited periods of time based on its capacity and state of charge. Load shedding may be used to prevent completely discharging the battery 85 by limiting peak load based not only on the peak output of the fuel cell system 12 , but also taking into consideration the battery's state of charge. During periods of low load (i.e., low output power), the battery is recharged using the fuel cell system's excess capacity.
The fuel cell control circuit 15 may shed the controlled residential loads 16 from the electrical system 10 based on the output power (of the fuel cell system 12 ) that is depicted by an exemplary waveform 79 in FIG. 6 . In some embodiments, the fuel cell control circuit 15 regulates the total load on the fuel cell system 12 to satisfy the following criteria: 1. The output power does not exceed a maximum power threshold level (called TH U (see FIG. 6 )); 2. The output power does not exceed a middle power threshold level (called TH M ) for a time interval that is longer than a predefined window 100 of time; and 3. The output power does not exceed a lower power threshold level (called TH L ) for a time interval that is longer than a predefined window 105 of time. The window 105 is longer than the window 100 , as depicted in FIG. 6 .
Although the fuel cell system 12 may be sized to provide an output power up to the TH L lower power threshold level, the ability of the fuel cell system 12 to temporarily furnish power above this level due to the battery 85 . In this manner, as further described below, the fuel cell system 12 may use the battery 85 to temporarily boost the output power when the output power exceeds the TH L lower power threshold level. However, because the energy that is stored by the battery 85 is limited, the fuel cell system 12 may monitor the remaining energy that is stored in the battery 85 and set the durations of the windows 100 and 105 accordingly. Thus, the durations of the windows 100 and 105 are dynamic and are a function of how long the battery 85 has recharged between successive power surges. As a more specific example, at a particular moment, the duration of the window 100 may be approximately one half of a second (as an example), and the duration of the window 105 may be approximately 30 seconds (as an example). However, the fuel cell system 12 may change the window durations as needed in accordance with the available energy that is stored in the battery 85 .
In some embodiments, to accomplish the above-described regulation criteria, the fuel cell control circuit 15 may operate switches 29 (see FIG. 1) in the following manner to shed the controlled residential loads 16 . If the fuel cell control circuit 15 determines that the output power of the fuel cell system 12 is above the TH U upper power threshold level, then the fuel cell control circuit 15 immediately switches off one or more of the controlled residential loads 16 to return the output power below the TH U upper power threshold level. If the output power rises above the TH M middle power threshold level, then the fuel cell control circuit 15 sheds one or more of the controlled residential loads 16 to bring the power level under the TH M middle power threshold level within the window 100 . If the output power is above the TH L lower power threshold level, then the fuel cell control circuit 15 sheds one or more of the controlled residential loads 16 to bring the output power below the TH L lower power threshold level within the window 105 .
As depicted in FIG. 1, each switch 29 is located between the power lines 21 and a different set of power lines 27 that extend to an associated controlled residential load 16 . Therefore, if the fuel cell control circuit 15 determines that the output power needs to be reduced, then the fuel cell system 12 sheds the appropriate controlled residential load(s) 16 by opening one or more of the switches 29 to disconnect the controlled residential load(s) 16 from the electrical system 10 (and from the fuel cell system 12 ). The uncontrolled residential loads 18 may be directly connected to the power lines 21 .
Each switch 29 may be part of a load sense and switch circuit 24 (circuits 24 1 , 24 2 , 24 3 , . . . 24 N , as examples) that is associated with the same controlled residential load 16 as the switch circuit 29 . In some embodiments, each switch circuit 24 may provide various indications to the fuel cell control circuit 15 . For example, the circuit 24 may communicate an indication of whether its associated controlled residential load 16 is turned on or off and may communicate, for example, an indication of the power that is currently being consumed by its associated controlled residential load 16 . Therefore, for example, if the fuel cell control circuit 15 needs to connect one of the controlled residential loads 16 , the fuel cell control circuit 15 may communicate with the associated circuit 24 to determine the most recent historical power consumption profile of the associated controlled residential load 16 for purposes of ensuring that turning on this controlled residential load 16 does not exceed the TH L lower power threshold level. For example, the circuit 24 may track the maximum power level that has been consumed by the associated controlled residential load 16 during the last hour (for example) and communicate this maximum power level to the fuel cell control circuit 15 . Other arrangements are possible.
The fuel cell control circuit 15 may, in some embodiments, use the indications from the circuits 24 to identify the connected controlled residential loads 16 that are connected and are not currently consuming power, i.e., to identify which controlled residential loads 16 are turned off. In this manner, the fuel cell control circuit 15 may shed these identified controlled residential loads 16 to prevent a momentary overload that may occur if the identified controlled loads 16 are turned on.
Referring to FIG. 2, the fuel cell control circuit 15 may follow a predefined priority scheme when shedding, or disconnecting, the controlled residential loads 16 to bring the output power within the specified range. For example, in some embodiments, the fuel cell control circuit 15 assigns a different priority level to each controlled residential load 16 and may use a round robin disconnection priority scheme 40 to select the next controlled residential load 16 that is to be disconnected from the electrical system 10 (and from the fuel cell system 12 ). As an example, in the disconnection priority scheme 40 , the controlled residential loads 16 may have the following disconnection priority (according to the reference numbers of the controlled residential loads 16 , as listed from the top to the bottom disconnection priority level in order): 16 1 , 16 2 , 16 3 , . . . 16 N . Thus, the fuel cell control circuit 15 may disconnect the controlled residential load 16 1 (assuming that the controlled residential load 16 1 is connected) before disconnecting the controlled residential load 16 2 (assuming that the controlled residential load 16 2 is connected), as depicted in FIG. 2 .
In some embodiments, the controlled residential loads 16 that consume more power may have a higher disconnection priority and therefore, may be disconnected before the other controlled residential loads 16 . In some embodiments, if a particular controlled residential load 16 is associated with an electrical device/appliance that has a substantial potential energy, then the controlled residential load 16 is assigned a higher priority for shedding purposes.
For example, a high thermal mass is one type of potential energy that permits a particular electrical device/appliance to function after being disconnected and thus, the disconnection may go unnoticed inside the house. For example, one such device that has a high thermal mass (and substantial potential energy) is a hot water heater, as the hot water inside a tank of the hot water heater may remain hot for a substantial time after electricity to the water heater has been disconnected.
Similarly, an air conditioner may have a high thermal mass (and substantial potential energy) in that evaporation coils of the air conditioner may remain cold when a compressor (that is part of a controlled residential load 16 ) is turned off. The blower of the air conditioner may remain electrically connected to the system 10 (i.e., the blower is not part of the circuit that forms the controlled residential load 16 that is disconnected) to continue to blow air over the evaporation coils to produce cold air in the house. Therefore, disconnection of the compressor may go unnoticed for a substantial time. Other controlled residential loads 16 that may have a high thermal mass (and substantial potential energy) may be a heat pump, an oven, an electric dryer and a pool heater, as just a few examples.
Referring to FIG. 8, as another example of a load that has a substantial potential energy may be a system that includes a well 202 and a well pump 200 . The well pump 200 pumps water into a pressurized reservoir tank 204 . In this manner, the pressurized reservoir tank 204 may house an air bladder 206 , for example, that is compressed when water 208 is stored in the reservoir tank 204 . Therefore, by temporarily disconnecting the water pump 200 , water may still be supplied to a water outlet line 210 (of the reservoir tank 204 ) that furnishes water to the house, and residents inside the house may not notice a temporary disconnection of the water pump 200 .
Referring to FIG. 3, for purposes of connecting the controlled residential loads 16 to the electrical system 10 when the fuel cell system 12 is producing output power that is less the TH L lower power threshold level (see FIG. 6 ), the fuel cell control circuit 15 may use a connection priority scheme 42 . In particular, the connection priority scheme 42 may include connecting the controlled residential loads 16 in an order that is opposite to the disconnection order of the disconnection priority scheme 40 , described above. In this manner, in the connection priority scheme 42 , the controlled residential loads 16 may have the following connection priority (according to the reference numbers of the controlled residential loads 16 , as listed from the top to the bottom connection priority in order): 16 N , 16 3 , 16 2 , . . . 16 1 . Therefore, as an example, the fuel cell control circuit 15 may connect the load 16 3 before the fuel cell control circuit 15 connects the load 16 2 .
In some embodiments, the fuel cell control circuit 15 may be a processor-based (a microcontroller-based, for example) circuit that stores a program 19 that the fuel cell control circuit 15 executes to perform the above-described disconnection and connection of the controlled residential loads 16 . For example, referring to FIG. 4, the program 19 may include a routine 23 that the fuel cell control circuit 15 executes to perform the shedding, or disconnection, of the controlled residential loads 16 . In particular, the fuel cell control circuit 15 may determine (diamond 62 ) whether the output power is below the TH U upper power threshold level. If so, then the fuel cell control circuit 15 selectively disconnects (block 64 ) one of more of the controlled residential loads 16 (pursuant to the disconnection priority scheme 40 described above) until the power output of the fuel cell system 12 is below the upper power threshold level TH U .
Next, the fuel cell control circuit 15 determines (diamond 66 ) whether the power output of the fuel cell system 12 is below the TH M middle power threshold level during a window 100 from a time when the output power exceeded the TH M middle power threshold level. If not, then the fuel cell control circuit 15 selectively disconnects (block 68 ) the controlled residential load(s) 16 until the power output of the fuel cell system 12 is below the TH M middle power threshold level. Subsequently, the fuel cell control circuit 15 determines (diamond 70 ) whether the power output is below the TH L lower power threshold level for a window 105 from a time when the output power exceeded the TH L lower power threshold level. If not, then the fuel cell control circuit 15 selectively disconnects (block 72 ) the controlled residential load(s) 16 until the power output of the fuel cell system 12 is below the TH L lower power threshold level. The routine 23 may cause the fuel cell control circuit 15 to return to the diamond 62 as long as the power is above the TH L lower power threshold level.
Referring to FIG. 5, for purposes of connecting the controlled residential loads 16 to the electrical system 10 , the program 19 may include a routine 31 . In particular, the routine 31 , when executed, may cause the fuel cell control circuit 15 to determine (diamond 74 ), in accordance with the connection priority scheme 41 , whether a particular controlled residential load 16 is connected. If so, the fuel cell control circuit 15 returns to diamond 74 . Otherwise, the fuel cell control circuit 15 determines (diamond 76 ) whether the total output power of the fuel cell system 12 will remain below the TH L lower power threshold level when the targeted controlled residential load 16 is connected. The fuel cell control circuit 15 may make this determination by, for example, interacting with the associated circuit 24 to retrieve the most recent history of the controlled residential load 16 . If the fuel cell control circuit 15 (based on the power history that is provided by the circuit 24 ) determines that the power output after connection of the targeted controlled residential load 16 will remain below the TH L lower power threshold level, then the fuel cell control circuit 15 connects (block 78 ) the targeted controlled residential load 16 .
Referring back to FIG. 1, in some embodiments, the fuel cell control circuit 15 may further base the disconnection/connection on other criteria than assigned priority levels. For example, the fuel cell control circuit 15 may use one or more temperature sensors 17 to sense a temperature that is associated with the controlled residential load 16 and further base the connection\disconnection on the sensed temperature. For example, the fuel cell control circuit 15 may sense an air temperature inside the house and base the disconnection of an air conditioner (i.e., a controlled residential load 16 for this example) on the sensed temperature. In this manner, if the sensed temperature is below a predetermined temperature level, the fuel cell control circuit 15 may disconnect another controlled residential load 16 (instead of the air conditioner) that has a lower priority level. As other examples, the fuel cell control circuit 15 may use the temperature sensors 17 to sense the temperatures of water in a pool and water in a hot water heater and base connection/disconnection of a pool heater and a hot water heater on these sensed temperatures.
Referring to FIG. 7, in some embodiments, the fuel cell system 12 may include the fuel cell control circuit 15 that stores the program 19 (that includes the above-described routines 23 and 31 ) in a memory (an electrically erasable programmable read only memory (EEPROM) or a flash memory, as just a few examples) of the fuel cell control circuit 15 . Copies of the program 19 may also be stored, as an example, on a mass storage device (a hard disk drive, for example) or on removable media (a floppy disk or an optical disk, as examples), as just a few examples.
The fuel cell system 12 also includes a fuel cell stack 80 that is electrically coupled to the power lines 21 . In this manner, the fuel cell stack 80 furnishes DC power to an inverter 84 that furnishes AC power to the power lines 21 . An inverter controller 82 may be coupled to the inverter 84 to monitor the power output of the fuel cell system 12 and may communicate the monitored power to the fuel cell control circuit 15 via a serial bus 81 , for example. For purposes of establishing communication between the circuits 24 and the fuel cell control circuit 15 , the fuel cell system 12 may include a power line modem 92 . In this manner, the modem 92 may use a power line transmission protocol (an X-10 bus protocol, for example) to communicate with the circuits 24 via the power lines 21 . A reformer controller 88 (that controls a reformer (not shown) via control lines 90 ) may be coupled to the serial bus 81 along with a motor driver board 86 that controls the motors 14 .
Among the other features of the fuel cell system 12 , the fuel cell control circuit 15 may monitor the voltages and currents of the fuel cell stack 80 via a fuel cell voltage scanner circuit 44 . The battery 85 may be coupled to the inverter 84 so that the battery 85 is discharged during power output levels that exceed the TH L lower power threshold level (during the windows 100 and 105 ) and recharged otherwise. A supervisory controller 87 determines the energy that is currently stored in the battery 85 by monitoring the power that charges the battery 85 and the power that is depleted from the battery 85 . One way that the supervisory controller 87 may accomplish this is to use a current sensing circuit 91 (that is coupled between the battery 85 and the inverter 84 ) to monitor the current to/from the battery 85 . The supervisory controller 87 may include other control lines 89 that the supervisory controller 87 uses to coordinate the above-described activities of the fuel cell system 12 .
Referring to FIG. 9, in some embodiments, the circuit 24 may be packaged to be installed in a breaker panel socket and may include the following circuitry. The circuit 24 may include a reactive power measuring circuit 112 that measures the power transmitted via the power lines 21 to the associated controlled residential load 16 . A controller 114 (a microcontroller, for example) may be coupled to the circuit 112 to receive an indication of the load and communicate the results to the fuel cell control circuit 15 via a power line modem 110 that is coupled to the power lines 21 . The power line modem 110 communicates with the power line modem 92 using the power line transmission protocol. In this manner, the fuel cell control circuit 15 may communicate via the power lines 21 and the power line modem 110 to the controller 114 to instruct the controller 114 to close the switch 29 . The switch 29 may be formed from relay driver 116 and a relay 118 . The controller 114 may interact with the relay driver 116 to open or close the relay 118 to disconnect or connect, respectively, the associated controlled residential load 16 .
The circuit 24 may also include a current breaker switch 25 to disconnect the associated controlled residential load 16 if the current through the switch 29 exceeds a predefined current level. The current breaker switch 25 may also be opened or closed by a manual switch lever, for example.
While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of the invention.
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A system includes a fuel cell subsystem, switches and a controller. The fuel cell subsystem is adapted to provide power that is capable of being consumed by residential loads, and the fuel cell subsystem is sized to provide power up to a first power threshold that is less than a maximum power threshold that is capable of being consumed by the residential loads. The controller is adapted to determine the power that is consumed by the residential loads and based on the determined power, operate the switches to selectively regulate electrical connections between the residential loads and the fuel cell subsystem to keep the power approximately below the first power threshold.
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FIELD OF INVENTION
[0001] The present invention relates to a detergent formulation which is useful in a dishwasher. The inventiveness of the present invention applies by adding an enzyme in the formulation. The present invention further relates to a novel detergent formulation that is useful in automatic dishwashing machine, wherein the formulation comprises a thermostable lipase. Also, the detergent formulation provides cleaning and finishing benefits across a wide range of temperatures, improves energy profile of a dishwashing process.
BACKGROUND OF THE INVENTION
[0002] Detergents are synonymous with any chemical that cleans or get rid of stains. They have been used to remove stains since centuries ago, particularly when the most fundamental form of a detergent or surface active agents (surfactants)—soaps, were created out of ashes and fat (Levey, M. (1958) Gypsum, salt and soda in ancient Mesopotamian chemical technology. Isis. 49(3): p. 336-342.). Soaps, however, do not work in water with high level of metal ions or ‘hard water’ because soaps are ionic, and these imminent ionic interactions between soaps and metal ions would just deactivate soaps, and emulsification would be impossible. Considering that water quality in general is unpredictable, detergent formulations must be considered to work in most conditions.
[0003] Fortunately, modem detergents nowadays consist of complex chemicals, such as highly developed surfactants and water softeners. These surfactants are better than normal soap because they can perform better in water that is high in metal ions, especially calcium, magnesium, and iron. Many of the ingredients of modern detergents are also made from renewable raw materials, such as sugar alcohols and biodegradable polymers. The trend of shifting from petrochemical-based to oleochemical-based surfactants can be seen as the awareness on the environment and petroleum depletion rises.
[0004] In recent years there has been an ever increasing trend towards safer and environmentally friendly detergent compositions. This trend imposes additional constrains onto the dishwashing formulator. In terms of energy efficiency and raw material savings, it is desirable to design products which provide good performance even at low temperatures and with a reduction on the amount of chemicals, in particular non-readily biodegradable chemicals.
[0005] The use of enzymes in detergent formulations is becoming popular due to the concerns on the environment. It has been found to be very useful to have enzymes in dishwashing detergent compositions because enzymes are very effective in removing food soils from the surface of glasses, dishes, pots, pans and eating utensils. Björkling, F., Godtfredsen, S. E., and Kirk, O. (1991).
[0006] The future impact of industrial lipases. Trends Biotechnol. 9(1): p. 360-363 reports rapid gaining interest in enzyme use in a detergent formulation due to its biodegradability and ability to function at lower temperature. Unlike conventional detergents that get rid of stains and enter waterways, the use of enzymes could help alleviate water pollution in which the enzymes can degrade the stains and be degraded before they enter waterways. In addition, some enzymes can perform specific functions better than conventional methods involving chemicals. For example is cellulase, which can enhance fabric appearance and structure by modifying the cellulose fibers [Kuhad, R. C., Gupta, R., and Singh, A. (2011) Microbial cellulases and their industrial applications. Enzyme Res. 2011: p. 280696]. Like other detergent components, detergent enzymes are also constantly being improved; for example, a better protease [Souter, P. F. U. (2011) Automatic Dishwashing Detergent Composition. U.S. Pat. No. 8,008,241 B2] with better functionality and a better amylase [Aehle, W. and Amin, N. S. (2011) Variants of An Alpha-Amylase with Improved Production Levels in Fermentation Processes. U.S. Patent 2011/0027252 A1] with better stability. Unlike proteases and amylases, lipases have not Been extensively used in automatic dishwashing detergents but are becoming more popular, especially in reducing the amount of surfactant use.
[0007] Thus in view of the state of art cited above it is a major interest of the present invention to provide a novel detergent formulation for an automatic dishwashing machine, wherein the formulation comprising an improved enzymatic system comprising an improved lipase [preferably a thermostable lipase (T1 lipase)]. T1 lipase (E.C. 3.1.1.3) was evaluated for its stability and performance in dishwashing along with other common components of an automatic dishwashing detergent. The formulation of the invention provides cleaning and finishing benefits across a wide range of temperatures, including high temperatures, improving the energy profile of the dishwashing process. Surprisingly, the formulation of the invention allows for a more energy efficient dishwashing processes without compromising in cleaning and finishing. This invention is a new approach to simplify conventional methods in the development of a detergent formulation for an automatic dishwasher.
[0008] The T1 lipase was tested in hard water with fairly low builders, whereas other known Formulations mostly focused on high amount of builders or builders that are efficient, such as phosphates, in order to make the surfactants work. In addition, the formulation developed in the present invention is stable at high temperature, so it is suitable for automatic dishwasher, which are normally intended for high temperature washings.
[0009] The functionally of the enzyme is said to remove food soils from the surface of glasses, dishes, pots, pans and eating utensils. However, in order for the enzyme to be highly effective, the formulation must be chemically stable, and it must maintain an effective activity at the operating temperature of the automatic dishwasher.
[0010] In view of the above discussion, an objective of the present invention is to provide an eco-friendly product that at the same time provides excellent cleaning and finishing benefits.
Advantage
[0011] The present invention is in the field of cleaning agent in particular detergents. In particular, it relates to a novel detergent formulation for an automatic dishwashing comprising. The formulation provides excellent cleaning and finishing; it is environmentally friendlier than traditional compositions and allows for a more energy efficient automatic dishwashing process. The said formulation is phosphate free, therefore it will not cause the environmental pollution. To compensate the elimination of an excellent cleaning power by phosphates, the formulation includes a powerful anti-scaling agent (polyacrylate). Polyacrylate is a moderate builder, which can bind to calcites of hard water and prevent the calcite from accumulating on the cleaned surface. Together, the T1 lipase and polyacrylates, has shown synergistic effects in cleaning by supplying anions, which resuspend the soils in the solution, increasing the contact angle between the enzyme and the fatty soil.
[0012] Use
[0013] The T1 lipase enzyme binds to the ester bonds in triglycerides molecules and cuts the bonds, releasing fatty acids and glycerol. The released products that is less hydrophobic and more soluble in water. Unlike conventional non-enzymatic detergency, e.g. using surfactants, the enzyme system is less dependent on solubility and can work at wide range of temperature, including at lower than effective temperature. Although T1 lipase works optimally at elevated temperature, it has shown to work at room temperature but with reduced reaction rate. The chemical reaction, on the other hand, i.e. surfactants, depends on critical micelle concentration (CMC) and solubility to function properly.
SUMMARY OF THE INVENTION
[0014] The present invention provides a detergent formulation for dishwashing machine, wherein the formulation having the means for improving tableware or dishware cleaning, sanitizing, and/or stain removal, the said formulation is characterized in that it comprises:
[0015] Nonionic surfactant (preferably Alkyl polyglucoside) and having a working concentration between 5% and 10%; Dispersing agent (preferably sodium polyacrylate, sodium carboxymethyl cellulose (CMC), or sodium carboxymethyl inulin (CMI) and having a working concentration between 2% and 5%; Builder agent (preferably sodium or potassium carbonate and wherein the builder/pH agent having a working concentration between 3% and 10%); Enzyme stabilizer (preferably sodium citrate, glycine, or sodium bicarbonate and wherein the enzyme stabilizer having a working concentration between 7% and 20%; Enzyme which is a purified thermostable T1 lipase enzyme and the purified thermostable T1 lipase having a working concentration between 3% and 10%; Fillers(s) (preferably sodium or potassium sulfate and having a working concentration between 20% and 50%) or water.
[0016] For the present invention ,the formulation has a pH of at least 9.0 at a concentration of 1.5 grams per liter in water.
[0017] It is said that the formulation is housed in a permeable container such that it is conveniently located inside a typical automatic dishwasher without interfering with said dishwasher's normal usage; wherein said container comprises a material selected from the group consisting of glass, plastic, ceramic, metal, and combinations thereof. Also the formulation is present in the form selected from the group consisting of liquid, gel, tablet, powder, water-soluble pouch, and mixtures thereof.
[0018] Another aspect of the invention relates a method for washing tableware or dishware in dishwashing machine, comprising washing the said tableware or dishware at operating temperatures of 40° C. to 65° C. with the formulation.
DESCRIPTION OF THE DRAWINGS
[0019] The accompanied drawings constitute part of this specification and include an exemplary or preferred embodiment of the invention, which may be embodied in various forms. It should be understood, however, the disclosed preferred embodiments are merely exemplary of the invention. Therefore, the figures disclosed herein are not to be interpreted as limiting, but merely as the basis for the claims and for teaching one skilled in the art of the invention.
[0020] FIG. 1 shows: Dishwashing performance of detergent A containing 10% surfactant, 2.5% dispersing agent, and 50 mg T1 lipase in water of 0 ppm CaCO 3 (soft water) buffered with glycine-NaOH (pH 9.0) at 40° C., 50° C., and 60° C.
[0021] FIG. 2 shows: Dishwashing performance of detergent B containing 10% surfactant, 2.5% dispersing agent, and 50 mg T1 lipase in hard water of 350 ppm CaCO 3 buffered with glycine-NaOH (pH 9.0) at 40° C., 50° C., and 60° C.
[0022] FIG. 3 shows Dishwashing performance of detergent C containing 10% surfactant, 50 mg T1 lipase, and 0-10% dispersing agent in hard water of 350 ppm at CaCO 3 buffered with glycine-NaOH (pH 9.0) at 50° C.
[0023] Error! Reference source not found. FIG. 4 shows Dishwashing performance of detergent D containing 5-10% surfactant, 2.5% dispersing agent, 10% alkalinity agent, and 50 mg T1 lipase in hard water of 350 ppm CaCO 3 at 60° C.
[0024] FIG. 5 shows Dishwashing performance of detergent E containing 10% surfactant, 2.5% dispersing agent, 10% alkalinity agent, and 0-100 mg of T1 lipase in hard water of 350 CaCO 3 at 60° C.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.
[0026] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
[0027] As used herein, the terms “detergent formulation” refer to mixtures of chemical ingredients intended for use in a wash medium for the cleaning of soiled objects. Detergent compositions/formulations generally include at least one surfactant, and may optionally include hydrolytic enzymes, oxido-reductases, builders, bleaching agents, bleach activators, bluing agents and fluorescent dyes, caking inhibitors, masking agents, enzyme activators, antioxidants, and solubilizers.
[0028] Since this research focuses on automatic dishwashing, the enzyme of interest should be able to remove the main components of food stains, i.e., proteins, carbohydrates, and fats. Preferred in the context of the present invention is further described by thermostable T1 lipase (E.C. 3.1.1.3) (which is locally (Malaysia) produced) having potential as a detergent enzyme. Like most lipases, T1 lipase cuts the insoluble triglycerides at the ester bond into glycerol and free fatty acids. It is relatively stable at temperature of 55° C. up to 80° C. and between pH 6.0 and 11.0. The wide range of working temperature makes T1 lipase suitable for detergent formulation(s), especially in automatic dishwashing where washing temperature can reach 100° C. In addition, the T1 lipase showed high activity with nonionic surfactants and many cooking oils, especially soybean and olive oil [Leow, T. C., Rahman, R. N. Z. R. A., Basri, M., and Salleh, A. B. (2007) A thermoalkaliphilic lipase of Geobacillus sp. T1. Extremophiles. 11(3): p. 527-535.], which were also the constituting oils of the soil (peanut butter) being used. The other main components in detergent formulation(s) such as surfactants, bleaches, alkalinity agents, and dispersing agents were also evaluated for compatibilities with T1 lipase and dishwashing performance. The T1 lipase is alkalophilic, detergent builder-stable, and has high activity. In addition, the T lipase having the means of improving its performance by the addition of calcium ions; thus, the enzyme is suitable and works well in hard water, which contains mostly calcium and magnesium ions. The presence of these ions normally prevents surfactants from performing properly; thus, the enzyme will give a synergistic effect when it is being added together with the surfactant. The surfactant helps in increasing enzyme digestion through emulsification of the fatty soil.
EXAMPLES OF CARRYING OUT THE INVENTION
[0029] While the present invention has been described with specificity in accordance with certain of its preferred embodiments, the following examples serve only to illustrate the invention and are not intended to limit the invention within the principles and scope of the broadest interpretations and equivalent configurations thereof.
[0030] Materials
[0031] All materials used in the experiments were obtained from the stated suppliers and used without any further modification. Oil Red (Sudan III) CI 26100, Polyethylene glycol 300 “PEG 300” (nonionic), polysorbate 80 (Tween 80, nonionic), sodium dodecyl sulfate “SDS” (anionic), cetyl trimethylammonium bromide “CTAB” (cationic), sodium carboxymethyl cellulose “CMC” (M w =90,000 g/mol) and sodium polyacrylate “NaPA” (M w =2100 g/mol) were all obtained from Sigma-Aldrich, St. Louis, Mo.; sodium carboxymethyl inulin “CMI” (Carboxyline) was obtained from Royal Cosun, Netherland; alkyl polyglucoside “APG” (Glucopon 600 CS UP, nonionic) was obtained from Henkel KgaA, Düsseldorf, Germany; APG (Triton CG-600) was obtained from Dow, Midland, Mich.; acetone, calcium chloride dihydrate, copper (II) acetate monohydrate, magnesium sulfate heptahydrate, glycine, sodium bicarbonate, sodium carbonate, sodium citrate, sodium hydroxide, sodium perborate, sodium percarbonate, and sodium tripolyphosphate were all obtained from Merck KGaA, Darmstadt, Germany; olive oil (Bertolli, Italy) and Skippy creamy peanut butter (Unilever, Malaysia) were obtained from a local supermarket; The peanut butter consisted of approximately 50% triglycerides from different sources (i.e. peanut, rapeseed, cottonseed, and soybean oil).
[0032] Methods
[0033] Enzyme Production
[0034] The T1 lipase protein was expressed in E. coli BL21 containing the heterologous protein from Geobacillus zalihae strain T1. The E. coli BL21 bacteria were grown in a 200 ml LB containing 35 mg/ml chloramphenicol and 50 mg/ml ampicillin at 37° C. and 200 rpm of agitation rate. The culture was then induced with 0.025 mM isopropyl β-D-thiogalactopyranosidase (IPTG) when the optical density (OD) at 600 nm of the cell culture reached 0.75. After 12 hours, the culture was centrifuged at 10,000 rpm, 4° C. for 10 min, and the pellet was kept in −80° C. freezer. The pellet was resuspended in 50 mM Glycine-NaOH buffer (pH 9.0), and the solution was sonicated (Branson, USA) for 4 min (inclusive of 30 s rest for every 30 s sonication interval). The solution was then centrifuged at 12,000×g, and the resulting supernatant containing the crude enzyme was kept in −80° C. freezer and thawed upon use.
[0035] Lipase Stability Tests
[0036] The compatibility of the T1 lipase with the other components of the formulated detergent was evaluated by incubating the enzyme in 0.2% (w/v) of those components, i.e., surfactants, bleaches, and alkalinity agents in a water bath (Protech, Malaysia) at 60° C. for 30 min. After 30 min, the enzyme was assayed for its residual activity.
[0037] Lipase Assay
[0038] The residual activity of the T1 lipase was assayed colorimetrically using a method previously described with slight modifications [Kwon, D. and Rhee, J. (1986) A simple and rapid colorimetric method for determination of free fatty acids for lipase assay. J Am Oil Chem Soc. 63(1): p. 89-92]. A cupric acetate pyridine reagent was prepared by mixing 5% (w/v) copper (II) acetate with DI water and adjusting the solution pH to 6.1 with pyridine. The substrate emulsion used consisted of olive oil/50 mM of Glycine-NaOH buffer at pH 9.0 (1:1), which was homogenized using a homogenizer (Heidolph, Germany). The reaction mixture, which consisted of 2.5 ml substrate emulsion, 0.01 ml T1 lipase (29.8 U/mg), 0.99 ml 50 mM Glycine-NaOH buffer (pH 9.0), and 20 μl 20 mM CaCl 2 , was incubated in the same water bath at the enzyme optimum temperature of 70° C. for 30 min at 200 rpm. After 30 min, the reaction was stopped by adding 5 ml isooctane and 1 ml 6 N HCl, and the mixture was vortexed for 30 s and left for 15 min. 4 ml of the upper layer of the mixture, which contained the fatty acids, was transferred to a test tube containing 1 ml of the cupric acetate pyridine reagent, and the mixture was vortexed for 30 s and left for 1 hour. The color of the solution was then evaluated colorimetrically by reading the OD using the Ultraspec 2100 Pro spectrophotometer (Amersham Bioscience, Sweden) at 715 nm. All assays were done in triplicates. 1 unit (U) of lipase activity was defined as the rate of 1 μmol of fatty acid released per minute under standard assay conditions.
[0039] Detergent Formulation
[0040] The detergent formulation was prepared by adding components that have shown stability towards T1 lipase. The detergent formulation and their quantities were summarized below:
1. Alkyl polyglucoside (nonionic surfactant) E.g. Glucopon, Triton (5-10%) 2. Polyacrylate (dispersing agent) E.g. sodium polyacrylate, sodium carboxymethyl cellulose (CMC), or sodium carboxymethyl inuline (CMI) (2-5%) 3. Carbonate (builder/pH agent) E.g. sodium or potassium carbonate (3-10%) 4. Enzyme stabilizer E.g. sodium citrate, glycine, or sodium bicarbonate (7-20%) 5. T1 lipase (enzyme) (3-10%) 6. Water or Sulfate (filler) E.g. sodium or potassium sulfate (20-50%)
[0047] Hard Water Preparation
[0048] A stock solution of hard water was prepared by mixing 30 mM CaCl 2 .2H 2 O and 10 mM MgSO 4 .7H 2 O with 1 L water, which corresponded to 5000 ppm CaCO 3 . The stock solution was then diluted and standardized to 350 ppm CaCO 3 by using a water hardness indicator (HI 96735 Hardness ISM, Hanna Instruments, Italy).
[0049] Dishwashing Tests
[0050] Dishwashing tests were done using the Leenert's Improved Detergency Tester (Japan) as described previously but with slight modifications [8]. Sets of microscope glass slides (6 pieces per set) were dipped for 1-2 s in a soil bath containing 20 g of peanut butter, 0.1 g of Oil Red lysochrome, and 60 ml of acetone, and dried for 2 hours. The dishwashing solutions were prepared by mixing 1.5 g of the formulated detergent solution with appropriate amount of T1 lipase (29.8 U/mg) and 1000 ml water of either 0 or 350 ppm CaCO 3 . The dried slides were washed in the dishwashing solutions prepared previously at different temperatures (40° C., 50° C., and 60° C.) with a stirring speed of 250±10 rpm for 3 minutes. The washed slides were then rinsed with water of the same hardness for 1 minute. After rinsing, the slides were air-dried for 24 hours after which the slides were immersed in 100 ml acetone, and the OD at 518 nm of the red-colored acetone was evaluated using a spectrophotometer. The dishwashing performance was evaluated according to this formula:
[0000]
Percent
soil
removed
(
%
)
=
[
(
BW
-
AW
)
BW
]
×
100
[0051] where BW was the OD of the red-colored acetone immersed with a set of slides that were not washed, and AW was the OD of the red-colored acetone immersed with the set of slides that were washed. All washing and reading tests were done in duplicates to ensure reproducibility.
[0052] Statistical Analysis
[0053] Statistical analyses were done using one-way ANOVA and the Turkey test at 0.05 level using the SPSS Statistics 20.0.0 (SPSS Inc., Chicago, Ill., USA).
[0054] Results and Discussions
[0055] Stability of T1 Lipase in Detergent Components
[0056] Stability of T1 lipase in various surfactants and bleaches was checked, and the results are shown in Table 1. The nonionic surfactants were mostly compatible. The interaction between nonionic surfactants and lipase is usually hydrophobic [9]; thus, the interaction might not seriously damage the protein structure. The surfactants that are made of sugar alcohol such as the Glucopon 600 CS UP (G600) and Tween 80 (T80) showed the highest stability with T1 lipase followed by PEG 300 (Table 1). One study showed that the protective effect of polyhydric or sugar alcohol improved lipase stability regardless of the nature of the sugar alcohol [10]. Another study also showed that the addition of a sugar alcohol, sorbitol showed improved lipase stability compared to incubating in ethylene glycol alone [11]. These results showed that sugar alcohol improved the stability of lipases, especially at elevated temperature.
[0057] Table 2 also shows that T1 lipase was not compatible with ionic surfactants. Although anionic bile salt helps in lipid digestion in human intestines [12], the anionic sodium dodecyl sulfate (SDS), which is a popular choice of surfactant in detergent formulations, destabilized T1 lipase (Table 1). SDS is generally known to denature proteins by binding to the protein backbone and unfolding the native structure, and it is common for lipases to be denatured by SDS. However, the combination of nonionic and anionic surfactants has shown to prevent enzyme denaturation. Table 1 showed that the combination of the nonionic G600 and anionic SDS prevented further denaturation of T1 lipase. This method has been used not only for the stability of enzymes in formulation but also for overall cleaning in which some studies have shown better cleaning when two surfactant systems were mixed [13]. The cationic CTAB strongly destabilized T1 lipase because the enzyme has a slight negative charge [6]. Consequently, T1 lipase might have precipitated and lost its functionality. The stability and improvement of enzymes by surfactants therefore vary depending on the enzyme and its characteristics [9].
[0058] Perborates and percarbonates strongly destabilized T1 lipase (Table 1) albeit being mild bleaching/oxidizing agents. It is generally known that enzymes are susceptible to denaturation by bleaching agents unless they are genetically engineered to be more resistant to bleaching agents. Proteases such as Durazym and Purafect are two examples of proteases that are genetically engineered using site-directed mutagenesis to improve their stability with bleaching agents [14]. This implied that T1 lipase could also be genetically modified to be stable with bleaching agents. Bleaches are essential because some stains such as tea and coffee stains cannot be easily removed by surfactants and unless specific enzymes that can break down these polyaromatic compounds are employed as well.
[0059] Stability of T1 lipase in various alkalinity agents was also checked, and the relative activities and resulting pH of the alkalinity agents in solutions were summarized in Table 1.
[0000]
TABLE 1
Stability of T1 lipase in various surfactants and bleaches
Surfactant or bleach
Relative activity (%)
PEG 300 (nonionic)
61
G600 (nonionic)
136
Tween 80 (nonionic)
98
SDS (anionic)
14
SDS/G600 (1:1)
43
CTAB (cationic)
1.9
Sodium perborate
3.4
Sodium percarbonate
0.3
w/o (control)
100
[0060] Most of the alkalinity agents also bind to cations to reduce water hardness. Sodium carbonate (SC) and sodium tripolyphosphate (STPP) gave good pHs but showed the lowest residual activities. This might be due to the binding of SC and STPP to Ca 2+ that were essential to T1 lipase in maintaining its structural stability. This occurrence was shown in a study whereby both SC and STPP bound to Ca 2+ , producing CaCO 3 precipitates and Ca 3 (PO 4 ) 2 , respectively [15]. On the other hand, sodium citrate, which was also proven to be a good metal chelator, did not greatly affect the stability of T1 lipase compared to that of SC and STPP (Table 2). Sodium citrate had a binding constant 1-3 orders lower than that of enzymes [16], which might explain why the stability of T1 lipase was not greatly affected. Since sodium citrate has a low pKa, it could only be used as an auxiliary component with other mild builders in a detergent formulation.
[0061] Since T1 lipase has an optimum pH of 9.0 and stable in between pH 6.0 and 11.0 [6], carbonate and bicarbonate were chosen due to their high pKa values. However, the buffering capacity of bicarbonate is only moderate, and T1 lipase was greatly destabilized by carbonate. Fortunately, a combination of carbonate/glycine at a ratio of 30:70 in an aqueous solution, which gave a resulting pH of 9.25 (close to the T1 lipase optimum pH at pH 9.0), showed high enzymatic stability (Table 2). This might indicate that glycine has a stabilizing effect on T1 lipase, compensating the effect of the reduction of Ca 2+ .
[0000]
TABLE 2
Stability of T1 lipase in various alkalinity agents
Alkalinity agents
Relative activity (%)
pH
Sodium carbonate (SC)
1
10.84
SC:glycine (30:70)
129
9.25
Sodium bicarbonate (SB)
94
8.63
SC:SB (30:70)
0
9.50
Sodium citrate
48
8.30
Sodium tripolyphosphate
0
9.60
Glycine-NaOH (control)
100
9.00
[0062] Dishwashing Performance
[0063] Dishwashing performance was evaluated in term of percent soil removed.
[0064] The dishwashing performance of detergent A in ion-free water at various temperatures is shown in FIG. 1 . As expected, the dishwashing performance improved as the temperature increased. At 0 ppm of CaCO 3 , a full detergency was almost achievable without the help of T1 lipase. The improvement after adding T1 lipase also became smaller after each increment in temperature, showing that elevated temperature lowered surface tension of water and promoted better soil removal. In addition, the dishwashing performance of the formulated detergent was quickly observable in the absence of ionic interference, especially at 60° C. where 50% of soil removal was observed within half of the duration of the test.
[0065] FIG. 2 compares the dishwashing performance of detergent B in hard water of 350 ppm CaCO 3 at various temperatures. Similar to the previous results, the dishwashing performance improved as the temperature increased but not as much as that in water of 0 ppm CaCO 3 . The performance of the nonionic surfactant was severely affected by the high amount of Ca 2+ and Mg 2+ presence in the water. This might be due to the formation of a highly charged structure made of the surfactant and ions, which prevented the removal of soil from the hard surface [13].
[0066] Although nonionic surfactants (i.e. ethoxylates) are mostly insensitive to hard water, alkyl polyglucosides (APG) are different as they are made of sugar alcohols. A study showed that unlike ethoxylates, which are mostly uncharged, APG micelles are negatively charged [17]. This might explain the severe performance deterioration of APG in the presence of electrolytes, specifically cationic electrolytes.
[0067] FIG. 2 also shows that the improvements in dishwashing performance by the addition of T1 lipase were more apparent in hard water because the enzyme was not negatively affected by the Ca 2+ and Mg 2+ presence in the water [6]. The improvement after adding T1 lipase was also more dramatic at 60° C. as the crude T1 lipase reached its optimum temperature. The purified T1 lipase has an optimum temperature of 70° C., and relative activities of 50% and 75% at 50° C. and 60° C., respectively [6]. At higher temperature, the active site of T1 lipase might become more exposed; thus, giving higher activity.
[0068] FIG. 3 compares the dishwashing performance of detergent C in hard water of 350 ppm CaCO 3 at 50° C. with increasing concentration of dispersing agent. Polyacrylate polymer is an excellent dispersing agent with mild chelating power and can reduce the effect of hard water by inhibiting calcium carbonate crystal formation. The effect of polyacrylate polymer can be seen in the improvement of dishwashing performance, especially when the concentration of dispersing agent was increased (with or without adding T1 lipase) ( FIG. 3 ). However, better improvements were seen when dispersing agent and T1 lipase were combined. The improvements in detergency could be due to the synergistic effect between the dispersant and T1 lipase. Polyacrylates increased the negative charges in the solution, increasing the repulsive forces between the polymer and soil, and preventing redeposition of soil back to the hard surface. This may allow more soil to disperse into the bulk phase, exposing and increasing the surface area of the substrate for T1 lipase digestion.
[0069] The increase in negative charges had also shown to increase lipase activity through another mechanism. In one study, polyelectrolyte complex micelles consisting of Lipolase (a lipase), a negatively charged polyacrylate polymer with molecular weight of 10,000 g/mol, and a positively charged copolymer showed higher activity than the free lipase [18]. This finding inferred that the negative charges from the polymer led to an open confirmation of the lipase; thus, increasing the activity of the lipase, which would otherwise be in a closed confirmation in the bulk. The activity of lipase is also generally known to increase when it is activated whereby its lid is in the open confirmation, which occurs at the oil/water interface.
[0070] FIG. 3 also shows that at the highest concentration of polyacrylates (10%), the dishwashing performance was not significantly improved by the addition of T1 lipase. This might be due to the reduction of hard water by polyacrylates, improving the functionality of the surfactant. A study showed that hard water reduction was achieved through adsorption of the polyacrylates to the calcium carbonate surface [19]. This study showed that polyacrylates with lower molecular weight (2000-5000 g/mol) were shown to be better at adsorbing compared to those of higher than 5000 g/mol in which precipitation would occur instead of adsorption. This study also showed that precipitation would reduce the amount of polyacrylates available in the solution.
[0071] Besides reducing hard water, polyacrylates had also shown to reduce water spot formation due to precipitation of calcium and carbonates. This reduction was achieved due to reduction of calcium carbonate by the polyacrylates through inhibition of crystal formations. One study showed that polyacrylates with molecular weight between 2100 and 240,000 g/mol were shown to be effective in dispersing a large soil into smaller fragments [20]. In addition, the dispensability would not only inhibit the crystal formations but also reduce redeposition of soil back to the cleaned surface.
[0072] After the formulated detergent and T1 lipase had been evaluated for dishwashing performance in hard water, they were tested in the presence of water softening agents, i.e. sodium carbonate, while maintaining the T1 lipase stability using glycine in the ratio previously mentioned. This stabilizing system served as a substitute for the glycine-NaOH buffer (pH 9.0). Glycine-NaOH buffer was effective only at certain concentration and thus was deemed not applicable for dishwashing.
[0073] FIG. 4 shows the dishwashing performance of detergent D in hard water of 350 ppm CaCO 3 at 60° C. Sodium carbonate improved dishwashing performance of the detergent D (10% surfactant) by approximately 7% and 2% without and with T1 lipase, respectively ( FIGS. 2 and 4 ). This showed that sodium carbonate might have reduced the hard water and slightly improved the surfactant functionality, while T1 lipase did not show any significant improvement.
[0074] FIG. 4 also shows that the dishwashing performance decreased by almost 50% when the surfactant was reduced by 50% and T1 lipase was removed. However, the dishwashing performance of the halved concentrated surfactant was higher when T1 lipase was added compared to the performance of the halved concentrated surfactant alone. This proved again that T1 lipase was not negatively affected by the presence of Ca 2+ and Mg 2+ in the water, while the surfactant was. This could also be explained by the high efficiency of an enzyme system compared to a surfactant system, which the later depends on critical micelle concentration (CMC) and solubility to work efficiently.
[0075] While surfactant concentration showed an important aspect in dishwashing, it is interesting to see whether the amount of T1 lipase played an important role in dishwashing performance. FIG. 5 compares the dishwashing performance of detergent E with different amount of added T1 lipase in hard water of CaCO 3 at 60° C. The results show that adding T1 lipase almost doubled the dishwashing performance; however, adding more T1 lipase did not substantially improve the performance ( FIG. 5 ). All results showed significant mean differences at the 0.05 level, using the Turkey test.
[0076] In addition, the maximum dishwashing performance of the formulated detergent containing T1 lipase in hard water was slightly above 40%. This could be explained by the nature of the soil, which consisted of fat, protein, and carbohydrate. Since T1 lipase only break down fats, it is also important to consider other enzymes that can break down proteins and carbohydrates.
[0077] These dishwashing results may suggest that a substantial increase in dishwashing performance could be achieved by adding other enzymes that are compatible with T1 lipase and the other components, and which could become auxiliary components, especially in this case where the surfactant and T1 lipase showed synergistic effect in dishwashing performance in the presence of ionic interferences.
[0078] The performance of surfactants can be negatively affected by the presence of metal ions. Most ADD aims at reducing metal ion interferences during washing by incorporating chelating/complexing agents or builders, such as sodium tripolyphosphate (STPP), sodium silicates, sodium citrates, sodium carbonates, and zeolites. The chelating agents bind to metal ions, allowing the surfactant to perform effectively. However, it is well known that enzymes work well with metal ions, so our approach is to incorporate an enzyme into the formulation. STPP has been by far the best builder except that it is no longer allowed in modern formulations. Sodium carbonate has thus been widely used because of its cheap cost. Other formulations contains new, patented chemicals that work almost as good as STPP, such as carboxymethyl inuline (CMI) and different versions of polyacrylates.
[0079] Preferred in this respect is that the new formulation of this present invention contains polyacrylates, which prevent calcite formations and disperse soils, and an enzyme that is able to digest the soil even in hard water.
[0080] Table 4 to 6 represents temperature improved detergency. Hard water reduced detergency. Adding T1 improved detergency
[0000]
TABLE 4
Cleanliness (%)
0 ppm
350 ppm
(−T1)
(+T1)
(−T1)
(+T1)
40
0.3764
0.3884
1.1610
1.0828
40
0.5398
0.2543
1.1500
1.0700
50
0.1987
0.1432
1.1360
0.9949
50
0.1374
0.1504
1.0757
1.0632
60
0.0835
0.0705
1.0060
0.8663
60
0.0800
0.0750
0.9311
0.8273
[0000]
TABLE 5
Cleanliness (%)
0 ppm
350 ppm
(−T1)
(+T1)
(−T1)
(+T1)
40
69.03
68.04
4.48
10.91
40
55.59
79.08
5.38
11.96
50
83.65
88.22
6.53
18.14
50
88.70
87.63
11.50
12.53
60
93.13
94.20
17.23
28.72
60
93.42
93.83
23.39
31.94
[0000] TABLE 6 Cleanliness (%) 0 PPM 350 PPM Average Stdev Average Stdev (−T1) (+T1) (−T1) (+T1) (−T1) (+T1) (−T1) (+T1) 40 62.31 73.56 9.51 7.801795 4.93 11.44 0.64 0.74469 50 86.17 87.92 3.57 0.418888 9.01 15.33 3.51 3.970712 60 93.27 94.01 0.20 0.261805 20.31 30.33 4.36 2.271887
Table 7 represents the dispersing agent effect
[0000] Concentrations Read 1 Read 2 ReadAve Clean 1 Clean 2 CleanAve Stdev 0.0 (−T1) 1.2000 1.1900 1.1950 1.7 2.1 1.9 0.290895 (+T1) 1.1915 1.1800 1.1858 2.4 2.9 2.7 0.334529 2.5 (−T1) 1.1477 1.1000 1.1239 7.5 9.5 8.5 1.387568 (+T1) 1.0034 0.9700 0.9867 18.8 20.2 19.5 0.971588 5.0 (−T1) 1.0123 1.1000 1.0562 13.1 9.5 11.3 2.551146 (+T1) 0.8791 0.9000 0.8896 26.8 26.0 26.4 0.60797 10.0 (−T1) 1.5340 1.5000 1.5170 26.7 28.3 27.5 1.148614 (+T1) 1.4218 1.4000 1.4109 32.1 33.1 32.6 0.736464
Table 8 represents the surfactant concentration effect
[0000]
Clean
Clean
Read 1
Read 2
ReadAve
1
2
cleanave
stdev
D
0.9674
0.9090
0.9382
24.12
28.70
26.41
3.24
D + E
0.8910
0.8304
0.8607
30.11
34.87
32.49
3.36
D/2
1.1365
1.0359
1.0862
10.86
18.75
14.80
5.58
D/2 + E
0.9223
0.9108
0.9166
27.66
28.56
28.11
0.64
[0000] Enzyme (mg/L): 0 25 50 100 Read 1 1.3134 0.7523 0.9357 0.7795 Read 2 1.2297 1.0941 1.0904 0.9971 Read 3 0.7286 Clean 1 20.00 42.18 43.00 40.09 Clean 2 25.09 33.35 33.58 39.26 Clean 3 44.00 AveRead 22.55 37.77 38.29 41.12 AveClean 22.55 37.77 38.29 41.12 Stdev 3.600145 6.242399 6.663069 2.531287
Table 9 represents the effect of enzyme
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The objective of the present invention is in the field of cleaning agent in particular detergents. In particular, it relates to a novel detergent formulation for an automatic dishwashing. The formulation provides excellent cleaning and finishing; it is environmentally friendlier than traditional compositions and allows for a more energy efficient automatic dishwashing process.
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CLAIM OF PRIORITY
This application claims priority to an application entitled “Wavelength division multiplexed self-healing passive optical network using wavelength injection method,” filed in the Korean Intellectual Property Office on Jan. 9, 2004 and assigned Serial No. 2004-1754, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a self-healing passive optical network capable of detecting and healing cuts or deterioration of a feeder fiber or distribution fiber, thereby restoring the network by itself.
2. Description of the Related Art
A wavelength division multiplexing passive optical network (WDM-PON) can ensure the secrecy of communication and can easily accommodate special communication services required from each subscriber unit. The WDM-PON can enlarge channel capacity by assigning a specific wavelength to each subscriber unit and communicating with each subscriber unit. Also, the WDM-PON can easily increase the number of subscriber units by adding specific wavelengths to be assigned to new subscribers.
Generally, a WDM-PON uses a double star structure. That is, a central office (CO) and a remote node (RN) installed at an area adjacent to optical network units are connected to each other through one feeder fiber. The remote node and each optical network unit are connected to each other through a separate distribution fiber.
Multiplexed downstream optical signals are transmitted to the remote node through one feeder fiber. The multiplexed downstream optical signals are demultiplexed by a multiplexer/demultiplexer installed in the remote node and the demultiplexed signals are transmitted to subscriber units through the distribution fibers separately connected to optical network units.
Upstream signals outputted from the subscriber units are transmitted to the remote node through the distribution fibers separately connected to the optical network units. Then the multiplexer/demultiplexer installed in the remote node multiplexes the upstream signal according to each optical network unit, and transmits the multiplexed signal to the central office.
In the WDM-PON as described above, when an unexpected error occurs, such as a cut of a feeder fiber or a distribution fiber, a large quantity of transmitted data may be lost even though the error time period is short. For this reason, the error must be quickly detected and corrected.
Accordingly, it is necessary to develop a self-healing passive optical network (PON) capable of quickly detecting an error, such as a cut of a feeder fiber or a distribution fiber, on an installed optical link and correcting the error by itself.
FIGS. 1 a and 1 b are views of a conventional WDM self-healing ring network.
Generally, in a WDM optical communication network, a ring network connecting each node in a ring type is mainly used to smoothly cope with an error such as a cut of a transmission optical fiber.
The aforementioned conventional self-healing ring network connects a central office 100 to a first remote node 200 by means of two strands of optical fiber. Further, the self-healing ring network connects the central office 100 to a second remote node 300 by means of two strands of optical fiber.
Here, the two strands of optical fiber are a working fiber and a protection fiber. The central office 100 in a normal state transmits optical signals equal to each other, into which several wavelengths (e.g., λ 1 , λ 2 ) of signals are multiplexed, through the two strands of optical fibers. The first remote node 200 or the second remote node 300 drops the optical signals inputted through the two strands of optical fiber to add/drop multiplexers 108 and 109 or add/drop multiplexers 112 and 113 and receives an optical signal having good characteristics from among the inputted optical signals by means of optical switching devices 110 and 111 or optical switching devices 114 and 115 .
Meanwhile, the first remote node 200 or the second remote node 300 transmits optical signals equal to each other through the two strands of optical fiber. Then, the central office 100 demultiplexes optical signals according to each wavelength, and selects and receives one of two signals by means of optical switching devices 104 and 105 .
FIG. 1 b is a view illustrating a case in which an abnormality such as a cut of an optical fiber occurs in a working fiber.
When an abnormality occurs in the working fiber, the conventional self-healing ring network performs the following self-healing operation.
If the second remote node 300 cannot receive a second channel λ 2 through the working fiber in a counterclockwise rotation it is assumed that the working fiber between the first remote node 200 and the second remote node 300 is cut., When it is assumed that the working fiber is cut, the second remote node 300 receives the second channel λ 2 transmitted in a clockwise rotation through the protection fiber. Since the first remote node 200 cannot add and transmit a first channel λ 1 through the working fiber in a counterclockwise rotation, the first remote node 200 switches the optical switching device 110 to transmit the first channel λ 1 through the protection fiber in a clockwise rotation.
The aforementioned conventional self-healing ring network is efficient when a central office and a plurality of remote nodes are spaced away from each other by about several tens of kilometers. However, it is insufficient to introduce the aforementioned ring network structure to a PON which connects a central office to a remote node and connects the remote node to an optical network unit. That is, since a conventional PON has a star structure, a self-healing method having a concept different from a self-healing method in a ring network structure must be developed.
Furthermore, in the case of a WDM-PON using a wavelength injection method, an upstream/downstream injection light source exists and the directionality of the light source must be considered.
SUMMARY OF THE INVENTION
The present invention has been made to solve the aforementioned problems occurring in the prior art. An object of the present invention is to provide a wavelength division multiplexed self-healing passive optical network capable of detecting a cut of or deterioration of a feeder fiber or a distribution fiber. It is a further object of the present invention to correct an error due to the cut or deterioration by itself in a passive optical network having a star structure.
In order to accomplish the aforementioned objects, according to one aspect of the present invention, a wavelength division multiplexed self-healing passive optical network is provided using a wavelength injection method. The wavelength division multiplexed self-healing passive optical network may include a central office for coupling modulated multiplexing optical signals and broadband optical signals for an upstream light source. These signals may be combined into one signal and transmitted to a plurality of optical network units as a coupled signal through a working main fiber and a protection main fiber. The remote node may connect to the central office through the working main fiber and the protection main fiber and to the optical network units through working distribution fibers and protection distribution fibers. The remote node may demultiplex the modulated multiplexing optical signals and the broadband optical signals for an upstream light source. The remote node may transmit the demultiplexed signals to the optical network units. The optical network units may receive the modulated optical signals and the broadband optical signals for an upstream light source, which are transmitted from the remote node and correspond to predetermined optical network units, optically demodulate the modulated optical signals, and modulate upstream optical signals by means of the demultiplexed broadband optical signals for an upstream light source.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIGS. 1 a and 1 b are views of a conventional wavelength division multiplexed self-healing ring network;
FIG. 2 is a block diagram of a wavelength division multiplexed self-healing passive optical network using a wavelength injection method according to one embodiment of the present invention;
FIG. 3 shows a wavelength range of a downstream light source and a wavelength range of an upstream light source according to one embodiment of the present invention;
FIG. 4 is a block diagram illustrating a case in which an abnormality occurs in a working main fiber in a wavelength division multiplexed self-healing passive optical network using a wavelength injection method according to one embodiment of the present invention; and
FIG. 5 is a block diagram illustrating a case in which an abnormality occurs in a working distribution fiber in a wavelength division multiplexed self-healing passive optical network using a wavelength injection method according to one embodiment of the present invention.
DETAILED DESCRIPTION
A preferred embodiment according to the present invention will be described below with reference to the accompanying drawings. Detailed description of known functions and configurations incorporated herein will be omitted when it may make the subject matter of the present invention unclear.
FIG. 2 is a block diagram of a wavelength division multiplexed self-healing passive optical network using a wavelength injection method according to one embodiment of the present invention.
As shown in FIG. 2 , the wavelength division multiplexed self-healing passive optical network using the wavelength injection method includes a central office 21 , one strand of working fiber and one strand of protection fiber connecting the central office 21 to a remote node 22 , an N×N multiplexer/demultiplexer (waveguide grating router, wherein N is an integer greater than 1) 209 located in the remote node 22 , working fibers and protection fibers connecting the remote node 22 to optical network units 23 - 1 to 23 -( n - 1 ), and the optical network units 23 - 1 to 23 -( n - 1 ). The central office 21 includes downstream light sources 204 - 1 to 204 -( n - 1 ), upstream optical receivers 205 - 1 to 205 -( n - 1 ), an N×N multiplexer/demultiplexer (waveguide grating router) 203 , a broadband light source (BLS) 201 for a downstream light source, a broadband light source 207 for an upstream light source, a first and a second circulators 202 and 208 for determining an optical path, and a 2×2 optical coupler 206 . Each of the optical network units 23 - 1 to 23 -( n - 1 ) includes a downstream optical receiver 212 , an upstream light source 213 , a wavelength division multiplexer (WDMC) 211 for dividing/coupling an upstream/downstream signal, and a 1×2 optical switching device 210 .
Operation of the wavelength division multiplexed self-healing passive optical network using the wavelength injection method will be described with reference to FIG. 2 .
First, a downstream signal will be described. A broadband optical signal of the broadband light source 201 for a downstream light source in the central office 21 is inputted into a first terminal of one side of the N×N waveguide grating router 203 through the first circulator 202 , and is then demultiplexed. That is, the optical signal inputted into a first terminal of one side of the N×N waveguide grating router 203 is demultiplexed into (n- 1 ) number of optical signals corresponding to a first through an (n- 1 ) th terminal on the other side of the N×N waveguide grating router 203 .
Each of the demultiplexed optical signals as described above is injected into each of the downstream light sources 204 - 1 to 204 -( n - 1 ), assigned with respect to each optical network unit, and is then modulated according to transmission data.
The modulated optical signals are then inputted into the first through the (n- 1 ) th terminal of the other side of the N×N waveguide grating router 203 , and are then multiplexed into one optical signal. The multiplexed optical signal is outputted to a first terminal of one side of the N×N waveguide grating router 203 .
The multiplexed modulation optical signal outputted to a first terminal of one side of the N×N waveguide grating router 203 is sent to the 2×2 optical coupler 206 through the first circulator 202 , is coupled to a broadband optical signal of the broadband light source 207 for upstream light source by the 2×2 optical coupler 206 , and is transmitted to the working main fiber and the protection main fiber.
The coupled optical signal sent from the central office 21 to the remote node 22 through the working main fiber is inputted into a first terminal of one side of the N×N waveguide grating router 209 located in the remote node 22 . Meanwhile, the coupled optical signal sent from the central office 21 to the remote node 22 through the protection main fiber is inputted to an N th terminal of the other side of the N×N waveguide grating router 209 located in the remote node 22 . The optical signal transmitted from the central office 21 in this way is demultiplexed by the N×N waveguide grating router 209 and then is transmitted to each of the optical network units 23 - 1 to 23 -( n - 1 ).
The coupled optical signal sent from the central office 21 to the remote node 22 through the working main fiber is inputted into a first terminal of one side of the N×N waveguide grating router 209 located in the remote node 22 , is demultiplexed into (n- 1 ) number of optical signals corresponding to a first through an (n- 1 ) th terminal of the other side of the N×N waveguide grating router 209 , and then is transmitted to each of the optical network units 23 - 1 to 23 -( n - 1 ) through the working distribution fiber. The coupled optical signal sent from the central office 21 to the remote node 22 through the protection main fiber is inputted into the N th terminal of the other side of the N×N waveguide grating router 209 located in the remote node 22 , is demultiplexed into (n- 1 ) number of optical signals corresponding to the second through the N th terminal of one side of the N×N waveguide grating router 209 , and then is transmitted to each of the optical network units 23 - 1 to 23 -( n - 1 ) through the protection distribution fiber.
The working distribution fiber and the distribution fiber are connected to each of the optical network units 23 - 1 to 23 -( n - 1 ). For clarity, an operation of the optical network unit 23 - 1 will be described below as an example.
The optical signals transmitted to the optical network unit 23 - 1 through the working protection fiber and the protection distribution fiber are inputted to two input nodes of the 1×2 optical switching device 210 . Typically, the 1×2 optical switching device 210 is switched to the input node connected to the working distribution fiber. The optical signal inputted through the 1×2 optical switching device 210 is inputted to the wavelength division multiplexer 211 , and then is wavelength division demultiplexed. Then, the modulated optical signal of the coupled signal is inputted into the downstream optical receiver 212 and the broadband optical signal of the broadband light source for upstream light source 207 of the coupled signal is injected into the upstream light source 213 , and they are used for modulation of upstream data of the optical network unit 23 - 1 .
Next, an upstream signal will be described. When the broadband optical signal of the broadband light source for upstream light source 207 transmitted from the central office 21 is inputted and injected into the upstream light source 213 , the optical network unit 23 - 1 modulates the upstream signal with a preset wavelength.
The modulated upstream signal passes through the wavelength division multiplexer (WDMC) 211 . Then, the modulated upstream signal is transmitted to the remote node 22 through the working distribution fiber currently connected by the 1×2 optical switching device 210 . In this case, it is assumed that the 1×2 optical switching device 210 is connected to the working distribution fiber.
An upstream signal of each of the optical network units 23 - 1 to 23 -( n - 1 ) transmitted to the remote node 22 is multiplexed by the N×N waveguide grating router 209 and then is transmitted to the central office 21 through the working main fiber.
Here, the modulated optical signals transmitted from the optical network units 23 - 1 to 23 -( n - 1 ) to the remote node 22 through the working distribution fiber are inputted into the first through the (N- 1 ) th terminal of the other side of the N×N waveguide grating router 209 located in the remote node 22 . The inputted optical signals are multiplexed by the N×N waveguide grating router 209 and the multiplexed optical signal is outputted to a first terminal of one side of the N×N waveguide grating router 209 . Then, the multiplexed optical signal is transmitted to the central office 21 through the working main fiber. The modulated upstream signals transmitted from the optical network units 23 - 1 to 23 -( n - 1 ) to the remote node 22 through the protection distribution fiber are inputted into the second through the N th terminal of one side of the N×N waveguide grating router 209 located in the remote node 22 , are multiplexed by the N×N waveguide grating router 209 , and the multiplexed optical signal is outputted to the N th terminal of the other side of the N×N waveguide grating router 209 . Then, the multiplexed optical signal is transmitted to the central office 21 through the protection main fiber.
The upstream signal passing through the 2×2 optical coupler 206 and the second circulator 208 located in the central office 21 is inputted to the N th terminal of one side of the N×N waveguide grating router 203 , and is demultiplexed into (n- 1 ) number of optical signals corresponding to the second through the N th terminal of the other side of the N×N waveguide grating router 203 . Then, the demultiplexed signals are inputted into the upstream optical receivers 205 - 1 to 205 -( n - 1 ) according to the optical network units 23 - 1 to 23 -( n - 1 ), and then are converted into electrical signals.
FIG. 3 is a view showing a wavelength range of a downstream light source and a wavelength range of an upstream light source according to one embodiment of the present invention.
As shown in FIG. 3 , the wavelength range 31 of the downstream light source and the wavelength range 32 of the upstream light source according to the present invention are distinguished from each other in the bi-directional wavelength division multiplexed self-healing passive optical network transmitting an upstream signal and a downstream signal simultaneously using one strand of optical fiber. That is, since the waveguide grating routers 203 and 209 used as multiplexers/demultiplexers have a periodic pass characteristic with a free spectral range, an upstream/downstream signal can be multiplexed/demultiplexed simultaneously by means of one of the waveguide grating routers 203 and 209 even though the upstream wavelength range and the downstream wavelength range are distinguished from each other.
FIG. 4 is a block diagram illustrating a case in which an abnormality occurs in a working main fiber in a wavelength division multiplexed self-healing passive optical network using a wavelength injection method according to one embodiment of the present invention.
As shown in FIG. 4 , when an abnormality occurs in the working main fiber in the wavelength division multiplexed self-healing passive optical network using the wavelength injection method according to the present invention, since a downstream transmission signal and a broadband optical signal of a broadband light source for upstream light source transmitted from the central office 21 disappear, the optical signals are not transmitted to the working distribution fiber connected to each of the optical network units 23 - 1 to 23 -( n - 1 ). Accordingly, the state of the 1×2 optical switching device 210 in each of the optical network units 23 - 1 to 23 -( n - 1 ) is switched, thereby enabling communication between the central office 21 and each of the optical network units 23 - 1 to 23 -( n - 1 ) to be performed through the protection main fiber and the protection distribution fiber as shown in FIG. 4 .
Each of the optical network units 23 - 1 to 23 -( n - 1 ) informs the central office 21 of the state of the 1×2 optical switching device 210 , and the central office 21 analyzes the state of the 1×2 optical switching device 210 . Therefore, an existence or absence of abnormality of the working main fiber between the central office 21 and the remote node 22 can be checked.
FIG. 5 is a block diagram illustrating a case in which an abnormality occurs in a working distribution fiber in a wavelength division multiplexed self-healing passive optical network using a wavelength injection method according to one embodiment of the present invention.
As shown in FIG. 5 , when an abnormality occurs in the working distribution fiber in the wavelength division multiplexed self-healing passive optical network using the wavelength injection method according to the present invention (the embodiment of the present invention examples a case in which an abnormality occurs in the working distribution fiber connected to the optical network unit 23 - 1 ), since an input of a signal received in the downstream optical receiver 212 disappears, the state of the 1×2 optical switching device 210 in the optical network unit 23 - 1 is switched. Therefore, the optical network unit 23 - 1 receives a downstream signal through the protection distribution fiber. Here, the states of the 1×2 optical switching devices 210 in the remaining optical network units 23 - 2 to 23 -( n - 1 ) are not changed. Further, the central office 21 receives an upstream transmission signal corresponding to the optical network unit 23 - 1 through the protection main fiber, and continuously receives upstream transmission signals corresponding to the remaining optical network units 23 - 2 to 23 -( n - 1 ) through the working main fiber.
The optical network unit 23 - 1 informs the central office 21 of the state of the 1×2 optical switching device 210 , so that an existence or absence of abnormality of the distribution fiber between the remote node 22 and the optical network unit 23 - 1 can be checked.
As described above, the present invention provides a wavelength division multiplexed self-healing passive optical network using a wavelength injection method to transmit an upstream signal, a downstream signal, and a broadband optical signal for injection through working fibers and protection fibers, thereby improving efficiency of an optical fiber.
Further, according to the present invention, a central office and a remote node each use one N×N waveguide grating router, and an abnormality, such as a cut of an optical fiber, is quickly detected by means of a protection fiber connecting the central office to an optical network unit, and the detected abnormality is quickly healed. Therefore, a network can be managed economically and efficiently.
While the invention has been shown and described with reference to certain 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 as defined by the appended claims.
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A wavelength division multiplexed self-healing passive optical network using a wavelength injection method includes a central office for coupling modulated multiplexed optical signals (MMOS) and broadband optical signals (BOS)for an upstream light source into one signal transmitted to a plurality of optical network units (ONUs) through a working main fiber and a protection main fiber. A remote node connects to the central office via the main fiber and protection main fiber and to the ONUs through working distribution fibers and protection distribution fibers. The remote node demultiplexes the MMOS and the (BOS) for an upstream light source. The remote node transmits demultiplexed signals to the ONUs, which receive the modulated optical signals and the BOS for an upstream light source which corresponds to predetermined ONUs, and demodulate the modulated optical signals, and modulate upstream optical signals via demultiplexed BOS for an upstream light source.
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RELATED APPLICATION
[0001] The present patent application claims priority to the corresponding provisional patent application Ser. No. 62/159,984, entitled “CALF BUMPER SYSTEM” filed on May 12, 2015.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a Calf Bumper System and more particularly pertains to reducing the risk of scrapes and skin tears caused by wheelchair leg rest brackets.
[0004] 2. Description of the Prior Art
[0005] The use of protective covers for wheelchair leg rest brackets is known in the prior art. More specifically, protective covers for wheelchair leg rest brackets previously devised and utilized for the purpose of reducing the risk of scrapes and skin tears caused by exposed wheel chair leg rest brackets are known to consist basically of familiar, expected, and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which has been developed for the fulfillment of countless objectives and requirements.
[0006] While these devices fulfill their respective, particular objectives and requirements, they do not describe a Calf Bumper System readily deployable for reducing the risk of scrapes and skin tears caused by wheelchair leg rest brackets, such ready deployment and reducing of risk being done in a safe, convenient, and economical manner.
[0007] In this respect, the Calf Bumper System according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus primarily developed for the purpose of reducing the risk of scrapes and skin tears caused by wheelchair leg rest brackets.
[0008] Therefore, it can be appreciated that there exists a continuing need for a new and improved Calf Bumper System which can be used for reducing the risk of scrapes and skin tears caused by wheelchair leg rest brackets. In this regard, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
[0009] In view of the foregoing disadvantages inherent in the known types of systems used to reduce the risk of scrapes and skin tears caused by wheelchair leg rest brackets now present in the prior art, the present invention provides an improved Calf Bumper System. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved Calf Bumper System and method which has all the advantages of the prior art and none of the disadvantages.
[0010] To attain this, for a broad perspective, the present invention essentially comprises a calf bumper system readily deployable for reducing the risk of scrapes and skin tears caused by wheelchair leg rest brackets, such ready deployment and reduction of risk being done in a safe, convenient, and economical manner, such calf bumper system comprising a unitary device having a geometric configuration with an upper surface and a lower surface separated by a height, forward and rearward sides separated by a width, and first and second semi-circular ends. The unitary device has a unitary aperture extending from the upper surface to the lower surface and an interior chamber. The unitary device is fabricated of an elastomer.
[0011] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims attached.
[0012] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
[0013] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0014] It is therefore an object of the present invention to provide a new and improved Calf Bumper System which has all of the advantages of the prior art systems used to reduce the risk of scrapes and skin tears caused by wheelchair leg rest brackets and none of the disadvantages.
[0015] It is another object of the present invention to provide a new and improved Calf Bumper System which may be easily and efficiently manufactured and marketed.
[0016] It is a further object of the present invention to provide a new and improved Calf Bumper System which is of durable and reliable constructions.
[0017] An even further object of the present invention is to provide a new and improved Calf Bumper System which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such Calf Bumper System economically available to the buying public.
[0018] It is still another object of the current invention to provide a system that is reusable and may be quickly and easily removed and re-attached.
[0019] It is a still further object of the present invention to provide a system that may be easily cleaned and sanitized.
[0020] Lastly, it is an object of the present invention to provide a Calf Bumper System for reducing the risk of scrapes and skin tears caused by wheelchair leg rest brackets.
[0021] These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure.
[0022] For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] 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:
[0024] FIG. 1 is perspective view of a calf bumper system constructed in accordance with the principals of the current invention.
[0025] FIG. 2 is an exploded view of a calf bumper system constructed in accordance with the principals of the current invention.
[0026] FIG. 3 is a perspective view of a wheel chair having leg rest brackets configured for use with the calf bumper system.
[0027] FIG. 4 is a perspective view of the system installed on a wheel chair leg rest bracket taken along line 4 - 4 of FIG. 3 .
[0028] The same reference numerals refer to the same parts throughout the various Figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] With reference now to the drawings, and in particular to FIG. 1 through 4 thereof, the preferred embodiment of the new and improved Calf Bumper System embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
[0030] The present invention, the Calf Bumper System 10 is comprised of a plurality of components. Such components in their broadest context include a first section and a second section coupled together to form a unitary device having a central aperture. In this broad context, first provided is a calf bumper system readily deployable for reducing the risk of scrapes and skin tears caused by wheelchair leg rest brackets, such ready deployment and reduction of risk being done in a safe, convenient, and economical manner, such calf bumper system comprising a unitary device fabricated with a first section and a second section and having a geometric configuration with an upper surface and a lower surface separated by a height, forward and rearward sides separated by a width, and first and second semi-circular ends. The unitary device has a unitary aperture extending from the upper surface to the lower surface. The unitary device has a first chamber in the first section and a second chamber in the second section. The first and second chambers connect to form a unitary chamber. An opening on one side facilitates installation and removal of the device. The unitary device is fabricated of an elastomer.
[0031] Such components are individually configured and correlated with respect to each other so as to attain the desired objective.
[0032] From a specific perspective, the invention of the present application is a calf bumper system 10 readily deployable for reducing the risk of scrapes and skin tears caused by wheelchair leg rest brackets, such ready deployment and reducing of risk being done in a safe, convenient, and economical manner, such calf bumper system comprising, in combination:
[0033] A wheelchair shown in FIG. 3 having leg rest brackets normally adapted to cause scrapes and skin tears to a user if the leg rest brackets are not properly covered. The leg rest bracket is formed with a flat section having a generally oval shape and a perpendicular post for engaging a leg rest.
[0034] A bumper fabricated of a first section 18 and a second section 20 , the first section and the second section being coupled together to form a unitary device. The unitary device has a geometric configuration with an upper surface 22 and a lower surface 24 separated by a height of 0.5 inches, plus or minus 10 percent. The upper surface and lower surface have rounded edges.
[0035] The unitary device has a forward linear side 26 and a parallel rearward linear side 28 separated by a width of 2 inches, plus or minus 10 percent. The unitary device has a first end 30 and an opposed second end 32 , each end being semi-circular with a diameter of two inches, plus or minus 10 percent. The unitary device has a unitary aperture 34 extending from the upper surface to the lower surface. The unitary aperture includes a small extent 36 in the first section and a large extent 38 in the second section. The small extent is generally semi-circular with a generally rectangular extension. The large extent is generally semi-circular. The small extent and the large extend form a keyhole shape. The circular portion of the keyhole has beveled interior edges 40 . The small extent and the large extent form a keyhole shape. The rectangular extension of the small extent is adapted to receive the perpendicular post on the leg rest bracket. The unitary device is fabricated of a semi-rigid pliable material taken from a class of semi-rigid materials including plastic, polymer and rubber.
[0036] A first chamber 42 is formed in the first section, a second chamber 44 is formed in the second section. The first chamber and the second chamber form a unitary chamber with a configuration congruent with the geometric configuration of the unitary device. The unitary chamber is adapted to receive the flat section of the leg rest bracket. The unitary device has a wall thickness of 0.1875 inches, plus or minus 10 percent, over the majority of its extent.
[0037] A U-shaped recess 48 is formed in the first section extending from the interior of the upper surface along the interior of the rearward linear side, to the interior of the lower surface adjacent to the rearward linear side, and facing the second section. A U-shaped projection 52 is formed in the second section adjacent to the rearward linear side and extending into a space formed by the U-shaped recess.
[0038] A chemical weld is located between the U shaped recess and the U-shaped projection coupling the first section and the second section.
[0039] An opening 58 is located between the unitary aperture and the forward linear side to allow opening of the unitary device to expose the first chamber and the second chamber for facilitating putting the unitary device on the leg rest bracket and for facilitating removing the unitary device from the leg rest bracket, the opening being in a plane extending through a central extent of the U-shaped projection and the U-shaped recess.
[0040] The bumper is easily installed by twisting the device to open exposing the unitary aperture and unitary chamber and putting the device on the leg rest bracket of a wheel chair.
[0041] The calf bumper system provides an accessory that covers the metal bracket that holds a leg rest on a wheelchair. Often times the wheelchair leg rest is removed in order to allow a patient to propel the wheelchair using his/her feet. A patient propels the wheelchair using his/her feet by pulling the chair along as they take “steps”, causing his/her legs to swing under the chair and back. When the leg rest is removed, the support bracket protrudes into the space underneath the wheelchair seat. Scrapes, cuts and skin tears result when the patient's leg comes into contact with the exposed brackets when propelling the wheelchair using his/her feet, as well as when getting into the chair. The “Calf Bumper” provides protective buffer surrounding the exposed bracket reducing the risk of injuries. Preventing skin injuries in older patients is particularly important. Older patients can have very thin skin, making the injury very easy to occur. Healing is slowed by age-related problems such as poor circulation, diabetes, and likelihood of taking blood thinners. The injury is referred to in nursing documentation as a “skin tear”. Any time an “incident” occurs (such as a skin tear), the nurse must report and document the injury, notify the physician as well as the healthcare surrogate and/or power of attorney. An “intervention” must be put into place by the nurse to prevent another occurrence and the “incident” must also be documented.
[0042] As to the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
[0043] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
[0044] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A calf bumper that covers an exposed metal bracket used to hold a leg rest on a wheelchair. The protective device is made of a flexible elastomeric material and is separable on one side with a cavity for the leg rest bracket plate and a central hole to encompass the leg post and the bracket pin. When deployed the bumper provides protective buffer surrounding the exposed bracket reducing the risk of injuries such as scrapes and skin tears caused by exposed wheelchair leg rest brackets.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is based on and hereby claims priority to German Application No. 10 2006 019 466.7 filed on Apr. 26, 2006, the contents of which are hereby incorporated by reference.
BACKGROUND
The embodiments herein relate to a method and a system for manipulation-protected generation of a common cryptographic key between two nodes via a radio interface.
In near-field communication systems, such as Bluetooth, WLAN, ZigBee or WiMax, terminals communicate with each other via a radio interface. To protect the information transmitted via the radio interface against manipulation or eavesdropping by third parties the information is transmitted between the nodes or terminals of the near field communication systems in encrypted form. To do this it is necessary for the terminals or nodes to create a common cryptographic key.
With near field radio systems end users must create the cryptographic key themselves and are not supported by any network operator in doing so. For private end users the configuration or the creation of a cryptographic key is cumbersome and prone to errors. Many end users have a tendency to create easily recognizable keys or passwords, for example “1234”, which can be discovered relatively easily by third parties.
Conventional security protocols are known for the creation of a common cryptographic key, which create a secret key which is only known to those actively involved in the protocol execution sequence, but not however to an external passive, i.e. only eavesdropping, attacker. Two known security protocols are the security protocol according to Diffie-Hellman for key negotiation and an anonymous, non-authenticatable variant of the SSL/TLS (Secure Source Layer/Transport Layer Security) security protocol.
Key negotiation according to Diffie Hellman allows a key to be negotiated over an insecure channel. In such cases two subscribers A, B know two public values, a module value m, i.e. a large prime number, and an integer g.
In the key negotiation A initially computes a large random number a and subsequently computes X=g a mod m. The other subscriber B computes a large random number b and computes Y=g b mod m.
After subscriber A has sent the computed value X to the other subscriber B, this subscriber B computes a value W 1 =X b mod m.
The subscriber B sends the computed value Y to the subscriber A. Subsequently the subscriber A computes the value W 2 =Y a ·mod m. The values W 1 , W 2 computed by the two subscribers A, B are g DB mod m. The computed values W 1 , W 2 represent the common secret key of the two subscribers A, B. This negotiated key S cannot be created by a third party without the knowledge of A, B. The reversal of the exponentiation executed by A, B demands an extremely large number of computing steps and takes a correspondingly long time. This characteristic ensures the secrecy of the negotiated common key W 1 =W 2 =S.
A common cryptographic key S negotiated in this way is safe from passive attacks by third parties, i.e. safe from eavesdropping by third parties. However, such creation of a secret key is not secure against an active attacker (man-in-the-middle), who manipulates the communication between the two subscribers when the key negotiation runs without authentication. It is then namely possible for a “constructed” message not to originate from the supposed sender but from an unauthorized third party. The receiver of the message is not in a position to notice this difference.
FIG. 1 shows a schematic diagram of an active attack by a third node during creation of a common cryptographic key S between two nodes K 1 , K 2 in a conventional key negotiation protocol. The attacker A attempts, for example, to influence the execution sequence or the order of the messages exchanged in accordance with the security protocol such that, after execution of the security protocol, a security relationship between the first node K 1 and the attacker A and a further security relationship between the second node K 2 and the attacker A is configured, so that the attacker A is linked without being noticed by the two nodes K 1 , K 2 into communication between the two nodes K 1 , K 2 (man-in-the-middle).
SUMMARY
It is an aspect of the embodiments to create a method and a system for manipulation-protected creation of a common cryptographic key between two nodes via a radio interface which also offer effective protection against the use of a non-authenticated key negotiation protocol.
The embodiments create a method for manipulation-protected creation of a common cryptographic key between two nodes over a radio interface, with at least one of the two nodes monitoring within a creation period during the creation of the common cryptographic key whether a third node is communicating with one of the two nodes over the radio interface.
With the method a radio monitoring function is provided for detection of the possible presence of an active attacker (man-in-the-middle). Since the active attacker must communicate with both nodes, the distance between the nodes to be configured is small and the attacker communicates over a radio channel with the two nodes, an active attacker cannot manipulate the communication between the two nodes without the provided function noticing that the active attacker is involved as a third node.
The method thus combines a cryptographic security function with a non-cryptographic function monitoring method during the creation of a common cryptographic key, which is secure against active attackers.
In a first embodiment the monitoring node aborts the creation of the common cryptographic key with the other node if the monitoring node detects that a third node is communicating via the radio interface with one of the two nodes.
In an alternate embodiment the monitoring node does not abort the creation of the common cryptographic key with the other node when a third node communicates over the radio interface with one of the two nodes, however the configured cryptographic key is stored as an insecure key.
In an embodiment of the method the monitoring node monitors one or more radio channels of the radio interface.
In a further embodiment of the method the two nodes create the common cryptographic key in accordance with a predetermined key negotiation protocol by exchanging predefined key negotiation messages over at least one radio channel of the radio interface.
The monitoring node monitors in a preferred embodiment of the method whether key negotiation messages are being sent by a third node to one of the two nodes via the radio interface.
In an embodiment of the method the monitoring node monitors whether a warning message is being sent by another node.
In an embodiment of the method the monitoring node monitors whether a radio channel quality drops during the creation of the cryptographic key in the creation period.
In an embodiment of the method the monitoring node additionally monitors whether a third node is communicating during guard times before and after the creation period with one of the two nodes over the radio interface.
In an embodiment of the method the nodes are embodied by near field communication devices.
The embodiments further create a near field communication system with a number of near field communication devices which communicate with one another over a radio interface with, during creation of a common cryptographic key between two near field communication devices of the near field communication system, at least one of the two near field communication devices monitoring during the creation of the cryptographic key via the radio interface in a creation period whether a further near field communication device is communicating with one of the two near field communication devices via the radio interface.
The embodiments further create a near field communication device which, during creation of a common cryptographic key with another near field communication device over a radio interface, monitors this radio interface to detect manipulation by detecting whether, during the creation of the common cryptographic key, a third near field communication device is communicating with one of the two near field communication devices over a radio interface.
Embodiments of the method and of the near field communication system are described below with reference to the enclosed figures to explain features of importance thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects and advantages will become more apparent and more readily appreciated from the following description of the exemplary embodiments, taken in conjunction with the accompanying drawings of which:
The figures are as follows:
FIG. 1 is a diagram to illustrate the underlying problem;
FIG. 2 is a block diagram of a near field communication system with two near field communication devices with a watchdog monitoring function;
FIG. 3 is a block diagram of an embodiment of a near field communication device with watchdog function employed in the near field communication system;
FIG. 4 is a signal diagram to explain the method for creation of a common cryptographic key without an active attack by a third party;
FIG. 5 is a signal diagram of the method for creation of a common cryptographic key during an active attack by a third party.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the preferred embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
As can be seen from FIG. 2 , a near field communication system 1 can have at least two near field communication devices or nodes 2 - 1 , 2 - 2 . The near field communication devices 2 - 1 , 2 - 2 communicate with each other by means of transmit/receive antennas 5 - 1 , 5 - 2 via a radio interface 3 . At least one of the two near field communication devices or nodes has a watchdog (WD) monitoring function. During creation of a common cryptographic key between the two near field communication devices 2 - 1 , 2 - 2 of the near field communication system 1 the near field communication device 2 - 2 which contains a watchdog unit 4 monitors the creation of the cryptographic key via the radio interface 3 in a predetermined creation period to see whether a further near field communication device is communicating with one of the two near field communication devices 2 - 1 , 2 - 2 over the radio interface 3 .
FIG. 3 shows a schematic block diagram of an embodiment of a near field communication device or node 2 , as is used in the near field communication system 1 . The node 2 has a watchdog unit 4 which monitors radio signals transmitted over the radio interface 3 . The node 2 features a transmit/receive antenna 5 for emitting and for receiving radio signals. The transmit/receive antenna 5 is connected on the one hand to the watchdog unit 4 and on the other hand to a watchdog unit 6 of the node 2 . The watchdog unit 6 contains a transmit and a receive device for emitting and receiving radio signals. In one embodiment the watchdog unit 4 can also be realized as part of the watchdog unit 6 . In an alternate embodiment the watchdog unit 4 has its own separate transmit/receive antenna. The near field communication device 2 preferably also has a control unit 7 in which a program executes according to the method. The near field communication device 2 contains a memory 8 for storing a created cryptographic key, which will be used for encryption of messages.
As can be seen from FIG. 2 not all near field communication devices 2 or nodes 2 of the near field communication system 1 have to contain a near field communication device 4 , but only at least one of the two nodes wishing to negotiate a common cryptographic key. If the watchdog unit 4 of the monitoring node 2 - 2 for creation of the common cryptographic key detects that a third node is communicating via the radio interface 3 with one of the two nodes 2 - 2 , in a first embodiment of the method the creation process is aborted by the control unit 7 of the monitoring node 2 - 2 . In an alternate embodiment, to detect the third-party node, the monitoring node 2 - 2 does not abort the creation of the common cryptographic key; however the created cryptographic key is stored in each case as “insecure” in the two key stores 8 of the two nodes 2 - 1 , 2 - 2 . If communication by a third node over the radio interface 3 with one of the two nodes 2 - 1 , 2 - 2 is detected by the watchdog unit 4 of the monitoring node 2 - 2 , in an embodiment the monitoring node 2 - 2 sends out an error message and transmits the message via the radio interface 3 . In the method the creation of the common cryptographic key between the two nodes 2 - 1 , 2 - 2 over the radio interface 3 is undertaken in accordance with a predetermined key negotiation protocol, in which predefined key negotiation messages are exchanged over at least one radio channel of the radio interface 3 between the nodes 2 - 1 , 2 - 2 . This key negotiation protocol for example involves a Diffie-Hellman key negotiation protocol or an SSL/DLS key negotiation protocol. These two key negotiation protocols are non-authenticating key negotiation protocols, i.e. a node which receives messages does not have the option of securely establishing the transmitter from which the message originates.
To enhance protection, in the method, a non-authenticating key negotiation protocol can be followed by an authentication by means of a PIN number. In an alternate embodiment, to increase protection after negotiation of the common cryptographic key, the user compares at both near field communication devices the created cryptographic key or its hash value or the cryptographic key displayed by a near field communication device is entered at the other node or near field communication device. The method uses the watchdog function to enhance the security of creation of the common cryptographic key between two near field communication devices. If a non-authenticating key negotiation protocol is used, in the method the entry of a PIN number or of a password or the checking of the created common key by the user can be dispensed with. However, as an alternative, it is possible in addition to the watchdog function, to undertake an authentication during the key negotiation protocol in order to enhance the security from attack of the communication link between the near field communication devices.
In a first embodiment of the method the monitoring node 2 - 2 merely monitors one radio channel of the radio interface. In this case the common cryptographic key between the nodes is created on a previously defined radio channel. This has the advantage of requiring little circuitry for implementing the watchdog, since only radio transmissions on the predetermined radio channel are monitored.
In an alternate embodiment the watchdog unit monitors a number of radio channels of the radio interface 3 .
The radio channel is any given radio channel, for example an FDM (Frequency Division Multiplexing) radio channel, a TDM (Time Division Multiplexing) radio channel or CDM (Code Division Multiplexing) radio channel. The watchdog unit 4 monitors whether any suspect communication is taking place between one of the two nodes 2 - 1 , 2 - 2 and a third node. To this end the watchdog unit 4 of the monitoring node 2 - 2 monitors whether key negotiation messages are being sent by a third node to one of the two nodes via the radio interface 3 .
In addition the watchdog unit 4 monitors whether a generated warning message was sent out.
Furthermore, the watchdog unit 4 can monitor whether there was a drop in the quality of the radio channel during the creation of the cryptographic key in a predetermined creation period. A significant drop in the quality of the radio channel during creation procedure by comparison with a previously observed channel quality is an indication that further communication is taking place over the radio interface. A drop in the quality of the channel is especially manifests itself as an increased probability of packet loss. In a possible embodiment of the method the creation of the common cryptographic key between the two nodes is interrupted if a fault in the transmission channel, for example, the occurrence of a data packet loss, is observed by the monitoring node 2 - 2 .
Furthermore the watchdog unit 4 can monitor whether a further node is active on the same radio channel, with this able to be detected by its address, for example a MAC address. Furthermore the watchdog unit 4 can monitor whether the actual network name (WLAN-SSID) is specified at number of Access Points, i.e. on the same or on another radio channel. There is namely the option that a node with the same network name has been set up by an attacker.
If the watchdog unit 4 detects one of the aforementioned suspect forms of communication, there is the possibility that an active attack by a third party is taking place. The above-mentioned suspect types of communication are preferably separately observed, and on occurrence of at least one suspect communication type, in one possible embodiment of the method the creation of the common cryptographic key is aborted. In an alternate embodiment the various suspect forms of communication are monitored separately and subsequently added together with a weighting when they occur. If the weighted sum value thus created exceeds a specific threshold value, in one embodiment of the method, the creation of the common cryptographic key is aborted.
In a further embodiment of the method the monitoring node additionally monitors whether a third node is communicating during the guard times before and after the creation period with one of the two nodes via the radio interface 3 . The fact that monitoring also takes place before and after the actual creation period means that period which is perceived by the user as the creation phase is also protected, i.e. from the start of the creation up to its end. This prevents two or even more creation sequences following each other within a short period, i.e. barely or even not perceptible for the user. This prevents an attacker linking an attacking node firstly with the one node 2 - 1 and later independently with the other node 2 - 1 . The guard time periods before and after the creation period are therefore preferably selected to be large enough to allow attacks to be easily detected, for example in the range of 1 to 5 seconds.
For implementing the guard time periods, in an embodiment of the method, timers or counters are provided in order to monitor whether suspect communication has occurred in a previous guard time period or in a subsequent guard time period. The timers or counters are preferably provided in the control unit 7 of the node.
If suspect communication is detected by the watchdog unit 4 a timer is started. This is done regardless of whether the near field communication device or the node 2 is currently in linkage operating mode or not. The result is that the radio channel is monitored before the actual linkage procedure in which the common cryptographic key is created. If a linkage procedure is initiated it can be used to ask whether, in a period predetermined beforehand by the timer, this type of suspect communication has been observed. In an embodiment the radio channel or the radio channels is or are also monitored by the watchdog unit 4 after the completion of the creation process for creating the common cryptographic key. The watchdog function remains active in this case for a predetermined period of time after the creation of the key and reports suspect types of communication. The result is that the radio channel is monitored over the entire period, which includes a particular period of time before and after the creation period for creating the cryptographic key.
In an alternate embodiment this is achieved by delays during the linkage procedure. At the beginning of the linkage procedure the radio channel is monitored for a certain period to see whether a suspect type of communication is occurring. Although this increases the time required for the linkage, the monitoring function does not have to remain active beyond the linkage phase.
If a suspect communication type occurs, in a first embodiment the key creation is aborted entirely, i.e. no common cryptographic key is created. In an alternate embodiment, the cryptographic key is still created in the event of suspicion but is stored as less trustworthy in the key store 8 . The user subsequently obtains an explicit conformation by comparison or by additional authentication by means of a PIN number.
The nodes 2 - 1 , 2 - 2 are embodied by near field communication devices with a relatively short range. In a preferred embodiment the near field communication devices involve WLAN, Bluetooth, ZigBee or WiMax wireless devices. Nodes 2 - 1 , 2 - 2 or the wireless devices can be mobile terminals or fixed stations.
FIG. 4 shows a signal diagram, which depicts the creation of a common key S between two nodes 2 - 1 , 2 - 2 without an active attack by a third node.
The near field communication device 2 - 1 or the node K 1 sends a Setup_Start message to the second near field communication device 2 - 1 or the node K 2 . This is subsequently confirmed in a Setup_Start_Okay message by the second node. Subsequently the first near field communication device 2 - 1 sends to the second node 2 - 2 a value g x , with g representing an integer and x a random number computed by the first node 2 - 1 . The second node 2 - 2 conversely transmits to the first node 2 - 1 a value g y , with g representing an integer known solely to both nodes and y being a random value computed by the second node 2 - 2 . Both nodes 2 - 1 , 2 - 2 subsequently compute the common Key S=Y′ modm or S=X y mod m. The common cryptographic key S is subsequently stored in each case in the key store 8 of the respective node. In one possible embodiment a pseudo-random key derived from the cryptographic key, which for example has a smaller bit length, is stored in the key store 8 .
Preferably checking or verification is then undertaken as to whether both nodes 2 - 1 , 2 - 2 have determined the same common key. In this case, the system waits for a defined period of time during which no suspect communication may occur. To this end, a timer is used within the watchdog unit 4 of the monitoring node 2 - 2 . After the wait time elapses the checking or verification is finished.
Numerous variations of the process depicted in FIG. 4 are possible. For example, in one embodiment the common cryptographic key can be created directly without start messages. It is further possible for the waiting time to already begin after the message “Setup 2 ” or after computation and storage of the key K. In a further embodiment, a period is monitored as an additional monitoring wait time which only begins after the message “Setup_Ver OK 2 ”. In an alternate embodiment, the verification of the created common key is dispensed with entirely.
The period of time for monitoring random communications can vary within a large range. The period is selected so that in the period which the user employs to create the key, only two devices are active. Preferably a timer value in a range of appr. 1 to 5 seconds is set up.
FIG. 5 shows a signal diagram during an active attack by a third party node 9 , The node 2 - 2 can in this case not decide per se whether the node 2 - 1 or the third node 9 depicted in FIG. 5 is an attacking node. The watchdog unit 4 of the monitoring node 2 - 2 detects however that more than one node is communicating or is active over the radio interface 3 . The exchange of the key negotiation protocol messages begins as shown in FIG. 4 , but the creation is not between nodes 2 - 1 , 2 - 2 but between the node 2 - 1 and the attacking node 9 . However as soon as the attacking node 9 becomes active, i.e. likewise sends a Setup_Start message to the node 2 - 2 , the watchdog unit 4 of the monitoring node detects this and signals a suspect communication. The creation of the cryptographic key is then aborted by the control unit 7 of the monitoring node 2 - 2 . The monitoring node 2 - 2 only detects the suspect communication between the node 2 - 1 and the attacking node 9 as an error once it is also put into a mode for creating a common cryptographic key itself. Otherwise the communication between the node 2 - 1 and the node 9 could involve the desired creation of a key or a security relationship between the two nodes 2 - 1 , 9 . In the given example the monitoring node 2 - 2 is put into the mode for key creation by receiving the message “Setup_Start” (A, K 2 ). Alternatively the node 2 - 2 can also be put into the setup mode or into the mode for creating the signal by a user interaction.
As soon as the control unit 7 of the monitoring node 2 - 2 aborts the creation of the common key, the monitoring node 2 - 2 sends a Setup_Failure message via its antenna 5 - 2 to the other node or to all nodes detected as present in a multicast program or in a broadcast program. As soon as the node 2 - 1 receives the Setup_Failure message from the monitoring node 2 - 2 it likewise aborts the process of creating the common key. In one possible embodiment the aborting of the creation process is indicated to the user by a flashing error LED for example.
The diagram shown in FIG. 5 also illustrates a timer value which measures how long an observed suspect communication has already lasted. With the observation of the suspect communication “Setup” (K 1 , A) in the example depicted in FIG. 5 the counter or timer is started and counted down within 1 to 5 seconds, for example. The attempt to create the key with the monitoring node 2 - 2 before the timer elapses leads to the error message “Setup_Failure”. A suspect communication further back in time, for example 5 minutes before, does not lead to the process being aborted.
In a preferred embodiment the watchdog function of the watchdog unit 4 also remains active before and after the actual creation. If within this period of time a suspect radio signal is detected, the creation of the node is cancelled retrospectively or is rejected right from the outset with the error message “Setup_Failure”. In an alternate embodiment the watchdog function is only activated at the start of creation and/or deactivated again at the end of creation. In this embodiment no timer security buffer is provided before or after the actual creation. Alternatively, however, a corresponding wait time or delay can be provided during the creation process.
A degree of additional protection can be obtained by providing short timer protection buffers. In this case, the watchdog function is only active during the actual creation and there are also no waiting times provided for the watchdog during the creation process. In this case, attacks are actively detected if they occur within the usually only short creation period, which for example only lasts for fractions of seconds.
The method significantly improves security against an active attack even with a non-secure or non-authenticated cryptographic creation method.
The system also includes permanent or removable storage, such as magnetic and optical discs, RAM, ROM, etc. on which the process and data structures of the present invention can be stored and distributed. The processes can also be distributed via, for example, downloading over a network such as the Internet. The system can output the results to a display device, printer, readily accessible memory or another computer on a network.
A description has been provided with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV, 358 F3d 870, 69 USPQ2d 1865 (Fed. Cir 2004).
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The embodiments relate to a near field communication system including a plurality of near field communication devices which communicate with each other via a radio interface. During generation of a common cryptographic key between the near field communication devices of the near field communication system, at least one of the two near field communication devices monitors during generation of the cryptographic key via the radio interface in a generation period whether an additional near field communication device which could be a potential active attacker communicates with one of the near field communication devices via the radio interface. If such a suspicious type of communication is detected, generation of the common cryptographic key is optionally terminated.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119 to Norwegian Application Number 20076555, filed in the Norwegian patent office on Dec. 19, 2007, the entire contents of which is hereby incorporated by reference. The present application also claims the benefit of provisional application No. 61/015,051, entitled A Method for Improving Color Sharpness in Video and Images, filed on Dec. 19, 2007, the entire contents of which is hereby incorporated by reference.
FIELD OF TECHNOLOGY
[0002] Embodiments described herein relate to video and still-image compression systems and methods, and in particular to compression/decompression of digital video systems.
BACKGROUND
[0003] Transmission of moving pictures in real-time is employed in several applications like e.g. video conferencing, net meetings, TV broadcasting and video telephony.
[0004] However, representing moving pictures requires much information as digital video typically is described by representing each pixel in a picture with 24 bits (3 Byte). Such uncompressed video data results in large bitrates, and cannot be transferred over conventional communication networks and transmission lines in real time due to limited bandwidth.
[0005] Thus, enabling real time video transmission requires a high level of data compression. Data compression may, however, compromise picture quality. Therefore, great efforts have been made to develop compression techniques allowing real time transmission of high quality video over bandwidth limited data connections.
[0006] Many video compression standards have been developed over the last 20 years. Many of those methods are standardized through ISO (the International Standards organization) or ITU (the International Telecommunications Union). Besides, a number of other proprietary methods have been developed. The main standardization methods are: ITU: the H.261 standard, the H.262 standard, the H.263 standard, the H.264/AVC standard (each of which is incorporated herein by reference in its entirety); and ISO: the MPEG1 standard, the MPEG2 standard, and the MPEG4/AVC standard (each of which is incorporated herein by reference in its entirety).
[0007] Video compression formats rely on statistical properties of the input data. Prior to the standardized video compression/decompression, the raw video data has to be converted to a format suitable for compression. This format is described in the standards, but the process of converting to/from it is to some degree left to the developer. The conversion process is a lossy process as it includes spatial decimation and interpolation. The electronic representation of an image can commonly be interpreted as luma-information (roughly corresponding to “black-and-white” content) and a number of chroma (color-difference) channels that form an image. In this case, the luma and chroma information is transformed from a discrete 2-dimensional matrix of pixels, each containing a red-green-blue sub-pixel triplet, which typically is the case for image sensors and displays. The color-space of the luma and chroma information is often denoted as YCbCr (luma, blue chroma difference, red chroma difference) and the spatial information of the chroma channel are reduced (decimated) vertically and/or horizontally with a factor of between 1:1 and 4:1. One important format is “YCbCr 4:2:0”, which is used in different forms in most of the MPEGx and H.26x video compression formats mentioned above. The principle of spatial decimation (reducing the number of pixels) and interpolation (increasing the number of pixels) is to remove information that cannot be transmitted reliably, and to represent the available information in a perceptually pleasing way, respectively. Since the decimation/interpolation of chroma channels is a lossy process, different methods create different artifacts that may or may not be objectionable for a given set of full-resolution input images and viewers.
[0008] An example of a spatial linear decimation according to a conventional technique is described below. For a filter kernel of length K=2 indexed by k:
[0000] {hk}={0.5,0.5}
[0000] Linear filtering of input signal x(n) consisting of pixel values at offsets n, using kernel h:
[0000] y ( n )= conv ( x ( n ), h ( n ))=0.5 *x ( n )+0.5 *x ( n− 1)
[0000] Dropping samples and shifting to the desired phase:
[0000]
z
(
n
-
0.5
)
=
{
y
(
n
)
,
n
=
2
,
4
,
6
0
,
else
[0000] In practical systems, non-integer storage cells are uncommon, so z would be shifted to a practical phase, and zero-components discarded:
[0000]
g
(
m
)
=
{
y
(
2
*
m
)
,
1
<
m
<
3
0
,
else
[0009] The method outlined above is the basis for general image decimation and chroma-channel decimation. Interpolation can be described in a very similar manner. The objective is to “leak” values across pixel boundaries before or after changing the number of pixels so that the perceived image stays relatively constant even though the number of pixels used in describing it changes.
[0010] Video conference data containing a mixture of continuous tone content and palletized content are now quite common. Examples include screen capture images, web pages, educational and training videos (especially those containing screen capture images or web pages), and business presentations, among others. Web pages often include photographs interspersed among text and other palettized content. In addition to mixed content, it is also very common to transmit two parallel streams in a video conference, one including video content and one including data content, such as presentations or screen shots. However, all data is coded and decoded with a coding scheme as described above, which is most optimal for continuous tone pictures, i.e. video pictures captured by a video camera. This implies that the perceived quality for input-images containing sharp edges and abrupt transitions like in plain text or line art etc. are reduced, since the sharp edges to some degree are spread out spatially by the coding process. Why this occurs is explained in the following accompanied with the FIGS. 1-7 .
[0011] FIG. 1 contains a simplistic 1×6 pixel image containing the RGB-values [0 0 0] and [255 0 0]. The same image information is also shown in FIG. 2 as a 1-dimensional bar graph, showing how the red intensity has an abrupt change for the right half of this image.
[0000]
Image
rgb
=
{
red
:
0
0
0
255
255
255
green
:
0
0
0
0
0
0
blue
:
0
0
0
0
0
0
}
[0012] In FIG. 3 , the same image information is transformed to the ITU-R BT.601 YCbCr color space where black bars represent Y (luma) information, while cyan and magenta bars represent Cb and Cr values, respectively. The spatial resolution is not changed.
[0000]
Image
YCbCr
=
{
red
:
16
16
16
82
82
82
green
:
128
128
128
90
90
90
blue
:
128
128
128
240
240
240
}
[0013] In FIG. 4 , however, the chroma channels have been decimated by a factor of 2, with representation levels at 1.5, 3.5 and 5.5. The method for decimation was a simple mean of the 2 closest source pixels. This is similar to a FIR filter using a 2-tap kernel of [0.5 0.5] followed by picking every second pixels.
[0000]
Image
YcbCr
decimated
=
{
red
:
16
16
16
82
82
82
green
:
128
110
90
blue
:
128
184
240
}
[0014] While the edge is still visible for the luma channel, it has been smoothed out for the chroma channels, since they have to represent both the black and the red levels that fall into the x=[2.5,4.5] area.
[0015] In FIG. 5 , new, higher pixel-count chroma vectors were found by simply repeating the values from FIG. 4 . This is equivalent to zero-filling every second sample, then filtering with a FIR-kernel of [1 1].
[0000]
Image
YcbCr
interpolated
=
{
red
:
16
16
16
82
82
82
green
:
128
128
110
110
90
90
blue
:
128
128
184
184
240
240
}
[0016] Finally, FIG. 6 and FIG. 7 show that the reconstructed image has visible errors along the transition. Not only is the red color blurred, but we get discoloring (change in the relative rgb-mix). The exact value and size of such artifacts is a basic property of the decimation/interpolation technique employed.
[0000]
Image
YcbCr
interpolated
=
{
red
:
0
0
89
166
255
255
green
:
0
0
0
38
0
0
blue
:
0
0
0
38
0
0
}
[0017] The initial and final rgb matrixes use 6(pixels)×3(colors)=18 bytes to store or transmit this onedimensional image. The 2× subsampled YCbCr alternative used 6 (lumapixels) and 2×3 (chromapixels) for a total of 12 bytes. If a more realistic example was used, the savings could be larger by decimating chroma in two dimensions. If considered as a bandwidth-problem, this image clearly could be transmitted as a full-resolution luma channel, and a table mapping the luma-values to full-color rgb triplets:
[0000]
Image
mapped
=
{
Y
:
[
16
16
16
82
82
82
]
Map
Y
→
rgb
:
{
Y
16
=
[
0
0
0
]
Y
82
=
[
255
0
0
]
[0018] That could produce 6+2×3 bytes for transmission, just like the YCbCr-decimated in this example does, but with no quality loss. The problem basically is that the system for bandwidth reduction is optimized for slowly varying, full-color sources, such as photographic content. If the (full) spatial resolution of the luma-channel could be combined with the reduced spatial resolution of the chroma-channels to produce “local color maps”, images with sharp edges correlated in luma and chroma, but low usage of the entire color space would predictable look better. One way of solving this problem is described in U.S. Pat. No. 7,072,512 ('512), which is hereby incorporated by reference herein in its entirety. In this publication, an image segmentation algorithm identifying “continuous tone” image content e.g. photographic content, and “palletized” image content, e.g. text, is disclosed. Images to be transmitted are analyzed by the algorithm and based on the result of this analysis, coded by a codec specialized for the content type identified. By coding “palletized” image content with a coding scheme adjusted for this type of content, the problem of blurring sharp edges can be avoided.
[0019] However, since different coding schemes are used on the transmitting side, the receiving side is required to have the corresponding different decoding schemes installed and vice versa. Consequently, '512 is not able to solve the problem from in a media stream coded on a conventional, standardized way, but requires specialized codecs on both sides.
SUMMARY
[0020] A method in a decoding process for determining full-resolution chroma pixel information (Cx) corresponding to a spatial fraction of a still-image or a video-frame represented by full-resolution luma pixel information (Y) and decimated chroma pixel information (Cxd) decimated by a decimation process, including: receiving the full-resolution luma pixel information at video or image processing apparatus; decimating, at the video or image processing apparatus, the full-resolution luma pixel information (Y) by said decimation process resulting in a decimated spatial luma fraction (Yd); determining, with the video or image processing apparatus, if the decimated chroma pixel information (Cxd) at least approximately can be expressed by {(Yd+shift1)*scale−shift2}; storing, in an electronic memory of the video or image processing apparatus, values of scale, shift1, and shift2 that result in a minimum deviation between {(Yd+shift1)*scale−shift2} and Cxd; and calculating, with the video or image processing apparatus, {(Y+shift1)*scale−shift2} as a first candidate (Cx 1 ) for the full-resolution chroma pixel information (Cx).
[0021] The method may further include: calculating a quality parameter (Q) by comparing {(Yd+shift1)*scale−shift2} with Cxd; interpolating Cxd, by an interpolation process corresponding to the decimation process, resulting in a second candidate (Cx 2 ) for the full-resolution chroma pixel information (Cx); and combining the first and the second candidates according to the quality parameter to create the full-resolution chroma pixel information (Cx).
[0022] In the above-noted method, the quality parameter may be a floating number from 0 to 1, wherein 0 appears when there is no match between {(Yd+shift1)*scale−shift2} and Cxd, and 1 appears when there is an optimal match between {(Yd+shift1)*scale−shift2} and Cxd.
[0023] In the above-noted method, the step of combing the first and the second candidates according to the quality parameter may include creating the full-resolution chroma pixel information (Cx) as a linear mix between the first and second candidates according to the expression Cx=Q*Cx 1 +(1−Q)*Cx 2 .
[0024] In the above-noted method, the full resolution chroma pixel information may include blue chroma difference information.
[0025] In the above-noted method, the full resolution chroma pixel information may include red chroma difference information.
[0026] In the above-noted method, the spatial fraction may correspond to a square block of pixels, and that shift1 may be −Yd center , where Yd center is a center pixel value of Yd, shift2 may be −Cxd center , where Cxd center is a center pixel value of Cxd, and scale may be (Cxd+shift2)/(Yd+shift1).
[0027] An apparatus configured to implement a decoding process for determining full-resolution chroma pixel information (Cx) corresponding to a spatial fraction of a still-image or a video-frame represented by full-resolution luma pixel information (Y) and decimated chroma pixel information (Cxd) decimated by a decimation process, including: a decimating unit configured to decimate the full-resolution luma pixel information (Y) by said decimation process resulting in a decimated spatial luma fraction (Yd); a processor configured to determine if the decimated chroma pixel information (Cxd) at least approximately can be expressed by {(Yd+shift1)*scale−shift2}; and a storage unit configured to store values of scale, shift1, and shift2 that result in a minimum deviation between {(Yd+shift1)*scale−shift2} and Cxd, wherein the processor is configure to calculate {(Y+shift1)*scale−shift2} as a first candidate (Cx 1 ) for the full-resolution chroma pixel information (Cx).
[0028] In the above-noted apparatus, the processor may be is further configured to calculate a quality parameter (Q) by comparing {(Yd+shift1)*scale−shift2} with Cxd, interpolate Cxd, by an interpolation process corresponding to the decimation process, resulting in a second candidate (Cx 2 ) for the full-resolution chroma pixel information (Cx), and to combine the first and the second candidates according to the quality parameter to create the full-resolution chroma pixel information (Cx).
[0029] In the above-noted apparatus, the quality parameter may be a floating number from 0 to 1, wherein 0 appears when there is no match between {(Yd+shift1)*scale−shift2} and Cxd, and 1 appears when there is an optimal match between {(Yd+shift1)*scale−shift2} and Cxd.
[0030] In the above-noted apparatus, the processor may be further configured to create the full-resolution chroma pixel information (Cx) as a linear mix between the first and second candidates according to the expression Cx=Q*Cx 1 +(1−Q)*Cx 2 .
[0031] In the above-noted apparatus, the full resolution chroma pixel information may include blue chroma difference information.
[0032] In the above-noted apparatus, the full resolution chroma pixel information may include red chroma difference information.
[0033] In the above-noted apparatus, the spatial fraction may correspond to a square block of pixels, and that shift1 may be −Yd center , where Yd center is a center pixel value of Yd, shift2 may be −Cxd center , where Cxd center is a center pixel value of Cxd, and scale may be (Cxd+shift2)/(Yd+shift1).
[0034] A computer readable storage medium encoded with instruction, which when executed by a computer causes the computer to implement the above-noted method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 shows a reference picture containing abrupt transition from black to red,
[0036] FIG. 2 shows a RGB-triplet representation of the reference picture,
[0037] FIG. 3 shows a YCbCr-triplet representation of the reference picture,
[0038] FIG. 4 shows a decimated YCbCr representation of the reference picture,
[0039] FIG. 5 shows an interpolated YCbCr representation of the reference picture,
[0040] FIG. 6 shows interpolated RGB representation of the reference picture,
[0041] FIG. 7 illustrates the regained reference picture with color fringes along the transition,
[0042] FIG. 8 illustrates a concept of finding probable smoothed edges by observing luma behavior,
[0043] FIG. 9 shows a top-level block diagram of one exemplary embodiment of the present invention,
[0044] FIG. 10 illustrates a local access of luma/chroma pixels,
[0045] FIG. 11 shows a block diagram of an example of the “shape-fit” module in one exemplary embodiment of the present invention,
[0046] FIG. 12 shows a reference image,
[0047] FIG. 13 shows the reference image decimated and interpolated according to a conventional technique,
[0048] FIG. 14 shows the reference image decimated and interpolated according to an exemplary embodiment of the present invention, and
[0049] FIG. 15 is an exemplary computer system upon which an exemplary embodiment of the present invention may be implemented.
DETAILED DESCRIPTION
[0050] In the following, exemplary embodiments of the invention will be described. However, a person skilled in the art will realize other applications and modifications within the scope of the invention as defined in the enclosed claims.
[0051] One solution to the problem described above is to allow some “leakage” of edges and high-frequency content from the full-resolution luma-channel into the low-resolution chroma channels. This rests on the premise that luma and chroma source channels are highly correlated, as would be the case with, e.g., red text on a black background. The design of a practical interpolation for accomplishing this, with acceptable worst-case characteristics and complexity suitable for real-time low-cost applications, is however, non-trivial.
[0052] The exemplary embodiment of the present invention is adjusted to operate on parts of the image (blocks, lines etc), and to investigate the conformity between the available decimated chroma-information with decimated luma-information. If a good fit can be found, i.e. appropriate shift and scale-parameters can be determined to express decimated chroma values with decimated luma values, those parameters are applied on the full-resolution luma values for obtaining estimated full-resolution chroma values instead of interpolation. If a good fit cannot be found, the full-resolution chroma values will gradually deteriorate to a standard fallback interpolation method. This process is repeated for the entire picture and for each chroma-channel.
[0053] FIG. 8 shows the information that would normally be available to a receiver in a conventional code-transmit-decode communication link. By decimating the locally received luma component (black bars) with the exact same process that produced the chroma component, the edge between pixels 3 and 4 will be smoothed out. The original value of luma pixel 3 is a lot closer to the value of pixels 1 and 2 , while the original value of luma pixel 4 was a lot closer to pixels 5 and 6 . The values of the decimated luma channel may not be the same as the decimated chroma channels, but their shape (a linear ramp in this case) suggests that they are part of a simple edge correlated in all channels of the picture. In other words, one can be expressed as a function of another: x1=a*(x2−b)+c, where x1 and x2 is any pair of 3-element vectors Y′, Cb′ and Cr′. This exemplary embodiment of the invention attempts to express chroma as a function of luma, Cb′=a1*(Y′−b1)+c1, Cr′=a2*(Y′−b2)+c2 for the available decimated channels. If a good match can be found, then it is assumed that substituting Cb′ with a1*(Y−b1)+c1 is a better choice than interpolating Cb′. If a good match cannot be found, then this assumption cannot be made, and conventional interpolation of the available decimated chroma values is selected.
[0054] FIG. 9 shows a high-level block diagram of an exemplary embodiment of the invention involving a transmitter and a receiver. The transmitter and receiver may each be embodied by the exemplary computer system shown in FIG. 15 and described below. “Y” is the luma channel and “Cx” is a chroma component (e.g. Cb or Cr). Both are full-resolution. Prior to transmission across a limited bandwidth channel (and possibly video compression), the Cx channel is decimated to some sub sampling scheme, such as 4:2:2 or 4:2:0 producing Cxd. This decimation may be performed with a processor programmed to execute a decimation algorithm.
[0055] The receiving side has access to Y and Cxd. As Y is already full-resolution, it can be relayed downstream for further processing. Cxd has to be interpolated to be displayed. The luma-adaptive part of the interpolation takes as inputs Y and Cxd, and generates Yd (through a decimation algorithm executed by a processor), which is a luma channel decimated with the same algorithm as that used for the chroma channel(s). In the exemplary embodiment depicted in FIG. 9 , the bottom part leads to Cx′ 2 , a new interpolation leads to Cx′ 1 , and a “blend” component mixes these two as regulated by the “quality” of Cx′ 1 into a composite Cx′ output of the same resolution as Y. The Blend component can also be interpreted as a linear interpolation between the selection of Cx′ 1 and Cx′ 2 controlled by the result of the fitting test in the Shape-fit box.
[0056] The purpose of the Cx′ 2 signal path and the blend component is to be a fall-back in cases where luma and chroma does not align well, and in that case, a similar quality to that of a conventional chroma interpolator will be achieved.
[0057] The exemplary embodiment of the present invention should operate on regions of a frame, as local statistical correlation between luma and chroma is expected to be far greater than any global correlation. However, the regular interpolation/decimation components could operate outside of the segment-based core algorithm if desirable for more flexibility, if, e.g., those are available in specialized hardware or algorithms. A region could be a part of a line, a regular block of pixels, or irregular segments based on picture segmentation. The region used for processing could be larger than the region used for output, leading to e.g. overlapped block processing.
[0058] The main purpose of the module denoted in FIG. 9 as “shape-fit” is to find 3 parameters, “shift1”, “shift2” and “scale” that allows the Cxd signal to be described according to the expression mentioned as {(Yd+shift1)*scale shift2} with minimum “error”. The “shape-fit” module may be a processor that executes an algorithm to determine the above-noted parameters. The processor may be, for example, a Motorola 68000 or Intel 80286 micro-processor, although it will be understood by those skilled in the art that the processor may be virtually any general purpose processor of any size or speed, as this invention is by no means confined to a micro-processor environment. The premise is that any spatial blurring or other artifacts caused by decimation will be evident in both Yd and Cxd if they share edges—but not in Y. In addition, this module could also output a metric describing the quality of the fit as a function 0 . . . 1 where 1 is a perfect fit and 0 is no fit. Once the parameters shift1, shift2 and scale allowing Cxd to be expressed as a function of Yd is found, the parameters are applied in a corresponding way to express a new Cx′ 1 based on only those parameters and the full-resolution Y. That is, the new Cx′ 1 is found by the expression {(Y+shift1)*scale−shift2}. This will work as long as high-frequency content lost in the decimation Y−>Yd are correlated with high-frequency content lost in the decimation Cx−>Cxd, and a good match between Cxd and Yd can be found. The part of the exemplary embodiment of the present invention which is not regular decimation and interpolation operates on segments of the input frame, producing, e.g., one quality scalar and one separate blend of Cx′ 1 and Cx′ 2 for each segment. The full-resolution chroma pixel information (Cx) can be derived in the “blend” component from a linear mix between Cx′ 1 and Cx′ 2 according to the expression Cx=Q*Cx 1 +(1−Q)*Cx 2 .
[0059] FIG. 10 shows a selection of 2-dimensional pixel data for luma (Y), chroma-component (Cx) in both full resolution and 2×2 decimated forms. Y and Cxd are typically already available at the receiving side, while Yd normally can be obtained at low cost by a regular decimation process. Interpolating Cxd into an estimate of Cx is a more complex process. In this example a sliding window of 6×6 luma pixels (Y 11 . . . Y 66 ) corresponding to a 3×3 window of decimated pixels (Yd/Cxd 11 . . . . Cxd 66 ) is used to estimate Cx pixels Cx 33 , Cx 34 , Cx 43 and Cx 44 . However, the exemplary embodiments of the present invention can be used for a number of different configurations, including overlapping windows of varying size and overlap, non-overlapping windows of varying sizes and lines or line-segments.
[0060] FIG. 11 shows one example of how a “shape-fit” module as shown in FIG. 9 can be implemented. It is derived from the expression of the relation between luma and chroma Cxd={(Yd+shift1)*scale−shift2} having shift1, shift2 and scale as output. It is apparent from the expression above that the matrix Yd and Cxd can be divided by another, after first shifting them about their center value to create the scale parameter. Shift1 and shift2 will then consequently come out as the negative of the center value of the Yd block and the Cxd block, respectively. In addition, because nominators and denominators close to zero should be avoided, a block titled “Avoid 0/0” is inserted before the division block. A quality block creating the above-mentioned quality parameter is also added. Other than that, the circuit basically consists of picking the centre values from the current 3×3 matrix of decimated Yd and Cxd values, Yd 22 and Cxd 22 of FIG. 10 , subtracting those from the corresponding 3×3 matrixes Yd and Cxd and doing a 3×3 division.
[0061] The “Avoid 0/0” block mentioned above can be implemented in several ways. In the exemplary embodiment of the present invention illustrated in FIG. 11 , for each 3×3 input matrix the element-wise absolute value is compared to a threshold to avoid excessive large or small scaling factors. For 8-bit precision, an integer of 1 or 2 seems to work well. The consequence of setting a large threshold is that a larger number of blocks will have few or no pixel entries considered “safe”, and will tend to cause fall-back interpolation to be used more often. An AND-operation is performed on the Boolean outputs of the thresholding, as the division should be performed only on elements where both Yd-Yd 22 and Cxd-Cxd 22 are sufficiently far from 0. “Popcount” counts the number of true elements, giving a number of 0 . . . 8 (as the centre element is always false). A full 3×3 element-wise division is then carried out to the right of this module, but invalid elements are removed, the remaining elements are then summed up and scaled by their number.
[0062] Sum of Absolute Differences (SAD) is a simple vector instruction commonly found in video hardware and software for comparing the similarity of two vectors. In this case, it is used for comparing the Cxd input to an “estimated” Cxd originating from the decimated luma, Yd. The idea is that if the outputs “scale”, “shift1” and “shift2” are any good for describing Cxd in terms of Yd, then the SAD of those two should be small. To define what “small” is, the output of SAD is scaled to a range of 0 . . . 1 in the last block before the output “quality” is ready. The “Quality_scale” is a fixed parameter that should be adjusted to find the optimum balance between aggressive sharpening and “safe” fall-back interpolation. If window sizes are changed, Quality_scale should be changed to reflect the total size of the vector/matrix entering the SAD block.
[0063] FIG. 12 is a reference image (no decimation/interpolation) which is shown decimated and interpolated according to a conventional algorithm in FIG. 13 , and according to the present invention in FIG. 14 . It can be seen that the textual part of the image is clearly improved in FIG. 14 compared with the textual part of FIG. 13 , without reducing the quality of the pictorial part of the image.
[0064] FIG. 15 illustrates a computer system 1201 upon which an embodiment of the present invention may be implemented. For example, the receiver shown in FIG. 9 may be implemented by the computer system of FIG. 12 , wherein the communication interface 1213 receives information from the transmitter shown in FIG. 9 and the processor 1203 executes the algorithms discussed above and shown in FIGS. 9 and 11 . The computer system 1201 includes a bus 1202 or other communication mechanism for communicating information, and a processor 1203 coupled with the bus 1202 for processing the information. The computer system 1201 also includes a main memory 1204 , such as a random access memory (RAM) or other dynamic storage device (e.g., dynamic RAM (DRAM), static RAM (SRAM), and synchronous DRAM (SDRAM)), coupled to the bus 1202 for storing information and instructions to be executed by processor 1203 . In addition, the main memory 1204 may be used for storing temporary variables or other intermediate information during the execution of instructions by the processor 1203 . The computer system 1201 further includes a read only memory (ROM) 1205 or other static storage device (e.g., programmable ROM (PROM), erasable PROM (EPROM), and electrically erasable PROM (EEPROM)) coupled to the bus 1202 for storing static information and instructions for the processor 1203 .
[0065] The computer system 1201 also includes a disk controller 1206 coupled to the bus 1202 to control one or more storage devices for storing information and instructions, such as a magnetic hard disk 1207 , and a removable media drive 1208 (e.g., floppy disk drive, read-only compact disc drive, read/write compact disc drive, compact disc jukebox, tape drive, and removable magneto-optical drive). The storage devices may be added to the computer system 1201 using an appropriate device interface (e.g., small computer system interface (SCSI), integrated device electronics (IDE), enhanced-IDE (E-IDE), direct memory access (DMA), or ultra-DMA).
[0066] The computer system 1201 may also include special purpose logic devices (e.g., application specific integrated circuits (ASICs)) or configurable logic devices (e.g., simple programmable logic devices (SPLDs), complex programmable logic devices (CPLDs), and field programmable gate arrays (FPGAs)).
[0067] The computer system 1201 may also include a display controller 1209 coupled to the bus 1202 to control a display 1210 , such as a cathode ray tube (CRT), for displaying information to a computer user. The computer system includes input devices, such as a keyboard 1211 and a pointing device 1212 , for interacting with a computer user and providing information to the processor 1203 . The pointing device 1212 , for example, may be a mouse, a trackball, or a pointing stick for communicating direction information and command selections to the processor 1203 and for controlling cursor movement on the display 1210 . In addition, a printer may provide printed listings of data stored and/or generated by the computer system 1201 .
[0068] The computer system 1201 performs a portion or all of the processing steps of the invention in response to the processor 1203 executing one or more sequences of one or more instructions contained in a memory, such as the main memory 1204 . Such instructions may include the decimation algorithms, the functionality of the shape-fit module discussed supra, the functionality of the luma-adaptive module discussed supra, and the functionality of the blend module discussed supra.
[0069] Furthermore, such instructions may be read into the main memory 1204 from another computer readable storage medium, such as a hard disk 1207 or a removable media drive 1208 . One or more processors in a multi-processing arrangement may also be employed to execute the sequences of instructions contained in main memory 1204 . In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions. Thus, embodiments are not limited to any specific combination of hardware circuitry and software.
[0070] As stated above, the computer system 1201 includes at least one computer readable storage medium or memory for holding instructions programmed according to the teachings of the exemplary embodiments of the invention and for containing data structures, tables, records, or other data described herein. Examples of computer readable media are compact discs, hard disks, floppy disks, tape, magneto-optical disks, PROMs (EPROM, EEPROM, flash EPROM), DRAM, SRAM, SDRAM, or any other magnetic medium, compact discs (e.g., CD-ROM), or any other optical medium, punch cards, paper tape, or other physical medium with patterns of holes, or any other physical medium from which a computer can read.
[0071] Stored on any one or on a combination of computer readable media, the exemplary embodiments of the present invention include software for controlling the computer system 1201 , for driving a device or devices for implementing the invention, and for enabling the computer system 1201 to interact with a human user. Such software may include, but is not limited to, device drivers, operating systems, development tools, and applications software. Such computer readable media further includes the computer program product of the present invention for performing all or a portion (if processing is distributed) of the processing performed in implementing the invention.
[0072] The computer code devices of the exemplary embodiments of the present invention may be any interpretable or executable code mechanism, including but not limited to scripts, interpretable programs, dynamic link libraries (DLLs), Java classes, and complete executable programs. Moreover, parts of the processing of the present invention may be distributed for better performance, reliability, and/or cost. The term “computer readable storage medium” as used herein refers to any physical medium that participates in providing instructions to the processor 1203 for execution. A computer readable medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, optical, magnetic disks, and magneto-optical disks, such as the hard disk 1207 or the removable media drive 1208 . Volatile media includes dynamic memory, such as the main memory 1204 . Transmission media includes coaxial cables, copper wire and fiber optics, including the wires that make up the bus 1202 . Transmission media also may also take the form of acoustic or light waves, such as those generated during radio wave and infrared data communications.
[0073] Various forms of computer readable storage media may be involved in carrying out one or more sequences of one or more instructions to processor 1203 for execution. For example, the instructions may initially be carried on a magnetic disk of a remote computer. The remote computer can load the instructions for implementing all or a portion of the present invention remotely into a dynamic memory and send the instructions over a telephone line using a modem. A modem local to the computer system 1201 may receive the data on the telephone line and use an infrared transmitter to convert the data to an infrared signal. An infrared detector coupled to the bus 1202 can receive the data carried in the infrared signal and place the data on the bus 1202 .
[0074] The bus 1202 carries the data to the main memory 1204 , from which the processor 1203 retrieves and executes the instructions. The instructions received by the main memory 1204 may optionally be stored on storage device 1207 or 1208 either before or after execution by processor 1203 .
[0075] The computer system 1201 also includes a communication interface 1213 coupled to the bus 1202 . The communication interface 1213 provides a two-way data communication coupling to a network link 1214 that is connected to, for example, a local area network (LAN) 1215 , or to another communications network 1216 such as the Internet. For example, the communication interface 1213 may be a network interface card to attach to any packet switched LAN. As another example, the communication interface 1213 may be an asymmetrical digital subscriber line (ADSL) card, an integrated services digital network (ISDN) card or a modem to provide a data communication connection to a corresponding type of communications line. Wireless links may also be implemented. In any such implementation, the communication interface 1213 sends and receives electrical, electromagnetic or optical signals that carry digital data streams representing various types of information.
[0076] The network link 1214 typically provides data communication through one or more networks to other data devices. For example, the network link 1214 may provide a connection to another computer through a local network 1215 (e.g., a LAN) or through equipment operated by a service provider, which provides communication services through a communications network 1216 . The local network 1214 and the communications network 1216 use, for example, electrical, electromagnetic, or optical signals that carry digital data streams, and the associated physical layer (e.g., CAT 5 cable, coaxial cable, optical fiber, etc). The signals through the various networks and the signals on the network link 1214 and through the communication interface 1213 , which carry the digital data to and from the computer system 1201 maybe implemented in baseband signals, or carrier wave based signals. The baseband signals convey the digital data as unmodulated electrical pulses that are descriptive of a stream of digital data bits, where the term is “bits” is to be construed broadly to mean symbol, where each symbol conveys at least one or more information bits. The digital data may also be used to modulate a carrier wave, such as with amplitude, phase and/or frequency shift keyed signals that are propagated over a conductive media, or transmitted as electromagnetic waves through a propagation medium. Thus, the digital data may be sent as unmodulated baseband data through a “wired” communication channel and/or sent within a predetermined frequency band, different than baseband, by modulating a carrier wave. The computer system 1201 can transmit and receive data, including program code, through the network(s) 1215 and 1216 , the network link 1214 and the communication interface 1213 . Moreover, the network link 1214 may provide a connection through a LAN 1215 to a mobile device 1217 such as a personal digital assistant (PDA) laptop computer, or cellular telephone.
[0077] The exemplary embodiments of the present invention described herein improve legibility and perceived quality of text and line-sharpness for image content typical of that originating in a computer or other synthetic image/video sources without exaggerating channel-noise or over-sharpening edges. Its relatively low complexity makes it feasible in a real-time communication context.
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A method in a decoding process for determining full-resolution chroma pixel information (Cx) corresponding to a spatial fraction of a still-image or a video-frame represented by full-resolution luma pixel information (Y) and decimated chroma pixel information (Cxd) decimated by a decimation process, including: receiving the full-resolution luma pixel information at video or image processing apparatus; decimating, at the video or image processing apparatus, the full-resolution luma pixel information (Y) by said decimation process resulting in a decimated spatial luma fraction (Yd); determining, with the video or image processing apparatus, if the decimated chroma pixel information (Cxd) at least approximately can be expressed by {(Yd+shift1)*scale−shift2}; storing, in an electronic memory of the video or image processing apparatus, values of scale, shift1, and shift2 that result in a minimum deviation between {(Yd+shift1)*scale−shift2} and Cxd; and calculating, with the video or image processing apparatus, {(Y+shift1)*scale−shift2} as a first candidate (Cx 1 ) for the full-resolution chroma pixel information (Cx).
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BACKGROUND
A variety of wrenches are commonly used to apply torque to a work piece, such as a threaded fastener. The work piece may have any number of different sizes and shapes. Accordingly, many wrenching tools include a driver which is mateable with any of a number of different adapters, such as sockets, to engage and rotate the different-sized work pieces.
Many times these wrenching devices are used to apply torque to fasteners that are in difficult-to-reach spaces or spaces which have limited room in which to adjust and/or turn the fasteners. In such situations, extensions are typically attached between the wrenching devices and sockets to enable the wrenching devices to reach fasteners in difficult locations. These extensions are typically solid, cylindrical extensions which connect to the head of the wrenching device and to the socket. The extensions come in many different sizes to accommodate different extension lengths and different-sized fasteners. These type of extensions are limited in that, when a fastener is tightened or loosened, the distance between the wrenching device and fastener changes as the fastener moves closer to the wrenching device as it is being loosened or away from the wrenching device as it is being tightened. In some situations, the user has to change to a different size extension to accommodate for the change in distance between the fastener and the wrenching device during use.
Other extensions include a tubular outer member and a solid inner member which slides within the outer member to adjust the extension to different incremental lengths without having to completely change the extension. One such extension is described in U.S. Pat. No. 4,376,397 and is directed to an adjustable extension including a driver-engaging member moveable within a work-engaging member. The extension includes a plurality of detents that are spaced along the length of the driver-engaging member and are engaged by a latch member to hold the work-engaging member at one of various different incremental positions. As a result, only one extension is needed. This type of extension, however, requires a user to continuously adjust the incremental position of the extension based on the distance between a wrenching device and a fastener, which takes significant time and effort.
Another type of extension includes an outer member and an inner member that is slidable within the outer member. A spring biases the inner member outwardly away from the outer member to adjust to the changing distances between the wrenching device and the fastener as the fastener is being tightened or loosened. These extensions have limited extension or compression lengths because space is needed for the spring seated inside the extension. Also, the diameters of the outer member and the inside member are very similar in size, which may lead to the extension binding or locking up during use. This type of extension therefore is limited in its extendability and can lead to increased costs and delays due to the extension binding up or breaking during use.
Accordingly, there is a need for an adjustable extension for a wrenching device which automatically adjusts during use and which helps to prevent the extension from binding during use.
SUMMARY
This application is directed to an adjustable extender and, more specifically, to an adjustable tool extender for a wrenching device, such as a ratchet, that enables a user to engage a connector in a hard to reach position and which automatically adjusts the length of the extender during the tightening or loosening of the connecr.
One embodiment provides an adjustable tool extender including a sleeve defining a receptacle and an extension member having a first end and a second end, where the second end defines a cavity and is slidable within the receptacle of the sleeve between fully extended and fully retracted positions. The adjustable tool extender also includes a bias member seated in the receptacle and an end disposed in the cavity, wherein the bias member biases the extension member outwardly from the sleeve to the fully extended position.
In an embodiment, the extension member has a first diameter, where at least a portion of the extension member intermediate to the first and second ends has a second diameter which is less than the first diameter.
In an embodiment, the bias member is a coil spring.
In an embodiment, the bias member is a tapered spring and the cavity is tapered to receive the tapered spring.
In an embodiment, the second end of the extension member has a polygonal shape.
In an embodiment, the receptacle has a polygonal interior surface.
In an embodiment, the second end of the extension member has a polygonal-shaped end that slidably engages the interior surface of the receptacle.
In an embodiment, the sleeve has a crimped end to capture the second end of the extension member in the receptacle.
In an embodiment, the sleeve has a side opening, and further comprises a pin that is at least partially inserted into the opening.
In an embodiment, further includes a seat member disposed in the receptacle and against which the bias member is seated.
In an embodiment, the extension member has at least one recess therein, and further includes a pawl connected to the sleeve and engageable with the at least one recess.
In an embodiment, the adjustable tool extender includes an actuator for releasing the pawl from engagement with the extension member.
Another embodiment provides an adjustable tool extender including a sleeve defining a receptacle and an extension member having a first end and a second end, where the second end is slidable within the receptacle of the sleeve. The extension member has an intermediate portion between the first and second ends which has a cross-sectional area that is substantially less than that of either of the first and second ends.
In an embodiment, the second end of the extension member has a polygonal shape.
In an embodiment, the receptacle has a polygonal interior surface.
In an embodiment, the second end of the extension member has a polygonal shape that slidably engages the polygonal interior surface of the receptacle.
In an embodiment, the sleeve has a crimped end to capture the second end of the extension member in the receptacle.
In an embodiment, the sleeve has a side opening, and further includes a pin that is at least partially inserted into the opening.
In an embodiment, the adjustable tool extender includes a bias member disposed between the sleeve and the extension member that biases the extension member to the fully extended position.
In an embodiment, the extension member has at least one recess therein, and further includes a pawl connected to the sleeve and engageable with the at least one recess.
In an embodiment, the adjustable tool extender includes an actuator coupled to the pawl for releasing the pawl from engagement with the extension member.
Accordingly, an advantage is to provide an adjustable extender for a tool that enables a user to easily and quickly adjust the length of the extender.
Another advantage is to provide an adjustable extender which automatically adjusts its length as it is being used.
A further advantage is to provide an adjustable extender for a tool which reduces the torque applied to the extender and the tool during use.
Other objects, features and advantages will be apparent from the following detailed disclosure, taken in conjunction with the accompanying sheets of drawings, wherein like numerals refer to like parts, elements, components, steps and processes.
DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of an embodiment of the adjustable extender connected to a ratchet at one end and to a socket at an opposite end.
FIG. 2 is a an enlarged perspective view of the adjustable extender shown in FIG. 1 .
FIG. 3 is an enlarged perspective view of the adjustable extender shown in FIG. 1 .
FIG. 4 is a longitudinal cross section view of the adjustable extender of FIG. 1 taken substantially along line 4 - 4 in FIG. 2 , wherein the adjustable extender is in a fully extended position.
FIG. 5 is a view similar to FIG. 4 wherein the adjustable extender is in a retracted position.
FIG. 6 is a perspective view of another embodiment of the adjustable extender.
FIG. 7 is a perspective view of a further embodiment of the adjustable extender.
DETAILED DESCRIPTION
Referring now to FIGS. 1 , 2 , 3 , 4 , and 5 , in one embodiment, an adjustable-length tool extender or adjustable extension 100 for a wrenching device, such as a ratchet wrench, is provided where the adjustable tool extender is connected at one end to a wrenching device such as a ratchet wrench 80 , and at an opposing end to a work piece or work piece-engaging device, such as a socket 90 . The adjustable extension 100 automatically adjusts the distance between the ratchet wrench 80 and the socket 90 as a fastener engaged by the socket 90 is being loosened or tightened. This saves significant time and effort and also minimizes the number of parts needed to perform these functions.
The adjustable tool extender 100 includes an extension member 102 that is slidably connected to or slidable within a tubular member or sleeve 104 . An extension member 102 is generally a solid part which is formed to have a polygonal-shaped inner end 106 and an opposing connecting end 110 . The polygonal-shaped end 106 of an extension member 102 corresponds to the cross-sectional shape of the inside surface 108 of the sleeve 104 . This facilitates the movement of an extension member 102 within the sleeve 104 and also minimizes the relative rotational movement between the extension member and the sleeve. The polygonal shape may be square or could be other shapes, such as hexagonal. The opposing end 110 of an extension member 102 may have a generally square-shaped surface to engage a similarly shaped receptacle of a socket or other connector.
In an embodiment, a detent ball 111 is positioned in the end 110 to engage a corresponding recess in the socket or other connector. A bias member, such as a spring 113 , biases the ball 111 outwardly to help maintain the connection between the socket and the adjustable extension 100 , in a known manner. It should be appreciated that the ends 106 and 110 may be any suitable size or shape. An extension member 102 also includes a reduced thickness intermediate section 112 which may be cylindrical in shape with a thickness smaller than the thickness of the ends 106 and 110 . This helps to absorb twisting forces applied to the tool extender 100 during use. This also minimizes the chance that extension member 102 will frictionally engage the inside surface of the sleeve 104 and thereby bind up or lock up the extender within the sleeve. This could cause the adjustable extension 100 to break or be non-functional and increase the cost and time for using the tool.
A spring, such as a helical coil spring 116 , is positioned within the sleeve 104 to bias the end 106 and thereby an extension member 102 outwardly away from the sleeve 104 to a fully extended position shown in FIG. 4 . Specifically, one end 117 of the coil spring 116 is seated against a seat member or ring 120 inside the sleeve 104 . The ring 120 may be a split ring seated in a groove defined by the interior surface 108 of the sleeve. The opposing end 118 of the coil spring 116 is received by a cavity 114 defined by the inner end 106 of an extension member 102 . The cavity 114 is sized and shaped to correspond to the size and shape of the end 118 of the coil spring 116 . By having the cavity 114 defined in an extension member 102 , substantial space within the sleeve is saved and also enables the spring to have more room to expand and/or contract. This enables the extension member 102 , and thereby the tool extender, to be able to extend to greater distances away from the tool or retract further within the sleeve.
As shown in FIGS. 4 and 5 , the coil spring 116 has a generally uniform diameter and shape. It should be appreciated that the coil spring 116 may be any suitable size and shape as will be discussed in more detail below. As shown in FIG. 4 , the coil spring 116 expands to push against the extension member 102 to move it outwardly from the sleeve 104 . The end 106 of the extension member 102 defines a shoulder 124 which engages a crimped end 122 of the sleeve 104 to prevent extension member 102 from moving completely out of the sleeve 104 . Specifically, the shoulder 124 contacts the crimped end 122 of the sleeve to stop an extension member 102 from moving further outwardly from the sleeve 104 . It should be appreciated that the end of the sleeve does not necessarily have to be crimped. In another embodiment, a roll pin 119 (shown in FIG. 6 ) or other suitable pin is inserted at least partially into or through a portion of the sleeve to engage the shoulder 124 and thereby stop the outward movement of the extension member. It should also be appreciated that any other suitable method or methods may be used to prevent extension member 102 from completely being moved out of or removed from the sleeve 104 .
As shown in FIG. 5 , an extension member 102 is being compressed or moved inwardly within the sleeve 104 . This causes the spring 116 to compress between the extension member 102 and the sleeve 104 and more specifically, between the end 106 of the extension member 102 and the ring 120 of the sleeve. The compressed spring shown in FIG. 5 will naturally expand back to its expanded position shown in FIG. 4 .
In the above embodiments, the adjustable tool extender 100 is a particular size and shape. It should be appreciated that the adjustable tool extender 100 may be any suitable size and shape to accommodate any devices, tools, work pieces and different work locations.
Referring now to FIG. 6 , another embodiment of the adjustable tool extender is illustrated. The adjustable tool extender 200 includes an extension member 102 and the sleeve 104 described above, as well as a bias member or spring 202 . In this embodiment, the spring 202 has a tapered or angled shape. Similarly, a cavity not shown) defined by the end of the extender also has a corresponding tapered shape. A tapered spring functions similar to the spring 116 described above and it biases an extension member 102 away from the sleeve 104 to allow the adjustable tool extender 100 to automatically adjust to the change and distances between a wrenching device and a fastener. The tapered spring 202 also requires less material to be removed from the end 106 of an extension member 102 , which improves the overall structural integrity of an extension member 102 due to the increase in material at this end. This extends the life of the extension member 102 and thereby, the life of the adjustable tool extender 100 .
Referring now to FIG. 7 , a further embodiment of the adjustable tool extender is illustrated generally by reference number 300 . The adjustable tool extender 300 includes an extension member 302 and a sleeve 304 . As described above, the extender 302 slides within the sleeve 304 . In this embodiment, the extension member 302 includes a plurality of notches or recesses 306 . A pawl or lever arm 308 is pivotably connected to arms 310 connected to the outside surface of the sleeve. The pivot arm 308 may be biased to pivot inwardly through an opening 311 in the sleeve to engage one of the recesses, grooves or notches 306 on the extension member. The pivot arm 308 thereby holds the extension member in place in a particular incremental position. In an embodiment, the lever arm 308 includes at least one actuator for releasing the lever arm from the recess. If a different incremental position is desired, a user presses against or pushes on the end of the pivot arm 308 to pivot it upwardly out of engagement with the recess or notch on the extension member 302 . The extension member 302 then can be moved inwardly or outwardly to adjust the length of the adjustable tool extender. The user releases the pivot arm 308 to enable it to engage a new recess or notch 306 that is positioned beneath the end of the pivot arm. Because the pivot arm 308 is biased into engagement with one of the recesses 306 on the extension member 302 , the adjustable tool extender 300 can be easily adjusted to different lengths as needed.
The above embodiments of the adjustable extension are generally made of a durable material such as a steel, stainless steel, or other suitable material or a combination of materials. It should be appreciated that the adjustable extension described above may be any suitable size or shape to accommodate different work pieces and working locations.
The embodiments set forth in the foregoing description and accompanying drawings are offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants' contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
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An adjustable tool extender includes a sleeve defining a receptacle and an extension member having a first end and a second end, wherein the second end defines a cavity and is slidable within the receptacle of the sleeve. The extender also includes a bias member seated in the receptacle and an end disposed in the cavity for biasing the extension member outwardly from the sleeve to a fully extended position.
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FIELD OF THE INVENTION
The field of the invention is barrier valves and more particularly valves for subterranean use that have a pressure equalizing feature that is operated by the control system for opening and closing the valve.
BACKGROUND OF THE INVENTION
Isolation valves are used in subterranean locations for separating one location from another by preventing flow. Some of these devices are safety valves that have the ability to control pressure differential in a direction from below to above. These safety valves have a closure device known as a flapper that is operated by a flow tube that is in turn actuated by a hydraulic piston operated through a hydraulic system controlled at a surface location. In flapper type valves the need to equalize pressure across the flapper when in the closed position has been met with a valve located in the flapper that is first encountered by the flow tube to open a passage through the flapper for pressure equalization before the flow tube pushes the flapper itself to turn 90 degrees to the open position as the flow tube advances past the displaced flapper. Examples of such designs can be seen in U.S. Pat. Nos. 4,478,286; 6,644,408; 6,848,509 and 6,877,564.
Other designs have focused on pressure equalizing across the hydraulic piston that actuates the flow tube in the event there is a seal leak or tubing failure in the control system. In those instances in systems with two control lines there is an equalizing valve in the hydraulic system that can open to put the operating piston in pressure balance so that a closure spring acting on the hydraulic piston pushes up the hydraulic piston and with it the connected flow tube so that the safety valve can close. One example of such a system is U.S. Pat. No. 6,109,351.
The present invention also deals with the concept of pressure equalization across a closed closure member. The reason to equalize pressure across the closure element is to make it possible for the operating system for the closure member to do its job. The control system components do not have to be designed to resist the higher differential pressures which for example can significantly increase seal friction when trying to for example rotate the ball or plug to the open position. There are basically three ways to equalize across a closed valve member before trying to open it. The flow can be equalized either through the member, between the member and one of its seats or between locations on opposed sides of the closed member but spaced apart from the member. In the present invention, the latter option is employed and the normal hydraulic system for opening and closing the valve member is employed in a manner that allows for equalization through passages that are discrete from the hydraulic lines that normally operate the valve member. In essence, in the preferred embodiment, the equalization takes place via the same mechanism that will ultimately open the valve. These and other aspects of the present invention will become more apparent to those skilled in the art from a review of the description of the preferred embodiment and the associated drawings while recognizing that the full scope of the invention is to be determined from the appended claims.
SUMMARY OF THE INVENTION
A barrier valve has an equalizing feature for the ball or plug when in the closed position before it is opened. A hydraulic open and a close line are connected to a housing so that they can move a piston in opposed directions. The piston ends are sealed and the exterior of the piston is tapered to push one or more bypass valves open to connect tubing pressure across the ball when ramped off its seat. Pressure on the main hydraulic line to close the ball reverses the piston movement and allows a spring bias to close the bypass valve or valves. The equalizing system can be integrated into the barrier valve housing or can be separate as a retrofit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall view showing the pressure equalizing system associated with the barrier valve;
FIG. 2 is the equalizing valve assembly in the closed position; and
FIG. 3 is the equalizing valve assembly in the open position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The valve 10 is shown in FIG. 1 . It has a top sub 12 and a bottom sub 14 for connection to a tubing string that is not shown. In between is a multi-component housing that has a ball 18 that is shown in the open position and flanked by sleeves 20 and 22 . Sleeves 20 and 22 have at their respective ends that face the ball 18 seals 24 and 26 . The ball 18 rotates on axis 28 supported in a frame 32 . A movable carriage 30 engages the ball 18 in an offset location from the axis 28 so that opposed translation of the carriage 30 results in rotation of the ball 18 between the open position that is shown and the closed position. Hydraulic pistons 34 and 36 are on opposed sides of the carriage 30 to urge it in opposed direction depending on where the hydraulic pressure is applied. Applying pressure in line 38 at connection 40 pushes the assembly of piston 34 , carriage 30 and piston 36 to the right to move the ball 18 to the shown open position. Hydraulic pressure in line 42 at connection 44 moves the carriage 30 and the pistons 34 and 36 in the opposite direction to close the ball 18 . Lines 38 and 42 continue to the surface where the controls are located for opening or closing the ball 18 by selectively applying pressure in one of those lines and removing applied pressure from the other. In this manner the operation of the ball 18 is controlled but without any feature for pressure equalization before attempting to operate the ball 18 .
The equalization in this design occurs when lines 46 and 48 are connected to the equalizer valve assembly 50 . Line 46 branches from line 38 and line 48 branches from line 42 . Line 46 connects at connection 52 and line 48 connects at connection 54 .
Referring to FIG. 2 the equalizing valve assembly 50 is shown in more detail. A passage 109 extends between connections 52 and 54 . A piston 56 has a seal 58 near connection 52 and a seal 60 near connection 54 . Piston 56 is solid and has ramps 62 and 64 that are spaced apart. In the view of FIG. 2 the ball 18 is in the closed position and poppet valves 68 and 70 are both in the closed position to block off connections 72 and 74 . Poppet 68 has a flange 76 that is sealing against a seat 78 and poppet 70 has a flange 80 that seals on seat 82 . Spring 84 bears on flange 76 to hold it against seat 78 . Spring 86 bears on flange 80 to hold it against seat 82 . Caps 88 and 90 respectively retain the assemblies of poppets 68 and 70 in the ports 92 and 94 . Ports 92 and 94 go into a reduced dimension where the poppets 68 and 70 extend. The reduced dimension defines the seats 78 and 82 . At their lower ends the poppets 68 and 70 have a T-shaped passage, respectively, 96 and 98 . In the FIG. 2 position the aligned opposed angled ends of the T-shaped passages are up against the reduced bores 100 and 102 formed in the housing 50 .
Line 104 carries tubing pressure above ball 18 and extends from the valve housing 16 to connection 72 while line 106 carries tubing pressure and extends from housing 110 and below the ball 18 to connection 74 . Annulus 108 extends around piston 56 and between seals 58 and 60 . When poppets 68 and 70 ride up ramps 62 and 64 the flanges 76 and 80 lift off the seats 78 and 82 and flow is established for tubing pressure between connections 72 and 74 and pressure on opposed sides of the closed ball 18 is equalized followed by pressure buildup on piston 34 that turns the ball to open. The open sequence is initiated with pressure on line 38 that goes into line 46 to move the piston 56 to the right to a travel stop. That movement ramps out the poppets 68 and 70 and immediately equalizes pressure on closed ball 18 by opening tubing flow between connections 72 and 74 . Further pressure buildup beyond what it took to slide the piston 56 against seal friction at seals 58 and 60 shifts the piston 34 , the carriage 30 and the piston 36 to the right in FIG. 1 to open the ball 18 after pressure is equalized across it. Putting pressure on line 42 pushes piston 56 to the FIG. 2 position from the FIG. 3 position and allows both poppets 68 and 70 to reseat after riding down ramps 62 and 64 .
While the housing 50 is shown in FIG. 1 separate from the body 16 of the barrier valve 10 , it can just as easily be integrated into the body 16 to take up less space and to facilitate making the tubing connections and to provide greater protection for the structures as an integrated unit. While FIGS. 2 and 3 show the use of a shifting piston ramping out poppets to cause pressure equalization for ball 18 there are other ways to cause that result and they are within the scope of the invention. Those skilled in the art will appreciate that the design allows for normally actuating the closed valve to open from the surface with a pressure applied to one control line and removed from another while automatically getting the benefit of equalizing pressure on the closed ball before the pistons that turn the ball are actuated. It should be noted that in a two control line system as illustrate the assembly is depth insensitive as the hydrostatic pressure in one of the control line is offset with the hydrostatic pressure in the adjacent line for the opposite function. Accordingly piston 56 is in pressure balance hydrostatically as are the operating pistons 34 and 36 . Those skilled in the art will appreciate that a single line system can be used instead of a two control line system where the closing force can be provided by a spring assembly either mechanically or pneumatically such as by using a charged pressure chamber. The piston 56 in such systems can also be similarly biased as the operating pistons 34 and 36 to the valve closed position of ball 18 .
The illustrated design has advantages over an equalizing method that involves separation of seals 24 or 26 from ball 18 . The problem is the separation at ball 18 can cause a momentary high flow situation past the seals 24 or 26 which can erode them to the point of being unserviceable after a predetermined number of cycles. The illustrated equalizing method orients the passages from the connections 72 and 74 at a shallow angle to the seats 78 and 82 so that erosion effects are minimized. In the FIG. 3 position when flow begins into the T-shaped passages 96 or 98 the entering flows abut each other to reduce their velocity and also minimize erosion. Optionally the entire poppet assembly and its mating seat can be a unit that is easily removed from housing 50 after use to put the assembly quickly back into service.
While there concerns regarding seal failures as there would be in any such device, from a perspective of a failsafe operation barrier valves are invariably installed in a well with other safety valves that have systems designed to allow well closure should the illustrated systems develop a seal problem to the point of being inoperable.
The operating personnel need not be concerned with the pressure equalizing before trying to open the valve 10 under differential pressures as high as full working pressure because the feature works automatically to equalize and resets the system when the ball is again closed.
The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below.
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A barrier valve has an equalizing feature for the ball or plug when in the closed position before it is opened. A hydraulic open and a close line are connected to a housing so that they can move a piston in opposed directions. The piston ends are sealed and the exterior of the piston is tapered to push one or more bypass valves open to connect tubing pressure across the ball when ramped off its seat. Pressure on the main hydraulic line to close the ball reverses the piston movement and allows a spring bias to close the bypass valve or valves. The equalizing system can be integrated into the barrier valve housing or can be separate as a retrofit.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of Ser. No. 10/647,930 filed Aug. 26, 2003, now U.S. Pat. No. 6,848,699 which claims the benefit of provisional application 60/453,283 filed on Mar. 11, 2003, and which is a continuation in part application of Ser. No. 09/819,189 filed Mar. 28, 2001.
FIELD OF THE INVENTION
This invention relates generally to toys and more particularly to directionally uncontrollable self-stabilizing rotating toys.
BACKGROUND OF THE INVENTION
Most vertical takeoff and landing aircraft rely on gyro stabilization systems to remain stable in hovering flight. For instance, applicant's previous U.S. Pat. No. 5,971,320 and International PCT application WO 99/10235 discloses a helicopter with a gyroscopic rotor assembly. The helicopter disclosed therein uses a yaw propeller mounted on the frame of the body to control the orientation or yaw of the helicopter. However, different characteristics are present when the body of the toy, such as a flying saucer model, rotates as gyro stabilization systems may not be necessary when the body rotates, for example, see U.S. Pat. Nos. 5,297,759; 5,634,839; 5,672,086; and co-pending co-assigned U.S. patent application Ser. No. 09/819,189.
However, a great deal of effort is made in the following prior art to eliminate or counteract the torque created by horizontal rotating propellers in flying aircraft in order to replace increased stability by removing gyro-stabilization systems. For example, Japanese Patent Application Number 63-026355 to Keyence Corp. provides a first pair of horizontal propellers reversely rotating from a second pair of horizontal propellers in order to eliminate torque. See also U.S. Pat. No. 5,071,383 which incorporates two horizontal propellers rotating in opposite directions to eliminate rotation of the aircraft. Similarly, U.S. Pat. No. 3,568,358 discloses means for providing a counter-torque to the torque produced by a propeller because, as stated in the '358 patent, torque creates instability as well as reducing the propeller speed and effective efficiency of the propeller.
The prior art also includes flying or rotary aircraft which have disclosed the ability to stabilize the aircraft without the need for counter-rotating propellers. U.S. Pat. No. 5,297,759 incorporates a plurality of blades positioned around a hub and its central axis and fixed in pitch. A pair of rotors pitched transversely to a central axis to provide lift and rotation are mounted on diametrically opposing blades. Each blade includes turned outer tips, which create a passive stability by generating transverse lift forces to counteract imbalance of vertical lift forces generated by the blades, which maintains the center of lift on the central axis of the rotors. In addition, because the rotors are pitched transversely to the central axis to provide lift and rotation, the lift generated by the blades is always greater than the lift generated by the rotors.
Nevertheless, there is always a continual need to provide new and novel self-stabilizing rotating toys that do not rely on additional rotors to counter the torque of a main rotor. Such a need should include a single main rotor to generate a major portion of the lift. Such self-stabilizing rotating toys should be inexpensive and relatively noncomplex.
SUMMARY OF THE INVENTION
In accordance with the present invention a self-stabilizing rotating flying toy that includes a main rotor is attached to a main body with a plurality of blades fixed with respect to the main body. The blades and main body rotate in a opposite direction caused by the torque of a motor mechanism used to rotate the main rotor positioned below the blades. The blades extend from a inner hub to an outer ring. The main hub connected above the inner hub is positioned above the blades and main body such that the Center of Gravity is above the center of lift, to provide a self-stabilizing rotating toy.
Numerous other advantages and features of the invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims, and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
A fuller understanding of the foregoing may be had by reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a flying rotating toy in accordance with the preferred embodiment of the present invention;
FIG. 2 is an exploded view of the flying rotating toy from FIG. 1 ;
FIG. 3 is a sectional view of the flying rotating toy from FIG. 1 ;
FIG. 4 is a partial sectional view of the relationship between the counter rotating blades and the main rotor;
FIG. 5 is a cross sectional view of another gear reduction box which may be incorporated by the present invention illustrating a dome section with a off-center motor placement;
FIG. 6 is a cross sectional view of a trigger mechanism designed to remotely control the speed of the motor mechanism; and
FIG. 7 is another trigger mechanism incorporating a fan or blower to move the rotating toy during operation.
FIG. 8 shows an exploded perspective view of another embodiment of the present invention; and
FIG. 9 shows a cross section view of a gear reduction box used in the embodiment of FIG 8 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
While the invention is susceptible to embodiments in many different forms, there are shown in the drawings and will be described herein, in detail, the preferred embodiments of the present invention. It should be understood, however, that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the spirit or scope of the invention and/or claims of the embodiments illustrated.
Referring to FIGS. 1 and 2 , in a first embodiment of the present invention a flying rotating toy 5 is provided. The rotating toy 5 includes a single main rotor 12 rotatably attached to a light weight counter rotating main body 10 . The counter rotating main body 10 includes a hub 14 that contains the drive and control mechanisms. The hub 14 is defined as having a lower hub section 16 and an upper hub section 18 that are received by an inner hub 20 . A plurality of blades 22 extend outwardly and downwardly from the hub 14 to an outer ring 24 . The lower hub section 16 houses a motor mechanism 26 that is used to rotate a main rotor 12 , while the upper hub section 18 houses at least a power supply 28 and a circuit board 30 . A clear dome 32 is positioned on top of the upper hub section 18 to protect the components and to provide a means for the reception of wireless signals, discussed in greater detail below.
Further reference is made to the cross sectional view of the rotating toy 5 illustrated in FIG. 3 . The motor mechanism 26 is a planetary reduction gear box 34 that includes a motor 36 . The planetary gear box 34 permits the motor mechanism 26 to be mounted along a single axis aligned with an axle 38 that is connected to the main rotor 12 .
As the main rotor 12 rotates, no attempt is made to counter the torque from driving the main rotor 12 , instead the torque causes the main body 10 to rotate in the opposite direction. Once the toy is flying the outer ring 24 protect the main rotor 12 and provides gyroscopic stability. As mentioned above, the outer ring 24 and hub 14 are connected by a plurality of blades 22 with lifting surfaces positioned to generate lift as the toy 5 rotates. Since the blades 22 are rotating in the opposite direction as the main rotor 12 but both are providing lift to the toy 5 , the blades 22 are categorized as counter-rotating lifting surfaces. (The interrelationship between the counter rotating blades and the main rotor is illustrated in partial sectional view FIG. 4. ) The induced drag characteristics of the main rotor 12 verses the blades 22 can also be adjusted to provide the desired body rotation speed.
The rotating toy 5 of the present invention has the ability to self stabilize during rotation. This self stabilization is categorized by the following: as the rotating toy 5 is perturbed in someway it tilts to one direction and starts moving in that direction. A blade, of the plurality of blades 22 , that is on the higher or preceding side of the rotating toy (since the rotating toy is tilted) will get more lift that the one on the lower or receding side. This happens because the preceding blade will exhibit a higher inflow of air. Depending on the direction of rotation the lift is going to be on one side or the other. This action provides a lifting force that is 90 degrees to the direction of travel and creates a gyroscopic procession with a reaction force that is 90 degrees out of phase with the lifting force such that the rotating toy 5 self-stabilizes. The self-stabilizing effect is thus caused by the gyroscopic procession and the extra lifting force on the preceding blade. For the self-stabilizing effect to work the gyroscopic procession forces generated by the rotating body must dominant over the gyroscopic procession forces generated by the main propeller 12 .
The placement of the center of gravity (CG, FIG. 3 ) above the center of lift was found to be very critical for the self-stabilizing effect. Experiments showed that the self-stabilizing effect depended on the aerodynamic dampening and on the relative magnitudes of the aforementioned forces. It was thus determined that the self-stabilizing effect was best when the CG is positioned above the bottom position 24 b of the outer ring 24 , preferably at a distance which is equal to about ⅓ to ½ the diameter D of the main rotor 12 and most preferred when the distance is about 65% of the main rotor 12 radius (½ D). (It is noted that the diameter of the main rotor 12 is equal to the length of the two blades, from tip to tip). It should also be noted that the cross sectional shape of the outer ring 24 and the height of the CG is inter dependent and very critical to the stability. It was also found that if the CG is higher, the rotating toy 5 becomes unstable and if the CG is lower, the rotating toy becomes unstable. And if the rotating toy 5 becomes unstable, the rotating toy will not self stabilize, meaning that it will just spiral further and further out of control as the rotating toy 5 flies off into a larger and larger oscillations.
Since it is most preferred to place the CG about 65% of the main rotor radius above the bottom of the outer ring 24 , most of the components are placed above the main body 10 . The motor 36 thus drives the main rotor 12 through a longer driveshaft. In addition, the weight contributes to the CG placement, thus, it is preferred to have the main body 10 including the blades 22 made from a light weight material.
The present invention is also particularly stable because there is a large portion of aerodynamic dampening caused by the blades 22 . As mentioned above, the entire blades 22 are curved and turned downwardly from the hub 14 to an outer ring 24 , and preferably inclined downwardly at about 20 to 30 degrees, which may be measured by drawing an imaginary line through an average of the curved blades. This causes dampening that resists sideward motion in the air because there's a large frontal area to the blades.
During operation, the main rotor 12 is spinning drawing the air above the toy downwardly through the counter rotating blades 22 within the outer ring 24 . The air is thus being conditioned by the blades before hitting the rotor. By conditioning the air it is meant that the air coming off the blades 22 is at an angle and at an acceleration, as opposed to placing the main rotor in stationary air and having to accelerate the air from zero or near zero. The efficiency of the main rotor 12 is thereby increased. It was found that the pitch on the main rotor 12 would have to be a lot shallower if the blades 22 were not positioned above the main rotor.
During various experiments the main rotor 12 and the main body 10 were rotated separately and together at about 600 rpms and the lift generated by the main rotor 12 and main body 10 were measured. It was found that when rotated separately, the main rotor 12 only generated about 60% of the lift exhibited by the combination of the main rotor 12 and the body 10 (with blades 22 ). However, it would be incorrect to state that the blades 22 generate the remaining 40% of the lift, because it was also found that the blades 22 spinning at the same speed by themselves only generated about 5 to 10% of the lift exhibited by the combination. Since separately the main rotor generated 60% and the blades generated 5 to 10% there is 30-35% of lift unaccounted. However, when the main rotor 12 is rotating separately the air that it is using is unconditioned or static (zero acceleration). Since the blades 22 are positioned on top of the main rotor 12 , the blades 22 will still only generate 5-10% of the lift in the combined state; concluding that the blades 22 increase the efficiency of the main rotor by conditioning the air before it is used by the main rotor 12 . Thus the combination of the two (the main rotor 12 and the blades 22 ) must generate the additional 30-35% of the lift when acting in concert and utilizing the conditioned air.
In another embodiment, an offset reduction gear box 60 ( FIG. 5 ) may also be used that have an offset motor 36 mounted off of the axle 38 . In an offset mount, a counter-weight (not shown) may be placed on the outer ring 24 about 180 degrees from the motor, to keep the balance of the rotating toy centered.
To control the motor mechanism 26 an IR sensor 40 or receiver is positioned in the dome 32 and is used in concert with an outside remote IR transmitter. The transmitter 52 may be positioned in a remote control unit 50 , illustrated in FIG. 6 . The remote control unit 50 has a simple trigger mechanism 54 designed to emit a signal when pushed inwardly by the user's finger. In addition, the self stabilizing effect will cause the rotating toy 5 to stabilize even when pushed by air currents, which will initially move the rotating toy 5 but eventually the toy 5 will stabilize to a substantially horizontal flying position. Referring to FIG. 7 , the remote control mechanism 50 may include a fan 56 that is able to be activated by the user. Activating the fan 56 will permit the user to blow a stream of air at the rotating toy 5 and push it around, providing a simple means of moving the rotating toy around. It is well known in the art and contemplated by the present invention that the transmitter and receivers can be radio, infrared or optical.
In another embodiment of the present invention, referred to FIGS. 8 and 9 , a battery pack 80 is used to counter the weight of an offset motor 36 . As illustrated, the battery pack 80 is arranged such that a motor 36 in the motor mechanism 26 is offset to counter balance each other such that the rotating toy is balanced. Moreover, in this embodiment the upper hub section 18 and the lower hub section 16 are integrally formed as a single piece; and an on/off switch 82 is attached to the circuit board 30 and positioned to be manipulated by a user through an aperture 84 in the dome 32 .
It should be further stated the specific information shown in the drawings but not specifically mentioned above may be ascertained and read into the specification by virtue of simple study of the drawings. Moreover, the invention is also not necessary limited by the drawings or the specification as structural and functional equivalents may be contemplated and incorporated into the invention without departing from the spirit and scope of the novel concept of the invention. It is to be understood that no limitation with respect to the specific methods and apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.
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A rotating toy may then include a hub having a central axis and a lower portion; a plurality of counter rotating blades extending outwardly from the lower portion of the hub, the plurality of counter rotating blades having a tip connected to an outer ring; a single means for rotating the hub and blades sufficiently quickly to generate a major portion of the lift generated by the aircraft through the single rotating means; and the hub having an upper portion above the plurality of counter rotating blades and above the single rotating means such that the aircraft includes a center of gravity above a bottom portion defined by the outer ring to improve self stabilization of the toy. In furtherance thereto the single rotating means may be secured on the central axis and positioned below the counter rotating blades.
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[0001] This application is a continuation application of U.S. application Ser. No. 14/635,144 (filed Mar. 2, 2015), which is a continuation application of U.S. application Ser. No. 13/131,425 (filed May 26, 2011), which is a 371 National Stage of PCT/EP2009/008258 (filed Nov. 20, 2009), which claims priority to EP 08170103.9 and EP 08170132.8 (both filed Nov. 27, 2008) and EP 09164400.5 (filed Jul. 2, 2009), the contents of each of which are incorporated herein by reference in their entirety.
[0002] The instant invention relates to improved liquid sizing compositions comprising derivatives of diaminostilbene, binders, protective polymers and divalent metal salts for the optical brightening of substrates suitable for high quality ink jet printing.
BACKGROUND OF THE INVENTION
[0003] Ink jet printing has in recent years become a very important means for recording data and images onto a paper sheet. Low costs, easy production of multicolor images and relatively high speed are some of the advantages of this technology. Ink jet printing does however place great demands on the substrate in order to meet the requirements of short drying time, high print density and sharpness, and reduced color-to-color bleed. Furthermore, the substrate should have a high brightness. Plain papers for example are poor at absorbing the water-based anionic dyes or pigments used in ink jet printing; the ink remains for a considerable time on the surface of the paper which allows diffusion of the ink to take place and leads to low print sharpness. One method of achieving a short drying time while providing high print density and sharpness is to use special silica-coated papers. Such papers however are expensive to produce.
[0004] U.S. Pat. No. 6,207,258 provides a partial solution to this problem by disclosing that pigmented ink jet print quality can be improved by treating the substrate surface with an aqueous sizing medium containing a divalent metal salt. Calcium chloride and magnesium chloride are preferred divalent metal salts. The sizing medium may also contain other conventional paper additives used in treating uncoated paper. Included in conventional paper additives are optical brightening agents (OBAs) which are well known to improve considerably the whiteness of paper and thereby the contrast between the ink jet print and the background. U.S. Pat. No. 6,207,258 offers no examples of the use of optical brightening agents with the invention.
[0005] WO 2007/044228 claims compositions including an alkenyl succinic anhydride sizing agent and/or an alkyl ketene dimmer sizing agent, and incorporating a metallic salt. No reference is made to the use of optical brightening agents with the invention.
[0006] WO 2008/048265 claims a recording sheet for printing comprising a substrate formed from ligno cellulosic fibers of which at least one surface is treated with a water soluble divalent metal salt. The recording sheet exhibits an enhanced image drying time. Optical brighteners are included in a list of optional components of a preferred surface treatment comprising calcium chloride and one or more starches. No examples are provided of the use of optical brighteners with the invention.
[0007] WO 2007/053681 describes a sizing composition that, when applied to an ink jet substrate, improves print density, color-to-color bleed, print sharpness and/or image dry time. The sizing composition comprises at least one pigment, preferably either precipitated or ground calcium carbonate, at least one binder, one example of which is a multicomponent system including starch and polyvinyl alcohol, at least one nitrogen containing organic species, preferably a polymer or copolymer of diallyldimethyl ammonium chloride (DAMAO), and at least one inorganic salt. The sizing composition may also contain at least one optical brightening agent.
[0008] The advantages of using a divalent metal salt, such as calcium chloride, in substrates intended for pigmented ink jet printing can only be fully realized when a compatible water-soluble optical brightener becomes available. It is well-known however that water-soluble optical brighteners are prone to precipitation in high calcium concentrations. (See, for example, page 50 in Tracing Technique in Geohydrology by Werner Käss and Horst Behrens, published by Taylor & Francis, 1998).
[0009] Accordingly, there is a need for improved optical brightening compositions which have good compatibility with sizing compositions containing a divalent metal salt.
DESCRIPTION OF THE INVENTION
[0010] It has now been found that certain polymers are surprisingly effective at improving the compatibility of optical brighteners of formula (1) with sizing compositions containing a divalent metal salt. Such polymers are henceforth referred to as protective polymers.
[0011] The present invention therefore provides a sizing composition for optical brightening of substrates, preferably paper, which is especially suitable for pigmented ink jet printing, comprising
[0012] (a) at least one optical brightener of formula (1);
[0000]
[0000] in which the anionic charge on the brightener is balanced by a cationic charge composed of one or more identical or different cations selected from the group consisting of hydrogen, an alkali metal cation, alkaline earth metal, ammonium, ammonium which is mono-, di- or trisubstituted by a C 1 -C 4 linear or branched alkyl radical, ammonium which is mono-, di- or trisubstituted by a C 1 -C 4 linear or branched hydroxyalkyl radical, or mixtures of said compounds,
[0013] R 1 and R 1′ may be the same or different, and each is hydrogen, C 1 -C 4 linear or branched alkyl, C 2 -C 4 linear or branched hydroxyalkyl, CH 2 CO 2 − , CH 2 CH 2 CONH 2 or CH 2 CH 2 CN,
[0014] R 2 and R 2′ may be the same or different, and each is C 1 -C 4 linear or branched alkyl, C 2 -C 4 linear or branched hydroxyalkyl, CH 2 CO 2 − , CH(CO 2 − )CH 2 CO 2 − )CH(CO 2 31 )CH 2 CH 2 CO 2 − , CH 2 CH 2 SO 3 − , benzyl, or
[0015] R 1 and R 2 and/or R 1′ and R 2′ , together with the neighboring nitrogen atom signify a morpholine ring and
[0016] p is 0, 1 or 2;
[0017] (b) at least one binder, the binder being selected from the group consisting of native starch, enzymatically modified starch and chemically modified starch;
[0018] (c) at least one divalent metal salt, the divalent metal salts being selected from the group consisting of calcium chloride, magnesium chloride, calcium bromide, magnesium bromide, calcium iodide, magnesium iodide, calcium nitrate, magnesium nitrate, calcium formate, magnesium formate, calcium acetate, magnesium acetate, calcium citrate, magnesium citrate, calcium gluconate, magnesium gluconate, calcium ascorbate, magnesium ascorbate, calcium sulfite, magnesium sulfite, calcium bisulfite, magnesium bisulfite, calcium dithionite, magnesium dithionite, calcium sulphate, magnesium sulphate, calcium thiosulphate, magnesium thiosulphate and mixtures of said compounds;
[0019] (d) at least one protective polymer which can be:
(i) a polyethylene glycol; (ii) a polyvinyl alcohol or a carboxylic acid containing polyvinyl alcohol; (iii) a homopolymer of methacrylic acid; (iv) a copolymer of acrylic acid or methacrylic acid with acrylamide or methacrylamide; (v) a cationic copolymer of acrylamide or methacrylamide with diallyldimethylammonium chloride; (vi) a polycationic polyquaternary product obtainable by reaction of an oligohydroxyalkane of the formula
[0000] X-(OH) x1 (Ia),
[0000] in which
[0026] X is the x1-valent radical of a C 3-6 -alkane, and
[0027] x1 is a number from 3 to the number of carbon atoms in X, or a mixture of oligohydroxyalkanes of formula (Ia), or a mixture of one or more oligohydroxyalkanes of formula (Ia) with a C 2-3 -alkanediol, with epichlorohydrin, in the ratio of (2 to 2·x1) moles of epichlorohydrin for every mole of oligohydroxy-C 3-6 -alkane of formula (Ia) plus 1-4 moles of epichlorohydrin for every molequivalent of C 2-3 -alkanediol, to give a chloro-terminated adduct (E 1 ), and reaction of (E 1 ) by cross-linking, quaternizing reaction with at least one aminocompound of formula
[0000]
[0000] in which
[0028] Y is C 2-3 -alkylene,
[0029] y is a number from 0 to 3,
[0030] R 1 is C 1-3 -alkyl or C 2-3 -hydroxyalkyl, and
[0031] R 2 is C 1-3 -alkyl or C 2-3 -hydroxyalkyl, if y is 1 to 4, or hydrogen, if y is 0;
[0032] (e) water.
[0033] Optionally a chain-terminating, quaternizing reaction with a tertiary amine of the formula N(R 1 ) 3 may follow in the production of the polycationic polyquaternary product (vi).
[0034] In optical brighteners for which p is 1, the SO 3 − group is preferably in the 4-position of the phenyl group. In optical brighteners for which p is 2, the SO 3 - groups are preferably in the 2,5-positions of the phenyl group.
[0035] The polycationic polymer (vi) is described in WO 99/67463 in more detail.
[0036] Preferred compounds of formula (1) are those in which the anionic charge on the brightener is balanced by a cationic charge composed of one or more identical or different cations selected from the group consisting of hydrogen, an alkali metal cation, alkaline earth metal, ammonium which is mono-, di- or trisubstituted by a C 1 -C 4 linear or branched hydroxyalkyl radical, or mixtures of said compounds,
[0037] R 1 and R 1′ may be the same or different, and each is hydrogen, C 1 -C 4 linear or branched alkyl, C 2 -C 4 linear or branched hydroxyalkyl, CH 2 CO 2 − , CH 2 CH 2 CONH 2 or CH 2 CH 2 CN,
[0038] R 2 and R 2′ may be the same or different, and each is C 1 -C 4 linear or branched alkyl, C 2 -C 4 linear or branched hydroxyalkyl, CH 2 CO 2 − , CH(CO 2 − )CH 2 CO 2 − or CH(CO 2′ )CH 2 CH 2 CO 2 − and
[0039] p is 0, 1 or 2.
[0040] More preferred compounds of formula (1) are those in which the anionic charge on the brightener is balanced by a cationic charge composed of one or more identical or different cations selected from the group consisting of Li, Na, K, Ca, Mg, ammonium which is mono-, di- or trisubstituted by a C 1 -C 4 linear or branched hydroxyalkyl radical, or mixtures of said compounds, R 1 and R 1′ may be the same or different, and each is hydrogen, methyl, ethyl, α-methylpropyl, β-methylpropyl, β-hydroxyethyl, β-hydroxypropyl, CH 2 CO 2 − , CH 2 CH 2 CONH 2 or CH 2 CH 2 CN,
[0041] R 2 and R 2′ may be the same or different, and each is methyl, ethyl, α-methylpropyl, β-methylpropyl, β-hydroxyethyl, β-hydroxypropyl, CH 2 CO 2 − or CH(CO 2 − )CH 2 CO 2 − , and
[0042] p is 0, 1 or 2,
[0043] Especially preferred compounds of formula (1) are those in which the anionic charge on the brightener is balanced by a cationic charge composed of one or more identical or different cations selected from the group consisting of Na, K and triethanolamine or mixtures of said compounds,
[0044] R 1 and R 1′ may be the same or different, and each is hydrogen, ethyl, β-hydroxyethyl, β-hydroxypropyl, CH 2 CO 2 − or CH 2 CH 2 CN,
[0045] R 2 and R 2′ may be the same or different, and each is ethyl, β-hydroxyethyl, β-hydroxypropyl, CH 2 CO 2 − or CH(CO 2 − )CH 2 CO 2 − , and
[0046] p is 2.
[0047] The concentration of optical brightener in the sizing composition may be between 0.2 and 30 g/l, preferably between 1 and 25 g/l, most preferably between 2 and 20 g/l.
[0048] The binder is selected from the group consisting of native starch, enzymatically modified starch and chemically modified starch. Modified starches are preferably oxidized starch, hydroxyethylated starch or acetylated starch, The native starch is preferably an anionic starch, an cationic starch, or an amphoteric starch. While the starch source may be any, preferably the starch sources are corn, wheat, potato, rice, tapioca or sago.
[0049] The concentration of binder in the sizing composition may be between 1 and 30% by weight, preferably between 2 and 20% by weight, most preferably between 5 and 15 % by weight.
[0050] More preferred divalent metal salts are selected from the group consisting of calcium chloride, magnesium chloride, calcium bromide, magnesium bromide, calcium sulphate, magnesium sulphate, calcium thiosulphate or magnesium thiosulphate or mixtures of said compounds.
[0051] Especially preferred divalent metal salts are selected from the group consisting of calcium chloride or magnesium chloride or mixtures of said compounds.
[0052] The concentration of divalent metal salt in the sizing composition may be between 1 and 100 g/l, preferably between 2 and 75 g/l, most preferably between 5 and 50 g/l.
[0053] When the divalent metal salt is a mixture of one or more calcium salts and one or more magnesium salts, the amount of calcium salts may be in the range of 0.1 to 99.9%.
[0054] The polyethylene glycol which may be employed as component (d) has an average molecular weight in the range of 100 to 8000, preferably in the range of 200 to 6000, most preferably in the range of 300 to 4500. When used as component (d), the weight ratio of polyethylene glycol to component (a) may be between 0.04:1 and 5:1, preferably between 0.05:1 and 2:1, most preferably between 0.1:1 and 1:1.
[0055] The polyvinyl alcohol which may be employed as component (d) has a degree of hydrolysis greater than or equal to 60% and a Brookfield viscosity of between 2 and 40 mPa·s for a 4% aqueous solution at 20° C. Preferably the degree of hydrolysis is between 70% and 95%, and the Brookfield viscosity is between 2 and 20 mPa·s (4% aqueous solution at 20° C.). Most preferably, the degree of hydrolysis is between 80% and 90%, and the Brookfield viscosity is between 2 and 20 mPa·s (4% aqueous solution at 20° C.). When used as component (d), the weight ratio of polyvinyl alcohol to component (a) may be between 0.01:1 and 2:1, preferably between 0.02:1 and 1:1, most preferably between 0.03:1 and 0.5:1.
[0056] The carboxylic acid containing polyvinyl alcohol which may be employed as component (d) has a degree of hydrolysis greater than or equal to 60% and a Brookfield viscosity of between 2 and 40 mPa·s for a 4% aqueous solution at 20° C. Preferably the degree of hydrolysis is between 70% and 95%, and the Brookfield viscosity is between 2 and 35 mPa·s (4% aqueous solution at 20° C.). Most preferably, the degree of hydrolysis is between 70% and 90%, and the Brookfield viscosity is between 2 and 30 mPa·s (4% aqueous solution at 20° C.). When used as component (d), the weight ratio of carboxylic acid containing polyvinyl alcohol to component (a) may be between 0.01:1 and 2:1, preferably between, 0.02:1 and 1:1, most preferably between 0.03:1 and 0.5:1.
[0057] The polymer of methacrylic acid which may be employed as component (d) has a Brookfield viscosity of between 100 and 40000 mPa·s for a 7-8% aqueous solution at 20° C. The polymer can be optionally used in its partial or full salt form. The preferred salt is Na, K, Ca, Mg, ammonium or ammonium which is mono-, di- or tri-substituted by a linear or branched alkyl or hydroxyalkyl radical. Preferably the viscosity is between 1000 and 30000 mPa·s (7-8% aqueous solution at 20° C.). Most preferably, the viscosity is between 5000 and 20000 mPa·s (7-8% aqueous solution at 20° C.). When used as component (d), the weight ratio of the polymer of methacrylic acid to component (a) may be between 0.0001:1 and 2:1, preferably between 0.001:1 and 1:1, most preferably between 0.002:1 and 0.5:1.
[0058] The copolymer of acrylic acid and acrylamide which may be employed as component (d) has a Brookfield viscosity of between 1 and 100 mPa·s for a 0.1% aqueous solution at 20° C. The copolymer can be either a block or a cross-linked copolymer. The copolymer can be optionally used in its partial or full salt form. The preferred salt is Na, K, Ca, Mg, ammonium or ammonium which is mono-, di- or tri-substituted by a linear or branched alkyl or hydroxyalkyl radical. Preferably the viscosity is between 1 and 80 mPa·s (0.1% aqueous solution at 20° C.). Most preferably, the viscosity is between 1 and 50 mPa·s (0.1% aqueous solution at 20° C.). When used as component (d), the weight ratio of the copolymer of acrylic or methacrylic acid and acrylamide or methacrylamide to component (a) may be between 0.001:1 and 1:1, preferably between 0.002:1 and 0.8:1, most preferably between 0.005:1 and 0.5:1.
[0059] The copolymer of methacrylic acid and methacrylamide which may be employed as component (d) has a Brookfield viscosity of between 1 and 100000 mPa·s for a 8% aqueous solution at 20° C. The copolymer can be either a block or a cross-linked copolymer. The copolymer can be optionally used in its partial or full salt form. The preferred salt is Na, K, Ca, Mg, ammonium or ammonium which is mono-, di- or tri-substituted by a linear or branched alkyl or hydroxyalkyl radical.
[0060] Preferably the viscosity is between 10000 and 80000 mPa·s (8% aqueous solution at 20° C.). Most preferably, the viscosity is between 40000 and 50000 mPa·s (8% aqueous solution at 20° C.). When used as component (d), the weight ratio of the copolymer of methacrylic acid and methacrylamide to component (a) may be between 0.001:1 and 1:1, preferably between 0.002:1 and 0.8:1, most preferably between 0.005:1 and 0.5:1.
[0061] The cationic copolymer of an acrylamide or methacrylamide and diallyldimethylammonium chloride which may be employed as component (d) has a Brookfield viscosity of between 100 and 40000 mPa·s for a 10% aqueous solution at 20° C. The copolymer can be either a block or a cross-linked copolymer. Preferably the viscosity is between 500 and 30000 mPa·s 10% aqueous solution at 20 DC). Most preferably, the viscosity is between 9000 and 25000 mPa·s (10% aqueous solution at 20° C.). When used as component (d), the weight ratio of the cationic copolymer of acrylamide or methacrylamide and diallyldimethylammonium chloride to component (a) may be between 0.001:1 and 1:1, preferably between 0.005:1 and 0.81, most preferably between 0.01:1 and 0.5:1.
[0062] Other cationic polymers which may be employed as component (d) are fully described in WO 99/67463, especially those described in claim 4 . The preparative process for the cationic polymer is characterized in that an oligohydroxyalkane is reacted with epichlorohydrin to give a chloro-terminated adduct which is then reacted with at least one aliphatic mono- or oligoamine to give a quaternized, optionally cross-linked, polymer. When used as component (d), the weight ratio of the cationic polymer to component (a) may be between 0.04:1 and 15:1, and preferably between 0.1:1 and 10:1.
[0063] The pH value of the sizing composition is typically in the range of 5-13, preferably 6-11.
[0064] In addition to one or more optical brighteners, one or more binders, one or more divalent metal salts, one or more protective polymers and water, the sizing composition may contain by-products formed during the preparation of the optical brightener as well as other conventional paper additives. Examples of such additives are antifreezes, biocides, defoamers, wax emulsions, dyes, inorganic salts, solubilizing aids, preservatives, complexing agents, thickeners, surface sizing agents, cross-linkers, pigments, special resins etc.
[0065] The sizing composition is prepared by adding the optical brightener, the protective polymer and the divalent metal salt to a preformed aqueous solution of the binder at a temperature of between 20° C. and 90° C.
[0066] In a preferred aspect of the invention the protective polymer is first formulated with an aqueous solution of the optical brightener. The protected brightener formulation is then added to an aqueous solution of the divalent metal salt and the binder at a temperature of between 50° C. and 70° C.
[0067] The sizing composition may be applied to the surface of a paper substrate by any surface treatment method known in the art. Examples of application methods include size-press applications, calendar size application, tub sizing, coating applications and spraying applications. (See, for example, pages 283-286 in Handbook for Pulp & Paper Technologists by G. A. Smook, 2 nd Edition Angus Wilde Publications, 1992 and US 2007/0277950). The preferred method of application is at the size-press such as puddle size press. A preformed sheet of paper is passed through a two-roll nip which is flooded with the sizing composition. The paper absorbs some of the composition, the remainder being removed in the nip.
[0068] The paper substrate contains a web of cellulose fibres which may be sourced from any fibrous plant. Preferably the cellulose fibres are sourced from hardwood and/or softwood. The fibres may be either virgin fibres or recycled fibres, or any combination of virgin and recycled fibres.
[0069] The cellulose fibres contained in the paper substrate may be modified by physical and/or chemical methods as described, for example, in Chapters 13 and 15 respectively in Handbook for Pulp & Paper Technologists by G. A. Smook, 2 nd Edition Angus Wilde Publications, 1992, One example of a chemical modification of the cellulose fibre is the addition of an optical brightener as described, for example, in EP 0,884,312, EP 0,899,373, WO 02/055646, WO 2006/061399 and WO 2007/017336.
[0070] One example of an especially preferred optical brightener of formula (1) is described by formula (2). The preparation of a compound of formula (2) in which the anionic charge on the brightener is balanced by a cationic charge composed of 6 identical sodium cations has been described previously in WO 02/060883 and WO 02/077106. No examples have been provided of the preparation of a compound of formula (2) in which the anionic charge on the brightener is balanced by a cationic charge composed of a mixture of two or more different cations. The instant invention therefore also provides a method for the preparation of compounds of formula (2) in which the anionic charge on the brightener is balanced by a cationic charge composed of a mixture of two or more different cations, characterized in that different inorganic or organic bases are used simultaneously or separately from each other, either during or after the three stages of the reaction.
[0000]
[0071] The compounds of formula (2) in which the anionic charge on the brightener is balanced by a cationic charge composed of a mixture of two or more different cations are therefore prepared by stepwise reaction of a cyanuric halide with
[0072] a) an amine of formula
[0000]
[0000] in the free acid, partial- or full salt form,
[0073] (b) a diamine of formula
[0000]
[0000] in the free acid, partial- or full salt form, and
[0074] c) diisopropanolamine of formula
[0000]
[0075] As a cyanuric halide there may be employed the fluoride, chloride or bromide, Cyanuric chloride is preferred.
[0076] Each reaction may be carried out in an aqueous medium, the cyanuric halide being suspended in water, or in an aqueous/organic medium, the cyanuric halide being dissolved in a solvent such as acetone. Each amine may be introduced without dilution, or in the form of an aqueous solution or suspension. The amines can be reacted in any order, although it is preferred to react the aromatic amines first. Each amine may be reacted stoichiometrically, or in excess. Typically, the aromatic amines are reacted stoichiometrically, or in slight excess; diisopropanolamine is generally employed in an excess of 5-30% over stoichiometry.
[0077] For substitution of the first halogen of the cyanuric halide, it is preferred to operate at a temperature in the range of 0 to 20° C., and under acidic to neutral pH conditions, preferably in the pH range of 2 to 7. For substitution of the second halogen of the cyanuric halide, it is preferred to operate at a temperature in the range of 20 to 60° C., and under weakly acidic to weakly alkaline conditions, preferably at a pH in the range of 4 to 8. For substitution of the third halogen of the cyanuric halide, it is preferred to operate at a temperature in the range of 60 to 102° C., and under weakly acidic to alkaline conditions, preferably at a pH in the range of 7 to 10.
[0078] The pH of each reaction is generally controlled by addition of a suitable base, the choice of base being dictated by the desired product composition. Preferred bases are, for example, alkali or alkaline earth metal (e.g., lithium, sodium, potassium, calcium, magnesium) hydroxides, carbonates or bicarbonates, or aliphatic tertiary amines e.g. triethanolamine or triisopropanolamine. Where a combination of two or more different bases is used, the bases may be added in any order, or at the same time.
[0079] Where it is necessary to adjust the reaction pH using acid, examples of acids that may be used include hydrochloric acid, sulphuric acid, formic acid and acetic acid.
[0080] Aqueous solutions containing one or more compounds of general formula (1) may optionally be desalinated either by membrane filtration or by a sequence of precipitation followed by solution using an appropriate base.
[0081] The preferred membrane filtration process is that of ultrafiltration using, e.g., polysulphone, polyvinylidenefluoride, cellulose acetate or thin-film membranes.
EXAMPLES
[0082] The following examples shall demonstrate the instant invention in more details. If not indicated otherwise, “parts” means “parts by weight” and “%” means “% by weight”.
[0083] Preparative Example 1
[0084] Stage 1: 31.4 parts of aniline-2,5-disulphonic acid monosodium salt are added to 150 parts of water and dissolved with the aid of an approx. 30% sodium hydroxide solution at approx. 25° C. and a pH value of approx. 8-9. The obtained solution is added over a period of approx. 30 minutes to 18.8 parts of cyanuric chloride dispersed in 30 parts of water, 70 parts of ice and 0.1 part of an antifoaming agent. The temperature is kept below 5° C. using an ice/water bath and if necessary by adding ice into the reaction mixture. The pH is maintained at approx. 4-5 using an approx. 20 % sodium carbonate solution. At the end of the addition, the pH is increased to approx. 6 using an approx. 20% sodium carbonate solution and stirring is continued at approx. 0-5° C. until completion of the reaction (3-4 hours).
[0085] Stage 2: 8.8 parts of sodium bicarbonate are added to the reaction mixture. An aqueous solution, obtained by dissolving under nitrogen 18.5 parts of 4,4′-diaminostilbene-2,2′-disulphonic acid in 80 parts of water with the aid of an approx. 30% sodium hydroxide solution at approx. 45-50° C. and a pH value of approx. 8-9, is dropped into the reaction mixture. The resulting mixture is heated at approx. 45-50° C. until completion of the reaction (3-4 hours).
[0086] Stage 3: 17.7 parts of Diisopropanolamine are then added and the temperature is gradually raised to approx. 85-90° C. and maintained at this temperature until completion of the reaction (2-3 hours) while keeping the pH at approx. 8-9 using an approx. 30% potassium hydroxide solution. The temperature is then decreased to 50° C. and the reaction mixture is filtered and cooled down to room temperature. The solution is adjusted to strength to give an aqueous solution of a compound of formula (2) in which the anionic charge on the brightener is balanced by a cationic charge composed of a mixture of sodium and potassium cations, the sodium cation being in the range 4.5-5.5 and the potassium cation being in the range 0.5-1.5 (0.125 mol/kg, approx. 18.0%).
[0087] Preparative Example 2
[0088] An aqueous solution of a compound of formula (2) in which the anionic charge on the brightener is balanced by a cationic charge composed of a mixture of sodium and potassium cations, the sodium cation being in the range 0-2.5 and the potassium cation being in the range 3.5-6 (0.125 mol/kg, approx. 18.8%) is obtained following the same procedure as in Example 1 with the sole differences that an approx. 30% potassium hydroxide and an approx. 20% potassium carbonate solution§ are used instead of an approx. 30% sodium hydroxide and an approx. 20% sodium carbonate solutions in Stages 1 and 2, and 10 parts of potassium bicarbonate are used instead of 8.8 parts of sodium bicarbonate in Stage 2.
[0089] Preparative Example 1a
[0090] Optical brightening solution la is produced by stirring together
an aqueous solution containing a compound of formula (2) prepared according to preparative example 1, a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s, and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature. The parts of each component are selected in order to get a final aqueous solution 1a comprising a compound of formula (2) prepared according to preparative example 1 at a concentration of 0.125 mol/kg and 2.5% of a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s. The pH of solution la is in the range 8-9.
[0094] Preparative Example 1b
[0095] Optical brightening solution lb is produced by stirring together
an aqueous solution containing a compound of formula (2) prepared according to preparative example 1, a polyethylene glycol having an average molecular weight of 1500, and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature. The parts of each component are selected in order to get a final aqueous solution 1b comprising a compound of formula (2) prepared according to preparative example 1 at a concentration of 0.125 mol/kg and 5% of a polyethylene glycol having an average molecular weight of 1500. The pH of solution lb is in the range 8-9.
[0099] Preparative Example 2a
[0100] Optical brightening solution 2a is produced by stirring together
an aqueous solution containing compound of formula (2) prepared according to preparative example 2, a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s, and water, while heating to 90-95°C., until a clear solution is obtained that remains stable after cooling to room temperature. The parts of each component are selected in order to get a final aqueous solution 2a comprising a compound of formula (2) prepared according to preparative example 2 at a concentration of 0.125 mol/kg and 2.5% of a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s. The pH of solution 2a is in the range 8-9.
[0104] Preparative Example 2b
[0105] Optical brightening solution 2b is produced by stirring together an aqueous solution containing a compound of formula (2) prepared according to preparative example 2,
a polyethylene glycol having an average molecular weight of 1500, and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0108] The parts of each component are selected in order to get a final aqueous solution 2b comprising a compound of formula (2) prepared according to preparative example 2 at a concentration of 0.125 mol/kg and 5% of a polyethylene glycol having an average molecular weight of 1500. The pH of solution 2b is in the range 8-9.
[0109] Preparative Example 2c
[0110] Optical brightening solution 2c is produced by stirring together
an aqueous solution containing a compound of formula (2) prepared according to preparative example 2, a carboxylic acid containing polyvinyl alcohol having a degree of hydrolysis between 85% and 90% and a Brookfield viscosity between 20 and 30 mPa·s for a 4 % aqueous solution at 20° C., and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0114] The parts of each component are selected in order to get a final aqueous solution 2c comprising a compound of formula (2) prepared according to preparative example 2 at a concentration of 0.125 mol/kg and 2.5% of a carboxylic acid containing polyvinyl alcohol having a degree of hydrolysis between 85% and 90% and a Brookfield viscosity between 20 arid 30 mPa·s for a 4% aqueous solution at 20° C. The pH of solution 2c is in the range 8-9.
[0115] 25
[0116] Preparative Example 2d
[0117] Optical brightening solution 2d is produced by stirring together
an aqueous solution containing a compound of formula (2) prepared according to preparative example 2, a poly(acrylamide-co-acrylic acid) having a Brookfield viscosity between 2 and 3 mPa·s for a 0.1% aqueous solution at 20° C., and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0121] The parts of each component are selected in order to get a final aqueous solution 2d comprising a compound of formula (2) prepared according to preparative example 2 at a concentration of 0.125 mol/kg and 0.5 % of a poly(acrylamide-co-acrylic acid) having a Brookfield viscosity between 2 and 3 mPa·s for a 0.1% aqueous solution at 20° C. The pH of solution 2d is in the range 8-9.
[0122] Preparative Example 2e
[0123] Optical brightening solution 2e is produced by stirring together
an aqueous solution containing a compound of formula (2) prepared according to preparative example 2, a 10 wt-% aqueous solution of poly(acrylamide-co-diallyldimethylammonium chloride) having a Brookfield viscosity between 9000 and 25000 mPa·s for a 10% aqueous solution at 20° C., and water, while heating to 90-95° C., until a clear solution is obtained that that remmains stable after cooling to room temperature.
[0127] The parts of each component are selected in order to get a final aqueous solution 2e comprising a compound of formula (2) prepared according to preparative example 2 at a concentration of 0.125 mol/kg and 10% of a 10 wt-% aqueous solution of poly(acrylamide-co-diallyldimethylammonium chloride) having a Brookfield viscosity between 9000 and 25000 mPa·s for a 10% aqueous solution at 20° C. The pH of solution 2e is in the range 8-9.
[0128] Preparative Example 3
[0129] Preparation of polymethacrylic acid ammonium salt polymer; 0.3 parts of radical initiator Vazo68 are mixed with 173 parts of methacrylic acid and 2000 parts of demineralized water. The mixture is stirred and heated under nitrogen to 74-76° C. over a period of 1 hour. After 10 minutes at 74-76° C., stirring is stopped and the mixture is left 16 hours at 74-76° C. 300 parts of demineralized water are added and the temperature is allowed to fall to 35° C. 178 parts of ammonia liquor are then slowly added and the resulting mixture is held at 35-40° C. for 6 hours.
[0130] Stirring is re-started and maintained at 35-40° C. for 1 additional hour. The pH is then adjusted to approx. 9.0-11.0 by addition of ammonia liquor and the viscosity is adjust to 5000-20000 mPa·s by addition of water. The aqueous solution so-formed (3000 parts) contains approx. 225 parts of polymethacrylic acid ammonium salt.
[0131] Preparative Example 3a
[0132] Optical brightening solution 3a is produced by stirring together
an aqueous solution containing compound of formula (2) prepared according to example 2, an aqueous solution containing a polymethacrylic acid ammonium salt prepared according to preparative example 3 and having a viscosity of 5000-20000 mPa·s, and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0136] The parts of each component are selected in order to get a final aqueous solution 3a comprising a compound of formula (2) prepared according to preparative example 2 at a concentration of 0.125 mol/kg and 2.5% of an aqueous solution containing a polymethacrylic acid ammonium salt prepared according to preparative example 3 and having a viscosity of 5000-20000 mPa·s. The pH of solution 3a is in the range 8-9.
[0137] Preparative Example 4a
[0138] Optical brightening solution 4a is produced by stirring together
an aqueous solution containing a compound of formula (6), a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s, and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0142] The parts of each component are selected in order to get a final aqueous solution 4a comprising a compound of formula (6) at a concentration of 0.125 mol/kg and 2.5% of a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s. The pH of solution 4a is in the range 8-9.
[0000]
[0143] Preparative Example 4b
[0144] Optical brightening solution 4b is produced by stirring together
an aqueous solution containing a compound of formula (6), a polyethylene glycol having an average molecular weight of 1500, and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0148] The parts of each component are selected in order to get a final aqueous solution 4b comprising a compound of formula (6) at a concentration of 0.125 mol/kg and 5% of a polyethylene glycol having an average molecular weight of 1500. The pH of solution 4b is in the range 8-9.
[0149] Preparative Example 5
[0150] Preparation of cationic polymer (Example 1 of WO 99/67463): 109.2 parts of sorbitol are mixed with 55.2 parts of glycerol and heated to 100° C. to form a solution. One part of boron trifluoride etherate is added, and the mixture is stirred and cooled to 70° C. 333 parts of epichlorohydrin are added dropwise over one hour at 70-80° C. with cooling. The reaction mixture is cooled to 20° C. and 135 parts of a 60% aqueous solution of diethylamine are added, and the reaction mixture is heated slowly to 90° C. and held there for one hour, The reaction mixture is then cooled to 50° C. and 150 parts of 30% sodium hydroxide and 100 parts of water are added. The mixture is held at 50-60° C. and the mixture slowly thickens as it polymerizes. During this time, extra water is added (275 parts) as the viscosity increases. Finally, when the reaction mixture reaches a viscosity of 1000 cP, the reaction is stopped by the addition of 20 parts of formic acid to give a pH of 4. The aqueous solution so-formed (1178 parts) contains 578 parts of cationic polymer.
[0151] Preparative Example 5a
[0152] 300 parts of a solution of 55.5 parts of an optical brightener of formula (6) in water are gradually added at 50° C. to 700 parts of a stirred solution containing 343 parts of cationic polymer prepared according to preparative example 5. The solution so-formed contains 5.55% optical brightener (0.037 mol/kg) and 34.3% cationic polymer.
[0153] Preparative Example 6a
[0154] Optical brightening solution 6a is produced by stirring together
an aqueous solution containing a compound of formula (7), a polyethylene glycol having an average molecular weight of 1500, and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0158] The parts of each component are selected in order to get a final aqueous solution 6a comprising a compound of formula (7) at a concentration of 0.178 mol/kg and 5% of a polyethylene glycol having an average molecular weight of 1500. The pH of solution 6a is in the range 8-9.
[0000]
[0159] Preparative Example 7
[0160] Preparation of poly(methacrylamide-co-methacrylic acid): 0.15 parts of radical initiator Vazo68 are mixed with 4325 parts of methacrylic acid, 43.18 parts of methacrylamide and 1000 parts of demineralized water. The mixture is stirred and heated under nitrogen to 74-76° C. over a period of 1 hour. After 10 minutes at 74-76° C., stirring is stopped and the mixture is left 16 hours at 74-76° C. 45.6 parts of aqueous sodium hydroxide (33%) are added, stirring is re-started and the temperature is allowed to fall to room temperature. The pH of the final product is approx. 7.0-8.0 and the viscosity is approx. 40000-50000 mPa·s. The aqueous solution so-formed (1132 parts) contains approx. 90 parts of poly(methacrylamide-co-methacrylic acid) as its sodium salt.
[0161] Preparative Example 7a
[0162] Optical brightening solution 7a is produced by stirring together
an aqueous solution containing a compound of formula (2) prepared according to preparative example 2, a poly(methacrylamide-co-methacrylic acid) prepared according to preparative example 7 and having a Brookfield viscosity between 40000 and 50000 mPa·s for a 8% aqueous solution at 20° C., and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0166] The parts of each component are selected in order to get a final aqueous solution 7a comprising a compound of formula (2) prepared according to preparative example 2 at a concentration of 0.125 mol/kg and 25% of a poly(methacrylamide-co-methacrylic acid) solution prepared according to preparative example 7 and having a Brookfield viscosity between 40000 and 50000 mPa·s for a 8% aqueous solution at 20° C. The pH of solution 7a is in the range 8-9.
[0167] Preparative Example 7b
[0168] Optical brightening solution 7b is produced by stirring together
an aqueous solution containing a compound of formula (8), a poly(methacrylamide-co-methacrylic acid) prepared according to preparative example 7 and having a Brookfield viscosity between 40000 and 50000 mPa·s for a 8% aqueous solution at 20° C., and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0172] The parts of each component are selected in order to get a final aqueous solution 2d comprising a compound of formula (8) at a concentration of 0.125 mol/kg and 25% of a poly(methacrylamide-co-methacrylic acid) solution prepared according to preparative example 7 and having a Brookfield viscosity between 40000 and 50000 mPa·s for a 8% aqueous solution at 20° C. The pH of solution 7b is in the range 8-9,
[0000]
[0173] Preparative Example 7c
[0174] Optical brightening solution 7c is produced by stirring together
an aqueous solution containing a compound of formula (8), a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s, and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0178] The parts of each component are selected in order to get a final aqueous solution 7c comprising a compound of formula (8) at a concentration of 0.125 mol/kg and 2.5% of a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s. The pH of solution 7c is in the range 8-9.
[0179] Preparative Example 7d
[0180] Optical brightening solution 7d is produced by stirring together
an aqueous solution containing a compound of formula (8), a poly(acrylamide-co-acrylic acid) having a Brookfield viscosity between 2 and 3 mPa·s for a 0.1% aqueous solution at 20° C., and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0184] The parts of each component are selected in order to get a final aqueous solution 7d comprising a compound of formula (8) at a concentration of 0.125 mol/kg and 0.5% of a poly(acrylamide-co-acrylic acid) having a Brookfield viscosity between 2 and 3 mPa·s for a 0.1% aqueous solution at 20° C. The pH of solution 7d is in the range 8-9.
[0185] Preparative Example 8
[0186] An aqueous solution of a compound of formula (2) in which the anionic charge on the brightener is balanced by a cationic charge composed of only sodium cations (0.150 mol/kg, approx. 21.4%) is obtained following the same procedure as in preparative example 1 with the sole differences that an approx. 30% sodium hydroxide is used instead of an approx. 30% potassium hydroxide in Stage 3 and that a smaller amount of water is added at the end of stage 3. The pH of the aqueous optical brightening solution obtained following this procedure is in the range 8-9.
[0187] Preparative Example 8a
[0188] Optical brightening solution 8a is produced by stirring together
an aqueous solution containing a compound of formula (2) prepared according to preparative example 8, a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 maPa·s, and water, while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0192] The parts of each component are selected in order to get a final aqueous solution 8a comprising a compound of formula (2) prepared according to preparative example 8 at a concentration of 0.125 mol/kg and 2.5% by weight (based on the total weight of the final aqueous optical brightening solution 8a) of a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s. The pH of the final aqueous optical brightening solution 8a obtained following this procedure is in the range 8-9.
[0193] Comparative Example 1 (without protective polymer)
[0194] Comparative optical brightening solution 1 containing compound of formula (2) in which the anionic charge on the brightener is balanced by a cationic charge composed of a mixture of sodium and potassium cations, the sodium cation being in the range 4.5-5.5 and the potassium cation being in the range 0.5-1.5 is prepared according to preparative example 1 at a concentration of 0.125 mol/kg and a pH in the range 8-9.
[0195] Comparative Example 2 (without protective polymer)
[0196] Comparative optical brightening solution 2 containing a compound of formula (2) in which the anionic charge on the brightener is balanced by a cationic charge composed of a mixture of sodium and potassium cations, the sodium cation being in the range 0-2.5 and the potassium cation being in the range 3.5-6 is prepared according to preparative example 2 at a concentration of 0.125 mol/kg and a pH in the range 8-9.
[0197] Comparative Example 4 (without protective polymer)
[0198] Comparative optical brightening solution 4 containing a compound of formula (6) is adjusted to a concentration of 0.125 mol/kg by addition of water.
[0199] Comparative Example 6 (without protective polymer)
[0200] Comparative optical brightening solution 6 containing a compound of formula (7) is adjusted to a concentration of 0.178 mol/kg by addition of water.
[0201] Comparative Example 7 (without protective polymer)
[0202] Comparative optical brightening solution 7 containing a compound of formula (8) is adjusted to a concentration of 0.125 mol/kg by addition of water.
[0203] Comparative example 8b (without protective polymer) Comparative optical brightening solution 8b containing compound of formula (2) in which the anionic charge on the brightener is balanced by a cationic charge composed of only sodium cations is prepared by adding the proper amount of water to the aqueous optical brightening solution prepared according to preparative example 8 at such a rate that the final concentration of compound of formula (2) in which the anionic charge on the brightener is balanced by a cationic charge composed of only sodium cations is 0.125 mol/kg. The pH of the final aqueous optical brightening solution 8b obtained following this procedure is in the range 8-9.
[0204] Application Examples 1a-b, 2a-e and 3a
[0205] Sizing compositions are prepared by adding an aqueous solution prepared according to preparative examples 1a-b, 2a-e and 3a at a range of concentrations from 0 to 80 g/l to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 1.
[0206] Comparative Application Examples 1 and 2
[0207] Sizing compositions are prepared by adding an aqueous solution prepared according to comparative examples 1 and 2 at a range of concentrations from 0 to 80 g/l to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 1.
[0208] Application Examples 4a and 4b
[0209] Sizing compositions are prepared by adding an aqueous solution prepared according to preparative examples 4a and 4b at a range of concentrations from 0 to 80 g/l to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l)(Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 2.
[0210] Comparative Application Example 4
[0211] Sizing compositions are prepared by adding an aqueous solution prepared according to comparative example 4 at a range of concentrations from 0 to 80 g/l to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 2.
[0212] Application Examples 5a
[0213] Sizing compositions are prepared by adding an aqueous solution prepared according to preparative example 5a at a range of concentrations from 0 to 270 g/l (0 to 0.01 mol/l optical brightener) into a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Perfectamyl A4692) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier.
[0214] The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 3.
[0215] Comparative application example 5
[0216] Sizing compositions are prepared by adding an aqueous solution prepared according to comparative example 4 at a range of concentrations from 0 to 80 g/l (0 to 0.01 mol/l optical brightener) into a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Perfectamyl A4692) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 3.
[0217] Application Example 6a
[0218] Sizing compositions are prepared by adding an aqueous solution prepared according to preparative example 6a at a range of concentrations from 0 to 50 g/l to a stirred. aqueous solution of calcium chloride (8 g/I) and an anionic starch (50 g/l) (Perfectamyl A4692) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 4.
[0219] Application Examples 6b
[0220] Sizing compositions are prepared by adding an aqueous solution prepared according to preparative example 6a at a range of concentrations from 0 to 50 g/l to a stirred, aqueous solution of magnesium chloride (8 g/l) and an anionic starch (50 g/l) (Perfectamyl A4692) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 4.
[0221] Comparative Application Example 6a′
[0222] Sizing compositions are prepared by adding an aqueous solution prepared according to comparative example 6 at a range of concentrations from 0 to 50 g/l to a stirred, aqueous solution of calcium chloride (8 g/l) and an anionic starch (50 g/l) (Perfectarnyl A4692) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 4.
[0223] Comparative Application Example 6b′
[0224] Sizing compositions are prepared by adding an aqueous solution prepared according to comparative example 6 at a range of concentrations from 0 to 50 g/l to a stirred, aqueous solution of magnesium chloride (8 g/l) and an anionic starch (50 g/l) (Perfectamyl A4692) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier, The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer, The results are shown in Table 4.
[0225] Application Example 7a
[0226] Sizing compositions are prepared by adding an aqueous solution prepared according to preparative example 7a at a range of concentrations from 0 to 80 g/l to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer, The results are shown in Table 1.
[0227] Application Example 7b-d
[0228] Sizing compositions are prepared by adding an aqueous solution prepared according to preparative example 7b-d at a range of concentrations from 0 to 80 g/l to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 5.
[0229] Comparative Application Example 7
[0230] Sizing compositions are prepared by adding an aqueous solution prepared according to comparative example 7 at a range of concentrations from 0 to 80 g/l to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier, The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 5.
[0231] Application Example 8a
[0232] Sizing compositions are prepared by adding an aqueous solution prepared according to preparative example 8a respectively at a range of concentrations from 0 to 80 g/l to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer, The results are shown in Table 6,
[0233] Comparative Application Example 8b
[0234] Comparative sizing compositions are prepared by adding an aqueous solution prepared according to comparative example 8b respectively at a range of concentrations from 0 to 80 g/l to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier. The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 6.
[0235] The results in Tables 1, 2, 3, 4 and 5 and 6 clearly demonstrate the improved compatibility between the optical brightener and the divalent metal salt in the presence of the protective polymer.
[0000]
TABLE 1
CIE Whiteness
Comparative
OBA
application
Sol. conc.
Application example
example
g/l
1a
1b
2a
2b
2c
2d
2e
3a
7a
1
2
0
101.7
101.7
104.2
104.2
104.2
104.2
104.2
104.2
104.2
101.7
104.2
10
125.0
125.0
126.1
125.6
126.0
125.8
125.5
125.5
125.6
124.9
125.5
20
133.4
132.4
132.6
134.4
133.7
133.1
132.5
132.9
132.8
131.7
132.5
40
139.2
138.5
139.2
139.5
139.6
140.1
139.2
138.6
139.0
137.3
138.0
60
142.1
140.3
141.1
144.2
141.8
42.9
141.7
140.8
141.5
139.2
140.6
80
143.4
140.9
143.0
142.3
143.1
144.6
143.3
142.2
142.3
139.6
141.5
[0000]
TABLE 2
CIE Whiteness
Comparative
OBA sol.
Application example
application example
Conc. g/l
4a
4b
4
0
101.7
101.7
101.7
10
124.1
124.1
123.9
20
130.7
130.8
130.6
40
135.4
135.3
135.0
80
137.0
135.9
134.7
[0000]
TABLE 3
Concentration of
CIE Whiteness
optical brightener
Comparative
(mol/l)
Application example 5a
application example 5
0
99.5
99.5
0.0025
124.0
123.6
0.0050
131.0
129.4
0.0075
136.6
131.6
0.0100
140.9
133.1
[0000]
TABLE 4
CIE Whiteness
8 g/l CaCl 2
8 g/l MgCl 2
Comparative
Comparative
Application
application
Application
application
OBA sol.
example
example
example
example
conc. g/l
6a
6a′
6b
6b′
0
104.8
104.8
104.7
104.7
10
123.4
123.4
126.7
126.7
20
128.1
128.0
133.0
133.0
30
130.5
128.6
135.4
133.7
40
130.5
128.2
136.4
134.4
50
130.0
127.2
136.3
134.2
[0000]
TABLE 5
CIE Whiteness
Comparative
OBA sol.
Application example
application example
conc. g/l
7b
7c
7d
7
0
103.3
103.3
103.3
103.3
10
124.1
123.2
122.4
122.8
20
131.3
131.1
132.1
131.0
40
135.9
135.8
137.7
135.8
60
137.7
137.2
139.4
136.0
80
136.7
136.03
141.0
135.4
[0000]
TABLE 6
CIE Whiteness
OBA sol.
Comparative
conc. g/l
Application example 8a
application example 8b
0
104.4
104.4
10
125.2
124.3
20
132.1
131.3
40
138.7
137.7
60
141.9
140.5
80
143.6
141.3
|
The instant invention relates to improved liquid sizing compositions comprising derivatives of diaminostilbene, binders, protective polymers and divalent metal salts for the optical brightening of substrates suitable for high quality ink jet printing.
| 3
|
FIELD OF THE INVENTION
The present invention is generally directed toward an apparatus for opening a roof access hatch from the ground.
BACKGROUND OF THE INVENTION
Roof hatches provide access to a roof or deck from the area below. Also known as access hatches, these hatches are typically designed to provide access to the roof of a building for servicing of roof-mounted equipment and are sometimes mandated in building codes. Roof access hatches are locked from the inside to prevent intruders from accessing the building through the hatch from above. To unlock the roof access hatch, the operator must climb an access ladder up to the hatch and, while bracing himself with one hand, attempt to unlock and open the hatch with the other hand. Of course, there are safety concerns in that, if his hand slips, the operator may fall several feet resulting in injury or even death. The current invention obviates these concerns by allowing the operator to remotely unlock and open the roof access hatch from the ground before climbing the ladder, thus greatly reducing the risk of injury.
SUMMARY OF THE INVENTION
An electrically operated remote unlocking and opening mechanism for a building roof access hatch is disclosed. A key-operated control panel at a distance remote to the roof access hatch unlocks and opens the roof access hatch so that the person accessing the hatch does not have to release both hands from the ladder. When a person activates the system from the control panel, the control panel directs the locking mechanism to unlock the roof access hatch and then directs the opening mechanism to open the roof access hatch. The system has a battery backup in the event of power failure and could be opened manually in the case of an emergency. Additional safety features may also be incorporated, such as sensors to prevent the hatch from closing while a person is accessing the opening and mechanisms to prevent the hatch from being blown shut by wind gusts.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages of the invention will become apparent by reference to the detailed description of preferred embodiments when considered in conjunction with the drawings:
FIG. 1 depicts the remote control panel that activates the roof access hatch.
FIG. 2 depicts the interior of the control panel.
FIG. 3 depicts the opening mechanism for the electrically-operated access hatch.
FIG. 4 depicts the locking mechanism for the roof access hatch.
FIG. 5 depicts another view of the opening mechanism for the roof access hatch.
FIG. 6 is a circuit diagram for the control panel lights.
FIG. 7 is a circuit diagram for the control panel.
FIG. 8 depicts the wiring from the control panel to the actuators.
FIG. 9 a depicts the exterior of the locking mechanism.
FIG. 9 b depicts the circuitry and mechanism of the locking mechanism, including the manual override.
FIG. 10 is a side-perspective of the electrically-operated access hatch.
FIG. 11 depicts the locking mechanism of the opening system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following detailed description is presented to enable any person skilled in the art to make and use the invention. For purposes of explanation, specific details are set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required to practice the invention. Descriptions of specific applications are provided only as representative examples. Various modifications to the preferred embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the invention. The present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.
The electric roof access hatch unlocking and opening system consists of a locking mechanism, an opening mechanism, and a control panel, each more fully described below. Through its electronic circuitry, the control panel controls the actions of the locking mechanism and the opening mechanism.
The locking mechanism is a device, as depicted in FIG. 4 , FIG. 9 , and FIG. 11 , which engages a lock on the roof access hatch. It is controlled by the control panel 1 (as depicted in FIG. 1 and FIG. 2 ) and may either lock or unlock upon application of a current. In the present embodiment, when current is applied, solenoid 4 retracts, pulling latch 19 into a recessed state. The locking system is preferably solenoid driven, as depicted in FIG. 9 . However, other electrically-operated locking mechanisms may be used, including, but not limited to, magnetic locks, motor-operated locks, and electric strikes.
The locking mechanism optionally includes a manual key override 3 , as depicted in FIG. 9 a , that allows the locking system to be unlocked in the event of emergency if the control panel circuitry or opening mechanism cannot function properly due to extended power outages or damage to any component. Lever 24 is operatively coupled to the manual key override. Inserting and turning a key in the manual key override 3 causes lever 24 to push against a protrusion 25 on the latch 19 , forcing the latch 19 into a recessed state, allowing access hatch 8 to be opened.
Opening mechanism 5 is depicted in FIG. 3 and in FIG. 5 . In the preferred embodiment, the opening mechanism is driven by a linear thrust actuator 6 . Linear thrust actuator 6 is coupled to access hatch 8 at a pivot point 7 on angled access hatch mounting bracket 27 . Angled access hatch mounting bracket 27 is configured such that pivot point 7 is located at a distance from the hinge side of the roof access hatch. When the control panel circuitry applies power to opening mechanism 5 , the thrust rod of linear thrust actuator 6 extends. As the linear thrust actuator 6 extends, it applies a force to pivot point 7 . The force of the linear thrust actuator 6 at pivot point 7 causes access hatch 8 to rotate about the axis of the roof access hatch hinge, causing the hatch to lift open from the side opposite the hinges. Other mechanisms for opening the roof access hatch may be used and include electric motors or pneumatic cylinders.
The opening mechanism 5 may be adjustable to accommodate different angles and mounting positions and varying thicknesses of insulation. As can be seen from FIG. 10 , the roof-mounted mounting bracket 12 may be coupled to linear thrust actuator 6 by use of adjustable bracket 14 . In the preferred embodiment, the bracket consists of a bar with equally spaced holes along its length. The linear thrust actuator 6 is affixed to the upper end of the adjustable bracket using bracket pin 13 . The lower end of adjustable bracket 14 is connected to the roof-mounted mounting bracket 12 . The roof-mounted mounting bracket 12 is further securely attached to the underside of the roof decking 16 .
To accommodate for varying thicknesses of installations or lowered mounting positions, bracket pin 13 can be inserted into any of the equally spaced holes situated along the length of the bar on the adjustable bracket. Bracket pin 13 can also be removed to disengage the roof access hatch 8 from the opening mechanism 5 .
Circuitry in the control panel 1 activates the locking mechanism 2 and the opening mechanism 5 . Although various methods of providing power to the locking and opening mechanisms are known and may be used, a simple circuit is disclosed herein. An example of such a circuit can be seen in FIG. 6 , FIG. 7 , and FIG. 8 . Control panel 1 can be placed into different modes of operation as the operator desires. In the OPEN mode, the control panel circuitry directs the roof access hatch to open. In the CLOSED mode, the control panel circuitry directs the roof access hatch to close. The OFF position is the default position to be used when the roof access hatch is not being utilized. In the preferred embodiment, the various modes are selected by use of a key switch 26 . As seen in FIG. 1 , status lights 10 on the front of the control panel 1 , may indicate the current mode of operation of the roof access hatch 8 .
When control panel 1 is placed in OPEN mode, power is applied to open relay 28 that sends power to the opening mechanism 5 and to a lock relay 29 for limited duration sufficient to unlock the locking mechanism 2 . The lock relay 29 transmits power to the locking mechanism 2 , causing it to unlock. In the current embodiment, this is a delay-on-break relay. This lock relay 29 keeps the latch 19 recessed until the hatch access 8 begins to open. Open relay 28 is set to output power to the linear thrust actuator 6 at a time after the lock relay 29 has unlocked the roof access hatch 8 , but before the flow of current to the locking mechanism 2 is terminated. In the preferred embodiment, the open relay 28 is a delay-on-make relay. When the open relay 28 permits current to flow, power is transmitted to the linear thrust actuator 6 in the opening mechanism 5 , causing the opening mechanism to lift open the roof access hatch 8 . The open relay 28 stops transmitting power after a duration sufficient for the linear thrust actuator 6 to fully open the roof access hatch 8 . The duration will vary based on the size and weight of the roof access hatch. Limit switches may be used on the roof access hatch to prevent the opening mechanism from forcing the roof access hatch beyond the fully open position.
When control panel 1 is placed in CLOSE mode, power is applied to the close relay 34 . The close relay 34 transmits current to the linear thrust actuator 6 with the polarity reversed such that the linear thrust actuator 6 returns to a retracted state, pulling the roof access hatch 8 closed. The close relay 34 transmits power only for a duration sufficient to close the roof access hatch. The spring loaded latch 19 on the locking mechanism 2 secures the roof access hatch 8 in a locked position when the roof access hatch 8 is in a fully closed position.
The control panel 1 is placed into either the OPEN mode, CLOSE mode, or OFF mode by use of a switch. In the preferred embodiment, a key switch 26 is used to place the control panel into one of the three modes, allowing the operator to remove the key for security purposes. Other known access control devices may be used to place the control panel into its various modes, including, but not limited to, pushbutton operation, biometric means, or computer-based access control. Indicator lights 10 on the front of the control panel 1 may be used to indicate the status of the electrically-operated access hatch 8 , such as whether the roof access hatch 8 is opening or closing and whether the lock is engaged.
Current is supplied to control panel 1 from an exterior source, such as a standard power outlet. The control panel 1 may optionally house a surge protector 30 , as seem in FIG. 2 , to protect the circuitry of the control panel 1 from electrical spikes. The current is transmitted to a DC transformer 31 that converts incoming power to a DC current. In the preferred embodiment, the transformer outputs 12V DC. However, any voltage may be adapted for use in the system.
The control panel optionally includes a battery charger 32 and battery 33 . The battery 33 provides emergency back-up power if the external power source fails. This allows the operator to use the roof access hatch 8 as an emergency egress if there is a power failure. Backup power relay 36 switches the source of power from the DC transformer 31 to the battery 33 in the event of a power outage.
The opening mechanism 5 optionally has an emergency release that allows the roof access hatch 8 to be separated from the opening mechanism 5 in the event that manual operation is required in an emergency. In the preferred embodiment, the emergency release is bracket pin 13 that may be removed from adjustable bracket 14 causing the linear thrust actuator 6 to disconnect from roof-mounted mounting bracket 12 .
In the event of an emergency, such as a malfunction or damage to the claimed device, or when the emergency battery 33 is depleted of reserve power during extended power outages, the roof access hatch can be manually opened. To open the roof access hatch 8 , the manual override key 3 is turned to unlock locking mechanism 2 , and bracket pin 13 is removed from adjustable bracket 14 . The roof access hatch 8 can then freely open.
To close the roof access hatch 8 in the event of an emergency, the roof access hatch 8 can be pulled closed manually. To do so, linear thrust actuator 6 must be disengaged from adjustable bracket 14 by removal of bracket pin 13 . The roof access hatch 8 can then be pulled shut using handle 17 which is preferably affixed to the outside of locking mechanism 2 . However, the handle 17 can be located anywhere on the roof access hatch 8 . As the roof access hatch 8 is pulled closed, the latch 19 on the locking mechanism is pushed inward toward the roof access hatch hinge. The latch 19 is springloaded by means of spring 18 so that latch 19 returns to its fully extended state once access hatch 8 is in the fully closed position.
Under normal operating conditions, the linear thrust actuator 6 maintains access hatch 8 in the open position while the operator is on the roof. The roof access hatch will not blow closed in gusty winds while the linear thrust actuator is in the open position. However, when the roof access hatch is opened manually by removal of bracket pin 13 , a prop bar similar to that used to keep the hood of a vehicle open can be used to keep the roof access hatch open. This prop bar will prevent the operator from being trapped on the roof by preventing the closure of the roof access hatch.
The electrically-operated access hatch 8 may also optionally include safety features to prevent accidental closure of the roof access hatch while a person is accessing the hatch. Sensors may be mounted to detect the presence of a person near the opening mechanism of the roof access hatch. In the preferred embodiment, a retro reflective photoelectric beam sensor is employed to ensure that a person is not injured by a closing roof access hatch. The retro reflective photoelectric beam sensor is mounted on the wall near the hinge side of the roof access hatch 8 . A reflector placed on the wall near the ladder 22 reflects emitted light back to the light sensor of the retro reflective photoelectric beam sensor. A person or object near the roof access hatch would prevent emitted light from reflecting back to the retro reflective photoelectric beam sensor. The retro reflective photoelectric beam sensor is configured to cause the control panel 1 to interrupt power to the linear thrust actuator 6 whenever light is not reflected back, indicating the presence of a person or object near the roof access hatch 8 . This is handled by the safety relay 35 in control panel 1 that directs power to the open relay 28 if the light is not reflected back to the retro reflective photoelectric beam sensor. The roof access hatch will cease closing and will enter OPEN mode.
The circuitry disclosed in this application is one possible embodiment of the invention. However, it is evident to a person of ordinary skill in the art that the circuitry can be designed in many variations to operate the opening and locking mechanisms of the roof access hatch. Specifically, a computer board or digital circuitry may be used that performs the same functions as the circuitry disclosed.
The electric roof access hatch unlocking and opening system can be mounted to a roof access hatch 8 that is already installed in a building. Alternatively, the electric roof access hatch unlocking and opening system may be part of a kit that includes the roof access hatch 8 and any accessories such as a ladder 22 .
It should be understood that features of any of these embodiments may be used with another in a way that will now be understood in view of the foregoing disclosure. Although the present invention has been described and illustrated with respect to at least one preferred embodiment and use therefor, it is not to be so limited since modifications and changes can be made therein which are within the fully intended scope of the invention.
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An electronically-activated roof access hatch is described that allows an operator to unlock the roof access hatch safely from the ground before ascending to the roof access hatch. The opening of the roof access hatch is controlled by a control panel that unlocks the roof access hatch and causes the roof access hatch to open.
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FIELD OF THE INVENTION
The present invention is directed generally to an ink fountain for printing machines. More particularly, the present invention is directed to an ink fountain having ink metering elements placed in a longitudinal gap of the ink fountain bottom. Most specifically, the present invention is directed to an ink fountain in which the longitudinal gap which houses the ink metering elements is completely filled with a lubricating means. The ink fountain includes a plurality of ink metering elements which are placed side by side in a longitudinal gap in the ink fountain bottom. Each of the ink metering elements is pivotably carried by a pivotable arm which passes out through a vertical opening in the opposite side of the ink fountain bottom and is positionable by means such as a stepping motor. In order to ensure smooth, uniform movement of the ink metering elements, the longitudinal gap is completely filled with a lubricating means and the gap is sealed from the ink fountain bottom. Accordingly, any particles of ink or dirt which may penetrate the seals are taken up by the lubricating means and do not hinder the operation of the ink fountain.
DESCRIPTION OF THE PRIOR ART
Ink fountains for use in printing machines are known generally in the art and are used to meter the amount of ink which an ink fountain roller carries away from the ink fountain. Exemplary of such ink fountains is German Unexamined Published Application No. 2,814,889 which corresponds to U.S. Pat. No. 4,170,177 to Iida et al. This patent discloses an ink fountain roller which contacts printing ink in an ink fountain. A plurality of ink metering elements are disposed side by side and in direct contact with each other. These elements extend longitudinally parallel to the axis of rotation of the ink fountain roller. These ink metering elements are pivotably mounted and secured to the ink fountain bottom and are rigidly secured to a pivotable arm. A control mechanism is provided to adjust a metering slot formed by the cooperation of the ink metering elements with the surface of the ink fountain roller.
It is a disadvantage of this ink fountain arrangement that the ink guiding surface of the ink fountain bottom and the ink metering elements are disposed at an angle of slightly more than 90° to each other and this complicates the cleaning of the ink fountain. A bottom plate of the ink fountain bottom removes ink from the ink guiding surface of the ink metering elements as these elements move in the "MORE INK" direction. It has been found in actual usage that during such adjustment, ink particles tend to get under the bottom plate of the ink fountain bottom and thus adversely effect the smooth running and operation of the ink metering elements so that the ink supply to the ink fountain is not properly controlled.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an ink fountain for printing machines.
Another object of the present invention is to provide an ink fountain having a plurality of ink metering elements.
A further object of the present invention is to provide a plurality of ink metering elements disposed in a longitudinal gap.
Yet another object of the present invention is to provide a plurality of ink metering elements which are capable of smooth operation.
Still a further object of the present invention is to provide a plurality of ink metering elements in a longitudinal gap which is completely filled with a lubricating means.
As will be discussed in greater detail in the description of a preferred embodiment, as set forth hereinafter, the ink fountain in accordance with the present invention is comprised generally of a plurality of ink metering elements that are placed side by side in contact with each other in a longitudinal gap which extends across the ink fountain bottom generally parallel to the axis of rotation of the ink fountain roller. Each of these ink metering elements is rigidly secured to a pivotable arm and these arms are movable to adjust the slot formed between the ink metering elements and the periphery of the ink fountain roller. The longitudinal gap is sealed from the ink fountain and is completely filled with a lubricating means to thereby prevent dirt and ink from interferring with the smooth operation of the ink metering elements.
It is a particular advantage of the present invention that it prevents machine shut-downs and the waste of paper caused by ink metering elements which will not operate or which operate sluggishly.
Smooth operation of the ink metering elements is particularly necessary if stepping motors are used to adjust the metering slot between the metering elements and the roller periphery. Since no dirt or ink can interfere with the ink metering elements because the lubricating means in the longitudinal gap will not allow such impurities to interfere with the metering elements, smooth running is assured. Because smooth operation is assured, it is possible to dispense with indicator means such as have been used in prior art devices to indicate the positions of the ink metering elements.
The ink fountain in accordance with the present invention can thus be seen as providing a smooth operation of the ink fountain roller which, in turn, results in higher quality printing, less machine down time and more uniform ink placement on the ink fountain rollers.
BRIEF DESCRIPTION OF THE DRAWINGS
While the novel features of the ink fountain for use in a printing machine in accordance with the present invention are set forth with particularity in the appended claims, a full and complete understanding of the invention may be had by referring to the description of a preferred embodiment as set forth hereinafter and as may be seen in the accompanying drawings in which:
FIG. 1 is a schematic side view of the ink fountain in accordance with the present invention with the ink fountain bottom and ink roller being shown in section and with the lateral end plates removed for clarity; and
FIG. 2 is a schematic front view of the ink fountain of FIG. 1 with the lateral end plates being shown.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning initially to FIG. 1, there may be seen an ink fountain generally at 1 with an ink fountain bottom member 2 provided therein. An inner bottom surface 3 of ink fountain bottom member 2 is covered with printing ink, when the ink fountain is filled with printing ink. A ceramic-coated ink fountain roller 4, which is driven in a conventional manner, plunges into the ink fountain 1. Ink metering extensions 5 of ink metering elements 6 form a slot with ink fountain roller 4 through which the printing ink passes. The ink fountain bottom 2 extends as an extension of the bottom surface 3 past all of the ink metering elements 6, thus forming a tail piece 7 having a tail face 8. A longitudinal gap 9 is provided in the ink fountain bottom 2, extending down into bottom 2 from the inner bottom surface 3. This longitudinal gap 9 preferably has a rhombus-shaped cross section and extends axially parallel to an axis of rotation of the ink fountain roller 4 near the point of closest proximity of the ink fountain roller 4 to the ink fountain bottom 2. A left guiding surface portion 12 of the longitudinal gap 9 abuts the bottom surface 3 at an angle α, which is preferably less than 90°, but which can be as great as 90°. An edge formed by the abutment of the left guiding surface 12 and the bottom surface 3 serves as a pivoting edge or pivoting line 21 for the ink metering elements 6. A right guiding surface 11 extends parallel to the left guiding surface 12 of the longitudinal gap 9, and a base surface 10 of the longitudinal gap 9 extends parallel to, and at a depth "a" below the bottom surface 3, of the ink fountain bottom 2. Vertical openings 13 in the ink fountain bottom 2 end in the base surface 10 of the longitudinal gap 9, these vertical openings 13 being spaced along the entire length "b" of the ink fountain bottom, for example, 30 mm from each other. The cross section of each of the openings 13 is dimensioned so that a pivotable arm 17 which is rigidly secured to each ink metering element 6 that extends horizontally in gap 9, is movable in opening 13. The pivotable arm 17 can move in a preselectable pivoting motion. It is provided for this purpose with an elongated hole 18 in its lower portion. A crank pin 19 which is driven by an electric motor engages this elongated hole 18. The pivotable arm 17 pivots about the point of intersection 21 of the guiding surface 12 with the bottom surface 3 of the ink fountain bottom 2. The pivoting edge 21 for the pivotable arm 17 is also the pivoting edge for each ink metering element 6 which is rigidly secured to the upper end of a corresponding arm 17. The inner bottom surface 3 of the ink fountain bottom 2 adjoins an ink guiding surface 22 of the ink metering elements 6, so that no groove or ridge which might impede the passage of ink over both surfaces 3 and 22 is formed. Ink guiding surface 22 extends initially in a straight direction, then turns into a concave curvature, which ends in an ink metering extension 5.
A vertical surface 4 of the ink metering element forms an angle β of approximately 90° with the ink guiding surface 22 of the ink metering element 6 and ends in a first carrier extension 26. This carrier extension 26 projects downwardly approximately 1 mm below a curved rear surface 27 of the ink metering element 6. A collar 28 at the upper end of the pivotable arm 17 is rigidly and permanently joined to the rear surface 27. The rear surface 27 also includes a second carrier extension 29. The first carrier extension 26 rests upon the base surface 10, whereas the second carrier extension 29 rests upon the right guiding surface 11 of the longitudinal gap 9. The carrier extensions 26, 29 each extend preferably over the entire length "c" of the ink metering element 6 and define an angle γ of approximately 80°. The carrier extensions 26, 29 may have a rectangular cross section while their front faces or carrier surfaces 14, 15 should be as narrow as possible. The carrier extensions 26, 29 may, however, be blade-shaped, or they may have a plane front or a curved front.
A borehole 20 is positioned coaxially with each opening 13 and extends into the side opposite the bottom surface 3 of the ink fountain 1. A plane borehole bottom 31 of each extension borehole 30 forms a surface of action for a conical compression spring 32, which is slipped over the pivotable arm 17. This compression spring 32 is held between the borehole bottom 31 and a bolt 33, which projects through the cross section of the pivotable arm 17 and which bolt 33 is rigidly secured to this arm 17. Both carrier extensions 26, 29 and thus the ink metering element 6 are pulled by the compression spring 32 towards the base surface 10 or the right guiding surface 11 of the longitudinal gap 9, respectively.
An elastic sealing membrane 34 which may be, for example, convex, is inserted between the borehole bottom 31 and the compression spring 32. This sealing membrane 34 has an aperture which sealingly engages the pivotable arm 17, sealing it completely. A sealing effect for the ink fountain bottom 2 is secured by pressing the edge of the sealing membrane 34 against the borehole bottom 31 by means of the compression spring 32. A narrow longitudinal groove 36, which extends the whole length "c" of the ink metering elements 6, is provided in a rear part 16 of each of the ink metering elements 6, above the second carrier extension 29, and receives a first lateral edge 38 of an elastic sealing strip 37 to seal the vertical openings 13 from the ink fountain roller 4. A second lateral edge 35 of the elastic sealing strip 37 is secured to the tail surface 8 of the ink fountain 2 thereby sealing this tail surface 8 of the ink fountain 2. The sealing strip 37 extends as a single element over the entire length "b" of the ink fountain bottom 2, and thus over all the ink metering elements 6 of the ink fountain 1, which are disposed side by side.
An axial groove 39 which extends along the entire length "c" of the ink metering elements 6 and parallel to the axis of rotation of ink fountain roller 4 is located in the vertical surface 24 of the ink metering elements 6 approximately 1 mm below the ink guiding surface 22. This groove 39 receives an elastic sealing cord 41 having, for example, a rectangular cross section. This sealing cord 41 extends without breaks over the length "b" of gap 9. It is of a suitable size so that in every operating position of the ink metering elements 6, the left guiding surface 12 of the longitudinal gap 9 is safely sealed to the vertical surface 24 of the ink metering element 6.
A lubricant chamber 43 which is defined and sealed by the sealing strip 37, a right side face 40 of the opening 13, the sealing membrane 34, a left side face 42 of the opening 13, the base surface 10, the left guiding surface 12, the sealing cord 41, the surfaces 24 and 27 of the ink metering element 6 facing the longitudinal gap 9, and by two lateral end plates 49 and 50, as seen in FIG. 2, extends over the length "b" of the gap 9, and is completely filled with a lubricating means, for example, grease. Printing ink or dirt is thus prevented from penetrating the lubricating means chamber 43 and cannot handicap the operation of the ink metering elements 6.
Each ink metering element 6 is provided with a through borehole 44 in its center. This borehole 44 ends on either front side 45, 46 of ink metering element 6, in a lubricating groove 47, 48 respectively. Every lubricating groove 47, 48 extends within the surface limits of the front sides 45, 46 and is approximately 10 mm long, 2 mm wide, and 0.5 mm deep. A grease nipple 20 is provided on the lateral end plate 49, through which grease can be forced into the boreholes 44 of the ink metering elements 6. An outlet nipple 25, which is capable of being closed and opened, is provided on the second lateral end plate 50, through which waste grease can be forced out. Since all the boreholes 44 of the ink metering elements are in connection with each other, it is possible to press grease through them in a way that the grease is pressed out between the front sides 45, 46 of adjacent ink metering elements 6, and thus dirt and ink pigments which may have accumulated between adjacent elements 6 are simultaneously pressed out.
In operation, the crank pins 19 are all caused to rotate by the electric drive motor (not shown), such motion causing the solid pivot arms 17 to pivot about pivot edge 21 whereby the ink metering elements 6, which are rigidly connected to pivotable arms 17, also pivot about pivot edge or line 21 to adjust the spacing between ink metering extension 5 and ink fountain roller 4. The ink in the ink fountain flows smoothly along the inner bottom surface 3 of ink fountain bottom 2 and along the curving ink guiding surface 22. The lubricating means chamber 43 is sealed by seal 41, by elastic sealing strip 37 and by elastic sealing membrane 34 so that no dirt or ink can get into the longitudinal gap 9. Thus the several ink metering elements 6 which are disposed side by side in gap 9 can operate smoothly and in uniformity to meter the ink applied to roller 4. Similarly, the lubricant which is forced through lubricant hole 44 in each metering element 6 and out through the lubricant grooves 47 and 48 keeps particles of dirt and ink from between end faces 45 and 46 of adjacent ink metering elements 6. Accordingly, the ink fountain in accordance with the present invention includes a plurality of individual ink metering elements which cooperate to uniformly meter ink on an ink roller. Furthermore, the ink fountain in accordance with the present invention allows the ink metering elements to operate smoothly and to remain dirt and ink free.
While an ink fountain for printing machines having means to maintain smooth operation of the ink metering elements in accordance with the present invention has been fully and completely described hereinabove, it will be obvious to one of ordinary skill in the art that a number of changes in, for example, the number of metering elements, the means for pivoting the arms, the securement means for the spring and the like may be made without departing from the true spirit and scope of the invention and that the invention is to be limited only by the following claims.
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An ink fountain for printing machines is disclosed. A plurality of ink metering elements are placed side by side in contact with each other in a longitudinal gap formed in an upper bottom surface of an ink fountain bottom. The longitudinal gap extends parallel to the axis of rotation of the ink fountain roller. Each ink metering element is rigidly secured to a pivotable arm that extends through a vertical opening which passes through the side of the ink fountain bottom opposite the inner bottom surface. Movement of the pivotable arms adjusts the metering slots formed by the ink metering elements and the ink fountain roller periphery. The longitudinal gap is sealed adjacent the inner bottom surface and the pivotable arms and a lubricant completely fills the chamber defined by the longitudinal gap and the vertical openings. Dirt and ink are prevented from interferring with the smooth operation of the ink metering elements since any dirt or ink which may pass by the seals is taken up by the lubricant in the chamber.
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FIELD OF THE INVENTION
The present invention relates to the new use of N-acetyl-L-cysteine in in vitro fertilization
BACKGROUND
In vitro fertilization (IVF) is a process by which an egg is fertilized by sperm outside the body. In vitro IVF is a major treatment for infertility when other methods of assisted reproductive technology have failed. The process involves monitoring a woman's ovulatory process, removing egg or eggs from the woman's ovaries and letting sperm fertilize them in a fluid medium in a laboratory. When a woman's natural cycle is monitored to collect a naturally selected ovum (egg) for fertilization, it is known as natural cycle IVF. The fertilized egg (zygote) is then transferred to the patient's uterus with the intention of establishing a successful pregnancy. The first successful birth of a “test tube baby”, Louise Brown, occurred in 1978. Louise Brown was born as a result of natural cycle IVF. Robert G. Edwards, the physiologist who developed the treatment, was awarded the Nobel Prize in Physiology or Medicine in 2010. (S K Kalra et al. Fertility and Sterility Vol 95, no 6 p 1888-1889. In vitro fertilization and adverse Childhood outcomes: what we know, where we are going, and how we will get there. A glimpse into what lies behind and beckons ahead. B Almog et al. Fertility and Sterility Vol 94, No 6 p 2026-2028. Promoting implantation by local injury to the endometrium).
In spite of dramatic progress in assisted reproduction technology over the past 25 years, the overall effectiveness of even the most advanced treatments such as IVF/embryo transfer (IVF/ET) is relatively low, averaging at about 20-30% live births per treatment cycle (Nyboe-Andersen et al., Hum Reprod. 2009; 24(6):1267-87).
Embryo transfer is an independent factor affecting the outcome of the treatment The determinants of success of embryo transfer involve the quality of embryo(s), uterine receptivity and the quality of the intrauterine environment (Cavagna and Mantese, Placenta. 2003; 24 Suppl B:S39-47).
Uterine contractions constitute the most fundamental components of uterine receptivity. Contractile activity of the uterus plays an important role in embryo implantation. Excessive uterine contractions may decrease implantation rates in IVF cycles as contractile activity might expel embryos from the uterus (Fanchin et al. Hum Reprod, 1998; 13: 1968-74). Up to date, treatment strategies to reduce uterine contractions before embryo transfer such as the use of beta agonists or non-steroid anti-inflammatory drugs have not been shown to provide sufficient benefit; Moon et al., Fertil Steril 2004; 82:816-20; Tsirigotis et al. Human Reproduction and Embryology, Jun. 25-28, 2000; Bologna, Italy:).
Treatment cycles induce an abundant increase in oestradiol concentrations which are about 10-20 nmol/l at the end of ovarian stimulation as compared with less than 2 nmol/l before the ovulation in the natural cycle Supraphysiological concentrations of oestradiol are expected to induce local (endometrial) production of oxytocin, formation of oxytocin receptors, and—indirectly—formation/release of PGF2a which is in fact similar to the prelabour status. Also, both oxytocin and vasopressin are involved in induction and maintenance of uterine contractions during labour
It has been shown that uterine contractile activity in IVF cycles is increased by approximately 6-fold when measured before embryo transfer as compared with the situation before ovulation in the natural cycle. Uterine contractions play an important role in human reproduction, being actively involved in rapid and directed sperm transport and high fundal embryo implantation
In IVF/ET treatments, a progressive decrease in uterine contractions is observed after the egg collection, reaching nearly a quiescent status at the time of blastocyst transfer (5-6 days after egg collection) (Fanchin et al., Fertil Steril 2001; 75: 1136-40). Such a decrease in contractile activity is thought to further augment the higher implantation rates achieved with blastocyst transfers. However, the majority of embryos are still transferred on day 2 or 3 after fertilization, during periods of noticeable uterine contractile activity.
The embryo transfer procedure itself is expected to increase the local oxytocin and prostaglandins release Any additional manipulation of the vagina or cervix, such as the use of a tenaculum, provides an additional stimulus for oxytocin/prostaglandin release (Dorn et al., 1999), which is coupled with increases in uterine contractions). Mansour et al. demonstrated that, in more than half of patients having mock embryo transfer with methylene blue dye, the dye was seen to be transported into the vagina after the procedure (Mansour et al., Hum Reprod 1994; 9: 1257-9). It was also demonstrated that less than 50% of transferred embryos remained in the uterus 1 h after transfer and about 15% of embryos could be found in the vagina after embryo transfer (Poindexteret al. Fertil Steril, 1986; 46:262-7).
Considering the above, it has been suggested that uterine contractile activity at the time of embryo transfer and especially fundo-cervical contractions could expel embryos from the uterus Fanchin et al. Human Reprod 1998; 13:1968-74 have estimated that about 30% of patients undergoing embryo transfer have pronounced uterine contractions. In that group, success rates of IVF/ET treatment were up to 3-fold less compared with the population of patients with ‘silent’ uteri (16% versus 53% of clinical pregnancies). The difference was independent of the direction of uterine contractions noted during the assessments. That could imply that pharmacological inhibition of increased contractions at the time of embryo transfer could be an attractive target for potential treatment.
Interfering with the PGF2a/oxytocin systems and possibly improving endometrial perfusion could be one mechanism by which uterine contractions would decrease and improve uterine receptivity.
The effectiveness of in vitro fertilization-embryo transfer (IVF-ET) usually does not exceed 30% per treatment cycle (NyboeAndersen A, Gianaroli L, Felberbaum R, de Mouzon J, Nygren K. Assisted reproductive technology in Europe, 2001. Results generated from European registers by ESHRE. Hum Reprod 2005; 20:1158-76) and is further reduced in women older than 36 years. (Stolwijk A, Wetzels A, Braat D. Cumulative probability of achieving an ongoing pregnancy after in-vitro fertilization and intracytoplasmic sperm injection according to a woman's age, subfertility diagnosis and primary or secondary subfertility. Hum Reprod 2000; 15:203-9)
Good quality of embryos and optimal intrauterine environment are the basic determinants of success for ET, and the whole IVF-ET procedure. Ideal intrauterine conditions that enable implantation include appropriate endometrial status, sufficient endometrial perfusion and absence of excessive uterine contractions. In particular, increased uterine contractile activity may expel embryos from the uterus. (Mansour R, Aboulghar M A, Serour G I, Amin Y M. Dummy embryo transfer using methylene blue dye. Hum Reprod 1994; 9:1257-9) (Poindexter A, Thompson D, Gibbons W. Residual embryos in failed embryo transfer. Fertil Steril 1986; 46:262-7)
Implantation and pregnancy rates are inversely correlated with the frequency of uterine contractions and prostaglandin synthesis (PG synthesis). High uterine contractile activity at ET (five or more contractions per minute) is found in about one-third of patients, and in these women clinical pregnancy rates reach 13% per cycle, in contrast to the 53% of successful pregnancies in women with lower uterine activity (three or less contractions per minute) (Fanchin R, Righini C, Olivennes F, Taylor S, de Ziegler D, Frydman R. Uterine contractions at the time of embryo transfer alter pregnancy rates after in-vitro fertilization. Hum Reprod 1998; 13:1968-74.) Moreover, irritation of the uterine cervix by the ET catheter is likely to induce additional PG synthesis and contractile reflexes and further decrease the chances of successful embryo Implantation (Lesny P, Killick S, Tetlow R, Robinson J, Maguiness S. Embryo transfer—can we learn anything new from the observation of junctional zone contractions? Hum Reprod 1998; 13:1540-6.)
However, uterine contractile activity, an important component of uterine receptivity, is currently not a subject of specific diagnosis or treatment in ET recipients. Progesterone supplementation, even when acting on uterine receptivity, improving endometrial status, and decreasing uterine contractions, shows no benefit for pregnancy rates after IVF-ET. (Fanchin R, Righini C, de Ziegler D, Olivennes F, Ledee N, Frydman R. Effects of vaginal progesterone administration on uterine contractility at the time of embryo transfer. Fertil Steril 2001; 75:1136-40.)
Studies assessing the effectiveness of piroxicam (cyclooxygenase inhibitor) and ritodrine (β2-adrenoreceptor agonist) have shown a positive effect on pregnancy rates. (Moon H, Park S, Lee J, Kim K, Joo B. Treatment with piroxicam before embryo transfer increases the pregnancy rate after in vitro fertilization and embryo transfer. Fertil Steril 2004; 82:816-20; Tsirigotis M, Pelekanos M, Gilhespie S, Gregorakis S, Pistofidis G. Ritodrine use during the peri-implantation period reduces uterine contractility and improves implantation and pregnancy rates post-implantation. Presented at the 16th annual meeting of the European Society of Human Reproduction and Embryology; Jun. 25-28, 2000; Bologna, Italy). The drugs mentioned above have failed to enter routine clinical use because of safety concerns.
Recently, Moraloglu et al. Treatment with oxytocin antagonists before embryo transfer may increase implantation rates after IVF. Reproductive biomedicine online Sep. 2010; 21(3): 338-43 reported a randomized, placebo controlled trial with a total i.v. dose of 37.5 mg of atosiban (oxytocin antagonist) infused before and up to 2 h after the embryo transfer in 160 patients. The authors noted significant improvement in both implantation rates and clinical pregnancies. Implantation rates per embryo transferred were 20.4% versus 12.6% and clinical pregnancy rates per cycle were 46.7% versus 28.9% (atosiban versus placebo). Fewer early miscarriages were noted in the study group (16.7% versus 24.4%, atosiban versus placebo).
N-acetyl-L-cysteine (hereinafter referred to as NAC) is a well-known drug, which has been used mainly as a mucolytic agent and in the treatment of paracetamol poisoning. In recent years it has also been acknowledged as having other beneficial properties, such as being anti-inflammatory and anti-proliferative, and has been suggested for the treatment of a variety of different disorders and symptoms in addition to endometriosis also schizophrenia, diabetes and cancer.
To date, NAC has not been considered a drug in fertility treatment although it has been used for oral treatment of endometrioses as described in EP 2305238. In that study no conclusions about pregnancies were made. To the contrary when being treated for endometriosis it was not expected that any pregnancies could occur. Although, it has not been disclosed before, when analysing the data the inventors have noticed that there was one person who had taken NAC orally for endometriosis had a successful IVF treatment. Also two previous IVF trials had failed and resulted in an abortion. This was one of the reasons why the present inventors started investigating whether NAC could be used in connection with IVF.
Indeed, in mice, NAC was confirmed to support embryo implantation. In the animal model, embryo implantation rate was decreased when the mice were given oxytocin. NAC dose-dependently restored implantation rates in oxytocin-treated mice, which provided evidence for involvement of oxytocin in embryo implantation.
PRIOR ART
Background art, describing the molecular effect of NAC in the treatment of cancer, include: T. Parasassi, et al. Cell Death and Differentiation (2005), Vol. 12, No. 10, pages 1285-1296; E. K. Krasnowska et al. Free Radicals Biology and Medicine 2008, 45(11):1566-72; A. C. Gustafsson et al. BMC Cancer (2005), 5:75. NAC in the treatment of endometriosis is described in Pittaluga et al. More than an antioxidant: N-acetyl-L-Cysteine in a murine model of endometriosis. Feral & Steril 2010; 94(7): 2905-8. Further, C. H. Kim et al. (Abstracts of the 22nd Annual Meeting of the ESHRE, Prague, Czech Republic, 18-21 Jun. 2006, P-463) describe treatment with N-Acetyl-Cysteine to improve insulin sensitivity. Formulations containing N-acetyl-L-cysteine(NAC) as such or together with (ii) selenium in the form of selenomethionine and/or (iii) melatonin and/or physiologically acceptable salts thereof are described in EP 12710062.6. Such formulations may also be used for treatment of IVF.
OBJECTS OF THE INVENTION
Already from the start of IVF it has been a problem that the clinical outcome in IVF treatment is low. As the cost of IVF is high and the treatment normally only give 20-30% live births per treatment cycle, many different treatments have been tested in order to give a higher percentage of live births. It has now unexpectedly been found that administration of NAC preferably a few days prior to IVF treatment gives a higher percentage of live births. Further, in cases where many earlier IVF treatments have been unsuccessful, the prior administration of NAC in connection with a new IVF treatment have resulted in live births.
The clinical outcome of NAC treatment as defined in the claims of the present application in in vitro fertilization (IVF) has, to the knowledge of the inventors, not been determined in the prior art, nor has an efficient dosage regimen for the treatment of IVF or the use of NAC for the treatment of indications associated with IVF been proposed.
It is therefore a general object of the present invention to provide a solution to the problem of providing a pharmaceutical composition comprising N-acetyl-L-cysteine (NAC) for the treatment of IVF and indications associated with IVF in humans and mammals.
SUMMARY OF THE INVENTION
According to the present invention a pharmaceutical composition comprising N-acetyl-L-cysteine (NAC) is used for intravenous and/or oral administration. The formulation contains N-acetyl-L-cysteine (NAC) as such or together with (ii) selenium in the form of selenomethionine and/or (iii) melatonin and/or physiologically acceptable salts thereof.
The formulation with NAC as such contains between 70-150 mg/kg body weight of NAC and is administered once a day for 1-3 days in connection with IVF treatment. It is also possible to administer only once, namely on the day of IVF administration. In that case the administration takes place about 1 hour before IVF.
EXAMPLES
Embryotoxicity
The eventual occurrence of NAC embryotoxicity was preliminary tested. To verify the embryotoxicity of NAC the application of two embryotoxicity tests—rabbit embryo bioassay and human sperm motility bioassay—were used (see Pierzynski et al., 2007a). Both failed to detect an embryotoxic effect of NAC in concentrations up to 50-fold therapeutic blood concentrations. NAC was shown not to affect the survival of 1-cell rabbit embryos, as well as not to decrease the percentage of hatched rabbit blastocysts. Tests performed on human spermatozoa also failed to show an adverse influence.
Toxicity Test—Human Sperm Motility Bioassay
Assessments of human sperm motility were performed on fresh samples taken from 3 healthy donors with good seminal parameters including sperm motility and velocity. Migration or “Swim-up” on human sperm preparation medium was applied to select motile spermatozoa. After selection each semen sample was divided into 3 aliquots transferred to Eppendorf tubes. In addition to one control tube, two tubes had NAC added at concentrations of 100 and 1,000 nM. Tubes were incubated in a 5% CO2 environment, with constant temperature and humidity conditions for 24 hours. Sperm motility was assessed using a contrast phase microscope at a 400 times magnification after 1, and 24 hours of exposure to NAC. Assessment was performed over a fixed time interval of 2 minutes. Nine samples were assessed for sperm motility and velocity by 36 measurements (2 measurements at 1 and 24 h per sample).
In the human sperm motility bioassay assessments, no effects of NAC on human sperm motility or velocity were detected when compared to controls. However, the duration of the experiment influenced motility, detected as a gradual decrease of activity and velocity of spermatozoa. This decrease was seen in both controls and NAC treated and did not differ between the groups. No interactions between time and concentration were found, so the effect of time did not differ significantly in the 2 groups of concentrations 100 and 1,000.
In Vitro
Integrins are expressed in a highly regulated manner at the maternal-fetal interface during implantation. However, the significance of extracellular matrix (ECM) ligands during the integrin-mediated embryo attachment to the endometrium is not fully understood. Thus, the distribution of fibronectin in the rat uterus and blastocyst was studied at the time of implantation. Fibronectin was absent in the uterine luminal epithelial cells but was intensely expressed in the trophoblast cells and the inner cell mass suggesting that fibronectin secreted from the blastocyst may be a possible bridging ligand for the integrins expressed at the maternal-fetal interface. An Arg-Gly-Asp (RGD) peptide was used to block the RGD recognition sites on integrins, and the effect on rat blastocyst attachment to Ishikawa cells was examined. There was a significant reduction in blastocyst attachment when either the blastocysts or the Ishikawa cells were pre-incubated with the RGD-blocking peptide. Thus, successful attachment of the embryo to the endometrium requires the interaction of integrins on both the endometrium and the blastocyst with the RGD sequence of ECM ligands, such as fibronectin. Pre-treatment of both blastocysts and Ishikawa cells with the RGD peptide also inhibited blastocyst attachment, but not completely, suggesting that ECM bridging ligands that do not contain the RGD sequence are also involved in embryo attachment (Kaneko Y, Murphy C R, Day M L. Extracellular matrix proteins secreted from both the endometrium and the embryo are required for attachment: A study using a co-culture model of rat blastocysts and Ishikawa cells. J Morphol. 2013; 274(1):63-72)
Experiment 1
The present experiments were carried out to elucidate if NAC treatment influence junction (adhesion) proteins including integrin/fibronectin.
Cell Adhesion Assay. Seven μg/ml of human fibronectin (Sigma Aldrich Chem Co) were saturated with 2% bovine serum albumin (BSA) for 30 min at 37° C. and washed twice with phosphate buffered saline (PBS). Jurkat cells were then seeded onto the wells for 2 h at 37° C.; then, nonadherent cells were aspirated, and the wells were rinsed with PBS. Adhering cells were fixed overnight with 2% formaldehyde and stained with eosin Y for 30 min. Eosin Y was then extracted by addition of a mixture of 1% of glacial acetic acid and 50% ethanol, and absorbance was measured at 540 nm.
Integrin alpha-4 (VLA-4) expression. VLA-4 antigen expression was detected on Jurkat cells by indirect immuno fluorescence with a monoclonal anti-VLA-4 (clone HP1/7) and flow cytometry. Staining of cells was performed according to standard protocols and flow cytometry analysis was performed by using a FACS-Calibur cytometer (Becton Dickinson).
Results With Reference to FIG. 1
NAC increases the adhesions of Jurkat cells on fibronectin. The adhesion assay was performed by using control or NAC (5 mM for 2 h)-treated Jurkat cells. The cells were photographed after staining with eosin Y. Incubation of the cells, after NAC treatment, with anti-VLA-4 antibody, inhibited adhesion. Cell adhesion was then quantitated by staining the cells attached to junction protein-coated plates with eosin Y and reading the absorbance in a microplate reader. As shown in FIG. 1 , NAC pretreatment augmented cell adhesion by nearly 35%, an effect that was abolished by anti-VLA-4.
Cells were solubilized and eosin Y and absorbance was quantitated at 540 nm. No antibody, illustrated by black bars; anti-VLA-4 (10 ng/ml) illustrated by grey bars; and anti-VLA-4 (10 μg/ml) illustrated by white bars. Data are means+/−SE( n =3).*, P less than 0.01 vs. control. From FIG. 1 it can be concluded that NAC treatment increases adhesion (junction protein molecules).
Experiment 2
The present experiments were carried out to elucidate if NAC treatment influence integrin and fibronectin gene expression by gene expression analysis using the Affymetrix GeneChip platform.
A micro array based gene expression analysis of the normal human epidermal keratinocytes was performed 1 and 12 hours after addition of NAC, compared to untreated (i.e. control samples at the same time points). Data obtained from GeneChip analysis were processed using the RNA analysis approach and samples were normalized to their corresponding controls. Filtering was done based on two criteria (p-value <0.1 and >1.5 fold up- or >0.5 down-regulation) for each time point. The labelling and hybridisation was done in duplicate.
1 hr after NAC treatment integrin alpha 2, was found up-regulated. At 12 hours fibronectin was found to be upregulated. These results suggest that NAC treatment results in an increased adhesion through the sequential up-regulation of integrin and fibronectin and that some of the effects are seen already one hour after treatment.
Experiment 3
In mice, NAC was confirmed to support embryo implantation. In the animal model, embryo implantation rate was decreased when the mice were given oxytocin. NAC dose-dependently restored implantation rates in oxytocin-treated mice, which provided evidence for involvement of oxytocin in embryo implantation.
To verify the embryotoxicity of NAC the application of two embryotoxicity techniques—rabbit embryo bioassay and human sperm motility bioassay—were used. Both failed to detect an embryotoxic effect of NAC in concentrations up to 50-fold therapeutic blood concentrations. NAC was shown not to affect the survival of 1-cell rabbit embryos, as well as not to decrease the percentage of hatched rabbit blastocysts. Tests performed on human spermatozoa also failed to show an adverse influence.
Experiment 4
Animal Model Showing that NAC Decreases the Contractions of the Uterus
Experimental Design
Animals were kept at 22° C., housed 3 per cage and fed ad libitum. Isolated uteri from virgin Wistar rats (200-280 g) in estrous, which was determined by examination of a daily vaginal smear, were used.
Reagents
Protamine sulphate (PS) and NAC were dissolved in pure water.
Isolated Organ Bath Studies
All rats were sacrificed by cervical dislocation. The uterine horns were excised, carefully cleaned and mounted vertically in a 10 ml volume organ bath containing De Jalon's solution (NaCl 154 mM, KCl 5.6 mM, CaCl 2 ×2H 2 O 0.41 mM, NaHCO 2 5.9 mM and glucose 2.8 mM), under 1 g tension, aerated with 95% oxygen and 5% carbon dioxide at 37° C. After an equilibration period (of 45 min), when uteri showed stable contractions (spontaneous or calcium ion-induced), indometacin (1 μg/ml) was added prior to PS. After 10 min increasing concentrations of PS were added until the total cessation of contractions was observed.
Myometrial tension was recorded isometrically with an organ bath and transducer.
Data Analysis and Statistical Procedures
Effects of treatments on uterine contractions were calculated as percentages for control, untreated and contracting conditions. Each data value is expressed as the mean±SEM. differences between groups were analyzed by two-way ANOVA. EC50 values were compared using one-way ANOVA
Results
PS caused dose-dependent relaxation of spontaneously active uteri. NAC pre-treatment (1 μg/ml) increased PS-induced relaxation. PS also caused dose-dependent relaxation of calcium ion-induced uterine contractions. NAC pre-treatment modulated PS-induced relaxation of uterine contractions and changed the curves of PS-induced relaxation.
The EC50 values for PS-treated uteri were analyzed. Significant differences in EC50 values were found with regard to the type of contraction used and the treatment used. The EC50 was lower in spontaneously active uteri than in calcium ion-induced uteri. The EC50 values for spontaneously active uteri pretreated with indometacin (1 μg/ml) were significantly lower than the other two EC50 values obtained. However, calcium ion-induced active uteri pretreated with indometacin presented higher EC50 values when compared to PS-treated uteri.
DETAILED DESCRIPTION OF THE INVENTION
NAC in General
N-acetyl-L-cysteine (NAC) is a well known low molecular weight pharmaceutical drug, with the chemical formula
The features of NAC are mainly related to its thiol group, which makes it effective in most biochemical pathways were the tripeptide glutathione (GSH), present in all human tissues at relatively high concentrations, even above 10 mM, acts. Cysteine is indeed among the three amino acids composing GSH, so NAC is considered a precursor of GSH with its de-acetylated cysteine. NAC has been and still is largely used as a mucolytic agent, where the mode of action is generally attributed to the redox breakage of sensitive cysteine disulfur bridges in the mucus proteins. In fact NAC participates to the complex redox cycling of thiol groups, where several enzymes act. Indeed, of extreme physiological importance is the disulfide formation and breakage cycle, a common mechanism by which protein activity and cellular signaling is regulated. Enzymes such as protein tyrosine phosphatases and tyrosine kinases, for example, play pivotal roles in the control of the cell cycle, cell proliferation and differentiation, and many of them are regulated by the redox state of their cysteines.
Overall, although detailed mechanisms of action have not been finally elucidated, NAC appears to act in all biochemical pathways where GSH does. Enzymes and proteins whose activity is modulated by GSH operate is several processes either directly or through a net of signals transduction pathways. In this picture, NAC may either parallel GSH action, or may be even more effective than GSH.
GSH is e.g. normally conjugated to reactive metabolites formed by paracetamol and helps detoxify them. When paracetamol is overdosed GSH is however depleted and the paracetamol metabolites start reacting with cellular proteins, eventually leading to cell death. In the treatment of fulminant hepatic failure after paracetamol poisoning NAC acts instead of GSH in the detoxification of paracetamol metabolites. NAC is believed to be virtually absent of undesired side effect, which is also indicated by the high NAC doses that are used in the treatment of paracetamol poisoning, estimated, for a 70 kg individual, of about 40 g/day.
Contrary to the tripeptide GSH, which can be degraded already in stomach, the simple NAC molecule freely diffuses in almost all tissues and cells. NAC pharmacokinetic studies determined a peak concentration in plasma reached in about one hour, with a half-life of about three hours. Total clearance occurs between six and twelve hours.
NAC as an Antiproliferative, Differentiating Agent
The inventors have recently found that N-acetyl-L-cysteine (NAC) possesses a marked antiproliferative effect on cancer cells of epithelial origin (Cell Death and Differentiation 2005, 12(10): 1285-1296).
NAC was used to arrest proliferation and induce differentiation in two adenocarcinoma cell lines and in primary normal keratinocyte cells, all of epithelial origin. In these systems, the differentiation was characterized morphologically, biochemically and through gene expression analysis (the gene expression analysis extensively reported in BMC Cancer 2005, 5: 75).
The antiproliferative effect of NAC, in the study of cancer, was not related to cell death or to toxicity but, instead, was due to the activation of a physiological differentiation pathway, which can be regarded as a normalization of cell functions towards the tissue of origin.
In addition to the decreased proliferation, the morphology of NAC-treated cancer cells was also altered. In vitro, epithelial cells under active proliferation display an irregular morphology—a mesenchymal morphology—and often form several multiple cell layers. On the contrary, when cells undergo a differentiation process, toward the structure and function of their final target tissue, they stop proliferation, their morphology becomes regularly polygonal, each cell sometimes thicker, and they form a single layer of adjacent cells. This process is accompanied by increased cell-cell and cell-substratum junctions, consistent with a shift from a proliferating mesenchymal to an adhesive, less motile and differentiated phenotype.
On a whole, a complex series of metabolic changes were detected after NAC supplementation to cancer cells, all converging in arresting the uncontrolled proliferation and in inducing their terminal differentiation. Notably, NAC treatment induced a considerable increase in cell-cell and cell-substratum adhesion complexes. Uncontrolled proliferation can be regarded to as a condition where cells have lost the contact inhibition and their ability to respond to differentiation signals. Cells entering the differentiation pathway exhibit a noticeable increase in cell-cell junction complexes, and the process is also generally indicated as contact inhibition. Several evidences indicate that signals for the cells to enter the differentiation end-point originate from the components of cell-cell complexes themselves. These junctions are also a way for the diffusion of signals between cells.
Dosage Regimen
From the study of NAC treatment on adenocarcinoma cell lines and primary normal keratinocyte cells (Cell Death and Differentiation 2005, 12(10): 1285-1296), it was concluded that the effective dose of NAC for induction of the antiproliferative-differentiating effect varied and was cell type dependent. The tissue of origin thus dictates the effective NAC concentration required to observe a complete block of proliferation, and has to be determined for each tissue. In addition, the dose of NAC was also related to the cell malignancy. In detail, while normal cells required a low dose to stop proliferating and start differentiating, carcinoma cells with characteristic poorer prognosis required a higher NAC concentration.
For the purpose of the present invention a dosage regimen of NAC for the treatment of IVF in a mammal, including human, was developed based on the following criteria:
1) a dosage of NAC per day which is in agreement with other current clinical treatments and is considered without undesirable side effects; 2) given a reported decrease in NAC plasma level after prolonged treatments (Pendyala L, Creaven P J. Cancer Epidemiol Biomarkers Prev. 1995; 4:245-51), the suspension of the treatment for about half of each week was considered for an optimal biological response in a treatment for two months or longer.
The composition of the present invention, comprising NAC for the treatment of IVF according to one embodiment to be administered intravenously at a dose between approximately 50 and 150 mg/kg/day. The lower limit has been shown to be effective in IVF and the higher limit is known to have virtually no side effects.
In still another embodiment of the present invention the composition comprises NAC to be administered orally at a dose of approximately 30-45 mg/kg/day. This low dosage has surprisingly been shown to be effective in the treatment of endometriosis and also give effect in connection with IVF.
In one embodiment the oral composition is to be administered for a period of time which is two months or more, or preferably three months or more. To counteract a decrease in NAC plasma level after prolonged treatment NAC may be administered at the prescribed dosage in an intermittent fashion, i.e. intermittent dosage regimen/treatment. By intermittent administration or treatment is meant that the treatment is interrupted in periods, i.e. that the pharmaceutical composition is administered for a period of time, e.g. a few days, followed by an interruption in administration, where no pharmaceutical composition is administered for a period of time, e.g. for a few days. Intermittent treatment can be regular, e.g. treatment for a fixed number of days or weeks, followed by interruption for a fixed number of days or weeks. Examples include repeated schemes with treatment for 4 days followed by interruption for 3 days each week or treatment for 2 weeks followed by interruption 1 week. A special case of regular intermittent treatment is pulsed treatment, i.e. with regular treatment and interruption duration, e.g. administration every other day or administration for two days followed by two days of interruption etc. Irregular intermittent treatment schemes that are not regularly repeated or have a more complex scheme that is repeated is also conceivable, e.g. dependent on response to treatment. In different exemplifying embodiments of the present invention the prescribed dose of NAC is administered for 3-5 consecutive days followed by 2-4 days of interruption, or administered for 1-3 consecutive days followed by 1-2 days of interruption.
In one embodiment, by referring to a body weight of approximately 60 kg, the NAC dose is in the range between 1.2 and 5.4 g/day, preferably between 1.8 and 3.6 g/day. The dose may be divided in two or more, preferably three or four, daily administrations of either one or two doses (e.g. pills) each, where each dose may comprise e.g. 0.15-2.7 g of NAC or preferably 0.6-1.2 g of NAC. The treatment includes the administration of the above mentioned doses pulsed or intermittently, e.g. every other day or for three to four consecutive days each week, with a suspension from four to three days, respectively. The minimum total duration of the treatment is of two months, with no maximum duration. For patients with other weights, e.g. over- or underweight persons the daily dose needs to be adjusted accordingly.
In one embodiment of the present invention the pharmaceutical composition for treatment of IVF NAC in a dose of 150-5400 mg to be administered in two or more administrations per day, for a period of at least 2 months, such as at least 3 months. In a preferred embodiment of the present invention the pharmaceutical composition comprises NAC in a dose of 230-3600 mg to be administered in two or more administrations per day, for a period of at least 2 months, such as a maximum of at least 3 months. The treatment includes the administration of the above mentioned doses pulsed or intermittently, e.g. every other day or for three to four consecutive days each week, with a suspension from four to three days, respectively.
NAC may also be administered together with selenium in the form of selenomethionine and/r melatonin. Such combinations are further described in EP 12710062.6
Pharmaceutical Formulations
A pharmaceutical composition according to the present invention may be prepared in a manner per se known by a person skilled in the pharmaceutical art. The composition may comprise an effective amount of NAC, in accordance with the invention, as well as a suitable carrier or excipient that serves as a vehicle or medium for the active ingredient. Such carriers or excipients are known in the art. The pharmaceutical composition is preferably for iv administration Other forms, such as tablets, capsules, suppositories, suspensions, syrups or the like are also conceivable. The invention requires a strict assessment of the pharmaceutical quality of NAC preparation for obtaining the effective dose. Therefore, brand or certified generic preparations have to be used. NAC is not a stable molecule, its active thiol residue can be easily oxidized by oxygen, light and other radiations, so that the effective dose would not be reached. The preparation is thus preferably protected from light, in soluble tablets, with sodium hydrogen carbonate, which helps in a partial removal of oxygen from water during dissolution.
It has been observed that high oral doses of NAC may cause abdominal pain. For overcoming this in cases of oral administration, an option is to provide NAC in a formulation with gastric protection, suitable for preventing NAC release/solubility in the stomach. Such formulations are well known in the art and may be used with the present invention. For example, tablet coatings that are resistant to gastric fluids and allow release of the drug only in the intestine, after its transit through the stomach, may be used. Commonly used formulations include polymers such as cellulose derivatives, methacrylate amino ester copolymers. The coating protects the tablet core from disintegration in the acidic environment of the stomach by employing pH sensitive polymer, which swell or solubilise after having passed through the stomach, in response to an increase in pH, to release the drug.
Another option is to lower the dose of NAC entering the blood stream at one time. Administration of NAC three or more times daily can be difficult to accomplish for the patient. Nevertheless, a repeated administration can be desirable to achieve a nearly constant serum concentration of NAC. To overcome these problems, a once or twice-a-day administration could be easier to handle for the patient, for instance morning and night. One option is to provide NAC in a slow-release formulation (also denoted sustained-release or controlled-release). By being able to reduce the rate of diffusion and uptake of NAC into the blood stream, such a formulation enables administration of a larger dose at longer intervals. The dose is then distributed in the blood over a long time in small quantities, e.g. over 12+12 hours in the case of a twice-a-day regimen scheme. Many different technologies and formulations for slow-release are since long known in the art and may be applied with the present invention. In such technologies the active substance is for example encapsulated in a coating or matrix that is insoluble or less soluble in the body fluid where it is administered.
Formulations having a combined effect of slow-release and gastric protection is also possible and may be used within the present invention.
Examples in Human
Administration in Connection with IVF Treatment
The very first case of clinical application of NAC prior to embryo transfer was recently documented. NAC was administered in a concentration of 50 mg/kg to a 42-year-old patient who had previously undergone five embryo transfers involving a total number of 8 good-quality embryos. Immediately before embryo transfer, the presence of increased uterine contractile activity was confirmed by ultrasound. NAC 50 mg/kg body weight was administered in intravenous infusion for 60 min. Embryo transfer was carried out 60 min from the end of the 60 min NAC 50 mg/kg body weight administration. Both before connecting the infusion and directly before embryo transfer, a transvaginal sagittal scan recording was performed. Thereby it was possible to confirm that uterine contractions decreased from 10 contractions per 3 min to five contractions per 3 min as well as recording an apparent decrease in their amplitude. Therapeutic success was confirmed by the delivery of a healthy daughter.
Pulsed Administration
Below is the result from giving pulsed administration of NAC to 15 patients, 8 of which became pregnant.
According to this, NAC was administered to patients per os for 3 months or more according to the following schedule: 600 mg three times a day, three consecutive days a week. The adoption of this procedure was based on the following considerations: (1) the daily total NAC dose of 1.8 mg is virtually free of side effects and was already considered for other clinical indications [K. R. Atkuri, J. J. Mantovani, L. A. Herzenberg, and L. A. Herzenberg, “N-acetylcysteine-a safe antidote for cysteine/glutathione deficiency,” Current Opinion in Pharmacology, vol. 7, no. 4, pp. 355-359, 2007.]; (2) splitting the total dose in 3 is simple for patients and, with reference to the known NAC pharmacokinetics [L. Pendyala and P. J. Creaven, “Pharmacokinetic and pharmacodynamic studies of N-acetylcysteine, a potential chemopreventive agent during a phase I trial,” Cancer Epidemiology Biomarkers and Prevention, vol. 4, no. 3, pp. 245-251, 1995.], grants a nearly constant plasma level of the drug; (3) the four-day medication-free interval provides a washout period useful to limit the reported decrease of NAC plasma level observed during prolonged treatments.
Results
pregnancy after months of attempt months post NAC type of pregnancy (1st or Patient of pregnancy treatment 2nd) 1 12 1 1 2 12 1 1 3 60 19 1 4 1 8 1 5 6 6 1 6 48 0 2 7 1 14 1 8 12 3 1
Formulations to be Used in Connection with the Invention
In one embodiment the invention provides a pharmaceutical composition comprising N-acetyl-L-cysteine (NAC) for intravenous administration of between 50-150 mg/kg body weight of NAC once a day for 1-3 days in connection with IVF treatment.
One aspect is a pharmaceutical composition comprising NAC for use in a dose of 150 mg/kg for 1-3 days.
Another aspect is a pharmaceutical composition comprising NAC for use only on the same day as IVF treatment.
In still another embodiment of the present invention the composition comprises NAC to be administered orally at a dose of approximately 30-45 mg/kg/day.
When NAC is combined with selenium and/or melatonin NAC is administered at a dose of 5-45 mg/kg/day, selenium, in the form of selenomethionine, for administration at a dose of 0.4-1.2 n/kg/day and melatonin for administration at a dose of 0.02-0.08 mg/kg/day. The medical product is in one embodiment a pharmaceutical composition comprising NAC, selenium in the form of selenomethionine, and melatonin.
Also the pulsed or intermittent, oral administration, for a time period of three months, at a dose of N-acetyl-L-cysteine that is between 20 and 90 mg/kg/day on days when administered will give a beneficial effect on success of IVF. In that case the composition is for continuous administration for three months or more, or 3-5 consecutive days followed by 2-4 days of interruption. In another embodiment the pharmaceutical composition comprising N-acetyl-L-cysteine is for administration for 1-3 consecutive days, followed by 1-2 days of interruption.
According to examples described in the specification 15 patients were treated with pulsed administration of N-acetyl-L-cysteine for use in IVF orally in a dose of 600 mg three times a day during three consecutive days followed by four days of interruption during 3 months or more.
Other possible administration regimens such as the following are described in EP 2305238.
In one embodiment the pharmaceutical composition comprising N-acetyl-L-cysteine for the above mentioned use, where the composition is for administration at a dose of N-acetyl-L-cysteine that is between 30 and 60 mg/kg/day on days when administered. In another embodiment the pharmaceutical composition is for administration at a dose of N-acetyl-L-cysteine that is between 30 and 45 mg/kg/day on days when administered.
In one embodiment the invention provides a pharmaceutical composition comprising N-acetyl-L-cysteine for the use described above where the pharmaceutical composition is protected from light. In another embodiment the pharmaceutical composition is a water soluble tablet. In still another embodiment the pharmaceutical composition contains sodium hydrogen carbonate. In one embodiment the pharmaceutical composition is a slow-release formulation and/or a formulation for gastric protection.
In one aspect the invention provides a method for the treatment of a mammal in connection with IVF, comprising intravenously administering a pharmaceutical composition comprising N-acetyl-L-cysteine(NAC) to said mammal between 50-150 mg/kg body weight of NAC once a day for 1-3 days in connection with IVF treatment.
One aspect is a method comprising intravenous administration of NAC in a dose of 150 mg/kg for 1-3 days.
Another aspect is a method comprising intravenous administration of NAC only on the same day as IVF treatment.
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The invention relates to a new use of NAC in IVF, in a human or mammalian animal patient. In addition an effective dose regimen of NAC in IVF is proposed.
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BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates to an apparatus for expanding and mounting or demounting an annular envelope of a flexible resilient material upon a tire.
II. Description of the Prior Art
In a tire retreading operation, a layer of bonding compound is applied to the buffed tire carcass and the new tread is then applied to the carcass. The tire is then inserted into an annular envelope of flexible rubber or synthetic sheet material which encloses the outer side walls and tread of the tire. The envelope is then sealed to the opposite outer sides of the tire along the tire beads and evacuated so that atmospheric pressure will firmly press the tread against the tire compound while bonding takes place. See U.S. Pat. No. 4,624,732 to King, which discloses an apparatus for sealing such an envelope to the tire and presents a somewhat more detailed description of the function of the envelope.
The envelope in question is of a general configuration similar to that of a tire, except that it is formed of a relatively thin, flexible rubber sheet. Like the tire, the annular envelope has circular openings through its opposite sides whose diameter is approximately equal to the inner diameter of the tire on which it is to be mounted. When mounted upon the tire, the envelope is sealed to the outer side of the tire beads around these openings in the envelope. The remainder of the envelope will loosely encase the tire.
Because the tire must be inserted into the envelope through one of the circular openings in the envelope, and the diameter of that opening is substantially less than the outer diameter of the tire, the envelope opening must be expanded or stretched to accommodate the insertion or removal of the tire into or out of the envelope. While this is frequently done manually, manual mounting and demounting of the envelope is a difficult, time consuming and frequently painful task. Tires most likely to be retreaded are those subjected to heavy duty usage, such as truck tires, for example, and these larger sized tires are more difficult to manually insert or remove from the envelope.
While various machines for mounting and demounting such envelopes on tires have been on the market, they have had but limited appeal to the retreading industry. High cost and operational problems seem to be the major drawbacks.
One such machine presently being marketed includes a hoist from which the tire is suspended in a horizontal (tire axis vertical) position. Below the hoist is a table-like housing having a circular array of articulated fingers mounted upon the top of the housing. After a tire has been manually mounted upon the hoist, the hoist is elevated clear of the fingers which are then located in a radially innermost position. The envelope is then placed on top of the housing. The edges of the uppermost central opening of the envelope are manually engaged with the fingers which are then power retracted radially outwardly to stretch the engaged envelope opening. The hoist is then operated to lower the tire downwardly through the expanded opening into the interior of the envelope. The fingers are then extended radially inwardly, and manually disengaged from the envelope. The enveloped tire may then be removed from the holder. Removal of the envelope is accomplished by reversing the foregoing procedure.
A disadvantage of these previously known tire envelope expanders is the floor space required to accommodate the size of the device.
A further disadvantage of these expander devices is the horizontal orientation of the tire and the envelope. The device forces an operator to lean over the machine in order to mount the envelope onto the envelope applicator.
The present invention is directed to apparatus for mounting and demounting envelopes upon tires which can be produced at a cost substantially less than the machine described above and which performs the mounting and demounting operation in a more efficient manner.
SUMMARY OF THE INVENTION
In accordance with the present invention, an envelope mounter-demounter is constructed with a gate-like rigid frame which lies in a general vertical plane. The frame is formed with a central opening extending horizontally through the frame, the central opening having a diameter greater than the maximum outer diameter of a tire to be presented to the apparatus.
A plurality of sprockets are mounted upon the frame about the periphery of the opening. The sprockets are interconnected by a chain, driven by hydraulic pumps. Rotation of the sprockets drives expanding members radially inwardly and outwardly toward and away from the central axis of the opening in the frame.
The expanding members are arcuately curved lengths of hollow tubing which are positioned within the frame to approximately conform to segments of a circle centered on the axis of the opening. The sprockets typically are semi-circular, rotating about a central pivot pin. The expanding members typically are fixedly mounted upon the pivot pins of the respective sprockets. The sprocket and driving mechanism is contained completely within the frame, thereby eliminating any potential clearance problems.
A semi-circular slot within each sprocket is guided by a pin fixedly attached to the frame. This slot and pin arrangement limits the rotation of the sprocket about the central pivot pin. This arrangement retains the respective expanding member in its desired relationship to the others.
The tubular expanding members may be positioned by their respective sprockets at a radially inner end limit of movement at which the curved expanding members roughly approximate a circle having a diameter which is but slightly greater than the relaxed diameter of one of the circular openings in the resilient envelope. With the expanding members in this position, the peripheral edge of the envelope opening can be mounted manually upon the expanding members with only a slight stretching of the envelope. Once so mounted, the pump is actuated creating pressure in the hydraulic pump and operating the piston rod connected to the chain. The chain is spring biased, pulling the members radially outwardly to expand the circular opening in the envelope to a diameter large enough to freely receive a tire.
In the present invention, no manual handling of the tire is required. The tire, upon which the envelope is to be mounted, is supported during the envelope mounting operation by some component of the retreading processing apparatus. Typically, the tire in one arrangement will be supported in a vertical (axis horizontal) position upon an arbor which may be used in the tread applying step. In this case, the rigid frame which carries the expander members is mounted for pivotal movement about a vertical axis for a gate-like swinging movement in a path such that the tire supported upon the arbor will pass through the opening in the rigid frame.
In another arrangement, tires are suspended from an overhead monorail conveyor in a vertical position by a hook-like support and the rigid frame, which carries the expanding members, is mounted at a location extending across the path of movement of the tires along the monorail. The frame is so located that the tires will be conveyed through the central opening in the frame, and the frame is provided with an opening in the portion of the frame above the central opening which will accommodate passage of a conveyor suspension hook upon which the tire is supported.
Other objects and features of the invention will become apparent by reference to the following specification and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of one form of envelope expander embodying the present invention;
FIG. 2 is a detailed cross sectional view taken on the line 2--2 of FIG. 1;
FIG. 3 is a detailed cross sectional view taken on the line 3--3 of FIG. 1;
FIG. 4 is a detailed cross sectional view taken on the line 4--4 of FIG. 1;
FIGS. 5, 6 and 7 are perspective views, with certain parts omitted or broken away, showing successive steps of the operation of the expander of FIG. 1; and
FIG. 8 is a front view, with certain parts broken away, omitted or shown in cross section of a modified embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1 and 2, an envelope expander embodying the present invention includes a rigid gate-like frame, designated generally F, which is vertically disposed to lie in a vertical general plane. As best seen in FIG. 1, a portion 10 of frame F is of an open octagonal configuration which is symmetrical about a central, horizontal axis A. The size of the central opening through octagonal frame 10 is such as to define an opening of a diameter which is larger than the outer diameter of tires upon which the envelope expander is to operate.
A plurality of sprockets 12 are mounted at spaced locations around the periphery of octagonal frame 10. The sprockets 12 are typically semi-circular and rotate about a central pivot pin 14. A slot 16 is located inward of the sprocket's outer circumference. A pin -8 is fixedly attached to the frame 10 for sliding rotation of the slot 16 about the pin 18. This slot 16 and pin 18 arrangement defines the rotational limits of the sprocket 12.
A chain 20 engages the sprockets 12 for rotation about their respective pivot pins 14. One end of the chain 20 is attached to a piston rod 22 connected to a pump 24. The chain 20 is spring biased, as shown by the spring 26 attached to the opposite end of the chain 20 and fixedly attached to the frame 10.
Where insufficient floor clearance is present, or components of tire builders or stands are in the way, hydraulic cylinders, such as 28, may be mounted at locations on frame F, such as those shown in FIG. 1, and have their piston rods 30 coupled to a link 32 pivotally mounted on the frame. Thus, the links 32 could be incorporated where needed to provide clearance space. Pin 34 is rotatably connected to link 32 as by a key 36. Pin 34 is rotatably received within a bushing 38 mounted in a frame 10. Essentially, the links 32 are fixedly coupled to the frame 10 via the pivot pin 34 and key 36, to function as a lever in which the distal ends 40 of the links 32 will move generally radially of axis A upon reciprocation of the piston rods 30 of hydraulic cylinders 28.
Expanding members 42 of like construction are fixedly mounted upon the central pivot pin 14 of each sprocket 12. Each expanding member includes a mounting member 44 in the form of a flat plate bent upwardly at one end as at 46 to form a flange which is bolted to the end of expanding member 42 as by a bolt 48 as best shown in FIG. 3. At the opposite end of mounting member 44, a length of hollow metal tubing 50 is fixedly secured, as by welding, to mounting member 44 in a generally T-shaped relationship to the mounting member. The tube member 50, as best seen in FIG. 1, is bent so that its longitudinal axis follows an arcuate curve having a constant radius of curvature.
Referring now particularly to FIG. 1, frame F also includes an auxiliary frame portion, designated generally 52, which is fixedly mounted upon the octagonal frame 10 as by bolts 54. Frame 52 serves as a mounting location for one of the hydraulic cylinders 28.
As best seen in FIG. 1, a second auxiliary frame portion, designated generally 56, is fixedly mounted upon octagonal frame 10 at the opposite side of the frame, again as by bolts 58. Frame portion 56 is employed to mount the gate-like frame F for pivotal movement about a vertical axis relative to a fixed mounting post 60.
Mounting post 60 is fixedly mounted upon a base 62 which will be fixedly secured in position on the shop floor. Post 60 is formed from a length of square steel tubing. Upper 64 and lower 64a adjustable pivot brackets are received upon post 60 to be located at selected positions of vertical adjustment on the post. The upper bracket 64 takes the form of a square hollow tubular sleeve 66 which is slidably and adjustably received upon post 60. A mounting platform 68 is fixedly secured, as by welding, to one side of the sleeve 66 and projects horizontally outwardly from the sleeve and may be supported as by a triangular gusset 70. A vertical bore through platform 68 receives a vertically disposed pivot pin 72 which rotatably receives and supports a mounting strap 74 fixedly welded to frame 56.
Sleeve 66 may be fixedly clamped at a selected position of vertical adjustment on post 60 as by one or more clamping bolts 76 threaded through the wall of the sleeve and engaged with the side of post 60.
The lower mounting bracket 64a is of a construction similar to the upper bracket 64, described above, but functions not only to support frame 56, but to also serve as a mounting for a portion of a brake assembly, designated generally 78.
Referring now particularly to FIGS. 1 and 4, a circular metal band 80 is fixedly mounted upon the lower pivot bracket 64a as by suitably located rigid webs, such as 82, 84 and 86 (FIG. 4), welded to bracket 64a and the inner side of band 80 to fixedly mount band 80 on bracket 64a with the axis of band 80 coaxial with the axis of pivot pin 72a on bracket 64a. The outer surface of band 80 is engaged by an arcuate brake pad 88 fixedly mounted on the end of piston rod 90 of a hydraulic cylinder 92 (FIG. 1) fixedly mounted on frame 56.
Pump 96 supplies pressure to the head end of cylinder 92, while the rod end is vented, thereby applying the brake pad 88 against the fixed circular brake band 80. Upon manual actuation of the pump 96, the connections to cylinder 92 are reversed to retract the piston rod 90, thereby releasing the brake.
Referring now particularly to FIG. 1, a pump 24 circulates oil for operating, in this instance, two hydraulic cylinders 94. The cylinder 94 receives therein a double acting piston rod 22 which is reciprocated in a conventional manner as oil or other fluid is introduced into and removed from the rod and head ends of the piston (not shown).
The piston rod 22 is connected by a pivot pin 98 to a chain 20. The chain 20 is engaged by the sprockets 12 spaced equidistant about central axis A. The opposite end of the chain 20 is fixedly attached to a spring 26 which is in turn fixedly attached to the frame 10.
As the piston rod 22 is extended from a retracted position, the chain 20 is pulled by and towards the spring 26. This pulling rotates the sprockets 12 clockwise about pivot pins 14. The expanding members 42, fixedly attached to the pivot pins 14, also rotate or pivot clockwise into a closed position. The tube members 50, having an arcuate curve of constant radius, form the circumference of a circle.
As the piston rod 22 is retracted from an extended position, the chain 20 is pulled toward the cylinder 94. The chain 20 rotates the sprockets 12 counter-clockwise, pivoting the expanding members 42 into a full open position.
The movement of the expanding members 42 between the two positions just described is limited by a slot 16 and pin 18, the slot 16 being integrally formed with each respective sprocket 12 and the pin 18 being fixedly attached to the frame 10.
Operation of the apparatus described above is best seen in FIGS. 5-7.
Post 60 is mounted in the shop floor at a location relative to a tire supporting arbor, designated generally 110, such that a tire T supported on the arbor with its axis horizontal is located within the path of pivotal movement of the central opening in octagonal frame 10 of the expander. At the commencement of an envelope mounting operation, frame F is pivoted to a position, such as that shown in FIG. 5, in which the frame is well clear of the tire T. Frame F will be held in this position by the actuated brake assembly 78. The first step of the envelope mounting operation is to manually actuate cylinders 94 to fully extend their piston rods to locate the various expander members in the radially innermost end limit of movement shown in FIG. 1.
With the expander members at their radially inner end limit of movement, the operator manually grasps the envelope E and places the peripheral edge of one opening 01 of the envelope manually over all of the tubular expander members 42. This will require at least a slight stretching of the peripheral edge of the opening, and when the opening has been passed around all of the tubular members, the peripheral edge of the opening will be held in tension within the notch N (FIG. 3) defined by the circumference of the various tubular members 50 and the flat surface of the mounting member 44 which is in tangential relationship with the outer circumference of the tubular member.
With the periphery of opening 01 so engaged with the expander members, the operator then actuates pump 24 to cause cylinders 94 to retract their piston rods, thereby drawing all of the expanding members 42 radially outwardly. This expands opening 01 of the envelope, see FIG. 6. The resistance to this radial expansion of the opening diameter is evidenced in the resilient envelope primarily as a tension along the periphery of opening 01, and this tension acts to more firmly seat the edge of the opening on the respective expansion members.
When the piston rods of cylinder 94 have been fully retracted, opening 01 has now been expanded to a diameter larger than the outer diameter of the tire T.
The operator then grasps auxiliary frame 52 and manually activates pump 96 to release the brake. The operator manually pivots frame F to swing the frame from the position shown in FIG. 6 to that shown in FIG. 7. During this movement, the tire T on arbor 110 is passed through the expanded opening 01 in the envelope and through the opening in frame 10 so that when the frame F arrives in the position shown in FIG. 7, the tire is located within the interior of envelope E.
The operator then activates pump 96 to reapply the brake and again actuates cylinders 94 to extend their piston rods, thereby returning the expanding members to their radially inner end limit of movement. The operator may now easily disengage the periphery of opening 01 of the envelope from the expanding members, retract the expanding members clear of the tire, and return the frame to the original position of FIG. 5. Demounting of an envelope from a tire is accomplished by reversing the foregoing process.
The embodiment described above is adapted for use when the tire upon which the envelope is mounted is supported upon a stationary arbor such as 110. In some retreading operations, a conveying system, such as a monorail conveyor, may be employed to transport tires from the tread application station to a curing oven which accelerates the bonding of the tread to the carcass. With minor modifications, shown in FIG. 8, the envelope expander may be easily adapted to mount, or demount, envelopes to or from tires T which may, for example, be suspended from a monorail conveyor 200 as by a J-shaped carrier 202. In this case, the frame F is interrupted or formed with an opening in the octagonal frame 10a which will enable conveyance of the tire into or out of an expanded envelope on the expander by movement of the conveying means, rather than by the expander frame. In the case of a monorail conveyor, such a clearance opening through the frame is formed at the top of the frame as at 206.
When using the invention with a conveyor system, the opening 206 provided at the top of frame F must be reinforced during mounting of the envelope E. Once the tire T enters the expanded envelope E, an interlocking frame 208 is activated pneumatically 210, or by other well known means, about a hinge 212 to close the octagonal frame 10a (shown in phantom). This strengthens the frame F during operation. Once the expansion is performed, the interlocking frame 208 is returned to its open position, allowing the tire T to continue along the conveyor.
Where the expander is employed with a conveying system, as in FIG. 8, the frame 10a may be pivotally mounted upon a post as in the previous embodiment, so that the frame may be swung clear of the path of movement of the conveyor and tires suspended on the conveyor. Alternatively, the frame may be mounted in a fixed position on the shop floor at a selected location along the conveying path.
Operation of the expander to mount and demount the envelope will be according to the procedure previously described. Where the expander frame is mounted at a fixed location, i.e., not mounted for pivotal movement, the brake and brake actuator of the embodiment of FIG. 1 is not required.
While various embodiments of the invention have been described in detail, it will be apparent to those skilled in the art, the disclosed embodiments may be modified. Therefore, the foregoing description is to be considered exemplary rather than limiting and the true scope of the invention is that defined in the following claims.
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An envelope expander for mounting an annular envelope of a flexible resilient material upon a tire supported upon a tire support with the tire axis in a horizontal position includes a vertically disposed rigid gate-like frame having a central opening of a diameter exceeding that of a tire. A plurality of expander members adapted to grip the envelope at spaced locations along the edge of a circular opening in one side of the envelope are mounted on the frame for coordinated power driven movement radially of the frame opening between radially inner and outer end limits. With the expander members at their radially inner end limits, the envelope opening is slightly stretched and manually mounted on the members. The expanding members are then driven to their radially outer end limits, expanding the envelope opening to a diameter greater than that of the tire. Relative movement between the frame and tire support is then utilized to move the tire through the expanded envelope opening into the interior of the envelope. The expander members are then returned to their radially inner end limits and disengaged from the envelope.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a subsea valve apparatus to control the flow of fluid in a pipe. More particularly, this invention relates to a subsea valve that is insensitive to ambient hydrostatic pressure and automatically closes to stop fluid flow in a pipe when a loss of hydraulic operating pressure occurs.
2. Description of the Prior Art
As the production of oil and gas expands to deeper water depths, the use of fixed offshore structures which extend from the sea floor to above the water surface eventually becomes economically infeasible. One of the more practicable alternatives is the use of a subsea production system (see U.S. Pat. No. 3,777,812). However, in deep water environments it is essential that all the valves on a subsea production system used to control the flow of oil and gas be insensitive to the ambient hydrostatic pressures. That is, the operation of the valve under all conditions should not be affected by the local water pressure. In addition, it is important that these valves be fail-safe. If the hydraulic or pneumatic operating pressure fails, the valve should automatically close the pipe or pipeline to prevent further fluid flow.
Pressure insensitive (sometimes referred to as "balanced"), fail-safe valves which close or shut off the flow of fluid in pipelines during the loss of hydraulic operating pressures or the like are known in the art (see, for example, U.S. Pat. No. Re. 30,115). Such underwater valves generally include a piston-operated valve stem which reciprocates within a cylinder to open and close a gate. In a single acting valve, hydraulic pressure or power fluid forces the piston in one direction, commonly referred to as a power stroke, and a spring means returns the piston to its starting position, commonly referred to as an exhaust stroke. In the event the hydrostatic pressure acting on the exposed end of the piston (the difference between the operating pressure and the valve pressure multiplied by the piston stem diameter) is greater than the spring load in the piston operator, the valve will remain in the open position. If an opposing valve stem capable of contacting the valve element is added as illustrated in Reissue 30,115, the unwanted hydrostatic force exerted against the stem is balanced thereby permitting the spring to close the valve even when the ambient pressure is greater than the internal valve pressure. Reissue 30,115 discloses a balanced stem, fail-safe valve system which includes a balancing stem detached from the main valve element but engagable with it, thereby permitting the stem to balance the valve when the hydrostatic pressure is greater than the internal pressure. However, since the stem is detached, the valve operates as a conventional fail-safe valve when the ambient hydrostatic pressure is less than the internal operating pressure.
While fail-safe, pressure insensitive valves such as that disclosed in Reissue 30,115 are available, a need exists for a remotely operable, fail-safe, pressure insensitive valve which can be quickly attached and detached from a pipeline with a subsea manipulator tool or the like. This need is accentuated as oil and gas is produced in deeper water depths requiring the use of subsea valves which are not readily installed, maintained or removed by conventional diving techniques.
SUMMARY OF THE INVENTION
The present invention substantially satisfies the needs discussed above by providing a remotely operable, pressure insensitive valve that is capable of being attached and detached from a submerged pipeline by a manipulator tool and that will close the pipeline when the operating pressure is lost.
Briefly, the valve of the present invention comprises closure means for movement across the pipeline and reciprocating means to move the closure means across the pipeline. The closure means includes a valve element or gate for sealing off the pipeline and a valve stem extending outwardly from the element. The valve also includes means for encasing the valve in a waterproof manner to protect it from the ambient hydrostatic pressure.
More specifically, the valve comprises a housing that engages a receiving or mounting hub of the submerged pipeline and a valve body securably attached to the housing. Internally, the valve is partitioned into at least two end chambers, one within the valve body and a second within the housing at the opposite end of the housing from the valve body. A valve element is supported within the chamber of the valve body. A valve stem is attached to the valve element and extends longitudinally through the housing into the chamber of the housing. The valve stem is hollow thereby permitting fluid communication between the two chambers. In this manner, the pressure in each chamber is equalized and the forces against each end of the valve stem is substantially the same.
As mentioned above, the valve includes a reciprocating or biasing means located within an intermediate chamber between the two end chambers. Preferably, the reciprocating means comprises an annular piston positioned around the valve stem and compression springs positioned around the valve stem within the intermediate chamber. The spring means is positioned so as to longitudinally displace the valve element across the pipeline during a loss of the operating pressure. This provides for a fail-safe mechanism to shut the pipeline off.
Preferably, the reciprocating means also includes pressure means to operably displace the piston longitudinally within the housing in opposition to the force of the compression springs. In this manner, the pressure means and compression springs work in a counterbalancing manner to displace the piston and, therefore, the valve element in a reciprocating manner which thereby opens and closes the pipeline.
Examples of the more important features of this invention have been summarized rather broadly in order that the detailed description which follows may be better understod. There are, of course, additional features of the invention which will be described hereafter and which will also form the subject of the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to more fully understand the drawings used in the detailed description of the present invention, a brief description of each drawing is provided.
FIG. 1 is a sectional view of a valve of the present invention wherein the valve is in the open position to permit fluid flow through the pipeline.
FIG. 2 is a sectional view of the valve shown in FIG. 1 wherein the valve is in the closed position to prevent fluid flow through the pipeline.
FIG. 3 is a schematic view of the moving components of the valve of the present invention illustrating the internal forces associated with the operation of the valve.
FIG. 4 is a sectional view of the valve similar to FIG. 2, but attached to the submerged pipeline. FIG. 4 also schematically illustrates the hydraulic components that may be used to operate the valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a valve of the present invention which comprises a housing 10, an actuator end 12 and a valve body 28. The actuator end includes an upper cap 14, a lower cap 16 and a sleeve element 18 therebetween. The upper and lower caps 14 and 16 are held together by screws 20a. The lower cap 16 is secured to the housing 10 by screws 20b (only one of each of the screws 20a and 20b are illustrated in FIG. 1; however, several such screws would be located peripherally about each cap 14 and 16). The housing 10 includes a valve bonnet 22 and a hollow cylindrical member 24 which are preferably integral components. The valve bonnet 22 is attached to the valve body 28 by screws 26 (only one screw 26 is shown in FIG. 1).
The valve of FIG. 1 also includes a lower sleeve 32 which provides a continuously flush outer lower surface for the valve. The lower sleeve is held in place along one edge by a retainer ring 34 and along the other edge by a locking ring 36. The ring 36, which is rotatable with respect to the valve bonnet 22 and body 28, includes threads 38 thereby permitting the engagement of the valve with a mounting hub on the pipeline (see FIG. 4).
Referring still to FIG. 1, the valve body 28 has a cylindrical passageway 30 which forms part of a first chamber 40. The chamber 40 also includes all fluid space within the valve body up to a front face 42 of the bonnet 22. For purposes herein, the term "chamber" means an open region which may vary in size depending on the movement of the internal components of the valve.
The valve includes a valve element 44 having an aperture 45 to open and close the passageway 30. Preferably, the valve element 44 is made up of two gates 44a and 44b separated by a fluid gap 31. A bifurcated gate system is preferred because when the passageway 30 is closed (see FIG. 2), the high pipeline pressure on one side of the valve body will affect only the downstream gate. The other gate on the high pressure side of the pipeline will usually be substantially friction-free. The operation of a bifurcated gate system is discussed in greater detail below. For purposes of the operation of the valve, the valve element 44 does not need to be bifurcated. Indeed, a single gate having a single aperture for alignment with the passageway 30 is sufficient.
The valve also includes a self-sealing system 33. The self-sealing system 33 ensures that a fluid-tight seal exists between the valve body 28 and the valve element 44. An example of a suitable self-sealing system is that manufactured by the McEvoy Oil Field Equipment Company and described at page 4608 of volume 3 of the Composite Catolog of Oil Field Equipment and Services by World Oil, 1978-79 edition.
The valve element 44 is supported within the first chamber 40 by lifting lugs 46. The lifting lugs (such as that manufactured by McEvoy and illustrated in valve Model C described at page 4610 of volume 3 of the Composite Catalog of Oil Field Equipment and Services by World Oil, 1978-79 edition) are connected to a valve stem 48. The valve stem extends from the first chamber 40, through an aperture 58 of the bonnet 22, an aperture 17 of the lower cap 16 and into a second chamber 50 at the other end of the valve. The second chamber 50 is formed by a pressure cap 52 secured between the upper and lower caps 14 and 16.
The valve stem 48 includes a hollow passageway 54 which extends throughout its entire length. The passageway 54 provides fluid communication between the first chamber 40 and the second chamber 50. In this manner, the pressure acting against the end of the valve stem 48 in the first chamber 40 is substantially the same as the pressure against the other end of the valve stem 48 in the second chamber 50. The valve stem 48 does not need to be a separate component from the valve element 44 and the lifting lugs 46 for purposes of this invention. The stem, lifting lugs and element (or gate) may be an integral component.
When a bifurcated gate system is used, as previously discussed, compression springs are located between the gates 44a and 44b to maintain the gates against the sides of the sealing system 33. Compression springs are not shown in FIGS. 1-4, but they are illustrated on the gates of valve Model C at page 4610 of volume 3 of the Composite Catalog and discussed in note 13 at page 4611 of volume 3 of the Composite Catalog. When the passageway 30 is closed by the gates 44a and 44b (see FIG. 2), one side of the passageway 30 will have a higher pipeline pressure than the other side. The compression forces of the springs between the gates are chosen so that the gate immediately adjacent the high pressure side of the passageway 30 is displaced slightly. This permits the high pressure to enter the first chamber 40, passageway 54 and second chamber 50. However, the sealing system prevents the high pressure from leaking past the other gate into the low pressure side of the passageway 30 (see discussion of the sealing system at page 4608 of volume 3 of the Composite Catalog).
The valve also includes a reciprocating system 55 for operably moving the valve stem 48 and, therefore, the valve element 44 across the passageway 30. The reciprocating system is within a third or intermediate chamber located within the cylindrical member 24 and between the lower cap 16 and the valve bonnet 22.
The reciprocating system includes an annular piston 56, attached to the valve stem 48, and a spring cartridge. The spring cartridge comprises two mounting heads 60, inter-connected by two sliding sleeves 62a-b, and three concentric helical springs 64a-c mounted in compression between the heads 60. Thus, the piston 56 is biased outwardly with respect to the valve body 28. The sleeves 62a-b prevent the full extension of the springs 64a-c when the screws 20a and 20b and the caps 14 and 16 are removed. Due to the springs cartridge, the springs can be maintained in a pre-stressed condition for ease of assembly and disassembly.
Referring still to FIG. 1, the valve further includes a conduit 65 which extends from a first compartment 66 of the intermediate chamber, through the wall of the cylindrical member 24, the valve bonnet 22 and into the valve body 28. The first compartment 66 varies in size and is defined to be between a first face 68 of the piston and the lower cap 16. The conduit 65 terminates into a quick-disconnector 71 such as model MJC69307-12 manufactured by the Aeroquip Corporation of Jackson, Mich.
The valve also includes a second conduit 70 which extends from a second compartment 72 of the intermediate chamber (the second compartment 72 also varies in size and is defined to be beteen a second face 74 of the piston and the valve bonnet 22), through the valve bonnet 22 and valve body 28 into a quick-disconnector 73 similar to quick-disconnector 71. For reasons of clarity, the conduits 65 and 70 and quick-disconnectors 71 and 73 are shown 90° out of phase in FIGS. 1, 2 and 4. Actually, these conduits are quick-disconnectors are aligned co-axially with the valve system 48 so that the conduits need not include a U-shaped section to pass around the passageway 30.
Preferably, the valve also includes pressure seals 77a-c to maintain the pressure integrity of the chambers 40 and 50 and the compartments 66 and 72. The seals 77a-c are used to prevent leaks between the chambers and compartments along the outer surface of the valve stem. Such seals should be located between the first chamber 40 and the second compartments 72 on the inner wall of the bonnet at aperture 58, between the first and second compartments 66 and 72 on the inside surface of the piston 56, and between the first compartment 66 and the second chamber 50 on the inner walls of the lower cap 16 and the pressure cap 52.
As noted above, the valve of FIG. 1 is in the "open" position. The piston 56 is illustrated in its "inward" position contacting a lip 76 of the cylindrical member 24. The lip 76 prevents further inward displacement of the piston and forms a metal-to-metal seal with the shoulder of the piston. The lip 76 limits the maximum stroke of the piston, valve stem and valve element. In order to aid quick closing of the valve when the operating pressure in compartment 66 is lost, the piston may include an orifice 69 which permits a relatively small leak between the compartments 66 and 72 when a metal-to-metal seal beteen the lip 76 and the shoulder of the piston is not achieved.
FIG. 2 is similar to FIG. 1 except that the piston 56 is in its "outward" position, contacting the bottom surface 82 of the lower cap 16. The valve stem 48, lifting lugs 46 and valve element 44 are advanced outwardly with respect to the valve body 28, closing the passageway 30.
To advance the valve element 44 across the passageway 30, hydraulic or pneumatic pressure is introduced through the conduit 65 into the first compartment 66 (see FIG. 1). When the pressure force, within the first compartment acting against the first face 68 of the piston, exceeds the compressive force of the springs 64a-c and the reservoir pressure, within the second compartment 72 acting against the second face 74 of the piston, the piston moves inward. In this manner, the valve element 44 is also advanced inward and the passageway 30 is opened.
FIG. 3 is an enlarged schematic view of the major moving components of the valve except for the valve element 44 which has been removed for clarity. The hollow passageway 54 provides for the same pipeline pressure (P p ) to be exerted on both ends 104 and 106 of the valve stem 48. Since the second chamber 50 is isolated from the ambient hydrostatic pressure (P a ) and since the pipeline pressure (P p ) is the same on both ends of the valve stem, the force (F p , not shown in FIG. 3) against both ends of the valve stem will be the same provided the cross-sectional areas of both ends of the valve stem are the same. This is the pressure balanced feature of the valve. And, as discussed above, the valve is pressure balanced even when the passageway 30 is closed because the bifurcated gate system admits pressure from the high pressure side of the passageway 30 only. The lifting lugs 46 will not prevent pressure in the first chamber from contacting the entire cross-sectional end area of the valve stem because the connection between the valve stem and lifting lugs is a loose fitting lug-in-groove connection. If the valve stem, lifting lugs and valve elements are manufactured as an integral component, as mentioned above, the geometry of the valve stem is chosen so that the cross-sectional end area of the valve stem within the first chamber is substantially the same as the cross-sectional end area of the valve stem within the second chamber.
Referring still to FIG. 3, to move the valve element 44 inward, operating pressure (P o ) is introduced into the first compartment 66. Once the operating force (F o , not shown in FIG. 3 but resulting from the operating pressure, P o , acting against the first face 68) exceeds the spring force (F s ) and the reservoir force (F r , not shown in FIG. 3 but resulting from the reservoir pressure, P r , acting against the second face 74), the piston is advanced inwardly. Thus, the valve stem and element are also advanced inwardly to open a pipeline 102 to fluid flow. Because the valve stem is protected from the ambient pressure (P a ) by the pressure cap 52, a large hydrostatic pressure will not influence the overall operation of the valve. Thus, the piston is displaced inward when:
F.sub.o >F.sub.s +F.sub.r (1)
The valve is referred to as being fail-safe because the valve closes any time the operating pressure (P o ) is lost. Loss of operating pressure causes the piston to advace outward due to the force of the spring which is the only unbalanced force. Any friction between the valve element 44 and valve body 28 which might dampen the biasing of the springs 64 is minimized by the friction-reducing effect of the self-sealing system 33, previously discussed.
FIG. 4 illustrates the engagement of the valve to a mounting hub 100 of the pipeline 102. FIG. 4 is substantially similar to FIG. 2 except that the valve is rotatably connected to the mounting hub by the locking ring 36 and the hydraulic operating components are also illustrated schematically.
The mounting hub 100 includes a passageway 30a which is an extension of the passageway 30 in the valve body 28 and of the interior of the pipeline 102. The mounting hub may include a flange 107 which is bolted to a matching flange 109 of the pipeline. Alternatively, the mounting hub may be an integral component of the pipeline (not shown).
FIG. 4 also illustrates the hydraulic components which could be used to operate the present invention. The operating pressure (P o ) is supplied by a pump 110 which charges a hydraulic accumulator 112. The accumulator maintains a pre-selected operating pressure. In normal operation, the operating pressure passes from the accumulator or pump, if the accumulator is being charged, through a conduit 118, a two-phase valve 114, a conduit 118' (which extends through the mounting hub to the quick-disconnector 71), conduit 65 and into the first compartment 66. The piston is displaced inwardly when the operating force (F o ) exceeds the spring force (F s ) plus the back-up reservoir force (F r , see equation (1)).
The hydraulic system also permits the evacuation of excessive reservoir pressure within the second compartment 72. The conduit 70 (which extends from the second compartment 72 through the bonnet 22) connects with a conduit 120 by means of the quick-disconnector 73. The conduit 120 passes through the mounting hub 100 and the two-phase valve 114 to a reservoir equalizer 116. The reservoir pressure within the second compartment 72 is maintained at ambient hydrostatic pressure (P a ) by the reservoir equalizer 116. Since the reservoir is maintained at ambient pressure, the operating pressure must exceed the ambient pressure (not to mention the force of the springs) to displace the piston. Thus, the hydraulic system is capable of balancing ambient pressure on both sides of the piston and capable of eliminating the influence of the ambient pressure on the housing at substantially the same time. Alternatively, the reservoir equalizer 116 may be housed in a pressure vessel (not shown) and maintained at less than ambient pressure. This would then require a lesser operating pressure to displace the piston inward.
With a loss of operating pressure or other emergency, the two-phase valve 114 automatically shifts under the bias of a spring (not shown) to its other position. In this position, the operating pressure in the conduit 118 flowing from the pump 110 or the accumulator 112 is blocked. Thus, the operating pressure remaining in the first compartment 66 is exhausted through the conduit 120 along with the reservoir pressure in the second compartment 72, which is exhausted through the conduit 118', into the equalizer 116. Since the pressures in the compartments 66 and 72 are balanced, the unbalanced spring force biases the piston outward, closing the pipeline off.
The valve is capable of being remotely installed and removed by a manipulator tool. an example of such a manipulator tool is reference numeral 103 in U.S. Pat. No. 3,777,812 (see also column 4, lines 24 to 44 of U.S. Pat. No. 3,777,812).
In a normal installation, the tool grasps the valve housing and initially positions the valve body adjacent to the opening of the mounting hub 100. Since it is necessary that the correct quick-disconnectors (71 or 73) engage to properly operate the hydraulic system, a nose 130 of the valve body 28 is fabricated in a rectangular or similar cross-sectional shape so that it will fit into an open channel 122 of the mounting hub in only one or two positions. If two positions are possible, the operator of the manipulator tool would initially position the valve, once adjacent to the mounting hub, so that the correct quick-disconnectors would engage when the nose 130 of the valve body is fully extended into the channel 122. The manipulator tool would then rotate the locking ring 36 engaging the threads 38 and securably fastening the valve to the mounting hub. To remove the valve from the mounting hub, the same procedure would be performed in the reverse order.
The valve has been described in terms of a preferred embodiment. Modifications and alternations to this embodiment will be apparent to those skilled in the art in view of this disclosure. It is, therefore, intended that all such equivalent modifications and variations fall within the spirit and scope of the present invention as claimed.
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A pressure insensitive, fail-safe subsea valve is disclosed. The valve is manipulator operable for deep water application and does not require conventional diving techniques to install, maintain or remove. The valve is pressure balanced by employing a hollow valve stem which equalizes the pressure on both ends of the stem.
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BACKGROUND
The present disclosure relates generally to mobile devices, and in particular to techniques for locating quality mobile communication signals for mobile devices.
Computers and other electronic devices can communicate with each other over networks such as local area networks, wide area networks, and the Internet. Mobile devices such as cell phones, including so-called smart phones, can communicate with each other wirelessly over a variety of wireless networks including 3G and 4G networks. The quality of communications over such wireless networks typically depends strongly on the strength of the wireless network signal. As a mobile device travels farther and farther away from a wireless network signal transmitter/receiver, such as a cell phone tower or WiFi access point, the wireless network signal coming from that transmitter/receiver becomes weaker and weaker. Additionally, if the line of sight between a mobile device and a wireless network signal transmitter/receiver becomes obstructed—such as might occur if the mobile device were to enter a deep valley or pass around a high mountain—then the wireless network signal coming from that transmitter/receiver can be weakened significantly. Some geographical locations may be so remote, undeveloped, and/or obstructed that it may be impossible for a mobile device to receive any wireless network signal at all. Weakened wireless network signals may at first cause the mobile device's audio communications (e.g., cellular telephone calls) to become audibly choppy, and then later may cause the mobile device's audio communications to terminate completely (leading to dropped cellular telephone calls). Weakened wireless network signals also may require data packet communications to be retransmitted, since some data packets may become dropped while the wireless network signal is weak, resulting in reduced data bandwidth and slower data transmission.
The modern world has become an increasingly busy place, often requiring people to find time to communicate during times that those people are traveling. While a person is traveling in an automobile or on a train, that person might be conducting a telephone call or transmitting and receiving packetized data through his mobile device. The information involved in the person's communications might be important and time-sensitive, such that interruption of those communications could cause considerable hardship to the person. Unfortunately, the fairly fast speeds and which automobiles and trains travel, combined with the often limited communication range of wireless network signal transmitters/receivers, sometimes further complicated by highly varied types of geographical terrain in some regions, can unexpectedly lead to a much-weakened wireless network signal right in the middle of the communication session that a traveling person is conducting using his mobile device. When such communication sessions are lengthy in duration, and when the route of travel is long, the opportunities for dropped calls and/or poor packetized data transmissions can become irritatingly frequent. A traveling person needing to conduct an important but lengthy communication session using his mobile device often will have a difficult time planning an opportune time to engage in that session.
SUMMARY
Certain embodiments of the present invention can enable a mobile device, such as a so-called smart phone, to obtain wireless network signal strength map data that indicates, for various nearby geographical regions, the wireless network signal strength in each such region. Having obtained such wireless network signal strength map data, such a mobile device can then transmit that data to a vehicular navigation system—potentially a software application executing on the mobile device itself or a hardware component built-in to a vehicle in which the mobile device's user is traveling. The vehicular navigation system, which is responsible for automatically selecting a high-quality route of vehicular travel between a specified source and destination, can take the wireless network signal map data into account when selecting that route. For example, when selecting from among multiple different routes of vehicular travel between a specified source and destination, the vehicular navigation system may employ an algorithm that gives some weight to wireless network signal strengths along those routes, in addition to the other factors that such a vehicular navigation usually considers (e.g., distance, speed limits, current traffic congestion, etc.). Depending on the importance given to having a strong wireless network signal during a trip, the vehicular navigation system can select a longer, slower route having better total wireless network signal strength over a shorter, faster route having worse total wireless network signal strength. The vehicular navigation system can then suggest the selected route to the system's user or present the selected route to the system's user within a set of multiple different suggested routes, potentially along with reasons for each route's suggestion.
Certain embodiments of the invention can provide the user of a mobile device with information that the user can employ in choosing his own route, or in choosing when and where to begin conducting a wireless communication session (e.g., a cellular telephone call or a packetized data transmission session) using his mobile device. For example, after obtaining wireless network signal strength map data as discussed above, a mobile device can display a graphical map that indicates, for each geographical region nearby to the mobile device's current location, an indication of the current wireless signal strength for that geographical region.
The following detailed description together with the accompanying drawings will provide a better understanding of the nature and advantages of the present invention.
BRIEF DESCRIPTION
FIG. 1 is a block diagram of a computer system according to an embodiment of the present invention.
FIG. 2 is a flow diagram illustrating an example of a technique whereby a vehicular navigation system can select a vehicular travel route based at least in part on the wireless network signal strength along that route, according to an embodiment of the invention.
FIG. 3 is a flow diagram illustrating an example of a technique 300 whereby a mobile device collects wireless network signal strength data for transmission to server, according to an embodiment of the invention.
FIG. 4 is a block diagram illustrating an example of a system 400 in which embodiments of the invention can be implemented.
DETAILED DESCRIPTION
FIG. 1 illustrates a computing system 100 according to an embodiment of the present invention. Computing system 100 can be implemented as any of various computing devices, including, e.g., a desktop or laptop computer, tablet computer, smart phone, personal data assistant (PDA), or any other type of computing device, not limited to any particular form factor. Computing system 100 can include processing unit(s) 105 , storage subsystem 110 , input devices 120 , display 125 , network interface 135 , a camera 145 , and bus 140 . Computing system 100 can be an iPhone or an iPad.
Processing unit(s) 105 can include a single processor, which can have one or more cores, or multiple processors. In some embodiments, processing unit(s) 105 can include a general-purpose primary processor as well as one or more special-purpose co-processors such as graphics processors, digital signal processors, or the like. In some embodiments, some or all processing units 105 can be implemented using customized circuits, such as application specific integrated circuits (ASICs) or field programmable gate arrays (FPGAs). In some embodiments, such integrated circuits execute instructions that are stored on the circuit itself. In other embodiments, processing unit(s) 105 can execute instructions stored in storage subsystem 110 .
Storage subsystem 110 can include various memory units such as a system memory, a read-only memory (ROM), and a permanent storage device. The ROM can store static data and instructions that are needed by processing unit(s) 105 and other modules of computing system 100 . The permanent storage device can be a read-and-write memory device. This permanent storage device can be a non-volatile memory unit that stores instructions and data even when computing system 100 is powered down. Some embodiments of the invention can use a mass-storage device (such as a magnetic or optical disk or flash memory) as a permanent storage device. Other embodiments can use a removable storage device (e.g., a floppy disk, a flash drive) as a permanent storage device. The system memory can be a read-and-write memory device or a volatile read-and-write memory, such as dynamic random access memory. The system memory can store some or all of the instructions and data that the processor needs at runtime.
Storage subsystem 110 can include any combination of computer readable storage media including semiconductor memory chips of various types (DRAM, SRAM, SDRAM, flash memory, programmable read-only memory) and so on. Magnetic and/or optical disks can also be used. In some embodiments, storage subsystem 110 can include removable storage media that can be readable and/or writeable; examples of such media include compact disc (CD), read-only digital versatile disc (e.g., DVD-ROM, dual-layer DVD-ROM), read-only and recordable Blu-Ray® disks, ultra density optical disks, flash memory cards (e.g., SD cards, mini-SD cards, micro-SD cards, etc.), magnetic “floppy” disks, and so on. The computer readable storage media do not include carrier waves and transitory electronic signals passing wirelessly or over wired connections.
In some embodiments, storage subsystem 110 can store one or more software programs to be executed by processing unit(s) 105 . “Software” refers generally to sequences of instructions that, when executed by processing unit(s) 105 cause computing system 100 to perform various operations, thus defining one or more specific machine implementations that execute and perform the operations of the software programs. The instructions can be stored as firmware residing in read-only memory and/or applications stored in magnetic storage that can be read into memory for processing by a processor. Software can be implemented as a single program or a collection of separate programs or program modules that interact as desired. Programs and/or data can be stored in non-volatile storage and copied in whole or in part to volatile working memory during program execution. From storage subsystem 110 , processing unit(s) 105 can retrieves program instructions to execute and data to process in order to execute various operations described herein.
A user interface can be provided by one or more user input devices 120 , display device 125 , and/or and one or more other user output devices (not shown). Input devices 120 can include any device via which a user can provide signals to computing system 100 ; computing system 100 can interpret the signals as indicative of particular user requests or information. In various embodiments, input devices 120 can include any or all of a keyboard, touch pad, touch screen, mouse or other pointing device, scroll wheel, click wheel, dial, button, switch, keypad, microphone, and so on.
Display 125 can display images generated by computing system 100 and can include various image generation technologies, e.g., a cathode ray tube (CRT), liquid crystal display (LCD), light-emitting diode (LED) including organic light-emitting diodes (OLED), projection system, or the like, together with supporting electronics (e.g., digital-to-analog or analog-to-digital converters, signal processors, or the like). Some embodiments can include a device such as a touchscreen that function as both input and output device. In some embodiments, other user output devices can be provided in addition to or instead of display 125 . Examples include indicator lights, speakers, tactile “display” devices, printers, and so on.
In some embodiments, the user interface can provide a graphical user interface, in which visible image elements in certain areas of display 125 are defined as active elements or control elements that the user can select using user input devices 120 . For example, the user can manipulate a user input device to position an on-screen cursor or pointer over the control element, then click a button to indicate the selection. Alternatively, the user can touch the control element (e.g., with a finger or stylus) on a touchscreen device. In some embodiments, the user can speak one or more words associated with the control element (the word can be, e.g., a label on the element or a function associated with the element). In some embodiments, user gestures on a touch-sensitive device can be recognized and interpreted as input commands; these gestures can be but need not be associated with any particular array in display 125 . Other user interfaces can also be implemented.
Network interface 135 can provide voice and/or data communication capability for computing system 100 . In some embodiments, network interface 135 can include radio frequency (RF) transceiver components for accessing wireless voice and/or data networks (e.g., using cellular telephone technology, advanced data network technology such as 3G, 4G or EDGE, WiFi (IEEE 802.11 family standards, or other mobile communication technologies, or any combination thereof), GPS receiver components, and/or other components. In some embodiments, network interface 135 can provide wired network connectivity (e.g., Ethernet) in addition to or instead of a wireless interface. Network interface 135 can be implemented using a combination of hardware (e.g., antennas, modulators/demodulators, encoders/decoders, and other analog and/or digital signal processing circuits) and software components.
Bus 140 can include various system, peripheral, and chipset buses that communicatively connect the numerous internal devices of computing system 100 . For example, bus 140 can communicatively couple processing unit(s) 105 with storage subsystem 110 . Bus 140 also connects to input devices 120 and display 125 . Bus 140 also couples computing system 100 to a network through network interface 135 . In this manner, computing system 100 can be a part of a network of multiple computer systems (e.g., a local area network (LAN), a wide area network (WAN), an Intranet, or a network of networks, such as the Internet. Any or all components of computing system 100 can be used in conjunction with the invention.
A camera 145 also can be coupled to bus 140 . Camera 145 can be mounted on a side of computing system 100 that is on the opposite side of the mobile device as display 125 . Camera 145 can be mounted on the “back” of such computing system 100 . Thus, camera 145 can face in the opposite direction from display 125 . Camera 145 can continuously capture video images of the scene that currently is visible behind computing system 100 , from the perspective of the user that is looking at display 125 .
Some embodiments include electronic components, such as microprocessors, storage and memory that store computer program instructions in a computer readable storage medium. Many of the features described in this specification can be implemented as processes that are specified as a set of program instructions encoded on a computer readable storage medium. When these program instructions are executed by one or more processing units, they cause the processing unit(s) to perform various operation indicated in the program instructions. Examples of program instructions or computer code include machine code, such as is produced by a compiler, and files including higher-level code that are executed by a computer, an electronic component, or a microprocessor using an interpreter.
Through suitable programming, processing unit(s) 105 can provide various functionality for computing system 100 . For example, processing unit(s) 105 can execute a wireless network signal strength map-gathering application.
It will be appreciated that computing system 100 is illustrative and that variations and modifications are possible. Computing system 100 can have other capabilities not specifically described here (e.g., mobile phone, global positioning system (GPS), power management, one or more cameras, various connection ports for connecting external devices or accessories, etc.). Further, while computing system 100 is described with reference to particular blocks, it is to be understood that these blocks are defined for convenience of description and are not intended to imply a particular physical arrangement of component parts. Further, the blocks need not correspond to physically distinct components. Blocks can be configured to perform various operations, e.g., by programming a processor or providing appropriate control circuitry, and various blocks might or might not be reconfigurable depending on how the initial configuration is obtained. Embodiments of the present invention can be realized in a variety of apparatus including electronic devices implemented using any combination of circuitry and software.
FIG. 4 is a block diagram illustrating an example of a system 400 in which embodiments of the invention can be implemented. System 400 includes a remote server 402 that is communicatively coupled via one or more wireless networks to a mobile device 404 such as a cellular telephone, smart phone, or other kind of mobile device. Mobile device 404 is communicatively coupled, either wirelessly or via a guided medium, to a vehicular navigation system 406 . Examples of behaviors of each of these components of system 400 are described in further detail below.
Vehicular Navigation System Using Wireless Network Signal Strength
FIG. 2 is a flow diagram illustrating an example of a technique 200 whereby a vehicular navigation system can select a vehicular travel route based at least in part on the wireless network signal strength along that route, according to an embodiment of the invention. In block 202 , a mobile device, such as a smart phone, can request wireless network signal strength map data over a wireless network from a remote server. The request can indicate the mobile device's current geographical location. The mobile device can determine its current geographical location using the mobile device's built-in global positioning system (GPS). In block 204 , the mobile device can receive the wireless network signal strength map data over the wireless network in response to the mobile device's request. The wireless network signal strength map data can indicate, for multiple geographical regions within a specified distance from the mobile device's current geographical location, a current wireless network signal strength in each such region. In block 206 , the mobile device can transmit the wireless network signal strength map data to a vehicular navigation system of an automobile or other vehicle. The mobile device can transmit this map data wirelessly to the vehicular navigation system using Bluetooth communication technology or other wireless network communication technology. Alternatively, the mobile device can transmit the map data over a guided medium, such as a universal serial bus (USB) cable, to a vehicular navigation system to which the mobile device is currently and temporarily tethered via the guided medium.
In block 208 , the vehicular navigation system can receive the map data from the mobile device. In block 210 , the vehicular navigation system can determine one or more routes along available travel channels (e.g., streets, roads, highways, railways, subways, etc.) from the mobile device's (and, presumably, the vehicle's) current geographical location, or another specified source location, to a specified destination. In block 212 , the vehicular navigation system can calculate, for each such route, a score based at least in part on the wireless network signal strengths of the regions through which that route passes. Routes passing through regions having total higher wireless network signal strength can be scored more favorably than routes passing through regions having total lower network signal strength. In determining the score for a particular route, the vehicular navigation system can compute a sub-score for each geographical region through which the particular route passes by multiplying the wireless network signal strength level of that geographical region (from the map data) by the quantity of time that the vehicle is predicted to travel through that geographical region on the particular route (e.g., based on the length of that segment of the particular route and the speed limits along that segment of the particular route). The vehicular navigation system can then calculate the sum of the sub-scores as a part of computing the score for the particular route. In determining the score for a particular route, the vehicular navigation system also can take into account other factors such as the total length of the particular route and the estimated time that the vehicle is predicted to require to traverse the particular route. Each factor, including those based on wireless network signal strength, can be multiplied by a different specified weighting factor. These specified weighting factors can be specified by the user of the mobile device or the user of the vehicular navigation system.
In block 214 , the vehicular navigation system sorts the multiple routes for which scores have been calculated based on the calculated scores for those routes. In block 216 , the vehicular navigation system presents, to a user of the vehicular navigation system, one or more suggested routes from the specified source (potentially the mobile device's and/or vehicle's current geographical location) to the specified destination. The vehicular navigation system may present, as the suggested routes, the routes having the top N highest scores, where N is some specified quantity. The vehicular navigation system may present the routes on a geographical map shown on a graphical display of the system (e.g., a liquid crystal display (LCD), a light-emitting diode (LED) display, a cathode ray tube (CRT), etc.). The geographical map can depict the available travel channels from the specified source to the specified destination. The geographical map can highlight routes that are among the suggested routes. For each such route, the geographical map can indicate (a) a distance of that route, (b) a required time estimate to travel that route, (c) a wireless network signal strength score for that route, and/or other information pertaining to that route.
In one embodiment of the invention, the geographical map visually distinguishes each geographical region on the map based on that region's wireless network signal strength. For example, a spectrum of colors, ranging from green through yellow to red, can indicate a spectrum of wireless network signal strengths, from strong (green) through medium (yellow) to weak (red). Each geographical region on the map can be painted in a color that is representative of that region's wireless network signal strength. The color for a region can be constant throughout the region or may be a gradient reflecting the weakening of a wireless network signal as the distance increases from that signal's point of origin within the region. Wireless network signal transmitters/receivers, such as cell phone towers and WiFi access points, also can be indicated symbolically on the map. In one embodiment of the invention, instead of complete geographical regions on the map, only route segments of the suggested routes are colorized based on the foregoing scheme, so that the viewer of the map gains a clear understanding of how strong a wireless network signal is for each segment of each suggested route.
According to one embodiment of the invention, the technique described above is repeated periodically or constantly during the duration of a trip. For example, as the vehicle travels, the mobile device can request and receive fresh wireless network signal strength map data from the server repeatedly over time. As circumstances change (e.g., due to wireless network congestion, hardware failures, weather interference, or other factors), the most current wireless signal strength map data can vary from previously received wireless signal strength map data. The mobile device can transmit each refreshed instance of the wireless signal strength map data to the vehicular navigation system. In response to receiving revised wireless signal strength map data, the vehicular navigation system can re-compute scores for available routes from the mobile device's or vehicle's current geographical location to the specified destination. The re-computed scores can lead the vehicular navigation system to suggest different routes than those that the vehicular navigation system previously suggested. In one embodiment of the invention, if the vehicular navigation system determines that a particular route other than the current route on which the vehicle is currently traveling has a higher score than the current route, then the vehicular navigation system can audibly and/or visually alert the user of the vehicular navigation system that a more preferable route than the currently traveled route may be available.
Collecting Wireless Network Signal Strength Map Data
In an embodiment of the invention discussed above, a mobile device can request wireless network signal strength map data over a wireless network from a remote server at which such map data is stored. There are various ways in which such map data can be generated for storage at the remote server. Indeed, in one embodiment of the invention, a mobile device does not need to contact the remote server at all, but instead can collect and use wireless network signal strength map data that it has collected and stored based on its own historical experiences alone. In an alternative embodiment of the invention, many separate mobile devices can cooperatively collect such data based on their own historical experiences and wirelessly upload that data to the remote server, where the data from all of the mobile devices can be aggregated in order to obtain potentially more accurate, more complete, and more current map data that then can be distributed wirelessly back to requesting mobile devices.
FIG. 3 is a flow diagram illustrating an example of a technique 300 whereby a mobile device collects wireless network signal strength data for transmission to server, according to an embodiment of the invention. In block 302 , the mobile device can determine its current geographical location. The mobile device can determine its current geographical location using a built-in GPS of the mobile device. In block 304 , the mobile device can determine a current wireless network signal strength for its current geographical location. There are various ways in which such a signal strength can be determined. For example, the mobile device can determine the signal strength based at least in part on a value that is used to compute the number of signal strength bars that smart phones typically present on their displays. For another example, the mobile device can determine the signal strength based at least in part on whether a previously ongoing call has now been dropped, indicating that the signal strength at the current geographical location is poor. For another example, the mobile device can determine the signal strength based at least in part on a quantity of dropped or re-requested data packets during a packetized data communication session. For another example, the mobile device can determine the signal strength based at least in part on an estimated bandwidth or data transmission rate during a packetized data communication session. In block 306 , the mobile device can store, in its local memory, a mapping between the current geographical location, the current wireless network signal strength rating (e.g., a quantitative or qualitative value), the current date, and the current time of day.
In block 308 , the mobile device can wirelessly transmit the mappings stored in its local memory over a wireless network to a remote server. The mobile device can transmit these mappings periodically, or in response to an instruction by the mobile device's user, or in response to some other specified event. Once received at the remote server, the server can store these mappings in a database maintained by the server. The remote server can populate this database continuously with mappings of this kind received from multiple separate mobile devices at various different times. The remote server can aggregate this data in order to calculate, for each particular geographical location for which one or more mappings have been received, an estimated current wireless network signal strength for that particular geographical location. In performing this aggregation, the remote server can give greater weight to mappings bearing more recent timestamps than it gives to mappings bearing less recent timestamps. The remote server can distill and segregate the aggregated data in various ways. For example, for a particular geographical location, the server can calculate average signal strengths for a particular time of day on a particular day of the week, such that each time of day for each particular day of the week can have a separate aggregated wireless network signal strength rating for the same particular geographical location.
In response to requests for wireless network signal strength map data received from mobile devices, the remote server can provide all or a relevant portion or “slice” of the aggregated map data. The remote server can “slice” the aggregated map data for service to the requesting mobile device in various different ways. For example, the remote server can provide aggregated map data that pertains only to the geographical regions that are within a specified distance away from the requesting mobile device's current geographical location. For another example, the remote server can provide aggregated map data that pertains only to the current time of day and/or day of the week. For another example, the remote server can provide aggregated map data that pertains only to the current calendar date. As is discussed above, in response to receiving such wireless network signal strength map data, a vehicular navigation system in communication with a mobile device that requested the map data can calculate scores for different routes from a specified source to a specified destination.
As is described above, in one embodiment of the invention, a mobile device requests wireless network signal strength map data wirelessly from a remote server. However, in an alternative embodiment, the mobile device can supply, to the vehicular navigation system, the mapping data that it has collected individually, lacking mapping data from any other mobile device, and stored in its local memory over time. This technique can be especially beneficial during moments that wireless communication with the remote server is unavailable to the mobile device. For example, if the mobile device has traveled along a particular route a dozen times, then the mobile device can have accumulated wireless network signal strength data for each geographical point along that route a dozen times. If the mobile device has traveled several different routes, then the mobile device can have accumulated wireless network signal strength data for each geographical point along each of those different routes. For each geographical point along each route that the mobile device has previously traveled, the mobile device can aggregate the wireless network signal strength data mapped to that geographical point in the mobile device's memory in order to produce a locally generated wireless network signal strength map. The mobile device can transmit this locally generated map data to the vehicular navigation system for its use in lieu of map data downloaded from the remote server. As in other embodiments, the mobile device can provide greater weight to more recent signal strength measurements than it provides to less recent signal strength measurements.
In certain embodiment of the invention discussed above, wireless network signal strength map data can be generated based on quality measurements actually obtained in the experiences of one or more mobile devices over time. However, in alternative embodiments of the invention, such wireless network signal strength map data can be generated based additionally or alternatively upon other data sources. For example, various cell phone companies can already have data pertaining to the wireless network signal strengths within different areas of their own networks. In one embodiment of the invention, the server described above can request and obtains such signal strength data from each cell phone company that is willing to provide that data to the server. The server can request and obtain refreshed data from the cell phone companies periodically or continuously. The server can aggregate and segregate the wireless signal strength data based on the wireless network of the cell phone company from which that data was received. For example, the server can aggregate all signal strength data from one cell phone company separately from all signal strength data from another cell phone company. In one embodiment of the invention, a mobile device's request for wireless network signal strength map data also can identify the particular cell phone company that provides the wireless network that the mobile device exclusively uses. In response to such a request, the server can return, to the mobile device, wireless network map data that pertains only to the particular cell phone company's wireless networks, excluding data that pertains to wireless networks of other cell phone companies.
Embodiments of the present invention can be realized using any combination of dedicated components and/or programmable processors and/or other programmable devices. The various processes described herein can be implemented on the same processor or different processors in any combination. Where components are described as being configured to perform certain operations, such configuration can be accomplished, e.g., by designing electronic circuits to perform the operation, by programming programmable electronic circuits (such as microprocessors) to perform the operation, or any combination thereof. Further, while the embodiments described above can make reference to specific hardware and software components, those skilled in the art will appreciate that different combinations of hardware and/or software components can also be used and that particular operations described as being implemented in hardware might also be implemented in software or vice versa.
Computer programs incorporating various features of the present invention can be encoded and stored on various computer readable storage media; suitable media include magnetic disk or tape, optical storage media such as compact disk (CD) or DVD (digital versatile disk), flash memory, and other non-transitory media. Computer readable media encoded with the program code can be packaged with a compatible electronic device, or the program code can be provided separately from electronic devices (e.g., via Internet download or as a separately packaged computer-readable storage medium).
Thus, although the invention has been described with respect to specific embodiments, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.
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A mobile device can obtain wireless network signal strength map data that indicates, for various nearby geographical regions, the wireless network signal strength in each such region. A mobile device can transmit that data to a vehicular navigation system responsible for automatically selecting a high-quality route of vehicular travel between a specified source and destination. The system can take the wireless network signal map data into account when selecting that route. When selecting from among multiple different routes of vehicular travel between a specified source and destination, the system may employ an algorithm that considers wireless network signal strengths along those routes, in addition to the other factors. Consequently, the system can select a longer route having better signal strength over a shorter route having worse signal strength. The system can present the selected route within a set of suggested routes, potentially along with reasons for each route's suggestion.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present patent application is a continuation of and claims priority from patent application Ser. No. 11/037,387, filed on Jan. 18, 2005 and titled COMBINED BASE TRANSCEIVER STATION AND BASE STATION CONTROLLER DATA CALL AND QUALITY OF SERVICE, the contents of which are enclosed by reference herein. The present patent application is related to patent application Ser. No. 11/037,063 filed on Jan. 18, 2005 entitled Combined Base Transceiver Station and Base Station Controller, patent application Ser. No. 11/037,813 filed on Jan. 18, 2005 entitled Combined Base Transceiver Station and Base Station Controller Call Origination and Termination, patent application Ser. No. 11/037,814 filed on Jan. 18, 2005 entitled Combined Base Transceiver Station and Base Station Controller Handoff, patent application Ser. No. 11/037,386 filed on Jan. 18, 2005 now issued U.S. Pat. No. 7,509,128 entitled Combined Base Transceiver Station and Base Station Controller Data Call, and patent application Ser. No. 11/07,388 filed on Jan. 18, 2005 entitled Combined Base Transceiver Station and Base Station Controller Optimized Assignment Of Frame Offsets, each of which is assigned to the assignee of the present invention.
BACKGROUND OF THE INVENTION
[0002] The present invention is related to a base transceiver station and a base station controller, and, more specifically to a combined base transceiver station and a base station controller.
[0003] Current cellular operators predominantly provide services via very large or macro coverage areas. Limitations encountered by these operators include the difficulty of providing reliable in-building or campus coverage. Such coverage should provide subscribers with seamless services at a particular quality level, and should provide operators with additional revenue sources.
[0004] Therefore, what is needed is a wireless solution that overcomes the aforementioned limitations by providing a micro solution that compliments the wireless macro network by providing increased voice and data capacity and coverage.
SUMMARY OF THE INVENTION
[0005] The present invention provides a radio access network (RAN) system (which contains a base transceiver station and a base station controller integrated into a single compact platform) for wireless coverage and in-building services, as well as for providing additional capacity in a macro network when it comes to filling “hotspots.” Such a RAN system, which preferably operates in or in conjunction with a CDMA network, supports signaling, traffic, handoff, power, and control, while providing multiple interfaces to the core network.
[0006] In one embodiment, a method for determining a data call rate comprises determining if a supplemental channel (SCH) should be allocated, if the SCH should be allocated, potentially altering the data rate, requesting an SCH allocation at a current data rate or the altered data rate, and receiving a response to the request with the current data rate, the altered data rate, or a further altered data rate.
[0007] In another embodiment, a system for determining a data call rate comprises a base station controller (BSC) adapted to determine if a supplemental channel (SCH) should be allocated, a base transceiver station (BTS) adapted to receive an SCH allocation at a current data rate or an altered data rate from the BSC, and the BSC adapted to receive the current data rate, the altered data rate, or a further altered data rate from the BTS.
[0008] In a further embodiment, a computer readable medium comprises instructions for: determining if a supplemental channel (SCH) should be allocated, requesting an SCH allocation at a current data rate or an altered data rate, and receiving a response to the request with the current data rate, the altered data rate, or a further altered data rate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 depicts a radio access network (RAN) in accordance with a preferred embodiment of the present invention;
[0010] FIG. 2 depicts a stackable RAN in accordance with a preferred embodiment of the present invention;
[0011] FIG. 3 depicts a further stackable RAN in accordance with a preferred embodiment of the present invention;
[0012] FIG. 4 depicts a message flow of a data call setup in accordance with a preferred embodiment of the present invention;
[0013] FIG. 5 depicts a message flow of a data call using a forward supplemental channel in accordance with a preferred embodiment of the present invention;
[0014] FIG. 6 depicts a message flow of a data call using a reverse supplemental channel in accordance with a preferred embodiment of the present invention;
[0015] FIG. 7 depicts a Quality of Service flow chart for a data call in accordance with a preferred embodiment of the present invention;
[0016] FIG. 8 depicts a table indicating a supplemental channel (SCH) rate for a data call in accordance with a preferred embodiment of the present invention;
[0017] FIG. 9 depicts a plurality of tables that describe each attempted FCH calls in accordance with a preferred embodiment of the present invention; and
[0018] FIG. 10 depicts a maximum SCH rate for plurality of data call attempts in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring now to FIG. 1 , radio access network (RAN) 10 comprises a base station controller (BSC) 12 and a base transceiver station (BTS) 14 that comprise a number of blocks or modules. These blocks or modules are software, hardware, firmware, and/or a combination of software, hardware, and/or firmware. The BSC 12 comprises a selector distribution unit (SDU) 20 coupled to a main call control (MCC) 22 and to a packet control function (PCF) 24 which is also coupled to the MCC 22 , a signaling control connection part (SCCP) 26 coupled to an interoperability system (IOS) 28 which is also coupled to the MCC 22 , a call agent simulator (CA_SIM) 30 which is coupled to the SCCP 26 , and an operation, administration, and maintenance (OA&M) 32 module coupled to the PCF 24 .
[0020] Main Call Control (MCC) 22
[0021] The MCC 22 , which performs the operations that pertain to individual subscribers including registration, call setup, call release, handoff and other subscriber features, is associated with the following functionality:
[0022] Registration
[0023] Mobile registration is a process where mobile characteristics such as location or status are provided to the network. Registration may be initiated by a mobile station (MS, not shown), by a network, or implied during access by the MS. To support these features, the MCC 22 interfaces with a radio call control module (RCC) 18 , which will be described further below, and with a call agent (CA) 104 . The CA 104 is preferably a soft switch whose functions include call processing, supplementary service, registration, interacts with a Home Location Register (HLR) in the macro network, and provides common PBX functions.
[0024] Mobile Originated Call Setup for Voice and Circuit Data Calls
[0025] The MCC 22 receives an Origination Message from the MS via the RCC 18 and then communicates with CA 104 to request call service, confirm the validity of the MS, as well as get the resource information from a media gateway (MG, not shown). The MG mediates the elements between circuit switched voice networks and an IP network. For example, the MG relays voice, fax, modem and data traffic over the EP network. The MCC 22 interfaces with the RCC 18 to request a radio resource and with the SDU 20 to allocate a selector resource.
[0026] Mobile Terminated Call Setup for Voice and Calls and Circuit Data Calls
[0027] The MCC 22 receives a Paging Request message from the CA 104 and passes it to the RCC 18 to initiate a mobile terminated call setup scenario. The MCC 22 receives a Page Response Message then communicates with the CA 104 to get the resource information from the MG and indicate for the call to be answered at the MS. The MCC 22 interfaces with the RCC 18 to request a radio resource and with the SDU 20 to allocate a selector resource.
[0028] Call Clearing of Voice and Circuit Data Calls
[0029] Call clearing may be initiated by either the MS, the SDU 20 or the CA 104 . The MCC 22 sends clear messages to the SDU 20 or to the CA 104 and releases internal resources.
[0030] Mobile Originated Call Setup for Packet Data Calls
[0031] The MCC 22 receives an Origination Message from the MS via the RCC 18 with a data rate to send set to ‘true’ (DRS=1) and a packet data service option, and then communicates with the CA 104 to request packet data service and confirm the validity of the MS. The MCC 22 interfaces with the PCF 24 to setup a connection to a packet data serving node (PDSN) 101 , which exchanges packets with the MS over the radio and the other IP networks, with the RCC 18 to requests a radio resource, and with the SDU 20 to allocate a selector resource.
[0032] Reactivation of Packet Data Calls
[0033] The MCC 22 supports either the MS initiated or network initiated reactivation from a dormant state. With a MS initiated reactivation, a normal packet data call setup procedure in the MCC ensues, while with a network initiated reactivation, the MCC 22 sends a base station (BS, not shown) Service Request to the CA 104 to begin an initiated call setup as a request from the PCF 24 . The BS, which is a fixed station that communicates with the MS, may be a cell, a sector within a cell, a mobile switching center (MSC), or other part of the wireless system.
[0034] Call Clearing of Packet Data Calls
[0035] Call clearing may be initiated by either the MS, the SDU 20 , the CA 104 or the PCF 24 . During a call clearing scenario, the MCC 22 sends clear messages to the SDU 20 , the CA 104 and the PCF 24 and releases internal resources.
[0036] Transition to Dormancy for Packet Data Calls
[0037] If the MS transits to a Dormant State, the MCC 22 proceeds in a normal packet call release scenario and notifies the CA while setting the release cause to “packet call going dormant.” The MCC 22 also supports Dormant Handoff.
[0038] Short Data Bursts
[0039] The MCC 22 supports a Short Data Burst which consists of a small number of frames that are transmitted to a MS with a dormant packet data service instance.
[0040] Inter-BS Handoff
[0041] The MCC 22 supports soft handoff, inter-frequency assignment (FA) hard handoff and intra-FA hard handoff. The MCC 22 interfaces with the RCC 18 to get radio resources as request from the SDU 20 and manages neighbor lists.
[0042] Inter-CA Hard Handoff
[0043] When the MCC 22 receives a handoff request message from the SDU 20 and the handoff type is inter-CA hard handoff, the MCC 22 sends a Handoff Required message to the CA 104 to initiate an inter-CA hard handoff as a serving part. If the MCC 22 receives a Handoff Request message from the CA 104 , the MCC 22 initiates an inter-CA hard handoff scenario as a target part.
[0044] Terminal Authentication
[0045] Terminal authentication is the process by which information is exchanged between the MS and the network to confirm the identity of the MS. The MCC 22 delivers relegated messages to the SDU 20 , the RCC 18 and the CA 104 .
[0046] Short Message Service
[0047] Short Message Service (SMS) is a mechanism of delivery of short messages over the mobile network. The MCC 22 supports messages and process for SMS mobile originated calls, SMS mobile terminated calls, and SMS Broadcast calls.
[0048] Supplementary Services
[0049] The MCC 22 supports various supplementary services including Message Waiting, Call Forwarding, Call Delivery, Call Transfer, Three Way Calling, and Conference Calling in terms of communicating with the RCC 18 using a Feature Notification Message or with the SDU 20 using Flash with an Information Message.
[0050] Test Calls
[0051] The MCC 22 initiates the test call process as a request from the base station manager (BSM 99 ) or on receiving an Origination Message with a look back service option from the MS.
[0052] Call Trace
[0053] The MCC 22 initiates the call trace process as a request from the WPM. The MCC 22 stores the related information to a buffer and starts a trace whenever the MS requests call service.
[0054] Selector Distribution Unit (SDU) 20
[0055] The SDU 20 , which includes an air interface portion that processes air messages between the SDU and a MS, a router interface portion that processes messages between the SDU and other software blocks, and a portion that processes voice and data calls, is associated with the following functionality:
[0056] Multiplex and De-Multiplex
[0057] This function multiplexes and de-multiplexes user traffic and signaling traffic for the air interface.
[0058] Forward and Reverse Traffic Frame Selection and Distribution
[0059] This function is responsible for selecting the best quality incoming air interface reverse link frame involved in the soft handoff, and distributes forward air interface frames to all channel elements involved in a call.
[0060] Handoff Type Decision and Handoff Direction
[0061] This function decides a handoff type that will be processed including soft handoff, softer handoff, hard handoff, etc., and directs handoff processing to other software blocks such as the MCC 22 and a traffic channel element (TCE) in the CEC 16 .
[0062] Process Radio Link Protocol (RLP) Procedures
[0063] A RLP Type 1 , 2 , and 3 is used with IS-95A/B or cdma2000 traffic channels to support CDMA data services. The RLP, which is a connection-oriented, negative-acknowledgement based data delivery protocol, provides an octet stream transport service over forward and reverse traffic channels. The RLP includes procedures to reduce the error rate exhibited by CDMA traffic channels.
[0064] Forward and Reverse Power Control
[0065] This function generates or utilizes relevant power control information that is exchanged over the air interface or the channel element.
[0066] Process Test Call Procedures
[0067] This function supports an MS loop-back call, such as a service option 2 and a service option 9 call.
[0068] Process Real Time Protocol (RTP) Procedures
[0069] This function is responsible for interfacing with a MG or other BSCs.
[0070] Process Signaling Layer 2 Procedures
[0071] This function performs the layer 2 functionality of the air interface signaling protocol and is responsible for the reliable delivery of the layer 3 signaling messages between the BSC and the MS.
[0072] Process Generic Routing Encapsulation (GRE) Procedures
[0073] This function is responsible for interfacing with the PDSN 101 .
[0074] Media Gateway (G/W) 103
[0075] The SDU 20 receives data, formats it and then sends it to the GAW 103 . Similarly, data received from the G/W 103 can be formatted by the SDU 20 .
[0076] Signaling Control Connection Part (SCCP) 26
[0077] The SCCP 26 is used to provide a referencing mechanism to identify a particular transaction relating to, for instance, a particular call. The current implementation of the Al interface using TCP/IP protocol employs an SCCP implementation which provides the minimal functionality required to create the CALL context in which to pass IOS messages and monitor the TCP/IP connection. The SCCP 26 is associated with the following functionality:
[0078] TCP/IP Connection Establishment—The SCCP creates a TCP/IP socket as a client to communicate with the CA 104 .
[0079] Signaling Connection Establishment—A new transaction, such as location updating, or an incoming or outgoing call, is initiated on the radio path. Following an Access Request made by the MS on the access channel, the connection establishment is then initiated by the BS. If the CA 104 decides to perform an inter-CA hard handoff, the connection establishment is initiated by the CA 104 .
[0080] Signaling Connection Release
[0081] This procedure is normally initiated at the CA 104 but in the case of abnormal SCCP connection release, the BS may initiate a connection clearing.
[0082] Interoperability System (IOS) 28
[0083] The IOS 28 processes messages from the CA 104 or the MCC 22 and converts between internal message format and standard format. A Base Station Application Part (BSAP) is the application layer signaling protocol that provides messaging to accomplish the functions of the A1 Interface component of the CA—BS Interface. The BSAP is split into two sub-application parts: the BS Management Application Part (BSMAP), and the Direct Transfer Application Part (DTAP). The BSMAP supports all Radio Resource Management and Facility Management procedures between the CA 104 and the BS, or to a cell(s) within the BS. BSMAP messages are not passed to the MS, but are used to perform functions at the CA 104 or the BS. A BSMAP message (Complete Layer 3 Information) is also used together with a DTAP message to establish a connection for a MS between the BS and the CA 104 , in response to the first layer 3 air interface message sent by the MS to the BS for each MS system request. The DTAP messages are used to transfer call processing and mobility management messages between the CA 104 and BS. DTAP messages carry information that is primarily used by the MS. The BS maps the DTAP messages going to and coming from the CA from/into the appropriate air interface signaling protocol.
[0084] The IOS 28 is associated with the following functionality:
[0085] Encoding Messages
[0086] The IOS messages proprietary format from the MCC 22 as the A interface specifications for sending to the CA.
[0087] Decoding Messages
[0088] The IOS 28 converts messages from the CA 104 to internal messages.
[0089] Packet Control Function (PCF) 24
[0090] The PCF 24 is a packet control function to manage the relay of packets between the BS and the PDSN 101 . In a cdma2000 wireless network, access to packet data services is provided by the PDSN 101 . The PCF 24 provides call processing functionality within the Radio Access Network (RAN) interfaces with the PDSN 101 and interfaces with the MCC 22 and the SDU 20 to provide internal signaling and packet delivery. The interface between the PCF 24 and the MCC 22 is called the A9 interface and the interface between the PCF 24 and the SDU 20 is the A8 interface. The interface between the PDSN 101 and the PCF 24 , which is the interface between the radio and packet network, is known as the R-P interface or the A10/A11 interface.
[0091] The PCF 24 is associated with the following functionality: Main Processing which creates tasks and receives messages over IP, Message Processing which generates and extracts message by packing and unpacking, A10/A11 Processing which processes the A10/A11 interface, A8/A9 Processing which processes the A8/A9 interface, Hash Processing which performs the MD5 hashing function, Timer Processing which handles timer set, timer cancel, and timeout processing, Utility for primitives and debugging commands, and Call Control for call processing of originating, terminated and handoff calls.
[0092] Call Agent Simulator (CA SIM) 30
[0093] For wireless voice and data communications, various components, such as the CA 104 in the core network and the IP-BS in the Radio-Access Network, are necessary components. The installation of other components in the core network, such as the CA 104 , a HLR, etc., constitutes a large expense. To increase the efficiency and flexibility, a CA-simulator 30 can be provided so that voice and data calls are possible without connecting to the CA 104 or to an HLR. As such, an IP-BS can be installed in a small wireless network without a CA or HLR.
[0094] Operation, Administration and Maintenance (OAM) 32
[0095] The OAM block 32 is associated with the following functionality: a Configuration Management (CM) block 34 that configures each block or module of the BSC 12 based on program load data (PLD) information (which includes parameters, such as a system ID, an IP address, etc., to configure the system)which can be downloaded from a server, a Status Management (SM) block 36 that obtains a status of the BSC 12 and reports the status to the BSM 99 , and a Fault Management (FM) block 38 that checks and detects system faults or alarms and reports them to the BSM.
[0096] Referring again to FIG. 1 , the radio access network (RAN) 10 further comprises a base transceiver station (BTS) 14 . The BTS 14 comprises a Channel Element Control (CEC) 16 coupled to the Radio Call Control (RCC) 18 , an Operation, Administration and Maintenance (OAM) 52 block coupled to the CEC, to the RCC, and to a Transmit and Receive Interface (TRX) 40 .
[0097] The Channel Element Control (CEC) 16
[0098] The CEC block 16 controls the call processing to interface with the MS. The CEC also interfaces with upper layer blocks to handle over the air messages to set-up, maintain, and terminate voice and data calls. In order to make these calls, both signaling and traffic frames must be transmitted and received to and from the MS. It is also important for these frames to be transmitted and received at the right time with correct information. This is accomplished by using, for example, a modem chip, such as the Qualcomm CSM5000 modem chip 60 , I/F chips 62 , a transceiver 64 and a power amplifier 66 . The components 60 - 66 are predominantly hardware components that can be co-located within the RAN 10 . The CEC block 16 is associated with the following functionality:
[0099] Overhead Channel Configurations
[0100] The CEC 16 receives overhead channel configuration messages from the RCM and sets the parameters to the driver of the modem chip 60 .
[0101] Air Message Encapsulation and Transmission
[0102] The CEC 16 encapsulates and sends a frame for sync channel message transmission (at, for example, every 80 msec) and sends a frame for paging channel message transmission (at, for example, every 20 msec). To transmit each frame of the sync and paging channel, the CEC 16 revokes semaphores periodically by external interrupt request source.
[0103] CSM Built-In Test
[0104] The CEC 16 provides a built-in test function for the modem chip 60 which includes checking a register test, an interrupt test, as well as a reverse ARM test. This test can be performed by an operator's request to show if the modem chip 60 is functioning properly or not.
[0105] Forward and Reverse Power Control
[0106] The CEC 16 supports forward and reverse power control processing.
[0107] Process Time of Day (TOD) Message
[0108] The CEC 16 receives the TOD message via a GPS (at, for example, every 2 sec) and processes it to get the system time and GPS status.
[0109] Process Loopback Call Procedures
[0110] This function supports MS-BTS loop-back call, This function can show if air-interface between MS and BTS works well.
[0111] Process Traffic Channel Processing
[0112] The CEC 16 is responsible for assigning a traffic channel and clearing it by the order of RCC 18 . When the traffic channel is setup, the CEC 16 delivers traffic packets between the SDU 20 and the MS.
[0113] Maintain Forward and Reverse Link
[0114] The CEC 16 checks the forward and reverse path and reports them to a status or statistics block.
[0115] Process High Speed Data Service
[0116] The CEC 16 is responsible for processing supplemental channel (SCH) packets for high speed data service which supports up to, for example, 128 kbps. The SCH packets are used if additional channels are needed to handle the transfer of the data.
[0117] Process Soft and Softer Handoff procedure
[0118] The CEC 16 is responsible for processing Soft and Softer Handoffs.
[0119] Provide H/W Characteristics Test Functionalities
[0120] The CEC 16 supports various hardware characteristics tests such as an access probe test, a AWGN test, etc. Theses tests determine if the RF or the IF properties of each of the basestations are in order to ensure (via, for example, a good path) that messages can be transferred.
[0121] The CSM application 48 is adapted to receive data from the CSM (or modem chip 60 ) Driver 50 .
[0122] Radio Call Control (RCC) 18
[0123] The call control of the air interface is provided by the RCC 18 . The air interface between the MS and the BTS 14 is specified by, for example, the TIA/EIA-95-A/B and the cdma2000 standards, which include the core air interface, minimum performance, and service standards. The functionalities of the RCC 18 consist of call processing, resource management, and supplementary services. The RCC 18 provides call processing functionality in order to setup and release call and resource management of radio resources such as CDMA channels, traffic channel elements, Walsh code channels, frame offsets, etc. The RCC 18 also provides signaling functionality by interfacing with other relevant software blocks.
[0124] The RCC 18 provides various processing functions including: Main Processing which creates tasks and receives messages over IP, Resource Management which processes resource allocation and de-allocation, Message Processing which generates and extracts message by packing and unpacking, Initialization Processing which initializes buffers and variables, RCV. from RSCH processing which processes all messages on the reverse common signaling channel, RCV. from RDCH processing which processes some messages on the reverse dedicated signaling channel, RCV. from MCC processing which processes all messages from the MCC, SND. to FSCH processing which processes all messages sent to MS on the forward common signaling channel, SND. to FDCH processing which processes some messages sent to MS and CEC on forward dedicated signaling channel, SND. to MCC processing which processes all messages sent to the MCC, Layer 2 Processing which processes Layer 2 information, Hash Processing which performs the hash function to decide CDMA channel and Paging Channel number, Timer Processing which handles timer set, timer cancel, and timeout processing, and Utility which provides primitives and debugging commands.
[0125] Transmit and Receive Interface (TRX) 40
[0126] The TRX block 40 controls and diagnoses hardware devices in the BTS 14 , and includes:
[0127] The PUC/PDC Block 42
[0128] The PUC/PDC 42 up-converts and down-converts between a baseband signal and an IF signal.
[0129] The Transceiver Control (XCVR) Block 44
[0130] The Transceiver Control Block (XCVR) 44 controls transceiver operations which carry IF signals to a carrier frequency band.
[0131] AMP Control Block
[0132] For high power amplification of the signal, the IP-BS provides the interface to the AMP. The AMP control block controls AMP operations such as ON/OFF.
[0133] Hardware Diagnostic Test Module
[0134] The diagnostic test module provides the functionalities for hardware characteristics test of pn3383 such as AWGN test, access probe test, etc. For example, the pn3383 test implements test environment conditions.
[0135] The power amplifier (PA) 66 , via the RRCU 46 , amplifies the output signal because the output of the XCVR 44 tends to be small. As such, a broader coverage area is possible.
[0136] Operation, Administration and Maintenance (OAM) Block 52
[0137] The OAM block 32 is associated with the following functionality: a Configuration Management (CM) block 34 that configures each block or module of the BTS 14 based on program load data (PLD) information (which includes parameters, such as a system ID, an IP address, etc., to configure the system) received from the BSM (or IP-BS) 99 , a Status Management (SM) block 36 that obtains a status of the BTS 14 and reports the status to the BSM, and a Fault Management (FM) block 38 that checks and detects system faults or alarms and reports them to the BSM.
[0138] Referring now to FIG. 2 , the components of a stackable IP Radio Access Network (RAN) 70 are depicted. The blocks in the RAN 70 perform a similar functionality to their respective blocks in the RAN 10 . Such a stackable RAN 70 provides increased bandwidth and redundancy without utilizing a card based expansion scheme as has been previously employed. Rather, the RAN 70 is modular and stackable (in a very small footprint) and includes a control portion (the Main Control Processor (MCP)) 72 and a device portion (the SDU/CEC Processor (SCP)) 74 . With a centralized control portion 72 , various device portions 74 can be utilized with a single control portion.
[0139] A difference between the RAN 70 and the RAN 10 is that the SDU 20 is now co-located with the CEC 16 , and the RCC 18 is co-located with the MCC 22 . As such, messaging between these co-located blocks is decreased providing an increase in system performance.
[0140] Referring now to FIG. 3 , a stackable configuration 80 of the RAN of the present invention is depicted. The configuration 80 includes a RAN 70 that includes a master MCP 72 and a RAN 70 ′ that includes a slave MCP 72 . The master and slave MCPs preferably have the same IP address for redundancy. If the master MCP fails, a seamless transition to the slave MCP occurs. Backhaul timing is a limited issue because information is transferred between a BTS and a BSC in one “box” and not across a longer distance as with a typical network. The configuration 80 further includes RANs 76 which do not contain an MCP but rather, are controlled by the master MCP 72 in RAN 70 . Each of the RANs depicted 70 , 70 ′, and 76 include at least one transceiver 64 , power supply 82 , and GPS receiver 92 that synchronizes the timing between the BSC 12 and the BTS 14 and between the MCP 72 and the SCP 74 per information received from a database 91 and/or GPS related satellites.
[0141] The configuration 80 may also include a combiner 86 that may combine a plurality of frequency segments to a common transmission line or antenna, a power amplifier 88 (which is similar to power amplifier 66 ), and a power supply 90 that could be used to re-set or re-start the RANs 70 , 70 ′, and 76 . A switch hub 84 may be included to provide a single access (via, for example, an IP address), between the configuration 80 and the IP network 92 .
[0142] Referring now to FIG. 4 , a message flow of a data call setup 100 is depicted. The RCC 18 receives an Origination message 106 from the MS 102 through the CEC 16 (with access information, the MS identification, service option, DSR (=1) and other call related information), unpacks the message, stores significant call related information for furthermore processing, and sends a Base Station Acknowledgement message 108 to the MS 102 and an origination message 110 to the MCC 22 with the MS identification information. The MCC 22 constructs a CM Service Request 112 message (based on, for example, the IS- 2001 -B specification), places it in the Complete Layer 3 Information message, and sends the message to the CA 104 . When an Assignment Request message 114 is received from the CA 104 , the MCC 22 allocates an SDU ID, and sends an Assignment Request message 116 to the RCC 18 to request an assignment of radio resources. This message includes information on the SDU resource information for the A.sub.bis interface, Service Option, MS identification, etc.
[0143] Upon receiving the Assign Request message 116 from the MCC 22 , the RCC 18 allocates radio resources and then sends a Traffic Channel Assign message 118 with assign type (=NEW) to the CEC 16 in order to assign Forward and Reverse Traffic Channel Elements. The RCC 18 sends a TC assign message 120 with traffic channel allocation information to the MCC 22 . When the CEC 16 receives the Tc Mobile Assign message 118 from the RCC 18 , it sets the CSM driver with the parameters in the message to activate the CSM ASICs 60 to prepare call setup. The CEC 16 sends a null traffic frame 122 to the MS 102 and an OTA_TX_ON message 124 (indicating the CEC 16 is sending a null frame to MS) to the RCC. The RCC 18 makes and sends an Extended Channel Assignment message 126 to the MS 102 through the CEC 16 .
[0144] After receiving the TC Assign message 120 from the RCC 18 with the result of ASSIN_OK or ASSIGN_ALTERNATIVE, the MCC 22 sends a Call_Setup_Cs message 128 with the information on the MS as well as the BTS resource to the SDU 20 for initialization. The SDU 20 receives the Call_Setup_Cs message 128 that is sent from the MCC 22 to request selector initialization. The SDU 20 sends a Link_Active_Se message 130 with the SDU 20 resource information to the CEC 16 which assumes that the link between the CEC and the SDU 20 has been established, and sends a Link_Act_Ack_Es message 132 to the SDU 20 to acknowledge the receipt of the Link_Active_Se message.
[0145] Upon acquiring the signal 134 of the MS 102 , the CEC 16 sends a SEL_LINK_ON message 136 indicating that call setup is complete to the RCC which updates the call state with Active (BUSY). When the CEC 16 acquires the signal of the MS 102 , it sends a Mob_Acquire_Es message 138 to the SDU 20 , indicating the reverse traffic channel has been established. Once the SDU 20 acquires the reverse traffic channel, it sends a Forward Traffic message 140 including a Base Station Acknowledgement Order with layer 2 acknowledgement required, to the MS 102 over the forward traffic channel. Upon receiving the MS Ack Order message 142 from the MS 102 , the SDU 20 sends a Service Connect message 144 with layer 2 acknowledgement required to the MS 102 over the forward traffic channel. The SDU 20 receives a Service Connect Completion message 146 that is sent from the MS 102 , and then sends a Mobile Connect message 148 to the MCC 22 to indicate the MS 102 connection.
[0146] The SDU 20 starts RLP processing 149 with the MS 102 . Upon receiving the Mobile Connect message 148 from the SDU 20 , the MCC 22 transmits an A9-Setup-A8 message 150 to the PCF 24 with a Data Ready Indicator set to 1 to establish an A8 connection. The PCF 24 receives the A9-Setup-A8 message 150 with the Data Ready Indicator set to 1 from the MCC 22 in order to establish an A8 connection, and stores call related information for further processing. The PCF 24 selects a PDSN 101 to establish the A10 connection for the new service instance, and sends an A11-Registration Request message 152 with non-zero Lifetime value to the selected PDSN with accounting data. The PCF 24 unpacks an A11-Registration Reply message 154 and verifies a reply result with code value. If the code value is valid, the PCF establishes the A10 connection. The PCF 24 establishes the A8 connection and sends an A9-Connect-A8 message 156 with a value set to successful operation.
[0147] Upon receiving the A9-Connect-A8 message 156 from the PCF 24 , the MCC 22 transmits a Pdsn_Info_Cs message 158 with the PCF 24 reference ID to the SDU 20 and an Assignment Complete message 160 to the CA 104 . The SDU 20 receives the Pdsn_Info_Cs message 158 from the MCC 22 to indicate the PDSN 101 is connected and relays data packet using the PDSN 101 information. A PPP connection 162 with MIP Registration is established between the MS 102 and the PDSN 101 through the BS. A Data Transfer 164 occurs between the MS 102 and the PDSN 101 through the BS.
[0148] Referring now to FIG. 5 , a message flow of a data call using a forward supplemental channel 200 is depicted. The SDU 20 determines a forward supplemental channel (SCH) should be needed for an increased forward data rate (=X times) and sends a Supplemental Channel Request Control message 202 to the CEC 16 to request a resource allocation related to the Supplemental Channel (requested parameter: forward SCH data rate, Walsh code for forward SCH, number of forward SCH, frame duration for forward SCH).
[0149] When the CEC 16 receives the forward SCH setup request with required number of F_SCH and its data rate from the SDU 20 , it sends a Supp_Ch_Req_Msg 204 (channel type=F_SCH) with the number of F_SCH required, data rate and radio configuration to the RCC 18 to request a traffic channel resource assignment for the F_SCH.
[0150] Upon receiving the Supplemental Channel Request message (with channel type=F_SCH), a number of channels needed, a data rate (=x times), and RC information from the CEC 16 , the RCC 18 checks if forward traffic channels are available. If available, the RCC 18 allocates forward supplemental channels and a Walsh code channel. Otherwise, the RCC 18 attempts to decrease the data rate and allocates as much as it can. The updates add resource allocation information into this call related resource buffer.
[0151] The RCC 18 sends a Traffic Channel Assign message 206 with channel type and assign type to the CEC 16 based on the allocated forward supplemental channels. The RCC 18 sends a Supplemental Channel Response message 208 with assigned channel type (=F_SCH), number of channels, and a data rate to the CEC 16 . The CEC 16 sets a CSM driver with the parameters in the message to activate the CSM ASICs 60 and starts the service of the F_SCH which sends an OTA_TX_ON 210 message to notify the RCC 18 that the F_SCH sends forward packets. When the CEC (FCH task) receives the Supp_Ch_Resp_Msg (channel type=F_SCH), it responds to the SDU 20 that the F_SCH call setup for the forward data service SDU request has been completed.
[0152] The CEC 16 sends a Supplemental Channel Response Control message 212 to the SDU 20 to acknowledge the forward SCH assignment with allocated information. The SDU 20 sends an Extended Supplemental Channel Assignment message 214 with forward SCH data rate, Walsh code for the forward SCH, a number of forward SCH, and a frame duration for the forward SCH to allow the MS 102 use utilize them for higher data processing. The MS 102 then sends an acknowledgement message 216 to the SDU 20 .
[0153] During processing X times data rate 218 , the SDU 20 may decide to change a data rate to Y times. In such a scenario, the SDU sends a Supplemental Channel Request Control message 220 to the CEC 16 to request a resource allocation related to the Supplemental Channel (requested parameter: forward SCH data rate, Walsh code for forward SCH, number of forward SCH, and frame duration for forward SCH). When the CEC receives a Ctl_Sch_Req_Se message from the SDU 20 for changing the data rate of the current F_SCH, it sends a Supp_Ch_Rel_Req_Msg 222 to the RCC 18 to make the RCC release the current F_SCH for the data rate change.
[0154] The RCC 18 releases the forward supplemental channels (as much as were requested) and sends a Release message 224 to each F_SCH 17 b. The RCC also transmits a Supplemental Channel Release Response message 226 with a number of channels and channel identifications released in order to notify it to the F_FCH. The CEC 16 stops the F_SCH service and removes the resource occupied for the F_SCH, and sends a Supp_Ch_Req_Msg 228 with new data rate the SDU 20 requested to the RCC 18 in order to request a new F_SCH data call setup.
[0155] Upon receiving Supplemental Channel Request message 228 with channel type (=F_SCH), number of channels needed, data rate (=y times), and RC information from the CEC 16 , the RCC 18 checks if forward traffic channels are available (as much as are required). If available, the RCC 18 allocates forward supplemental channels and Walsh code channel. Otherwise, the RCC 18 tries to decrease the data rate and allocates as much as it can. The updates add resource allocation information into this call related resource buffer.
[0156] The RCC 18 sends a Traffic Channel Assign message 230 with channel type and assign type to the CEC 16 (as much as is allocated) and forward supplemental channels. The RCC 18 sends a Supplemental Channel Response message 232 with assigned channel type (=F_SCH), number of channels, and data rate to the CEC 16 . When the CEC 16 receives a TC Assign message 230 from the RCC 18 , it sets a CSM driver with the parameters (radio configuration, data rate, forward power control parameter, SDU IP address, etc.) in the message to activate the CSM ASICs 60 , and starts the service of F_SCH. After the F_SCH sends a forward packet over the air, the CEC 16 sends an OTA_TX_ON message 234 to the RCC 18 to notify it. Upon receiving the Supp_Ch_Resp_Msg 232 from the RCC 18 , the CEC 16 responds 236 to the SDU 20 that the F_SCH has been changed and served with the data rate the SDU 20 requested.
[0157] The SDU 20 updates and changes the forward data rate (Y times) per the response in the Ctl_Sch_Rsp_Es message and sends an Extended Supplemental Channel Assignment message 238 with forward SCH data rate, Walsh code for forward SCH, number of forward SCH, and a frame duration for forward SCH to allow the MS 102 to use them for the changed data processing rate. The MS 102 sends an acknowledgement message 240 to the SDU 20 . During processing of the Y times data rate 242 , the SDU 20 may determine that it does not need the F_SCH any more for forward data service because the data rate has been decreased. In such a scenario, the SDU sends an Extended Supplemental Channel Assignment message 244 with ZERO duration to inform the MS 102 to not use the assigned F_SCH.
[0158] After receiving the Ms Ack Order Message 246 from the MS 102 , the SDU 20 sends a Ctl_Sch_Rel_Req_Se message 248 with a number of F_SCH to be released to request a F_SCH release to the CEC 16 . When the CEC 16 receives the CtlF_SchRel_Re_Se message 248 from the SDU 20 to stop forward packet transmission with current F_SCH, it sends a Supp_Ch_Rel_Req_Msg 250 (channel type=F_SCH) with a number of F_SCH and an identification to the RCC 18 to release the current F_SCH. Upon receiving the Supplemental Channel Release Request message, the RCC 18 releases the forward supplemental channels (as much as requested) and sends a Release message 252 to each F_SCH 17 b. The RCC 18 transmits a Supplemental Channel Release Response message 254 with a number of channels and channel identifications released to the F_FCH 17 a. The CEC 16 stops the F_SCH service and removes the resource occupied for F_SCH.
[0159] The CEC 16 sends a Ctl_Sch_Rel_Rsp_Es message to the SDU 20 to notify the SDU that the CEC 16 released the F_SCH. The SDU 20 sets the number of F_SCH used to ZERO and does not use the F_SCH for forward data processing 258 .
[0160] Referring now to FIG. 6 , a message flow of a data call using a reverse supplemental channel 300 is depicted. While the data call is engaged with the FCH 302 , the MS 102 may determine it needs the R_SCH for higher reverse data processing 304 and thus sends a Supplemental Channel Request message 306 to the BS. The SDU 20 receives and sends an Acknowledge Order message 308 to the MS 102 . The SDU 20 sends a Supplemental Channel Request Control message 310 to the CEC 16 to request a resource allocation related to Supplemental Channel (requested parameter: reverse SCH data rate, Walsh cover ID for reverse SCH, number of reverse SCH, and a frame duration for reverse SCH) to get the R_SCH as much of the data rate requested by the MS 102 .
[0161] When the CEC receives the Ctl_Sch_Res_Se message with number of reverse SCH and the data rate from the SDU 20 , it sends a Supp_Ch_Req_Msg 312 (channel type=R_SCH) to the RCC 18 to setup a reverse data service with R_SCH. Upon receiving a Supplemental Channel Request message (with channel type=R_SCH, number of channels needed, data rate (=x times), and RC information from the CEC), the RCC 18 checks if the reverse traffic channels are available (as much as required). If available, the RCC 18 allocates reverse supplemental channels. Otherwise, the RCC 18 attempts to decrease the data rate and allocate as much as it can. The updates add resource allocation information into this call related to a reverse resource buffer.
[0162] The RCC 18 sends a Traffic Channel Assign message 314 with channel type and assign type to the CEC 16 (as much as allocated reverse supplemental channels). The RCC 18 sends a Supplemental Channel Response message 316 with an assigned channel type (=R_SCH), a number of channels, and data rate to the CEC 16 . The CEC 16 sets a CSM driver with the parameters (such as radio configuration, data rate, long code mask, reverse power control parameter, Walsh cover, search window length, SDU IP address, etc.) in the message to activate the CSM ASICs 60 , and starts the R_SCH service.
[0163] Upon receiving the Supp_Ch_Resp_Msg 316 with the assign result and information from the RCC 18 , the CEC 16 sends a Ctl_Sch_Rsp_Es message 318 to the SDU 20 to respond that the R_SCH call setup for reverse data service is complete. The SDU 20 sends an Extended Supplemental Channel Assignment message 320 with a reverse SCH data rate, Walsh cover ID for reverse SCH, number of reverse SCH, and frame duration for reverse SCH to let the MS 102 utilize them for higher data processing 322 . An acknowledgement message 321 is sent from the MS 102 to the SDU 20 in response to the message 320 .
[0164] Referring now to FIG. 7 , a Quality of Service (QoS) flow chart for a data call 400 is depicted. The data call is, for example, a 1 .times.RTT data call. The QoS functionality permits users (mobile stations) to use similar data speed for various data services in limited radio resource circumstances. The maximum throughput is about 140 Kbps in, for example, a 1.times.RTT data call. However, it is not possible to support over 3 users at the 140 Kbps rate within a single sector due to the Walsh code structure. Further, within a sector, the maximum serviceable sector throughput is about 500 Kbps. As such, there is a need to reallocate radio resources to all users according to the number of calls attempted.
[0165] The flow begins at step 402 when a data call is in service utilizing only a fundamental channel (FCH). A check 404 is performed to determine if the SDU 20 should allocate a supplemental channel (SCH) to provide a proper throughput of the data. This determination is based on an amount of buffering data from the PDSN 101 . If a SCH is not needed, the flow resumes at step 402 . However, if it is determined that the SDU should allocate a SCH, a function 406 of a SCH rate decision for load balancing in a sector is added. This function takes into account the available radio resource and thus may alter the data rate assumed by the SDU. For example, the SDU may believe that a 16.times. data rate is warranted, but based on the radio resource condition, an 8.times. data rate may be utilized as shown in step 408 . As such, the load is balanced for each sector.
[0166] More specifically, at step 408 , an SCH allocation to a BTS 14 is requested by the SDU 20 with an X.times. rate (which, as the example above stated, is 8.times.). This request is preferably for a service option of 33, which, for a 1.times.RTT data call provides for a max data rate of 16.times. The BTS 14 responds to the request with a Y.times. rate SCH at step 410 . Although the SDU 20 has made the decision that the X.times. data rate is appropriate, the CEC 16 and the RCC 18 (in the BTS 14 ) may determine that it is not appropriate due to additional bandwidth requirements. In such a scenario, the data rate can change and if it did, the SDU 20 would also utilize that changed data rate. In various instances, however, the X.times. data rate will be equal to the Y.times. data rate. At step 412 , a negotiation of the Y.times. rate SCH to interface with a mobile station occurs. At this point 416 , the data call with the FCH and the Y.times. rate SCH is in service.
[0167] A check 418 is performed to determine if the SDU 20 should change the SCH rate. This check is performed because radio resources may be impacted if additional users are utilizing SCHs. During such a scenario, the data rate may again have to be adjusted to accommodate the increased bandwidth requirements. Various parameters are used to determine if the SCH rate should change including an upSchRateThreshold and upSchDelayCount (which are used if the data rate is to be increased) and downSchRateThreshold and downSchDelayCount (which are used if the data rate is to be decreased). As such, the SDU could determine the SCH data rate should be changed or could determine the Y.times. data rate is appropriate. If the Y.times. rate is appropriate, the flow reverts back to step 416 . If, however, it is determined that the Y.times. data rate for the SCH should change, a function 420 of a SCH rate decision for load balancing in a sector is added. This function takes into account the available radio resource and thus may alter the data rate assumed by the SDU 20 . For example, the SDU 20 may believe that an 8.times. data rate is warranted, but based on the radio resource condition, a 4.times. data rate may be utilized as shown in step 422 . As such, the load is balanced for each sector. It is important to note that the SDU 20 regularly performs a data rate traffic check between the PDSN 101 and the mobile station and the data rate can be increased and/or decreased.
[0168] More specifically, at step 422 , an SCH allocation to the BTS 14 is requested by the SDU 20 with a Z.times. rate (which, as the example above stated, is 4.times.). The BTS 14 responds to the request with an A.times. rate (which may be, for example, 2.times.) SCH at step 424 . Although the SDU 20 made the decision that the Z.times. data rate is appropriate, the CEC 16 and the RCC 18 (in the BTS 14 ) may determine that it is not appropriate due to additional bandwidth requirements. In such a scenario, the data rate can change and if it did, the SDU 20 would also utilize that changed data rate. In various instances, however, the Z.times. data rate will be equal to the A.times. data rate. At step 426 , a negotiation of the A.times. rate SCH to interface with the mobile station occurs. At this point 428 , the data call with the FCH and the A.times. rate SCH is in service. The flow continues to check 418 .
[0169] Referring now to FIG. 8 , a table 500 indicating a supplemental channel (SCH) rate for a data call is depicted. The table 500 provides a view of using Walsh codes based on a number of FCHs utilized 510 in a 16.times. data rate 502 , an 8.times. data rate 504 , a 4.times. data rate 506 , and a 2.times. data rate 508 . A Walsh code is one of 64 chip patterns which are 64 chips long. CDMA channels are differentiated by which Walsh code they use. These 64 codes are also known as Walsh sequences. Since every signal is spread over a particular channel (such as a 1.25 MHz channel) and transmitted over the entire bandwidth at once, up to 64 mobile stations could use the channel at once. In practice, however, the number depends on the data throughput.
[0170] Referring now to FIG. 9 , a plurality of tables 600 (and specifically tables 602 - 640 ) more fully describe each of the utilized FCHs 510 . The tables 600 , which coincide with the table 500 , describes the use of 1 to 20 FCHs in relation to a number of data rates including 16.times., 8.times., 4.times., and 2.times. In each instance, the 0, 1, and 32 code are used for overhead channels (such as pilot channels and synch channels) and the 33 code is used for a FCH. In the table 602 , a single FCH and a single 16 rate SCH 602 a are depicted. In the table 606 , three FCHs ( 606 a, 606 b, and 606 c ), two 16 rate SCHs ( 606 d and 606 e ), as well one 8 rate SCH ( 606 f ) are depicted. In the table 614 , seven FCHs ( 614 a - g ), one 4 rate SCH ( 614 h - k ), and six 8 rate SCHs ( 614 l - q ) are depicted. In the table 626 , thirteen FCHs ( 626 a, less the fixed channels), eleven 4 rate SCHs ( 626 b, less the 2 rate channels), and two 2 rate channels ( 626 c ).
[0171] Referring now to FIG. 10 , a table 700 indicating a maximum SCH rate according to a number of data call attempts 702 is depicted. For example, if twelve data calls were attempted in one sector, the maximum SCH rate could be supported by twelve 4 rate channels, while if thirteen data calls were attempted in one sector, the maximum SCH rate could be supported by eleven 4 rate channels and two 2 rate channels.
[0172] Although an exemplary embodiment of the system of the present invention has been illustrated in the accompanied drawings and described in the foregoing detailed description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions without departing from the spirit of the invention as set forth and defined by the following claims. For example, the capabilities of the invention can be performed fully and/or partially by one or more of the modules RANs 70 , 70 ′, and 76 , and/or by one or more of the blocks 16 - 58 . Also, these capabilities may be performed in the current manner or in a distributed manner and on, or via, any device able to transfer information between the RANs, the blocks, and/or other components. Further, although depicted in a particular manner, various blocks may be repositioned without departing from the scope of the current invention. For example, the RCC 18 may be positioned in the BSC 12 , while the SDU 20 may be positioned in the BTS 14 . Still further, although depicted in a particular manner, a greater or lesser number of RANs and/or blocks may be utilized without departing from the scope of the current invention. For example, additional RANs 76 may be utilized in the configuration 80 of the present invention.
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A system, method, and computer readable medium for determining a data call rate comprises determining if a supplemental channel (SCH) should be allocated, if the SCH should be allocated, potentially altering the data rate, requesting an SCH allocation at a current data rate or the altered data rate, and receiving a response to the request with the current data rate, the altered data rate, or a further altered data rate.
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FIELD OF THE INVENTION
This invention relates to handling bulk textile fiber and more particularly to processes and equipment for handling textile fiber in a pneumatic conveying system.
BACKGROUND OF THE INVENTION
One of the difficulties in handling textile fiber is the tendency for fiber to settle in mounds or piles when it is desirable that the fiber be generally uniformly dispersed. It appears to be a problem regardless of whether the fiber is individualized fiber filaments, in clumps, tufts or in some other form. In the production of spunlaced nonwoven fabrics, more uniform basis weight distribution is obtained when the fiber is more uniformly dispersed across the width of the fabric at the earliest stages of formation. E. I. du Pont de Nemours and Company, Wilmington, Del. (DuPont) has invested considerable time and effort to improve uniformity in the manufacture of its Sontara® spunlaced fabrics. DuPont's focus for providing the desired uniformity has been the chute feeder which creates a batt of fibers for processing into the finished spunlaced fabric. The chute feeder is disclosed in U.S. Pat. No. 5,606,776 to Freund et al. and includes a bin or hopper in which fiber is first provided. The fiber is typically supplied by a pneumatic conveyor and in the conventional arrangement, the fiber enters an inlet in one wall of the bin or hopper. The fiber in the bin or hopper tends to pile into a mound close to the center near the inlet. The batt from the chute feeder tends to have a heavier or denser portion along the center where the fiber was mounded in the hopper. The denser and heavier portion tends to be found throughout the process and even in the final product.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to overcome the above noted drawbacks of the prior art and more particularly to provide improved fiber distribution of fiber in fiber handling system.
One idea proposed to better distribute the fiber across the width of the bin is to divide the pneumatic conveyor into a plurality of flows of fiber. Each of the flows would be provided to separate inlets in the bin and being evenly separated so that the one central mound would be separated into a series of smaller mounds. The chute feeder would then be able to even out the less dramatic unevenness of the plurality inlet. However, it has been found that the effects of even small scale unevenness can be found in the final product. Moreover, fiber does not naturally distribute itself uniformly across a pneumatic conveying tube thus making separation into a plurality of evenly divided flows quite unlikely.
Thus, it is a further object of the present invention to divide a single flow of pneumatically conveyed fiber into a plurality of generally evenly divided flows of fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more easily understood by a detailed explanation of the invention including drawings. Accordingly, drawings which are particularly suited for explaining the invention are attached herewith; however, it should be understood that such drawings are for explanation only and are not necessarily to scale. The drawings are briefly described as follows:
FIG. 1 is a cross sectional side elevational view of a chute feeder with a pneumatic conveying system illustrated schematically providing fiber to the chute feeder.
FIG. 2 is a cross sectional view of the chute feeder of FIG. 1 taken along the Line 2--2.
FIG. 3 is a perspective view of a first embodiment of a distributor.
FIG. 4 is a cross sectional view of the distributor of FIG. 3 taken along the Line 4--4.
FIG. 5 is a perspective view of a second embodiment of a distributor.
FIG. 6 is a cross sectional view of the distributor of FIG. 5 taken along the Line 6--6.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, there is shown in FIG. 1 a chute feeder 10 which receives fiber in the form of fiber tufts from a pneumatic conveying system 20 and forms a batt 12 from the fiber. The chute feeder 10 includes a hopper 15 for receiving the fiber. It is preferred that the fiber be as uniformly distributed across the hopper 15 as possible. Thus, in accordance with the invention as shown in FIG. 2, the hopper 15 includes a plurality of inlets 18 which are evenly spaced across the width thereof. The inlets 18 are fed by a plurality of feed conduits 24 of the pneumatic conveying system 20.
Pneumatic conveying systems are well known and in common usage in the textile industry and the pneumatic conveying system 20 of the present invention is intended to be generally representative of such systems with the addition of a unique element. As with all pneumatic conveying systems, fiber typically in the form of tufts is fed into a moving airstream within a duct or conduit and carried along with the air stream. The pneumatic conveying system 20 comprises a primary conduit 21 into which such fiber is fed and carried by the airstream. However, in the subject invention the pneumatic conveying system 20 includes a distributor 30 which divides the fiber laden airstream into a plurality of fiber laden airstreams which are then carried in the feed conduits 24. The distributor 30 is not just a simple branching of the conduit because it is also intended to evenly divide or distribute the fiber in each of the airstreams in the feed conduits 24. Because the fiber is not generally evenly distributed across the duct of a pneumatic system, evenly dividing the fiber is no simple task. The fiber tends to be carried along primarily at the bottom of the duct or along the outside of any bend. These considerations would need to be incorporated into any means for evenly dividing the fiber.
Turning now to FIGS. 3 and 4, a first embodiment of the distributor 30 is illustrated as having the appearance of a rather flat square box. The box or housing is defined by generally parallel, opposed and spaced apart first and second walls 36 and 37 with deflector walls 38 extending between the first and second walls 36 and 37 at about the periphery thereof enclosing an interior space 39. In the illustrated embodiment, there are shown to be four deflector walls 38 closing the space between the first and second walls 36 and 37. In addition, there are four peripheral walls 43 at the edges of the first and second walls 36 and 37 and just outside of the deflector walls 38 from the interior space 39. The peripheral walls 43 provide structural support for the distributor 30 and may be replaced by other suitable bracing or deleted entirely should the deflector walls 38 provide adequate rigidity and structural integrity. From the drawings, the deflector walls are not arranged at a normal or perpendicular angle to the first or second walls 36 and 37 for reasons which will be discussed below, so in the preferred embodiment, peripheral walls 43 provide structural integrity.
The distributor 30 includes a primary inlet 31 connected to the primary air conduit 21 of the pneumatic conveying system 20 for receiving fiber. The primary inlet 31 is connected to the second wall 37 by a conically diverging portion 32. The conically diverging portion 32 has an inner diameter that substantially increases from the primary inlet 21 to the primary opening 41 which is about twice the diameter of the primary inlet 31. The primary opening 41 is positioned in about the center of the second wall 37 and more preferably, at the center of the interior space 39 between the deflector walls 38. In the illustrated embodiment, there are four outlets 34 arranged adjacent the intersections of the deflector walls 38. The outlets 34 are connected to the feed conduits 24 as shown in FIG. 1 to the chute feeder 10.
As briefly noted above, the distributor 30 divides the fiber laden airstream in the pneumatic conveying system 20 in a way that rather equally divides the fiber into a plurality of separate airstreams. The process of separation is rather simple and may be understood by following the path of the fiber and air in the distributor. Clearly, it is understood that the air will be moving through the distributor 30 by the force of whatever fans or blowers are used within the overall pneumatic conveying system 20 and the to the extent that the separate ports 34 and their associated feed conduits have similar back pressure, the air flow (not considering the fiber) will be generally equally divided. Thus the challenge is to get the air to carry roughly equal amounts of fiber out each port 34.
The fiber and airstream is primarily divided by a blunt impact against the first wall 36. The airstream tends to react to the blunt impact by spreading radially outwardly in the relatively flat distributor 30 towards the deflecting walls 38. The fiber is also spread radially outward by the blunt impact except that it tends to remain close to the first wall 36 as it moves towards the deflector walls 38. The deflector walls 38 are arranged at an angle A to the first wall 36, being slightly greater than perpendicular or 90 degrees thereby directing the fiber away from the first wall 36 and back towards the center of the interior space 39. Preferably the angle A is about 105° but it should be understood that a fairly broad range from near 95° up to about 135° may be suitable.
Bumping the fiber back toward the center of the interior space 39 reduces the opportunity for the fiber to settle out of the airstream by keeping the system flowing. It is also preferred that the ports 34 are positioned at the intersection of the deflector walls 38 thereby being farthest from the primary inlet 31. Although some fiber will surely impact the center of each of the deflector walls 38, the air will naturally move toward the ports 34 picking up fiber with it.
There are of course other considerations that will help optimize the operation of the distributor 30. For example, it is most desirable that the primary conduit have a generally straight run in a vertical direction for the last fifteen or more feet leading to the primary inlet 31 without making any significant turns or bends which would tend to make the fiber favor any one side of the primary inlet 31 as it enters the distributor. For the best results, the primary conduit 21 should make about a fifteen foot vertical run upwards into the bottom of a horizontally arranged distributor 30. By providing that the final run be vertically upward, gravity tends to help distribute fiber in the primary air conduit 21 providing the most even distribution of fiber. It should be noted that at any one instant in time, the fiber may not be evenly distributed since it may be in clumps. However, even over relatively short periods of time, such as several minutes, the amount of fiber going through each of the ports 34 can be fairly even. With the fiber being fairly evenly divided among the various feed conduits 24, then the fiber may be more evenly distributed laterally across the chute feeder 10.
It should be noted that the distributor 30 is amenable to having more or less outlets. For example, the illustrated embodiment (FIG. 3) has the shape of a square box with four outlets. Other designs were tested having six and eight outlets. The six outlet design had the shape of a hexagon and the eight outlet design had the shape of a octagon. Clearly, one can envision a design having a large number of outlets where the deflecting walls start to appear like a continuous circle.
A second embodiment of the distributor, indicated by the number 130 is illustrated in FIGS. 5 and 6. The distributor 130 has the appearance of a centrifugal fan with a plurality of outlets. The distributor 130 comprises a housing 135 with a paddle fan 143 arranged to rotate about a shaft or hub 144. The hub 144 is driven by a motor (not shown) arranged outside the housing 135 and preferably attached to the outside of the housing 135 by suitable means such as bolts. The paddle fan 143 includes a number of paddle blades 145 which rotate about the hub 144 so as to push air and fiber toward the outlets 134. An inlet 131 is arranged to coincide with the hub 144 of the paddle fan 143 such that the primary air conduit leading to the inlet 131 is generally coaxial with the hub 144. With this arrangement, the air and fiber enter the housing from the primary air conduit 21 along a path generally coaxial with the hub 144 and turns and centrifugally spreads out within the housing 135 moving to one of the outlets 134.
In the second embodiment, there are preferably four outlets 134 although more or less outlets may be suitable. Four outlets were selected as a practical matter since more outlets would have made the design and construction of the housing 135 more complicated. The housing 135 comprises first and second generally parallel, opposed and spaced apart walls 136 and 137 and contoured side walls 138 connecting the first and second walls at about their periphery. The contoured side walls 138 of the housing 135 are arranged radially from the distal ends of the paddle blades 145 and contoured to at least partially follow the circular path of the distal ends of the paddle blades 145. The contoured side walls 138 straighten to form a tangential portion terminating at the outlet 134. As the outlets 134 are generally equally spaced around the periphery of the housing 135, the amount of fiber and air will be substantially evenly divided among the outlets.
One particular advantage of the second embodiment of the distributor 130 is revealed when one of the outlets may become blocked or occluded by fiber which has stopped or settled down in the feed conduit 24. In this second embodiment, the paddle fan 143 continues to push air and fiber into each outlet 134 at the urging of the motor (not shown) such that the pressure in the occluded duct will increase urging the blockage to move along and in most cases abate the blockage. Another feature and advantage of the second embodiment is that it is less sensitive to gravitational effects as the centrifugal forces created by the motor (not shown) and fan blades 145 have more influence on the distribution of fiber in the distributor 130. The second embodiment may provide an additional advantage in that it may eliminate the need for an additional fan for the pneumatic conveying system or reduce the energy requirements of the pneumatic conveying system.
The foregoing description and drawings were intended to explain and describe the invention so as to contribute to the public base of knowledge. In exchange for this contribution of knowledge and understanding, exclusive rights are sought and should be respected. The scope of such exclusive rights should not be limited or narrowed in any way by the particular details and preferred arrangements that may have been shown. Clearly, the scope of any patent rights granted on this application should be measured and determined by the claims that follow.
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A device and process for dividing a pneumatic flow of fiber into a plurality of streams of pneumatically-conveyed fiber which aid in distributing the fiber more uniformly across an area such as a fiber bin.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present disclosure is related to the application titled APPARATUS AND METHOD FOR INCREASING MONOPOLE CAPACITY USING EXTERNAL STRENGTHENING filed concurrently herewith by the same inventive entity. The disclosure of such related patent application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Antennas for over-the-air communications, such as cellular telephone systems, are usually supported on hollow tubular steel monopoles. Monopoles are located throughout most metropolitan and suburban areas. The location and density of monopoles in any particular area depend on the density of users, the elevation of the monopole sites, the height of each monopole and the coverage required. The height of each monopole can vary from only a few feet up to hundreds of feet.
[0003] As areas have more and more over-the-air communication demands, monopoles are becoming more and more ubiquitous. Many neighborhoods are resisting the installation of monopoles with great vigor. In addition to the resistance to installation of new monopoles, many of the prime sites for monopoles have already been acquired and are thus not available for new entrants into the field, or for upgrading of an existing system. Many remaining sites are less desirable for companies seeking to enter or expand in the field of over-the-air communication. Reacting to pressure from constituents, many local governments are reluctant to grant permits for new monopoles.
[0004] Therefore, there is a need for a means for increasing over-the-air coverage while meeting the requirements placed on locating monopoles.
[0005] One way of increasing the over-the-air coverage is to increase the number of antennas available for such coverage. In view of the restrictions placed on adding new monopoles, this will require adding antennas to existing monopoles. It is possible to achieve this end using new antenna technology whereby new antennas do not need to be located as high as antennas embodying older technology. Thus, new antennas could be simply mounted onto existing monopoles and this will achieve the goal of increasing antenna coverage for an over-the-air system without requiring the placement of more monopoles.
[0006] However, this approach is not as simple as it appears at first blush. The problem with adding more antennas to an existing monopole is that such addition of antennas increases the loading on the monopole. Loading on the monopole is increased both from a dead load standpoint and from a live load standpoint.
[0007] Thus, simply adding more antennas to a monopole will increase the load on the monopole by the addition of the weight associated with the additional antennas. This weight is manifested in added compression stresses placed on the monopole.
[0008] Another problem associated with adding antennas to an existing monopole is that live loads on the monopole associated with wind loading on the antennas (both the existing antennas and the newly added antennas) will be increased by a factor determined by the wind area added to the monopole.
[0009] It is also noted that wind forces on the antennas can also cause a twisting stress on the monopole, and this stress will also be increased by the addition of antennas to the existing monopole.
[0010] The wind forces on the antennas creates both live loading on the monopole and may create a possibility of misaligning antennas. Misalignment of one antenna can be created by wind loading on other antennas on the same monopole due to the twisting or deflection of the monopole associated with such wind forces on the monopole and other antennas.
[0011] Yet another problem with simply adding antennas to an existing monopole arises because many existing monopoles have been designed for loads associated with a certain number of antennas. Thus, adding antennas and the forces associated with those additional antennas may create a situation for some existing monopoles in which the loading on the monopole is not within design parameters.
[0012] Therefore, there is a need for apparatus and methods for increasing the number of antennas that can be supported on an existing monopole whereby advantage can be taken of new antenna technology without exceeding the design limits of existing monopoles.
[0013] It may also not be possible to simply re-enforce existing monopoles by purchasing additional land to accommodate the guy wires or the like. Many municipalities have aesthetic requirements that will be violated by such guys, and some monopole sites are not large enough to include such guys. Still further, adding guys may be so expensive that it overwhelms the cost savings associated with the addition of antennas.
[0014] Therefore, there is a need for an apparatus and methods for increasing the number of antennas that can be supported on an existing monopole without requiring guy re-enforcement of the monopole.
[0015] Of course, one approach to accommodating additional antennas would be to simply replace existing monopoles with new and stronger monopoles. However, this approach may prove to be too costly to be feasible.
[0016] Therefore, there is a need for a means and a method for modifying existing monopoles to accommodate additional antennas without requiring replacement of such existing monopoles.
SUMMARY OF THE INVENTION
[0017] The inventive entity of the present invention has observed that existing monopoles are generally hollow tubular structures. These structures have been designed according to deflection limitations or to allowable stress placed on the wall of the tubular structure. The inventive entity has also observed that design calculations indicate that design stresses are well under allowable stresses when the design is based on deflection. Therefore, there will be strength available if the monopole can be stiffened to reduce deflection when antennas are added to the structure.
[0018] When design limits associated with hollow tubular structures such as monopoles are based on stress, the allowable stress is based on compression failure rather than tension failure. When antennas supported on a monopole are subject to wind forces, the forces transferred to the monopole are manifested in tension forces on some parts of the structure wall and in compression forces on other parts of the structure wall. It has also been observed that the forces associated with the weight of the antennas and the monopole are compression forces and thus added to the compression forces associated with wind loading on the antennas and the monopole. This will exacerbate any problems that may be associated with compression forces applied to the monopole. Still further exacerbating the problem is the observed fact that allowable stress associated with compression is generally less than the yield point stress which is associated with allowable stress using tension as a design criterion. It is also noted that adding guys generally does not increase the structure's ability to accommodate compressive loading.
[0019] The steel used in monopoles is high strength steel. When the design of such monopoles is based on deflection, the steel is often stressed to less than seventy per cent of the yield point stress of the steel. Plate used for bent plate structures commonly has a yield point of sixty-five thousand pounds per square inch (psi). However, the allowable stress, when compression governs, is often about fifty-two thousand psi. Thus, if it is possible to retrofit an existing monopole that has been designed using limits associated with compression to actually be limited by tension instead, an additional percentage (in the case presented above, an additional twenty-five per cent) in design limits could be gained. Further, if mill tests for plates in a particular structure are available, it may be possible to determine that the yield point stress exceeds the minimum specified value thereby creating an opportunity to further increase the design limits associated with an existing monopole. As can be understood from the teaching of the above discussion, increasing the design limits of an existing monopole will permit that monopole to support additional antennas without requiring guys or the like or without requiring replacement of existing monopoles.
[0020] The present inventive entity has discovered that the design limits of an existing monopole can be increased by strengthening the monopole in its ability to accommodate compressive loading. This increase of strength in compression thus permits the design limits to be based on tension rather than compression. As discussed above, the allowable stress associated with compression is generally less than the yield point stress which would be the allowable stress if tension governs the design. This thus increases the load carrying capacity of a monopole.
[0021] Thus, the present invention overcomes the above-discussed problems and drawbacks by increasing the compression limits of an existing monopole by supporting the compression faces and by increasing its section modulus which allows more load-carrying capacity. One form of the invention achieves this goal by placing filler material that is strong in compression inside the monopole.
[0022] This takes advantage of the fact that most existing monopoles are hollow. By increasing the compression design limits of a monopole, expense and effort are directed to the most efficient use of resources and are not wasted on increasing design limits that are not as efficiently utilized for increasing compression limits.
[0023] Still further, increasing the compression limits of an existing monopole by filling the monopole with material that is strong in compression takes advantage of the fact that most existing monopoles are already hollow and the filler material can be installed in an economical manner. Still further, using the hollow nature of existing monopoles to add strengthening material internally to the monopole permits strengthening the monopole without endangering the aesthetics of such poles that have already been approved. Thus, the inventive means and method of the present invention is a way of increasing the design limits of an existing monopole in a manner that is both efficient and economical thereby increasing the strength of a monopole to accommodate additional antennas becomes economically feasible.
[0024] The present invention also includes strengthened base plates and foundations supporting monopoles.
TECHNICAL FIELD OF THE INVENTION
[0025] The present invention relates to the general art of static structures, and to the particular field of monopoles.
OBJECTS AND ADVANTAGES OF THE INVENTION
[0026] It is a main object of the present invention to provide a means for increasing over-the-air coverage while meeting the requirements placed on locating monopoles.
[0027] It is another object of the present invention to provide an apparatus and methods for increasing the number of antennas that can be supported on an existing monopole without requiring guy re-enforcement of the monopole.
[0028] It is another object of the present invention to strengthen an existing monopole without changing the aesthetics of the existing monopole.
[0029] It is another object of the present invention to strengthen an existing monopole by adding strengthening material internally of the monopole.
[0030] It is another object of the present invention to strengthen an existing monopole in the most efficient and cost effective manner.
[0031] It is another object of the present invention to provide a means and a method for modifying existing monopoles to accommodate additional antennas without requiring replacement of such existing monopoles.
[0032] It is a more specific object of the present invention to strengthen an existing monopole by increasing the design limit that is most effective in providing the overall increase in design limits that will be most effective and efficient to increase the load carrying capacity of the monopole.
[0033] Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
[0034] The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] [0035]FIG. 1 is an elevational view of one form of a monopole.
[0036] [0036]FIG. 2 is an elevational view of another form of a monopole.
[0037] [0037]FIG. 3 is a sketch that illustrates loading on a monopole subject to wind forces.
[0038] [0038]FIG. 4 is an elevational view of one form of a monopole that has been modified and strengthened according to the teaching of the present invention.
[0039] [0039]FIG. 5 is an elevational view of another form of a monopole that has been modified and strengthened according to the teaching of the present invention.
[0040] [0040]FIG. 6 is a top plan view of a base of a monopole.
[0041] [0041]FIG. 7 is an elevational view of a base of a monopole.
[0042] [0042]FIG. 8 is a top plan view of a template used in a base of a monopole.
[0043] [0043]FIG. 9 is a partial view of a multi-sided monopole which has been strengthened by affixing strengthening elements to the outside surface, or surfaces, of the monopole.
[0044] [0044]FIG. 10 is an enlarged view of a portion of the monopole shown in FIG. 9.
[0045] [0045]FIG. 11 is a cross-section of a twelve-sided pole.
[0046] [0046]FIG. 12 is an enlarged view of FIG. 10.
[0047] [0047]FIG. 13 is similar to FIG. 12 but with an access flange through which internal cables pass into a pole.
[0048] FIGS. 14 - 16 are similar to FIGS. 11 - 13 respectively, showing a monopole that is circular in perimetric shape.
DETAILED DESCRIPTION OF THE INVENTION
[0049] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
[0050] It is noted that the present disclosure will refer to antennas or antenna structures. It is intended that the term “antenna” will cover any element used in over-the-air communication systems, including microwave dishes, supporting platforms and the like and it is not intended to limit the scope of this invention to antennas per se. It is also intended that the broad term “over-the-air communication system” covers cellular telephone systems as well as any other such system.
[0051] Two types of existing monopoles are shown in FIGS. 1 and 2. Both monopoles are tubular and hollow and are formed of steel to have a hollow interior and are anchored at the base thereof in the ground. One type of existing monopole is unitary and is shown in FIG. 1 as monopole 10 . Monopole 10 has a base 12 that is cast in ground G and a base assembly 14 . Monopole 10 extends upward from ground G and tapers to a top area 15 . As indicated, monopole supports a variety of elements that are associated with over-the-air communication systems, such as antennas 16 , dishes 18 and the like. These elements are positioned on monopole 10 at levels above the ground, indicated by level 20 which corresponds to the lowest level of the elements existing on the monopole. One form of existing monopole is one hundred fifty feet tall, has a fourteen inch top diameter and a sixty inch base diameter. Antennas are located at the one hundred fifty foot level and at the one hundred thirty foot level, with the one hundred thirty foot level being indicated as level 20 .
[0052] Monopole 10 is hollow as indicated by dotted lines 22 to define an inner bore 24 and has been designed to safely support the communications elements in position to effectively carry out the functions associated with such elements in over-the-air communications systems. Thus, design stresses, yield points, and the like have been selected to achieve this goal.
[0053] An alternative form of monopole 10 ′ is shown in FIG. 2 as including a plurality of sections, such as sections 30 and 32 , that have outside diameters differing from each other to produce a stepped shape with a shoulder 34 between adjacent sections. Otherwise, monopole 10 ′ is identical to monopole 10 and includes a hollow bore 24 ′ and supports elements such as an antenna dish 18 at a first level, with the lowest level element being at a level 20 above the ground. Other forms of monopoles may occur to those skilled in the art based on the disclosure herein and these additional types of monopoles are also intended to be included in the scope of this disclosure and invention.
[0054] For convenience, the elements on the monopoles as these monopoles exist prior to being modified according to the teaching of the present invention to support additional elements will be referred to as first elements. Elements added to the existing monopoles to accommodate additional traffic in over-the-air communications systems will be referred to as second elements.
[0055] Referring to FIG. 3, the various forces of interest to this disclosure are identified. Thus, the wall W of monopole M is subject to a force associated with the weight W t which manifests itself as a compressive force C on the wall of the hollow monopole. As the structure is exposed to wind D, the pole deflects in direction X from vertical. Due to this deflection, various portions of the monopole wall are subjected to forces. Thus, one portion T 1 of wall W is subject to tension T due to the deflection of the monopole, while another portion C 1 of wall W is subject to compression force C 2 . This compression force is added to the compression force C associated with the weight of the monopole and the elements supported thereon.
[0056] As discussed above, the inventive entity of the present invention has discovered that if the design of an existing monopole can be controlled by tension, there is additional bending capacity that can be utilized so more antennas can be installed on an existing monopole that has been thus modified. This is achieved by adding elements to the existing monopole that adds to the strength of the monopole in regard to compression.
[0057] Accordingly, the best mode of the present invention includes placing a filler element that is strong for compression forces inside the hollow bore of the existing monopole. Specifically, the best mode of the present invention includes placing expanding foam and aggregate, lightweight aggregate concrete normal aggregate concrete or the like in the bore of the hollow existing monopole. The concrete is the most efficient and economical element that can be used to achieve the purposes of this invention. One form of the aggregate used for this concrete is manufactured under the trademark HADITE. Other types of concrete, including that which uses standard weight aggregate, can also be used as will occur to those skilled in the art based on the teaching of the present disclosure. These additional types of fills and concrete are intended to be included in the scope of this invention as well.
[0058] Referring to FIGS. 4 and 5, it can be seen that monopole 10 is modified to monopole 10 R, or retrofit, by locating filler material 50 into the hollow bore 24 as by flowing the filler into the bore via a hole defined through the wall of the pole, or the like. The filler material is filled in the bore to a level 52 . While this level can vary according to the factors associated with each monopole, the best mode of the present invention includes level 52 being essentially co-level with the level of the lowest element of the first elements existing on the monopole before the monopole is modified to include the filler material. That is, level 52 is essentially co-level with level 20 .
[0059] Once filler material 50 is in place, additional elements, 16 ′ and/or 18 ′ can be added to the monopole. These additional, or second, elements can be located at levels that are lower than levels 20 and/or 52 because they are manufactured using technology that is newer than the technology used for first elements 16 and/or 18 . However, it may be possible to add antennas above the first elements.
[0060] Referring to FIG. 5, it is seen that monopole 10 ′ is modified, or retrofit, as monopole by locating filler material 50 in bore 24 of monopole 10 ′ to level 52 ′ that is co-level with antennas 16 ′. Antennas 16 ′ are located at a level that is above level 20 ; however, this is illustrated to emphasize that the actual level of the filler material is dictated by the particular conditions associated with the particular monopole being modified. The level of the concrete will depend on the added antennas and the specific pole and any other appropriate design criteria as will be understood by those skilled in the art based on the teaching of this disclosure.
[0061] As will be understood by those skilled in the art based on the teaching of this disclosure, the steel monopole is not the only area of concern. Foundation structure 60 shown in FIGS. 6, 7 and 8 includes a central section 62 to which plates 64 and 66 are attached and on which anchor bolts 68 are mounted by nuts 70 . Central section 62 is pre-existing and is placed when the pre-existing monopole is erected. In order to accommodate the extra weight and forces associated with the modified monopole, foundation 60 is modified to include a collar 70 of concrete or the like to add further stability to the foundation structure. One form of the modified foundation includes an outside diameter of eighty-four inches and a thirty foot depth, with a collar 70 of twelve inches in width and a depth of seven and one-half inches.
[0062] The base plates can be replaced or stiffened to accommodate the added forces and anchor bolts can be replaced or added to accommodate the added forces as well.
[0063] If suitable, guys, such as guy 80 indicated in FIGS. 4 and 5, can be added. The guys can be colored or the like to accommodate aesthetic considerations. Additionally, seismic considerations can be addressed in a manner that is common to such considerations, as by adding material, or special elements that can accommodate seismic events.
[0064] Additionally, the filler material includes sufficient internal as well as external passages to accommodate water as from rain, snow, or the like. Additives can also be used to meet these considerations as well as to address shrinkage, adherence and the like as will be understood by those skilled in the art based on the teaching of this disclosure.
[0065] Design criteria can be implemented in a software program so filler height, filler density, foundation structure design, economics and the like can be analyzed before a monopole is modified.
[0066] It is noted that any coaxial communication cables that are located inside an existing monopole should be removed and either moved to the outside of the monopole or be replaced by new coaxial cables on the outside of the monopole before filler material is added.
[0067] It is noted that, in the embodiments disclosed hereinbelow, the strengthening of the monopole is achieved by affixing strengthening elements, such as plates, to the external surface, or surfaces, of the monopole; whereas, the strengthening of an existing monopole discussed above has been achieved by adding strengthening material internally of the monopole.
[0068] The foregoing discussion has been directed to a monopole which will be strengthened by adding filler material internally; however, some monopoles have one or more external surfaces that are amenable to accommodating strengthening elements. In fact, some monopoles can have as many as eight or twelve sides. The present invention takes advantage of this feature to increase the strength of an existing monopole. This approach is illustrated in FIGS. 9 - 13 in which a polygonal monopole 10 P is supported by an anchor assembly 60 P and has an antenna structure 16 P supported thereon. As discussed above, additional antenna structures 16 ′P are to be added for the reasons discussed above. In order to achieve this goal, monopole 10 P should be strengthened. This is achieved by fixing strengthening plates 100 to one or more faces of the polygonal monopole 10 P. In one form of the invention, plates 100 are affixed to each face of the polygonal monopole. As shown in FIG. 9, a bridge structure 102 is included to support cables as they enter the monopole. As those skilled in the art will understand based on the teaching of this disclosure, such a bridge structure can be used in connection with any of the monopoles disclosed herein.
[0069] As is best shown in FIG. 9, plates 100 are formed to conform to the shape of the faces on the monopole to which they are attached. Thus, as can be seen in FIG. 9, the plates taper outwardly near the bottom of the in-place plate. That is, the width of a base plate as measured between sides 104 and 106 near the bottom 108 of the plate is greater than the width of the plate near the top 110 of the plate.
[0070] As is best indicated in FIG. 12, one method of fixing the plates to the outer surface of the monopole wall is by adhesive 112 . The surface preparation required will be known to those skilled in the art based on the conditions and materials used in the monopole, the adhesive and the plates. For example, a monopole that is galvanized metal having steel plates fixed thereto will have one form of surface preparation while a painted monopole may have another form of surface preparation as well as another adhesive. A cable or band 114 can be used to encircle the plates mounted on the monopole and support those plates in position while adhesive 112 is setting up. Only a portion of the cable is shown for simplicity of illustration, but it is understood that the cable will encircle the plates and several cables can be used if necessary. The plates preferably are formed of steel, but other shapes and materials can also be used based on the requirements of a particular application. In one form of the plates, the plates are one-eighth inch thick but other thicknesses can be used without departing from the scope of the present invention.
[0071] As indicated in FIG. 13, one of the strengthening plates, plate 100 ′, can have a bore 122 defined therethrough to accommodate an access collar 124 . Cables, such as cable 126 extend into interior 128 of the monopole via collar 124 . Collar 124 can be located in conjunction with bridge 102 if desired and suitable.
[0072] As discussed above, the strengthening plates can extend from adjacent to the ground in which the monopole is supported to adjacent to the level of the lowest antenna structure to be added. Thus, as illustrated in FIG. 9, a future antenna structure 16 ′ P will be added beneath the lowest level of existing antenna structures 16 P. However, it may be possible to add antennas above the first elements. The level of the lowest existing antenna structure 16 P is indicated at 20 ′ and the level and the level of the highest proposed antenna structure is indicated as 20 P. Strengthening plates 100 are fixed to the monopole to adjacent to level 20 P. That is, for example, the length of each plate 100 in the installed condition as measured from top end 100 T to bottom end 100 B, is essentially equal to, but can be slightly less than, distance 20 P. A bottom plate 130 can encircle the bottom of the monopole if desired. The level of the top of the strengthening elements will depend on the added antennas and the specific pole and any other appropriate design criteria as will be understood by those skilled in the art based on the teaching of this disclosure.
[0073] The technique in which strengthening plates are fixed to the outer surface of a wall of a monopole can be used to strengthen a monopole having a circular outer perimetric shape as well. This provides an option for strengthening a circular monopole that is in addition to the method discussed above in which concrete is placed in the hollow bore of the monopole. This second option is illustrated in FIGS. 14 - 16 . Strengthening plates 100 C are fixed to outer surface 140 of circular monopole 10 C using suitable fixing means 142 to strengthen monopole 10 C in the manner discussed hereinabove. Plates 100 C can be steel and the fixing means can be any of the above-discussed means. Thus, suitable adhesive, or chemical bonds, or metallurgical bonds or the like can be used depending on the conditions and requirements. Plates 100 C can also taper if necessary to match the shape of the existing monopole to be strengthened as discussed above with regard to monopole 10 P shown in FIG. 9. A cable or band 114 ′ or a plurality of cables and/or bands, can also be used to secure the plates in place while the bonds between the plates and the monopole are formed and set up. The cable or band is shown spaced from the plates in FIGS. 12 and 14, but will contact those plates as necessary to hold them in place during the formation of the bond between the plates and the monopole.
[0074] As discussed above, plates 100 C will extend from adjacent to the ground supporting a monopole to be strengthened, to a level adjacent to the level of the highest added antenna structure. As the case with the foregoing forms of the invention, antenna structures can be added to the monopole at levels below the level of the highest added strengthening structure. Such antenna structures will be mounted on the strengthening plates in the embodiments using strengthening plates fixed to the outer surface of the monopole. Alternatively, the level of the top ends of the plates added in either monopole 10 P or 10 C can be essentially equal to the level of the lowest existing antenna structure, such as level 20 ′ in FIG. 9. Also, the top end of internally added strengthening material in the forms of the monopole discussed in relation to FIGS. 4 and 5 can reach the level of the lowest level existing antenna structure, such as level 20 in FIGS. 1 and 2. The level of the strengthening elements in this embodiment, like that of the other embodiments, will depend on the added antennas and the specific pole and any other appropriate design criteria as will be understood by those skilled in the art based on the teaching of this disclosure.
[0075] As is the case with the polygonal monopole, one of the plates fixed to a circular monopole, plate 100 ′C can have a bore 122 ′ defined therethrough to accommodate a collar 124 ′ through which cables 126 extend into bore 128 C of monopole 10 C having a circular perimeter.
[0076] It is also noted that the external strengthening that has been discussed hereinabove can be used in conjunction with the internal strengthening discussed in association with FIGS. 4 and 5. That is, strengthening material 50 can be located inside a monopole, and strengthening plates, such as plates 100 and/or 100 C can be applied to the outside of the monopole as well, depending on whether the monopole is circular or polygonal in outer perimetric shape. Thus, in appropriate circumstances, a monopole can be strengthened both internally and externally. This is indicated in FIGS. 4 and 5. While only one strengthening element is shown on each monopole, it is understood that as many as necessary can be used, and the showing of only one strengthening element is merely for the ease of illustration and is not intended to be limiting.
[0077] It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.
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An existing monopole is strengthened to accommodate loading associated with additional elements included in over-the-air communications systems by placing expanding foam and aggregate, light weight aggregate concrete, normal weight aggregate concrete or other types of fill material into the hollow bore in the interior of the monopole. Monopole strengthening may equire base plate strengthening, adding anchor bolts and/or foundation strenghtening. This permits an existing monopole to accommodate more elements than were initially envisioned when the monopole was initially erected.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 61/416,081 filed Nov. 22, 2010, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to novel derivatives, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals, as modulators of sphingosine-1-phosphate receptors. The invention relates specifically to the use of these compounds and their pharmaceutical compositions to treat disorders associated with sphingosine-1-phosphate (SIP) receptor modulation.
BACKGROUND OF THE INVENTION
Sphingosine-1 phosphate is stored in relatively high concentrations in human platelets, which lack the enzymes responsible for its catabolism, and it is released into the blood stream upon activation of physiological stimuli, such as growth factors, cytokines, and receptor agonists and antigens. It may also have a critical role in platelet aggregation and thrombosis and could aggravate cardiovascular diseases. On the other hand the relatively high concentration of the metabolite in high-density lipoproteins (HDL) may have beneficial implications for atherogenesis. For example, there are recent suggestions that sphingosine-1-phosphate, together with other lysolipids such as sphingosylphosphorylcholine and lysosulfatide, are responsible for the beneficial clinical effects of HDL by stimulating the production of the potent antiatherogenic signaling molecule nitric oxide by the vascular endothelium. In addition, like lysophosphatidic acid, it is a marker for certain types of cancer, and there is evidence that its role in cell division or proliferation may have an influence on the development of cancers. These are currently topics that are attracting great interest amongst medical researchers, and the potential for therapeutic intervention in sphingosine-1-phosphate metabolism is under active investigation.
SUMMARY OF THE INVENTION
We have now discovered a group of novel compounds which are potent and selective sphingosine-1-phosphate modulators. As such, the compounds described herein are useful in treating a wide variety of disorders associated with modulation of sphingosine-1-phosphate receptors. The term “modulator” as used herein, includes but is not limited to: receptor agonist, antagonist, inverse agonist, inverse antagonist, partial agonist, partial antagonist.
This invention describes compounds of Formula I, which have sphingosine-1-phosphate receptor biological activity. The compounds in accordance with the present invention are thus of use in medicine, for example in the treatment of humans with diseases and conditions that are alleviated by S1P modulation.
In one aspect, the invention provides a compound having Formula I or a pharmaceutically acceptable salt thereof or stereoisomeric forms thereof, or the geometrical isomers, enantiomers, diastereoisomers, tautomers, zwitterions and pharmaceutically acceptable salts thereof:
In one embodiment of the invention, there are provided compounds having the Formula I below and pharmaceutically accepted salts thereof, its enantiomers, diastereoisomers, hydrates, solvates, crystal forms and individual isomers, tautomers or a pharmaceutically acceptable salt thereof,
wherein:
R 1 is N or C—R 9 ;
R 2 is substituted or unsubstituted aromatic heterocycle, C 5-8 cycloalkenyl or C 6-10 aryl;
R 3 is O, N—R 10 , CH—R 11 , S, —CR 12 ═CR 13 —, —C≡C— or —C(O)—;
R 4 is H, C 5-8 cycloalkenyl, C 3-8 cycloalkyl or substituted or unsubstituted C 6-10 aryl;
R 5 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl;
R 6 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl;
a is 0, 1, 2, 3 or 4;
b is 0, 1, 2, 3 or 4;
L is CHR 7 , O, S, NR 8 or —C(O)—;
R 7 is H, C 1-3 alkyl, —OC 1-3 alkyl, halogen, hydroxyl or NR 9 R 10 ;
R 8 is H or C 1-3 alkyl;
R 9 is H, halogen or C 1-3 alkyl;
R 10 is H or C 1-3 alkyl;
R 11 is H or C 1-3 alkyl;
R 12 is H or C 1-3 alkyl;
R 13 is H or C 1-3 alkyl;
Q 1 is —CR 14 R 15 —;
R 14 is H, halogen, or C 1-3 alkyl;
R 15 is H, halogen, or C 1-3 alkyl;
m is 0, 1, 2 or 3;
T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 , O, or S; Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH
with the proviso that when R 3 is O, N—R 10 , S, —CR 12 ═CR 13 —, —C≡C— or —C(O)— and b is 0 or 1 then L is not O, S, NR 8 or —C(O)—.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ; R 2 is a five-membered aromatic substituted or unsubstituted heterocycle or C 5-8 cycloalkenyl; R 3 is O, N—R 10 , CH—R 11 , S; R 4 is substituted or unsubstituted C 6-10 aryl; R 5 is H, or halogen; R 6 is H or halogen; R 8 is H or C 1-3 alkyl; R 9 is H or C 1-3 alkyl; R 10 is H or C 1-3 alkyl; R 11 is H or C 1-3 alkyl; a is 0, 1, 2, 3 or 4; b is 0, 1, 2, 3 or 4; L is CH 2 ; m is 0; T is —NH-Q 2 ; Q 2 is —C 1-6 alkyl,
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ; R 2 is furan, 2-furyl and 3-furyl derivatives; thiophene, 2-thienyl and 3-thienyl derivatives; pyrrole, oxazole, thiazole, pyrrolidine, pyrroline, imidazole, pyrazole, pyrazoline, isoxazole, isothiazole, pyrazolidine, imidazoline, thiazoline, oxazoline, dihydrothiophene, dihydrofuran, tetrazole, triazole, oxadiazole, 1,2,5-oxadiazole, thiadiazole, 1,2,3-triazole, 1,2,4-triazole, pyrrolidinone, pyrrol-2(3H)-one, imidazolidin-2-one, or 1,2,4-triazol-5(4H)-one and the like 5-membered heterocyclic rings; R 3 is O, N—R 10 , CH—R 11 , S; R 4 is phenyl with ortho, meta and para substitution with groups such as: halogens fluoro, chloro and bromo; short chain alkyls methyl, ethyl, propyl, isopropyl and other, methoxy, trifluoromethoxy, trifluoromethyl and perfluorinated short chain alkyl groups; R 5 is H, or halogen; R 6 is H or halogen; R 8 is H or C 1-3 alkyl; R 9 is H or C 1-3 alkyl; R 10 is H or C 1-3 alkyl; R 11 is H or C 1-3 alkyl; a is 0, 1, 2, 3 or 4; b is 0, 1, 2, 3 or 4; L is CH 2 ; m is 0; T is —NH-Q 2 ; Q 2 is —C 1-6 alkyl,
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered aromatic substituted or unsubstituted heterocycle or C 5-8 cycloalkenyl; R 3 is O, N—R 10 , CH—R 11 , S; R 4 is substituted or unsubstituted C 6-10 aryl; R 5 is H, or halogen; R 6 is H or halogen; R 8 is H or C 1-3 alkyl; R 9 is H or C 1-3 alkyl; R 10 is H or C 1-3 alkyl; R 11 is H or C 1-3 alkyl; a is 0, 1, 2, 3 or 4; b is 0, 1, 2, 3 or 4; L is CH 2 ; m is 0; T is —NH-Q 2 ; Q 2 is —C 1-6 alkyl,
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered aromatic substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H, Cl, Br or F; R 6 is H, Cl, Br or F; a is 1, 2, or 3; b is 1, 2, or 3; L is CHR 7 ; R 7 is H or C 1-3 alkyl; m is 0; T is —NH-Q 2 ; Q 2 is —C 1-6 alkyl or
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered aromatic substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H, Cl, Br or F; R 6 is H, Cl, Br or F; a is 1, 2, or 3; b is 1, 2, or 3; L is CHR 7 ; R 7 is H or C 1-3 alkyl; m is 0; T is —NH-Q 2 ; Q 2 is —C 1-6 alkyl or
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered aromatic substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or F; R 6 is H or F; R 8 is H or C 1-3 alkyl; R 9 is H or C 1-3 alkyl; a is 1, 2, or 3; b is 1, 2, or 3; L is CH 2 ; m is 0; T is —NH-Q 2 ; Q 2 is —C 1-6 alkyl or
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered aromatic substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or F; R 6 is H or F; R 9 is H; a is 2; b is 2; L is CH 2 ; m is 0; T is —NH-Q 2 ; Q 2 is —C 1-6 alkyl,
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 or N; R 2 is a five-membered aromatic substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted C 6-10 aryl; a is 0, 1, 2, 3 or 4; b is 0, 1, 2, 3 or 4; R 5 is H, or F, R 6 is H, or F, R 9 is H or C 1-3 alkyl; L is CH 2 ; Q 1 is —CR 14 R 15 —; R 14 is H; R 15 is H; m is 2; T is
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ; Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 or N; R 2 is a five-membered substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H, or F; R 6 is H or F; a is 1, 2, or 3; b is 1, 2, or 3; R 9 is H or C 1-3 alkyl; L is CH 2 ; Q 1 is —CR 14 R 15 —; R 14 is H; R 15 is H; m is 2; T is
“*” represents the point of attachment to the rest of the molecule;
Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered aromatic substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or F; R 6 is H or F; R 9 is H; a is 2; b is 2; L is CH 2 ; Q 1 is —CR 14 R 15 —; R 14 is H; R 15 is H; m is 2; T is
“*” represents the point of attachment to the rest of the molecule;
Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ; R 2 is a five-membered aromatic substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H, or F; R 6 is H, or F; a is 1, 2, or 3; b is 1, 2, or 3; L is CH 2 ; R 9 is H or C 1-3 alkyl; m is 0; T is
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ; Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 R 2 is a five-membered aromatic substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H, or F; R 6 is H, or F; R 9 is H; a is 2; b is 2; L is CH 2 ; m is 0; T is
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ; Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ; R 2 is substituted or unsubstituted heterocycle, C 5-8 cycloalkenyl or C 6-10 aryl; R 3 is O, N—R 10 , CH—R 11 , S, —CR 12 ═CR 13 —, —C≡C— or —C(O)—; R 4 is H, C 5-8 cycloalkenyl, C 3-8 cycloalkyl or substituted or unsubstituted C 6-10 aryl; R 5 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl; R 6 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl; a is 0, 1, 2, 3 or 4; b is 0, 1, 2, 3 or 4; L is CHR 7 , O, S, NR 8 or —C(O)—; R 7 is H, C 1-3 alkyl, —OC 1-3 alkyl, halogen, hydroxyl or NR 9 R 10 ; R 8 is H or C 1-3 alkyl; R 9 is H, halogen or C 1-3 alkyl; R 10 is H or C 1-3 alkyl; R 11 is H or C 1-3 alkyl; R 12 is H or C 1-3 alkyl; R 13 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 14 is H, halogen, or C 1-3 alkyl; R 15 is H, halogen, or C 1-3 alkyl; m is 0, 1, 2 or 3; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 , O, or S; Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH
with the proviso that when R 3 is O, N—R 10 , S, —CR 12 ═CR 13 —, —C≡C— or —C(O)— and b is 0 or 1 then L is not O, S, NR 8 or —C(O)—.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted C 6-10 aryl; R 5 is H or halogen; R 6 is H or halogen; a is 1 or 2; b is 1 or 2; L is CHR 7 ; R 7 is H; R 9 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 14 is H; R 15 is H; m is 2; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ; Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —P(O)MeOH, —P(O)(H)OH, —OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted C 6-10 aryl; R 5 is H or halogen; R 6 is H or halogen; a is 1 or 2; b is 1 or 2; L is CHR 7 ; R 7 is H; R 9 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 14 is H; R 15 is H; m is 2; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ; Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —P(O)MeOH, —P(O)(H)OH, —OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted C 6-10 aryl; R 5 is H or halogen; R 6 is H or halogen; a is 1 or 2; b is 1 or 2; L is CHR 7 ; R 7 is H; R 9 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 14 is H; R 15 is H; m is 2; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —P(O)MeOH, —P(O)(H)OH, —OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH,
The term “alkyl”, as used herein, refers to saturated, monovalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 6 carbon atoms. One methylene (—CH 2 —) group, of the alkyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, or by a divalent C 3-6 cycloalkyl. Alkyl groups can be substituted by halogen, amino, hydroxyl, cycloalkyl, amino, non-aromatic heterocycles, carboxylic acid, phosphonic acid groups, sulphonic acid groups, phosphoric acid.
The term “short chain alkyl” as used herein, refers to saturated monovalent linear or branched moieties containing 1 to 3 carbon atoms.
The term perfluorinated short chain alkyl groups as used herein, refers to but CF 3 —CF 2 —, CF 3 , (CF 3 ) 2 —CH—, CF 3 —(CF 3 ) 2 —.
The term “alkylene”, as used herein, refers to saturated, divalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 6 carbon atoms. One methylene (—CH 2 —) group of the alkylene can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl.
The term “cycloalkyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms, derived from a saturated cyclic hydrocarbon. Cycloalkyl groups can be monocyclic or polycyclic. Cycloalkyl can be substituted by 1 to 3 C 1-3 alkyl groups or 1 or 2 halogens.
The term “cycloalkenyl”, as used herein, refers to a monovalent or divalent group of 5 to 8 carbon atoms, derived from a saturated cycloalkyl having one double bond. Cycloalkenyl groups can be monocyclic or polycyclic. Cycloalkenyl groups can be substituted by C 1-3 alkyl groups or halogens.
The term “halogen”, as used herein, refers to an atom of chlorine, bromine, fluorine, iodine.
The term “alkenyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one double bond. C 2-6 alkenyl can be in the E or Z configuration. Alkenyl groups can be substituted by C 1-3 alkyl.
The term “alkynyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one triple bond.
The term “heterocycle” as used herein, refers to a 3 to 10 membered ring, which is aromatic or non-aromatic, saturated or non-saturated and containing at least one heteroatom selected form O or N or S or combinations of at least two thereof, interrupting the carbocyclic ring structure. The heterocyclic ring can be interrupted by a C═O; the S heteroatom can be oxidized. Heterocycles can be monocyclic or polycyclic. Heterocyclic ring moieties can be substituted by hydroxyl, C 1-3 alkyl or halogens. Examples of aromatic heterocycles are, but not limited to: furan, 2-furyl and 3-furyl derivatives; thiophene, 2-thienyl, 3-thienyl derivatives; pyrrole, oxazole, thiazole, imidazole, pyrazole, isoxazole, isothiazole, tetrazole, triazole, oxadiazole, 1,2,5-oxadiazole, thiadiazole, 1,2,3-triazole, 1,2,4-triazole.
Examples of non-aromatic heterocycles are, but not limited to: pyrrolidine, pyrroline, pyrazoline, pyrazolidine, imidazoline, thiazoline, oxazoline, dihydrothiophene, dihydrofuran, pyrrolidinone, pyrrol-2(3H)-one, imidazolidin-2-one, or 1,2,4-triazol-5(4H)-one.
Usually, in the present case, heterocyclic groups are 5 or 6 membered rings including but not limited to: 1-substituted-1H-1,2,4-triazole, 1-substituted-azetidine-3-CO 2 H, 4-linked-indole, 6-methyl-5-linked-indazole or 6-hydro-5-linked-indazole. Some preferred heterocycles at the R 2 position include the following: furan, 2-furyl and 3-furyl derivatives; thiophene, 2-thienyl and 3-thienyl derivatives; pyrrole, oxazole, thiazole, pyrrolidine, pyrroline, imidazole, pyrazole, pyrazoline, isoxazole, isothiazole, pyrazolidine, imidazoline, thiazoline, oxazoline, dihydrothiophene, dihydrofuran, tetrazole, triazole, oxadiazole, 1,2,5-oxadiazole, thiadiazole, 1,2,3-triazole, 1,2,4-triazole, pyrrolidinone, pyrrol-2(3H)-one, imidazolidin-2-one, or 1,2,4-triazol-5(4H)-one and the like 5-membered heterocyclic rings.
The term “aryl” as used herein, refers to an organic moiety derived from an aromatic hydrocarbon consisting of a ring containing 6 to 10 carbon atoms by removal of one hydrogen. Aryl is optionally substituted by halogen atoms or by C 1-3 alkyl groups. Preferred aryl groups at the R 4 position include: phenyl with ortho, meta and para substitution with groups such as: halogens fluoro, chloro and bromo; short chain alkyls methyl, ethyl, propyl, isopropyl and other, methoxy, trifluoromethoxy, trifluoromethyl and perfluorinated short chain alkyl groups.
The group of formula “—CR 12 ═CR 13 —”, as used herein, represents an alkenyl radical.
The group of formula “—C≡C—”, as used herein, represents an alkynyl radical.
The term “hydroxyl” as used herein, represents a group of formula “—OH”.
The term “carbonyl” as used herein, represents a group of formula “—C(O)”.
The term “carboxyl” as used herein, represents a group of formula “—C(O)O—”.
The term “sulfonyl” as used herein, represents a group of formula “—SO 2 ”.
The term “sulfate” as used herein, represents a group of formula “—O—S(O) 2 —O—”.
The term “carboxylic acid” as used herein, represents a group of formula “—C(O)OH”.
The term “sulfoxide” as used herein, represents a group of formula “—S═O”.
The term “phosphonic acid” as used herein, represents a group of formula “—P(O)(OH) 2 ”.
The term “phosphoric acid” as used herein, represents a group of formula “—(O)P(O)(OH) 2 ”.
The term “boronic acid”, as used herein, represents a group of formula “—B(OH) 2 ”.
The term “sulphonic acid” as used herein, represents a group of formula “—S(O) 2 OH”.
The formula “H”, as used herein, represents a hydrogen atom.
The formula “O”, as used herein, represents an oxygen atom.
The formula “N”, as used herein, represents a nitrogen atom.
The formula “S”, as used herein, represents a sulfur atom.
Some compounds of the invention are:
(2R)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate; (2S)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate; 2-amino-3-hydroxy-2-methyl-N-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}propanamide; 2-amino-3-hydroxy-2-methyl-N-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}propanamide; (2S)-2-amino-3-({3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate; (2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate; 2-amino-N-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-3-hydroxy-N-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}propanamide; 2-amino-3-({3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate; 2-amino-3-{[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]amino}-3-oxopropyl dihydrogen phosphate; 2-amino-3-({3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate; 2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}amino)propyl dihydrogen phosphate; 2-amino-3-({6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}amino)-3-oxopropyl dihydrogen phosphate; 2-amino-N-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-N-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-N-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-3-hydroxy-N-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}propanamide; 2-amino-N-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-3-hydroxypropanamide; 2-amino-4-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-2-(hydroxymethyl)-4-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}butyl dihydrogen phosphate; 2-amino-4-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-4-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-4-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-2-(hydroxymethyl)-4-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}butyl dihydrogen phosphate; 2-amino-4-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-2-(2-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}ethyl)propane-1,3-diol; 2-amino-2-{2-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]ethyl}propane-1,3-diol; 2-amino-2-(2-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}ethyl)propane-1,3-diol; 2-amino-2-(4-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-{4-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]-1H-imidazol-2-yl}ethyl dihydrogen phosphate; 2-amino-2-(4-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethanol; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}-1H-imidazol-2-yl)ethanol; 2-amino-2-(4-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethanol; 2-amino-2-{4-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]-1H-imidazol-2-yl}ethanol; 2-amino-2-(4-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethanol; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}-1H-imidazol-2-yl)ethanol; 2-amino-2-(4-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-1H-imidazol-2-yl)ethanol.
Some compounds of Formula I and some of their intermediates have at least one stereogenic center in their structure. This stereogenic center may be present in an R or S configuration, said R and S notation is used in correspondence with the rules described in Pure Appli. Chem. (1976), 45, 11-13.
The term “pharmaceutically acceptable salts” refers to salts or complexes that retain the desired biological activity of the above identified compounds and exhibit minimal or no undesired toxicological effects. The “pharmaceutically acceptable salts” according to the invention include therapeutically active, non-toxic base or acid salt forms, which the compounds of Formula I are able to form.
The acid addition salt form of a compound of Formula I that occurs in its free form as a base can be obtained by treating the free base with an appropriate acid such as an inorganic acid, for example, a hydrohalic acid, such as hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; or an organic acid such as for example, acetic, hydroxyacetic, propanoic, lactic, pyruvic, malonic, fumaric acid, maleic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, citric, methylsulfonic, ethanesulfonic, benzenesulfonic, formic and the like (Handbook of Pharmaceutical Salts, P. Heinrich Stahal & Camille G. Wermuth (Eds), Verlag Helvetica Chemica Acta-Zürich, 2002, 329-345).
Compounds of Formula I and their salts can be in the form of a solvate, which is included within the scope of the present invention. Such solvates include for example hydrates, alcoholates and the like.
With respect to the present invention reference to a compound or compounds, is intended to encompass that compound in each of its possible isomeric forms and mixtures thereof unless the particular isomeric form is referred to specifically.
Compounds according to the present invention may exist in different polymorphic forms. Although not explicitly indicated in the above formula, such forms are intended to be included within the scope of the present invention.
The compounds of the invention are indicated for use in treating or preventing conditions in which there is likely to be a component involving the sphingosine-1-phosphate receptors.
In another embodiment, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier.
In a further embodiment of the invention, there are provided methods for treating disorders associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one compound of the invention.
These compounds are useful for the treatment of mammals, including humans, with a range of conditions and diseases that are alleviated by S1P modulation: not limited to the treatment of diabetic retinopathy, other retinal degenerative conditions, dry eye, angiogenesis and wounds.
Therapeutic utilities of S1P modulators are ocular diseases, such as but not limited to: wet and dry age-related macular degeneration, diabetic retinopathy, retinopathy of prematurity, retinal edema, geographic atrophy, glaucomatous optic neuropathy, chorioretinopathy, hypertensive retinopathy, ocular ischemic syndrome, prevention of inflammation-induced fibrosis in the back of the eye, various ocular inflammatory diseases including uveitis, scleritis, keratitis, and retinal vasculitis; or systemic vascular barrier related diseases such as but not limited to: various inflammatory diseases, including acute lung injury, its prevention, sepsis, tumor metastasis, atherosclerosis, pulmonary edemas, and ventilation-induced lung injury; or autoimmune diseases and immunosuppression such as but not limited to: rheumatoid arthritis, Crohn's disease, Graves' disease, inflammatory bowel disease, multiple sclerosis, Myasthenia gravis, Psoriasis, ulcerative colitis, antoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermititis, and organ transplantation; or allergies and other inflammatory diseases such as but not limited to: urticaria, bronchial asthma, and other airway inflammations including pulmonary emphysema and chronic obstructive pulmonary diseases; or cardiac protection such as but not limited to: ischemia reperfusion injury and atherosclerosis; or wound healing such as but not limited to: scar-free healing of wounds from cosmetic skin surgery, ocular surgery, GI surgery, general surgery, oral injuries, various mechanical, heat and burn injuries, prevention and treatment of photoaging and skin ageing, and prevention of radiation-induced injuries; or bone formation such as but not limited to: treatment of osteoporosis and various bone fractures including hip and ankles; or anti-nociceptive activity such as but not limited to: visceral pain, pain associated with diabetic neuropathy, rheumatoid arthritis, chronic knee and joint pain, tendonitis, osteoarthritis, neuropathic pains; or central nervous system neuronal activity in Alzheimer's disease, age-related neuronal injuries; or in organ transplant such as renal, corneal, cardiac or adipose tissue transplant; inflammatory skin diseases, scleroderma, dermatomyositis, atopic dermatitis, lupus erythematosus, epidermolysis bullosa, and bullous pemphigold. Topical use of S1P (sphingosine) compounds is of use in the treatment of various acne diseases, acne vulgaris, and rosacea.
In still another embodiment of the invention, there are provided methods for treating disorders associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a therapeutically effective amount of at least one compound of the invention, or any combination thereof, or pharmaceutically acceptable salts, hydrates, solvates, crystal forms and individual isomers, enantiomers, and diastereomers thereof.
The present invention concerns the use of a compound of Formula I or a pharmaceutically acceptable salt thereof, for the manufacture of a medicament for the treatment of ocular disease, wet and dry age-related macular degeneration, diabetic retinopathy, retinopathy of prematurity, retinal edema, geographic atrophy, glaucomatous optic neuropathy, chorioretinopathy, hypertensive retinopathy, ocular ischemic syndrome, prevention of inflammation-induced fibrosis in the back of the eye, various ocular inflammatory diseases including uveitis, scleritis, keratitis, and retinal vasculitis; or systemic vascular barrier related diseases, various inflammatory diseases, including acute lung injury, its prevention, sepsis, tumor metastasis, atherosclerosis, pulmonary edemas, and ventilation-induced lung injury; or autoimmune diseases and immunosuppression, rheumatoid arthritis, Crohn's disease, Graves' disease, inflammatory bowel disease, multiple sclerosis, Myasthenia gravis, Psoriasis, ulcerative colitis, antoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermititis, and organ transplantation; or allergies and other inflammatory diseases, urticaria, bronchial asthma, and other airway inflammations including pulmonary emphysema and chronic obstructive pulmonary diseases; or cardiac protection, ischemia reperfusion injury and atherosclerosis; or wound healing, scar-free healing of wounds from cosmetic skin surgery, ocular surgery, GI surgery, general surgery, oral injuries, various mechanical, heat and burn injuries, prevention and treatment of photoaging and skin ageing, and prevention of radiation-induced injuries; or bone formation, treatment of osteoporosis and various bone fractures including hip and ankles; or anti-nociceptive activity, visceral pain, pain associated with diabetic neuropathy, rheumatoid arthritis, chronic knee and joint pain, tendonitis, osteoarthritis, neuropathic pains; or central nervous system neuronal activity in Alzheimer's disease, age-related neuronal injuries; or in organ transplant such as renal, corneal, cardiac or adipose tissue transplant; inflammatory skin diseases, scleroderma, dermatomyositis, atopic dermatitis, lupus erythematosus, epidermolysis bullosa, and bullous pemphigold.
The actual amount of the compound to be administered in any given case will be determined by a physician taking into account the relevant circumstances, such as the severity of the condition, the age and weight of the patient, the patient's general physical condition, the cause of the condition, and the route of administration.
The patient will be administered the compound orally in any acceptable form, such as a tablet, liquid, capsule, powder and the like, or other routes may be desirable or necessary, particularly if the patient suffers from nausea. Such other routes may include, without exception, transdermal, parenteral, subcutaneous, intranasal, via an implant stent, intrathecal, intravitreal, topical to the eye, back to the eye, intramuscular, intravenous, and intrarectal modes of delivery. Additionally, the formulations may be designed to delay release of the active compound over a given period of time, or to carefully control the amount of drug released at a given time during the course of therapy.
In another embodiment of the invention, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier thereof. The phrase “pharmaceutically acceptable” means the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
Pharmaceutical compositions of the present invention can be used in the form of a solid, a solution, an emulsion, a dispersion, a patch, a micelle, a liposome, and the like, wherein the resulting composition contains one or more compounds of the present invention, as an active ingredient, in admixture with an organic or inorganic carrier or excipient suitable for enteral or parenteral applications. Invention compounds may be combined, for example, with the usual non-toxic, pharmaceutically acceptable carriers for tablets, pellets, capsules, suppositories, solutions, emulsions, suspensions, and any other form suitable for use. The carriers which can be used include glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, medium chain length triglycerides, dextrans, and other carriers suitable for use in manufacturing preparations, in solid, semisolid, or liquid form. In addition auxiliary, stabilizing, thickening and coloring agents and perfumes may be used. Invention compounds are included in the pharmaceutical composition in an amount sufficient to produce the desired effect upon the process or disease condition.
Pharmaceutical compositions containing invention compounds may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known in the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of a sweetening agent such as sucrose, lactose, or saccharin, flavoring agents such as peppermint, oil of wintergreen or cherry, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets containing invention compounds in admixture with non-toxic pharmaceutically acceptable excipients may also be manufactured by known methods. The excipients used may be, for example, (1) inert diluents such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents such as corn starch, potato starch or alginic acid; (3) binding agents such as gum tragacanth, corn starch, gelatin or acacia, and (4) lubricating agents such as magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed.
In some cases, formulations for oral use may be in the form of hard gelatin capsules wherein the invention compounds are mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the invention compounds are mixed with water or an oil medium, for example, peanut oil, liquid paraffin or olive oil.
The pharmaceutical compositions may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids (including oleic acid), naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
Invention compounds may also be administered in the form of suppositories for rectal administration of the drug. These compositions may be prepared by mixing the invention compounds with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters of polyethylene glycols, which are solid at ordinary temperatures, but liquefy and/or dissolve in the rectal cavity to release the drug.
Since individual subjects may present a wide variation in severity of symptoms and each drug has its unique therapeutic characteristics, the precise mode of administration and dosage employed for each subject is left to the discretion of the practitioner.
The compounds and pharmaceutical compositions described herein are useful as medicaments in mammals, including humans, for treatment of diseases and/or alleviations of conditions which are responsive to treatment by agonists or functional antagonists of sphingosine-1-phosphate receptors. Thus, in further embodiments of the invention, there are provided methods for treating a disorder associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one invention compound. As used herein, the term “therapeutically effective amount” means the amount of the pharmaceutical composition that will elicit the biological or medical response of a subject in need thereof that is being sought by the researcher, veterinarian, medical doctor or other clinician. In some embodiments, the subject in need thereof is a mammal. In some embodiments, the mammal is human.
The present invention concerns also processes for preparing the compounds of Formula I. The compounds of formula I according to the invention can be prepared analogously to conventional methods as understood by the person skilled in the art of synthetic organic chemistry. The synthetic schemes set forth below, illustrate how compounds according to the invention can be made. Those skilled in the art will be able to routinely modify and/or adapt the following schemes to synthesize any compounds of the invention covered by Formula I.
In Scheme 1, aryl amines or aryl amine derivatives or precursors react with functionalized compounds such as halogenated or hydroxylated compounds in the presence of reagents that promote alkylation as known to synthetic chemists to give the corresponding ether intermediate. This intermediate from the last step is coupled with the boronic acid or the stannate, generally involving a metal catalyst under appropriate conditions with an R 2 group to give the corresponding intermediate. The previous intermediate from the coupling procedure may be converted to an aryl amine as required for the next step by deprotection or reduction methods. The intermediate from the previous step reacts to form an amide under conditions that may employ carboxylic acids and the like to give an intermediate of Formula I. This intermediate from the last step is reacted with appropriate reagents to promote phosphorylation and yield a derivative of Formula I as a Compound of the invention upon removal of any required protecting groups.
In Scheme II, aryl amines/amine precursors that may contain a halogen such as a bromine atom, react with functionalized compounds such as a halogenated or hydroxylated compound, in the presence of reagents that promote alkylation well known to synthetic chemists to give the corresponding ether intermediate. This intermediate from the last step is coupled with the boronic acid or the stannate involving a metal catalyst under appropriate conditions with an R 2 group (shown as a 2-furyl derivative below) to give the corresponding intermediate. The intermediate from the previous step may be converted to an aryl amine as required for the next step by deprotection or reduction methods. This aryl amine from the last step reacts to form an amide under conditions that may employ carboxylic acids and the like to give an intermediate of Formula I. This intermediate is reacted with appropriate reagents to promote phosphorylation and yield a derivative of Formula I as a Compound of the invention upon removal of any required protecting groups.
In Scheme III, elaborated aryl bromides, are obtained according to application of appropriate synthetic preparation, may react with compounds in the presence of reagents that promote alkylation. This intermediate from the last step that contains the R 3 group (representing an —O—, —S— —NH—, —CH 2 —) or other group is coupled with the boronic acid or the stannate under appropriate conditions with an R 2 group to give the corresponding intermediate. This intermediate from the previous step is reacted with appropriate reagents to promote phosphorylation and yield a derivative of Formula I as a Compound of the invention upon removal of any required protecting groups.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts lowered lymphocyte count after 24 hours (<1 number of lymphocytes 10 3 /μL blood) by Compound 4.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention claimed. As used herein, the use of the singular includes the plural unless specifically stated otherwise.
It will be readily apparent to those skilled in the art that some of the compounds of the invention may contain one or more asymmetric centers, such that the compounds may exist in enantiomeric as well as in diastereomeric forms. Unless it is specifically noted otherwise, the scope of the present invention includes all enantiomers, diastereomers and racemic mixtures. Some of the compounds of the invention may form salts with pharmaceutically acceptable acids or bases, and such pharmaceutically acceptable salts of the compounds described herein are also within the scope of the invention.
The present invention includes all pharmaceutically acceptable isotopically enriched compounds. Any compound of the invention may contain one or more isotopic atoms enriched or different than the natural ratio such as deuterium 2 H (or D) in place of protium 1 H (or H) or use of 13 C enriched material in place of 12 C and the like. Similar substitutions can be employed for N, O and S. The use of isotopes may assist in analytical as well as therapeutic aspects of the invention. For example, use of deuterium may increase the in vivo half-life by altering the metabolism (rate) of the compounds of the invention. These compounds can be prepared in accord with the preparations described by use of isotopically enriched reagents.
The following examples are for illustrative purposes only and are not intended, nor should they be construed as limiting the invention in any manner. Those skilled in the art will appreciate that variations and modifications of the following examples can be made without exceeding the spirit or scope of the invention.
As will be evident to those skilled in the art, individual isomeric forms can be obtained by separation of mixtures thereof in conventional manner. For example, in the case of diasteroisomeric isomers, chromatographic separation may be employed.
Compound names were generated with ACD version 8, and some intermediates' and reagents' names used in the examples were generated with software such as Chem Bio Draw Ultra version 12.0 or Auto Nom 2000 from MDL ISIS Draw 2.5 SP1 or from a commercial supplier catalog such as Sigma-Aldrich.
In general, characterization of the compounds is performed using NMR spectra which were recorded on 300 and/or 600 MHz Varian and acquired at room temperature. Chemical shifts were given in ppm referenced either to internal TMS or to the solvent signal. Coupling constant J reported in Hz, hertz.
All the reagents, solvents, catalysts for which the synthesis is not described are purchased from chemical vendors such as Sigma Aldrich, Fluka, Bio-Blocks, Combi-blocks, TCI, VWR, Lancaster, Oakwood, Trans World Chemical, Alfa, Fisher, Maybridge, Frontier, Matrix, Ukrorgsynth, Toronto, Ryan Scientific, SiliCycle, Anaspec, Syn Chem, Chem-Impex, MIC-scientific, Ltd; however some known intermediates, were prepared according to published procedures.
Usually the compounds of the invention were purified by column chromatography (Auto-column) on a Teledyne-ISCO CombiFlash with a silica gel column, unless noted otherwise.
The following abbreviations are used in the examples:
s, m, h, d second, minute, hour, day CH 3 CN acetonitrile PSI pound per square inch DCM dichloromethane DMF N,N-dimethylformamide NaOH sodium hydroxide MeOH methanol CD 3 OD deuterated methanol NH 3 ammonia HCl hydrochloric acid Na 2 SO 4 sodium sulfate RT or rt room temperature MgSO 4 magnesium sulfate EtOAc ethyl acetate CDCl 3 deuterated chloroform DMSO-d 6 deuterated dimethyl sulfoxide Auto-column automated flash liquid chromatography TFA trifluoroacetic acid THF tetrahydrofuran M molar PdCl 2 (PPh 3 ) 2 bis(triphenylphosphine)palladium(II) chloride AcOH acetic acid K 2 CO 3 potassium carbonate NaCl sodium chloride CHCl 3 chloroform HATU (O-(7-azabenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate)
Those skilled in the art will be routinely able to modify and/or adapt the following procedures to synthesize any compound of the invention covered by Formula I.
Example 1
Intermediate 1
2-bromo-4-nitro-1-((5-phenylpentyl)oxy)benzene
A mixture of 2-bromo-4-nitrophenol (CAS 5847-59-6) (2.05 g, 9.4 mmol), (5-bromopentyl)benzene (CAS 14469-83-1) (2.41 g, 10.6 mmol) and K 2 CO 3 (3.5 g, 19.1 mmol) was dissolved in DMF (20 mL). The reaction mixture was heated at 100° C. for ˜18 h. The mixture was diluted with hexanes:EtOAc (1:1) (˜200 mL) and washed with H 2 O (3×). The organic solution was dried over MgSO 4 , filtered, and concentrated onto silica gel under vacuum. Auto-column (9.5 hexanes: 0.5 EtOAc) gave Intermediate 1 as a white solid 1.91 g (56%).
Example 2
Intermediate 2
2-[5-nitro-2-(5-phenyl-pentyloxy)-phenyl]-thiophene
A mixture of Intermediate 1 (1.91 g, 5.25 mmol), tributyl-thiophen-2-yl-stannane (CAS 54663-78-4) (3.4 mL, 10.7 mmol) and PdCl 2 (PPh 3 ) 2 (0.55 g, 15 mol %) in DMF (12 mL) was reacted under MWI at 160° C. for 15 m. The mixture was cooled to rt and diluted with hexanes:EtOAc (1:1, 200 mL). The mixture was washed with water (3×), dried over MgSO 4 , filtered and concentrated onto silica gel under vacuum. Auto-column (9.5 hexanes: 0.5 EtOAc) produced Intermediate 2 as an orange solid, 1.10 g (57%).
Example 3
Intermediate 3
4-(5-phenyl-pentyloxy)-3-thiophen-2-yl-phenylamine
A mixture of iron chips (0.62 g, 11.1 mmol), NH 4 Cl (0.88 g, 16.4 mmol), water (3.3 mL), and ethanol (10 mL) were heated to reflux for 15 m. This mixture was transferred into a solution of Intermediate 2 (1.0 g, 2.72 mmol) in EtOH (8 mL). The resulting mixture was heated to reflux for 5 h. The mixture was filtered, washed with EtOAc and partitioned between EtOAc and water. The organic layers were dried over MgSO 4 , filtered and concentrated onto silica gel. Auto-column (7 hexane: 3 EtOAc) gave Intermediate 3, as a tan solid 0.55 g (60%).
Example 4
Intermediate 4
(R)-tert-butyl (3-hydroxy-2-methyl-1-oxo-1-((4-((5-phenylpentyl)oxy)-3-(thiophen-2-yl)phenyl)amino)propan-2-yl)carbamate
Intermediate 3 (0.30 g, 0.89 mmol), Boc-D-serine (CAS 84311-18-2) (0.25 g, 1.11 mmol), HATU (CAS 148893-10-1) (0.51 g, 1.34 mmol), diisopropylethylamine (CAS 7087-68-5) (0.46 mL) in DMF (20 mL) was reacted at rt for ˜18 h. After an aqueous workup and extraction with (hexanes:EtOAc) the organic layers were combined and concentrated onto silica gel. Auto-column (3% MeOH in CH 2 Cl 2 ) gave Intermediate 4 0.28 g, (58%).
Example 5
Intermediate 5
2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate
Intermediate 4 (0.28 g, 5.20 mmol), tetrazole (7.0 mL, 3.15 mmol; 0.45 M in CH 3 CN), and di-tert-butyl diisopropyl-phosphoramidite (0.65 mL, 2.06 mmol) in DMF (5 mL) were stirred at RT for ˜18 h. Hydrogen peroxide 35% (0.19 mL, 2.2 mmol) excess was added at 0° C. and the mixture was warmed to RT and stirred for 1 h. The solvent was removed under vacuum and the residue was quenched with sat. Na 2 S 2 O 3 (10% aq) and extracted with EtOAc. The organic layers were dried over MgSO 4 , filtered, concentrated onto silica gel under vacuum. Auto-column (6 hexanes: 4 EtOAc) gave Intermediate 5 as a white solid 0.27 g (71%).
Example 6
Compound 1
(2R)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate
Intermediate 5 was dissolved in CH 2 Cl 2 and reacted with HCl in dioxane. The mixture was reacted for ˜18 h at rt. The solvent was removed under vacuum and the crude material was titrated several times with diethyl ether to give Compound 1 as a solid, ˜160 mg.
(300 MHz, CD 3 OD): δ 7.89 (d, J=2.4, 1H), 7.50-7.44 (m, 2H), 7.37 (d, J=5.4, 1H), 7.26-7.21 (m, 2H), 7.17-7.13 (m, 3H), 7.06-7.00 (m, 2H), 4.42 (dd, J=5.1, 11.4, 1H), 4.20 (dd, J=4.8, 11.7, 1H), 4.08 (t, J=6.3, 2H), 2.63 (t, J=7.2, 2H), 1.91-1.84 (m, 2H), 1.74-1.65 (m, 2H), 1.68 (s, 3H), 1.62-1.53 (m, 2H).
Compound 2 prepared from the corresponding starting materials in a similar manner to the procedure described for Compound 1. The results are tabulated below in Table 1.
TABLE 1
Compound 2
IUPAC Name
(2S)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-
thienyl)phenyl}amino)propyl dihydrogen phosphate
Structure
1 H NMR δ (ppm)
(600 MHz, CD 3 OD/CDCl 3 ) δ: 7.91 (d, J = 2.4, 1H), 7.51 (d, J = 3.0, 1H), 7.45 (dd,
J = 2.4, 9.0, 1H), 7.33 (d, J = 4.8, 1H), 7.25 (t, J = 7.8, 2H), 7.18-7.14 (m, 3H), 7.06 (t,
J = 4.8, 1H), 6.95 (d, J = 9.0, 1H), 4.27 (dd, J = 5.4, 10.8, 1H), 4.07 (t, J = 6.6, 2H), 3.96
(dd, J = 5.4, 9.6, 1H), 2.65 (t, J = 7.8, 2H), 1.93-1.89 (m, 2H), 1.74-1.68 (m, 2H),
1.61-1.57 (m, 2H), 1.50 (s, 3H).
Intermediate(s)
1, 2 and 3
starting
Boc-L-serine
material(s)
Example 7
Intermediate 7
2-(2-(benzyloxy)-5-nitrophenylfuran
Intermediate 7 was prepared from Intermediate 1 and tributyl-2-furanyl-stannane, in a similar manner to the procedure described in Example 2 for Intermediate 2.
Example 8
Intermediate 8
3-furan-2-yl-4-(5-phenyl-pentyloxy)-phenylamine
Intermediate 8 was prepared from Intermediate 7 in a similar manner to the procedure described in Example 3 for Intermediate 3.
Example 9
Intermediate 9
{(S)-1-[3-furan-2-yl-4-(5-phenyl-pentyloxy)-phenylcarbamoyl]-2-hydroxy-ethyl}-carbamic acid benzyl ester
Intermediate 8 (0.98 g, 3.05 mmol), N-carbobenzoxy-L-serine (0.82 g, 3.36 mmol), HATU (2.0 g, 5.1 mmol), and diisopropylethylamine (1.8 mL, 10.3 mmol) in DMF (30 mL) was allowed to react for ˜18 h at RT. Auto column (6 hexanes:4 EtOAc) gave a crude Intermediate 9 as a yellow solid, 1.32 g (80%).
Example 10
Intermediate 10
benzyl[2-({3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-1-{[(3-oxido-1,5-dihydro-2,4,3-benzodioxaphosphepin-3-yl)oxy]methyl}-2-oxoethyl]carbamate
Intermediate 9 (1.32 g, 2.43 mmol), tetrazole (16.2 mL, 7.29 mmol; 0.45 M in CH 3 CN), and 3-(diethylamino)-1,5-dihydro-2,4,3-benzodioxaphosphepine (CAS 82372-35-8) (0.88 mL, 3.67 mmol) in THF (25 mL) were stirred at RT for ˜24 h. Hydrogen peroxide 35% (4.7 mL, 54.6 mmol) excess was added and the mixture was stirred for 1 h. The solvent was removed under vacuum and the residue was quenched with sat. Na 2 S 2 O 3 and extracted with EtOAc. The organic layers were dried over MgSO 4 . Auto-column (5 hexanes: 5 EtOAc) gave a crude Intermediate 10 as a yellow oil ˜0.86 g.
Example 11
Compound 3
(2S)-2-amino-3-({3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate
Intermediate 10 (0.86 g, 1.19 mmol) was treated with 10% Pd on C (0.30 g) and hydrogen at 50 psi for 3 h. The mixture was filtered through celite. The filtrate was concentrated onto silica gel and purified with auto-column (gradient 0→100% MeOH in CH 2 Cl 2 ) to give Compound 3 as a solid ˜50 mg.
(300 MHz, DMSO-d 6 ) δ: 8.10 (d, J=2.7, 1H), 7.70 (s, 1H), 7.47 (dd, J=2.1, 8.7, 1H), 7.27-7.14 (m, 6H), 6.99 (d, J=8.7, 1H), 6.85 (d, J=3.0, 1H), 6.54 (dd, J=1.8, 3.6, 1H), 4.02 (t, J=6.3, 2H), 3.98-3.90 (m, 3H), 2.58 (t, J=7.5, 2H), 1.84-1.78 (m, 2H), 1.67-1.62 (m, 2H), 1.52-1.44 (m, 2H).
Compound 4 prepared from Intermediate 3 and the corresponding procedure(s) as described for preparation of Intermediate 10 and in Example 11 for Compound 3. The results are tabulated below in Table 2.
TABLE 2
Compound 4
IUPAC Name
(2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl
dihydrogen phosphate
Structure
1 H NMR δ (ppm)
(600 MHz, CF 3 C(O)OD) δ: 7.68 (d, J = 3.0, 1H), 7.30-7.28 (m, 1H), 7.25-7.22 (m, 3H),
7.20-7.16 (m, 3H), 7.14 (t, J = 7.2, 1H), 7.10 (d, J = 9.0, 1H), 7.06 (d, J = 3.0, 1H),
5.02-4.97 (m, 2H), 4.80-4.77 (m, 1H), 4.17 (t, J = 6.6, 2H), 2.65 (t, J = 7.2, 2H),
1.96-1.92 (m, 2H), 1.75-1.70 (m, 2H), 1.59-1.56 (m, 2H).
Intermediate
3
Biological Examples
In Vitro Assay
Compounds were tested for S1P1 activity using the GTP γ 35 S binding assay. These compounds may be assessed for their ability to activate or block activation of the human S1P1 receptor in cells stably expressing the S1P1 receptor.
GTP γ 35 S binding was measured in the medium containing (mM) HEPES 25, pH 7.4, MgCl 2 10, NaCl 100, dithitothreitol 0.5, digitonin 0.003%, 0.2 nM GTP γ 35 S, and 5 μg membrane protein in a volume of 150 μl. Test compounds were included in the concentration range from 0.08 to 5,000 nM unless indicated otherwise. Membranes were incubated with 100 μM 5′-adenylylimmidodiphosphate for 30 min, and subsequently with 10 μM GDP for 10 min on ice. Drug solutions and membrane were mixed, and then reactions were initiated by adding GTP γ 35 S and continued for 30 min at 25° C. Reaction mixtures were filtered over Whatman GF/B filters under vacuum, and washed three times with 3 mL of ice-cold buffer (HEPES 25, pH 7.4, MgCl 2 10 and NaCl 100). Filters were dried and mixed with scintillant, and counted for 35 S activity using a β-counter. Agonist-induced GTP γ 35 S binding was obtained by subtracting that in the absence of agonist. Binding data were analyzed using a non-linear regression method. In case of antagonist assay, the reaction mixture contained 10 nM S1P in the presence of test antagonist at concentrations ranging from 0.08 to 5000 nM.
Activity potency: S1P1 receptor from GTP γ 35 S: nM, (EC 50 ),
TABLE 3
S1P1
IUPAC name
EC 50 (nM)
(2R)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-
96
(2-thienyl)phenyl}amino)propyl dihydrogen phosphate
(2S)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-
34
(2-thienyl)phenyl}amino)propyl dihydrogen phosphate
(2S)-2-amino-3-({3-(2-furyl)-4-[(5-
8
phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen
phosphate
(2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-
3
thienyl)phenyl}amino)propyl dihydrogen phosphate
Lymphopenia Assay in Mice
Test drugs are prepared in a solution containing 3% (w/v) 2-hydroxy propyl β-cyclodextrin (HPBCD) and 1% DMSO to a final concentration of 1 mg/ml, and subcutaneously injected to female C57BL6 mice (CHARLES RIVERS) weighing 20-25 g at the dose of 10 mg/Kg. Blood samples are obtained by puncturing the submandibular skin with a Goldenrod animal lancet at 24, 48, 72, and 96 hrs post drug application. Blood is collected into microvettes (SARSTEDT) containing EDTA tripotassium salt. Lymphocytes in blood samples are counted using a HEMAVET Multispecies Hematology System, HEMAVET HV950FS (Drew Scientific Inc.).
(Hale, J. et al Bioorg. & Med. Chem. Lett. 14 (2004) 3351).
A lymphopenia assay in mice; as previously described, was employed to measure the in vivo blood lymphocyte depletion after dosing with (2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate. This S1P1 agonist is useful for S1P-related diseases and exemplified by the lymphopenia in vivo response. Test drug, (25)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate was prepared in a solution containing 3% (w/v) 2-hydroxy propyl β-cyclodextrin (HPBCD) and 1% DMSO to a final concentration of 1 mg/ml, and subcutaneously injected to female C57BL6 mice (CHARLES RIVERS) weighing 20-25 g at the dose of 10 mg/Kg. Blood samples were obtained by puncturing the submandibular skin with a Goldenrod animal lancet at different time intervals such as: 24, 48, 72, and 96 h post drug application. Blood was collected into microvettes (SARSTEDT) containing EDTA tripotassium salt. Lymphocytes in blood samples were counted using a HEMAVET Multispecies Hematology System, HEMAVET HV950FS (Drew Scientific Inc.). Results are shown in FIG. 1 that depicts lowered lymphocyte count after 24 hours (<1 number of lymphocytes 10 3 /μL blood).
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The present invention relates to novel derivatives, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals as modulators of sphingosine-1-phosphate receptors.
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BACKGROUND OF THE INVENTION
The platform for radiological examination of the foot and ankle generally relates to medical furniture and more specifically to a platform that positions a radiological plate below or adjacent to a foot.
In medical offices and x-ray rooms across the country, numerous radiological examinations, hereinafter x-rays, are taken of patients and their conditions. Conditions include wounds and injuries to the foot. To determine the extent of a wound or injury, or the progress of healing, x-rays are taken of a foot. X-ray equipment can be positioned at various angles to shoot a beam through the subject part of the body and into a plate. The plate is then developed and the resulting x-ray film is provided to a doctor for evaluation. X-rays can be taken of a patient's foot and ankle as the patient sits and the equipment is positioned near the foot. However, such x-ray films show a foot or ankle without bearing a load, or weight. Those x-ray films show the bony structure in the absence of stress thus limiting the appearance of cracks in the bony structure.
As feet and ankles move and support a person's weight throughout the day and during exertion, x-rays of feet and ankles when under stress provide a more accurate view of the condition of the feet and ankles. Feet and ankles x-rayed while under stress may reveal cracks in the bony structure closed when the feet and ankles are not stressed. Operators of x-ray equipment and doctors have sought devices to assist in x-raying feet and ankles while supporting weight.
DESCRIPTION OF THE PRIOR ART
Over the years, feet and ankles have been x-rayed with the support of various devices. Initially, feet and ankles were merely positioned between an x-ray source and a plate containing x-ray film, usually with the patient seated upon a chair or upon a bench. This method did not provide x-rays of feet and ankles when supporting weight. Operators then placed the plate containing the film upon a floor and the patient stood with a foot upon the plate. As the plate has a thickness, the posture of the patient went out of alignment and the x-ray of the foot showed bony structure also out of position. Operators then had a patient stand upon an elevated platform, such as books or boxes, and suspend the foot and ankle above the plate. As before, this method showed a foot and ankle on the x-ray film that was not supporting weight and with posture out of line.
The prior art has developed various stands. Clear Image Devices of Ann Arbor Michigan has a two step positioning platform for timely and accurate x-rays of the lower extremities. This platform has an upper step with three spaced apart grooves extending longitudinally. The upper step is opaque to visible light but presumably transparent to x-ray and other radiation. The slots allow upright positioning of the x-ray plate and the two step design raises the foot to the height of the x-ray emitter. As the x-ray plate is positioned upright, the platform does not provide a location for the plate to capture an image of the foot from above when the foot supports a person's weight. This platform appears directed primarily to x-rays of the ankle to the exclusion of the remainder of the foot.
The present invention overcomes the difficulty of x-raying the foot from above when bearing weight.
SUMMARY OF THE INVENTION
Generally, the present invention provides a two step platform with a horizontally located chamber. The chamber receives a slide that carries an x-ray film beneath a foot of a standing patient. Additionally, the patient stands upon a visual light and x-ray transparent deck. The deck has one slot for upright positioning of an x-ray film cartridge and a chamber for horizontal positioning of an x-ray film cartridge. The platform of the present invention allows a radiologist to take an x-ray image of a patient's foot and ankle from both the side and from above.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and that the present contribution to the art may be better appreciated. The present invention also includes a slide for carrying the x-ray film cartridge into and out of the chamber, casters upon the rear for easing movement of the invention when it is up ended, and front and rear feet for raising the platform above a floor surface. Additional features of the invention will be described hereinafter and which will form the subject matter of the claims attached.
Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of the presently preferred, but nonetheless illustrative, embodiment of the present invention when taken in conjunction with the accompanying drawings. Before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
One object of the present invention is to provide a new and improved platform for radiological examination of the foot and the ankle of a person.
Another object is to provide such a platform that positions a radiological film cartridge below a person's weight bearing foot for examination from above.
Another object is to provide such a platform that allows a person to see the radiological cartridge below the person's foot during examination.
Another object is to provide such a platform that inserts and removes a radiological film cartridge from within a chamber across the width of said platform.
Another object is to provide such a platform that moves easily when raised upright onto its rear.
Another object is to provide such a platform that occupies a minimum of floor space when raised upon end.
Another object is to provide such a platform that resists racking and distortion both widthwise and lengthwise.
These together with other objects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In referring to the drawings,
FIG. 1 shows an isometric view of the present invention ready for use with its appurtenant slide;
FIG. 2 shows another isometric view of the present invention with the slide placed within the chamber;
FIG. 3 describes a front view of the present invention;
FIG. 4 describes a rear view of the present invention;
FIG. 5 shows a side view of the platform with the slide resting in the chamber;
FIG. 6 shows the other side view of the platform with the slide inserted into the chamber from this side;
FIG. 7 illustrates a top view of the platform; and,
FIG. 8 illustrates a bottom view of the platform of this invention.
The same reference numerals refer to the same parts throughout the various figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention of the platform overcomes the prior art limitations by providing a platform 1 that has a chamber 2 and a nearby slot 3 for placing radiological film cartridges, hereinafter x-ray film, for usage in taking images of a person's ankle or foot while bearing the weight of a person as shown in FIG. 1 . The chamber is located beneath a transparent front deck 4 generally rectangular in shape and preferably square. The front deck is spaced apart from the rear deck 5 by the slot 3 . The rear deck is also transparent and rectangular in shape with the same width as the front deck. The front deck and the rear deck are generally coplanar so that a person, or patient, may stand with one foot upon each deck and the foot for examination upon the front deck 4 . The front deck and the rear deck are supported upon spacers 14 that elevate them from the remaining framework of the platform. The front deck and the rear deck are raised upon spacers 14 so that the chamber has sufficient height to admit an x-ray film when carried upon a slide 6 and the slot has sufficient depth to support an upright x-ray film respectively. The slot 3 has sufficient width to hold an x-ray film securely but permits medical staff to remove an exposed film.
The framework of the platform includes a plate 13 , two inwardly angled sides 7 , a kickplate 8 in two parts upon the front, a step 9 , a base 10 upon the rear, a front foot 11 , and a rear foot 12 . The plate 13 is located below the front deck 4 and the rear deck 5 generally parallel to and spaced apart from the front deck. The spacers 14 upon the plate raise the front deck to create the chamber 2 for admitting an x-ray film upon the slide 6 . The plate has longitudinal sides and lateral ends. The front deck extends slightly beyond the front lateral end of the plate. Two spaced apart sides 7 extend downwardly from the plate and flare outwardly. The sides are planar and substantially rectangular in shape. The sides have an extension 15 forward of the front deck 4 that serves as a riser for step 9 . The extension is generally half the width of the remainder of a side. Ahead of the front deck and between the sides 7 , the framework has two kickplates, one kickplate 8 located beneath the step 9 and between the extensions 15 has a handle 17 , and a second kickplate 8 located immediately beneath the front deck between the sides where each extension joins the remainder of a side.
Then a step connects to the first kickplate at the end of the extensions and extends rearward upon the interior edge of the extension until it contacts the remainder of the sides. The step has a width slightly larger than the width of the front deck. The front of the step, or nose, is rounded over for the ease and comfort of patients during usage of the invention. Opposite the kickplates 8 and near the intersection of the rear deck 5 and the sides 7 , the framework has a base 10 that connects the plate to the sides and supports casters 16 as later shown in FIG. 4 . Below the rear deck where the base connects with the sides at their widest point, the framework has the rear foot 12 . The rear foot spans the sides with generally the same width as the rear deck. The rear foot has a length less than that of the rear deck. Forward of the rear foot, the framework has a front foot 11 located below the step where the first kickplate connects to the sides. The front foot has a length much less than the step and a width proximate to that of the step. The front foot, rear foot, kickplates, base, sides, and plate cooperate to form a generally trapezoidal shaped framework that supports the front and rear decks when a patient climbs upon the present invention in the position shown in FIG. 1 .
Two spaced apart sides connect the plate, base, rear foot, front foot, kickplates, and step. The sides are mirror images so only one will be described. A side has a generally rectangular shape that spans in height from the plate to the rear foot and in length from the base to the inside edge of the step and the kickplate above the step. The side has an extension 15 forward that passes under the step and connects to the front foot. The extension also has a rectangular shape coplanar with the remainder of the side. The extension has a length slightly less than the depth of the step and a height similar to that of the lower kickplate, generally proportional to a stair riser in height. The side is tilted at an inward angle so the framework attains a generally trapezoidal shape when viewed on end.
The present invention also includes a slide 6 that carries an x-ray into the chamber 2 . The slide has a generally rectangular form with a length slightly greater than the length of the chamber and a width similar to that of the chamber. The slide has a forward edge 6 a that enters the chamber and a stop 6 b proximate the forward edge. The stop has less width than the slide and retains the x-ray film upon the slide when the slide is pulled out of the chamber. As later shown in FIG. 2 , the slide has a rearward edge 6 c with at least one grip 6 d located below the slide, generally opposite the stop.
The present invention is shown ready for a patient to have a foot x-rayed upon the front deck in FIG. 2 . As before, the platform has a framework of members that support the front deck and the rear deck with a slot between the two decks. Here, the front deck 4 connects to spacers 14 laterally near the front of the plate 13 and the slot 3 . The spacers in raising the front deck above the plate establish a chamber 2 that receives the slide 6 as in FIG. 2 . The slide has a rearward edge 6 c shown outward of the side in this view with grips 6 d shown below the slide proximate the edge of the plate. The grips prevent the slide from fully entering the chamber and assists in proper positioning of x-ray film within the chamber during usage.
The platform is shown from the front in FIG. 3 as a patient would access the invention during usage. The platform has a front foot 11 spanning the width of the invention and a kickplate 8 extending upwardly from the front foot. In an alternate embodiment, the kickplate has a handle 17 generally centered thereon to assist a person in lifting the platform upward for movement and storage as later described. Outwardly of the kickplate, the front has the extensions 15 of the sides 7 that connect the kickplate to the front foot and support the step 9 . The step is connected to the extensions and the kickplate generally parallel to the front foot. The step spans across the width of the platform at generally one half of the total height of the platform. The step has a rounded edge towards the front for the comfort of the patients who access the platform generally barefoot.
Behind the step, the sides 7 extend upwardly and have a second kickplate 8 spanning between them. At the top of the sides and the kickplate, the plate 13 connects to the sides. The plate is generally parallel to the step and the front foot. The plate extends rearward for the length of the side without extension. The plate has a spacer 14 extending perpendicular and upward from the front edge that raises the front deck 4 to its operational height, the full height of the invention. The front deck is generally planar and horizontal when in use as shown in this figure. The front deck, plate, step, and front foot are mutually parallel and spaced apart. Behind the spacer, the slide 6 is shown inserted with the forward edge to the left and the stop 6 b extending upwardly. The upward stop retains the x-ray film upon the slide when the slide is removed from the chamber 2 . The slide shows the rearward edge to the right and the grips 6 d extending below the slide 6 . The grips below abut the plate 13 and prevent the slide for slipping further into the chamber or falling out of the chamber while carrying an x-ray film during usage.
Rotating the invention, FIG. 4 shows the rear of the invention where a rear foot 12 has a similar width to the front foot that establishes the width of the invention. The sides 7 extend upwardly from the rear foot towards the full height of the invention. The sides angle inwardly to form a trapezoidal shape with the plate 13 at the top. The plate spans across the invention from side to side. Within the sides, rear foot, and plate, the rear has a base 10 . The base connects to the adjoining members and in cooperation with the kickplates and step in the front provides stiffness, or rigidity, to the invention when bearing the weight of a patient. Behind the base, the step 9 is shown in the background with portions extending outwardly from the sides 7 . As in the front, the rear has a spacer 14 a connected to the plate at the end near the base. The spacer extends for the width of the plate and raises the rear deck 5 above the plate to the same elevation as the front deck. The spacer 14 a beneath the rear deck is shown wider than the spacer 14 for the front deck because the rear deck lacks a chamber beneath it. In an alternate embodiment, the platform includes a second, narrower chamber beneath the rear deck and similarly sized second slide. As before, the slide 6 extends through the chamber as shown in the foreground. The stop 6 b is shown to the right and the grip is shown to the left. The platform has at least three casters 16 installed near the base with four shown here. The casters are of swiveling, Simpson type and rotate into the direction of movement for the platform. Here, two casters mount to the corners of the base with the rear foot and two casters mount upon the flush ends of the rear deck and the spacer.
FIG. 5 shows a side view of the platform 1 with the forward edge 6 a and stop 6 b of the slide shown. The side 7 has a generally rectangular form with an extension 15 upon one lateral end. The extension supports the step 9 that attaches to the length of the extension upon the inside angle of the extension and the remainder of the side. The front foot 11 attaches beneath the extension at the outside corner. Opposite the front foot, the rear foot 12 attaches to the side at the other outside corner below the elevation of the step. Above the front foot, rear foot, and the step, the plate attaches to the top of the sides generally parallel to the step. Upon the plate, the spacers 14 attach, mutually parallel and spaced apart to form the slot and then the chamber. The spacer adjacent to the base and away from the step is the same width as the rear deck above. The spacer near the base ends at the slot 3 that itself has a width to admit an x-ray film. The chamber 2 is formed between two spacers 14 of generally inverted L shape cross section, mutually parallel and spaced apart to admit the slide 6 . Upon the spacer 14 a near the base, the rear deck 5 attaches and the front deck 4 attaches to the two spaced apart spacers 14 above the chamber 2 . Upon the base, spacer, and plate, the casters attach and generally have their axes of rotation parallel to the plane of the base.
FIG. 6 shows the opposite side view of FIG. 5 . The sides, front foot, and rear foot and related framework are symmetric to that described above. In this view, the slide 6 is shown inserted into the chamber 2 . In the background the slide has the stop 6 b shown within the outline of the chamber. In the foreground the slide 6 has the rearward edge 6 c shown with the grips 6 d below. The stop extends for substantially the width of the slide and is generally a narrow elongated cross section. The grip is generally shown in two separated pieces that allow for grasping of the slide from either the front or the rear by an x-ray operator.
The platform appears from above in FIG. 7 as seen by the patient, or the x-ray emitter above. A patient enters the platform from the front at the step 9 . Above the step, the sides support the plate and then the front deck 4 . The front deck is located rearward of the step and has a chamber below it for the x-ray film. The x-ray film is inserted and removed from the chamber using the slide 6 . Here, the slide is inserted into the chamber with the stop 6 b shown to the left. The stop extends substantially across the width of the slide to hold an x-ray film placed thereupon. Behind the front deck, the platform has a slot 3 that receives an x-ray film located upon edge. Behind the slot, the platform comes to an end with the rear deck 5 . The rear deck and front deck are coplanar and at the same elevation above the step. And, FIG. 8 shows a bottom view of the platform 1 and a view of the platform when lifted upright upon the casters for movement. The platform has a framework assembled from the spaced apart sides 7 , the laterally extending kickplates 8 locating above the front foot 11 and the step 9 , the base 10 at the rear or bottom of the invention, and the rear foot 12 under the base. The front foot and the rear foot are generally perpendicular to the sides and located below the sides. The front foot and the rear foot are generally rectangular in shape with the rear foot being wider than the front foot. A handle upon the front kickplate 8 assists in lifting the invention and in steering it when in motion. Above the handle in this view, the step 9 extends outwardly across the width of the platform. Opposite the step, the platform has casters 16 upon the base and adjacent members that allow for movement of the platform. Between the front foot and the rear foot, this view shows the slide 6 inserted into the chamber 2 . The slide has the grip 6 d upon the left of the figure.
In the preferred embodiment as described above, the framework, its component members, and the slide are made from plywood and joined with carpentry joints and methods. Preferably, the component members are assembled using adhesives reinforced with screws and blocks.
From the aforementioned description, a platform for radiological examination of the foot and ankle has been described. The platform is uniquely capable of supporting a patient while standing upon a deck with an x-ray film beneath. The platform also supports the x-ray film on edge for side views of the foot and ankle while bearing weight. The platform is predominantly made from wood with a front deck made from Plexiglas to permit transmission of x-rays and light therethrough. The platform and its various components may be manufactured from many materials, including but not limited to, polymers, polyvinyl chloride, high density polyethylene, polypropylene, nylon, steel, ferrous and non-ferrous metals, their alloys, and composites.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. Therefore, the claims include such equivalent constructions insofar as they do not depart from the spirit and the scope of the present invention.
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A two step platform elevates a standing patient upon a horizontally located chamber for examination of the foot and ankle by radiological methods. The chamber receives a slide that carries an x-ray film beneath a foot of a standing patient. Additionally, the patient stands upon a visually and radiologicaly transparent deck. The deck has one slot for upright positioning and a chamber for horizontal positioning of a radiological film cartridge. The platform of the present invention allows a radiologist to take a radiological image of a patient's foot and ankle from both the side and above.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of pouring spouts and is particularly concerned with a pouring spout adapted to be releasably and threadaly mounted on a conventional lubricating oil container. The pouring spout has a built-in selective flow stopping mechanism.
2. Prior Art
Lubricating oil is widely used in order to minimize the ware created by friction between the moving components of most conventional internal combustion engines. Since the viscosity of the oil has a tendency to break down over a given period of use, the routine maintenance of most conventional internal combustion engines such as the ones found in most conventional vehicles involves replacing the used lubricating oil. During the oil changing operation, the user must pour the oil from a container into an oil filler neck, part of the engine.
Because of the positioning of the oil filler neck and because of the specific shape of the oil container, it often happens that during the pouring operation of the oil from the container into the oil filer neck, some of the lubricating oil is spilled on the exterior surface of the engine block. The oil which is spilled on the exterior surface of the engine block not only deteriorates the aesthetically pleasing appearance of the latter, but also creates an unpleasant smell when the temperature of the engine rises during ulterior operation.
Furthermore, the presence of oil on the exterior surface of the engine block makes it more difficult to evaluate if the engine consumes or loses lubricating oil.
Accordingly, most users resort to utilizing a pouring funnel during the pouring operation in order to minimize the amount of oil which might get spilled on the exterior surface of the engine block. However, since the flow rate of the funnel is often smaller than the flow rate through the discharging aperture of the oil container, the pouring operation is slowed down. Furthermore, some oil droplets often fall onto the exterior surface of the engine block once the pouring operation is over and the funnel is pulled out of the oil filler neck.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide an improved pouring device. The pouring device in accordance with an embodiment of the present invention is adapted to be readily and releasably mounted over the discharged aperture of most conventional lubricating oil containers.
The pouring device in accordance with an embodiment of the present invention is adapted to prevent the oil contained in the conventional oil container from flowing out of the discharged aperture of the conventional container before the neck of the oil container is inserted into the oil filler neck of the engine block.
The pouring device in accordance with an embodiment of the present invention will selectively allow the oil contained in the container to flow out of the discharged aperture into the oil filler neck of the engine block once the pouring device reaches a predetermined relationship with the exterior surface of the engine block.
The pouring device in accordance with the present invention will conform to conventional forms of manufacturing, be of simple construction and easy to use has to provide a pouring device which will be economically feasible, long lasting and relatively trouble free in operation.
The pouring device in accordance with an embodiment of the present invention thus prevents the spilling of lubricating oil onto the exterior surface of an engine block when the lubricating oil is transferred from a conventional oil container to the oil filler neck of an engine.
According to one embodiment of the present invention, ther is provided a pouring device for pouring lubricating oil out of a conventional oil container and into an oil filler neck part of an engine, said oil container having an oil container discharge aperture, said pouring device comprising: a releasable securing for releasably securing said device over said oil container discharge aperture, a pouring spout, said pouring spout extending integrally from said releasable securing means, said pouring spout having a spout inlet aperture, a sealing membrane, said sealing membrane being hingely connected to said releasable securing means, adjacent said spout inlet aperture, said sealing membrane being pivotable between a closed position wherein said sealing membrane prevents said lubricating oil from flowing through said spout inlet aperture and an open position wherein said sealing membrane allows said lubrificating oil to flow through said spout inlet aperture, a releasable locking means for releasably locking said sealing membrane in said closed position, an actuating means for selectively releasing the locking action of said locking means on said sealing membrane upon said actuating means being pushed against said engine.
Preferrably, said oil container has a container screw-thread positioned adjacent said discharge aperture and wherein said releasable securing means is a substantially cylindrical connecting neck, said connecting neck having a connecting neck screw-thread, whereby said connecting neck screw-thread is adapted to engage said container thread and cooperate with said container thread for releasably securing said pouring device over said container discharge aperture.
Conveniently, said connecting neck has an inner surface and wherein said pouring device further comprises an abutting seat extending integrally from said connecting neck, said abutting seat projecting substantially perpendicularly from said inner surface of said connecting neck, said abutting seat peripherally delimiting said spout inlet aperture, said abutting seat having an abutting seat peripheral surface, said sealing membrane being adapted to sealingly abut against said abutting seat peripheral surface when said sealing membrane is in said closed position.
Preferrably, said releasable locking means is a locking lip extending integrally from a fraction of said abutting seat peripheral surface, said locking lip being adapted to override a fraction of said sealing membrane when said sealing membrane is in said closed position for preventing said sealing membrane from pivoting into said open position.
Conveniently, said actuating means comprises a biasing means attached to said sealing membrane for creating an initial biasing force which biases said sealing membrane against said locking lip and a trigger means attached to said biasing means for selectively increasing the value of said initial biasing force to a level at which it will allow said sealing membrane to overcome the locking action of said locking lip on said sealing membrane and cause said sealing membrane to pivot said open position.
Preferrably, said pouring device further comprises an hinge means for hingely connecting said sealing membrane to said releasable securing means, an anchoring means for releasably anchoring said biasing means in a biased configuration, and wherein said biasing means is a substantially "L"-shaped strip of relatively resilient material, said strip having a strip spacing segment fixed to said sealing membrane adjacent its periphery and opposite said hinge means, said strip spacing segment extending substantially perpendicularly away from said sealing membrane and a strip transversal segment extending across said sealing membrane in an overriding relationship with the latter, said strip transversal segment having a distal free end, said distal free end being adapted to be releasably attached to said anchoring means when said biasing means is in said biased configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will now be described, by way of example, in reference to the following drawings in which:
FIG. 1: in an elevational view, illustrates a pouring device in accordance with an embodiment of the present invention secured over the discharged aperture of a conventional lubricating oil container, the pouring device is shown in longitudinal cross-section to illustrate the relationship between the pouring device and the discharge aperture of the conventional oil container.
FIG. 2: in a perspective view, illustrates a pouring device in accordance with an embodiment of the present invention with sections taken out in order to show some of the components of the pouring device.
FIG. 3: in a detailed perspective view taken inside arrows 3--3 of FIG. 2, illustrates the relationship between a locking lip part of the invention and a sealing membrane also part of the invention.
FIG. 4: in a longitudinal cross sectional view illustrates a pouring device in accordance with an embodiment of the present invention threadaly mounted over the discharged aperture of a conventional lubricating oil container with its sealing membrane in a closed position and its actuating mechanism in an unbiased configuration,
FIG. 5: in a longitudinal cross sectional view illustrates a pouring device in accordance with an embodiment of the present invention threadaly mounted over a discharged aperture of a conventional lubricating oil container with its sealing membrane in a closed position and its trigger mechanism in a biased configuration.
FIG. 6: in a longitudinal cross sectional view illustrates a pouring device in accordance with an embodiment of the present invention with its sealing membrane in a partially opened configuration and its actuating mechanism in an unbiased configuration.
FIG. 7: in a top view illustrates a pouring device in accordance with an embodiment of the present invention with its sealing membrane in a closed position and its trigger mechanism in an unbiased configuration.
FIG. 8: in a perspective view with sections taken out, illustrates a pouring device in accordance with an embodiment of the present invention being inserted into the oil filler neck of an engine.
FIG. 9: in a perspective view with sections taken out, illustrates a pouring device in accordance with an embodiment of the present invention being pushed into the oil filler neck of a conventional engine.
FIG. 10: in a perspective view with sections taken out, illustrates a pouring device in accordance with an embodiment of the present invention fully inserted into the oil filler neck of an engine.
DETAILED DESCRIPTION
Referring to FIG. 1, there is shown a pouring device 10 in accordance with an embodiment of the present invention. The pouring device 10 is threadaly mounted on a conventional lubricating oil container 12. The container 12 has a substantially parallelepiped-shaped main containing body 14. The main containing body 14 extends integrally into a pouring neck 16. The pouring neck 16 has a discharge aperture 18. The discharge aperture 18 has a peripheral rim 20. The pouring neck 16 also has a connecting segment 22. The connecting segment 22 is positioned adjacent the discharge aperture 18. The outer surface of the connecting segment 22 has an integrally projecting connecting segment screw-thread 24.
The connecting segment 22 is adapted to threadaly receive and releasably retain a conventional oil container cap (not shown). The conventional oil container cap has a cap disk-shaped wall and an integrally and perpendicularly depending peripheral connecting skirt. The inner surface of the connecting skirt of the conventional oil container cap has an integrally projecting connecting skirt screw-thread. The skirt screw-thread of the cap is adapted to engage the connecting segment screw-thread 24 and cooperate with the latter for releasably securing the cap over the discharge aperture 18.
A disk-shaped foil (not shown) made of relatively thin metallic or polymeric material is sealingly mounted over the discharge aperture 18 of an unused container 12 under the removable cap. The disk-shaped foil is adapted to seal-in the oil inside the container 12 and prevent the oil from leaking out of the cap during shipping and handling of the container 12 prior to its first use. The peripheral edge of the disk-shaped foil is glued to the peripheral rim 20 of the discharge aperture 18. The foil is adapted to be peeled-off from the discharge aperture 18 before the initial pouring of the oil out of the container 12.
The pouring device 10 has a generally cylindrical shape. The pouring device 10 has a connecting neck portion 28. The connecting neck portion 28 has a substantially cylindrical neck wall 30. The substantially cylindrical neck wall 30 has a longitudinal axis indicated in FIG. 5 by the reference letter A. The neck wall 30 has an outer surface 32 and an inner surface 34. The inner surface 34 of the neck wall 30 has an integrally projecting neck screw-thread 36. The neck screw-thread 36 of the device 10 is adapted to engage the connecting segment screw-thread 24 of the container 12 and cooperate with the latter for releasably securing the pouring device 10 to the connecting segment 22 of the container 12. The neck wall 30 extends integrally into an abutting seat 38. The abutting seat 38 projects inwardly and substantially perpendicularly from the inner surface 34 of the neck wall 30. The abutting seat 38 is adapted to abut against the peripheral rim 20 of the discharge aperture 18 of the container 12 when the pouring device 10 is screwed onto the connecting segment 22 of the container 12. The abutting seat 38 has an abutting seat arcuate segment 40 and an abutting seat platform segment 42. The abutting seat arcuate segment 40 has substantially the shape of a truncated ring. The abutting seat arcuate segment 40 extends circumferentially from the inner surface 34 of the neck wall 30 over a partial circumference covering approximately 260 degrees. The abutting seat arcuate segment 40 has an outer peripheral edge which merges into the inner surface 34 of the neck wall 30 and an arcuate inner peripheral edge 44. The platform segment 42 has substantially the shape of a fraction of a truncated disk. The platform segment 42 has an outer peripheral edge which merges into the inner surface 34 of the neck wall 30 and a substantially rectilinear inner peripheral edge 46. The rectilinear inner peripheral edge 46 intercepts the abutting seat arcuate segment 40. As illustrated more specifically in FIGS. 4 through 6, the rectilinear inner peripheral edge 46 has a substantially bevelled cross-sectional configuration.
A pouring spout 48 extends integrally from the outer peripheral edge of the abutting seat arcuate segment 40. The pouring spout 48 has a longitudinally truncated, substantially cylindrical, arcuate spout wall 50. The arcuate spout wall 50 has an arcuate, generally "C"-shaped cross-sectional configuration. The arcuate spout wall 50 has an inner surface 52 and an outer surface 54. The outer surface of the arcuate spout wall 50 is in register with the outer surface 32 of the neck wall 30. The outer surface 54 of the arcuate spout wall 50 and the outer surface 32 of the neck wall 30 thus form a substantially continuous arcuate surface. Each end segment of the arc formed by the arcuate spout wall 50 extends integrally into a rectilinear spout wall segment 56. The rectilinear spout wall segments 56 extend inwardly towards each other in a direction parallel to the rectilinear inner peripheral edge 46 of the abutting seat 38. In fact, the rectilinear spout wall segments 56 extend integrally from a portion of the rectilinear inner peripheral edge 46, on each side of the latter. The rectilinear spout wall segments 56 stop short of merging into each other. A spacing 58 extends between the rectilinear spout wall segments 56.
A pair of relatively thin locking blocks 60 extend integrally from a fraction of the rectilinear spout wall segments 56 and a fraction of the abutting seat platform segment 42. The locking blocks 60 extend generally perpendicularly to the rectilinear spout wall segments 56 and away from the rectilinear inner peripheral edge 46. Each locking block 60 defines a set of exposed surfaces. Each locking block 60 has a first inclined locking block surface 62 which extends from the abutting seat platform segment 42 in an inclined direction simultaneously away from the abutting seat platform segment 42 and away from the rectilinear spout wall segments 56. The first inclined locking block surface 62 extends in a direction forming an angle, indicated in FIG. 4 by the reference letter B, relatively to the abutting seat platform segment 42. The first inclined locking block surface 62 bends integrally into a locking block locking surface 64 which extends perpendicularly away from the rectilinear spout wall segments 56. The locking block locking surface 64 bends integrally into a locking block spacing segment 66. The locking block spacing segment 66 extends in a plane substantially parallel to the rectilinear spout wall segments 56. The locking block spacing segment 66 bends integrally into a locking block guiding segment 68. The locking block guiding segment 68 extends in a direction which is oriented simultaneously towards the rectilinear spout wall segments 56 and away from the abutting seat platform segment 42. The locking block guiding segment 68 merges into the rectilinear spout wall segments 56 at a distance from the abutting seat platform segment 42 which corresponds approximately to one third of the length of the rectilinear spout wall segments 56.
A sealing membrane 70 is hingely connected to the substantially rectilinear inner peripheral edge 46 of the platform segment 42 of the abutting seat 38. The sealing membrane 70 has a peripheral edge divided into a sealing membrane peripheral arcuate segment 72 and a sealing membrane peripheral rectilinear segment 74. The sealing membrane 70 thus has substantially the shape of a truncated disk. As illustrated in FIGS. 4 through 6, the sealing membrane peripheral rectilinear segment 74 has a substantially bevelled cross-sectional configuration. The substantially bevelled sealing membrane peripheral rectilinear segment 74 and the substantially bevelled rectilinear inner peripheral edge 46 of the platform segment 42 of the abutting seat 38 are hingely joined by a relatively thin hinge strip 76. The hinge strip 76 extends integrally from the adjacent edges of both the rectilinear segment 74 and the inner peripheral edge 46. The hinge strip 76 is thus adapted to allow the pivotal action of the sealing membrane 70 in the direction indicated by arrow P in FIG. 9 and to prevent the pivotal action of the sealing membrane 70 in the opposite direction.
The hinge strip 76 allows the sealing membrane 70 to pivot between a closed position illustrated in FIG. 8 and an open position illustrated in FIG. 10. In the closed position, the sealing membrane 70 is in register with the abutting seat 38 and the sealing membrane peripheral arcuate segment 72 sealingly abuts against the abutting seat arcuate segment 40. The sealing membrane 70 is thus adapted to prevent through passage of a fluid between the connecting neck portion 28 and the pouring spout 48. The sealing membrane 70 has a sealing membrane spout surface 78 which faces into the pouring spout 48 when the sealing membrane 70 is in its closed position. The sealing membrane 70 also has a sealing membrane connecting neck surface 80 which faces into the connecting neck portion 28 when the sealing membrane 70 is in its closed position.
In the open position, the sealing membrane 70 is pivoted away from the connecting neck portion 28 and lies in a plane substantially parallel to the rectilinear spout wall segments 56. In the open position, the sealing membrane 70 thus allows through passage of a fluid between the connecting neck portion 28 and the pouring spout 48.
A locking lip 82 extends integrally from a portion of the abutting seat arcuate segment 40 which is located opposite the abutting seat platform segment 42. The locking lip 82 has a locking lip locking surface 84 which is adapted to override and abut against a fraction of the sealing membrane spout surface 78 for preventing the sealing membrane 70 from pivoting to its open position.
An actuating component 86 is solidly attached to the sealing membrane spout surface 78. The actuating component 86 has an actuating component connecting strip 88 which protrudes integrally from the sealing membrane spout surface 78 opposite the sealing membrane peripheral rectilinear segment 74. The actuating component connecting strip 88 bends integrally into a substantially "L"-shaped biasing strip 90. The biasing strip 90 is adapted to be moved between an unbiased configuration illustrated in FIGS. 2 and 4 and a biased configuration illustrated in FIGS. 5, 6 and 9. The biasing strip 90 has a biasing strip spacing segment 92 which projects generally in a direction which is substantially perpendicular to the sealing membrane spout surface 78. The biasing strip spacing segment 92 is itself divided into a biasing strip spacing segment rectilinear portion 94 and a biasing strip spacing segment arcuate portion 96. The biasing strip spacing segment rectilinear portion 94 is relatively thicker than the biasing strip spacing segment arcuate portion 96. The biasing strip spacing segment arcuate portion 96 extends integrally into a biasing strip transversal segment 98. The biasing strip transversal segment 98, when the biasing strip 90 is in its unbiased configuration, extends in a plane which is substantially parallel to the sealing membrane 70. The biasing strip transversal segment 98 has a biasing strip transversal segment flexible portion 100 and an integrally extending biasing strip transversal segment rigid portion 102. The biasing strip transversal segment rigid portion 102 extends through the spacing 58 between the rectilinear spout wall segments 56. The biasing strip transversal segment flexible portion 100 is relatively thinner than the biasing strip transversal segment rigid portion 102. When the biasing strip 90 is in its unbiased configuration, the biasing strip transversal segment flexible portion 100 overrides the sealing membrane spout surface 78 and the biasing strip transversal segment rigid portion 102 overrides the seat platform segment 42.
The biasing strip transversal segment rigid portion 102 extends integrally into a trigger lever 104. The trigger lever 104 extends substantially perpendicularly from the biasing strip transversal segment rigid portion 102 in a direction away from the seat platform segment 42. The trigger lever 104 has a substantially "U"-shaped cross-sectional configuration. A pair of locking wings 106 project laterally from both sides of the biasing strip transversal segment rigid portion 102 adjacent its junction with the trigger lever 104. Each locking wing 106 has a locking wing first abutting surface 108 lying in a plane substantially parallel to the biasing strip transversal segment rigid portion 102 and a locking wing second abutting surface 110 lying in a plane substantially parallel to the trigger lever 104.
The specific design of the pouring device 10, in accordance with an embodiment of the present invention, allows it to be manufactured out of a single piece of injection moldable polymeric material.
In use, the pouring device 10 is adapted to be releasably fixed to the connecting segment 22 of a conventional oil container such as the oil container 12. In order to releasably secure the pouring device 10 to the connecting segment 22 of the oil container 10, a user must first remove the conventional oil container cap from the connecting segment 22 by unscrewing the conventional oil container cap. Before securing the pouring device 10 to the oil container 12, the user must also position the sealing membrane 70 in its closed position by inserting the portion of the sealing membrane spout surface 78 adjacent the locking lip 82 underneath the locking lip 82. Once the conventional oil container cap is removed from the oil container 12 and the sealing membrane 70 is in its closed position, the user then proceeds to releasably secure the pouring device 10 to the oil container 12.
The user screws the device 10 unto the connecting segment of the oil container by having the neck screw-thread 36 of the neck wall 30 engage the connecting segment screw-thread 24 of the container 12, as illustrated in FIGS. 4 and 5.
Once the device 10 is properly secured to the connecting segment 22 of the oil container 12, the user brings the biasing strip 90 to its biased configuration. The biasing strip 90 is brought to its biased configuration by pulling on the trigger lever 104, clearing the locking block spacing segment 66 of the locking blocks 60 and anchoring the locking wings 106 in a locking abutting relationship with the locking blocks 60. The pulling action flattens the biasing strip spacing segment arcuate portion 96 which is thinner and thus more flexible then the biasing strip spacing segment rectilinear portion 94. The biasing strip 90 is made of a resilient material. The resilient material allows for the flattening of the biasing strip spacing segment arcuate portion 96 and creates a biasing force which has a tendency to force the biasing strip spacing segment arcuate portion 96 back towards its unbiased arcuate configuration. Consequently, the biasing strip spacing segment arcuate portion 96 pulls on the locking wings 106 which are releasably anchored to the locking blocks 60. When the locking wings 106 are releasably anchored to the locking blocks 60, the second abutting surfaces 110 are forced against the first inclined locking block surfaces 62. The locking wings 106 are releasably prevented from slipping off the first inclined locking block surfaces 62 by the locking block locking surface 64. In order for the second abutting surfaces 110 to abut flatly against the first inclined locking block surfaces 62, the biasing strip transversal segment 98 bends about the transition between the biasing strip transversal segment rigid portion 102 and the biasing strip transversal segment flexible portion 100, as illustrated in FIG. 9. When the locking wings 106 are releasably anchored to the locking blocks 60, the biasing strip transversal segment rigid portion 102 and the trigger lever 104 are tilted from their unbiased configuration and the longitudinal axis of the trigger lever, indicated by the reference letter V in FIG. 5 is angled relatively to the longitudinal axis A of the cylindrical neck wall 30. The angle between the longitudinal axis V of the trigger lever 104 and the longitudinal axis A of the cylindrical neck wall 30 is indicated by the reference letter D in FIG. 5,
As stated previously, when the sealing membrane 70 is in its closed position, the sealing membrane peripheral arcuate segment 72 sealingly abuts against the abutting seat arcuate segment 40, thus sealingly preventing through passage of a fluid such as oil between the connecting neck portion 28 and the pouring spout 48. The oil container 12 with the pouring device 10 fined to its connecting segment 22 and the sealing membrane 70 locked in its closed position can thus be inverted so that its discharge aperture 18 faces downwardly without having oil pouring out of the oil container.
Once inverted, the oil container is lowered towards the engine into which oil is to be poured. The engine has an engine block wall 114 and an oil filler neck aperture 116 extending therethrough. The oil container 12 and its associated pouring device 10 is lowered until the pouring spout 48 penetrates into the oil filler neck aperture and the longitudinal peripheral edge of the trigger lever 104 abuts against the engine block wall 114, as illustrated in FIG. 8.
In order to release the locking action of the locking lip 82 on the sealing membrane 70, the user then exerts a downward pressure on the oil container which, in turn, forces the trigger lever 104 against the engine block wall 114. Since the longitudinal axis V of the trigger lever 104 is in an angled relationship relatively to the outer surface of the engine block wall 114, the pressure will cause the trigger lever 104 to pivot outwardly as indicated by the arrow L in FIG. 9. The pivoting of the trigger lever 104 will cause the biasing strip transversal segment rigid portion 102 to also pivot solidarly. The pivoting of the biasing strip transversal segment rigid portion 102 will further pull on the biasing strip spacing segment arcuate portion 96, causing the actuating component connecting strip 88 to further pull on the sealing membrane and eventually causing the sealing membrane 70 to clear the locking tongue 82, The pivoting of the trigger lever 104 will also cause the latter to slide-off the locking block 60, as illustrated in FIG. 9.
Once the sealing membrane 70 has cleared the locking tongue 82, the pressure exerted on the container and transmitted to the actuating lever 104 will cause the sealing membrane 70 to pivot to its open position. The sealing membrane being in its open position, the oil is free to flow from the container 12 into the oil filler neck aperture 116. The pressure exerted on the container and transmitted to the actuating lever 104 will also cause the spout 48 to penetrate deeper into the oil filler neck aperture 116 and the trigger lever 104 to lie flat against the engine block wall 114, as illustrated in FIG. 10.
The oil container 12 can thus be inverted and its content can be poured into the appropriate oil filler neck aperture without any oil dripping onto the engine block wall 114. Once the pouring operation is completed, the user merely pulls the spout 48 out of the oil filler aperture 116 and the pouring device can be unscrewed from the oil container 12 for an ulterior usage.
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A pouring device for pouring lubricating oil into the oil filler neck of a conventional engine. The pouring device is adapted to prevent unwanted spilling of oil onto the exterior surface of the engine block during the pouring operation. The pouring device has a cylindrical connecting neck portion which is adapted to be threadaly mounted over the discharge aperture of a conventional lubricating oil container. The connecting neck portion extends integrally into a spout. The spout has an inlet surface. A sealing membrane is hingely connected to the connecting neck portion, adjacent the inlet surface. The sealing membrane is adapted to pivot between a closed position wherein it prevents the lubricating oil from flowing through the inlet aperture and an open position wherein the sealing membrane allows the lubrificating oil to flow through the inlet aperture. The sealing membrane is adapted to be releasably locked in its close position by a locking lip which abuts against its peripheral edge. A biasing strip extends integrally from the sealing membrane. The biasing strip is adapted to create an initial biasing force which biases the sealing membrane against the locking lip. A trigger mechanism is attached to the biasing strip for selectively increasing the value of the initial biasing force to a level at which it will allow the sealing membrane to overcome the locking action of the locking lip on the sealing membrane and cause the sealing membrane to pivot into its open position. The trigger mechanism has a trigger lever which is adapted to abut against the exterior surface of the engine when the spout is pushed into the oil filler neck.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a Z-stilbenes derivative and a pharmaceutical composition thereof, more particularly, to a Z-stilbenes derivative which can inhibit microtubules polymerization and a pharmaceutical composition thereof.
[0003] 2. Description of Related Art
[0004] The microtubule system of eukaryotic cells is an important target for the development of anticancer agents. For a more concrete description, the microtubule polymerization/depolymerization is a popular target for the development of new chemotherapy agents. A number of clinically used agents (such as paclitaxel, epothilone A, vinblastine, combretastatin A-4 (CA-4), dolastatin 10, and colchicines), taking microtubule polymerization/depolymerization as the target, all exhibit their anticancer properties by disrupting cellular microtubule structure and function resulting in mitotic arrest, as well as inhibiting the growth of epithelium of newly formed vasculature to shut down the blood supply to tumors (please refer to Jordan et. al., (1998) Med. Res. Rev. 18: 259-296).
[0005] Therefore, according to the microtubule system (such as tubulin polymerization/depolymerization) as the target for developing compounds, the new therapy used for the treatment or the prevention of cancers or cancer related symptoms, or the treatment of angiogenesis related disease, such as cardiovascular disease (e.g. atherosclerosis), chronic inflammation (e.g. rheumatoid arthritis or Crohn's disease), diabetes (e.g. diabetic retinopathy), psoriasis, and retinal neovascularization or corneal neovascularization can be developed (please refer to Griggs rt. al., (2002) Am. J. Pathol. 160(3):1097-1103).
[0006] It is discovered that colchicine and combretastatin A-4, such as the following ZD6126, CA4P, and AVE-8062, can exhibit the anticancer property by rapidly depolymerizing microtubules of newly formed vasculature to shut down the blood supply to tumors:
[0000]
The aforementioned compounds are now undergoing human clinical trials for either single use or combination use with chemotherapy drugs to inhibit cancers.
[0007] The analysis of Structure-Activity Relationship (SAR) can interpret the effect of the chemical structure on the activity so as to develop the most effective drugs to treat diseases. Through the analysis of SAR, it is found that the B ring of the aforementioned CA4P structure is the site on which the polar functional group(s) is often located. Thereby, new Z-stilbenes derivatives having anticancer activity can be developed by modifying the functional group(s) located on the B ring. In addition, the solubility of the CA-4 like compounds can be enhanced by introducing a phosphate group, amino group, or others. Therefore, considerable research focuses on developing novel Z-stilbenes derivatives different from conventional ones, having solubility, and exhibiting anticancer activity to afford a series of compounds, which can inhibit cancers.
SUMMARY OF THE INVENTION
[0008] The present invention relates to novel Z-stilbenes derivatives as the following formula 1:
[0000]
[0000] wherein, X is H, NHR, or nitro (NO 2 ), wherein R is H; Y and Z is independently H, halogen, C 1-10 alkyl, or C 1-10 alkoxyl; and A is H, OH, or amino.
[0009] Preferably, NHR is amino, Y is methoxy, and Z is methoxy. The halogen can be F, Cl, Br, or I, but preferably, the halogen is Br.
[0010] The term “alkyl” as used herein refers to a straight or branched saturated hydrocarbon chain containing from 1 to 10 carbon atoms. Representative examples of alkyl include, but are not limited to methyl, ethyl, n-propyl, isopropyl, tert-butyl, and n-pentyl.
[0011] The compounds of the present invention include 2-amino-3,4,4′,5-tetramethoxy-stilbene, 2-nitro-3,4,4′,5-tetramethoxy-stilbene, 2-amino-3,4′,5-triamethoxy-stilbene, 2-amino-4,4′,5-triamethoxy-stilbene, 3-bromo-4,4′,5-triamethoxy-stilbene, 2-amino-3′-hydroxy-3,4,4∝,5-tetramethoxy-stilbene, and 2,3′-diamino-3,4,4′,5-tetramethoxy-stilbene.
[0012] A non-aromatic double bond and one or more asymmetric centers may exist in the Z-stilbenes derivatives of the present invention. The chemical structure depicted herein encompasses meso compounds, racemic mixtures, enantiomers, diastereomers, diastereomer mixtures, cis-isomers, and trans-isomers. The present invention encompasses all isomeric forms, including E-form isomers, and Z-form isomers.
[0013] The application field of the Z-stilbenes derivatives of the present invention is not limited. Preferably, the Z-stilbenes derivatives of the present invention are used for inhibiting tubulin polymerization, and tubulin polymerization related cancers or angiogenesis related diseases.
[0014] In addition, the present invention further provides a pharmaceutical composition, comprising the Z-stilbenes derivative of the present invention and a pharmaceutically acceptable carrier to inhibit tubulin polymerization, or tubulin polymerization related cancers or diseases.
[0015] The Z-stilbenes derivatives of the present invention encompass the compounds themselves, their pharmaceutically acceptable salts, and prodrugs thereof. For example, the salt can be prepared by reacting the positive group (such as amino) of the compound with an anion. The satiable anions include, but are not limited to chloride, bromide, iodide, sulfate, nitrate, phosphate, citrate, alkylsulfonate, trifluoroacetate, and acetate. Also, the salt can be prepared by reacting the negative group (such as carboxy) with a cation. The satiable cations include, but are not limited to sodium, potassium, magnesium, calcium, and ammonium (such as tetramethylammonium). The examples of the prodrugs include the ester derivatives derived from the aforementioned compounds and other pharmaceutically acceptable derivatives.
[0016] The pharmaceutical composition comprising the Z-stilbenes derivatives of the present invention can be administered intravenously, orally, nasally, rectally, locally, or sublingually. Intravenous administration includes subcutaneous, intraperitoneal, intravenous, intramuscular, intraarticular, intraaortic, intrapleural, spinal, intrathecal, local injection at the site attacked by a disease, or other suitable administration techniques.
[0017] The sterile injectable composition can be a solution, or suspension in a non-toxic intravenous diluent or solvent (such as 1,3-butanediol). The acceptable carrier or solvent can be mannitol or water. In addition, the fixed oil is conventionally employed as a solvent or suspending medium (such as synthetic mono- or diglycerides). [I feel the following sentence would be slightly better as “Use of the fatty acid . . . is found in the operation . . . ” as an acid probably cannot find any use.]> The fatty acid such as oleic acid and the glycerine ester derivative thereof find use in the preparation of pharmaceutically acceptable injectables, such as olive oil or castor oil, especially in polyoxyethylated form. The oily solution or suspension can comprise long chain aliphatic alcohol diluents or dispersion, carboxymethylcellulose, or a similar dispersion. Examples of the generally used materials include surfactants (e.g. Tween, or Spans), other similar emulsifying agents, pharmaceutically acceptable solid, liquid generally used in the pharmaceutical industry, or other bioavailable potentiating agents used for developing new formulations.
[0018] The pharmaceutical composition may be in a form suitable for oral use, for example, as capsule, troche, emulsifying agent, liquid suspension, dispersion, or solvent. For administration in a troche form, the generally used carrier is lactose or corn starch, flotation reagent (e.g. magnesium stearate as an elementary additive). For oral administration in a capsule form, the useful diluents include lactose and corn starch. For oral administration in a liquid suspension or emulsifying agent, the active material can be suspended or dissolved in an oily medium containing an emulsifying agent or suspension. If necessary, suitable sweetenting agents, flavoring agents, or coloring agents can be added.
[0019] Compositions intended for nasal aerosol or inhalation may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions. For example, the composition prepared in the isotonic sodium chloride solution can further contain benzyl alcohol or other suitable preservative, an absorbefacient to enhance bioavailability, fluorocarbon, or other known soluble dispersion. The compositions comprising one or more active compounds of the present invention may also be administered in the form of suppositories for rectal administration of the drug.
[0020] The carrier of the pharmaceutical composition containing the Z-stilbenes derivative must be acceptable. The term “acceptable” means the carrier is compatible with the active ingredient (more preferably, the carrier can stabilize the active ingredient), and does not hurt the patient. One or more agents can be a pharmaceutical elixir which can deliver the active compound of the present invention. Examples of other carriers include silicon oxide, magnesium stearate, cellulose, sodium lauryl sulfate, and D&C Yellow 10.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] None.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] The Z-stilbenes derivatives of the present invention, the analysis method thereof, and the determination method thereof are presented in the following:
[0023] Melting points were determined on a Buichi (B-545) melting point apparatus and are uncorrected.
[0024] Nuclear magnetic resonance ( 1 H NMR and 13 C NMR) spectra were obtained with the Bruker DRX-500 spectrometer (operating at 500 MHz and at 125 MHz, respectively), Varian Mercury-400 spectrometer (operating at 400 MHz and at 100 MHz, respectively), and the Varian Mercury-300 spectrometer (operating at 300 MHz and at 75 MHz, respectively), with chemical shift in parts per million (ppm,δ) downfield from TMS as an internal standard.
[0025] High-resolution mass spectra (HRMS) were measured with a Finnigan (MAT-95XL) electron impact (EI) mass spectrometer.
[0026] Elemental analyses were performed on a Heraeus CHN-O Rapid microanalyzer.
[0027] Flash column chromatography was done using silica gel (Merck Kieselgel 60, No. 9385, 230-400 mesh ASTM).
[0028] All reactions were carried out under an atmosphere of dry nitrogen.
[0029] The preparation involved a reaction sequence (overall 30-46% yield in two or three steps): (1) Wittig reaction of (4-methoxybenzyl)phosphonium bromide (scheme 1) and (2-nitro-3,4,5-trimethoxybenzyl)phosphonium bromide (scheme 2), with various substituted benzaldehydes including 2-nitro or 3-nitrobenzaldehydes yielded the corresponding Z- and E-stilbenes as an about ratio of 3/1. (2) Reduction of nitro group of Z-stilbenes by Zn/AcOH to afford the desired substituted 2-amino and 2′-aminocombretastatins derivatives. Ylide (compound B2) was synthesized from the 2-nitro-3,4,5-trimethoxybenzyl bromide (compound B1). The methoxy-substituted benzaldehydes A3-A6, and B3 are commercially available. The 2-nitrobenzaldehydes A1-A2 and 3-(tert-butyldimethylsilyl) protected isovanillin B4 were prepared in two-four steps.
[0030] The synthetic schemes of the compounds of the present invention and the prodrugs thereof are shown in the following.
[0000]
[0000]
EXAMPLES OF PREPARATION
Compound A1: 2-Nitro-3,4,5-trimethoxy-benzaldehyde
[0031]
[0032] To a stirred solution of the 3,4,5-Trimethoxy-2-nitrobenzoic acid (2 g, 7.77 mmol) and BH 3 (1.0 M in THF, 13.2 ml) in THF (10 ml) was stirred and refluxed for 3 hours. After cooling, the reaction mixture was extracted with water and CH 2 Cl 2 . The combined organic layers were dried over MgSO 4 , and then evaporated to afford 4-methoxy-2-nitrobenzyl methanol. The crude 4-methoxy-2-nitrobenzyl methanol was dissolved in anhydrous CH 2 Cl 2 (20 mL) and was subjected to pyridinium dichromate, PDC oxidation (5.84 g, 15.55 mmol)/molecular sieves (powder, 6 g) at room temperature for 16 h. The reaction mixture was filtrated by Celite and extracted with water and CH 2 Cl 2 . The organic layers were combined and evaporated. The residue was purified by flash chromatography (EtOAc: n-hexane=1:1) to afford compound A1 as a yellow soild, yield 69%. mp 73.8-75.1° C., 1 H NMR (500 MHz, CDCl 3 ) δ 3.97 (s, 3H), 3.99 (s, 6H), 7.21 (s, 1H), 9.86 (s, 1H).
Compound A2: 3,5-Dimethoxy-2-nitro-benzaldehyde
[0033]
[0034] The 3,5-Dimethoxybenzaldehyde (0.5 g, 3 mmol) was added to 70% nitric acid (0.88 mL, 14.44 mmol) at 0° C. in portion. After stirring for 1 hour, the reaction mixture was quenched and extracted by water and CH 2 Cl 2 . The organic layers were combined and evaporated to give a residue, which was purified by flash chromatography (EtOAc : n-hexane=1:2.5) to give the brown crystals, yield 64%. mp 104.0-104.6° C., 1 H NMR (500 MHz, CDCl 3 ) δ 3.93 (s, 3H), 3.93 (s, 3H), 6.76 (d, J=2.4 Hz), 6.96 (d, J=2.4 Hz, 1H), 9.94 (s, 1H).
Compound B1: 2-Nitro-3,4,5-trimethoxybenzyl bromide
[0035]
[0036] To a stirred solution of the 3,4,5-Trimethoxy-2-nitrobenzoic acid (5 g, 19.40 mmol) in THF (30 ml) was added by BH 3 (1.0 M in THF, 29.1 ml) under nitrogen. The mixture was stirred and refluxed for 2 hours. After cooling, the reaction mixture was extracted with water and CH 2 Cl 2 . The combined organic layers were dried over MgSO 4 , and then evaporated to afford 3,4,5-Trimethoxy-2-nitrobenzyl methanol. The crude 3,4,5-trimethoxy-2-nitrobenzyl methanol was dissolved in anhydrous CH 2 Cl 2 (20 mL) and was subjected to PBr 3 (2.40 ml, 25.22 mmol) in an ice bath. After 2 h, the mixture was extracted with water and CH 2 Cl 2 . The organic layers were combined and evaporated. The residue was purified by flash chromatography (EtOAc:n-hexane=1:2) to afford B1 as a pale yellow oil, yield 68%. 1 H NMR (500 MHz, CDCl 3 ) δ 3.90 (s, 3H), 3.92 (s, 3H), 3.98 (s, 3H), 4.44 (s, 2H), 6.72 (s, 1H).
Compound B2: 2-Nitro-3,4,5-trimethoxybenzyl-triphenylphosphonium bromide
[0037]
[0038] To a stirred suspension of B1 (4 g, 13.06 mmol) and triphenylphosphine (3.77 g, 14.37 mmol) in anhydrous toluene (50 ml) was heated to reflux for 3-5 hr under N 2 . After cooling, the reaction mixture was filtrated, and recrystallized from CH 3 OH to give B2 as a pale yellow powder, yield 74%. mp 173-174° C., 1 H NMR (500 MHz, CDCl 3 ) δ 3.70 (s, 3H), 3.83 (s, 3H), 3.84 (s, 3H), 5.56 (d, J=14.0 Hz, 2H), 7.34 (d, J=2.4 Hz, 1H), 7.72 (m, 15H).
Compound B4: 3-(tert-Butyl-dimethyl-silyloxy)-4-methoxy-benzaldehyde
[0039]
[0040] To a solution of 3-hydroxy-4-methoxybenzaldehyde (1 g, 6.57 mmol) and N,N-diisopropylethylamine (1.32 mL, 9.86 mmol) in THF (20 mL) was stirred at room temperature. After stirring for 30 min, tert-butyl-dimethyl-silylchloride (1.19 g, 7.88 mmol) was added then stirred for 3 h. The reaction mixture was extracted with water and CH 2 Cl 2 . The organic layers were combined and evaporated to afford B4 as a yellow soild, yield 92%. 1 H NMR (500 MHz, CDCl 3 ) δ 0.15 (s, 6H), 0.99 (s, 9H), 3.87 (s, 3H), 6.94 (d, J=8.2 Hz, 1H), 7.35 (d, J=2.0 Hz, 1H), 7.45 (dd, J=8.3, 2.0 Hz, 1H).
Example 1
2-Amino-3,4,4′,5-tetramethoxy-(Z)-stilbene (compound 1)
[0041]
[0042] The title compound was obtained in 39% overall yield from (4-methoxybenzyl)triphenylphosphonium bromide and 2-nitro-3,4,5-trimethoxybenzaldehyde (compound A1). 1 H NMR (500 MHz, CD 3 OD) δ 3.52 (s, 3H), 3.73 (s, 3H), 3.82 (s, 3H), 3.83 (s, 3H), 6.35 (d, J=11.9 Hz, 1H), 6.45 (s, 1H), 6.55 (d, J=12.0 Hz, 1H), 6.74 (d, J=8.6 Hz, 2H), 7.15 (d, J=8.6 Hz, 2H). 13 C NMR (125 MHz, CD 3 OD) δ 55.6, 56.9, 60.8, 61.3, 110.3, 114.5, 120.0, 125.0, 130.8, 131.2, 131.4, 133.6, 142.8, 143.4, 146.6, 160.4. MS (EI) m/z: 315 (M + , 100%), 300 (58%). HRMS (EI) for C 18 H 21 NO 4 (M + ): calcd, 315.1469; found, 315.1470. Anal. (C 18 H 21 NO 4 ) C, H, N.
Example 2
2-Nitro-3,4,4′,5-tetramethoxy-(Z)-stilbene (compound 2)
[0043]
[0044] The title compound was obtained in 53% overall yield from 4-trimethoxybenzyl-triphenylphosphonium bromide and 3,4,5-trimethoxy-2-nitrobenaldehyde (compound A1). 1 H NMR (500 MHz, CDCl 3 ) δ 3.56 (s, 3H), 3.78 (s, 3H), 3.89 (s, 3H), 3.99 (s, 3H), 6.35 (d, J=12.0 Hz, 1H), 6.50 (s, 1H), 6.66 (d, J=12.0 Hz, 1H), 6.76 (d, J=8.5 Hz, 2H), 7.12 (d, J=8.5 Hz, 2H). MS (EI) m/z: 345 (M + , 71%), 194 (100%). HRMS (EI) for C 18 H 19 NO 6 (M + ): calcd, 345.1202; found, 345.1207.
Example 3
2-Amino-3,4′,5-trimethoxy-(Z)-stilbene (compound 3)
[0045]
[0046] The title compound was obtained in 40% overall yield from (4-methoxybenzyl)triphenylphosphonium bromide and 3,5-dimethoxy-2-nitrobenzaldehyde (compound A2); mp 83.2-86.3° C. 1 H NMR (500 MHz, CDCl 3 ) δ 3.63 (s, 3H), 3.75 (s, 3H), 3.83 (s, 3H), 6.31 (d, J=2.3 Hz, 1H), 6.39 (s, 1H), 6.41 (d, J=12.9 Hz, 1H), 6.58 (d, J=12.0 Hz, 1H), 6.73 (d, J=8.7 Hz, 2H), 7.19 (d, J=8.7 Hz, 2H). 13 C NMR (125 MHz, CDCl 3 ) δ 55.0, 55.5, 98.4, 103.9, 113.4, 123.5, 124.2, 127.2, 129.2, 130.0, 130.8, 148.4, 152.1, 158.8. MS (EI) m/z: 285 (M + , 100%), 270 (29%). HRMS (EI) for C 17 H 19 NO 3 (M + ): calcd, 285.1369; found, 285.1367. Anal. (C 17 H 19 NO 3 ) C, H. N.
Example 4
2-Amino-4,4′,5-trimethoxy-(Z)-stilbene (compound 4)
[0047]
[0048] The title compound was obtained in 43% overall yield from 4-trimethoxybenzyl-triphenylphosphonium bromide and 6-nitroveratraldehyde (compound A3). mp 62.7-63.8° C., 1 H NMR (500 MHz, CDCl 3 ) δ 3.65 (s, 3H), 3.76 (s, 3H), 3.84 (s, 3H), 6.28 (s, 1H), 6.34 (d, J=12.0 Hz, 1H), 6.52 (d, J=12.0 Hz, 1H), 6.64 (s, 1H), 6.74 (dd, J=8.8, 2.0 Hz, 2H), 7.20 (dd, J=8.8, 2.0 Hz, 2H). 13 C NMR (125 MHz, CDCl 3 ) δ 55.1, 55.6, 56.2, 100.4, 113.0, 113.5, 114.6, 124.0, 129.4, 130.0, 130.1, 137.6, 141.8, 149.2, 158.7. MS (EI) m/z: 285 (M + , 100%), 270 (47%). HRMS (EI) for C 17 H 19 NO 3 (M + ): calcd, 285.1373; found, 285.1369.
Example 5
3-Bromo-4,4′,5-trimethoxy-(Z)-stilbene (compound 5)
[0049]
[0050] The title compound was obtained in 45% overall yield from 4-trimethoxybenzyl-triphenylphosphonium bromide and 5-bromoveratraldehyde (compound A6). 1 H NMR (300 MHz, CDCl 3 ) δ 3.61 (s, 3H), 3.77 (s, 3H), 3.87 (s, 3H), 6.35 (d, J=12.0 Hz, 1H), 6.53 (d, J=12.0 Hz, 1 H), 6.77 (d, J=1.2 Hz, 1 H), 6.79 (d, J=8.6 Hz, 2H), 7.05 (d, J=1.1 Hz, 1H), 7.20 (d, J=8.6 Hz, 2H). 13 C NMR (75 MHz, CDCl 3 ) δ 55.1, 55.7, 60.5, 111.9, 113.5, 117.2, 125.1, 126.9, 129.0, 130.1, 130.4, 134.5, 145.2, 153.0, 158.8. MS (EI) m/z: 350 (M + , 98%), 348 (100%). HRMS (EI) for C 17 H 17 BrO 3 (M + ): calcd, 350.0312; found, 350.0340.
Example 6
2-Amino-3′-hydroxy-3,4,4′,5-tetramethoxy-(Z)-stilbene (compound 6)
[0051]
[0052] The title compound was obtained in 30% overall yield from 2-nito-(3,4,5-trimethoxybenzyl)triphenylphosphonium bromide (compound B2) and 3-(tert-butyldimethylsilyloxy)-4-methoxybenzaldehyde (compound B4) according to the above procedure and one extra procedure, which was 3 equiv of tetra-n-butylammonium floride/THF at room temperature stirring 1 h. 1 H NMR (500 MHz, CD 3 OD) δ 3.55 (s, 3H), 3.79 (s, 3H), 3.82 (s, 3H), 3.83 (s, 3H), 6.33 (d, J=12 Hz, 1H),6.49 (s, 1H), 6.50 (d, J=11.9 Hz, 1H), 6.71 (dd, J=8.2, 1.9 Hz, 1H), 6.74 (d, J=1.8 Hz, 1H), 6.77 (d, J=8.2 Hz, 1H). 13 C NMR (125 MHz, CD 3 OD) δ 56.3, 57.0, 60.9, 61.3, 110.4, 112.3, 116.5, 120.0, 122.0, 125.1, 131.4, 131.5, 133.5, 142.9, 143.4, 146.7, 147.1, 148.5. MS (EI) m/z: 331 (M + , 100%), 284 (25%). HRMS (EI) for C 18 H 21 NO 5 (M + ): calcd, 331.1422; found, 331.1421. Anal. (C 18 H 21 NO 5 ) C, H. N.
Example 7
2,3′-Diamino-3,4,4′,5-tetramethoxy-(Z)-stilbene (compound 7)
[0053]
[0054] The title compound was obtained in 34% overall yield from 2-nito-3,4,5-(trimethoxybenzyl)triphenylphosphonium bromide (compound B2) and 4-methoxy-3-nitrobenzaldehyde (compound B3). mp 97.3-98.1° C. 1 H NMR (500 MHz, Acetone-d 6 ) δ 3.54 (s, 3H), 3.77 (s, 3H), 3.79 (s, 3H), 3.80 (s, 3H), 4.01 (s, 2H), 4.25 (s, 2 H), 6.26 (d, J=12.1 Hz), 6.39 (d, J=12.1 Hz, 1H), 6.53 (s, 1H), 6.56 (dd, J=8.2, 1.7 Hz, 1H), 6.66 (d, J=8.2 Hz, 1H), 6.68 (d, J=1.8 Hz, 1H). 13 C NMR (125 MHz, Acetone-d 6 ) δ 56.1, 57.1, 61.0, 61.4, 110.5, 111.2, 117.0, 120.4, 120.9, 124.9, 131.3, 132.1, 133.6, 137:3, 143.0, 143.5, 146.8, 148.8. MS (EI) m/z: 330 (M + , 100%), 315 (27%). HRMS (EI) for C 18 H 22 N 2 O 4 (M + ): calcd, 330.1578; found, 330.1570. Anal. (C 18 H 22 N 2 O 4 ) C, H, N.
Example 8
Biological Test
[0055] (a) Material Regents for cell culture were obtained from Gibco-BRL Life Technologies (Gaitherburg, Md.). Microtubule-associated protein (MAP)-rich tubulin was purchased from Cytoskeleton, Inc. (Denver, Colo.). [ 3 H]Colchicine (specific activity, 60-87 Ci/mmol) was purchased from PerkinElmer Life Sciences (Boston, Mass.).
(b) Cell Growth Inhibitory Assay
[0056] Human oral epidermoid carcinoma KB cells, colorectal carcinoma HT29 cells, non small cell lung carcinoma H460 cells, and two stomach carcinoma TSGH, MKN45 cells were maintained in RPMI-1640 medium supplied with 5% fetal bovine serum.
[0057] KB-VIN10 cells were maintained in growth medium supplemented with 10 nM vincristine, generated from vincristine-driven selection, and displayed overexpression of P-gp170/MDR.
[0058] Cells in logarithmic phase were cultured at a density of 5000 cells/mL/well in a 24-well plate. KB-VIN10 cells were cultured in a drug-free medium for 3 days prior to use. The cells were exposed to various concentrations of the test drugs for 72 hours. The methylene blue dye assay was used to evaluate the effect of the test compounds on cell growth as described previously.1 The IC 50 value resulting from 50% inhibition of cell growth was calculated graphically as a comparison with the control.
[0059] The result of the examination shows that among the compounds 1-7 of the present invention, IC 50 of at least five compounds is <5 μM, and IC 50 of the other compounds is <50 nM.
[0000] (c) Tubulin Polymerization in Vitro Assay
[0060] Turbidimetric assays of microtubules were performed as described by Bollag et al.
[0061] MAP-rich tubulin (2 mg/mL) in 100 μL buffer containing 100 mM PIPES (pH 6.9), 2 mM MgCl 2 , 1 mM GTP, and 2% (v/v) dimethyl sulfoxide were placed in 96-well microtiter plate in the presence of test compounds. The increase in absorbance was measured at 350 nm in a PowerWave X Microplate Reader (BIO-TEK Instruments, Winooski, Vt.) at 37° C. and recorded every 30 sec for 30 min. The area under the curve (AUC) was used to determine the concentration that inhibited tubulin polymerization to 50% (IC 50 ). The AUC of the untreated control and 10 μM of colchicine was set to 100% and 0% polymerization, respectively, and the IC 50 was calculated by nonlinear regression in at least three experiments.
[0062] According to the results, the tested stilbenes derivatives (<5 μM, in the average) exhibit the property of inhibiting microtubulin polymerization.
[0063] Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the scope of the invention as hereinafter claimed.
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A series of Z-stilbenes derivatives are disclosed, which have the structure as shown by formula 1. In the structure of formula 1, X is hydrogen, NHR, or nitro group, and R is hydrogen. Y and Z is independently hydrogen, halogen, C 1 -C 10 alkyl, or C 1 -C 10 alkoxyl. Furthermore, A is hydrogen, hydroxyl, or amino group. The compounds of the present invention have both aqueous solubility and anti-tumor activity. The Z-stilbenes derivatives of the present invention can further include a pharmaceutical carrier to form pharmaceutical compositions as potent anti-mitotic agents and anti-cancer agents.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. Ser. No. 12/043,421, filed on Mar. 6, 2008, now U.S. Pat. No. 7,566,719 issued on Jul. 28, 2009, which is a continuation of U.S. Ser. No. 11/489,011 filed on Jul. 18, 2006, now U.S. Pat. No. 7,368,452 issued on May 6, 2008, which is a continuation of U.S. Ser. No. 10/826,743, filed on Apr. 16, 2004, which issued on Feb. 13, 2007 as U.S. Pat. No. 7,176,208, now reissued as RE 42375 on May 17, 2011, which claimed priority to U.S. 60/509,071, filed Apr. 18, 2003. The entire teachings of the above applications are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to novel macrocycles having activity against the hepatitis C virus (HCV) and useful in the treatment of HCV infections. More particularly, the invention relates to macrocyclic compounds, compositions containing such compounds and methods for using the same, as well as processes for making such compounds.
BACKGROUND OF THE INVENTION
HCV is the principal cause of non-A, non-B hepatitis and is an increasingly severe public health problem both in the developed and developing world. It is estimated that the virus infects over 200 million people worldwide, surpassing the number of individuals infected with the human immunodeficiency virus (HIV) by nearly five fold. HCV infected patients, due to the high percentage of individuals inflicted with chronic infections, are at an elevated risk of developing cirrhosis of the liver, subsequent hepatocellular carcinoma and terminal liver disease. HCV is the most prevalent cause of hepatocellular cancer and cause of patients requiring liver transplantations in the western world.
There are considerable barriers to the development of anti-HCV therapeutics, which include, but are not limited to, the persistence of the virus, the genetic diversity of the virus during replication in the host, the high incident rate of the virus developing drug-resistant mutants, and the lack of reproducible infectious culture systems and small-animal models for HCV replication and pathogenesis. In a majority of cases, given the mild course of the infection and the complex biology of the liver, careful consideration must be given to antiviral drugs, which are likely to have significant side effects.
Only two approved therapies for HCV infection are currently available. The original treatment regimen generally involves a 3-12 month course of intravenous interferon-α (IFN-α), while a new approved second-generation treatment involves co-treatment with IFN-α and the general antiviral nucleoside mimics like ribavirin. Both of these treatments suffer from interferon related side effects as well as low efficacy against HCV infections. There exists a need for the development of effective antiviral agents for treatment of HCV infection due to the poor tolerability and disappointing efficacy of existing therapies.
In a patient population where the majority of individuals are chronically infected and asymptomatic and the prognoses are unknown, an effective drug would desirably possess significantly fewer side effects than the currently available treatments. The hepatitis C non-structural protein-3 (NS3) is a proteolytic enzyme required for processing of the viral polyprotein and consequently viral replication. Despite the huge number of viral variants associated with HCV infection, the active site of the NS3 protease remains highly conserved thus making its inhibition an attractive mode of intervention. Recent success in the treatment of HIV with protease inhibitors supports the concept that the inhibition of NS3 is a key target in the battle against HCV.
HCV is a flaviridae type RNA virus. The HCV genome is enveloped and contains a single strand RNA molecule composed of circa 9600 base pairs. It encodes a polypeptide comprised of approximately 3010 amino acids.
The HCV polyprotein is processed by viral and host peptidase into 10 discreet peptides which serve a variety of functions. There are three structural proteins, C, E1 and E2. The P7 protein is of unknown function and is comprised of a highly variable sequence. There are six non-structural proteins. NS2 is a zinc-dependent metalloproteinase that functions in conjunction with a portion of the NS3 protein. NS3 incorporates two catalytic functions (separate from its association with NS2): a serine protease at the N-terminal end, which requires NS4A as a cofactor, and an ATP-ase-dependent helicase function at the carboxyl terminus. NS4A is a tightly associated but non-covalent cofactor of the serine protease.
The NS3.4A protease is responsible for cleaving four sites on the viral polyprotein. The NS3-NS4A cleavage is autocatalytic, occurring in cis. The remaining three hydrolyses, NS4A-NS4B, NS4B-NS5A and NS5A-NS5B all occur in trans. NS3 is a serine protease which is structurally classified as a chymotrypsin-like protease. While the NS serine protease possesses proteolytic activity by itself, the HCV protease enzyme is not an efficient enzyme in terms of catalyzing polyprotein cleavage. It has been shown that a central hydrophobic region of the NS4A protein is required for this enhancement. The complex formation of the NS3 protein with NS4A seems necessary to the processing events, enhancing the proteolytic efficacy at all of the sites.
A general strategy for the development of antiviral agents is to inactivate virally encoded enzymes, including NS3, that are essential for the replication of the virus. Current efforts directed toward the discovery of NS3 protease inhibitors were reviewed by S. Tan, A. Pause, Y. Shi, N. Sonenberg, Hepatitis C Therapeutics: Current Status and Emerging Strategies, Nature Rev. Drug Discov., 1, 867-881 (2002). Other patent disclosures describing the synthesis of HCV protease inhibitors are: WO 00/59929 (2000); WO 99/07733 (1999); WO 00/09543 (2000); WO 99/50230 (1999); U.S. Pat. No. 5,861,297 (1999); and US2002/0037998 (2002).
SUMMARY OF THE INVENTION
The present invention relates to novel macrocyclic compounds and methods of treating a hepatitis C infection in a subject in need of such therapy with said macrocyclic compounds. The present invention further relates to pharmaceutical compositions comprising the compounds of the present invention, or pharmaceutically acceptable salts, esters, or prodrugs thereof, in combination with a pharmaceutically acceptable carrier or excipient.
In one embodiment of the present invention there are disclosed compounds represented by Formulas I and II, or pharmaceutically acceptable salts, esters, or prodrugs thereof:
wherein
A is
(a) hydrogen; (b) —(C═O)—O—R 1 , wherein R 1 is hydrogen, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, C 1 -C 6 alkenyl, substituted C 1 -C 6 alkenyl, C 1 -C 6 alkynyl, substituted C 1 -C 6 alkynyl, C 3 -C 12 cycloalkyl, substituted C 3 -C 12 cycloalkyl, aryl, substituted aryl, arylalkyl, substituted arylalkyl, heteroaryl, substituted heteroaryl, heteroarylalkyl, substituted heteroarylalkyl, heterocycloalkyl, or substituted heterocycloalkyl; (c) —(C═O)—R 2 , wherein R 2 is hydrogen, C 1 -C 6 alkyl, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, C 1 -C 6 alkenyl, substituted C 1 -C 6 alkenyl, C 1 -C 6 alkynyl, substituted C 1 -C 6 alkynyl, C 3 -C 12 cycloalkyl, substituted C 3 -C 12 cycloalkyl, alkylamino, dialkylamino, arylamino, diarylamino, aryl, substituted aryl, arylalkyl, substituted arylalkyl, heteroaryl, substituted heteroaryl, heteroarylalkyl, substituted heteroarylalkyl, heterocycloalkyl, or substituted heterocycloalkyl; (d) —C(═O)—NH—R 2 , wherein R 2 is previously defined; (e) —C(═S)—NH—R 2 , wherein R 2 is previously defined; or (f) —S(O) 2 —R 2 , wherein R 2 is previously defined;
G is
(a) —OH; (b) —O—(C 1 -C 12 alkyl); (c) —NHS(O) 2 —R 1 , wherein R 1 is previously defined; (d) —(C═O)—R 2 , wherein R 2 is previously defined; (e) —(C═O)—O—R 1 , wherein R 1 is previously defined; or (f) —(C═O)—NH—R 2 , wherein R 2 is previously defined;
L is
(a) —S—; (b) —SCH 2 —; (c) —SCH 2 CH 2 —; (d) —S(O) 2 —; (e) —S(O) 2 CH 2 CH 2 —; (f) —S(O)—; (g) —S(O)CH 2 CH 2 —; (h) —O—; (i) —OCH 2 —; (j) —OCH 2 CH 2 —; (k) —(C═O)—CH 2 —; (l) —CH(CH 3 )CH 2 —; (m) —CFHCH 2 —; or (n) —CF 2 CH 2 —;
X and Y taken together with the carbon atoms to which they are attached form a cyclic moiety selected from
(a) aryl; (b) substituted aryl; (c) heteroaryl; or (d) substituted heteroaryl;
W is absent, —O—, —S—, —NH—, or —NR 1 —, wherein R 1 is previously defined;
Z is
(a) hydrogen; (b) —CN; (c) —SCN; (d) —NCO; (e) —NCS; (f) —NHNH 2 ; (g) —N 3 ; (h) halogen; (i) —R 4 , wherein R 4 is
(i) —C 1 -C 6 alkyl containing 0, 1, 2, or 3 heteroatoms selected from O, S, or N, optionally substituted with one or more substituent selected from halogen, aryl, substituted aryl, heteroaryl, or substituted heteroaryl; (ii) —C 2 -C 6 alkenyl containing 0, 1, 2, or 3 heteroatoms selected from O, S, or N, optionally substituted with one or more substituent selected from halogen, aryl, substituted aryl, heteroaryl, or substituted heteroaryl; (iii) —C 2 -C 6 alkynyl containing 0, 1, 2, or 3 heteroatoms selected from O, S, or N, optionally substituted with one or more substituent selected from halogen, aryl, substituted aryl, heteroaryl, or substituted heteroaryl;
(j) —C 3 -C 12 cycloalkyl; (k) substituted —C 3 -C 12 cycloalkyl; (l) aryl; (m) substituted aryl; (n) heteroaryl; (o) substituted heteroaryl; (p) heterocycloalkyl; and (q) substituted heterocycloalkyl;
j=0, 1, 2, 3, or 4;
m=0, 1, or 2;
s=0, 1 or 2; and
R 5 and R 6 are each independently hydrogen or methyl.
DETAILED DESCRIPTION OF THE INVENTION
A first embodiment of the invention is a compound represented by Formula I as described above, or a pharmaceutically acceptable salt, ester or prodrug thereof, in combination with a pharmaceutically acceptable carrier or excipient.
A second embodiment of the invention is a compound represented by Formula II as described above, or a pharmaceutically acceptable salt, ester or prodrug thereof, in combination with a pharmaceutically acceptable carrier or excipient.
Representative subgenera of the invention include, but are not limited to:
A compound of Formula I, wherein W is absent and Z is thiophen-2-yl; A compound of Formula I, wherein L is absent, R 5 and R 6 are hydrogen, j=3, m=1, and s=1; A compound of Formula III:
wherein A, B, G, L, W, Z, R 5 , R 6 , j, m, and s are as previously defined and R 7 and R 8 are independently selected from R 4 as previously defined; and
A compound of Formula IV:
wherein A, B, G, L, W, Z, R 5 , R 6 , j, m, and s are as previously defined and R 7 and R 8 are independently selected from R 4 as previously defined;
Representative compounds of the invention include, but are not limited to, the following compounds:
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=2-(formamido)-thiazol-4-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=ethyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=phenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=4-methoxyphenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=4-ethoxyphenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=5-bromothiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=2-pyrid-3-yl ethylenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=3,4-Dimethoxy-phenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=2-thiophen-2-yl ethylenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, Z=indole-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=1H-indol-3-yl methyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=furan-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=1H-benzoimidazol-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=1H-imidazol-2-ylmethyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OEt, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=chloro, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, Z=thiophen-3-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=2-pyrid-3-yl acetylenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=2,3-dihydrobenzofuran-5-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W=—NH—, Z=propargyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W=—N(ethyl)-, Z=benzyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W=—NH—, Z=pyrid-3-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=tetrazolyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=morpholino, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W=—O—, Z=thiophen-3-yl-methyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OEt, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =cyclopentyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =cyclobutyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =cyclohexyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =
G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =
G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =
G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—R 1 , wherein R 1 =cyclopentyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—NH—R 1 , wherein R 1 =cyclopentyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═S)—NH—R 1 , wherein R 1 =cyclopentyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—S(O) 2 —R 1 , wherein R 1 =cyclopentyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—O-phenethyl, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—NH-phenethyl, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—NHS(O) 2 -phenethyl L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—(C═O)—OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—(C═O)—O-phenethyl, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—(C═O)—NH-phenethyl, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—(C═O)—NH—S(O) 2 -benzyl, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=—(C═O)CH 2 —, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=—CH(CH 3 )CH 2 —, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=—O—, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 =methyl, and R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=—S—, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 =methyl, and R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=—S(O)—, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 =methyl, and R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=—S(O) 2 , X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 =methyl, and R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=—SCH 2 CH 2 —, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 =methyl, and R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=CF 2 CH 2 , X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen;
Compound of Formula I, wherein A=tBOC, G=OH, L=—CHFCH 2 —, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen; and
Compound of Formula II, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
According to an alternate embodiment, the pharmaceutical compositions of the present invention may further contain other anti-HCV agents. Examples of anti-HCV agents include, but are not limited to, α-interferon, β-interferon, ribavirin, and amantadine.
According to an additional embodiment, the pharmaceutical compositions of the present invention may further contain other HCV protease inhibitors.
According to yet another embodiment, the pharmaceutical compositions of the present invention may further comprise inhibitor(s) of other targets in the HCV life cycle, including, but not limited to, helicase, polymerase, metalloprotease, and internal ribosome entry site (IRES).
According to a further embodiment, the present invention includes methods of treating hepatitis C infections in a subject in need of such treatment by administering to said subject an anti-HCV virally effective amount of the pharmaceutical compositions of the present invention.
Yet a further aspect of the present invention is a process of making any of the compounds delineated herein employing any of the synthetic means delineated herein.
DEFINITIONS
Listed Below are Definitions of Various Terms Used to Describe this Invention. these definitions apply to the terms as they are used throughout this specification and claims, unless otherwise limited in specific instances, either individually or as part of a larger group.
The terms “C 1 -C 3 alkyl,” “C 1 -C 6 alkyl” or “C 1 -C 12 alkyl,” as used herein, refer to saturated, straight- or branched-chain hydrocarbon radicals containing between one and three, one and twelve, or one and six carbon atoms, respectively. Examples of C 1 -C 3 alkyl radicals include methyl, ethyl, propyl and isopropyl radicals; examples of C 1 -C 6 alkyl radicals include, but are not limited to, methyl, ethyl, propyl, isopropyl, n-butyl, tert-butyl, neopentyl and n-hexyl radicals; and examples of C 1 -C 12 alkyl radicals include, but are not limited to, ethyl, propyl, isopropyl, n-hexyl, octyl, decyl, dodecyl radicals.
The term “substituted alkyl,” as used herein, refers to a “C 2 -C 12 alkyl” or “C 1 -C 6 alkyl” group substituted by independent replacement of one, two or three of the hydrogen atoms thereon with F, Cl, Br, I, OH, NO 2 , CN, C 1 -C 6 -alkyl-OH, C(O)—C 1 -C 6 -alkyl, OCH 2 —C 3 -C 12 -cycloalkyl, C(O)-aryl, C(O)-heteroaryl, CO 2 -alkyl, CO 2 -aryl, CO 2 -heteroaryl, CONH 2 , CONH—C 1 -C 6 -alkyl, CONH-aryl, CONH-heteroaryl, OC(O)—C 1 -C 6 -alkyl, OC(O)-aryl, OC(O)-heteroaryl, OCO 2 -alkyl, OCO 2 -aryl, OCO 2 -heteroaryl, OCONH 2 , OCONH—C 1 -C 6 -alkyl, OCONH-aryl, OCONH-heteroaryl, NHC(O)—C 1 -C 6 -alkyl, NHC(O)-aryl, NHC(O)-heteroaryl, NHCO 2 -alkyl, NHCO 2 -aryl, NHCO 2 -heteroaryl, NHCONH 2 , NHCONH—C 1 -C 6 -alkyl, NHCONH-aryl, NHCONH-heteroaryl, SO 2 —C 1 -C 6 -alkyl, SO 2 -aryl, SO 2 -heteroaryl, SO 2 NH 2 , SO 2 NH—C 1 -C 6 -alkyl, SO 2 NH-aryl, SO 2 NH-heteroaryl, C 1 -C 6 -alkyl, C 3 -C 12 -cycloalkyl, CF 3 , CH 2 CF 3 , CHCl 2 , CH 2 NH 2 , CH 2 SO 2 CH 3 , C 1 -C 6 alkyl, halo alkyl, C 3 -C 12 cycloalkyl, substituted C 3 -C 12 cycloalkyl, aryl, substituted aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, benzyl, benzyloxy, aryloxy, heteroaryloxy, C 1 -C 6 -alkoxy, methoxymethoxy, methoxyethoxy, amino, benzylamino, arylamino, heteroarylamino, C 1 -C 3 -alkylamino, thio, aryl-thio, heteroarylthio, benzyl-thio, C 1 -C 6 -alkyl-thio, or methylthiomethyl.
The terms “C 2 -C 12 alkenyl” or “C 2 -C 6 alkenyl,” as used herein, denote a monovalent group derived from a hydrocarbon moiety containing from two to twelve or two to six carbon atoms having at least one carbon-carbon double bond by the removal of a single hydrogen atom. Alkenyl groups include, but are not limited to, for example, ethenyl, propenyl, butenyl, 1-methyl-2-buten-1-yl, and the like.
The term “substituted alkenyl,” as used herein, refers to a “C 2 -C 12 alkenyl” or “C 1 -C 6 alkenyl” group substituted by independent replacement of one, two or three of the hydrogen atoms thereon with F, Cl, Br, I, OH, NO 2 , CN, C 1 -C 6 -alkyl-OH, C(O)—C 1 -C 6 -alkyl, OCH 2 —C 3 -C 12 -cycloalkyl, C(O)-aryl, C(O)-heteroaryl, CO 2 -alkyl, CO 2 -aryl, CO 2 -heteroaryl, CONH 2 , CONH—C 1 -C 6 -alkyl, CONH-aryl, CONH-heteroaryl, OC(O)—C 1 -C 6 -alkyl, OC(O)-aryl, OC(O)-heteroaryl, OCO 2 -alkyl, OCO 2 -aryl, OCO 2 -heteroaryl, OCONH 2 , OCONH—C 1 -C 6 -alkyl, OCONH-aryl, OCONH-heteroaryl, NHC(O)—C 1 -C 6 -alkyl, NHC(O)-aryl, NHC(O)-heteroaryl, NHCO 2 -alkyl, NHCO 2 -aryl, NHCO 2 -heteroaryl, NHCONH 2 , NHCONH—C 1 -C 6 -alkyl, NHCONH-aryl, NHCONH-heteroaryl, SO 2 —C 1 -C 6 -alkyl, SO 2 -aryl, SO 2 -heteroaryl, SO 2 NH 2 , SO 2 NH—C 1 -C 6 -alkyl, SO 2 NH-aryl, SO 2 NH-heteroaryl, C 1 -C 6 -alkyl, C 3 -C 12 -cycloalkyl, CF 3 , CH 2 CF 3 , CHCl 2 , CH 2 NH 2 , CH 2 SO 2 CH 3 , C 1 -C 6 alkyl, halo alkyl, C 3 -C 12 cycloalkyl, substituted C 3 -C 12 cycloalkyl, aryl, substituted aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, benzyl, benzyloxy, aryloxy, heteroaryloxy, C 1 -C 6 -alkoxy, methoxymethoxy, methoxyethoxy, amino, benzylamino, arylamino, heteroarylamino, C 1 -C 3 -alkylamino, thio, aryl-thio, heteroarylthio, benzyl-thio, C 1 -C 6 -alkyl-thio, or methylthiomethyl.
The terms “C 1 -C 12 alkynyl” or “C 1 -C 6 alkynyl,” as used herein, denote a monovalent group derived from a hydrocarbon moiety containing from two to twelve or two to six carbon atoms having at least one carbon-carbon triple bond by the removal of a single hydrogen atom. Representative alkynyl groups include, but are not limited to, for example, ethynyl, 1-propynyl, 1-butynyl, and the like.
The term “substituted alkynyl,” as used herein, refers to a “C 2 -C 12 alkynyl” or “C 1 -C 6 alkynyl” group substituted by independent replacement of one, two or three of the hydrogen atoms thereon with F, Cl, Br, I, OH, NO 2 , CN, C 1 -C 6 -alkyl-OH, C(O)—C 1 -C 6 -alkyl, OCH 2 —C 3 -C 12 -cycloalkyl, C(O)-aryl, C(O)-heteroaryl, CO 2 -alkyl, CO 2 -aryl, CO 2 -heteroaryl, CONH 2 , CONH—C 1 -C 6 -alkyl, CONH-aryl, CONH-heteroaryl, OC(O)—C 1 -C 6 -alkyl, OC(O)-aryl, OC(O)-heteroaryl, OCO 2 -alkyl, OCO 2 -aryl, OCO 2 -heteroaryl, OCONH 2 , OCONH—C 1 -C 6 -alkyl, OCONH-aryl, OCONH-heteroaryl, NHC(O)—C 1 -C 6 -alkyl, NHC(O)-aryl, NHC(O)-heteroaryl, NHCO 2 -alkyl, NHCO 2 -aryl, NHCO 2 -heteroaryl, NHCONH 2 , NHCONH—C 1 -C 6 -alkyl, NHCONH-aryl, NHCONH-heteroaryl, SO 2 —C 1 -C 6 -alkyl, SO 2 -aryl, SO 2 -heteroaryl, SO 2 NH 2 , SO 2 NH—C 1 -C 6 -alkyl, SO 2 NH-aryl, SO 2 NH-heteroaryl, C 1 -C 6 -alkyl, C 3 -C 12 -cycloalkyl, CF 3 , CH 2 CF 3 , CHCl 2 , CH 2 NH 2 , CH 2 SO 2 CH 3 , C 1 -C 6 alkyl, halo alkyl, C 3 -C 12 cycloalkyl, substituted C 3 -C 12 cycloalkyl, aryl, substituted aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, benzyl, benzyloxy, aryloxy, heteroaryloxy, C 1 -C 6 -alkoxy, methoxymethoxy, methoxyethoxy, amino, benzylamino, arylamino, heteroarylamino, C 1 -C 3 -alkylamino, thio, aryl-thio, heteroarylthio, benzyl-thio, C 1 -C 6 -alkyl-thio, or methylthiomethyl.
The term “C 1 -C 6 alkoxy,” as used herein, refers to a C 1 -C 6 alkyl group, as previously defined, attached to the parent molecular moiety through an oxygen atom. Examples of C 1 -C 6 -alkoxy include, but are not limited to, methoxy, ethoxy, propoxy, isopropoxy, n-butoxy, tert-butoxy, neopentoxy and n-hexoxy.
The terms “halo” and “halogen,” as used herein, refer to an atom selected from fluorine, chlorine, bromine and iodine.
The term “aryl,” as used herein, refers to a mono- or bicyclic carbocyclic ring system having one or two aromatic rings including, but not limited to, phenyl, naphthyl, tetrahydronaphthyl, indanyl, idenyl and the like.
The term “substituted aryl,” as used herein, refers to an aryl group, as defined herein, substituted by independent replacement of one, two or three of the hydrogen atoms thereon with F, Cl, Br, I, OH, NO 2 , CN, C 1 -C 6 -alkyl-OH, C(O)—C 1 -C 6 -alkyl, OCH 2 —C 3 -C 12 -cycloalkyl, C(O)-aryl, C(O)-heteroaryl, CO 2 -alkyl, CO 2 -aryl, CO 2 -heteroaryl, CONH 2 , CONH—C 1 -C 6 -alkyl, CONH-aryl, CONH-heteroaryl, OC(O)—C 1 -C 6 -alkyl, OC(O)-aryl, OC(O)-heteroaryl, OCO 2 -alkyl, OCO 2 -aryl, OCO 2 -heteroaryl, OCONH 2 , OCONH—C 1 -C 6 -alkyl, OCONH-aryl, OCONH-heteroaryl, NHC(O)—C 1 -C 6 -alkyl, NHC(O)-aryl, NHC(O)-heteroaryl, NHCO 2 -alkyl, NHCO 2 -aryl, NHCO 2 -heteroaryl, NHCONH 2 , NHCONH—C 1 -C 6 -alkyl, NHCONH-aryl, NHCONH-heteroaryl, SO 2 —C 1 -C 6 -alkyl, SO 2 -aryl, SO 2 -heteroaryl, SO 2 NH 2 , SO 2 NH—C 1 -C 6 -alkyl, SO 2 NH-aryl, SO 2 NH-heteroaryl, C 1 -C 6 -alkyl, C 3 -C 12 -cycloalkyl, CF 3 , CH 2 CF 3 , CHCl 2 , CH 2 NH 2 , CH 2 SO 2 CH 3 , C 1 -C 6 alkyl, halo alkyl, C 3 -C 12 cycloalkyl, substituted C 3 -C 12 cycloalkyl, aryl, substituted aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, benzyl, benzyloxy, aryloxy, heteroaryloxy, C 1 -C 6 -alkoxy, methoxymethoxy, methoxyethoxy, amino, benzylamino, arylamino, heteroarylamino, C 1 -C 3 -alkylamino, thio, aryl-thio, heteroarylthio, benzyl-thio, C 1 -C 6 -alkyl-thio, or methylthiomethyl.
The term “arylalkyl,” as used herein, refers to a C 1 -C 3 alkyl or C 1 -C 6 alkyl residue attached to an aryl ring. Examples include, but are not limited to, benzyl, phenethyl and the like.
The term “substituted arylalkyl,” as used herein, refers to an arylalkyl group, as previously defined, substituted by independent replacement of one, two or three of the hydrogen atoms thereon with F, Cl, Br, I, OH, NO 2 , CN, C 1 -C 6 -alkyl-OH, C(O)—C 1 -C 6 -alkyl, OCH 2 —C 3 -C 12 -cycloalkyl, C(O)-aryl, C(O)-heteroaryl, CO 2 -alkyl, CO 2 -aryl, CO 2 -heteroaryl, CONH 2 , CONH—C 1 -C 6 -alkyl, CONH-aryl, CONH-heteroaryl, OC(O)—C 1 -C 6 -alkyl, OC(O)-aryl, OC(O)-heteroaryl, OCO 2 -alkyl, OCO 2 -aryl, OCO 2 -heteroaryl, OCONH 2 , OCONH—C 1 -C 6 -alkyl, OCONH-aryl, OCONH-heteroaryl, NHC(O)—C 1 -C 6 -alkyl, NHC(O)-aryl, NHC(O)-heteroaryl, NHCO 2 -alkyl, NHCO 2 -aryl, NHCO 2 -heteroaryl, NHCONH 2 , NHCONH—C 1 -C 6 -alkyl, NHCONH-aryl, NHCONH-heteroaryl, SO 2 —C 1 -C 6 -alkyl, SO 2 -aryl, SO 2 -heteroaryl, SO 2 NH 2 , SO 2 NH—C 1 -C 6 -alkyl, SO 2 NH-aryl, SO 2 NH-heteroaryl, C 1 -C 6 -alkyl, C 3 -C 12 -cycloalkyl, CF 3 , CH 2 CF 3 , CHCl 2 , CH 2 NH 2 , CH 2 SO 2 CH 3 , C 1 -C 6 alkyl, halo alkyl, C 3 -C 12 cycloalkyl, substituted C 3 -C 12 cycloalkyl, aryl, substituted aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, benzyl, benzyloxy, aryloxy, heteroaryloxy, C 1 -C 6 -alkoxy, methoxymethoxy, methoxyethoxy, amino, benzylamino, arylamino, heteroarylamino, C 1 -C 3 -alkylamino, thio, aryl-thio, heteroarylthio, benzyl-thio, C 1 -C 6 -alkyl-thio, or methylthiomethyl.
The term “heteroaryl,” as used herein, refers to a mono-, bi-, or tri-cyclic aromatic radical or ring having from five to ten ring atoms of which one ring atom is selected from S, O and N; zero, one or two ring atoms are additional heteroatoms independently selected from S, O and N; and the remaining ring atoms are carbon. Heteroaryl includes, but is not limited to, pyridinyl, pyrazinyl, pyrimidinyl, pyrrolyl, pyrazolyl, imidazolyl, thiazolyl, oxazolyl, isooxazolyl, thiadiazolyl, oxadiazolyl, thiophenyl, furanyl, quinolinyl, isoquinolinyl, benzimidazolyl, benzooxazolyl, quinoxalinyl, and the like.
The term “substituted heteroaryl,” as used herein, refers to a heteroaryl group as defined herein, substituted by independent replacement of one, two or three of the hydrogen atoms thereon with F, Cl, Br, I, OH, NO 2 , CN, C 1 -C 6 -alkyl-OH, C(O)—C 1 -C 6 -alkyl, OCH 2 —C 3 -C 12 -cycloalkyl, C(O)-aryl, C(O)-heteroaryl, CO 2 -alkyl, CO 2 -aryl, CO 2 -heteroaryl, CONH 2 , CONH—C 1 -C 6 -alkyl, CONH-aryl, CONH-heteroaryl, OC(O)—C 1 -C 6 -alkyl, OC(O)-aryl, OC(O)-heteroaryl, OCO 2 -alkyl, OCO 2 -aryl, OCO 2 -heteroaryl, OCONH 2 , OCONH—C 1 -C 6 -alkyl, OCONH-aryl, OCONH-heteroaryl, NHC(O)—C 1 -C 6 -alkyl, NHC(O)-aryl, NHC(O)-heteroaryl, NHCO 2 -alkyl, NHCO 2 -aryl, NHCO 2 -heteroaryl, NHCONH 2 , NHCONH—C 1 -C 6 -alkyl, NHCONH-aryl, NHCONH-heteroaryl, SO 2 —C 1 -C 6 -alkyl, SO 2 -aryl, SO 2 -heteroaryl, SO 2 NH 2 , SO 2 NH—C 1 -C 6 -alkyl, SO 2 NH-aryl, SO 2 NH-heteroaryl, C 1 -C 6 -alkyl, C 3 -C 12 -cycloalkyl, CF 3 , CH 2 CF 3 , CHCl 2 , CH 2 NH 2 , CH 2 SO 2 CH 3 , C 1 -C 6 alkyl, halo alkyl, C 3 -C 12 cycloalkyl, substituted C 3 -C 12 cycloalkyl, aryl, substituted aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, benzyl, benzyloxy, aryloxy, heteroaryloxy, C 1 -C 6 -alkoxy, methoxymethoxy, methoxyethoxy, amino, benzylamino, arylamino, heteroarylamino, C 1 -C 3 -alkylamino, thio, aryl-thio, heteroarylthio, benzyl-thio, C 1 -C 6 -alkyl-thio, or methylthiomethyl.
The term “C 3 -C 12 -cycloalkyl” denotes a monovalent group derived from a monocyclic or bicyclic saturated carbocyclic ring compound by the removal of a single hydrogen atom. Examples include, but not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, bicyclo[2.2.1]heptyl, and bicyclo[2.2.2]octyl.
The term “substituted C 3 -C 12 -cycloalkyl,” as used herein, refers to a C 3 -C 12 -cycloalkyl group as defined herein, substituted by independent replacement of one, two or three of the hydrogen atoms thereon with F, Cl, Br, I, OH, NO 2 , CN, C 1 -C 6 -alkyl-OH, C(O)—C 1 -C 6 -alkyl, OCH 2 —C 3 -C 12 -cycloalkyl, C(O)-aryl, C(O)-heteroaryl, CO 2 -alkyl, CO 2 -aryl, CO 2 -heteroaryl, CONH 2 , CONH—C 1 -C 6 -alkyl, CONH-aryl, CONH-heteroaryl, OC(O)—C 1 -C 6 -alkyl, OC(O)-aryl, OC(O)-heteroaryl, OCO 2 -alkyl, OCO 2 -aryl, OCO 2 -heteroaryl, OCONH 2 , OCONH—C 1 -C 6 -alkyl, OCONH-aryl, OCONH-heteroaryl, NHC(O)—C 1 -C 6 -alkyl, NHC(O)-aryl, NHC(O)-heteroaryl, NHCO 2 -alkyl, NHCO 2 -aryl, NHCO 2 -heteroaryl, NHCONH 2 , NHCONH—C 1 -C 6 -alkyl, NHCONH-aryl, NHCONH-heteroaryl, SO 2 —C 1 -C 6 -alkyl, SO 2 -aryl, SO 2 -heteroaryl, SO 2 NH 2 , SO 2 NH—C 1 -C 6 -alkyl, SO 2 NH-aryl, SO 2 NH-heteroaryl, C 1 -C 6 -alkyl, C 3 -C 12 -cycloalkyl, CF 3 , CH 2 CF 3 , CHCl 2 , CH 2 NH 2 , CH 2 SO 2 CH 3 , C 1 -C 6 alkyl, halo alkyl, C 3 -C 12 cycloalkyl, substituted C 3 -C 12 cycloalkyl, aryl, substituted aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, benzyl, benzyloxy, aryloxy, heteroaryloxy, C 1 -C 6 -alkoxy, methoxymethoxy, methoxyethoxy, amino, benzylamino, arylamino, heteroarylamino, C 1 -C 3 -alkylamino, thio, aryl-thio, heteroarylthio, benzyl-thio, C 1 -C 6 -alkyl-thio, or methylthiomethyl.
The term “heterocycloalkyl,” as used herein, refers to a non-aromatic 5-, 6- or 7-membered ring or a bi- or tri-cyclic group fused system, where (i) each ring contains between one and three heteroatoms independently selected from oxygen, sulfur and nitrogen, (ii) each 5-membered ring has 0 to 1 double bonds and each 6-membered ring has 0 to 2 double bonds, (iii) the nitrogen and sulfur heteroatoms may optionally be oxidized, (iv) the nitrogen heteroatom may optionally be quaternized, and (iv) any of the above rings may be fused to a benzene ring. Representative heterocycloalkyl groups include, but are not limited to, [1,3]dioxolane, pyrrolidinyl, pyrazolinyl, pyrazolidinyl, imidazolinyl, imidazolidinyl, piperidinyl, piperazinyl, oxazolidinyl, isoxazolidinyl, morpholinyl, thiazolidinyl, isothiazolidinyl, and tetrahydrofuryl.
The term “substituted heterocycloalkyl,” as used herein, refers to a heterocycloalkyl group, as previously defined, substituted by independent replacement or one, two, or three of the hydrogen atoms thereon with F, Cl, Br, I, OH, NO 2 , CN, C 1 -C 6 -alkyl-OH, C(O)—C 1 -C 6 -alkyl, OCH 2 —C 3 -C 12 -cycloalkyl, C(O)-aryl, C(O)-heteroaryl, CO 2 -alkyl, CO 2 -aryl, CO 2 -heteroaryl, CONH 2 , CONH—C 1 -C 6 -alkyl, CONH-aryl, CONH-heteroaryl, OC(O)—C 1 -C 6 -alkyl, OC(O)-aryl, OC(O)-heteroaryl, OCO 2 -alkyl, OCO 2 -aryl, OCO 2 -heteroaryl, OCONH 2 , OCONH—C 1 -C 6 -alkyl, OCONH-aryl, OCONH-heteroaryl, NHC(O)—C 1 -C 6 -alkyl, NHC(O)-aryl, NHC(O)-heteroaryl, NHCO 2 -alkyl, NHCO 2 -aryl, NHCO 2 -heteroaryl, NHCONH 2 , NHCONH—C 1 -C 6 -alkyl, NHCONH-aryl, NHCONH-heteroaryl, SO 2 —C 1 -C 6 -alkyl, SO 2 -aryl, SO 2 -heteroaryl, SO 2 NH 2 , SO 2 NH—C 1 -C 6 -alkyl, SO 2 NH-aryl, SO 2 NH-heteroaryl, C 1 -C 6 -alkyl, C 3 -C 12 -cycloalkyl, CF 3 , CH 2 CF 3 , CHCl 2 , CH 2 NH 2 , CH 2 SO 2 CH 3 , C 1 -C 6 alkyl, halo alkyl, C 3 -C 12 cycloalkyl, substituted C 3 -C 12 cycloalkyl, aryl, substituted aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, benzyl, benzyloxy, aryloxy, heteroaryloxy, C 1 -C 6 -alkoxy, methoxymethoxy, methoxyethoxy, amino, benzylamino, arylamino, heteroarylamino, C 1 -C 3 -alkylamino, thio, aryl-thio, heteroarylthio, benzyl-thio, C 1 -C 6 -alkyl-thio, or methylthiomethyl.
The term “heteroarylalkyl,” as used herein, refers to a C 1 -C 3 alkyl or C 1 -C 6 alkyl residue residue attached to a heteroaryl ring. Examples include, but are not limited to, pyridinylmethyl, pyrimidinylethyl and the like.
The term “substituted heteroarylalkyl,” as used herein, refers to a heteroarylalkyl group, as previously defined, substituted by independent replacement or one, two, or three of the hydrogen atoms thereon with F, Cl, Br, I, OH, NO 2 , CN, C 1 -C 6 -alkyl-OH, C(O)—C 1 -C 6 -alkyl, OCH 2 —C 3 -C 12 -cycloalkyl, C(O)-aryl, C(O)-heteroaryl, CO 2 -alkyl, CO 2 -aryl, CO 2 -heteroaryl, CONH 2 , CONH—C 1 -C 6 -alkyl, CONH-aryl, CONH-heteroaryl, OC(O)—C 1 -C 6 -alkyl, OC(O)-aryl, OC(O)-heteroaryl, OCO 2 -alkyl, OCO 2 -aryl, OCO 2 -heteroaryl, OCONH 2 , OCONH—C 1 -C 6 -alkyl, OCONH-aryl, OCONH-heteroaryl, NHC(O)—C 1 -C 6 -alkyl, NHC(O)-aryl, NHC(O)-heteroaryl, NHCO 2 -alkyl, NHCO 2 -aryl, NHCO 2 -heteroaryl, NHCONH 2 , NHCONH—C 1 -C 6 -alkyl, NHCONH-aryl, NHCONH-heteroaryl, SO 2 —C 1 -C 6 -alkyl, SO 2 -aryl, SO 2 -heteroaryl, SO 2 NH 2 , SO 2 NH—C 1 -C 6 -alkyl, SO 2 NH-aryl, SO 2 NH-heteroaryl, C 1 -C 6 -alkyl, C 3 -C 12 -cycloalkyl, CF 3 , CH 2 CF 3 , CHCl 2 , CH 2 NH 2 , CH 2 SO 2 CH 3 , C 1 -C 6 alkyl, halo alkyl, C 3 -C 12 cycloalkyl, substituted C 3 -C 12 cycloalkyl, aryl, substituted aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, benzyl, benzyloxy, aryloxy, heteroaryloxy, C 1 -C 6 -alkoxy, methoxymethoxy, methoxyethoxy, amino, benzylamino, arylamino, heteroarylamino, C 1 -C 3 -alkylamino, thio, aryl-thio, heteroarylthio, benzyl-thio, C 1 -C 6 -alkyl-thio, or methylthiomethyl.
The term “alkylamino” refers to a group having the structure —NH(C 1 -C 12 alkyl) where C 1 -C 12 alkyl is as previously defined.
The term “dialkylamino” refers to a group having the structure —N(C 1 -C 12 alkyl) 2 where C 1 -C 12 alkyl is as previously defined. Examples of dialkylamino are, but not limited to, N,N-dimethylamino, N,N-diethylamino, N,N-methylethylamino, and the like.
The term “diarylamino” refers to a group having the structure —N(aryl) 2 or —N(substituted aryl) 2 where substituted aryl is as previously defined. Examples of diarylamino are, but not limited to, N,N-diphenylamino, N,N-dinaphthylamino, N,N-di(toluenyl)amino, and the like.
The term “diheteroarylamino” refers to a group having the structure —N(heteroaryl) 2 or —N(substituted heteroaryl) 2 , where heteroaryl and substituted heteroaryl is as previously defined. Examples of diheteroarylamino are, but not limited to, N,N-difuranylamino, N,N-dithiazolidinylamino, N,N-di(imidazole)amino, and the like.
The compounds described herein contain two or more asymmetric centers and thus give rise to enantiomers, diastereomers, and other stereoisomeric forms that may be defined, in terms of absolute stereochemistry, as (R)- or (S)-, or as (D)- or (L)- for amino acids. The present invention is meant to include all such possible isomers, as well as their racemic and optically pure forms. Optical isomers may be prepared from their respective optically active precursors by the procedures described above, or by resolving the racemic mixtures. The resolution can be carried out in the presence of a resolving agent, by chromatography or by repeated crystallization or by some combination of these techniques which are known to those skilled in the art. Further details regarding resolutions can be found in Jacques, et al., Enantiomers, Racemates, and Resolutions (John Wiley & Sons, 1981). When the compounds described herein contain olefinic double bonds or other centers of geometric asymmetry, and unless specified otherwise, it is intended that the compounds include both E and Z geometric isomers. Likewise, all tautomeric forms are also intended to be included. The configuration of any carbon-carbon double bond appearing herein is selected for convenience only and is not intended to designate a particular configuration unless the text so states; thus a carbon-carbon double bond depicted arbitrarily herein as trans may be cis, trans, or a mixture of the two in any proportion.
The term “subject” as used herein refers to a mammal. Preferably the mammal is a human. A subject also refers to, for example, dogs, cats, horses, cows, pigs, guinea pigs, and the like.
As used herein, the term “pharmaceutically acceptable salt” refers to those salts which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of humans and lower animals without undue toxicity, irritation, allergic response and the like, and are commensurate with a reasonable benefit/risk ratio. Pharmaceutically acceptable salts are well known in the art. For example, S. M. Berge, et al. describe pharmaceutically acceptable salts in detail in J. Pharmaceutical Sciences, 1977, 66, 1-19, incorporated herein by reference. The salts can be prepared in situ during the final isolation and purification of the compounds of the invention, or separately by reacting the free base function with a suitable organic acid. Examples of pharmaceutically acceptable, nontoxic acid addition salts include, but are not limited to, salts of an amino group formed with inorganic acids such as hydrochloric acid, hydrobromic acid, phosphoric acid, sulfuric acid and perchloric acid or with organic acids such as acetic acid, maleic acid, tartaric acid, citric acid, succinic acid or malonic acid or by using other methods used in the art such as ion exchange. Other pharmaceutically acceptable salts include, but are not limited to, adipate, alginate, ascorbate, aspartate, benzenesulfonate, benzoate, bisulfate, borate, butyrate, camphorate, camphorsulfonate, citrate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, formate, fumarate, glucoheptonate, glycerophosphate, gluconate, hemisulfate, heptanoate, hexanoate, hydroiodide, 2-hydroxy-ethanesulfonate, lactobionate, lactate, laurate, lauryl sulfate, malate, maleate, malonate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, nitrate, oleate, oxalate, palmitate, pamoate, pectinate, persulfate, 3-phenylpropionate, phosphate, picrate, pivalate, propionate, stearate, succinate, sulfate, tartrate, thiocyanate, p-toluenesulfonate, undecanoate, valerate salts, and the like. Representative alkali or alkaline earth metal salts include sodium, lithium, potassium, calcium, magnesium, and the like. Further pharmaceutically acceptable salts include, when appropriate, nontoxic ammonium, quaternary ammonium, and amine cations formed using counterions such as halide, hydroxide, carboxylate, sulfate, phosphate, nitrate, C 1 -C 6 sulfonate and aryl sulfonate.
As used herein, the term “pharmaceutically acceptable ester” refers to esters which hydrolyze in vivo and include those that break down readily in the human body to leave the parent compound or a salt thereof. Suitable ester groups include, but are not limited to, those derived from pharmaceutically acceptable aliphatic carboxylic acids, particularly alkanoic, alkenoic, cycloalkanoic and alkanedioic acids, in which each alkyl or alkenyl moiety advantageously has not more than 6 carbon atoms. Examples of particular esters include, but are not limited to, formates, acetates, propionates, butyrates, acrylates and ethylsuccinates.
The term “pharmaceutically acceptable prodrugs” as used herein refers to those prodrugs of the compounds of the present invention which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of humans and lower animals without undue toxicity, irritation, allergic response and the like, commensurate with a reasonable risk/reward ratio, and effective for their intended use, as well as the zwitterionic forms, where possible, of the compounds of the invention. The term “prodrug” refers to compounds that are rapidly transformed in vivo to yield the parent compound of the above formulae, for example, by hydrolysis in blood. A thorough discussion is provided in T. Higuchi and V. Stella, Prodrugs as Novel delivery Systems , Vol. 14 of the A.C.S. Symposium Series and in Edward B. Roche, ed., Bioreversible Carriers in Drug Design (American Pharmaceutical Association and Pergamon Press, 1987), both of which are incorporated by reference herein.
The compounds of this invention may be modified by appending various functionalities via any synthetic means delineated herein to enhance selective biological properties. Such modifications are known in the art and include those which increase biological penetration into a given biological system (e.g., blood, lymphatic system, central nervous system), increase oral availability, increase solubility to allow administration by injection, alter metabolism and alter rate of excretion.
Pharmaceutical Compositions
The pharmaceutical compositions of the present invention comprise a therapeutically effective amount of a compound of the present invention formulated together with one or more pharmaceutically acceptable carriers. As used herein, the term “pharmaceutically acceptable carrier” means a non-toxic, inert solid, semi-solid or liquid filler, diluent, encapsulating material or formulation auxiliary of any type. Some examples of materials which can serve as pharmaceutically acceptable carriers are sugars such as lactose, glucose and sucrose; starches such as corn starch and potato starch; cellulose and its derivatives such as sodium carboxymethyl cellulose, ethyl cellulose and cellulose acetate; powdered tragacanth; malt; gelatin; talc; excipients such as cocoa butter and suppository waxes; oils such as peanut oil, cottonseed oil; safflower oil; sesame oil; olive oil; corn oil and soybean oil; glycols; such a propylene glycol; esters such as ethyl oleate and ethyl laurate; agar; buffering agents such as magnesium hydroxide and aluminum hydroxide; alginic acid; pyrogen-free water; isotonic saline; Ringer's solution; ethyl alcohol, and phosphate buffer solutions, as well as other non-toxic compatible lubricants such as sodium lauryl sulfate and magnesium stearate, as well as coloring agents, releasing agents, coating agents, sweetening, flavoring and perfuming agents, preservatives and antioxidants can also be present in the composition, according to the judgment of the formulator. The pharmaceutical compositions of this invention can be administered to humans and other animals orally, rectally, parenterally, intracisternally, intravaginally, intraperitoneally, topically (as by powders, ointments, or drops), buccally, or as an oral or nasal spray.
Liquid dosage forms for oral administration include pharmaceutically acceptable emulsions, microemulsions, solutions, suspensions, syrups and elixirs. In addition to the active compounds, the liquid dosage forms may contain inert diluents commonly used in the art such as, for example, water or other solvents, solubilizing agents and emulsifiers such as ethyl alcohol, isopropyl alcohol, ethyl carbonate, ethyl acetate, benzyl alcohol, benzyl benzoate, propylene glycol, 1,3-butylene glycol, dimethylformamide, oils (in particular, cottonseed, groundnut, corn, germ, olive, castor, and sesame oils), glycerol, tetrahydrofurfuryl alcohol, polyethylene glycols and fatty acid esters of sorbitan, and mixtures thereof. Besides inert diluents, the oral compositions can also include adjuvants such as wetting agents, emulsifying and suspending agents, sweetening, flavoring, and perfuming agents.
Injectable preparations, for example, sterile injectable aqueous or oleaginous suspensions may be formulated according to the known art using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution, suspension or emulsion in a nontoxic parenterally acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution, U.S.P. and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil can be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid are used in the preparation of injectables.
The injectable formulations can be sterilized, for example, by filtration through a bacterial-retaining filter, or by incorporating sterilizing agents in the form of sterile solid compositions which can be dissolved or dispersed in sterile water or other sterile injectable medium prior to use.
In order to prolong the effect of a drug, it is often desirable to slow the absorption of the drug from subcutaneous or intramuscular injection. This may be accomplished by the use of a liquid suspension of crystalline or amorphous material with poor water solubility. The rate of absorption of the drug then depends upon its rate of dissolution which, in turn, may depend upon crystal size and crystalline form. Alternatively, delayed absorption of a parenterally administered drug form is accomplished by dissolving or suspending the drug in an oil vehicle. Injectable depot forms are made by forming microencapsule matrices of the drug in biodegradable polymers such as polylactide-polyglycolide. Depending upon the ratio of drug to polymer and the nature of the particular polymer employed, the rate of drug release can be controlled. Examples of other biodegradable polymers include poly(orthoesters) and poly(anhydrides). Depot injectable formulations are also prepared by entrapping the drug in liposomes or microemulsions which are compatible with body tissues.
Compositions for rectal or vaginal administration are preferably suppositories which can be prepared by mixing the compounds of this invention with suitable non-irritating excipients or carriers such as cocoa butter, polyethylene glycol or a suppository wax which are solid at ambient temperature but liquid at body temperature and therefore melt in the rectum or vaginal cavity and release the active compound.
Solid compositions of a similar type may also be employed as fillers in soft and hard-filled gelatin capsules using such excipients as lactose or milk sugar as well as high molecular weight polyethylene glycols and the like.
The active compounds can also be in micro-encapsulated form with one or more excipients as noted above. The solid dosage forms of tablets, dragees, capsules, pills, and granules can be prepared with coatings and shells such as enteric coatings, release controlling coatings and other coatings well known in the pharmaceutical formulating art. In such solid dosage forms the active compound may be admixed with at least one inert diluent such as sucrose, lactose or starch. Such dosage forms may also comprise, as is normal practice, additional substances other than inert diluents, e.g., tableting lubricants and other tableting aids such a magnesium stearate and microcrystalline cellulose. In the case of capsules, tablets and pills, the dosage forms may also comprise buffering agents. They may optionally contain opacifying agents and can also be of a composition that they release the active ingredient(s) only, or preferentially, in a certain part of the intestinal tract, optionally, in a delayed manner. Examples of embedding compositions which can be used include polymeric substances and waxes.
Dosage forms for topical or transdermal administration of a compound of this invention include ointments, pastes, creams, lotions, gels, powders, solutions, sprays, inhalants or patches. The active component is admixed under sterile conditions with a pharmaceutically acceptable carrier and any needed preservatives or buffers as may be required. Ophthalmic formulation, ear drops, eye ointments, powders and solutions are also contemplated as being within the scope of this invention.
The ointments, pastes, creams and gels may contain, in addition to an active compound of this invention, excipients such as animal and vegetable fats, oils, waxes, paraffins, starch, tragacanth, cellulose derivatives, polyethylene glycols, silicones, bentonites, silicic acid, talc and zinc oxide, or mixtures thereof.
Powders and sprays can contain, in addition to the compounds of this invention, excipients such as lactose, talc, silicic acid, aluminum hydroxide, calcium silicates and polyamide powder, or mixtures of these substances. Sprays can additionally contain customary propellants such as chlorofluorohydrocarbons.
Transdermal patches have the added advantage of providing controlled delivery of a compound to the body. Such dosage forms can be made by dissolving or dispensing the compound in the proper medium. Absorption enhancers can also be used to increase the flux of the compound across the skin. The rate can be controlled by either providing a rate controlling membrane or by dispersing the compound in a polymer matrix or gel.
Antiviral Activity
“An effective amount” refers to an amount of a compound which confers a therapeutic effect on the treated subject. The therapeutic effect may be objective (i.e., measurable by some test or marker) or subjective (i.e., subject gives an indication of or feels an effect). An effective amount of the compound described above may range from about 0.1 mg/Kg to about 500 mg/Kg, alternatively from about 1 to about 50 mg/Kg. Effective doses will also vary depending on route of administration, as well as the possibility of co-usage with other agents.
Combinations of substituents and variables envisioned by this invention are only those that result in the formation of stable compounds. The term “stable”, as used herein, refers to compounds which possess stability sufficient to allow manufacture and which maintains the integrity of the compound for a sufficient period of time to be useful for the purposes detailed herein (e.g., therapeutic or prophylactic administration to a subject).
The synthesized compounds can be separated from a reaction mixture and further purified by a method such as column chromatography, high pressure liquid chromatography, or recrystallization. As can be appreciated by the skilled artisan, further methods of synthesizing the compounds of the formulae herein will be evident to those of ordinary skill in the art. Additionally, the various synthetic steps may be performed in an alternate sequence or order to give the desired compounds. Synthetic chemistry transformations and protecting group methodologies (protection and deprotection) useful in synthesizing the compounds described herein are known in the art and include, for example, those such as described in R. Larock, Comprehensive Organic Transformations , VCH Publishers (1989); T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 2d. Ed., John Wiley and Sons (1991); L. Fieser and M. Fieser, Fieser and Fieser's Reagents for Organic Synthesis , John Wiley and Sons (1994); and L. Paquette, ed., Encyclopedia of Reagents for Organic Synthesis , John Wiley and Sons (1995), and subsequent editions thereof.
According to the methods of treatment of the present invention, viral infections are treated or prevented in a subject such as a human or lower mammal by administering to the subject a therapeutically effective amount of a compound of the invention, in such amounts and for such time as is necessary to achieve the desired result. The term “anti-hepatitis C virally effective amount” of a compound of the invention, as used herein, means a sufficient amount of the compound so as to decrease the viral load in a subject, thus decreasing said subject's chronic HCV symptoms. As well understood in the medical arts an anti-hepatitis C virally effective amount of a compound of this invention will be at a reasonable benefit/risk ratio applicable to any medical treatment.
Upon improvement of a subject's condition, a maintenance dose of a compound, composition or combination of this invention may be administered, if necessary. Subsequently, the dosage or frequency of administration, or both, may be reduced, as a function of the symptoms, to a level at which the improved condition is retained when the symptoms have been alleviated to the desired level, treatment should cease. The subject may, however, require intermittent treatment on a long-term basis upon any recurrence of disease symptoms.
It will be understood, however, that the total daily usage of the compounds and compositions of the present invention will be decided by the attending physician within the scope of sound medical judgment. The specific anti-HCV virally effective dose level for any particular patient will depend upon a variety of factors including the disorder being treated and the severity of the disorder; the activity of the specific compound employed; the specific composition employed; the age, body weight, general health, sex and diet of the patient; the time of administration, route of administration, and rate of excretion of the specific compound employed; the duration of the treatment; drugs used in combination or coincidental with the specific compound employed; and like factors well known in the medical arts.
The total daily dose of the compounds of this invention administered to a subject in single or in divided doses can be in amounts, for example, from 0.01 to 50 mg/kg body weight or more usually from 0.1 to 25 mg/kg body weight. Single dose compositions may contain such amounts or submultiples thereof to make up the daily dose. In general, treatment regimens according to the present invention comprise administration to a patient in need of such treatment from about 10 mg to about 1000 mg of the compound(s) of this invention per day in single or multiple doses.
Unless otherwise defined, all technical and scientific terms used herein are accorded the meaning commonly known to one with ordinary skill in the art. All publications, patents, published patent applications, and other references mentioned herein are hereby incorporated by reference in their entirety.
ABBREVIATIONS
Abbreviations which have been used in the descriptions of the schemes and the examples that follow are:
ACN for acetonitrile; BME for 2-mercaptoethanol; BOP for benzotriazol-1-yloxy-tris(dimethylamino)phosphonium hexafluorophosphate; COD for cyclooctadiene; DAST for diethylaminosulfur trifluoride; DABCYL for 6-(N-4′-carboxy-4-(dimethylamino)azobenzene)-aminohexyl-1-O-(2-cyanoethyl)-(N,N-diisopropyl)-phosphoramidite; DCM for dichloromethane; DIAD for diisopropyl azodicarboxylate; DIBAL-H for diisobutylaluminum hydride; DIEA for diisopropyl ethylamine; DMAP for N,N-dimethylaminopyridine; DME for ethylene glycol dimethyl ether; DMEM for Dulbecco's Modified Eagles Media; DMF for N,N-dimethyl formamide; DMSO for dimethylsulfoxide;
DUPHOS for
EDANS for 5-(2-Amino-ethylamino)-naphthalene-1-sulfonic acid;
EDCI or EDC for 1-(3-diethylaminopropyl)-3-ethylcarbodiimide hydrochloride;
EtOAc for ethyl acetate;
HATU for O(7-Azabenzotriazole-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate;
Hoveyda's Cat. for Dichloro(o-isopropoxyphenylmethylene) (tricyclohexylphosphine)ruthenium(II);
KHMDS is potassium bis(trimethylsilyl)amide;
Ms for mesyl;
NMM for N-4-methylmorpholine;
PyBrOP for Bromo-tri-pyrrolidino-phosphonium hexafluorophosphate;
Ph for phenyl;
RCM for ring-closing metathesis;
RT for reverse transcription;
RT-PCR for reverse transcription-polymerase chain reaction;
TEA for triethyl amine;
TFA for trifluoroacetic acid;
THF for tetrahydrofuran;
TLC for thin layer chromatography;
TPP or PPh 3 for triphenylphosphine;
tBOC or Boc for tert-butyloxy carbonyl; and
Xantphos for 4,5-Bis-diphenylphosphanyl-9,9-dimethyl-9H-xanthene.
SYNTHETIC METHODS
The compounds and processes of the present invention will be better understood in connection with the following synthetic schemes which illustrate the methods by which the compounds of the invention may be prepared.
All of the quinoxaline analogs were prepared from the common intermediate 1f. The synthesis of compound (1-6) is outlined in Scheme 1. Commercially available boc-hydroxyproline (1-1) is treated with HCl in dioxane and is further coupled with acid (1-2) using HATU to afford intermediate (1-3). Other amino acid derivatives containing a terminal alkene may be used in place of (1-2) in order to create varied macrocyclic structures (for further details see WO/0059929). Hydrolysis of (1-3) with LiOH followed by another peptide coupling with cyclopropyl amine (1-4) yielded the tri-peptide (1-5). Finally, ring closure methathesis with a Ruthenium-based catalyst gave the desired key intermediate (1-6) (for further details on ring closing metathesis see recent reviews: Grubbs et al., Acc. Chem. Res., 1995, 28, 446; Shrock et al., Tetrahedron 1999, 55, 8141; Furstner, A. Angew. Chem. Int. Ed. 2000, 39, 3012; Trnka et al., Acc. Chem. Res. 2001, 34, 18; and Hoveyda et al., Chem. Eur. J. 2001, 7, 945).
The quinoxaline analogs of the present invention were prepared via several different synthetic routes. The simplest method, shown in Scheme 2, is to condense commercially available 1H-quinoxalin-2-one analogs including, but not limited to, compounds 2-1-2-5 with key intermediate 1-6 by using Mitsunobu conditions followed by hydrolysis with LiOH. The existing literature predicts Mistonobu product formation at the 1 position nitrogen, however attachment at the carbonyl oxygen was observed to form compound 2-2. A detailed discussion of the identification and characterization of the unexpected oxo Mitosunobu addition product appears in the examples herein. For further details on the Mitsunobu reaction, see O. Mitsunobu, Synthesis 1981, 1-28; D. L. Hughes, Org. React. 29, 1-162 (1983); D. L. Hughes, Organic Preparations and Procedures Int. 28, 127-164 (1996); and J. A. Dodge, S. A. Jones, Recent Res. Dev. Org. Chem. 1, 273-283 (1997).
Various quinoxaline derivatives of formula (3-3) can be made with phenyl diamines of formula (3-1), wherein R 4 is previously defined, and keto acids or esters of formula (3-2), wherein R 4 is previously defined, in anhydrous methanol at room temperature (see Bekerman et al., J. Heterocycl. Chem. 1992, 29, 129-133 for further details of this reaction). Examples of phenyl diamines suitable for creating quinoxaline derivatives of formula (3-3) include, but are not limited to, 1,2-diamino-4-nitrobenze, o-phenylenediamine, 3,4-diaminotoluene, 4-chloro-1,2-phenylenediamine, methyl-3,4-diaminobenzoate, benzo[1,3]dioxole-5,6-diamine, 1,2-diamino-4,5-methylene dioxybenzene, 4-chloro-5-(trifluoromethyl)-1,2-benzenediamine, and the like. Examples of keto acids suitable for the reaction described in Scheme 3 include, but are not limited to, benzoylformic acid, phenylpyruvic acid, indole-3-glyoxylic acid, indole-3-pyruvic acid, nitrophenylpyruvic acid, (2-furyl)glyoxylic acid, and the like. Examples of keto esters suitable for the reaction described in Scheme 3 include, but are not limited to ethyl thiophene-2-glyoxylate, ethyl 2-oxo-4-phenylbutyrate, ethyl 2-(formylamino)-4-thiazolyl glyoxylate, ethyl-2-amino-4-thiozolyl glyoxylate, ethyl-2-oxo-4-phenylbutyrate, ethyl-(5-bromothien-2-yl)glyoxylate, ethyl-3-indolylglyoxylate, ethyl-2-methylbenzoyl formate, ethyl-3-ethylbenzoyl formate, ethyl-3-ethylbenzoyl formate, ethyl-4-cyano-2-oxobutyrate, methyl(1-methylindolyl)-3-glyoxylate, and the like.
3,6 substituted quinoxalin-2-ones of formula (4-4), wherein R 4 is previously defined, can be made in a regioselective manner to favor the 6-position substitution beginning with the amide coupling of 4-methoxy-2-nitro aniline (4-1) and substituted gloxylic acid (4-2) to yield compound (4-3). The 3,6-substituted quinoxalin-2-one (4-4) is created via catalytic reduction of the nitro of compound (4-3) followed by condensation to the 3,6-substituted quinoxalin-2-one (4-4). Other substituents may be introduced into (4-4) through the use of other 2-nitroanilines. Examples of keto acids suitable for the reaction described in Scheme 4 include, but are not limited to, benzoylformic acid, phenylpyruvic acid, indole-3-glyoxylic acid, indole-3-pyruvic acid, nitrophenylpyruvic acid, (2-furyl)glyoxylic acid, and the like. Examples of 2-nitro anilines suitable for the reaction described in Scheme 4 include, but are not limited to, 4-ethoxy-2-nitroaniline, 4-amino-3-nitrobenzotrifluoride, 4,5-dimethyl-2-nitroaniline, 4-fluoro-2-nitroaniline, 4-chloro-2-nitroaniline, 4-amino-3-nitromethylbenzoate, 4-benzoyl-2-nitroaniline, 3-bromo-4-methoxy-2-nitroaniline, 3′-amino-4′-methyl-2-nitroacetophenone, 5-ethoxy-4-fluoro-2-nitroaniline, 4-bromo-2-nitroaniline, 4-(trifluoromethoxy)-2-nitroaniline, ethyl-4-amino3-nitrobenzoate, 4-bromo-2-methyl-6-nitroaniline, 4-propoxy-2-nitroaniline, 5-(propylthio)-2-nitroaniline, and the like.
A. A key intermediate, 3-chloro-1H-quinoxalin-2-one (5-3), can be synthesized from phenyl diamines of formula (3-1), as previously defined, and oxalic acid diethyl ester (5-1) to yield 1,4-dihydro-quinoxaline-2,3-dione (5-2) under similar conditions as discussed in Scheme 3 (see Bekerman et al., J. Heterocycl. Chem. 1992, 29, 129-133) followed by treatment with SOCl 2 (1.37 equiv.) in (1:40 DMF:toluene) (see Loev et al, J. Med. Chem . (1985), 28, 363-366 for further details).
B. The key 3-chloro-quinoxalin-2-one (5-3) is added to the macrocyclic precursor (1-6) via Mitsunobu conditions, adding via the carbonyl oxygen, rather than the expected 1-position nitrogen, to give the key macrocylic intermediate of formula (5-4). This intermediate facilitates the introduction of various substituents at the 3-position of the quinoxaline.
Suzuki Coupling
Compounds of formula (5-5), wherein R 4 is previously defined, can be synthesized via Suzuki coupling reaction with an aryl, substituted aryl, heteroaryl, or substituted heteroaryl boronic acid in DME in the presence of Pd(PPh 3 ) 4 , and CsCO 3 . For further details concerning the Suzuki coupling reaction see A. Suzuki, Pure Appl. Chem. 63, 419-422 (1991) and A. R. Martin, Y. Yang, Acta Chem. Scand. 47, 221-230 (1993). Examples of boronic acids suitable for Suzuki coupling to macrocyclic key intermediate (5-5) include, but are not limited to, 2-bromo thiophene, phenylboronic acid, 5-bromothiophene-3-boronic acid, 4-cyanophenylboronic acid, 4-trifluormethoxyphenylboronic acid, and the like.
Sonogashira Reaction
Compounds of formula (5-6), wherein R 1 is as previously defined, can be synthesized via Sonagashira reaction with the macrocyclic key intermediate a terminal alkyne in acetonitrile in the presence triethylamine, PdCl 2 (PPh 3 ) 2 , and CuI at 90° C. for 12 hours. For further details of the Sonogashira reaction see Sonogashira, Comprehensive Organic Synthesis, Volume 3, Chapters 2,4 and Sonogashira, Synthesis 1977, 777. Terminal alkenes suitable for the Sonogashira reaction with macrocyclic key intermediate (5-5) include, but are not limited to, ethynylbenzene, 4-cyano-ethynylbenzene, propargylbenzene, and the like.
Stille Coupling
Compounds of formula (5-7), wherein R 4 is previously defined, can be synthesized via Stille coupling reaction with key macrocyclic intermediate of formula (5-4) and aryl stannanes in dioxane in the presence of Pd(PPh 3 ) 4 . For further details of the Stille Coupling reaction see J. K. Stille, Angew. Chem. Int. Ed. 25, 508-524 (1986), M. Pereyre et al., Tin in Organic Synthesis (Butterworths, Boston, 1987) pp 185-207 passim, and a review of synthetic applications in T. N. Mitchell, Synthesis 1992, 803-815. Organostannanes suitable for Stille coupling with key macrocyclic intermediate (5-4) include, but are not limited to, tributyltin cyanide, allyl-tri-n-butyltin, 2-tributyltin-pyridine, 2-tri-n-butyltin furan, 2-tri-n-butyltin thiophene, 2,3-dihydron-5-(tri-n-butyltin)benzofuran, and the like.
Via the key macrocyclic 3-chloro-quinoxalinyl intermediate (5-4), three additional classes of substituents may be introduced at the 3 position of the quinoxaline ring. Among the various groups that may be introduced are mono-substituted amino, di-substituted amino, ethers, and thio-ethers.
The amino-substituted quinoxaline (6-1), wherein R 1 and R 4 are as previously defined, can be formed through adding to a 0.1M solution of macrocyclic quinoxalinyl intermediate (5-4) in 10 ml DMF, K 2 CO 3 (2 equiv.) and HNR 1 R 4 (1.2 equiv.), and stirring the resulting reaction mixture at room temperature for 5-12 hours. Amines suitable for these conditions include, but are not limited to, ethyl amine, 2-phenyl ethyl amine, cyclohexylamine, ethylmethylamine, diisopropyl amine, benzylethyl amine, 4-pentenyl amine, propargyl amine and the like.
For amines wherein R 1 is hydrogen and R 4 is aryl, substituted aryl, heteroaryl, or substituted heteroaryl, a different set of conditions must be used to arrive on compound (6-1). Adding of NaH (2 equiv.) and HNR 5 R 6 (1.2 equiv.) to a 0.1M solution of the macrocyclic quinoxalinyl intermediate (5-4) in THF and stirring the resulting reaction mixture for 5-12 hours affords the aniline substituted compound (6-1). Amines suitable for the instant conditions are aniline, 4-methoxy aniline, 2-amino-pyridine, and the like.
Introduction of ethers to the 2 position of the quinoxaline ring, can be achieved through treating a 0.1M solution of macrocyclic quinoxalinyl intermediate (5-4) in DMF with K 2 CO 3 (2 equiv.) and HOR 4 (1.2 equiv.), wherein R 4 is previously defined. The resulting reaction mixture can then be stirred for 5-12 hours at room temperature to arrive at the desired ether moiety at the 3 position. Alcohols suitable for these conditions include, but are not limited to, ethanol, propanol, isobutanol, trifluoromethanol, phenol, 4-methoxyphenol, pyridin-3-ol, and the like. Thioesters can be made via the same procedure.
Derivation of the benzo portion of the quinoxaline ring may be achieved through the halogen-substituted quinoxaline of formula (7-2). Quinoxaline of formula (7-2) can be formed with chloro-substituted phenyldiamine (7-1) with diketo compound of formula (7-2), wherein W, Z, and R 3 are as previously defined, in anhydrous methanol as previously detailed. Intermediate (7-3) is formed under Mitsunobu conditions with macrocyclic precursor (7-6) and chlorosubstituted quinoxaline (7-2). Intermediate (7-3) may then undergo Suzuki coupling reactions, Sonogashira reactions, or Stille couplings at the position occupied by the chloro. See previous discussion of Suzuki couplings, Sonogashira reactions, and Stille couplings for further details. The Buchwald reaction allows for the substitution with amines, both primary and secondary, as well as 1H-nitrogen heterocycles at the aryl bromide. For further details of the Buchwald reaction see J. F. Hartwig, Angew. Chem. Int. Ed. 37, 2046-2067 (1998).
The 3-substituted 2-Oxo-1,2-dihydro-quinoxaline-6-carboxylic acid intermediate (8-4) can be formed via condensation of ethyl 3,4-diaminobenzoate (8-1) and oxo acetic acid of formula (8-2), wherein R 4 is previously defined, via the method described previously in Scheme 3 (see Bekerman et al., J. Heterocycl. Chem. 1992, 29, 129-133 for further details). The resulting ethyl ester (8-3) is then hydrolyzed with LiOH in MeOH at room temperature to yield carboxylic acid intermediate (8-4).
Carboxylic acid (8-4) then may be converted to substituted ketone (8-6) via Weinreb's amide (8-5) and subsequent treatment with various Grignard Reagents (see Weinreb et al. Tetrahedron Lett. 1977, 4171; Weinreb et al, Synth. Commun. 1982, 12, 989 for details of the formation and use of Weinreb's amide; and see B. S. Furniss, A. J. Hannaford, P. W. G Smith, A. R. Tatchell, Vogel's Textbook of Practical Organic Chemistry, 5 th ed., Longman, 1989). The addition is performed in an inert solvent, generally at low temperatures. Suitable solvents include, but are not limited to, tetrahydrofuran, diethylether, 1,4-dioxane, 1,2-dimethoxyethane, and hexanes. Preferably the solvent is tetrahydrofuran or diethylether. Preferably the reaction is run at −78° C. to 0° C.
In the alternative, carboxylic acid (8-4) may be used to form various amides of formula (8-7), wherein R 1 and R 4 are previously defined, in a manner generally described in Scheme 8. All of the various quinoxalin-2-one compounds described in Scheme 8 are further coupled to the macrocyclic precursor via the Mitsunobu conditions described above.
Further 6-substituted quinoxalin-2-one compounds can be made via the procedures set forth generally in Scheme 9.
A. Reduction of 6-Nitro and Amide Formation
6-nitro-1H-quinoxalin-2-one (9-3) can be formed in the manner previously described from the 3,4-diaminonitrobenzene and the oxo acetic acid of formula (9-2), wherein R 4 is previously described. Reduction of the nitro group at the 6-position can be achieved via Pd/C with H 2 NNH 2 .H 2 O in refluxing MeOH. The 6-position amine (2-4) then can be treated with a wide array of acid chlorides to arrive upon various amides of formula (2-5).
B. Oxidation of Benzyl alcohol and Reductive Amination
Quinoxalin-2-one of formula (2-7) can be formed via the condensation of 3,4-diaminobenzyl alcohol and various oxo acetic acids of formula (9-2), wherein R 4 is as previously defined as elucidated in previous schemes. The resulting benzyl alcohol (9-7) may then be oxidized under Swern conditions, or any other oxidation conditions to arrive on aldehyde of formula (2-8). For further details concerning the Swern reaction see A. J. Mancuso, D. Swern, Synthesis 1981, 165-185 passim; T. T. Tidwell, Org. React. 39, 297-572 passim (1990). For other oxidation conditions see B. S. Furniss, A. J. Hannaford, P. W. G Smith, A. R. Tatchell, Vogel's Textbook of Practical Organic Chemistry, 5 th ed., Longman, 1989. Subsequent reductive amination with primary or secondary amines in the presence of NaCNBH 3 and acetic acid can yield compounds of formula (9-9).
Reduction of the preceding quinoxalinyl macrocyclic compounds is performed by treating a solution of the ethyl ester (7-4) in THF/MeOH/H 2 O with LiOH.H 2 O to afford the corresponding free acid.
All references cited herein, whether in print, electronic, computer readable storage media or other form, are expressly incorporated by reference in their entirety, including but not limited to, abstracts, articles, journals, publications, texts, treatises, internet web sites, databases, patents, and patent publications.
EXAMPLES
The compounds and processes of the present invention will be better understood in connection with the following examples, which are intended as an illustration only and not to limit the scope of the invention. Various changes and modifications to the disclosed embodiments will be apparent to those skilled in the art and such changes and modifications including, without limitation, those relating to the chemical structures, substituents, derivatives, formulations and/or methods of the invention may be made without departing from the spirit of the invention and the scope of the appended claims.
Example 1
Synthesis of the Cyclic Peptide Precursor
1A. To a solution of Boc-L-2-amino-8-nonenoic acid 1a (1.36 g, 5 mol) and the commercially available cis-L-hydroxyproline methyl ester 1b (1.09 g, 6 mmol) in 15 ml DMF, DIEA (4 ml, 4 eq.) and HATU (4 g, 2 eq) were added. The coupling is carried out at 0° C. over a period of 1 hour. The reaction mixture is diluted with 100 mL EtOAc, and followed by washing with 5% citric acid 2×20 ml, water 2×20 ml, 1M NaHCO 3 4×20 ml and brine 2×10 ml, respectively. The organic phase is dried over anhydrous Na 2 SO 4 and then is evaporated, affording the dipeptide 1c (1.91 g, 95.8%) that is identified by HPLC (Retention time=8.9 min, 30-70%, 90% B), and MS (found 421.37, M+Na + ).
1B. The dipeptide 1c (1.91 g) is dissolved in 15 mL of dioxane and 15 mL of 1 N LiOH aqueous solution and the hydrolysis reaction is carried out at room temperature for 4 hours. The reaction mixture is acidified by 5% citric acid and extracted with 100 mL EtOAc, and followed by washing with water 2×20 ml, 1M NaHCO 3 2×20 ml and brine 2×20 ml, respectively. The organic phase is dried over anhydrous Na 2 SO 4 and then removed in vacuum, yielding the free carboxylic acid compound 1d (1.79 g, 97%), which is used for next step synthesis without need for further purification.
1C. To a solution of the free acid obtained above (1.77, 4.64 mmol) in 5 ml DMF, D-β-vinyl cyclopropane amino acid ethyl ester 1e (0.95 g, 5 mmol), DIEA (4 ml, 4 eq.) and HATU (4 g, 2 eq) were added. The coupling is carried out at 0° C. over a period of 5 hour. The reaction mixture is diluted with 80 mL EtOAc, and followed by washing with 5% citric acid 2×20 ml, water 2×20 ml, 1M NaHCO 3 4×20 ml and brine 2×10 ml, respectively. The organic phase is dried over anhydrous Na 2 SO 4 and then evaporated. The residue is purified by silica gel flash chromatography using different ratios of hexanes:EtOAc as elution phase (5:1→3:1→1:1→1:2→1:5). The linear tripeptide 1f is isolated as an oil after removal of the elution solvents (1.59 g, 65.4%), identified by HPLC (Retention time=11.43 min) and MS (found 544.84, M+Na + ).
1D. Ring Closing Metathesis (RCM). A solution of the linear tripeptide 1f (1.51 g, 2.89 mmol) in 200 ml dry DCM is deoxygenated by bubbling N 2 . Hoveyda's 1 st generation catalyst (5 mol % eq.) is then added as solid. The reaction is refluxed under N 2 atmosphere 12 hours. The solvent is evaporated and the residue is purified by silica gel flash chromatography using different ratios of hexanes:EtOAc as elution phase (9:1→5:1→3:1→1:1→1:2→1:5). The cyclic peptide precursor 1 is isolated as a white powder after removal of the elution solvents (1.24 g, 87%), identified by HPLC (Retention time=7.84 min, 30-70%, 90% B), and MS (found 516.28, M+Na + ). For further details of the synthetic methods employed to produce the cyclic peptide precursor 1, see WO 00/059929 (2000).
Example 2
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Step 2A.
To a cooled mixture of macrocyclic precursor 1,3-(thiophen-2-yl)-1H-quinoxalin-2-one 2a (1.1 equiv.), and triphenylphosphine (2 equiv.) in THF was added DIAD (2 equiv.) dropwise at 0° C. The resulting mixture was held at 0° C. for 15 min. before being warmed to room temperature. After 18 hours, the mixture was concentrated under vacuum and the residue was purified by chromatography eluting with 60% ethyl acetate-hexane to give 2b as a clear oil (35 mg, 99%).
MS (found): 704.4 (M+H).
H 1 —NMR [CDCl 3 , δ (ppm)]: 8.6 (d, 1H), 8.0 (d, 1H), 7.8 (d, 1H), 7.6 (m, 2H), 7.5 (d, 2H), 7.2 (t, 1H), 7.0 (brs, 1H), 6.0 (brt, 1H), 5.5 (m, 1H), 5.3 (brd, 1H), 5.2 (t, 1H), 5.0 (m, 1H), 4.6 (brt, 1H), 4.1-4.3 (m, 3H), 3.1 (m, 1H), 5.3 (m, 1H), 2.1-2.3 (m, 2H), 1.3 (brs, 9H), 1.2 (t, 3H).
Step 2B.
A solution of compound 2b and lithium hydroxide (10 equiv.) in THF/MeOH/H 2 O (2:1:0.5) was stirred at room temperature for 20 hours. The excess solvents were evaporated in vacuo, the resulting residue was diluted with water, followed by acidification to pH ˜5. The mixture was extracted 2 times with ethyl acetate. The combined organic extracts were washed once with brine, dried (MgSO 4 ), filtered and concentrated in vacuo to give an oily residue, which was purified by column chromatography eluting with 2-10% methanol-chloroform (87%).
MS (found): 676.3
1 H-NMR [CD 3 OD, δ (ppm)]: 8.14 (1H), 7.96 (1H), 7.86 (1H), 7.65 (1H), 7.62 (1H), 7.59 (1H), 7.19 (1H), 6.07 (1H), 5.53 (1H), 5.52 (1H), 4.81 (1H), 4.75 (1H), 4.23 (1H), 4.12 (1H), 2.65-2.75 (2H), 2.52 (1H), 2.21 (1H), 1.97 (1H), 1.80 (1H), 1.62 (2H), 1.54 (1H), 1.47 (2H), 1.44 (2H), 1.41 (2H), 1.09 (9H).
13 C-NMR [CD 3 OD, δ (ppm)]: 176.2, 174.1, 173.4, 156.0, 152.9, 141.0, 139.6, 138.9, 138.6, 131.5, 130.6, 130.0, 129.3, 128.1, 127.8, 127.1, 126.6, 78.6, 76.1, 59.8, 53.3, 52.3, 41.4, 34.5, 32.3, 30.0, 27.5, 27.4, 27.2 (3C), 26.1, 22.6, 22.4.
Example 3
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=2-(formamido)-thiazol-4-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Step 3A.
Commercially available 4-Methoxy-benzene-1,2-diamine 3a (3.6 mmol) and (2-Formylamino-thiazol-4-yl)-oxo-acetic acid ethyl ester 3b (1 equiv.) in ethanol (40 mL) was heated to reflux for 5 hours. After the mixture was cooled to room temperature, the excess ethanol was evaporated in vacuo, and the residue was placed under high vacuum for 2 hours to give compound 3c as a greenish yellow powder.
MS (found): 303.1 (M+H).
H 1 —NMR [DMSO-d, δ (ppm)]: 8.7 (s, 1H), 8.6 (m, 2H), 7.2-7.3 (m, 4H), 3.8 (s, 3H).
Step 3B.
To a cooled mixture of 1, quinoxalin-2-one 3c (1.1 equiv.), triphenylphosphine (2 equiv.) in THF was added DIAD (2 equiv.) dropwise at 0° C. The resulting mixture was kept at 0° C. for 15 min. before warming to room temperature. After 18 hours, the mixture was concentrated in vacuo and the residue was purified by chromatography eluting with 80-100% ethyl acetate-hexane to give 3d as a yellow oil.
MS (found): 778.5 (M+H).
Step 3C.
A solution of 3d and lithium hydroxide (10 equiv.) in THF/MeOH/H 2 O (2:1:0.5) was stirred at room temperature for 20 hours. The excess solvent was evaporated in vacuo, the residue was diluted with water and followed by acidification to pH ˜5. The mixture was extracted 2 times with ethyl acetate. The combined organic extracts were washed once with brine, dried (MgSO 4 ), filtered and concentrated in vacuo to give a solid residue which was purified by HPLC to give.
MS (found): 750.4 (M+H).
MS (found): 722.4 (M+H).
Example 4
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=ethyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with 3-ethyl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 5
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=phenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with 3-phenyl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 6
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=4-methoxyphenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with 3-(4-methoxyphenyl)-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 7
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=4-ethoxyphenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with 3-(4-ethoxyphenyl)-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 8
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=5-bromothiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with 3-(5-bromo-thiophen-2-yl)-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 9
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=2-pyrid-3-yl ethylenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with 3-[2-(pyrid-3-yl)-vinyl]-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 10
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=3,4-Dimethoxy-phenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with 3-[2-(3,4-Dimethoxy-phenyl)-vinyl]-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 11
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=2-thiophen-2-yl ethylenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with 3-[2-thiophen-2-yl-vinyl]-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 12
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, Z=indole-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 3-(1H-Indol-3-yl)-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared by heating the commercially available phenyl-1,2-diamine (3.6 mmol) and indole-3-glyoxylic acid (1 equiv.) in ethanol (40 mL) to reflux for 5 hours. After the mixture is cooled to room temperature, the excess ethanol was evaporated in vacuo, and the residue is placed under high vacuum for 2 hours to give 3-(1H-Indol-3-yl)-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 3-(1H-Indol-3-yl)-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 13
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=1H-indol-3-yl methyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 3-(1H-Indol-3-ylmethyl)-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with phenyl-1,2-diamine and indole-3-pyruvic acid via the method described in Example 12 to afford 3-(1H-Indol-3-ylmethyl)-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 3-(1H-Indol-3-ylmethyl)-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 14
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=furan-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 3-(furan-2-yl)-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with phenyl-1,2-diamine and furan-2-yl glyoxylic acid via the method described in Example 12 to afford 3-(furan-2-yl)-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 3-(furan-2-yl)-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 15
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=1H-benzoimidazol-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 3-(1H-benzoimidazol-2-yl)-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with phenyl-1,2-diamine and (1H-benzoimidazol-2-yl)oxo-acetic acid via the method described in Example 12 to afford 3-(1H-benzoimidazol-2-yl)-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 3-(1H-benzoimidazol-2-yl)-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 16
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=1H-imidazol-2-ylmethyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 3-(1H-Imidazol-2-ylmethyl)-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with phenyl-1,2-diamine and (1H-benzoimidazol-2-yl)oxo-acetic acid via the method described in Example 12 to afford 3-(1H-Imidazol-2-ylmethyl)-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 3-(1H-Imidazol-2-ylmethyl)-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 17
Compound of Formula I, wherein A=tBOC, G=OEt, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=chloro, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 3-chloro-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with phenyl-1,2-diamine and oxalic acid via the method described in Example 12 to afford the 1,4-Dihydro quinoxaline-2,3-dione. The 1,4-Dihydro quinoxaline-2,3-dione is then treated with SOCl 2 in 2.5% DMF:toluene, heated to 130° C., stirred for 2 h, filtered and concentrated to afford the 3-chloro-1H-quinoxalin-2-one in crude form.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 3-chloro-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2.
Example 18
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, Z=thiophen-3-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
To a mixture of the title compound of Example 17 (0.055 mmol), 3-thiophene boronic acid (0.28 mmol), cesium carbonate (0.22 mmol), potassium fluoride monohydrate (0.44 mmol) is placed in a round bottom flask and is flushed twice with nitrogen. To this mixture is added DME and the resulting solution is flushed again with nitrogen before palladium tetrakis(triphenylphosphine) (10 mol %) is added. After flushing two more times with nitrogen, the mixture is heated to reflux for 20 hours. The mixture is then cooled and then diluted with water and extracted three times with EtOAc. The combined EtOAc layers are washed once with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue is purified by column chromatography eluting with 20-40% EtOAc-hexane to yield the ethyl ester precursor of the title compound. The ethyl ester is then hydrolyzed to the free acid via treatment with LiOH as elucidated in Example 2 to arrive at the title compound.
Example 19
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=2-pyrid-3-yl acetylenyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared by reaction of a degassed solution of the title compound from Example 17 (4 mmol), 2-pyrid-3-yl acetylene (4 mmol), and 1 ml of triethylamine and 10 ml of acetonitrile with PdCl 2 (PPh 3 ) 2 (0.2 mmol) and CuI (0.1 mol). The resulting reaction mixture is degassed and stirred for 5 minutes at room temperature. The reaction is then heated to 90° C. and stirred for 12 hours. Subsequently, the reaction mixture is concentrated in vacuo and purified by silica column to afford the ethyl ester of the title compound. The ethyl ester is then hydrolyzed to the free acid via treatment with LiOH as elucidated in Example 2 to arrive at the title compound.
Example 20
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=2,3-dihydrobenzofuran-5-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
To a degassed solution of the title compound of Example 17 (1 mmol) and 2,3-dihydrobenzofuran-5-yl stannane (2 mmol) is added Pd(PPh 3 ) 4 (10 mol %). The mixture is degassed with nitrogen two additional times and heated to 100° C. for 3 hours. The cooled mixture is concentrated in vacuo and the residue is purified by column chromatography (30% EtOAc/Hexane) to give the ethyl ester of the title compound. The ethyl ester is then hydrolyzed via treatment with LiOH as elucidated in Example 2 to give the title compound.
Example 21
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W=—NH—, Z=propargyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is formed by reacting a 0.1M solution of the title compound from Example 17 in DMF with propargylamine (1.2 equiv.) in the presence of K 2 CO 3 (2 equiv.) at room temperature for 5-12 hours. The resulting reaction mixture is then extracted with EtOAc, washed with NaHCO 3 , water, and brine, and the washed extract is concentrated in vacuo. The residue is then purified by silica chromatography to yield the ethyl ester of the title compound. The ethyl ester is then hydrolyzed to the free acid via treatment with LiOH to arrive upon the title compound.
Example 22
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W=—N(Ethyl)-, Z=benzyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is formed by reacting a 0.1M solution of the title compound from Example 17 in DMF with benzylethylamine (1.2 equiv.) in the presence of K 2 CO 3 (2 equiv.) at room temperature for 5-12 hours. The resulting reaction mixture is then extracted with EtOAc, washed with NaHCO 3 , water, and brine, and the washed extract is concentrated in vacuo. The residue is then purified by silica chromatography to yield the ethyl ester of the title compound. The ethyl ester is then hydrolyzed to the free acid via treatment with LiOH to arrive upon the title compound.
Example 23
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W=—NH—, Z=pyrid-3-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is formed by reacting a 0.1M solution of the title compound from Example 17 in DMF with 3-aminopyridine (1.2 equiv.) in the presence of K 2 CO 3 (2 equiv.) at room temperature for 5-12 hours. The resulting reaction mixture is then extracted with EtOAc, washed with NaHCO 3 , water, and brine, and the washed extract is concentrated in vacuo. The residue is then purified by silica chromatography to yield the ethyl ester of the title compound. The ethyl ester is then hydrolyzed to the free acid via treatment with LiOH to arrive upon the title compound.
Example 24
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=tetrazolyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is formed by reacting a 0.1M solution of the title compound from Example 17 in DMF with tetrazole (1.2 equiv.) in the presence of K 2 CO 3 (2 equiv.) at room temperature for 5-12 hours. The resulting reaction mixture is then extracted with EtOAc, washed with NaHCO 3 , water, and brine, and the washed extract is concentrated in vacuo. The residue is then purified by silica chromatography to yield the ethyl ester of the title compound. The ethyl ester is then hydrolyzed to the free acid via treatment with LiOH to arrive upon the title compound.
Example 25
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=morpholino, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is formed by reacting a 0.1M solution of the title compound from Example 17 in DMF with morpholine (1.2 equiv.) in the presence of K 2 CO 3 (2 equiv.) at room temperature for 5-12 hours. The resulting reaction mixture is then extracted with EtOAc, washed with NaHCO 3 , water, and brine, and the washed extract is concentrated in vacuo. The residue is then purified by silica chromatography to yield the ethyl ester of the title compound. The ethyl ester is then hydrolyzed to the free acid via treatment with LiOH to arrive upon the title compound.
Example 26
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W=—O—, Z=thiophen-3-yl-methyl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is formed by reacting a 0.1M solution of the title compound from Example 17 in DMF with thiophen-3-yl methanol (1.2 equiv.) in the presence of K 2 CO 3 (2 equiv.) at room temperature for 5-12 hours. The resulting reaction mixture is then extracted with EtOAc, washed with NaHCO 3 , water, and brine, and the washed extract is concentrated in vacuo. The residue is then purified by silica chromatography to yield the ethyl ester of the title compound. The ethyl ester is then hydrolyzed to the free acid via treatment with LiOH to arrive upon the title compound.
Example 27
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 7-Methoxy-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with 4-Methoxy-benzene-1,2-diamine and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 7-Methoxy-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 7-Methoxy-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 28
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 7-Methoxy-3-thiophen-2-yl-1H-quinoxalin-2-one
The 2-nitro amide precursor of the present example is prepared with 4-Methoxy-2-nitroaniline (1 equiv.) and 2-(thiophen-2-yl)oxoacetic acid (1 equiv.) in DMF in the presence of DCC at room temperature to 80° C. to arrive at the precursor 2-nitro amide(N-(4-Methoxy-2-nitro-phenyl)-2-oxo-2-thiophen-2-yl-acetamide). The precursor 2-nitro amide is subjected to catalytic hydrogenation conditions (H 2 /Pd/C in MeOH) forming the amine followed by ring closure to form 6-Methoxy-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-Methoxy-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 29
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is Absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6,7-Methoxy-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with 4,5-Dimethoxy-benzene-1,2-diamine and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 6,7-Methoxy-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6,7-Methoxy-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 30
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-cyano-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with 4-cyano-benzene-1,2-diamine and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 6-cyano-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-cyano-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 31
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-tetrazol-5-yl-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with 4-cyano-benzene-1,2-diamine and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 6-cyano-3-thiophen-2-yl-1H-quinoxalin-2-one. The cyano compound is then treated with NaN 3 (5 eqiv.), Et 3 N (3 equiv.), in Xylenes in a sealed tube and heated to 140° C. and stirred 12 hours to afford the 6-tetrazol-5-yl-3-thiophen-2-yl-1H-quinoxalin-2-one after extraction and purification.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-tetrazol-5-yl-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 32
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is Absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 2-Thiophen-2-yl-4H-pyrido[2,3-b]pyrazin-3-one
The quinoxalin-2-one of the present example is prepared with 2,3-diamino pyridine and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 2-thiophen-2-yl-4H-pyrido[2,3-b]pyrazin-3-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 2-thiophen-2-yl-4H-pyrido[2,3-b]pyrazin-3-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 33
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 7-Thiophen-2-yl-5H-1,3-dioxa-5,8-diaza-cyclopenta[b]naphthalen-6-one
The quinoxalin-2-one of the present example is prepared with Benzo[1,3]dioxole-5,6-diamine and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 7-thiophen-2-yl-5H-1,3-dioxa-5,8-diaza-cyclopenta[b]naphthalen-6-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 7-thiophen-2-yl-5H-1,3-dioxa-5,8-diaza-cyclopenta[b]naphthalen-6-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 34
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 3-Thiophen-2-yl-1H-benzo[g]quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with naphthylene-2,3-diamine and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 3-Thiophen-2-yl-1H-benzo[g]quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 3-Thiophen-2-yl-1H-benzo[g]quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 35
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-Methanesulfonyl-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with 4-Methanesulfonyl-benzene-1,2-diamine and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 6-Methanesulfonyl-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-Methanesulfonyl-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 36
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-sulfonic acid
The quinoxalin-2-one of the present example is prepared with 3,4-Diamino-benzenesulfonic acid and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-sulfonic acid.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-sulfonic acid and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 37
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-Hydroxymethyl-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with (3,4-Diamino-phenyl)-methanol and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 6-Hydroxymethyl-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-Hydroxymethyl-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 38
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-Piperidin-1-ylmethyl-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared first via Swern oxidation with DMSO and (COCl) 2 of 6-Hydroxymethyl-3-thiophen-2-yl-1H-quinoxalin-2-one to form 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-carbaldehyde. The 6-carboxaldehyde compound then undergoes reductive amination with piperidine in acetonitrile in the presence of NaCNBH 3 and acetic acid to afford, after an aqueous workup and purification, 6-Piperidin-1-ylmethyl-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-Piperidin-1-ylmethyl-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 39
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-Nitro-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with 4-Nitro-benzene-1,2-diamine and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 6-Nitro-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-Nitro-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 40
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-amino-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared by reducing 6-nitro-3-thiophen-2-yl-1H-quinoxalin-2-one of Example 39 with H 2 NNH 2 .H 2 O in the presence of Pd/C in refluxing MeOH.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-amino-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 41
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of N-(2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxalin-6-yl)-2-phenyl-acetamide
The quinoxalin-2-one of the present example is prepared by treating 6-amino-3-thiophen-2-yl-1H-quinoxalin-2-one of Example 40 with phenethyl acid chloride to afford, after workup and purification, N-(2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxalin-6-yl)-2-phenyl-acetamide.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with N-(2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxalin-6-yl)-2-phenyl-acetamide and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 42
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-Nitro-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with 4-Nitro-benzene-1,2-diamine and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 6-Nitro-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-Nitro-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 43
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-hydroxy-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with 3,4-diaminophenol (which is prepared by treating 3,4-dinitrophenol with H 2 NNH 2 .H 2 O, Pd/C refluxed in MeOH), and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 6-hydroxy-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-hydroxy-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 44
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-Benzyloxy-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared treating 6-hydroxy-3-thiophen-2-yl-1H-quinoxalin-2-one from Example 43 in DMF with bromomethyl benzene in the presence of K 2 CO 3 at a temperature between 25° C. to 80° C. The resulting reaction mixture, after workup and purification, affords 6-benzyloxy-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-benzyloxy-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl ester via treatment with LiOH as elucidated in Example 2.
Example 45
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-carboxylic acid ethyl ester
The quinoxalin-2-one of the present example is prepared with 3,4-Diamino-benzoic acid ethyl ester and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-carboxylic acid ethyl ester.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-carboxylic acid ethyl ester and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl esters via treatment with LiOH as elucidated in Example 2.
Example 46
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-Phenylacetyl-3-thiophen-2-yl-1H-quinoxalin-2-one
Step 40a
The quinoxalin-2-one of the present example is prepared with 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-carboxylic acid ethyl ester from Example 45 via the hydrolysis of the ethyl ester according to the procedure of Example 2 to afford the carboxylic acid.
Step 40b
The carboxylic acid is then dissolved in DMF in the presence of DCC and triethylamine and to the resulting reaction mixture is added (MeO)NHMe to form Weinreb's amide. The Weinreb's amide is then treated with magnesium benzyl bromide in THF at −75° C. to afford, after extraction and purification, the 6-Phenylacetyl-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-Phenylacetyl-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl esters via treatment with LiOH as elucidated in Example 2.
Example 47
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-carboxylic acid benzylamide
Step 41a
The quinoxalin-2-one of the present example is prepared with 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-carboxylic acid benzylamide from Example 45 via the hydrolysis of the ethyl ester according to the procedure of Example 2 to afford the carboxylic acid.
Step 41b
The carboxylic acid is then dissolved in DMF in the presence of DCC and triethylamine and to the resulting reaction mixture is added benzyl amine to afford, after extraction and purification, 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-carboxylic acid benzylamide.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 2-Oxo-3-thiophen-2-yl-1,2-dihydro-quinoxaline-6-carboxylic acid benzylamide and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl esters via treatment with LiOH as elucidated in Example 2.
Example 48
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-Phenethyl-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with 6-Phenylacetyl-3-thiophen-2-yl-1H-quinoxalin-2-one from Example 46 via treatment with H 2 /Pd—C in the presence of acetic acid to form the 6-phenethyl compound.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-Phenethyl-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2, followed by the reduction of the ethyl esters via treatment with LiOH as elucidated in Example 2.
Example 49
Compound of Formula I, wherein A=tBOC, G=OEt, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Preparation of 6-bromo-3-thiophen-2-yl-1H-quinoxalin-2-one
The quinoxalin-2-one of the present example is prepared with 4-bromo-2-nitroaniline and (thiophen-2-yl)oxo-acetic acid via the method described in Example 12 to afford 6-bromo-3-thiophen-2-yl-1H-quinoxalin-2-one.
Mitsunobu Coupling to Macrocycle
The title compound is prepared with 6-bromo-3-thiophen-2-yl-1H-quinoxalin-2-one and the title compound from Example 1 under the Mitsunobu conditions described in Example 2 to afford the title compound.
Example 50
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
To a degassed solution of the title compound of Example 49 (1 mmol) and thiazol-2-yl stannane (2 mmol) is added Pd(PPh 3 ) 4 (10 mol %). The mixture is degassed with nitrogen two additional times and heated to 100° C. for 3 hours. The cooled mixture is concentrated in vacuo and the residue is purified by column chromatography (30% EtOAc/Hexane) to give the ethyl ester of the title compound. The ethyl ester is then hydrolyzed via treatment with LiOH as elucidated in Example 2 to give the title compound.
Example 51
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
To a mixture of the title compound of Example 49 (0.055 mmol), phenyl boronic acid (0.28 mmol), cesium carbonate (0.22 mmol), potassium fluoride monohydrate (0.44 mmol) is placed in a round bottom flask and is flushed twice with nitrogen. To this mixture is added DME and the resulting solution is flushed again with nitrogen before palladium tetrakis(triphenylphosphine) (10 mol %) is added. After flushing two more times with nitrogen, the mixture is heated to reflux for 20 hours. The mixture is then cooled and then diluted with water and extracted three times with EtOAc. The combined EtOAc layers are washed once with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue is purified by column chromatography eluting with 20-40% EtOAc-hexane to yield the ethyl ester precursor of the title compound. The ethyl ester is then hydrolyzed to the free acid via treatment with LiOH as elucidated in Example 2 to arrive at the title compound.
Example 52
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 ═R 6 =hydrogen.
The title compound is prepared by reaction of a degassed solution of the title compound from Example 49 (4 mmol), 2-pyrid-3-yl acetylene (4 mmol), and 1 ml of triethylamine and 10 ml of acetonitrile with PdCl 2 (PPh 3 ) 2 (0.2 mmol) and CuI (0.1 mmol). The resulting reaction mixture is degassed and stirred for 5 minutes at room temperature. The reaction is then heated to 90° C. and stirred for 12 hours. Subsequently, the reaction mixture is concentrated in vacuo and purified by silica column to afford the ethyl ester of the title compound. The ethyl ester is then hydrolyzed to the free acid via treatment with LiOH as elucidated in Example 2 to arrive at the title compound.
Example 53
Compound of Formula I, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are
W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 ═R 6 =hydrogen.
The title compound is prepared by adding to a dry mixture of the title compound from Example 49 (0.068 mmol), imidazole (2 eq.), Cs 2 CO 3 (3 eq.), Xantphos (30 mol %), and Pd(OAc) 2 under nitrogen dioxane. The reaction mixture is then degassed and stirred at 75° C. for 18 hours. Upon completion of the reaction, monitored via TLC, the reaction mixture is diluted with DCM, filtered, and concentrated in vacuo. The reaction mixture is then purified via silica column chromatography with 5% MeOH/CHCl 3 to afford the ethyl ester of the title compound. The ethyl ester is then hydrolyzed by the conditions set forth in Example 2 to afford the title compound.
Example 54
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =cyclopentyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
54a—Amine Deprotection.
0.041 mmol of the title compound of Example 2 is dissolved in 4 ml of a 4M solution of HCl in dioxane and stirred for 1 hour. The reaction residue 54a is concentrated in vacuo.
54b—Chloroformate Reagent
The chloroformate reagent 54b is prepared by dissolving 0.045 mmol of cyclopentanol in THF (3 ml) and adding 0.09 mmol of phosgene in toluene (20%). The resulting reaction mixture is stirred at room temperature for 2 hours and the solvent is removed in vacuo. To the residue is added DCM and subsequently concentrated to dryness twice in vacuo yielding chloroformate reagent 54b.
54c—Carbamate Formation
The title carbamate is prepared by dissolving residue 54a in 1 ml of THF, adding 0.045 mmol of TEA, and cooling the resulting reaction mixture to 0° C. To this 0° C. reaction mixture is added chloroformate reagent 54b in 3 ml of THF. The resulting reaction mixture is reacted for 2 hours at 0° C., extracted with EtOAc, washed by 1M sodium bicarbonate, water and brine, dried over MgSO 4 , and concentrated in vacuo to dryness. The crude compound is purified by silica column and the ethyl ester is subsequently hydrolyzed by the procedure set forth in Example 2.
Example 55
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =cyclobutyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared by the method described in Example 54 with the title compound of Example 2 and cyclobutanol.
Example 56
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =cyclohexyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared by the method described in Example 54 with the title compound of Example 2 and cyclohexanol.
Example 57
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =
G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared by the method described in Example 54 with the title compound of Example 2 and (R)-3-hydroxytetrahydrofuran.
Example 58
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =
G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared by the method described in Example 54 with the title compound of Example 2 and (S)-3-hydroxytetrahydrofuran.
Example 59
Compound of Formula I, wherein A=—(C═O)—O—R 1 , wherein R 1 =
G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared by the method described in Example 54 with the title compound of Example 2 and
Example 60
Compound of Formula I, wherein A=—(C═O)—R 1 , wherein R 1 =cyclopentyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with the title compound from Example 2 in 4 ml of a 4M solution of HCl in dioxane and stirring the reaction mixture for 1 hour. The reaction residue is concentrated in vacuo. To this residue, 4 ml of THF and 0.045 mmol of TEA is added, the mixture is cooled to 0° C., to which is added 0.045 mmol of the cyclopentyl acid chloride. The resulting reaction mixture is stirred for 2 hours at 0° C. The reaction mixture is then extracted with EtOAc, washed with 1M sodium bicarbonate, water and brine, dried over MgSO 4 and concentrated to dryness in vacuo. The crude compound is purified by silica column and the ethyl ester is subsequently hydrolyzed by the procedure set forth in Example 2.
Example 61
Compound of Formula I, wherein A=—(C═O)—NH—R 1 , wherein R 1 =cyclopentyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with the title compound from Example 2 in 4 ml of a 4M solution of HCl in dioxane and stirring for 1 hour. The resulting reaction residue is concentrated in vacuo, dissolved in 4 ml THF, and cooled to 0° C. To the 0° C. solution is added 0.045 mmol of cyclopentyl isocyanate and the resulting reaction mixture is stirred at room temperature for 4 hours. The solution is then extracted with EtOAc, washed with 1% HCl, water and brine, dried over MgSO 4 , and concentrated in vacuo to dryness. The crude compound is purified by silica column and the ethyl ester is subsequently hydrolyzed by the procedure set forth in Example 2.
Example 62
Compound of Formula I, wherein A=—(C═S)—NH—R 1 , wherein R 1 =cyclopentyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with the title compound from Example 2 in 4 ml of a 4M solution of HCl in dioxane and stirring for 1 hour. The resulting reaction residue is concentrated in vacuo, dissolved in 4 ml THF, and cooled to 0° C. To the 0° C. solution is added 0.045 mmol of cyclopentyl isothiocyanate and the resulting reaction mixture is stirred at room temperature for 4 hours. The solution is then extracted with EtOAc, washed with 1% HCl, water and brine, dried over MgSO 4 , and concentrated in vacuo to dryness. The crude compound is purified by silica column and the ethyl ester is subsequently hydrolyzed by the procedure set forth in Example 2.
Example 63
Compound of Formula I, wherein A=—S(O) 2 —R 1 , wherein R 1 =cyclopentyl, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with the title compound from Example 2 in 4 ml of a 4M solution of HCl in dioxane and stirring for 1 hour. To the resulting concentrated reaction residue, which has been dissolved in 4 ml THF, is added 0.045 mmol of TEA, and cooled to 0° C. To the 0° C. solution is added 0.045 mmol of cyclopentyl sulfonyl chloride and the resulting reaction mixture is stirred at 0° C. for 2 hours. The solution is then extracted with EtOAc, washed with 1M sodium bicarbonate, water and brine, dried over MgSO 4 , and concentrated in vacuo to dryness. The crude compound is purified by silica column and the ethyl ester is subsequently hydrolyzed by the procedure set forth in Example 2.
Example 64
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—O-phenethyl, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared by adding to a solution of the title compound of Example 54 and phenethyl alcohol 64a in 0.5 ml DCM, is added 1.2 eq. PyBrOP, 4 eq. DIEA, and catalytic amount of DMAP at 0° C. The resulting reaction mixture is stirred for 1 hour at 0° C. and then warmed to room temperature over a period of 4-12 hours. The reaction mixture is purified by silica gel flash chromatography using different ratios of hexanes:EtOAc as elution phase (9:1→5:1→3:1→1:1) to afford the title compound isolated phenethyl ester 64b.
Other esters can be made using the same procedures.
Example 65
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—NH-phenethyl, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared by adding to a solution of the title compound of Example 54 and phenethylamine 65a (0.05 ml) in 0.5 ml DMF, EDC (1.2 eq.) and DIEA (4 eq.) at 0° C. The resulting reaction mixture is stirred at 1 hour. Subsequently, the reaction is warmed to room temperature over a period of 4-12 hours. The reaction mixture is purified by silica gel flash chromatography using different ratios of hexanes:EtOAc as elution phase (9:1→5:1→3:1→1:1) to afford title compound phenethyl amide 65b. Other amides can be made via the same procedure.
Example 66
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—NHS(O) 2 -phenethyl, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared by adding to a solution of the title compound of Example 54 and α-toluenesulfonamide 66a (10 mg) in 0.5 ml DCM, is added 1.2 eq. PyBrOP, 4 eq. DIEA, and catalytic amount of DMAP at 0° C. The resulting reaction mixture is stirred for 1 hour and then allowed to warm to room temperature over a period of 4-12 hours. The reaction mixture is purified by silica gel flash chromatography using different ratios of hexanes:EtOAc as elution phase (9:1→5:1→3:1→1:1) to afford the title compound sulfonamide 66b.
Other sulfonamides can be made via the same procedure.
Example 67
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—(C═O)—OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared by adding to a solution of the title compound of Example 54 in 0.5 ml DMF, EDC (1.2 eq.) and DIEA (4 eq.) at 0° C. The resulting reaction mixture is stirred at 1 hour. Subsequently, the reaction is warmed to room temperature over a period of 4-12 hours. The reaction mixture is purified by silica gel flash chromatography to afford hydroxyamide. The hydroxyamide is then treated with DIBAL-H at −78° C. in THF for 2 hours. The reaction mixture is then diluted with 8 ml EtOAc, washed with water and brine, dried over Na 2 SO 4 , and concentrated in vacuo to yield aldehyde 67a. To a solution of aldehyde 67a in 0.5 ml THF, is added α-hydroxy-α-methyl-propionitrile (0.1 ml) and catalytic amount TFA at 0° C. The resulting reaction mixture is warmed from 0° C. to room temperature over a period of 4-12 hours followed by hydrolysis with concentrated hydrochloric acid in dioxane. The reaction is then extracted with EtOAc, and washed with water and brine to yield α-hydroxy compound 67b in its crude form. The crude compound 67b undergoes a Dess-Martin oxidation in THF (0.5 ml), providing the α-carbonyl compound 67c in crude form. The crude 67c is purified by silica gel flash chromatography using different ratios of hexanes:EtOAc as elution phase (9:1→5:1→3:1→1:1) to afford the title compound isolated keto acid 67c.
Example 68
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—(C═O)—O-phenethyl, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with the title compound keto acid of Example 67 and phenethanol according to the procedure set forth in Example 64.
Example 69
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—(C═O)—NH-phenethyl, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with the title compound keto acid of Example 67 and phenethyl amine according to the procedure set forth in Example 65.
Example 70
Compound of Formula I, wherein A=—(C═O)—O—R 1 , R 1 =cyclopentyl, G=—(C═O)—NH—S(O) 2 -benzyl, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
The title compound is prepared with the title compound keto acid of Example 67 and α-toluenesulfonamide according to the procedure set forth in Example 66.
Example 71
Compound of Formula I, wherein A=tBOC, G=OH, L=—(C═O)CH 2 —, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Synthesis of (2S)—N-Boc-amino-5-oxo-non-8-enoic acid
71A. The aforementioned amino acid is prepared by adding to a solution of monoallyl ester of malonic acid in dry THF under N 2 at −78° C., n-Bu 2 Mg dropwise over a period of 5 min. The resulting suspension is then stirred at room temperature for 1 hour and evaporated to dryness. Solid Mg salt 71b, is dried under vacuum.
Glutamic acid derivative 71a is first mixed with 1,1′-carbonyldiimidazole in anhydrous THF and the mixture is stirred at room temperature for 1 hour to activate the free acid moiety. Subsequently, the activated glutamic acid derivative is cannulated into a solution of Mg salt 49b and the reaction mixture obtained is stirred at room temperature for 16 hours. The mixture then is diluted with ethyl acetate and the organic solution is washed with 0.5 N HCl (at 0° C.) and brine, dried and evaporated. The residue obtained is resolved via silica chromatography with a 35-40% ethyl acetate in hexanes eluent system to yield diester 71c.
71B. To a stirred solution of tetrakis (triphenylphosphine) Pd (0) in dry DMF is added the diester in DMF. The mixture is stirred at room temperature for 3.5 hours. The DMF is evaporated under reduced pressure and the residue diluted with EtOAc. The EtOAc solution is washed with 0.5N 0° C. HCl, brine, dried and evaporated. The residue is chromatographed on silica gel using 15% to 20% EtOAc in hexane as eluent to afford the methyl ester intermediate.
The methyl ester intermediate is then diluted with THF and water, LiOH.H 2 O is added and the resulting mixture is stirred at room temperature for 25 hours, wherein the completion of the hydrolysis is monitored by TLC. The reaction mixture is concentrated under vacuum to remove a majority of the THF and further diluted with methylene chloride. The resulting solution is washed with 1 N HCl, dried with anhydrous Na 2 SO 4 and concentrated under vacuum. To remove minor impurities and excess Boc 2 O, the crude product is purified via flash chromatography using a solvent gradient from 100% hexane→100% EtOAc as the eluent. (2S)—N-Boc-amino-5-oxo-non-8-enoic acid 71d is obtained. For further details of the preceding amino acid synthesis may be found in T. Tsuda et al., J. Am. Chem. Soc., 1980, 102, 6381-6384 and WO 00/59929.
71C. Synthesis of Modified Cyclic Peptide Precursor Mesylate
The modified cyclic peptide precursor mesylate is prepared using the synthetic route detailed in Example 1 using (2S)—N-Boc-amino-5-oxo-non-8-enoic acid 71d in place of Boc-L-2-amino-8-nonenoic acid 1a followed by conversion to the corresponding mesylate via the method described in Example 2.
The title compound is prepared with the modified cyclic peptide precursor mesylate formed in 71C and 3-(thiophen-2-yl)-1H-quinoxylin-2-one by the Mitsunobu conditions elucidated in Example 2 followed by hydrolysis of the ethyl ester via the method set forth in Example 2.
Example 72
Compound of Formula I, wherein A=tBOC, G=OH, L=—CH(CH 3 )CH 2 —, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Synthesis of (2S,5R)—N-Boc-2-amino-5-methyl-non-8-enoic acid (72 h)
72A. To solid ethyl 2-acetamidomalonate 72b is added (R)-(+)-citronellal 72a in a solution of pyridine over 1 min. The resulting solution is cooled in a 10° C. bath and acetic anhydride is added over 4 min. The resulting solution is stirred for 3 hours at room temperature and another portion of ethyl 2-acetamidomalonate 72a is added. The resulting mixture is stirred at room temperature for an additional 11 hours. Ice is then added and the solution is stirred for 1.5 hours, then the mixture is diluted with 250 ml water and extracted with two portions of ether. The organic phase is washed with 1N HCl, sat. NaHCO 3 , dried Na 2 SO 4 , concentrated and purified by flash chromatography (40% EtOAc/hexane) to afford compound 72c.
72B. To a degassed solution of 72c in dry ethanol is added (S,S)-Et-DUPHOS Rh(COD)OTf. The mixture is subjected to 30 psi of hydrogen and stirred on a Parr shaker for 2 hours. The resulting mixture is evaporated to dryness to obtain the crude compound 72d, which is used in the subsequent step without purification.
72C. Compound 72d is dissolved in a mixture of tBuOH/acetone/H 2 O (1:1:1) and placed in an ice bath (0° C.). NMMO and OsO 4 is consecutively added and the reaction mixture is stirred at room temperature for 4 hours. A majority of the acetone is removed by evaporation under vacuum and then the mixture is extracted with ethyl acetate. The organic layer is further washed with water and brine, dried over anhydrous MgSO 4 and evaporated to dryness. The diol 72e is obtained in high purity after flash column chromatography using 1% ethanol in ethyl acetate as the eluent.
72D. To a solution of diol 72e in THF/H 2 O (1:1) at 0° C., NaIO 4 is added and the reaction mixture is stirred at room temperature for 3.5 hours. A majority of the THF solvent is subsequently removed by evaporation under vacuum and the remaining mixture is extracted with EtOAc. The combined organic layers are further washed with 5% aqueous citric acid solution, 5% aq. NaHCO 3 and brine, then the organic phase is dried over MgSO 4 and evaporated to dryness under vacuum. Aldehyde intermediate 72f is used in the following step in its crude form.
72E. To a solution of Ph 3 PCH 3 Br in anhydrous toluene, KHMDS is added forming a suspension which is stirred at room temperature for 30 min. under N 2 . After stirring, the suspension is cooled to 0° C., a solution of aldehyde intermediate 72f in THF is added, the mixture is warmed to room temperature, and stirred for 1 hour. A majority of the THF is evaporated under vacuum, EtOAc is added to the mixture and the organic phase is washed with water, 5% aq. NaHCO 3 and brine. The organic phase is then dried over MgSO 4 and evaporated to dryness under vacuum. Pure compound 72 g is isolated after purification via flash chromatography on silica gel, using hexane:EtOAc (3:2) as the eluent.
72F. To a solution of crude 72 g in THF, Boc 2 O, and DMAP is added and the reaction mixture is heated to reflux for 2.5 hours. Subsequently, a majority of the THF is evaporated, the crude mixture is diluted with methylene chloride and washed with 1 N HCl to remove DMAP. The organic layer is further extracted with saturated aq. NaHCO 3 , dried with anhydrous Na 2 SO 4 and concentrated under vacuum. The crude product is then diluted with THF and water, LiOH.H 2 O is added and the resulting mixture is stirred at room temperature for 25 hours, wherein the completion of the hydrolysis is monitored by TLC. The reaction mixture is concentrated under vacuum to remove a majority of the THF and further diluted with methylene chloride. The resulting solution is washed with 1 N HCl, dried with anhydrous Na 2 SO 4 and concentrated under vacuum. To remove minor impurities and excess Boc 2 O, the crude product is purified via flash chromatography using a solvent gradient from 100% hexane→100% EtOAc as the eluent. (2S,5R)—N-Boc-2-amino-5-methyl-non-8-enoic acid 72 h is obtained. For further details of the preceding amino acid synthesis see WO 00/59929.
Synthesis of Modified Cyclic Peptide Precursor Mesylate
The modified cyclic peptide precursor mesylate is prepared using the synthetic route detailed in Example 1 using ((2S,5R)—N-Boc-2-amino-5-methyl-non-8-enoic acid 72 h in place of Boc-L-2-amino-8-nonenoic acid 1a followed by conversion to the corresponding mesylate via the method described in Example 2.
The title compound is prepared with the modified cyclic peptide precursor mesylate formed in 72G and 3-(thiophen-2-yl)-1H-quinoxylin-2-one by the Mitsunobu conditions elucidated in Example 2 followed by hydrolysis of the ethyl ester via the method set forth in Example 2.
Example 73
Compound of Formula I, wherein A=tBOC, G=OH, L=—O—, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 =methyl, and R 6 =hydrogen.
Synthesis of N-Boc-O-allyl-(L)-threonine (73d)
73A. Boc-(L)-threonine 73a is partially dissolved in methylene chloride/methanol at 0° C. A solution of diazomethane in diethyl ether is added until yellow, indicating the presence of diazomethane. Upon evaporation of the solvents, crude methyl ester 73b is obtained.
73B. Intermediate 73b is dissolved in anhydrous diethyl ether, Ag 2 O is added and freshly activated 4 Å molecular sieves. Finally, allyl iodide is added to the reaction mixture and is stirred at reflux. Two additional portions of allyl iodide are added to the reaction mixture after a period of 20 hours and 30 hours and stirring is continued for a total of 36 hours. The mixture is then filtered through celite and purified by flash chromatography on silica gel, using EtOAc/hexane (1:4) as the eluent, to afford compound 73c.
73C. Compound 73c is dissolved in a mixture of THF/MeOH/H 2 O (2:1:1) and LiOH.H 2 O is added. The solution is stirred at room temperature for 2 hours, and is acidified with 1 N HCl to pH ˜3 before the solvents are removed under vacuum. The resulting crude compound 73d is obtained. For further details of the preceding synthesis see WO 00/59929, which is herein incorporated by reference in its entirety.
73D. Synthesis of Modified Cyclic Peptide Precursor Mesylate
The modified cyclic peptide precursor mesylate is prepared using the synthetic route detailed in Example 1 using N-Boc-O-allyl-(L)-threonine 73d in place of Boc-L-2-amino-8-nonenoic acid 1a followed by conversion to the corresponding mesylate via the method described in Example 2.
The title compound is prepared with the modified cyclic peptide precursor mesylate formed in 73D and 3-(thiophen-2-yl)-1H-quinoxylin-2-one by the Mitsunobu conditions elucidated in Example 2 followed by hydrolysis of the ethyl ester via the method set forth in Example 2.
Example 74
Compound of Formula I, wherein A=tBOC, G=OH, L=—S—, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 =methyl, and R 6 =hydrogen.
Synthesis of (2S,3S)—N-Boc-2 amino-3(mercaptoallyl)butanoic acid (74e)
74A. Compound 74a is dissolved in pyridine and the solution is cooled to 0° C. in an ice bath, tosyl chloride is added in small portions and the reaction mixture is partitioned between diethyl ether and H 2 O. The ether layer is further washed with 0.2 N HCl and brine, dried over anhydrous MgSO 4 , filtered and concentrated to dryness under vacuum. Purification of the crude material by flash chromatography on silica gel, using hexane/EtOAc (gradient from 8:2 to 7:3 ratio) as the eluent, leads to isolation of tosyl derivative 74b.
74B. To a solution of tosyl derivative 74b in anhydrous DMF, potassium thioacetate is added and the reaction mixture is stirred at room temperature for 24 hours. A majority of the DMF is then evaporated under vacuum and the remaining mixture is partitioned between EtOAc and H 2 O. The aqueous layer is re-extracted with EtOAc, the combined organic layers are washed with brine, dried over anhydrous MgSO 4 and evaporated to dryness. Purification of the crude material by flash chromatography on silica gel using hexane/EtOAc (4:1 ratio) as the eluent, affords thioester 74c.
74C. To a solution of thioester 74c is H 2 O/EtOH (3:5 ratio) and aqueous solution of 0.2M NaOH is added and the mixture is stirred at room temperature for 1.5 hours. Allyl iodide is then added and stirring is continued at room temperature for an additional 30 min. The reaction mixture is concentrated to half of its original volume and then extracted with EtOAc. The aqueous layer is acidified to pH ˜3 with cold, aqueous 0.5N HCl and re-extracted with EtOAc. The combined organic layers are washed with brine, dried over anhydrous MgSO 4 and evaporated to dryness under vacuum. The crude reaction mixture contains at least four products; all of the products are isolated after flash chromatography on silica gel, using hexane/EtOAc (gradient from 9:1 to 3:1). The desired product 74d is the least polar compound.
74D. A solution of compound 74d in MeOH/H 2 O (3:1) is mixed with aqueous NaOH (0.3 N) for 24 hours at room temperature and for 1 hour at 40° C. The reaction mixture is acidified with cold aqueous 0.5 N HCl, the MeOH is removed under vacuum and the remaining aqueous mixture is extracted with EtOAc. The organic phase is dried over MgSO 4 and evaporated to dryness in order to obtain compound 74e. For further details of the synthesis of amino acid 74e, see WO 00/59929, which is herein incorporated by reference in its entirety.
74E. Synthesis of Modified Cyclic Peptide Precursor Mesylate
The modified cyclic peptide precursor mesylate is prepared using the synthetic route detailed in Example 1 using (2S,3S)—N-Boc-2 amino-3(mercaptoallyl)butanoic acid 74e in place of Boc-L-2-amino-8-nonenoic acid 1a followed by conversion to the corresponding mesylate via the method described in Example 2.
The title compound is prepared with the modified cyclic peptide precursor mesylate formed in 74E and 3-(thiophen-2-yl)-1H-quinoxylin-2-one by the Mitsunobu conditions elucidated in Example 2 followed by hydrolysis of the ethyl ester via the method set forth in Example 2.
Example 75
Compound of Formula I, wherein A=tBOC, G=OH, L=—S(O)—, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 =methyl, and R 6 =hydrogen.
Formation of Modified Amino Acid
75A. The modified amino acid is prepared by dissolving sodium metaperiodate (1.1 eq.) in water and cooled to 0° C. in an ice bath followed by adding dropwise a solution of compound 75d in dioxane. The resulting reaction mixture is stirred for one hour at 0° C. and 4 hours at 40° C. The reaction mixture is concentrated, water is added, and the mixture is extracted with methylene chloride twice. The combined organic layers are washed with water, brine, dried with anhydrous MgSO 4 and concentrated in vacuo. The methyl ester is then reduced via the method set forth in Example 74D to arrive upon the modified amino acid 75a. For further details concerning the sulfur oxidation reaction, see S. A. Burrage et al., Tett. Lett., 1998, 39, 2831-2834, which is herein incorporated by reference in its entirety.
75B. Synthesis of Modified Cyclic Peptide Precursor Mesylate
The modified cyclic peptide precursor mesylate is prepared using the synthetic route detailed in Example 1 using the modified amino acid 75a in place of Boc-L-2-amino-8-nonenoic acid 1a followed by conversion to the corresponding mesylate via the method described in Example 2.
The title compound is prepared with the modified cyclic peptide precursor mesylate formed in 75B and 3-(thiophen-2-yl)-1H-quinoxylin-2-one by the Mitsunobu conditions elucidated in Example 2 followed by hydrolysis of the ethyl ester via the method set forth in Example 2.
Example 76
Compound of Formula I, wherein A=tBOC, G=OH, L=—S(O) 2 , X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, R 5 =methyl, and R 6 =hydrogen.
Formation of Modified Amino Acid
76A. The modified amino acid is prepared by dissolving sodium metaperiodate (1.1 eq.) in water and cooled to 0° C. in an ice bath followed by adding dropwise a solution of compound 76d in dioxane. The resulting reaction mixture is stirred for one hour at 0° C. and 4 hours at 40° C. The reaction mixture is concentrated, water is added, and the mixture is extracted with methylene chloride twice. The combined organic layers are washed with water, brine, dried with anhydrous MgSO 4 and concentrated in vacuo. The methyl ester is then reduced via the method set forth in Example 74D to arrive upon the modified amino acid 76a. For further details concerning the sulfur oxidation reaction, see S. A. Burrage et al., Tett. Lett., 1998, 39, 2831-2834.
76B. Synthesis of Modified Cyclic Peptide Precursor Mesylate
The modified cyclic peptide precursor mesylate is prepared using the synthetic route detailed in Example 1 using the modified amino acid 76a in place of Boc-L-2-amino-8-nonenoic acid 1a followed by conversion to the corresponding mesylate via the method described in Example 2.
The title compound is prepared with the modified cyclic peptide precursor mesylate formed in 76B and 3-(thiophen-2-yl)-1H-quinoxylin-2-one by the Mitsunobu conditions elucidated in Example 2 followed by hydrolysis of the ethyl ester via the method set forth in Example 2.
Example 77
Compound of Formula I, wherein A=tBOC, G=OH, L=—SCH 2 CH 2 —, X═Y=thiophen-3-yl, Z=hydrogen, j=0, m=s=1, and R 5 ═R 6 ═CH 3 .
77A. Synthesis of (S)—N-Boc-2-amino-3-methyl-3(1-mercapto-4-butenyl)butanoic acid (77b)
L-Penicillamine 77a is dissolved in DMF/DMSO (5:1), subsequently, 4-bromopentene and CsOH.H 2 O are added to the mixture and stirring is continued for an additional 12 hours. The DMF is subsequently removed in vacuo, the remaining mixture is diluted with 0.5 N HCl (at 0° C.) to adjust the pH to ˜4-5 and then extracted with 2 portions of EtOAc. The organic phase is washed with brine (2×), dried over MgSO 4 and evaporated to dryness to afford the crude carboxylic acid 77a.
77B. Synthesis of Modified Cyclic Peptide Precursor Mesylate
The modified cyclic peptide precursor mesylate is prepared using the synthetic route detailed in Example 1 using the modified amino acid 77a in place of Boc-L-2-amino-8-nonenoic acid 1a followed by conversion to the corresponding mesylate via the method described in Example 2.
The title compound is prepared with the modified cyclic peptide precursor mesylate formed in 77B and 3-(thiophen-2-yl)-1H-quinoxylin-2-one by the Mitsunobu conditions elucidated in Example 2 followed by hydrolysis of the ethyl ester via the method set forth in Example 2.
Example 78
Compound of Formula I, wherein A=tBOC, G=OH, L=CF 2 CH 2 , X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Synthesis of (2S)—N-Boc-amino-5-difluoro-non-8-enoic acid (78b)
78A. To a solution of the ketone compound 71d (0.30 g, 1 mmol) in 5 ml DCM, DAST (Diethylaminosulfurtrifluoride, 0.2 g, 1.2 eq) is added. The reaction is kept at room temperature over a period of 2-3 days. The solvent is evaporated and the residue is purified by silica gel flash chromatography using different ratios of hexanes:EtOAc as eluent (9:1→5:1→3:1→1:1), providing the isolated methyl ester 78a. For further details concerning the preceding synthesis, see Tius, Marcus A et al., Tetrahedron, 1993, 49, 16; 3291-3304, which is herein incorporated by reference in its entirety.
78B. Methyl ester 78a is dissolved in THF/MeOH/H 2 O (2:1:1) and LiOH.H 2 O is added. The solution is stirred at room temperature for 2 hours, and is then acidified with 1N HCl to pH ˜3 before the solvents are removed in vacuo to afford the crude (2S)—N-Boc-amino-5-difluoro-non-8-enoic acid 78b.
78C. Synthesis of Modified Cyclic Peptide Precursor Mesylate
The modified cyclic peptide precursor mesylate is prepared using the synthetic route detailed in Example 1 using crude (2S)—N-Boc-amino-5-difluoro-non-8-enoic acid 78b in place of Boc-L-2-amino-8-nonenoic acid 1a followed by conversion to the corresponding mesylate via the method described in Example 2.
The title compound is prepared with the modified cyclic peptide precursor mesylate formed in 78C and 3-(thiophen-2-yl)-1H-quinoxylin-2-one by the Mitsunobu conditions elucidated in Example 2 followed by hydrolysis of the ethyl ester via the method set forth in Example 2.
Example 79
Compound of Formula I, wherein A=tBOC, G=OH, L=—CHFCH 2 —, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
Synthesis of (2S)—N-Boc-amino-5-fluoro-non-8-enoic acid (79c)
79A. To a solution of the ketone compound 71d in 5 ml methanol, NaBH 4 (2.2 eq) is added. The reaction mixture is stirred at room temperature over a period of 2-6 hours, and then quenched by 1M ammonium chloride and extracted with EtOAc (30 ml). The solvent is evaporated and the crude hydroxy compound 79a is obtained.
79B. The hydroxy compound 79a is dissolved in 5 ml DCM to which DAST (0.2 g, 1.2 eq) is added and stirred at −45° C. for 1 hour. The reaction mixture is then warmed to room temperature and stirred over a period of 2-3 days. The solvent is evaporated and the residue is purified by silica gel flash chromatography using different ratios of hexanes:EtOAc as eluent (9:1→5:1→3:1→1:1), providing the isolated monofluoro compound methyl ester 79b. For further details concerning the preceding reaction, see Buist, Peter H et al., Tetrahedron Lett., 1987, 28, 3891-3894, which is herein incorporated by reference in its entirety.
79C. Methyl ester 79b is dissolved in THF/MeOH/H 2 O (2:1:1) and LiOH.H 2 O is added. The solution is stirred at room temperature for 2 hours, and is then acidified with 1N HCl to pH ˜3 before the solvents are removed in vacuo to afford the crude (2S)—N-Boc-amino-5-difluoro-non-8-enoic acid 79c.
79D. Synthesis of Modified Cyclic Peptide Precursor Mesylate
The modified cyclic peptide precursor mesylate is prepared using the synthetic route detailed in Example 1 using crude (2S)—N-Boc-amino-5-monofluoro-non-8-enoic acid 79b in place of Boc-L-2-amino-8-nonenoic acid 1a followed by conversion to the corresponding mesylate via the method described in Example 2.
The title compound is prepared with the modified cyclic peptide precursor mesylate formed in 79C and 3-(thiophen-2-yl)-1H-quinoxylin-2-one by the Mitsunobu conditions elucidated in Example 2 followed by hydrolysis of the ethyl ester via the method set forth in Example 2.
Example 80
Compound of Formula II, wherein A=tBOC, G=OH, L=absent, X and Y taken together with the carbon atoms to which they are attached are phenyl, W is absent, Z=thiophen-2-yl, j=3, m=s=1, and R 5 ═R 6 =hydrogen.
80A. The saturated cyclic peptide precursor is prepared by catalytic reduction of the cyclic peptide precursor of Example 1 with Pd/C in MeOH in the presence of H 2 .
The title compound is prepared with the saturated cyclic peptide precursor mesylate formed in 80A and 3-(thiophen-2-yl)-1H-quinoxylin-2-one by the Mitsunobu conditions elucidated in Example 2 followed by hydrolysis of the ethyl ester via the method set forth in Example 2.
The compounds of the present invention exhibit potent inhibitory properties against the HCV NS3 protease. The following examples elucidate assays in which the compounds of the present invention are tested for anti-HCV effects.
Example 81
NS3/NS4a Protease Enzyme Assay
HCV protease activity and inhibition is assayed using an internally quenched fluorogenic substrate. A DABCYL and an EDANS group are attached to opposite ends of a short peptide. Quenching of the EDANS fluorescence by the DABCYL group is relieved upon proteolytic cleavage. Fluorescence was measured with a Molecular Devices Fluoromax (or equivalent) using an excitation wavelength of 355 nm and an emission wavelength of 485 nm.
The assay is run in Corning white half-area 96-well plates (VWR 29444-312 [Corning 3693]) with full-length NS3 HCV protease 1b tethered with NS4A cofactor (final enzyme concentration 1 to 15 nM). The assay buffer is complemented with 10 μM NS4A cofactor Pep 4A (Anaspec 25336 or in-house, MW 1424.8). RET S1 (Ac-Asp-Glu-Asp(EDANS)-Glu-Glu-Abu-[COO]Ala-Ser-Lys-(DABCYL)-NH 2 , AnaSpec 22991, MW 1548.6) is used as the fluorogenic peptide substrate. The assay buffer contained 50 mM Hepes at pH 7.5, 30 mM NaCl and 10 mM BME. The enzyme reaction is followed over a 30 minutes time course at room temperature in the absence and presence of inhibitors.
The peptide inhibitors HCV Inh 1 (Anaspec 25345, MW 796.8) Ac-Asp-Glu-Met-Glu-Glu-Cys-OH, [−20° C.] and HCV Inh 2 (Anaspec 25346, MW 913.1) Ac-Asp-Glu-Dif-Cha-Cys-OH, were used as reference compounds.
IC50 values were calculated using XLFit in ActivityBase (IDBS) using equation 205:
y=A +(( B−A )/(1+(( C/x )^ D ))).
Example 82
Cell-Based Replicon Assay
Quantification of HCV Replicon RNA in Cell Lines (HCV Cell Based Assay)
Cell lines, including Huh-11-7 or Huh 9-13, harboring HCV replicons (Lohmann, et al Science 285:110-113, 1999) are seeded at 5×10 3 cells/well in 96 well plates and fed media containing DMEM (high glucose), 10% fetal calf serum, penicillin-streptomycin and non-essential amino acids. Cells are incubated in a 5% CO 2 incubator at 37° C. At the end of the incubation period, total RNA is extracted and purified from cells using Qiagen Rneasy 96 Kit (Catalog No. 74182). To amplify the HCV RNA so that sufficient material can be detected by an HCV specific probe (below), primers specific for HCV (below) mediate both the reverse transcription of the HCV RNA and the amplification of the cDNA by polymerase chain reaction (PCR) using the TaqMan One-Step RT-PCR Master Mix Kit (Applied Biosystems catalog no. 4309169). The nucleotide sequences of the RT-PCR primers, which are located in the NS5B region of the HCV genome, are the following:
HCV Forward primer “RBNS5bfor”:
5′GCTGCGGCCTGTCGAGCT
HCV Reverse primer “RBNS5Brev”:
5′CAAGGTCGTCTCCGCATAC
Detection of the RT-PCR product was accomplished using the Applied Biosystems (ABI) Prism 7700 Sequence Detection System (SDS) that detects the fluorescence that is emitted when the probe, which is labeled with a fluorescence reporter dye and a quencher dye, is processed during the PCR reaction. The increase in the amount of fluorescence is measured during each cycle of PCR and reflects the increasing amount of RT-PCR product. Specifically, quantification is based on the threshold cycle, where the amplification plot crosses a defined fluorescence threshold. Comparison of the threshold cycles of the sample with a known standard provides a highly sensitive measure of relative template concentration in different samples (ABI User Bulletin #2 Dec. 11, 1997). The data is analyzed using the ABI SDS program version 1.7. The relative template concentration can be converted to RNA copy numbers by employing a standard curve of HCV RNA standards with known copy number (ABI User Bulletin #2 Dec. 11, 1997).
The RT-PCR product was detected using the following labeled probe:
5′ FAM-CGAAGCTCCAGGACTGCACGATGCT-TAMRA
FAM = Fluorescence reporter dye.
TAMRA: = Quencher dye.
The RT reaction is performed at 48° C. for 30 minutes followed by PCR. Thermal cycler parameters used for the PCR reaction on the ABI Prism 7700 Sequence Detection System were: one cycle at 95° C., 10 minutes followed by 35 cycles each of which included one incubation at 95° C. for 15 seconds and a second incubation for 60° C. for 1 minute.
To normalize the data to an internal control molecule within the cellular RNA, RT-PCR is performed on the cellular messenger RNA glyceraldehydes-3-phosphate dehydrogenase (GAPDH). The GAPDH copy number is very stable in the cell lines used. GAPDH RT-PCR is performed on the same exact RNA sample from which the HCV copy number is determined. The GAPDH primers and probes, as well as the standards with which to determine copy number, are contained in the ABI Pre-Developed TaqMan Assay Kit (catalog no. 4310884E). The ratio of HCV/GAPDH RNA is used to calculate the activity of compounds evaluated for inhibition of HCV RNA replication.
Activity of Compounds as Inhibitors of HCV Replication (Cell Based Assay) in Replicon Containing Huh-7 Cell Lines
The effect of a specific anti-viral compound on HCV replicon RNA levels in Huh-11-7 or 9-13 cells was determined by comparing the amount of HCV RNA normalized to GAPDH (e.g. the ratio of HCV/GAPDH) in the cells exposed to compound versus cells exposed to the 0% inhibition and the 100% inhibition controls. Specifically, cells were seeded at 5×10 3 cells/well in a 96 well plate and were incubated either with: 1) media containing 1% DMSO (0% inhibition control), 2) 100 international units, IU/ml Interferon-alpha 2b in media/1% DMSO or 3) media/1% DMSO containing a fixed concentration of compound. 96 well plates as described above were then incubated at 37° C. for 3 days (primary screening assay) or 4 days (IC50 determination). Percent inhibition was defined as:
% Inhibition=[100−(( S−C 2)/ C 1 −C 2))]×100
where S=the ratio of HCV RNA copy number/GAPDH RNA copy number in the sample; C1=the ratio of HCV RNA copy number/GAPDH RNA copy number in the 0% inhibition control (media/i % DMSO); and C2=the ratio of HCV RNA copy number/GAPDH RNA copy number in the 100% inhibition control (100 IU/ml Interferon-alpha 2b).
The dose-response curve of the inhibitor was generated by adding compound in serial, three-fold dilutions over three logs to wells starting with the highest concentration of a specific compound at 10 uM and ending with the lowest concentration of 0.0 uM. Further dilution series (1 uM to 0.001 uM for example) was performed if the IC50 value was not in the linear range of the curve. IC50 was determined based on the IDBS Activity Base program using Microsoft Excel “XL Fit” in which A=100% inhibition value (100 IU/ml Interferon-alpha 2b), B=0% inhibition control value (media/1% DMSO) and C=midpoint of the curve as defined as C=(B−A/2)+A. A, B and C values are expressed as the ratio of HCV RNA/GAPDH RNA as determined for each sample in each well of a 96 well plate as described above. For each plate the average of 4 wells were used to define the 100% and 0% inhibition values.
Although the invention has been described with respect to various preferred embodiments, it is not intended to be limited thereto, but rather those skilled in the art will recognize that variations and modifications may be made therein which are within the spirit of the invention and the scope of the appended claims.
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The present invention relates to compounds of Formula I or II, or a pharmaceutically acceptable salt, ester, or prodrug, thereof:
which inhibit serine protease activity, particularly the activity of hepatitis C virus (HCV) NS3-NS4A protease. Consequently, the compounds of the present invention interfere with the life cycle of the hepatitis C virus and are also useful as antiviral agents. The present invention further relates to pharmaceutical compositions comprising the aforementioned compounds for administration to a subject suffering from HCV infection. The invention also relates to methods of treating an HCV infection in a subject by administering a pharmaceutical composition comprising the compounds of the present invention.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 61/098,656, filed on Sep. 19, 2008 by the same inventors, the contents of which are incorporated by reference as though fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to towers for drilling machines, and controlling the tilt thereof.
2. Description of the Related Art
There are many different types of drilling machines for drilling through a formation. Some of these drilling machines are mobile and others are stationary. Some examples of mobile and stationary drilling machines are disclosed in U.S. Pat. Nos. 820,992, 3,195,695, 3,245,180, 3,561,616, 3,692,123, 3,695,363, 3,708,024, 3,778,940, 3,805,902, 3,815,690, 3,833,072, 3,905,168, 3,968,845, 3,992,831, 4,016,687, 4,020,909, 4,595,065, 4,606,155, 4,616,454, 5,988,299, 6,527,063, 6,672,410, 6,675,915, 7,325,634, 7,347,285 and 7,413,036, as well as in U.S. Patent Application No. 20080210469. Some drilling machines, such as the one disclosed in U.S. Pat. No. 4,295,758, are designed to float and are useful for ocean drilling. The contents of these cited U.S. patents and the patent application are incorporated by reference as though fully set forth herein.
A typical mobile drilling machine includes a vehicle and tower, wherein the tower carries a rotary head and drill string. In operation, the drill string is driven into the formation by the rotary head. In this way, the drilling machine drills through the formation. More information about drilling machines, and how they operate, can be found in the above-identified references.
In some situations, it is desirable to drill at an angle. Drilling at an angle is useful so that more regions of a formation can be reached with the drill string. For example, in some situations, the drilling machine cannot be positioned directly over a desired region of the formation, so it is not possible to drill straight down and reach this region of the formation. Hence, angled drilling is useful so that the drilling machine can reach a desired region of a formation without being directly over it. In this way, there are many more options available when selecting the location to position the drilling machine.
Angled drilling is typically accomplished by tilting the tower relative to an axis of the drilling machine so that the drill string is tilted in response. More information regarding tilting a tower is provided in U.S. Pat. Nos. 3,245,180, 3,561,616, 3,815,690, 3,778,940, 3,905,168, and 3,992,831, and U.S. Patent Application No. 20080210469, as well as some of the other references mentioned above. However, it is desirable to better control the angle that the tower is tilted, and to provide more stability to the tower when it is in a tilted condition.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a drilling machine for angled drilling, as well as a method of manufacturing and using the drilling machine. The novel features of the invention are set forth with particularity in the appended claims. The invention will be best understood from the following description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a side view of a drilling machine with a tower rotatably mounted to a tower interface assembly, wherein the tower and tower interface assembly are carried by a platform, and the tower is in a stowed condition.
FIGS. 1 b and 1 c are opposed side views of the drilling machine of FIG. 1 a , wherein the tower is in a raised condition.
FIGS. 1 d and 1 e are close-up front and rear perspective views, respectively, of the drilling machine of FIG. 1 a , wherein the tower is in the raised condition.
FIG. 1 f is a perspective view of opposed tower brackets of the tower of the drilling machine of FIG. 1 a.
FIG. 2 a is a rear perspective view of the tower interface assembly being carried by the platform, as shown in FIGS. 1 a , 1 b and 1 c.
FIGS. 2 b and 2 c are close-up rear and front perspective views, respectively, of the tower interface assembly being carried by the platform, as shown in FIGS. 1 a , 1 b and 1 c.
FIG. 2 d is a front side view of the tower interface assembly being carried by the platform, as shown in FIGS. 1 a , 1 b and 1 c.
FIG. 2 e is a side view of the tower interface assembly being carried by the platform, as shown in FIGS. 1 a , 1 b and 1 c.
FIG. 2 f is a front perspective view of the tower interface assembly of FIGS. 1 a , 1 b and 1 c.
FIG. 3 a is a close-up rear perspective view of the opposed tower brackets of FIG. 1 f rotatably mounted to the tower interface assembly of the drilling machine of FIG. 1 a with a pivot pin actuator and angle pin actuator, wherein the tower is in the raised condition.
FIG. 3 b is a close-up rear side view of the pivot pin actuator and angle pin actuator of FIG. 3 a.
FIG. 4 a is a sectional front view, taken along a cut-line 4 a - 4 a of FIG. 3 a , of the opposed tower brackets and tower interface assembly.
FIG. 4 b is a perspective view of the pivot pin actuator of FIGS. 3 a and 3 b.
FIG. 4 c is an exploded perspective view of a pivot pin of the pivot pin actuator of FIGS. 3 a and 3 b , and a pivot pin insert and pivot pin bushing of the tower.
FIGS. 4 d and 4 e are perspective and side views, respectively, of the pivot pin of the pivot pin actuator of FIGS. 3 a and 3 b , and the pivot pin insert and pivot pin bushing of the tower.
FIGS. 5 a and 5 b are views of the pivot pin actuator of FIGS. 3 a and 3 b in retracted and extended conditions, respectively.
FIG. 6 a is a sectional front view, taken along a cut-line 6 a - 6 a of FIG. 3 a , of the opposed tower brackets and tower interface assembly.
FIG. 6 b is a perspective view of the angle pin actuator of FIGS. 3 a and 3 b.
FIG. 6 c is an exploded perspective view of an angle pin of the angle pin actuator of FIGS. 3 a and 3 b , and an angle pin insert and angle pin bushing of the tower.
FIGS. 6 d and 6 e are perspective and side views, respectively, of the angle pin of the angle pin actuator of FIGS. 3 a and 3 b , and the angle pin insert and angle pin bushing of the tower.
FIGS. 7 a and 7 b are views of the angle pin actuator of FIGS. 3 a and 3 b in retracted and extended conditions, respectively.
FIGS. 8 a , 8 b , 8 c and 8 d are side views of the opposed angle bracket assemblies of the tower interface assembly.
FIG. 8 e is a perspective view of the tower interface assembly showing planes which extend between opposed angle pin sockets.
FIGS. 9 a and 9 b are perspective views of the tower of FIG. 1 a held at an angle of 0° by the tower interface assembly.
FIGS. 9 c and 9 d are perspective views of the tower of FIG. 1 a held at an angle of 15° by the tower interface assembly.
FIGS. 9 e , 9 f and 9 g are perspective views of the tower of FIG. 1 a held at an angle of 30° by the tower interface assembly.
FIGS. 10 a , 10 b and 10 c are side views of different embodiments of angle bracket arms, which can be included with the tower interface assembly.
FIGS. 11 a , 11 b and 11 c are side, side and perspective views of another embodiment of opposed angle bracket assemblies, which each include the angle bracket arm of FIG. 10 c.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 a is a side view of a drilling machine 100 with a tower 102 rotatably mounted to a tower interface assembly 118 , wherein tower 102 and tower interface assembly 118 are carried by a platform 103 , and tower 102 is in a stowed condition. FIGS. 1 b and 1 c are opposed side views of drilling machine 100 , wherein tower 102 is in a raised condition. FIGS. 1 d and 1 e are close-up front and rear perspective views, respectively, of drilling machine 100 , wherein tower 102 is in the raised condition.
It should be noted that drilling machine 100 can be a stationary or mobile vehicle, but here it is embodied as being a mobile vehicle for illustrative purposes. Some examples of different types of drilling machines are the PV-235, PV-270, PV-271, PV-275 and PV-351 drilling machines, which are manufactured by Atlas Copco Drilling Solutions of Garland, Tex. It should be noted, however, that drilling machines are provided by many other manufacturers.
In this embodiment, drilling machine 100 includes an operator's cab 105 , which is carried by platform 103 . Operator's cab 105 is positioned proximate to a vehicle front 101 a of drilling machine 100 . A front 101 c of platform 103 is positioned proximate to operator's cab 105 , so that operator's cab 105 is positioned between front 101 c of platform 103 and vehicle front 101 a of drilling machine 100 . In this way, operator's cab 105 is positioned proximate to a vehicle front 101 a of drilling machine 100 .
In this embodiment, drilling machine 100 includes a power pack 104 which is carried by platform 103 . Power pack 104 typically includes many different components, such as a prime mover. Platform 103 extends to a vehicle back 101 b , and power pack 104 is positioned between platform front 101 c and vehicle back 101 b . In this way, power pack 104 is positioned proximate to a vehicle back 101 b of drilling machine 100 .
It should be noted that the components of drilling machine 100 are typically operated by an operator in operator's cab 105 . For example, in this embodiment, drilling machine 100 includes a control system (not shown), which is operatively coupled to power pack 104 . The control system includes one or more control inputs which can be adjusted by the operator in operator's cab 105 . In this way, power pack 104 is operated by an operator in operator's cab 105 . Further, the control system includes one or more input controls for controlling the operation of tower 102 , as will be discussed in more detail below.
Tower 102 generally carries a feed cable system (not shown) attached to a rotary head 107 , wherein the feed cable system allows rotary head 107 to move between raised and lowered positions along tower 102 . The feed cable system moves rotary head 107 between the raised and lowered positions by moving it towards a tower crown 102 b and tower base 102 a , respectively.
Rotary head 107 is moved between the raised and lowered positions to raise and lower, respectively, a drill string 108 through a borehole. Further, rotary head 107 is used to rotate drill string 108 , wherein drill string 108 extends through tower 102 . Drill string 108 generally includes one or more drill pipes connected together in a well-known manner. The drill pipes of drill string 108 are capable of being attached to an earth bit, such as a tri-cone rotary earth bit. It should be noted that the operation of the rotary head and feed cable system is typically controlled by the operator in operator's cab 105 .
In this embodiment, tower interface assembly 118 rotatably mounts tower 102 to platform 103 . In particular, tower base 102 a is rotatably mounted to tower interface assembly 118 . In this way, tower 102 is rotatably mounted to platform 103 through tower interface assembly 118 . Tower interface assembly 118 is positioned proximate to platform front 101 c . In particular, tower interface assembly 118 is positioned between platform front 101 c and power pack 104 .
In this embodiment, tower interface assembly 118 operatively couples platform 103 and tower 102 together. Tower 102 and platform 103 are operatively coupled together so that tower 102 can rotate relative to platform 103 . In this way, tower interface assembly 118 provides an interface between tower 102 and platform 103 .
Tower interface assembly 118 allows tower 102 to be repeatably moved between raised and lowered positions. In the lowered position, which is shown in FIG. 1 a , tower crown 102 b is towards platform 103 , and a back 106 a of tower 102 is towards platform 103 and prime mover 104 . In the lowered position, tower 102 extends parallel to a reference line 111 , which extends parallel to platform 103 . It should also be noted that tower 102 is in a stowed condition when it is in the lowered position of FIG. 1 a . Further, tower 102 is in a deployed condition when it is not in the lowered position of FIG. 1 a.
In the raised position, which is shown in FIGS. 1 b and 1 c , a tower crown 102 b of tower 102 is away from platform 103 . In the raised position, a front 106 b of tower 102 faces operator's cab 105 and back 106 a of tower 102 faces prime mover 104 . In the raised position, tower 102 extends parallel to a reference line 110 , which extends perpendicular to platform 103 and reference line 111 .
Tower interface assembly 118 allows tower 102 to be held at a desired predetermined angle relative to platform 103 . Tower interface assembly 118 allows tower 102 to be held at the desired predetermined angle relative to platform 103 so that drilling machine 100 can be used for angled drilling. As will be discussed in more detail below, tower interface assembly 118 allows better control of the angle that tower 102 is tilted, and provides more stability to tower 102 when tower 102 is in a tilted condition.
It should be noted that tower 102 is in the tilted condition when it is positioned between the raised and lowered positions of FIGS. 1 a and 1 b , respectively, as indicated by a reference line 112 . Reference line 112 extends at a non-zero angle θ relative to reference line 110 . Reference line 112 extends parallel to tower 102 when tower 102 is rotatably mounted to tower interface assembly 118 . Hence, reference line 112 is parallel to reference line 110 when tower 102 is in the raised position.
In this embodiment, drilling machine 100 includes tower actuators 117 a and 117 b , as shown in FIGS. 1 b and 1 c . Tower actuators 117 a and 117 b are operatively coupled between platform 103 and tower brackets 116 a and 116 b , respectively, of tower 102 . Tower brackets 116 a and 116 b are shown in a perspective view in FIG. 1 f , and can also be seen in FIGS. 1 a , 1 b , 1 c , 1 d and 1 e.
In this embodiment, tower bracket 116 a includes tower bracket lower opening 190 a , tower bracket intermediate opening 191 a and tower bracket upper opening 192 a . Tower actuator 117 a extends between platform 103 and tower bracket upper opening 192 a . It should be noted that tower bracket intermediate opening 191 a is positioned between tower bracket lower opening 190 a and tower bracket upper opening 192 a.
In this embodiment, tower bracket 116 b includes tower bracket lower opening 190 b , tower bracket intermediate opening 191 b and tower bracket upper opening 192 b . Tower actuator 117 b extends between platform 103 and tower bracket upper opening 192 b . It should be noted that tower bracket intermediate opening 191 b is positioned between tower bracket lower opening 190 b and tower bracket upper opening 192 b.
Tower actuators 117 a and 117 b can be of many different types of actuators, such as hydraulic cylinders capable of being repeatably moved between extended and retracted positions. When tower actuators 117 a and 117 b are in the retracted position, tower 102 is in the lowered position, as shown in FIG. 1 a . Further, when actuators 117 a and 117 b are in extended positions, tower 102 is in the raised position, as shown in FIGS. 1 b and 1 c . In this way, tower 102 is repeatably moveable between lowered and raised positions. It should be noted that the operation of tower actuators 117 a and 117 b is controlled by the operator in operator's cab 105 . In this way, the movement of tower 102 between the raised and lowered conditions is controlled by the operator in operator's cab 105 .
FIG. 2 a is a rear perspective view of tower interface assembly 118 being carried by platform 103 . FIGS. 2 b and 2 c are close-up rear and front perspective views, respectively, of tower interface assembly 118 being carried by platform 103 . FIG. 2 d is a front side view of tower interface assembly 118 being carried by platform 103 . FIG. 2 e is a side view of the tower interface assembly 118 being carried by the platform 103 , and FIG. 2 f is a front perspective view of tower interface assembly 118 .
In this embodiment, platform 103 includes longitudinal platform beams 180 a and 180 b . Longitudinal platform beams 180 a and 180 b are longitudinal beams because they extend longitudinally between platform front 103 a and vehicle back 101 b . Longitudinal platform beams 180 a and 180 b provide support for the components of drilling machine 100 , such as power pack 104 and a tower support cradle 109 . Tower support cradle 109 is positioned proximate to vehicle back 101 b , and holds tower 102 when tower 102 is in the stowed condition. Longitudinal platform beams 180 a and 180 b can be of many different types of beams, such as I beams.
In this embodiment, platform 103 includes forward platform cross beam 181 a and intermediate platform cross beam 181 b which extend between opposed longitudinal platform beams 180 a and 180 b . Forward platform cross beam 181 a and intermediate platform cross beam 181 b are cross beams because they extend transversely to longitudinal platform beams 180 a and 180 b . Forward platform cross beam 181 a is a forward cross beam because it is positioned proximate to front 101 c of platform 103 . Intermediate platform cross beam 181 b is an intermediate cross beam because it is positioned between forward platform cross beam 181 a and vehicle back 101 b . Further, intermediate platform cross beam 181 b is an intermediate cross beam because forward platform cross beam 181 a is positioned between front 101 c of platform 103 and intermediate platform cross beam 181 b.
As mentioned above, tower interface assembly 118 is positioned proximate to platform front 101 c , and between platform front 101 c and power pack 104 . In this embodiment, tower interface assembly 118 is positioned proximate to forward platform cross beam 181 a and intermediate platform cross beam 181 b . In particular, tower interface assembly 118 is carried by forward platform cross beam 181 a and intermediate platform cross beam 181 b , as shown in FIGS. 2 a , 2 b , 2 c , 2 d and 2 e.
In this embodiment, tower interface assembly 118 includes a tower support assembly 119 ( FIG. 2 f ). Tower support assembly 119 is capable of holding tower 102 at the desired predetermined angle relative to platform 103 , as will be discussed in more detail below. In this embodiment, tower support assembly 119 includes opposed angle bracket assemblies 120 a and 120 b . Angle bracket assembly 120 a includes an angle bracket 121 a coupled to forward platform cross beam 181 a , and an angle bracket arm 135 a . Angle bracket 121 a extends upwardly towards vehicle front 101 c and is coupled to angle bracket arm 135 a . As will be discussed in more detail below, angle bracket arm 135 a includes a plurality of angle pin sockets 125 a which extend therethrough. The angle pin sockets of angle bracket arm 135 a are positioned and spaced apart from each other so that tower 102 is held at the desired predetermined angle relative to platform 103 .
In this embodiment, angle bracket assembly 120 a includes an angle bracket support leg 122 a which includes an angle bracket support leg base 124 a . Angle bracket support leg base 124 a includes a pivot pin socket 133 a , which allows tower 102 to rotate relative to platform 102 , as will be discussed in more detail below. Angle bracket support leg 122 a is coupled to angle bracket arm 135 a , and angle bracket support leg base 124 a is coupled to forward platform cross beam 181 a . Angle bracket 121 a and angle bracket support leg 122 a hold angle bracket arm 135 a above longitudinal platform beam 180 a.
In this embodiment, angle bracket assembly 120 b includes an angle bracket 121 b coupled to forward platform cross beam 181 b , and an angle bracket arm 135 b . Angle bracket 121 b extends upwardly towards vehicle front 101 c and is coupled to an angle bracket arm 135 b . As will be discussed in more detail below, angle bracket arm 135 b includes a plurality of angle pin sockets 125 b which extend therethrough. The angle pin sockets of angle bracket arm 135 b are positioned and spaced apart from each other so that tower 102 is held at the desired predetermined angle relative to platform 103 .
In this embodiment, angle bracket assembly 120 b includes an angle bracket support leg 122 b which includes an angle bracket support leg base 124 b . Angle bracket support leg base 124 b includes a pivot pin socket 133 b , which allows tower 102 to rotate relative to platform 102 , as will be discussed in more detail below. Angle bracket support leg 122 b is coupled to angle bracket arm 135 b , and angle bracket support leg base 124 b is coupled to forward platform cross beam 181 b . Angle bracket 121 b and angle bracket support leg 122 b hold angle bracket arm 135 b above longitudinal platform beam 180 b.
In this embodiment, angle brackets 121 a and 121 b are positioned so they oppose each other. In this way, tower support assembly 119 includes opposed angle brackets. Further, angle bracket support legs 122 a and 122 b are positioned so they oppose each other. In this way, tower support assembly 119 includes opposed angle bracket support legs. Angle bracket support leg bases 124 a and 124 b are positioned so they oppose each other. In this way, tower support assembly 119 includes opposed angle bracket support leg bases. In this embodiment, angle bracket arm 135 a and angle bracket arm 135 b oppose each other. In this way, tower support assembly 119 includes opposed angle bracket arms. In this embodiment, angle pin sockets 125 a and angle pin sockets 125 b are positioned so they oppose each other. In this way, tower support assembly 119 includes opposed angle pin sockets.
It should be noted that, in some embodiments, angle bracket assembly 120 a is a single integral piece, and angle bracket assembly 120 b is a single integral piece. However, opposed angle bracket assemblies 120 a and 120 b are shown here as each including multiple pieces coupled together for illustrative purposes.
In some embodiments, tower interface assembly 118 includes components which provide support to tower support assembly 119 . The components which provide support to tower support assembly 119 provide more stability to tower 102 when tower 102 is in a tilted condition.
In this embodiment, tower interface assembly 118 includes an angle bracket support arm 123 a which provides support to angle bracket assembly 120 a . Angle bracket support arm 123 a is coupled at one end to longitudinal platform beam 180 a through a support arm bracket 139 a ( FIG. 2 f ). Further, angle bracket support arm 123 a is coupled at an opposed end to angle bracket arm 135 a through a support arm bracket 138 a . Angle bracket support arm 123 a restricts the ability of angle bracket arm 135 a to move towards and away from angle bracket assembly 120 b.
In this embodiment, tower interface assembly 118 includes an angle bracket support arm 123 b which provides support to angle bracket assembly 120 b . Angle bracket support arm 123 b is coupled at one end to longitudinal platform beam 180 b through a support arm bracket 139 b ( FIG. 2 f ). Further, angle bracket support arm 123 b is coupled at an opposed end to angle bracket arm 135 b through a support arm bracket 138 b . Angle bracket support arm 123 b restricts the ability of angle bracket arm 135 b to move towards and away from angle bracket assembly 120 a.
In this embodiment, tower interface assembly 118 includes an angle bracket cross beam 136 which is coupled to angle bracket leg 121 a and angle bracket leg 121 b . Angle bracket cross beam 136 restricts the ability of angle bracket leg 121 a and angle bracket leg 121 b to move towards and away from each other.
In this embodiment, tower interface assembly 118 includes a longitudinal angle bracket beam 144 a which is coupled to angle bracket leg 121 a and angle bracket support leg 122 a . Longitudinal angle bracket beam 144 a restricts the ability of angle bracket leg 121 a and angle bracket support leg 122 a to move towards and away from each other.
In this embodiment, tower interface assembly 118 includes a longitudinal angle bracket beam 144 b which is coupled to angle bracket leg 121 b and angle bracket support leg 122 b . Longitudinal angle bracket beam 144 b restricts the ability of angle bracket leg 121 b and angle bracket support leg 122 b to move towards and away from each other.
In this embodiment, tower interface assembly 118 includes an angle bracket cross diagonal beam 137 a which is coupled to angle bracket leg 121 a and angle bracket support leg base 124 b , as shown in FIGS. 2 d and 2 f . Angle bracket cross diagonal beam 137 a restricts the ability of angle bracket assembly 120 a and angle bracket assembly 120 b to move towards and away from each other.
In this embodiment, tower interface assembly 118 includes an angle bracket cross diagonal beam 137 b which is coupled to angle bracket leg 121 b and angle bracket support leg base 124 a , as shown in FIGS. 2 d and 2 f . Angle bracket cross diagonal beam 137 b restricts the ability of angle bracket assembly 120 a and angle bracket assembly 120 b to move towards and away from each other.
FIG. 3 a is a close-up rear perspective view of opposed tower brackets 116 a and 116 b rotatably mounted to tower interface assembly 118 with a pivot pin actuator 150 and angle pin actuator 140 , wherein tower 102 is in the raised condition. FIG. 3 b is a close-up rear side view of pivot pin actuator 150 and angle pin actuator 140 .
Pivot pin actuator 150 is positioned below angle pin actuator 140 , and proximate to forward platform cross beam 181 a , as shown in FIGS. 3 a and 3 b . Pivot pin actuator 150 extends between angle bracket assemblies 120 a and 120 b . In particular, pivot pin actuator 150 is positioned below angle pin actuator 140 so it extends between angle bracket support leg bases 124 a and 124 b and pivot pin sockets 133 a and 133 b ( FIG. 2 f ).
In this embodiment, pivot pin actuator 150 is carried by tower brackets 116 a and 116 b ( FIG. 1 f ). In particular, pivot pin actuator 150 is carried by tower brackets 116 a and 116 b so it extends between tower bracket lower openings 190 a and 190 b . As will be discussed in more detail below, pivot pin actuator 150 allows tower 102 to be coupled to tower interface assembly 118 so it can rotate relative to platform 103 and move between the raised and lowered positions.
Pivot pin actuator 150 is repeatably moveable between extended and retracted conditions. In the extended condition, and as discussed in more detail below, pivot pin actuator 150 extends through pivot pin sockets 133 a and 133 b ( FIG. 2 f ) and tower bracket lower openings 190 a and 190 b ( FIG. 1 f ). Pivot pin actuator 150 extends through pivot pin sockets 133 a and 133 b in the extended condition so that tower 102 can rotate relative to tower interface assembly 118 . In this embodiment, movement of pivot pin actuator 150 between the extended and retracted conditions is controlled by the operator in operator's cab 105 .
In the retracted condition, and as discussed in more detail below, pivot pin actuator 150 does not extend through pivot pin sockets 133 a and 133 b ( FIG. 2 f ). Pivot pin actuator 150 does not extend through pivot pin sockets 133 a and 133 b in the retracted condition so that tower 102 can be moved relative to tower interface assembly 118 .
In this embodiment, angle pin actuator 140 is positioned above pivot pin actuator 150 , and away from forward platform cross beam 181 a , as shown in FIGS. 3 a and 3 b . Angle pin actuator 140 extends between angle bracket assemblies 120 a and 120 b . In particular, angle pin actuator 140 is positioned above pivot pin actuator 150 so it extends between angle bracket arms 135 a and 135 b and angle pin sockets 125 a and 125 b.
In this embodiment, angle pin actuator 140 is carried by tower brackets 116 a and 116 b ( FIG. 1 f ). In particular, angle pin actuator 140 is carried by tower brackets 116 a and 116 b so it extends between tower bracket intermediate openings 191 a and 191 b . As will be discussed in more detail below, angle pin actuator 140 allows tower 102 to be coupled to tower interface assembly 118 so tower 102 can be held at the desired predetermined angle relative to platform 103 . Tower interface assembly 118 and angle pin actuator 140 allow tower 102 to be held at the desired predetermined angle relative to platform 103 so that drilling machine 100 can be used for angled drilling.
Angle pin actuator 140 is repeatably moveable between extended and retracted conditions. In the extended condition, and as discussed in more detail below, angle pin actuator 140 extends through a selected one of angle pin sockets 125 a ( FIG. 2 f ) and tower bracket intermediate opening 190 a ( FIG. 1 f ). Further, in the extended condition, angle pin actuator 140 extends through a selected one of angle pin sockets 125 b ( FIG. 2 f ) and tower bracket intermediate opening 191 b ( FIG. 1 f ). It should be noted that, in the extended condition, angle pin actuator 140 extends through opposed sockets of angle pin sockets 125 a and 125 b . Angle pin actuator 140 extends through angle pin sockets 125 a and 125 b in the extended condition so that tower 102 is held at the desired predetermined angle relative to platform 103 .
In the retracted condition, and as discussed in more detail below, angle pin actuator 140 does not extend through angle pin socket 125 a ( FIG. 2 f ). Further, in the retracted condition, angle pin actuator 140 does not extend through angle pin socket 125 b ( FIG. 2 f ). Angle pin actuator 140 does not extend through angle pin sockets 125 a and 125 b in the retracted condition so that tower 102 can be rotated and moved relative to tower interface assembly 118 . In this embodiment, movement of angle pin actuator 140 between the extended and retracted conditions is controlled by the operator in operator's cab 105 .
FIG. 4 a is a sectional front view, taken along a cut-line 4 a - 4 a of FIG. 3 a , of opposed tower brackets 116 a and 116 b and tower interface assembly 118 in a region 113 of FIG. 3 b . In this embodiment, mounting blocks 156 a and 156 b are mounted to opposed tower brackets 116 a and 116 b , respectively. Mounting block 156 a includes a mounting block opening 157 a which is aligned with tower bracket lower opening 190 a . Further, mounting block 156 b includes a mounting block opening 157 b which is aligned with tower bracket lower opening 190 b . Mounting blocks 156 a and 156 b are for holding pivot pin actuator 150 to opposed tower brackets 116 a and 116 b . As will be discussed in more detail below, pivot pin actuator 150 extends through mounting block openings 157 a and 157 b . In this way, pivot pin actuator 150 extends between opposed tower brackets 116 a and 116 b.
In this embodiment, a pivot pin insert 172 a extends through pivot pin socket 133 a of angle bracket support leg base 124 a , and a pivot pin insert 172 b extends through pivot pin socket 133 b of angle bracket support leg base 124 b . A pivot pin bushing 171 a extends through tower bracket lower opening 190 a of tower bracket 116 a and mounting block openings 157 a of mounting block 156 a . Further, a pivot pin bushing 171 b extends through tower bracket lower opening 190 b of tower bracket 116 b and mounting block openings 157 b of mounting block 156 b . Pivot pin insert 172 a , pivot pin insert 172 b , pivot pin bushing 171 a and pivot pin bushing 171 b each include central openings through which pivot pin actuator 150 moves in response to moving between the extended and retracted positions, as will be discussed below.
Mounting block openings 157 a and 157 b are repeatably moveable between aligned and unaligned positions with pivot pin sockets 133 a and 133 b , respectively. Mounting block openings 157 a and 157 b are repeatably moveable between aligned and unaligned positions with pivot pin sockets 133 a and 133 b , respectively, in response to moving tower 102 between the raised and lowered positions.
Mounting block openings 157 a and 157 b are aligned with pivot pin sockets 133 a and 133 b , respectively, when tower 102 is rotatably mounted to tower interface assembly 118 . Mounting block openings 157 a and 157 b are unaligned with pivot pin sockets 133 a and 133 b , respectively, when tower 102 is not rotatably mounted to tower interface assembly 118 . In particular, mounting block openings 157 a and 157 b are unaligned with pivot pin sockets 133 a and 133 b , respectively, when tower 102 is in the stowed condition of FIG. 1 a . It should be noted that mounting block openings 157 a and 157 b are aligned with pivot pin sockets 133 a and 133 b , respectively, in FIG. 4 a.
Tower bracket lower openings 190 a and 190 b are repeatably moveable between aligned and unaligned positions with pivot pin sockets 133 a and 133 b , respectively. Tower bracket lower openings 190 a and 190 b are repeatably moveable between aligned and unaligned positions with pivot pin sockets 133 a and 133 b , respectively, in response to moving tower 102 between the raised and lowered positions.
Tower bracket lower openings 190 a and 190 b are aligned with pivot pin sockets 133 a and 133 b , respectively, when tower 102 is rotatably mounted to tower interface assembly 118 . Tower bracket lower openings 190 a and 190 b are unaligned with pivot pin sockets 133 a and 133 b , respectively, when tower 102 is not rotatably mounted to tower interface assembly 118 . In particular, tower bracket lower openings 190 a and 190 b are unaligned with pivot pin sockets 133 a and 133 b , respectively, when tower 102 is in the stowed condition of FIG. 1 a . It should be noted that tower bracket lower openings 190 a and 190 b are aligned with pivot pin sockets 133 a and 133 b , respectively, in FIG. 4 a.
FIG. 4 b is a perspective view of one embodiment of pivot pin actuator 150 . In this embodiment, pivot pin actuator 150 includes a pivot pin cylinder 152 , which is repeatably moveable between extended and retracted conditions. The movement of pivot pin cylinder 152 between the extended and retracted conditions is controlled by the operator in operator's cab 105 . In this embodiment, pivot pin actuator 150 includes pivot pins 151 a and 151 b . Pivot pins 151 a and 151 b move away from and towards each other in response to moving pivot pin cylinder 152 between the extended and retracted conditions, respectively. In this way, pivot pin actuator 150 is repeatably moveable between extended and retracted conditions.
In this embodiment, pivot pins 151 a and 151 b are tapered pivot pins. More information regarding tapered pivot pins is provided in the above-identified related application. Tapered pivot pins are useful because they increase the likelihood that pivot pin actuator 150 will move from the retracted position to the extended position. For example, tapered pivot pins are useful because they increase the likelihood that pivot pin actuator 150 will move from the retracted position to the extended position in response to misalignment of pivot pin socket 133 a and tower bracket lower opening 190 a , and misalignment of pivot pin socket 133 b and tower bracket lower opening 190 b.
FIG. 4 c is an exploded perspective view of pivot pins 151 a and 151 b , and pivot pin inserts 172 a and 172 b and pivot pin bushings 171 a and 171 b . FIGS. 4 d and 4 e are perspective and side views, respectively, of pivot pins 151 a and 151 b , and pivot pin inserts 172 a and 172 b and pivot pin bushings 171 a and 171 b.
It should be noted that, in the retracted condition, pivot pins 151 a and 151 b extend through pivot pin bushings 171 a and 171 b , respectively. Further, in the retracted condition, pivot pins 151 a and 151 b do not extend through pivot pin inserts 172 a and 172 b , respectively. In the retracted condition, pivot pins 151 a and 151 b do not extend through pivot pin inserts 172 a and 172 b , respectively, so that tower 102 can be moved between the raised and lowered positions.
In the extended condition, pivot pin 151 a extends through pivot pin bushing 171 a and pivot pin insert 172 a , and pivot pin 151 b extends through pivot pin bushing 171 b and pivot pin insert 172 b . In the extended condition, pivot pin 151 a extends through pivot pin bushing 171 a and pivot pin insert 172 a , and pivot pin 151 b extends through pivot pin bushing 171 b and pivot pin insert 172 b so that tower 102 is rotatably mounted to tower interface assembly 118 .
FIGS. 5 a and 5 b are views of pivot pin actuator 150 in retracted and extended conditions, respectively. It should be noted that the view of FIGS. 5 a and 5 b correspond with the view of FIG. 4 a . In the retracted condition, pivot pin actuator 150 extends between pivot pin mounting blocks 156 a and 156 b , and extends through pivot pin mounting block openings 157 a and 157 b . In particular, pivot pins 151 a and 151 b extend through pivot pin mounting block openings 157 a and 157 b , respectively.
Further, in the retracted condition, pivot pin actuator 150 extends between tower brackets 116 a and 116 b , and extends through tower bracket lower openings 190 a and 190 b . In particular, pivot pins 151 a and 151 b extend through tower bracket lower openings 190 a and 190 b , respectively.
In the retracted condition, pivot pin actuator 150 does not extend through angle bracket support leg base 124 a and 124 b . In particular, pivot pins 151 a and 151 b do not extend through pivot pin sockets 133 a and 133 b , respectively. In the retracted condition, pivot pin actuator 150 does not extend through pivot pin sockets 133 a and 133 b so that tower 102 can be moved between the raised and lowered positions. It should be noted that tower 102 is not rotatably mounted to tower interface assembly 118 when pivot pin actuator 150 does not extend through pivot pin sockets 133 a and 133 b.
In the extended condition, pivot pin actuator 150 extends between pivot pin mounting blocks 156 a and 156 b , and extends through pivot pin mounting block openings 157 a and 157 b . In particular, pivot pins 151 a and 151 b extend through pivot pin mounting block openings 157 a and 157 b , respectively.
Further, in the extended condition, pivot pin actuator 150 extends between tower brackets 116 a and 116 b , and extends through tower bracket lower openings 190 a and 190 b . In particular, pivot pins 151 a and 151 b extend through tower bracket lower openings 190 a and 190 b , respectively.
In the extended condition, pivot pin actuator 150 extends through angle bracket support leg base 124 a and 124 b . In particular, pivot pins 151 a and 151 b extend through pivot pin sockets 133 a and 133 b , respectively. In the extended condition, pivot pin actuator 150 extends through pivot pin sockets 133 a and 133 b so that tower 102 is restricted from moving between the raised and lowered positions. It should be noted that tower 102 is rotatably mounted to tower interface assembly 118 when pivot pin actuator 150 extends through pivot pin sockets 133 a and 133 b . It should also be noted that tower 102 is moveable to a tilted condition when pivot pin actuator 150 extends through pivot pin sockets 133 a and 133 b , as will be discussed in more detail below.
As mentioned above, pivot pin actuator 150 is repeatably moveable between the extended and retracted conditions. Pivot pin 151 a moves away from angle bracket support leg base 124 a and pivot pin socket 133 a in response to pivot pin actuator 150 moving to the retracted condition. Further, pivot pin 151 b moves away from angle bracket support leg base 124 b and pivot pin socket 133 b in response to pivot pin actuator 150 moving to the retracted condition. Pivot pin 151 a moves towards angle bracket support leg base 124 a and pivot pin socket 133 a in response to pivot pin actuator 150 moving to the extended condition. Further, pivot pin 151 b moves towards angle bracket support leg base 124 b and pivot pin socket 133 b in response to pivot pin actuator 150 moving to the extended condition. Hence, pivot pins 151 a and 151 b are repeatably moveable towards and away from angle bracket support leg bases 124 a and 124 b in response to moving pivot pin actuator 150 between extended and retracted conditions, respectively. Further, pivot pins 151 a and 151 b are repeatably moveable towards and away from pivot pin sockets 133 b and 133 b in response to moving pivot pin actuator 150 between extended and retracted conditions, respectively.
FIG. 6 a is a sectional front view, taken along a cut-line 6 a - 6 a of FIG. 3 a , of opposed tower brackets 116 a and 116 b and tower interface assembly 118 in a region 114 of FIG. 3 b . In this embodiment, mounting blocks 146 a and 146 b are mounted to opposed tower brackets 116 a and 116 b , respectively. Mounting block 146 a includes a mounting block opening 147 a which is aligned with tower bracket intermediate opening 191 a . Further, mounting block 146 b includes a mounting block opening 147 b which is aligned with tower bracket intermediate opening 191 b . Mounting blocks 146 a and 146 b are for holding angle pin actuator 140 to opposed tower brackets 116 a and 116 b . As will be discussed in more detail below, angle pin actuator 140 extends through mounting block openings 147 a and 147 b . In this way, angle pin actuator 140 extends between opposed tower brackets 116 a and 116 b.
In this embodiment, an angle pin insert 162 a extends through an angle pin socket 126 a of angle bracket arm 135 a , and an angle pin insert 162 b extends through angle pin socket 126 b of angle bracket arm 135 b . An angle pin bushing 161 a extends through tower bracket intermediate opening 191 a of tower bracket 116 a and mounting block openings 147 a of mounting block 146 a . Further, an angle pin bushing 161 b extends through tower bracket intermediate opening 191 b of tower bracket 116 b and mounting block openings 147 b of mounting block 147 b . Angle pin insert 162 a , angle pin insert 162 b , angle pin bushing 161 a and angle pin bushing 161 b each include central openings through which angle pin actuator 140 moves in response to moving between the extended and retracted positions, as will be discussed below.
Mounting block openings 147 a and 147 b are repeatably moveable between aligned and unaligned positions with angle pin sockets 126 a and 126 b , respectively. Mounting block openings 147 a and 147 b are repeatably moveable between aligned and unaligned positions with angle pin sockets 126 a and 126 b , respectively, in response to moving tower 102 between the raised and tilted positions. More information regarding moving tower 102 between the raised and tilted positions is provided below.
Mounting block openings 147 a and 147 b are aligned with angle pin sockets 126 a and 126 b , respectively, when tower 102 is rotatably mounted to tower interface assembly 118 and in the raised position of FIGS. 1 a and 1 b . Mounting block openings 147 a and 147 b are unaligned with angle pin sockets 126 a and 126 b , respectively, when tower 102 is rotatably mounted to tower interface assembly 118 and not in the upright position of FIGS. 1 a and 1 b . In particular, mounting block openings 147 a and 147 b are unaligned with angle pin sockets 126 a and 126 b , respectively, when tower 102 is in a tilted position. It should be noted that mounting block openings 147 a and 147 b are aligned with angle pin sockets 126 a and 126 b , respectively, in FIG. 6 a.
Tower bracket intermediate openings 191 a and 191 b are repeatably moveable between aligned and unaligned positions with angle pin sockets 126 a and 126 b , respectively. Tower bracket intermediate openings 191 a and 191 b are repeatably moveable between aligned and unaligned positions with angle pin sockets 126 a and 126 b , respectively, in response to moving tower 102 between the raised and tilted positions.
Tower bracket intermediate openings 191 a and 191 b are aligned with angle pin sockets 126 a and 126 b , respectively, when tower 102 is rotatably mounted to tower interface assembly 118 and tower 102 is in the raised position. Tower bracket intermediate openings 191 a and 191 b are unaligned with angle pin sockets 126 a and 126 b , respectively, when tower 102 is rotatably mounted to tower interface assembly 118 and not in the raised position. It should be noted that tower bracket intermediate openings 191 a and 191 b are aligned with angle pin sockets 126 a and 126 b , respectively, in FIG. 6 a.
FIG. 6 b is a perspective view of one embodiment of angle pin actuator 140 . In this embodiment, angle pin actuator 140 includes an angle pin cylinder 142 , which is repeatably moveable between extended and retracted conditions. The movement of angle pin cylinder 142 between the extended and retracted conditions is controlled by the operator in operator's cab 105 . In this embodiment, angle pin actuator 140 includes angle pins 141 a and 141 b . Angle pins 141 a and 141 b move away from and towards each other in response to moving angle pin cylinder 142 between the extended and retracted conditions, respectively. In this way, angle pin actuator 140 is repeatably moveable between extended and retracted conditions.
In this embodiment, angle pins 141 a and 141 b are tapered angle pins. More information regarding tapered angle pins is provided in the above-identified related application. Tapered angle pins are useful because they increase the likelihood that angle pin actuator 140 will move from the retracted position to the extended position. For example, tapered angle pins are useful because they increase the likelihood that angle pin actuator 140 will move from the retracted position to the extended position in response to misalignment of angle pin sockets 125 a and tower bracket intermediate opening 191 a , and misalignment of angle pin sockets 125 b and tower bracket intermediate opening 191 b.
FIG. 6 c is an exploded perspective view of angle pins 141 a and 141 b , and angle pin inserts 162 a and 162 b and angle pin bushings 161 a and 161 b . FIGS. 6 d and 6 e are perspective and side views, respectively, of angle pins 141 a and 141 b , and angle pin inserts 162 a and 162 b and angle pin bushings 161 a and 161 b.
It should be noted that, in the retracted condition, angle pins 141 a and 141 b extend through angle pin bushings 161 a and 161 b , respectively. Further, in the retracted condition, angle pins 161 a and 161 b do not extend through angle pin inserts 162 a and 162 b , respectively. In some situations, in the retracted condition, angle pins 161 a and 161 b do not extend through angle pin inserts 162 a and 162 b , respectively, so that tower 102 can be moved between the raised and lowered positions. In other situations, in the retracted condition, angle pins 161 a and 161 b do not extend through angle pin inserts 162 a and 162 b , respectively, so that tower 102 can be moved between tilted positions.
In the extended condition, angle pin 141 a extends through angle pin bushing 161 a and angle pin insert 162 a , and angle pin 161 b extends through angle pin bushing 161 b and angle pin insert 162 b . In the extended condition, angle pin 141 a extends through angle pin bushing 161 a and angle pin insert 162 a , and angle pin 141 b extends through angle pin bushing 161 b and angle pin insert 162 b so that tower 102 is held in the upright position.
FIGS. 7 a and 7 b are views of angle pin actuator 140 in retracted and extended conditions, respectively. It should be noted that the view of FIGS. 7 a and 7 b correspond with the view of FIG. 6 a . In the retracted condition, angle pin actuator 140 extends between angle pin mounting blocks 146 a and 146 b , and extends through angle pin mounting block openings 147 a and 147 b . In particular, angle pins 141 a and 141 b extend through angle pin mounting block openings 147 a and 147 b , respectively.
Further, in the retracted condition, angle pin actuator 140 extends between tower brackets 116 a and 116 b , and extends through tower bracket intermediate openings 191 a and 191 b . In particular, angle pins 141 a and 141 b extend through tower bracket intermediate openings 191 a and 191 b , respectively.
In the retracted condition, angle pin actuator 140 does not extend through angle bracket arms 135 a and 135 b . In particular, angle pins 141 a and 141 b do not extend through angle pin sockets 126 a and 126 b , respectively. It should be noted that pivot pins 151 a and 151 b do not extend through pivot pin sockets 133 a and 133 b , respectively, in the situations in which it is desirable to move tower 102 between the raised and lowered positions. However, angle pin actuator 140 does extend through angle pin sockets 126 a and 126 b so that tower 102 can be moved between the raised and lowered positions. Hence, tower 102 is rotatably mounted to tower interface assembly 118 through angle pin actuator 140 when tower 102 is moved to and from the stowed condition. In particular, tower 102 is rotatably mounted to tower interface assembly 118 through angle pins 141 a and 141 b when tower 102 is moved to and from the stowed condition ( FIG. 1 a ). In this embodiment, angle pins 141 a and 141 b extend through angle pin sockets 126 a and 126 b , respectively, when tower 102 is moved to and from the stowed condition.
In other situations, in the retracted condition, angle pin actuator 140 does not extend through angle pin sockets 126 a and 126 b so that tower 102 can be moved between tilted positions. It should be noted that pivot pins 151 a and 151 b extend through pivot pin sockets 133 a and 133 b , respectively, in the situations in which it is desirable to move tower 102 between tilted positions.
In the extended condition, angle pin actuator 140 extends between angle pin mounting blocks 146 a and 146 b , and extends through angle pin mounting block openings 147 a and 147 b . In particular, angle pins 141 a and 141 b extend through angle pin mounting block openings 147 a and 147 b , respectively.
Further, in the extended condition, angle pin actuator 140 extends between tower brackets 116 a and 116 b , and extends through tower bracket intermediate openings 191 a and 191 b . In particular, angle pins 141 a and 141 b extend through tower bracket intermediate openings 191 a and 191 b , respectively.
In the extended condition, angle pin actuator 140 extends through angle bracket arms 135 a and 135 b . In particular, angle pins 141 a and 141 b extend through angle pin sockets 126 a and 126 b , respectively. In the extended condition, angle pin actuator 140 extends through angle pin sockets 126 a and 126 b so that tower 102 is held in the upright position.
As mentioned above, angle pin actuator 140 is repeatably moveable between the extended and retracted conditions. Angle pin 141 a moves away from angle bracket arm 135 a and angle pin socket 126 a in response to angle pin actuator 140 moving to the retracted condition. Further, angle pin 141 b moves away from angle bracket arm 135 b and angle pin socket 126 b in response to angle pin actuator 140 moving to the retracted condition. Angle pin 141 a moves towards angle bracket arm 135 a and angle pin socket 126 a in response to angle pin actuator 140 moving to the extended condition. Further, angle pin 141 b moves towards angle bracket arm 135 b and angle pin socket 126 b in response to angle pin actuator 140 moving to the extended condition. Hence, angle pins 141 a and 141 b are repeatably moveable towards and away from angle bracket arm 135 a and 135 b in response to moving angle pin actuator 140 between extended and retracted conditions, respectively. Further, angle pins 141 a and 141 b are repeatably moveable towards and away from angle pin sockets 126 b and 126 b in response to moving angle pin actuator 140 between extended and retracted conditions, respectively.
FIGS. 8 a and 8 b are side views of angle bracket assembly 120 a , and FIGS. 8 c and 8 d are side views of angle bracket assembly 120 b . In this embodiment, angle pin sockets 125 a include seven angle pin sockets, denoted as angle pin sockets 126 a , 127 a , 128 a , 129 a , 130 a , 131 a , and 132 a . Angle pin sockets 126 a , 127 a , 128 a , 129 a , 130 a , 131 a , and 132 a extend through angle bracket 121 a and along the length of angle bracket 121 a and away from support arm socket 134 a . Further, angle pin sockets 125 b include seven angle pin sockets, denoted as angle pin sockets 126 b , 127 b , 128 b , 129 b , 130 b , 131 b , and 132 b . Angle pin sockets 126 b , 127 b , 128 b , 129 b , 130 b , 131 b , and 132 b extend through angle bracket 121 b and along the length of angle bracket 121 b and away from support arm socket 134 b . In general, the number of angle pin sockets extending through angle brackets 121 a and 121 b is the same.
In this embodiment, angle pin sockets 126 a , 127 a , 128 a , 129 a , 130 a , 131 a , and 132 a are spaced apart from each other so that they are at predetermined positions along angle bracket arm 135 a . The predetermined positions of angle pin sockets 126 a , 127 a , 128 a , 129 a , 130 a , 131 a , and 132 a are chosen so that reference planes extend at predetermined angles through pivot pin socket 133 a and angle pin sockets 126 a , 127 a , 128 a , 129 a , 130 a , 131 a , and 132 a , wherein, in this embodiment, the predetermined angle is relative to reference line 110 . It should be noted that angle pin sockets 126 a , 127 a , 128 a , 129 a , 130 a , 131 a , and 132 a are equidistantly spaced apart from each other in this embodiment. However, the spacing between adjacent angle pin sockets 126 a , 127 a , 128 a , 129 a , 130 a , 131 a , and 132 a can be different, if desired.
In this embodiment, angle pin sockets 126 b , 127 b , 128 b , 129 b , 130 b , 131 b , and 132 b are spaced apart from each other so that they are at predetermined positions along angle bracket arm 135 b . The predetermined positions of angle pin sockets 126 b , 127 b , 128 b , 129 b , 130 b , 131 b , and 132 b are chosen so that reference planes extend at predetermined angles through pivot pin socket 133 b and angle pin sockets 126 b , 127 b , 128 b , 129 b , 130 b , 131 b , and 132 b , wherein, in this embodiment, the predetermined angle is relative to reference line 110 . It should be noted that angle pin sockets 126 b , 127 b , 128 b , 129 b , 130 b , 131 b , and 132 b are equidistantly spaced apart from each other in this embodiment. However, the spacing between adjacent angle pin sockets 126 b , 127 b , 128 b , 129 b , 130 b , 131 b , and 132 b can be different, if desired. Further, it should be noted that angle pin sockets 126 b , 127 b , 128 b , 129 b , 130 b , 131 b , and 132 b oppose angle pin sockets 126 a , 127 a , 128 a , 129 a , 130 a , 131 a , and 132 a , respectively.
FIG. 8 e is a perspective view of tower interface assembly 118 and the reference planes mentioned above. As shown in FIGS. 1 a , 1 b and 1 c , reference line 110 extends between angle pin socket 126 a and pivot pin socket 133 a along the length of angle bracket support leg 122 a . Further, reference line 110 extends between angle pin socket 126 b and pivot pin socket 133 b along the length of angle bracket support leg 122 b.
As shown in FIG. 8 e , a reference plane 200 extends between angle pin sockets 126 a and 126 b and pivot pin sockets 133 a and 133 b at angle θ 0 relative to reference line 110 , wherein angle θ 0 is about 0° in this example. It should be noted that reference plane 200 extends perpendicular to reference line 111 of FIGS. 1 a , 1 b and 1 c . FIGS. 9 a and 9 b are perspective views of tower 102 held at an angle of about 0° by tower interface assembly 118 . It should be noted that, in FIGS. 9 a and 9 b , angle pins 141 a and 141 b extend through angle pin sockets 126 a and 126 b , respectively.
A reference plane 201 extends between angle pin sockets 127 a and 127 b and pivot pin sockets 133 a and 133 b at an angle θ 5 relative to reference line 110 , wherein angle θ 5 is about 5° in this example. A reference plane 202 extends between angle pin sockets 128 a and 128 b and pivot pin sockets 133 a and 133 b at an angle θ 10 relative to reference line 110 , wherein angle θ 10 is about 10° in this example.
A reference plane 203 extends between angle pin sockets 129 a and 129 b and pivot pin sockets 133 a and 133 b at an angle θ 15 relative to reference line 110 , wherein angle θ 15 is about 15° in this example. FIGS. 9 c and 9 d are perspective views of tower 102 held at an angle of about 15° by tower interface assembly 118 . It should be noted that, in FIGS. 9 c and 9 d , angle pins 141 a and 141 b extend through angle pin sockets 129 a and 129 b , respectively.
A reference plane 204 extends between angle pin sockets 130 a and 130 b and pivot pin sockets 133 a and 133 b at an angle θ 20 relative to reference line 110 , wherein angle θ 20 is about 20° in this example. A reference plane 205 extends between angle pin sockets 131 a and 131 b and pivot pin sockets 133 a and 133 b at an angle θ 25 relative to reference line 110 , wherein angle θ 25 is about 25° in this example.
A reference plane 206 extends between angle pin sockets 132 a and 132 b and pivot pin sockets 133 a and 133 b at an angle θ 30 relative to reference line 110 , wherein angle θ 30 is about 30° in this example. FIGS. 9 e , 9 f and 9 g are perspective views of tower 102 held at an angle of about 30° by tower interface assembly 118 . It should be noted that, in FIGS. 9 e , 9 f and 9 g , angle pins 141 a and 141 b extend through angle pin sockets 132 a and 132 b , respectively. In this way, the angle pin sockets that extend through angle bracket arms 135 a and 135 b are spaced apart from each other at positions which correspond to predetermined angles relative to reference line 110 .
It should be noted that angle pin socket 132 a is rearward of angle pin sockets 126 a , 127 a , 128 a , 129 a , 130 a and 131 a because angle θ 30 is greater than angles θ 0 , θ 5 , θ 10 , θ 15 , θ 20 , and θ 25 . Further, angle pin socket 131 a is rearward of angle pin sockets 126 a , 127 a , 128 a , 129 a and 130 a because angle θ 25 is greater than angles θ 0 , θ 5 , θ 10 , θ 15 and θ 20 . Angle pin socket 130 a is rearward of angle pin sockets 126 a , 127 a , 128 a and 129 ab because angle θ 20 is greater than angles θ 0 , θ 5 , θ 10 and θ 15 . Angle pin socket 129 a is rearward of angle pin sockets 126 a , 127 a and 128 a because angle θ 15 is greater than angles θ 0 , θ 5 and θ 10 . Angle pin socket 128 a is rearward of angle pin sockets 126 a and 127 a because angle θ 10 is greater than angles θ 0 and θ 5 . Angle pin socket 127 a is rearward of angle pin socket 126 a because angle θ 5 is greater than angles θ 0 .
It should be noted that angle pin socket 132 b is rearward of angle pin sockets 126 b , 127 b , 128 b , 129 b , 130 b and 131 b because angle θ 30 is greater than angles θ 0 , θ 5 , θ 10 , θ 15 , θ 20 , and θ 25 . Further, angle pin socket 131 b is rearward of angle pin sockets 126 b , 127 b , 128 b , 129 b and 130 b because angle θ 25 is greater than angles θ 0 , θ 5 , θ 10 , θ 15 and θ 20 . Angle pin socket 130 b is rearward of angle pin sockets 126 b , 127 b , 128 b and 129 b because angle θ 20 is greater than angles θ 0 , θ 5 , θ 10 and θ 15 . Angle pin socket 129 b is rearward of angle pin sockets 126 b , 127 b and 128 b because angle θ 15 is greater than angles θ 0 , θ 5 and θ 10 . Angle pin socket 128 b is rearward of angle pin sockets 126 b and 127 b because angle θ 10 is greater than angles θ 0 and θ 5 . Angle pin socket 127 b is rearward of angle pin socket 126 b because angle θ 5 is greater than angles θ 0 .
As mentioned above, reference line 112 ( FIGS. 1 a , 1 b and 1 c and FIGS. 9 c and 9 d ) extends parallel to tower 102 . Hence, tower 102 extends angle θ 0 relative to reference line 110 and reference line 112 extends through reference plane 200 when tower 102 is in the raised position and angle pin actuator 140 extends through angle pin sockets 126 a and 126 b . In particular, tower 102 extends at angle θ 0 relative to reference line 110 and reference line 112 extends through reference plane 200 when tower 102 is in the raised position and angle pins 141 a and 141 b extend through angle pin sockets 126 a and 126 b , respectively.
Tower 102 extends at angle θ 5 relative to reference line 110 and reference line 112 extends through reference plane 201 when tower 102 is in the tilted position and angle pin actuator 140 extends through angle pin sockets 127 a and 127 b . In particular, tower 102 extends at angle θ 5 relative to reference line 110 and reference line 112 extends through reference plane 201 when tower 102 is in the tilted position and angle pins 141 a and 141 b extend through angle pin sockets 127 a and 127 b , respectively.
Tower 102 extends at angle θ 10 relative to reference line 110 and reference line 112 extends through reference plane 202 when tower 102 is in the tilted position and angle pin actuator 140 extends through angle pin sockets 128 a and 128 b . In particular, tower 102 extends at angle θ 10 relative to reference line 110 and reference line 112 extends through reference plane 202 when tower 102 is in the tilted position and angle pins 141 a and 141 b extend through angle pin sockets 128 a and 128 b , respectively.
Tower 102 extends at angle θ 15 ( FIGS. 9 c and 9 d ) relative to reference line 110 and reference line 112 extends through reference plane 203 when tower 102 is in the tilted position and angle pin actuator 140 extends through angle pin sockets 129 a and 129 b . In particular, tower 102 extends at angle θ 15 relative to reference line 110 and reference line 112 extends through reference plane 203 when tower 102 is in the tilted position and angle pins 141 a and 141 b extend through angle pin sockets 129 a and 129 b , respectively.
Tower 102 extends at angle θ 20 relative to reference line 110 and reference line 112 extends through reference plane 204 when tower 102 is in the tilted position and angle pin actuator 140 extends through angle pin sockets 130 a and 130 b . In particular, tower 102 extends at angle θ 20 relative to reference line 110 and reference line 112 extends through reference plane 204 when tower 102 is in the tilted position and angle pins 141 a and 141 b extend through angle pin sockets 130 a and 130 b , respectively.
Tower 102 extends at angle θ 25 relative to reference line 110 and reference line 112 extends through reference plane 205 when tower 102 is in the tilted position and angle pin actuator 140 extends through angle pin sockets 131 a and 131 b . In particular, tower 102 extends at angle θ 25 relative to reference line 110 and reference line 112 extends through reference plane 205 when tower 102 is in the tilted position and angle pins 141 a and 141 b extend through angle pin sockets 131 a and 131 b , respectively.
Tower 102 extends at angle θ 30 ( FIGS. 9 e , 9 f and 9 g ) relative to reference line 110 and reference line 112 extends through reference plane 206 when tower 102 is in the tilted position and angle pin actuator 140 extends through angle pin sockets 132 a and 132 b . In particular, tower 102 extends at angle θ 30 relative to reference line 110 and reference line 112 extends through reference plane 206 when tower 102 is in the tilted position and angle pins 141 a and 141 b extend through angle pin sockets 132 a and 132 b , respectively.
Reference line 112 extends at angle θ 90 relative to reference line 110 and reference line 112 extends parallel to reference line 111 ( FIGS. 1 a , 1 b and 1 c ) when tower 102 is in the lowered position. As mentioned above, when tower 102 is in the lowered position, pivot pin actuator 150 is in the retracted condition and does not extend through pivot pin sockets 133 a and 133 b . In particular, when tower 102 is in the lowered position, pivot pin actuator 150 is in the retracted condition and pivot pins 151 a and 151 b do not extend through pivot pin sockets 133 a and 133 b , respectively. However, angle pin actuator 140 does extend through angle pin sockets 126 a and 126 b so that tower 102 can be moved between the raised and lowered positions. Hence, tower 102 is rotatably mounted to tower interface assembly 118 through angle pin actuator 140 when tower 102 is moved to and from the stowed condition. In particular, tower 102 is rotatably mounted to tower interface assembly 118 through angle pins 141 a and 141 b when tower 102 is moved to and from the stowed condition ( FIG. 1 a ). In this embodiment, angle pins 141 a and 141 b extend through angle pin sockets 126 a and 126 b , respectively, when tower 102 is moved to and from the stowed condition.
FIGS. 10 a , 10 b and 10 c are side views of other embodiments of angle bracket arms which can be included with drilling machine 100 . In FIG. 10 a , an angle bracket arm 135 includes a number N of angle bracket sockets so that a corresponding number of discrete angles are available. As number N increases, the number of discrete angles available increases and, as number N decreases, the number of discrete angles available decreases. In general, the number of discrete angles available range from 0° to 90°. In this way, the angles available for tower 102 to be tilted correspond to N discrete angular values. It should be noted, however, that the angles can be negative angles wherein tower 102 tilts towards cab 105 and vehicle front 101 a.
The number N can have many different values. In one embodiment, the number N has values in a range from two to about ten. In another embodiment, the number N has values in a range from two to about fifteen. In one particular example, N is equal to two. It should be noted, however, that the number N can have values outside of these ranges in other embodiments.
In FIG. 10 b , angle bracket arm 135 a includes a number of angle bracket sockets which corresponds to seven. More information regarding angle bracket arm 135 a is provided above with the discussion of tower interface assembly 118 . In the embodiment of FIG. 10 b , the available angles that tower 102 can be tilted correspond to angle values equal to 0° and 30°, as well as values therebetween that are at 5° increments (i.e. 5°, 10°, 15°, 20°, 25°). In this way, the angles available for tower 102 to be positioned correspond to seven discrete angular values. It should be noted, however, that the angles can have other discrete angular values, and these discrete values can be greater than 30°.
In FIG. 10 c , an angle bracket arm 135 d includes a number of angle bracket sockets which corresponds to three. In the embodiment of FIG. 10 c , the available angles that tower 102 can be tilted correspond to angle values equal to 0° and 30°, as well as values therebetween that are at 15° increments. In this way, the angles available for tower 102 to be positioned correspond to three discrete angular values, as will be discussed in more detail presently.
FIGS. 11 a and 11 b are side views of angle bracket assemblies 120 d and 120 e , respectively, which include angle bracket arms 135 d and 135 e , respectively. More information regarding angle bracket arm 125 d is provided with FIG. 10 c above. It should be noted that, in this embodiment, angle bracket arm 135 e is the same as angle bracket arm 135 d . Hence, for angle brackets 135 d and 135 e , N is equal to three so that angle bracket arms 135 d and 135 e each include three angle pin sockets. The angle pin sockets of angle bracket arms 135 d and 135 e are positioned so they oppose each other.
In this embodiment, the angle pin sockets of angle bracket arm 135 d are denoted as angle pin sockets 126 a , 129 a , and 132 a . Further, the angle pin sockets of angle bracket arm 135 e are denoted as angle pin sockets 126 b , 129 b , and 132 b.
In this embodiment, angle pin sockets 126 a , 129 a , and 132 a are spaced apart from each other so that they are at predetermined positions along angle bracket arm 135 d . The predetermined positions of angle pin sockets 126 a , 129 a , and 132 a are chosen so that reference planes extend at predetermined angles through pivot pin socket 133 a and angle pin sockets 126 a , 129 a , and 132 a , wherein, in this embodiment, the predetermined angle is relative to reference line 110 . It should be noted that angle pin sockets 126 a , 129 a , and 132 a are equidistantly spaced apart from each other in this embodiment. However, the spacing between adjacent angle pin sockets 126 a , 129 a , and 132 a can be different, if desired.
In this embodiment, angle pin sockets 126 b , 129 b , and 132 b are spaced apart from each other so that they are at predetermined positions along angle bracket arm 135 b . The predetermined positions of angle pin sockets 126 b , 129 b , and 132 b are chosen so that reference planes extend at predetermined angles through pivot pin socket 133 b and angle pin sockets 126 b , 129 b , and 132 b , wherein, in this embodiment, the predetermined angle is relative to reference line 110 . It should be noted that angle pin sockets 126 b , 129 b , and 132 b are equidistantly spaced apart from each other in this embodiment. However, the spacing between adjacent angle pin sockets 126 b , 129 b , and 132 b can be different, if desired. Further, it should be noted that angle pin sockets angle pin sockets 126 b , 129 b , and 132 b oppose angle pin sockets angle pin sockets 126 a , 129 a , and 132 a , respectively.
FIG. 11 c is a perspective view of tower interface assembly 118 a , which includes angle bracket assemblies 120 d and 120 e and the reference planes mentioned above with the discussion of FIGS. 11 a and 11 b . As shown in FIG. 11 c , reference plane 200 extends between angle pin sockets 126 a and 126 b and pivot pin sockets 133 a and 133 b at angle θ 0 relative to reference line 110 , wherein angle θ 0 is about 0° in this example.
Reference plane 203 extends between angle pin sockets 129 a and 129 b and pivot pin sockets 133 a and 133 b at an angle θ 15 relative to reference line 110 , wherein angle θ 15 is about 15° in this example. Further, reference plane 206 extends between angle pin sockets 132 a and 132 b and pivot pin sockets 133 a and 133 b at an angle θ 30 relative to reference line 110 , wherein angle θ 30 is about 30° in this example. In this way, the angle pin sockets that extend through angle bracket arms 135 d and 135 e are spaced apart from each other at positions which correspond to predetermined angles relative to reference line 110 .
As mentioned above, reference line 112 ( FIGS. 1 a , 1 b and 1 c ) extends parallel to tower 102 . Hence, tower 102 extends angle θ 0 relative to reference line 110 and reference line 112 extends through reference plane 200 when tower 102 is in the raised position and angle pin actuator 140 extends through angle pin sockets 126 a and 126 b . In particular, tower 102 extends at angle θ 0 relative to reference line 110 and reference line 112 extends through reference plane 200 when tower 102 is in the raised position and angle pins 141 a and 141 b extend through angle pin sockets 126 a and 126 b , respectively.
Tower 102 extends at angle θ 15 relative to reference line 110 and reference line 112 extends through reference plane 203 when tower 102 is in the tilted position and angle pin actuator 140 extends through angle pin sockets 129 a and 129 b . In particular, tower 102 extends at angle θ 15 relative to reference line 110 and reference line 112 extends through reference plane 203 when tower 102 is in the tilted position and angle pins 141 a and 141 b extend through angle pin sockets 129 a and 129 b , respectively.
Tower 102 extends at angle θ 30 relative to reference line 110 and reference line 112 extends through reference plane 206 when tower 102 is in the tilted position and angle pin actuator 140 extends through angle pin sockets 132 a and 132 b . In particular, tower 102 extends at angle θ 30 relative to reference line 110 and reference line 112 extends through reference plane 206 when tower 102 is in the tilted position and angle pins 141 a and 141 b extend through angle pin sockets 132 a and 132 b , respectively.
The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention.
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An interface apparatus between a tower and platform includes a tower support assembly with opposed angle brackets and a first tower support assembly coupler/decoupler which is repeatably moveable between coupled and decoupled conditions with the tower support assembly. In the coupled condition, the coupler/decoupler is capable of coupling to the tower support assembly at a plurality of predetermined positions along the opposed angle brackets. The interface apparatus includes a second tower support assembly coupler/decoupler which allows the tower to pivot relative to the tower support assembly and rotate relative to the platform.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to manufacture of capacitors. More particularly, it relates to an improved method for forming capacitor elements for incorporation in a capacitor housing by pressing the capacitor element into a form.
2. State of the Prior Art
It is known in the prior art to fabricate wound film capacitors from strips or webs of dielectric material having electrically conductive material formed thereon and formed with a tight coil. Characteristically two or more such webs are wound together with dielectric material between the electrically conductive layers so that the electrodes thus formed are insulated from each other. Various types of materials, forms of encapsulations, and means for coupling terminals to the electrodes have been utilized.
Another capacitor structure and method of their manufacture involves the so-called chip capacitors. These are described in detail by Lavene in U.S. Pat. No. 4,378,620, which is herein incorporated by reference. In summary he describes fabricating small capacitors from a mated pair of dielectric webs having a plurality of electrically conductive spaced-apart electrodes formed thereon. The webs are aligned such that an electrode on one layer is juxtaposed a non-conductive portion of the web on the other layer in a manner such that the electrodes are off-set on the layers and to not lie one above the other. The webs are then wound, and the electrodes and dielectric material are bonded by applying pressure to the coil. Individual capacitors are then formed by chopping the coil into lengths. The layers of conductive material are electrically interconnected at each end, as by metal plating, and terminals are attached thereto. The assembly can be encapsulated or placed in a suitable housing to form the completed capacitor.
Due to the methods used to flatten and bond the coils in the prior art, the capacitors did not have precise forms, and required housings to be of a sufficiently large size to accommodate the capacitor elements. This was true for both discrete wound capacitors and chip capacitors. The additional size of the housing is undesirable for components to be used on printed circuit boards. Further, the irregular shapes create problems in automated assembly systems, and cause problems for environmental sealing.
It has been recognized that capacitors that are encapsulated and permit planar mounting to supporting assemblies are desirable. Such a device was described in co-pending Application Ser. No. 586,014 filed Mar. 5, 1984 and now Pat. No. 4,538,205. There is described a housing of a length somewhat longer than the capacitor element, forming a cavity at each end when the capacitor element is inserted. Conductive material is placed in the cavities for contacting respective electrodes, and end caps are fitted over each end. The end caps make electrical contact and are shaped for permitting surface mounting. An irregular shape of the capacitor element can cause problems of automated handling for insertion in the housing.
An object of the invention is to form capacitors by pressing capacitor elements constructed of interleaved layers of electrically conductive material and dielectric material into a form selected to match the interior shape of an associated housing. The capacitor component is less expensive to fabricate, and has an improved volumetric efficiency.
SUMMARY OF THE INVENTION
The invention comprises an improved capacitor component assembly and the method of manufacture. A metallized wrapped capacitor element of elongated mated dielectric webs, each having electrically conductive material on at least a part thereof, is formed by wrapping the mated dielectric webs into a coil of concentric turns, with the electrically conductive material on each web electrically insulated from that on the other web. The coil is formed such that conductive material for forming one plate of the capacitor is exposed at one end and conductive material for forming the other plate of the capacitor is exposed at the other end. The coil is formed to eliminate edge radii in a mold having a predetermined width, by pressure being applied to the coil and causing it to conform to the shape of the mold. The shape is selected to match end caps, one of which is placed over each end of the formed capacitor element, and each end cap is electrically connected to the associated capacitor conductors. The entire assembly is treated to provide physical strength and to provide moisture protection by vacuum impregnation with epoxy resin.
BRIEF DESCRIPTION OF THE DRAWINGS
The stated objectives of the invention and other more detailed objectives will be understood from a consideration of the Detailed Description of the Preferred Embodiment when considered with Drawings, in which:
FIG. 1 is an exploded isometric view of two mated dielectric webs having electrically conductive elements deposited thereon;
FIG. 2 is an isometric view showing the coil formed by winding the two mated webs of FIG. 1 together;
FIG. 3 is an isometric view of the coil of FIG. 2 after having been pressed and tempered to form bonded capacitor elements suitable for chopping to form chip capacitor elements;
FIG. 4 is a diagrammatic view illustrating a wrapping for a wound capacitor;
FIG. 5 is a perspective view of a finished wound capacitor adapted for surface mounting;
FIG. 6 is an exploded perspective view of a wound capacitor terminated for planar mounting, utilizing a would capacitor element formed by prior art methods;
FIG. 7 illustrates a prior art system of pressing wound capacitors with the press open;
FIG. 8 illustrates a prior art system of pressing wound capacitors with the press closed, and illustrates the radius at each edge of the capacitor;
FIG. 9 is a side view of a capacitor element mold having a portion broken away to illustrate the wound capacitor prior to compression and forming;
FIG. 10 is a side view of the capacitor element mold of FIG. 9, having a portion broken away to illustrate the capacitor element after compression and forming;
FIG. 11 is a pictorial view showing the capacitor element formed according to the present invention being formed into a novel capacitor component; and
FIG. 12 is an exploded perspective view of a mold structure that can be utilized to form capacitor elements in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is an exploded isometric view of two mated dielectric webs having electrically conductive elements deposited thereon. The structure is described in detail by Lavene in the above-mentioned U.S. Pat. No. 4,378,620, but in general wound capacitor elements can be formed by positioning a pair of dielectric webs 10 and 10', each having a plurality of thin parallel metallic electrodes 12 and 12' deposited thereon, one above the other with the centerlines of the electrodes 12 and 12' off-set. The electrodes 12 and 12' are separated on the respective webs 10 and 10' by a spacing 14 and 14', such that each conductor on each web can be either above or below an associated spacing. The ratio of electrode 12 and 12' to spacing 14 and 14' is selected according to the capacitance desired.
FIG. 2 is an isometric view showing the coil formed by winding the two mated webs of FIG. 1 together. The webs 10 and 10' are wound in concentric coils. The metallic strips 12'-1 at each edge are about one-half the width of strips 12'-2 to accommodate chopping. Similarly, spacings 14-1 are about one-half spacings 14-2.
FIG. 3 is an isometric view of the coil of FIG. 2 after having been pressed and tempered to form bonded capacitor elements suitable for chopping to form chip capacitor elements. The pressing and bonding cause the flattened coil to have rounded ends 16. Chopping is accomplished by causing a chopping element (not shown) to pass through the coil at dashed lines 18, thereby resulting in the individual capacitor elements 20 being formed, each having a conductive coil exposed at each end thereof as described in U.S. Pat. No. 4,378,620. It is the minimization of the rounding of rounded ends 16 to which the invention is directed.
Other forms of wound capacitors adapted for surface mounting are known, and one is illustrated in FIG. 4 and FIG. 5. This type of capacitor is described in detail in Applicant's co-pending application Ser. No. 513,271 filed July 17, 1983 now U.S. Pat. No. 4,516,187 and in U.S. Pat. No. 4,470,097, issued Sept. 4, 1984, to B. Lavene, entitled "Dual Film Metallized Capacitor" which is assigned to the assignee herein. This patent is incorporated herewith by reference.
FIG. 4 is a diagrammatic view illustrating wrapping of a wound capacitor, and FIG. 5 is a perspective view of a finished capacitor adapted for surface mounting. The capacitor 30 is formed from winding a first dielectric web 32 having an electrode 36 on the surface opposite that of the connective electrode 34, on a mating but reversed web 38 which has a conductive layer 34'. The arrangement is such that the narrow metallic layers 36 and 34 are arranged for contacting alternating coils of capacitor conductors.
The outer wrapping dielectric web 42 has a pair of narrow conductors 44 and 46, and when wound around the mated coil of webs 32 and 38, forms a protective sleeve with electrodes 44 and 46 exposed around the outer periphery. The wrapped coil is then pressed and tempered to cause bonding of the capacitor elements. The flattened coil has rounded edges as shown in FIG. 5. The ends 48 are coated or sprayed with conductive material forming the electrical connection of the associated metallic layers on webs 32 and 38.
FIG. 6 is an exploded perspective view of a wound capacitor terminated for planar mounting, utilizing a wound capacitor element formed by prior art methods. A structure of this type is described in detail by Lavene in co-pending application Ser. No. 586,014 now U.S. Pat. No. 4,538,205. A wound capacitor element 50, formed for example as described above, and having the rounded edges, is slipped into a sleeve 52. The sleeve is made of dielectric material and is longer than the capacitor element 50, thereby leaving cavities 54 and 56 at the ends. The ends of the capacitor element 50 are treated with conductive material to form the basis of making the electrical connection thereto. The cavities 54 and 56 are then filled with an electrically conductive material, such as paste, and conductive end caps 58 and 60 are slipped over respective ends of sleeve 52. The end caps 58 and 60 contact the conductive paste and thereby form terminals for surface mounting to an electrical assembly.
It is apparent that the rounded edges of capacitor element 50 require that the size of the sleeve 52 and end caps 58 and 60 be larger than would be required if capacitor element 50 matched exactly the inner dimensions of sleeve 52.
The prior art method of pressing and forming wound capacitor elements is illustrated in FIG. 7 and FIG. 8. FIG. 7 illustrates the prior art system of pressing wound capacitors with the press open. Essentially a pair of press plates 70 and 72 are positioned on each side of the wound capacitor element 74. Pressure was then applied in the direction of arrows 76, causing the press plates 70 and 72 to move toward each other.
FIG. 8 illustrates a prior art system of pressing wound capacitors with the press closed, and illustrates the radius at each edge of the capacitor. The press plates 70 and 72 have been forced in the direction of arrows 76 to a point where the capacitor element 74 has been formed to the desired thickness. There remains the radius at each edge 74-1 and 74-2 that causes the problems mentioned above. Once formed, the capacitor element is treated, as by the application of heat, to cause the entire wound assembly to become physically bonded, and the balance of the assembly steps can be completed.
To alleviate the form problem encountered in the prior art, and to maximize generation of a consistent form factor particularly adapted to robotic handling, the forming process has been improved by providing a predetermined capacitor mold for use in the forming process. The improved forming process is illustrated in FIG. 9 and FIG. 10.
FIG. 9 is a side view of a capacitor element mold having a portion broken away to illustrate the wound capacitor prior to compression and forming. The capacitor element 80 within the mold is preferably a wound chopped capacitor element such as capacitor elements 20 formed from the coil of FIG. 3. Element 80 is positioned within a predetermined cavity 82 in the capacitor element mold 84. The mold 84 has end members 84-1 and 84-2 for limiting the outward movement of any portion of capacitor element 80. The mold 84 also has a bottom 84-3 connecting ends 84-1 and 84-2 together and providing a surface against which capacitor element 80 can be pressed. A press member 86 has a dimension to fit between ends 84-1 and 84-2, and has a surface 86-1 for contacting the capacitor element 80 when the press member 86 is moved in the direction of arrow 88.
FIG. 10 is a side view of the capacitor element mold of FIG. 9 having a portion broken away to illustrate the capacitor element after compression and forming. The press member 86 has been moved a predetermined distance in the direction of arrow 88 within cavity 82 to force capacitor element 80 to be flattened and forced against mold ends 84-1 and 84-2. As thus formed, capacitor element 80 is devoid of the objectionable radii at the edges, as encountered in the prior art. After pressing, the capacitor element may be treated to cause it to become a fixed unitary element. It is subjected to such other steps as are required to form the desired type of packaged capacitor component.
FIG. 11 is a pictorial view showing the capacitor element formed according to the present invention being formed into a novel capacitor. After forming as described above, capacitor element 80 can be slipped into sleeve 90 in a manner similar to that described with respect to FIG. 6. In this arrangement sleeve 90 can be of a smaller size to accommodate the closely controlled dimensions of the capacitor element 80. Caps 91 can be used without sleeve 90.
FIG. 12 is an exploded view of a mold structure that can be utilized to form capacitor elements in accordance with the present invention. A mold base 92 has a predetermined length, and mold channel 94 formed by walls 96 and 98 and bearing surface 100. The channel 94 is the functional equivalent of cavity 82 in FIGS. 9 and 10. The mold base 92 has a pair of apertures 102 and 104 extending at least part way therethrough, and arranged near each end thereof, and centered on the centerline of bearing surface 100.
The mold press 106 is substantially the same length as mold base 92, and has a press member 108 that mates closely with channel 94 at the walls 96 and 98. The height of press member 108 is less than the depth of channel 94, it being arranged such that the movement of press member 108 into channel 94 will be limited when stop surfaces 110 and 112 come into contact with the respective upper surfaces of walls 98 and 96.
The mold press 106 has apertures 114 and 116 therethrough, and in axial alignment with associated ones of apertures 102 and 104. Threaded bolt 118 is passed through apertures 114 and 102 to cooperate with nut 120. Similarly, bolt 122 is passed through apertures 116 and 104 to cooperate with nut 124.
When a wound capacitor is positioned in channel 94 and nuts 120 and 124 are tightened, mold press 106 is forced toward mold base 92, and press member 108 causes it to be forced into conformity with channel 94. It is apparent that this form of mold is illustrative only and that the configuration and mechanics of operation can be varied to suit the needs of the individual cases. Similarly, the mold structure can be multiplied as desired to allow forming of multiple capacitor elements in a single forming step.
The length of channel is not critical, it only being required that the capacitor element be narrower than the distance between bolts 118 and 122. For many types of small capacitors, some of which are no longer than 21 millimeters, it has been found to be advantageous to provide a mold long enough to press several capacitor elements simultaneously in the channel.
As indicated above in the consideration of FIG. 11, an improved capacitor component can be achieved with the forming process described and the use of the end caps 91. With the insulating outer layer on the capacitor element 80, and the conductive bands at the ends, it is dusted as described in the co-pending applications, and the end caps 91 are put in place and electrically connected, as by use of epoxy silver, to the capacitor element. At this point a completed capacitor component has been described. If it is desirable to provide moisture protection, the completed assembly can be subjected to epoxy impregnation under vacuum impregnation processes, of a type that is known.
The elimination of the sleeve 90, and the use of end caps 91 as just described, allow the capacitor element 80 to have additional turns for the same volume of finished capacitor component, thereby allowing for additional capacitance in the same volume. The component thus formed is less expensive, but somewhat less sealed, and provides the additional volumetric efficiency mentioned.
The use of the vacuum impregnation with an epoxy resin provides additional mechanical strength to the assembly, and allows the component to withstand temperature variations that are encountered in various solder processes in assembly of printed circuit board assemblies on which these capacitor components are frequently used. During the vacuum impregnation process, the end caps are protected, for example, by masking off with a silicon adhesive polypropylene tape, that keeps the epoxy off the contact surfaces. Once the impregnation is completed, the tape is removed, and the component can be readily put in the manufacturing process for the circuits in which the capacitors will be used.
From the foregoing descriptions of the preferred embodiment, the stated purposes and objectives have been met. It is understood that the particular embodiments shown and described are preferred, and that various modifications and alternatives will become apparent to those skilled in the art without departing from the spirit and scope of the invention. Accordingly, what is intended to be protected by Letters Patent is set forth in the appended claims.
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An improved metallized wrapped capacitor pressed into a predetermined cross-sectional form substantially without edge radii, together with its method of manufacture are disclosed. The capacitor is formed from elongated mated dielectric webs, each having an electrode deposited on its face. The webs are superposed and rolled into a coil having concentric turns. The coil is pressed into a mold to derive a cross-section that mates with electrically conductive end caps. The end caps are affixed physically and electrically at each end of the formed capacitor element. The entire assembly with the exception of portions of the end caps are subjected to vacuum impregnation of epoxy resin to provide physical strength and to provide environmental protection. A form of coil mold is described.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of German Patent Application No. 103 11 345.2, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to an apparatus for determining fibre lengths and fibre length distribution from a fibre material sample, especially in spinning preparation. In such apparatus, sample preparation elements may be located upstream of the measuring, evaluating and indicating device, said preparation elements comprising a clamping device and a combing element for the treatment of collected fibre material, the combing element producing a fibre fringe that is used for the measurement.
[0003] In the practical operation of spinning, fibre slivers taken from production are brought into a fibre laboratory, where the following testing is carried out:
[0004] (a) several slivers are placed by hand in clamps previously opened by hand and are carefully, that is, homogeneously, distributed across the width of the clamp and then the clamp is closed by hand.
[0005] (b) The fleece is clamped between two leather-covered plates. The plates are pressed into flat abutment with one another. There is no actually defined clamping point.
[0006] (c) The fleece is combed by hand using a single-row straight comb.
[0007] (d) A round brush is finally used to brush out the fibre fringe again.
[0008] (e) One side of the clamp is offered up to a fibrograph, then the clamp is turned over and the other side is offered up to the fibrograph. Using the fibrograph, two fibre fringes are transported past light sources. The source light passing through falls on light receivers and is registered and evaluated.
[0009] To test fibre slivers and flyer spinning frame slubbings, the leaflet “Fibrograph 630 ” of Spinnlab, Knoxville, Tenn., USA describes how, for preparation of a sample, the fibre material sample is opened and spread out and placed in a fibre clamp. The clamp members hold the fibres in their actual arrangement in sample zones. The randomly connected, overlapping, non-parallel relationship between the fibres remains as it is. When the sample has been thus prepared, the fibre clamp is placed in the fibrograph, which brushes out the fibre fringe, scans the sample optically and displays the result of the measurement.
[0010] The known sample preparation is time-consuming. Manual handling and processing of the sample and placing thereof in the measuring apparatus are additional to transportation from the spinning works to the test laboratory. It is a further disadvantage that owing to the individual handling of the sample preparation, the samples are not uniformly consistent. Finally, it is inconvenient that a fibre measurement at the location of the spinning machine is not possible.
[0011] It is an aim of the invention to produce an apparatus of the kind described in the introduction that avoids or mitigates the said disadvantages, and which in particular makes possible within a short time a sample preparation founded on an equal basis and allows an accurate measurement of the samples.
SUMMARY OF THE INVENTION
[0012] The invention provides an apparatus for determining fibre lengths and fibre length distribution from a fibre material sample, comprising a conveyor device for conveying the fibre material, a take-up device for taking up a length of fibre material which can be separated from the conveyor device, and a transport arrangement for conveying the separated length of fibre material to a combing device, at least one end of the length of fibre material being combable by the combing device to form a combed fibre fringe, which combed fibre fringe is subsequently detectable by a measuring device.
[0013] Because a conveying device, a clamping device and a combing device, for example at least one combing roller, as well as transfer devices are provided, wherein not only the operation of the afore-mentioned devices as such but also the transfer between the devices is to be effected automatically, the same preconditions for the preparation of all samples are created. In particular, anomalies attributable to manual handling are excluded. It is a further particular advantage that the apparatus can be used in the works directly at the machines or fibre sliver cans. Added to the quicker sample preparation within the apparatus is the considerable time saving gained by carrying out testing away from the fibre laboratory. The fibre lengths and fibre length distribution ascertained can be used for optimum setting of the carding machines (fibre shortening/nep count) and can also be utilised in reducing or removing short fibres from the processed fibre material.
[0014] The collected fibre material may be a fibre sliver or the like. The collected fibre material may consist of fibre flocks. Advantageously, the conveyor device comprises at least one roller, a conveyor belt or the like. Advantageously, the conveyor device consists of a roller pair. Advantageously, at least two roller pairs in the form of a tractive drawing system are present. Advantageously, the conveyor device consists of a conveyor roller and a conveyor trough. Advantageously, the conveyor device consists of two continuously revolving conveyor belts. Advantageously, a clamp-type conveyor device is provided. Advantageously, the conveyor device clamps the collected fibre material so that it can be torn off. Within the drawing system the draft is advantageously increased such that a thinned area is created in the collected fibre material (fibre sliver). Advantageously, the conveyor device, especially the drawing system, converts the collected fibre material to a wide and flat structure, for example, a fibre fleece. Advantageously, the number of fibres per length of the fleece length and/or per width of the fleece is variable by way of the draft of the drawing system. Advantageously, the fibres are rendered parallel in the drawing system. Advantageously, fibre hooks are removable in the drawing system. Advantageously, the take-up device is capable of gripping the collected fibre material. Advantageously, the take-up device is capable of holding and/or clamping the collected fibre material. Advantageously, the take-up device comprises a clamping device. Advantageously, the clamping device is capable of clamping the collected fibre material only with its edge regions. Advantageously, the jaws of the clamping device are capable of clamping a fibre sliver sample only with their edge regions. Advantageously, the jaws of the clamping device are capable of clamping a fibre flock sample flat. Advantageously, the clamping device comprises at least one moveable clamping jaw. Advantageously, the collected fibre material can be firmly clamped between the clamping jaws. Advantageously, the clamping device is arranged at the output of the conveyor device, e.g. the delivery roller of the drawing frame. Advantageously, the distance between the output of the conveyor device and the clamping device is the same as or larger than the length of the longest fibre. Advantageously, the clamping device is arranged between the conveyor device and a conveyor element. The conveyor element may be, for example, a suction element, e.g. suction pipe or the like, or a mechanical gripping element, e.g. tongs or the like. Advantageously, the conveyor element is displaceable, e.g. slidable, in the direction of the delivery end of the conveyor device. Advantageously, the clamping device is used as conveyor element.
[0015] Advantageously, the clamping device is arranged beneath the conveyor device such that the collected fibre material enters the clamping device by force or gravity. Advantageously, the take-up device and the conveyor device are movable relative to one another. Advantageously, the take-up device is movable in relation to the conveyor device such that the collected fibre material tears away. The take-up device may be movable away from the conveyor device substantially at a right angle, or in an oblique direction. The take-up device may be movable rotationally or pivotally in relation to the conveyor device such that the collected fibre material tears away.
[0016] Both ends of the separated length of fibre material may be combed. Advantageously, the combing device, e.g. at least one rotating combing roller, and the clamped collected fibre material are movable relative to one another. Advantageously, the combing roller is equipped with a clothing, needles, saw-teeth or similar. Advantageously, the speed and/or direction of rotation is alterable, especially controllable. Advantageously, the relative movement between clamping device and combing roller is alterable, especially controllable. Advantageously, the combing roller rotates at a low speed, for example, 10 to 50 rpm. Advantageously, the combing roller comprises a perforated roller base body. Advantageously, a high-speed cleaning roller is associated with the combing roller. Advantageously, an extraction device is associated with the combing roller and/or cleaning roller. Advantageously, the end regions of the collected fibre material (fibre fringe) are alignable in a defined manner, preferably substantially straight. Advantageously, a suction element, e.g. suction pipe or the like, or a mechanical element, e.g. tongs, gripper, or the like, is provided as aligning element. Advantageously, the aligning element and the clamping element are movable relative to one another.
[0017] Advantageously, a fibrograph device is provided as a measuring device. Advantageously, the fibrograph comprises at least one light source and at least one light receiver. Advantageously, the fibrograph device and the clamping device are movable relative to one another. Advantageously, in the measuring device, e.g. fibrograph, measuring is carried out by traversing forwards and backwards across the collected fibre material (fibre fringe).
[0018] The apparatus is advantageously portable. Advantageously, the apparatus has a supply interface and a data interface to at least one spinning machine. Advantageously, an electronic microcomputer control device, with microprocessor, is provided, to which at least one of the elements drive motor of the conveyor device, actuator for the clamping movement of the clamping device, actuator for moving the clamping device, actuator for moving the at least one aligning device, combing roller drive motor and actuator for moving the measuring device are connected.
[0019] Advantageously, the fibre material sample to be measured is prepared automatically by the sample-preparation device. Advantageously, the sample preparation and the measuring are effected automatically. Advantageously, as collected fibre material a fibre sliver can be drawn from a spinning can, which may be connected downstream of a card or downstream of a draw frame. Advantageously, the spinning can is connected downstream of a drawing system, e.g. card drawing system, drawing system of a draw frame, drawing system of a combing machine, drawing system of a flyer spinning frame.
[0020] Advantageously, the collected fibre material is arranged to be conveyed continuously by the conveyor device. Advantageously, the torn-away collected fibre material is about 200 mm long. The collected fibre material may be removed from a spinning machine, e.g. a card. For example, the collected fibre material may be removed from the feed region or the incoming fibre flock feed of the card. The collected fibre material may be removed before treatment with clothing elements, e.g. clothed or needled rollers, fixed carding elements or the like. The collected fibre material may be removed from the delivery region of the card. The collected fibre material may be removed after treatment with clothing elements, e.g. clothed or needled rollers, fixed carding elements or the like. The collected fibre material may be removed from a roller of a card, for example, from a licker-in or doffer of the card. Advantageously, the determined measured values of the fibre lengths (staple) and fibre length distribution from the feed region of the card, e.g. fibre flock feed, and from the delivery region of the card, e.g. card sliver in the spinning can, are compared with one another. Advantageously, the determined measured values of the fibre length distribution from the sliver in aggressive and in gentle processing are compared with one another. Advantageously, the determined measured values of the fibre length distribution from the sliver in aggressive and gentle settings of individual assemblies are compared with one another. Advantageously, fibre shortening and/or fibre damage due to processing on the card are ascertained from the comparison of the measured values. From the fibre lengths and the fibre length distribution a characteristic number is advantageously determined, which describes the fibre stress during processing. From the fibre lengths and the fibre length distribution a characteristic number is advantageously determined, which describes the extent of hooks in the sliver. The fibre sliver may be tested several times at one section, and then the same sliver automatically be drawn off further in order to be tested several times at a different point. The collected fibre fringe may be removed from the open clamp by suction, by means of brushes, or by means of combing rollers. Advantageously, a device for moving the clamping elements of the clamping device is present. Advantageously, a device for moving the take-up device is present. Advantageously, a device for moving the clamping device is present. Advantageously, a device for moving each combing roller is present. Advantageously, a device for moving the measuring device is present. Advantageously, at least one measuring device is connected to the electronic machine control and regulating system, e.g. the card. Advantageously, the measured values are used to set the spinning machine, e.g. the card. Advantageously, actuators for setting the machine elements and operating elements of the machine, e.g. the card, are connected to the electronic machine control and regulating system.
[0021] Advantageously, the determined measured values of the fibre lengths (staple) and the fibre length distribution from the feed region of the card, e.g. fibre flock supply, and from the delivery region of the card, e.g. the card sliver in the spinning can, are compared with one another. The measured values of the fibre length distribution determined from the sliver in aggressive and gentle processing are preferably compared with one another. The measured values of the fibre length distribution determined from the sliver in aggressive and gentle settings of individual assemblies, e.g. clothed revolving card top or fixed card top, are preferably compared with one another. Advantageously, fibre shortening and/or fibre damage due to processing on the card are ascertained from the comparison of the measured values. A fibre damage sensor (fibre stress sensor FSS) is created by the above-mentioned measures. It is possible to obtain accurate information about staple shortening caused by the card. By adjusting operating elements or machine elements, it is therefore possible to achieve the least possible damage to the fibre at the card.
[0022] The invention also provides an apparatus for determining fibre lengths and fibre length distribution from a fibre material sample, especially in spinning preparation, in which sample preparation elements are located upstream of the measuring, evaluating and indicating device, said preparation elements comprising a clamping device and a combing element for the treatment of collected fibre material, the combing element producing a fibre fringe that is used for measurement, characterised in that the collected fibre material is automatically conveyable by a conveyor device, is arranged to be supplied to a clamp-type take-up device, is separable from the conveyor device and transportable to at least one rotating combing device, each end region of the collected fibre material protruding from the take-up device being combable by the combing device and subsequently detectable by the measuring device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a schematic side view of a card on which the apparatus according to the invention can be used;
[0024] [0024]FIG. 2 is a block circuit diagram of an electronic card-control and regulating system, to which at least the apparatus according to the invention and an actuator, e.g. motor, are connected;
[0025] [0025]FIG. 3 shows the dependency of the short fibre proportion and the nep count on the speed of the cylinder for different fibre qualities;
[0026] [0026]FIG. 4 is a side view of the apparatus according to the invention;
[0027] [0027]FIG. 4 a shows a suction pipe as conveyor element with a gripper flap as shown in FIG. 4 for the fibre material leaving the drawing system;
[0028] [0028]FIG. 4 b is a side view of the take-up device shown in FIG. 4;
[0029] [0029]FIG. 4 c is a side view of the detector device shown in FIG. 4;
[0030] [0030]FIGS. 5 a to 5 k shows schematically the mode of operation of the apparatus according to the invention;
[0031] [0031]FIG. 6 shows a spectogram, and
[0032] [0032]FIG. 7 is a block circuit diagram of an electronic control and regulating system of the apparatus according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] [0033]FIG. 1 shows a carding machine 15 , for example, a high performance card DK 903 made by Trützschler GmbH & Co. KG of Mönchengladbach, Germany, with feed roller 1 , feed table 2 , licker-ins 3 a , 3 b , 3 c , cylinder 4 , doffer 5 , stripping roller 6 , squeezing rollers 7 , 8 , web-guide element 9 , web funnel 10 , take-off rollers 11 , 12 and revolving card top 13 with carding segments 14 . The directions of rotation of the rollers are shown by respective curved arrows. The letter A denotes the working direction. A chute feed 16 for the flocks, for example, a Direktfeed DFK made by Trützschler GmbH & Co. KG, is located upstream of the card 15 . The chute feed 16 comprises an upper reserve hopper 17 a and a lower feed chute 17 b . The pneumatically compacted (not illustrated) fibre flock material is removed at the end of the feed chute 17 b by the feed roller 1 and directed through the gap between feed roller 1 and feed table 2 to the high-speed licker-in 3 a . A can coiler 18 is located at the delivery end of the card 15 ; the fibre sliver 19 discharged from the card 15 is laid by the can coiler in coils in a spinning can 20 .
[0034] Referring to FIG. 2, the apparatus according to the invention with measuring element 23 for the fibre lengths, a measuring element 22 for the nep count, e.g. a Nepcontroll NCT made by Trützschler GmbH & Co. KG, and an actuator 24 for the card 15 are connected to an electronic control and regulating system 21 , for example a machine control system with microprocessor. The measuring element 23 can be used to measure in succession the fibre material at the feed region 15 , for example, the fibre flock feed, and at the delivery end of the card 15 , for example, to measure the card sliver 19 . From the measured values of the fibre lengths at the feed and delivery ends of the card 15 , fibre damage is assessed in the control 21 . From the fibre damage and the nep count measured, the control determines an optimum setting value for operating elements of the card 15 , which is adjusted by way of the actuator 24 , for example, a controllable drive motor, stepping motor or similar.
[0035] Referring to FIG. 3, as the speed of the cylinder 4 increases, the nep count decreases and fibre shortening increases. The dependency of fibre shortening is illustrated for the fibre qualities A, B and C. The intersection point between the curves for the nep count and for fibre shortening constitutes the optimum value (see broken line). This optimum value is calculated and determined in the control and regulating system 21 from the entered curves for nep count and for fibre shortening. This involves a comparison with characteristic curves contained in the desired value memory.
[0036] According to FIG. 4, the device for determining fibre length and fibre length distribution from a fibre material sample, e.g. the fibre sliver 28 , fibre flocks or similar, comprises a measuring, evaluating and indicating device in the form, for example, of a fibrograph 23 . Sample preparation elements are arranged upstream of the fibrograph 23 . For that purpose a drawing system 25 is provided as conveying device, for example, a 2-over-2 drawing system known per se, that is, it consists of two bottom rollers I, II, (I being the bottom delivery roller, II being the bottom feed roller) and two top rollers 26 , 27 . Drafting of the fibre material 28 , for example, a fibre sliver 19 from a card 15 , takes place in the drawing system 25 . The roller pairs 26 /I and 27 /II are driven by variable speed drive motors 29 and 30 respectively. The directions of rotation of the rollers I, II, 26 and 27 are indicated by curved arrows. The letter A denotes the working direction (direction of travel of the fibre sliver 28 ). Substantially in alignment with the nip lines between the roller pairs 26 /I and 27 /II, a conveyor element 31 is provided at a distance from the roller pair 26 /I for transporting the fibre sliver 28 emerging from the delivery rollers 26 /I. As shown in FIG. 4 a , the conveyor element 31 is mounted on two guide elements 32 a , 32 b , for example, bars, guideways, rails or the like, and is displaceable in the direction of arrows B, C. The conveyor element 31 comprises a suction pipe 31 a , which is connected to a source of suction (not shown) that draws air in direction D through the suction pipe 31 a . In an end region of the suction pipe 31 a a gripping flap element 31 b or similar is provided, which at one end is mounted at a pivot bearing 33 so as to rotate in the direction of arrows E, F. The flap element 31 b can be driven by a drive element (not shown), for example, a pneumatic cylinder or similar. In its closed position (direction of rotation F), the flap 31 b clamps the fibre sliver 28 firmly against the inner wall of the suction pipe 31 a . Also substantially in alignment with and spaced from the delivery roller pair 26 /I is a clamp-type take-up device 34 , which clamps the transported fibre sliver 28 firmly and hence holds or fixes it. As shown in FIG. 4 b , the take-up device 34 comprises two clamping elements 35 a , 35 b , for example, clamping jaws or similar. The clamping jaw 35 a is mounted at a pivot bearing 36 so as to rotate in the direction of arrows G, H, and one end of a pneumatic cylinder 37 is articulated on the clamping jaw 35 a . The clamping jaws 35 a , 35 b together form a module, which can be moved to the desired location (see FIG. 5 e , arrow I). Substantially perpendicularly beneath the take-up device 34 there is a combing device 38 , which comprises two combing rollers 39 , 40 with their axes parallel to one another, which are driven by two variable speed drive motors 41 , 42 respectively. The combing rollers 39 and 40 turn slowly, for example, at 20 rpm in the direction of arrows 39 1 and 40 1 . The direction of rotation of the combing rollers 39 , 40 is reversible, in order to comb out the fibre fringes 28 a , 28 b from two sides. The combing rollers 39 , 40 are equipped on their circumferential surfaces with a respective combing clothing 39 2 and 40 2 . At their outer side, each combing roller 39 and 40 is associated with a suction device 43 , 44 respectively connected to sources of suction air (not illustrated) for extracting in directions N and O respectively the fibre material surplus to the fibre fringes 28 a , 28 b , especially the fibre material combed out of the fibre fringes 28 a , 28 b . Beneath the combing device 38 there is a fibre-aligning unit 45 , which comprises two conveyor elements 46 and 47 , which can essentially be of a construction identical to that of the conveyor element 31 (cf. FIG. 4 a ). The conveyor elements 46 and 47 also have in this case a respective suction pipe 48 , 49 , which are arranged coaxially with respect to one another. The inlet openings of the suction pipes 48 , 49 , with which the pivoting gripper flaps 50 , 51 respectively are associated, face towards one another. The direction of the suction air currents is denoted by letters P and Q. The conveyor elements 46 , 47 serve to align the fibre fringes 28 a , 28 b , which are angled or bent upwards or downwards by the direction of rotation 39 1 , 40 1 of the combing rollers 39 , 40 . As measuring device, a fibrograph 23 is arranged beneath the fibre-aligning unit 45 . The fibrograph 23 consists of a housing 52 in which there is provided a sensor element 53 movable, for example, slidable, in the direction of arrows L, M. As shown in FIG. 4 c , the sensor element 53 is U-shaped in cross-section, a light emitter 54 , for example a lamp or similar, being arranged in the limb 53 a and a light receiver 55 , for example, a photocell or similar, being arranged in the limb 53 b . The sensor 53 is movable in the direction of the arrows L, M (see FIG. 4) such that the take-up device 43 with the fibre fringes 28 a , 28 b that is stationary between the light transmitter 54 and the light receiver 55 can be detected by the light transmitter 54 and the light receiver 55 . To convey the fibre material 28 from the level of the drawing system 25 and the conveyor element 31 substantially perpendicularly from top to bottom by means of the take-up device 34 via the combing device 38 and the fibre-aligning device 45 to the fibrograph 23 , a vertical guide element 52 , for example, a rod, guideway, rail or the like is provided. The take-up device 34 is movable, for example, slidable, on the guide element 52 in the direction of the arrows I, K. Retainers (not shown), for example, locking devices, are provided here at the level of the elements 38 , 45 and 23 .
[0037] Referring to FIG. 5 a , a fibre sliver 28 of round or oval cross-section is transported right through the drawing system 25 and converted by the draft and the pressure of the roller pairs 26 /I and 27 /II to a flat, fleece-form structure. The fibre material 28 is at the same time spread out laterally (parallel to the roller axes of the drawing system 25 ). The conveyor device 31 is moved in direction C towards the roller pair 26 /I until it is a short distance therefrom, the short end of the fibre material 28 protruding from the roller nip of the delivery rollers 26 /I being taken up and sucked by the current of suction air D into the inner space of the suction pipe 31 a (FIG. 4 a ). The conveyor element 31 is subsequently moved in direction B, as shown in FIG. 5 b , the delivery speed of the drawing system 25 and the speed of movement of the conveyor element 31 being co-ordinated with one another or synchronised with one another such that the structure of the fibre sliver 28 is not impaired, in particular the fibre material 28 is not torn. As FIGS. 5 b and 5 c show, the fibre material 28 is pulled right through the take-up device 34 . The clamping jaws 35 a , 35 b (FIG. 4 b ) are subsequently moved towards one another or closed, so that the fibre sliver 28 is firmly clamped or fixed between the clamping jaws 35 a , 35 b , as shown in FIG. 5 d . In a next step, the take-up device 34 , together with the gripped fibre sliver 28 is displaced downwards along the guide 52 (FIG. 4) in direction I. As this happens, the gripped fibre material 28 tears away from the fibre material 28 clamped in the drawing system 25 and the fibre material 28 gripped in the conveyor element 31 , a short fibre fringe 28 a , 28 b protruding from the take-up device 34 from a respective one of the two sides thereof. The take-up device 34 is moved between the two combing rollers 39 , 40 , as shown in FIG. 5 e , whereupon the fibre fringes 28 a , 28 b come into the operating range of the rotating clothings 39 2 , 40 2 . The fibre fringes 28 a , 28 b are thus combed out, the fibre material removed by combing in the clothings 39 2 , 40 2 being extracted by suction through the suction pipes 43 and 44 respectively. The process illustrated in FIGS. 5 e and 5 f can be repeated several times, by displacing the take-up device 34 in the direction of arrows I and K (see FIG. 4) into and out of the space between the combing rollers 39 , 40 , the directions of rotation 39 , 40 being reversed each time. In this way, the fibre fringes 28 a , 28 b are combed several times from two sides each. If rotation is effected in the directions 391 , 40 , illustrated in FIG. 5 g , the fibre fringes 28 a , 28 b are bent correspondingly downwards. To align the fibre fringes 28 a , 28 b in a straight line, the conveyor elements 46 , 47 shown in FIG. 5 g are moved in the direction of arrows R and S respectively such that the fibre fringes 28 a , 28 b are taken up and clamped as shown in FIG. 5 h . The conveyor elements 46 and 47 shown in FIG. 5 h are subsequently moved slowly in the direction of arrows T and U respectively, with the result that the fibre fringes 28 a , 28 b are aligned straight and substantially horizontally or parallel to the axis of the take-up device 34 . As shown in FIGS. 5 i and 5 k , the take-up device 34 with the aligned fibre fringes 28 a , 28 b is moved along the guide 52 (FIG. 4) into the fibrograph 23 . The take-up device 34 reaches the level of the intermediate space between the light transmitter 54 and the light receiver 55 (see FIG. 4 c ) within the sensor 53 . The sensor 53 is subsequently displaced back and forth in the direction of arrows L, M (FIG. 4) over the take-up device 34 . As this happens, the light transmitter irradiates the fibre fringes 28 a , 28 b ; the light rays passing through are received by the light receiver 55 , converted into electrical signals and fed (in known manner) to an evaluating and display device.
[0038] In this way, the fibre lengths and fibre length distribution in the fibre fringes 28 a , 28 b are ascertained by means of the fibrograph 23 , which reproduces the analysis in the form of a fibrogram (fibre fringe curve, length distribution of the fibres). Such a graph is shown in FIG. 6. Frequency in percent is plotted on the horizontal axis and the fibre length in millimetres is plotted on the vertical axis. The fibrogram shown in FIG. 6 as an example shows that 100% of all fibres have a length of at least 3.8 mm. About 93% of all fibres have length of more than 5 mm and about 88% of all fibres have a length of more than 6.5 mm. As the graph shows, the longer is the fibre length, so the proportion of fibres of the total amount of fibre becomes less, until ultimately at fibre lengths of more than about 34 mm no more fibres are to be found. It has been shown that fibres of less than 6 to 6.5 mm length are unable to contribute to the strength of the spun yarn. For that reason, from the curve shown in FIG. 6 it is possible to determine what percentage of all fibres has a length that is less than the set minimum length of 5 to 6.5 mm. The fibrogram shows for 5 mm, for example, that 7% of all fibres are shorter than 5 mm. This same curve shows that 12% of all fibres are shorter than 6.5 mm. This 7 to 12% thus established is used preferably for setting the carding intensity of the card. The data for the staple diagram can be entered in the electronic control and regulating system 21 shown in FIG. 2. From this data and from the data for the nep count, an optimum value serving for setting the carding intensity of the card 15 is calculated.
[0039] Referring to FIG. 7, an electronic control and regulating system 56 for the apparatus according to the invention comprises a microcomputer with microprocessor, to which are connected the drive motors 29 , 30 for the drawing system 25 , a drive motor 57 for moving the conveyor element 31 , a drive device 58 for control of the flap 31 b , an actuator 37 for the clamping device 35 a , 35 b , an actuator 59 for moving the take-up device 34 , the drive motors 41 , 42 of the combing rollers 39 , 40 , actuators 60 , 61 for moving the conveyor elements 47 , 48 , a drive motor 62 for moving the sensor 53 , and a display means, for example, a screen 64 , printer or the like. The machine control and regulating system 21 (FIG. 2) can also be used, via an interface, as control and regulating system for the fibrograph 23 . Using the apparatus according to the invention, both the work of the sample-preparation elements and of the fibrograph 23 and the displacement of the fibre material 28 and the fibre fringes 28 a , 28 b between the sample preparation elements and the fibrograph 23 are controlled and hence automatically realised.
[0040] The following advantages inter alia are obtained with the device according to the invention, hereinafter abbreviated to FSS:
[0041] the FSS measurement is carried out more quickly than all known measurements.
[0042] The FSS sample preparation and measurement is effected fully automatically.
[0043] The entire FSS sample testing ensures a consistent sample preparation and measurement.
[0044] The FSS sample preparation is carried out carefully and uniformly.
[0045] Fibre lengths of clearly below 3.8 mm are reliably detected with the FSS test apparatus.
[0046] More fibres than in the HVI measurement procedure are tested with the FSS testing method.
[0047] All types of fibre can be measured with the FSS apparatus.
[0048] The fibre material can be removed directly from the spinning can with the FSS apparatus.
[0049] A random size sample per test can be measured automatically with the FSS apparatus.
[0050] If required, fibre tests can be carried out with the FSS apparatus automatically at constant sliver length intervals transversely through an entire spinning can.
[0051] Measurements can be carried out directly at the spinning machine with the FSS apparatus.
[0052] The FSS apparatus can be connected via an interface directly to a spinning machine.
[0053] The forwards and backwards measurement enables characteristic values to be calculated and allows information to be obtained about fibre hooks.
[0054] The sliver structure can be quantified using the FSS apparatus.
[0055] The FSS apparatus is portable.
[0056] Although the foregoing invention has been described in detail by way of illustration and example for purposes of understanding, it will be obvious that changes and modifications may be practised within the scope of the appended claims.
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In an apparatus for determining fibre lengths and fibre length distribution from a fibre material sample, especially in spinning preparation, collected fibre material is automatically conveyable by a conveyor device, is arranged to be supplied to a take-up device that grips it, is separable from the conveyor device and transportable to at least one rotating combing device, each end region of the collected fibre material protruding from the take-up device being combable by combing device, and subsequently detectable by a measuring device. The apparatus permits within a short time a sample preparation founded on a uniform basis and an accurate measurement of the samples.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a reclosable package and to a method for producing the same. More specifically this invention relates to a reclosable package for food products where the package is evacuated and hermetically sealed within an interlocking strip.
2. Description of the Prior Art
A substantial volume of the cheese, bacon frankfurters, sliced luncheon meat and other processed meats are sold in packages which are formed from flexible thermoplastic materials. The freshness of the product within the package is to a large measure dependent upon the fact that the thermoplastic package is hermetically sealed and has been evauated and, in some instances, gas flushed. However, in many instances, when an evacuated package of this type is purchased not all of its contents are used at once by the consumer. When the initial seal has been broken and part of the package removed it is difficult to reclose the package for satisfactory storage in a refrigerator; and, in order to preserve the contents in a fresh state without loss of flavor and texture, it is often necessary to completely repackage the product. To overcome this problem, there are many prior art package designs which offer means of opening and resealing but many of these have the disadvantage that wordly printed directions are needed and many times the thermoplastic packaging material is so stiff and so strong that even a carefully designed reclosure device can be destroyed.
Another problem which is encountered with prior art reclosable packages is the problem of manufacturing them at a commercially acceptable rate. Placing tear tabs, tear strips, or the like in combination with resealing means such as pressure sensitive adhesive strips calls for extreme care in registration and alignment of each of the packaging components and rather precise sealing must take place in order to achieve a satisfactory product. Accordingly, some manufacturers and methods for producing a reclosable package use what is commonly referred to as closure strips on each of the two inner surfaces of the packaging material. These closure strips consist of thermoplastic beads either extruded or attached to the packaging materials. These beads have an interlocking profile. Several patents in this area have been issued. However, the closure strip is always found within the confines of the hermetic seal of the package. Such a process means that the closure strip must be indented from the edge of the packaging material and after sealing the closure strip forms void and pockets within the package and product cavity itself.
U.S. Pat. No. 4,246,288 and U.S. Pat. No. 4,437,293 describe a reclosable package and a method and apparatus for making such a reclosable package.
U.S. Pat. No. 3,647,485 describes a package and a method for making the same which has an improved hermetic breakaway or peelable seal formed between an ethelene-polar monomer polymer film or coating and a thermoplastic film.
U.S. Pat. No. 3,740,237 describes a continuous method of enclosing the product between a pair of films so as to provide a package having a product enclosing portion and a peripheral flange. The pair of films are joined to form a hermetic dual seal by applying a continuous strip of peelable bond adhesive through a portion of the film destined to become a peripheral flange and extending partially into that portion of the film destined to become the product enclosing portion and providing the remainder of the peripheral flange with means for permanently bonding the pair of film.
U.S. Pat. No. 4,273,815 describes an improved laminated film having at least one lamina of polyvinylidene chloride film adhered to at least one lamina of chlorinated polyethylene, and the method of forming this improved lamina, and to packages produced therewith. Polyvinylidene chloride films, commonly as "Saran", are used extensively in the packaging of food products and the like which are susceptible to deterioration by oxygen and other gases. This film is adequately flexible and effectively impermeable to air and oxygen. In addition, polyvinylidene chloride films exhibit very unique properties in a so-called "supercooled" or amorphous condition during which these films can be readily formed around a product to be packaged without incurring undesirable folds, pleats or the like.
SUMMARY OF THE INVENTION
The improved packages of the present invention exhibit significant advantages in that they are generally characterized by a seal which closely conforms to the shape of the packaged product. This product-conforming seal has a number of significant advantages and is possible due to the placement of the closure strip away from the product cavity and outside the hermetic seal. For example, the unsightly appearance produced by the free movement of water and the product juices loosely contained in many conventional reclosable packages with the closure strip contained in the package product compartment is avoided. Furthermore, these packages provide a maximum seal area for a given product particularly where such product is of irregular shape thereby providing the maximum seal area afforded by a package of given size and likewise minimizing the amount residual oxygen present in such package. For these reasons and others the improved packages of the prevent invention are particularly suitable for the packaging of the food products such as weiners, bacon, sliced luncheon meat, chops, cheese and the like.
It is, therefore, an important object of the present invention to provide an improved reclosable package characterized by closure strips capable of resealing the package and an inner hermetic, peelable, breakaway seal which can be readily and easily separated when access to the contents of said package is desirable.
Another object of the present invention is to provide a reclosable package which may be made on a single machine and straight through process rather than making a pouch on one machine and performing the filling, evacuating and sealing process on another machine.
Accordingly, another of the objects of the present invention is to provide a reclosable package which may be made rapidly and reliably.
Other and further objects of the present invention will be apparent from the following detailed description thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view illustrating a preferred film product package in accordance with this invention.
FIG. 2 is an elevational side view of the package illustrated in FIG. 1.
FIG. 3 is an enlarged fragmentary cross-sectional elevational view taken approximately along the line 3--3 of FIG. 1.
FIG. 4 is an enlarged fragmentary cross-sectional elevational view taken approximately along the line 4--4 of FIG. 1.
FIG. 5 is a fragmentary sectional view of a three ply laminate film embodied in the present invention.
FIG. 6 is a schematic plain view of a modified form of bacon package embodying principles of the present invention.
FIG. 6a is an enlarged fragmentary sectional view of the package shown in FIG. 6 taken along the line 5--5 therein.
DETAILED DESCRIPTION OF THE INVENTION
In the detailed description of certain preferred embodiments of the present invention set out below, it will be noted that these packages generally include one or more lamina of a polyvinylidene chloride film. These polyvinylidene chloride films are not essential to the present invention in that suitable peelable or breakaway seals can be formed between ethylene-polar monomer copolymer films or coatings and other thermoplastic materials. There are, however, certain unique properties of polyvinylidene chloride films which, by reason of their own individual characteristics and cooperative characteristics exhibited with ethylene-polar monomer copolymer films and coatings, make these films particularly suitable for use in the improved packages of the present invention.
FIGS. 1-4 illustrate package 10 formed of top laminate 11 and bottom laminate 12 which cooperatively enclose therebetween a plurality of wieners or wiener shaped products 13. Laminates 11 and 12 are combined preferably about product 13 to form a continuous edge seal 24 and peripheral flange 22. The laminates are also drawn inwardly about the product to conform to the contour thereof to provide package 10 with improved rigidity for efficient handling.
As best shown in FIG. 3 bottom laminate 12 is formed out of outer lamina 15 of plasticized polyvinyl chloride which is combined in adhering relationship with middle lamina 16 of ethylene-vinyl acetate which is in turn combined in adhering relationship with inner lamina 17 of Saran copolymer (polyvinylidene chloride). Top laminate 11, as shown in FIG. 3 and 5 is similarly formed with outer plasticized polyvinyl chloride film 20 and middle "Saran" copolymer lamina 19 and inner ethylene vinyl acetate lamina 18. The Saran copolymer has generally crystalline structure with random crystal distribution throughout and provides suitable oxygen barrier properties. Typically a Saran copolymer film having a composition of approximately 85% vinylidene chloride and 15% vinyl chloride provides suitable oxygen barrier properties.
In accordance with the preferred aspect of the present invention hermetic seal barrier 22 between "Saran" copolymer lamina 17 and ethylene vinyl acetate lamina 18 generally designated by the numeral 22 can be readily separated by peeling back the top or bottom lamina 11 or 12 to gain access to the package. Thereafter the closure strips 14 may be interlocked to reseal the package. Separation of the laminates, however, does not result in destruction to either of laminates 11 or 12, or closure strips 14. To insure that the structural and functional integrity of the laminates, closure strips and remaining seals is maintained, it is critical that the opening forces of the easy-open or breakaway seal 22 be sufficient to withstand processing, handling and shipping yet low enough to allow access to the product. Therefore, it has been determined that the inner hermetic, easy-open seal 22 should have an opening force of from about 1.5 to about 6.0 pounds and preferably from about 2.5 to about 3.5 pounds.
FIGS. 6 and 7 illustrate a package embodying principles of the present invention which are particularly suited for packaging bacon strips and similar elongated meat products. In particular, package 23 provides a method by which the bacon product can be packaged. In particular, package 23 includes upper film lamination 26 composed of an outer oxygen barrier film lamina 27 and inner lamina 28 as well as interlocking closure stip 33. As is shown, film lamination 26 extents over bacon product 29 in conforming relationship therewith extending along the edges of the product and outwardly therefrom in adherent contact with bottom film lamination 30 formed from inner lamina 31 composed of a suitable thermoplastic film which will form a peelable or breakaway seal with film 28. Bottom lamina 32 of film lamination 30 is composed of a suitable oxygen barrier film of the type previously described. The attached closure stips 34 provided outside of the hermetic seal area 35 in addition to providing the reclosable means also facilitate the peeling of upper film lamination 26 when access to the product is desired.
In addition to the above disclosures, the closure strips or profiles of the present invention may be formed out of thermoplastic materials known to be suitable by those skilled in the art such as polyethylene, ethyl-vinyl acetate and polyester. It is also expected that the closure strip profiles may take any form or appearance, i.e. single or a plurality of interlocking rib or groove beads, and that any means of attachment to the laminates is permissible.
While various embodiments of packages and laminate films embodying the present invention have been described, it will be apparent that certain modifications and variations therefrom may be made without departing from the spirit and scope of this invention. Accordingly, only such limitations are to be imposed thereon as are indicated in the appended claims.
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A reclosable package comprising interlocking closure strips positioned outside of a hermetic seal or seal area and the method for producing same. The hermetic seal is of the easy-open or peelaway type so as to not destroy the integrity of the package or closure strips upon opening of the package.
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BACKGROUND OF THE INVENTION
The present invention relates generally to improving performance of a pump-turbine unit. In particular, the invention relates to a technique for optimizing performance of pump-turbines by identifying wicket gate settings optimizing one or more operating parameters such as efficiency during a pumping mode of operation, cavitation, vibration and the like, capable of adversely affecting profitability or long term operation of the unit. The invention also permits optimal gate settings or data from which such settings may be determined to be associated with operating parameters defining the operating condition of the unit in a multi-dimensional virtual cam matrix for subsequent use when similar conditions are encountered.
Pump-turbine power generation techniques have become well established over recent decades as an alternative or complement to conventional turbine power production arrangements. Generally, pump-turbine machines include a set of wicket gates and a runner/impeller which can operate as a Francis-style turbine in one direction of rotation and as a centrifugal pump in an opposite direction. A motor-generator coupled to the pump turbine functions both as a power generator during a turbining mode of operation and as a motor or prime mover for the pump during a pumping mode.
Pump-turbine installations provide energy storage systems by utilizing excess electric capacity on power distribution grids in times of reduced energy demand to pump water, previously used to generate power, back into an upper reservoir. The water is then again used to generate electricity when needed, such as during peak demand periods. Pump-turbine units are presently in use over a wide range of heads and power output levels. The overall efficiency of pump-turbine units depends not only on the ability of the equipment to effectively produce power from water flow from the upper reservoir during the turbining mode of operation, but equally on its ability to efficiently move water back to the upper reservoir during the pumping mode. To maximize the cost effectiveness of the pump-turbine installation, it is therefore necessary to generate power as efficiently as possible during turbining, while utilizing as little power as possible for the needed water displacement during pumping.
Various techniques have been proposed and are currently in use for regulating operation of pump-turbine units during turbining and pumping modes of operation. In the pumping mode of operation, older governors position the wicket gates in a fixed, predetermined position to let water through the pump to the upper reservoir. However, because the pumping efficiency of the unit is influenced by the wicket gate position, the flow rate and the head across the unit, a single wicket gate position will generally not provide optimal efficiency for different flow rate and head conditions.
Other techniques are known that attempt to improve operation of the pump-turbine in similar manners for both phases of operation. For example, it is known to estimate desired wicket gate positional settings from test data generated on a small scale model for the installation. Such model test data may be used to establish a mechanical or computerized ("virtual") cam surface relating head, flow and power in such a way as to identify desired wicket gate settings. Surfaces, real or virtual, of this type are typically referred to as "3D CAMs." In the pumping mode of operation the power parameter represents the power input needed to drive the pump and thereby displace water at particular head and flow rates to the upper reservoir. It is also known to identify certain preferred wicket gate positions for the pumping mode of operation through special test sequences, such as index tests.
While model-based 3D CAM techniques are generally preferable to the fixed wicket gate approach, they fail to account for differences between model test performance and that of actual equipment. Where index testing is used to identify preferred wicket gate positions, such testing typically requires at least temporary interruption of normal service of the facility, and generally does not identify desired settings over a broad range of operating conditions. Moreover, model testing and index testing do not typically account for the impact of other parameters such as cavitation or vibration during pumping. Because modest improvements in performance can result in considerable gains in revenue for the installation, such drawbacks may amount to large real or opportunity costs for the plant.
There is a need, therefore, for an improved method of controlling pump-turbine installations that allows optimal wicket gate positions for pumping mode operation to be determined for actual operating equipment and during normal operation of the facility. In addition, there is a need for techniques of this type that can account for factors other than head, flow and power input in evaluating the desired gate positions.
SUMMARY OF THE INVENTION
The present invention features a novel technique for improving or optimizing pumping mode performance of a pump-turbine designed to respond to the needs identified above. The invention provides a method and apparatus for optimizing or improving performance of a pump-turbine power generating unit operating in pumping mode. Such improvements in performance may comprise improvements in operating efficiency (e.g., reducing energy costs during pumping), reductions in maintenance costs and associated operational down time, or both. The invention is particularly suited for application in a generating unit including a pump-turbine in fluid communication between a headwater reservoir and a tailwater reservoir, a motor-generator coupled to the pump-turbine for generating electrical power as water flows through the pump-turbine from the headwater reservoir to the tailwater reservoir during a turbining mode of operation and for driving the pump-turbine to displace water from the tailwater reservoir to the headwater reservoir during a pumping mode of operation, and a plurality of movable gates for regulating flow through the pumpturbine. In accordance with one aspect of the invention, the method includes the steps of (a) determining influences of gate positions on at least one operating parameter of interest and (b) monitoring levels of a plurality of operating parameters during normal pumping mode operation of the pump-turbine. Based on the influences determined in step (a) and on the monitored levels, a desired gate position is selected to optimize the parameter of interest, and the gates are positioned in the desired gate position. In accordance with a particularly preferred embodiment, a plurality of parameters of interest are considered in determining the desired gate position, and the relative impact of each parameter on the selected gate position may be altered by assigning values to weighting coefficients associated with each parameter.
In accordance with another feature of the invention, a method for improving performance of a pump-turbine unit calls for dividing operating ranges of each of a plurality of operating parameters for the pump-turbine into a plurality of operating range segments to define a virtual cam matrix comprising matrix locations bounded by the operating range segments, the operating parameters including head, flow rate, power input level during pumping operation of the pump-turbine and at least one other operating parameter. The virtual cam matrix is stored in a memory circuit. Optimal gate setting data for at least one of the matrix locations is then determined, and the optimal gate setting data is stored in the memory circuit for reference in positioning the gates when operating parameter levels are detected corresponding to the associated matrix location.
The method of the invention may be adapted to identify the desired gate position based upon an index value determined from several factors capable of affecting overall or long term operation of the unit. Thus, the method may include the steps of moving the gates to a plurality of positions during the pumping mode of operation, and monitoring the operating parameters for each of the plurality of gate positions. Reference levels are then derived from the operating parameters for each of the plurality of gate positions. The reference levels are then combined to determine an index value for each of the plurality of gate positions. The index values for each of the plurality of gate positions are then compared and a desired gate position is selected from the plurality of gate positions based upon the comparison. Each of the reference values, which may represent such factors as pumping efficiency, cavitation and vibration, may be weighted to reflect the relative priority among the values.
The system of the invention preferably includes a plurality of sensors, a memory circuit and a control circuit. Each of the sensors detects an operating parameter of the pump-turbine unit during the pumping mode of operation, and generates a parameter signal representative thereof. The control circuit is coupled to the plurality of sensors, to the memory circuit and to actuators for moving the wicket gates. The control circuit is configured to identify influences of gate positions on the parameter of interest, to monitor the parameter signals, to determine, based on the parameter signals and the influences, a desired gate position, and to command movement of the at least one actuator for placing the gates in the desired gate position.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the following detailed description, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts, in which:
FIG. 1 is an exemplary perspective view of a turbine power generating facility including a pump-turbine unit between upper and lower reservoirs;
FIG. 2 is a diagrammatical side elevational view of the installation of FIG. 1, illustrating certain of the instrumentation for optimizing performance of the unit during pumping;
FIG. 3 is a diagrammatical elevational view of a portion of the facility illustrating additional instrumentation for optimizing the unit performance;
FIG. 4 is a more detailed elevational view of the pump-turbine unit illustrating the additional instrumentation for optimizing the unit performance;
FIG. 5 is a block diagram of certain of the functional circuits in an exemplary control system for monitoring various operating parameters during a pumping mode of operation of the pump-turbine unit;
FIGS. 6A-6C are flow charts illustrating steps of exemplary control logic for determining optimal wicket gate settings for the pumping mode of operation of the pump-turbine installation; and
FIG. 7 is a graphical illustration of exemplary curves relating several operating parameters to gate position as a basis for determining a preferred gate positional setting in accordance with one aspect of the present technique.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings and referring to FIG. 1, a pump-turbine power generating facility 10 is illustrated in fluid communication with an upper or headwater reservoir 12, partially bounded by an earthworks or dam 14, via an upstream conduit 16. Facility 10 is also in fluid communication with a lower or tailwater reservoir 18 via a downstream fluid conduit 20. As best shown in FIG. 2, in the illustrated embodiment, fluid conduits 16 and 20 are conduits linking upper and lower reservoirs 12 and 18 to facility 10, respectively. A headwater trash rack 22 is provided adjacent to the mouth of conduit 16 in reservoir 12 for preventing large objects from entering conduit 16 and potentially fouling or damaging facility 10. Similarly, a tailwater trash rack 24 is provided at the mouth of conduit 20 in lower reservoir 18. Trash racks 22 and 24 may be of any known type, typically consisting of a series of parallel pipes or bars extending vertically or at an incline between points below and above the mouths of conduits 16 and 20, respectively.
As best shown in FIGS. 3 and 4, facility 10 includes a housing and superstructure for supporting a pump-turbine generating unit, designated generally by the reference numeral 26, and associated equipment, and for allowing servicing of the equipment. In addition, facility 10 includes an operations control center or room (not shown) housing control and communications equipment for monitoring performance of unit 26. Pump-turbine generating unit 26 includes a pump-turbine 28 coupled to a motor-generator 30. Pump-turbine 28 and motor generator 30 are supported by a support structure, designated generally by the reference numeral 32 in FIG. 3, including thrust and guide bearings in a manner generally known in the art. Pump-turbine 28, which includes a rotating impeller 29, is coupled to motor-generator 30 via a drive shaft 34. In operation, impeller 29 of pump-turbine 28 is forced to rotate as water is permitted to flow from upper reservoir 12 to lower reservoir 18 through conduits 16 and 20 during a turbining mode of operation, thereby driving motor-generator 30 to generate electrical power. Electrical power is then output through a power grid (not shown). In a pumping mode of operation, motor-generator 30 drives impeller 29 of pump-turbine 28 to pump water from lower reservoir 18 to upper reservoir 12.
As illustrated in FIG. 4, unit 26 includes a series of movable wicket gates 36 surrounding pump-turbine 28 for regulating flow and efficiency of the unit. Wicket gates 36 are positioned by one or more actuators 38 coupled to hydraulic control valving (not shown) in a conventional manner. During turbining operation of unit 26, water enters pump-turbine 28 through a spiral 40 coupled to conduit 16 and exits through the center of impeller 29. Conversely, during pumping operation, water enters through the center of impeller 29 and exits through spiral 40. Wicket gates 36 are situated between pump-turbine 28 and spiral 40 and are pivoted angularly by movement of actuator 38 to open and close the flow area between pump-turbine 28 and spiral 40.
In accordance with the present technique, a number of operating parameters for unit 26 are sensed during pumping operation and used as the basis for selection of preferred positions of gates 36. Exemplary instrumentation for sensing the various parameters of interest is illustrated in FIGS. 2, 3 and 4. This instrumentation forms part of a control system further including a controller 120, illustrated diagrammatically in FIG. 5, which receives sensed parameter signals from the sensors, and processes the signals to determine the preferred gate positions as described below.
As shown in FIG. 2, preferred instrumentation for optimizing pumping operation of unit 26 includes a headwater reservoir elevation sensor 50 and a tailwater reservoir elevation sensor 52. Both sensors 50 and 52 are preferably water level transducers of a type generally known in the art. Signals produced by sensors 50 and 52 are used to determine the gross differential head between reservoirs 12 and 18. In addition, signals from tailwater elevation sensor 52 may be used to determine a submersion factor a in a manner known in the art, providing a relative indication of the submersion level of pump-turbine 28 relative to (typically below) tailwater reservoir 18.
Pressure transducers 54, 56, 58 and 60 are preferably provided on either side of headwater and tailwater trash racks 22 and 24 as illustrated in FIG. 2. Output signals from these transducers, representative of pressure head on either side of the trash racks, are used to determine differential pressure or head loss across the racks. Such differential pressure provides a relative indication of the degree of fouling of the trash racks. Also indicated in FIG. 2 are pressure transducers 62 and 64, positioned adjacent to upstream and downstream ends of conduit 16. Similar transducers 66 and 68 are preferably positioned in downstream conduit 20. Transducer sets 62-64 and 66-68 provide signals representative of pressure at their respective locations and may be used to determine head losses through each conduit.
As shown in FIG. 3, instrumentation for controller 120 also preferably includes a motor-generator power monitor 70 coupled to electrical service conductors (not shown) between motor-generator 70 and power grid interface circuitry (not shown). Monitor 70 provides an indication of electrical power input to motor-generator 30 for driving pump-turbine 28 during the pumping mode of operation. High and low side pressure transducers 72 and 74 are positioned adjacent to pump-turbine 28 in upstream conduit 16 and downstream conduit 20, respectively. Output from transducers 72 and 74, representative of pressure at their respective locations, serves as a basis for determining total pump head across pump-turbine 28. Also as shown in FIG. 3, a differential pressure transducer set 76 is provided in conduit 20 for determining flow rate through pump-turbine 28. Such differential pressure signals provide an indirect indication of flow rate, which can be subsequently calculated by well known techniques, such as a Winter-Kennedy type method. Alternatively, direct flow measurement devices, such as acoustic or ultrasonic flow meters, could be provided within the flow path of pump-turbine 28 to provide the desired flow rate indication.
Referring to FIG. 4, a position feedback sensor 78 is preferably associated with actuator 38 or a portion of the linkages between actuator 38 and gates 36. Sensor 78, which may be any suitable type of position transducer, such as a potentiometer, linear variable differential transformer or the like, provides a signal indicative of the relative angular position of gates 36. Cavitation sensors 80 and 82 are preferably provided in the vicinity of the pump-turbine draft tube 81, headcover 83 and on the wicket gates 36. Sensors 80 and 82, which are preferably acoustic emission sensors, provide an indication of the relative level of cavitation in pump-turbine 28 by detecting water-borne noise produced by such cavitation.
In addition to the sensors outlined above, in the presently preferred embodiment, a number of additional sensors are provided for indicating the states of vibration, seal clearances and bearing loads at various locations in unit 26. In particular, accelerometers 84, 86, 88 and 90 are provided in the vicinities of the pump-turbine head cover 83, the gate actuating linkages, the thrust bearing 89 and the motor-generator upper bridge 91, respectively, as shown in FIG. 4. Accelerometers 84, 86, 88 and 90 provide an indication of structural vibration imparted on support structure 32 by operation of pump-turbine 28. In addition, proximity probes 92, 94, 96 and 98 are provided in the vicinities of turbine guide bearing 93, trust bearing 89, lower motor-generator guide bearing 97 and upper motor-generator guide bearing 99, respectively. Probes 92, 94, 96 and 98 provide signals proportional to loading on the respective bearings as an indication of lateral displacement and axial loading of shaft 34. Another indication of loading is provided by proximity probes 100 and 102 positioned in the vicinity of upper and lower sealing surfaces of impeller 29. Probes 100 and 102 provide signals indicative of displacement of impeller 29 within the housing of pump-turbine 28, and of seal clearance gaps between stationary and rotating wear rings on the impeller and the pump-turbine housing surrounding the impeller. Additional bearing loading information is preferably provided by strain gauge sets 104, 106, 108 and 110 secured to turbine guide bearing 93, thrust bearing 89, lower motor-generator guide bearing 97 and upper motor-generator guide bearing 99, respectively. Strain gauge sets 104, 106, 108 and 110 provide signals indicative of deformation resulting from bearing loading, in a manner well known in the art. Finally, bearing temperature sensors (not shown) are preferably provided on bearings 93, 89, 97 and 99 to provide signals representative of the temperature of the bearing sets, as a further indication of bearing loading.
As mentioned above, the preferred instrumentation is used in the present technique to detect and monitor levels of key operating parameters of pump-turbine 26. Certain of these parameters, such as head, flow rate and input power level are used to define a virtual cam matrix as described more fully below. However, as distinguished from conventional virtual 3D cams, the present technique permits the creation of a virtual cam having additional dimensions and providing additional classification of particular operating conditions. For example, presently preferred additional dimensions of the virtual cam include a relative submersion factor (σ), determined in accordance with well known techniques, upper and lower impeller seal clearance, neighboring unit operating state, trash rack head losses and conduit head losses. Each of these additional parameters may affect performance of the pump-turbine unit in unique ways. For example, where unit 26 shares a length of penstock with one or more additional units, the operating state of those units (e.g., operating or not operating) can significantly affect the dynamic flow characteristics of both units, and ultimately, the optimal gate settings for pumping mode operation. Thus, because data relating to optimal gate settings is ultimately determined for each matrix location as described below, such optimal settings are preferably determined taking into account all of the parameters or dimensions of the virtual cam matrix.
The above instrumentation also serves to provide parameter signals for the specific parameters optimized by the gate settings selected. Each of these parameters also affects performance of unit 26. For example, seal clearance is a parameter which can have significant impact on performance. The shape of the head-flow characteristic and efficiency-flow characteristic of the pump-turbine in the pumping mode at a constant wicket gate opening position can change as a result of the seal clearance, adversely affecting efficiency, and particularly head and vibration at higher heads of operation. Similarly, leakages due to seal clearances may influence stability of the pump-turbine. Mechanical vibration tends to reduce the useful life of mechanical components and linkages, such as bushings, leading to costly down time for maintenance and component replacement. Excessive guide bearing temperatures may be caused by side loading and may be indicative of overloading that will eventually lead to the need to replace the bearings. In the same way, excessive cavitation levels may be considered indicative of operation at levels that will eventually lead to the need for cavitation blade repair. All of these factors may potentially reduce efficiency of the unit or accelerate costly maintenance or even component failure. Moreover, because these factors may be influenced by wicket gate position during pumping, the present optimization technique preferably considers such adverse affects in combination in selecting desired gate positions. In particular, in the embodiment described below, optimized parameters include pumping efficiency, vibration and cavitation. However, other parameters on which optimization may be based include sealing clearances, bearing loading and bearing temperature.
All of the sensing devices outlined above are coupled to controller 120 through appropriate data links and apply their respective signals to controller 120 as illustrated diagrammatically in FIG. 5. As shown in FIG. 5, controller 120 includes several functional circuits, including an input interface circuit 122, a central processing circuit 124, an output interface circuit 126, a memory circuit 128, an optimization circuit 130 and a comparison circuit 132. Interface circuit 122, which typically includes appropriate multiplexing, analog-to-digital converting and signal conditioning circuitry receives operating parameter signals from sensors 50-110, and applies these signals to central processing circuit 124. Similarly, interface circuit 126, which typically includes signal conditioning and valve driver circuits for operating gate actuators 38, receives control signals from central processing circuit 124 and commands corresponding servo movement of gates 36. Interface circuit 126 also includes appropriate drivers and signal conditioning circuitry for an operator interface 134, preferably including a monitor and keyboard at an operations control station (not shown).
Central processing circuit 124 is also linked to memory circuit 128, optimization circuit 130 and comparison circuit 132. In operation, central processing circuit 124 executes a cyclical control routine stored within memory circuit 128 for controlling operation of unit 26. For the present purposes, details of the main control routine unrelated to optimization of pumping mode performance are not discussed herein for the sake of clarity. As described more fully below, during certain phases of the control routine, central processing circuit 124 calls upon comparison circuit 132 to perform comparisons of the sensed operating parameters with a set of reference values for the same parameters stored in memory circuit 128. These comparisons enable central processing circuit 124 to locate the set of current operating parameters in a multi-dimensional matrix (i.e. an N-dimensional virtual cam) defined by the reference values for the pumping mode of operation of unit 26. When the comparison indicates that an optimal gate setting for the set of operating parameters needs to be identified, central processing circuit 124 calls upon optimization circuit 130 to perform a search for the desired gate position as summarized below. Following the search, the optimal gate position is stored in memory circuit 128 for future use when the same set of operating parameter values is encountered. Alternatively, data representative of the influence of gate positions on optimized parameters may be stored in memory circuit 128 and used as a basis for deriving the optimal gate position for the current location in the virtual cam matrix.
As will be appreciated by those skilled in the art, the functional circuitry represented in FIG. 5 may be defined by standard input/output circuitry, memory circuitry and programming code in a standard programmable logic controller, personal computer, computer workstation or the like. For example, in the presently preferred embodiment, central processing circuit 124, in the form of a programmable logic controller dedicated to facility 10, is provided with resident memory for executing the main control routine. Optimization circuit 130 and comparison circuit 132 are configured in a portable computer system that can be selectively linked to the programmable logic controller to execute optimization of gate settings when desired. Alternatively, optimization and comparison circuitry may be configured in a single controller with central processing circuit 124, or may be entirely remote from facility 10 and selectively linked to central processing circuit 124 by modem or other telecommunication device.
FIGS. 6A, 6B and 6C illustrate steps in exemplary control logic executed by controller 120 for determining desired or optimal positional settings for gates 36 in the pumping mode of operation of pump-turbine 28. In the preferred embodiment, the present technique divides key operating parameters, including head across pump-turbine 28, flow rate through pump-turbine 28 and power input to drive pump-turbine 28 into operational range segments, such as 10 segments over the allowable or expected operating range for each parameter. The resulting range segments thus form a matrix of operational parameter levels stored in memory circuit 128 (i.e., the "N-dimensional virtual cam matrix" referred to above). During normal pumping mode operation of unit 26, central processing circuit 124 identifies desired or current operating conditions and calls on comparison circuit 132 to compare the current operating parameters with the range segments for the same parameters stored in memory circuit 128. When a particular combination of parameter range segments is encountered for which an optimal gate setting has yet to be established, optimization circuit 130 identifies a desired gate positional setting through an optimization search as described below. The optimization may be based on one or more parameters of interest, such as pumping efficiency. However, the search preferably identifies the influence of various gate positions on the operating parameters of interest and these influences are combined, through weighting factors, into an optimization index value. This index value then provides an indication of the optimal gate positional setting for the combination of weighted parameter influences and for the virtual cam matrix location being populated.
FIG. 6A illustrates a portion of a main control routine 200 executed by controller 120. Routine 200 begins at step 202, and at step 204 all monitored operating parameter values are initialized. At step 206, controller 120 establishes communication with an electronic governor module, which may be remote to controller 124. This electronic governor module provides operational control of various settings for pump-turbine 28 under normal operation in a manner well known in the art. At step 208, controller 120 evaluates the communication link with the electronic governor, and if the communication link is determined to be faulty, displays an error message on operator interface 134, as indicated at step 210. At step 212, controller 120 prompts an operator to select whether the communication link should be retried. If so, controller 120 returns to step 206, otherwise, routine 200 is exited by closing all files at step 234 and stopping the application at step 236.
Once communication is established with the unit's electronic governor, signals from all sensors monitoring parameter values are polled at step 214 to measure the parameter values. As will be appreciated by those skilled in the art, certain of the "measured" parameters referred to in step 214 are, in practice, derived from sensed parameter signals. For example, when flow rate is measured indirectly, central processing circuit 124 will typically include appropriate program code for deriving flow rate values from measured pressure data. At step 216, controller 120 prompts the operator through interface 134 to select whether optimization weighting coefficients should be altered from their current settings. These weighting coefficients generally establish the relative influence of the various optimized parameters in selecting preferred gate positional settings as discussed in greater detail below. If the operator selects to change the weighting coefficients, the new coefficients are entered at step 218. Following step 218, or if the coefficients are not changed, controller 120 advances to step 220.
At step 220, comparison circuit 132 compares the current levels of operating parameters in the virtual cam matrix with reference levels defining the range segments in the matrix to determine the location of the current operating conditions in the virtual cam matrix. In the presently preferred embodiment, the virtual cam matrix accessed at step 220 is based on flow rate, head and power input levels, although this matrix can be expanded to include additional operating parameters as discussed above. By accessing a memory location assigned to the particular combination of parameter ranges, central processing circuit 124 then determines whether an optimal gate setting has been determined for the matrix location. If not, controller 120 proceeds to step 222, where an optimization routine 300 is executed as summarized below with reference to FIG. 6B. Once optimization routine 300 is completed, controller 120 returns to main routine 200 at step 224, and at step 226 transmits the optimal gate position to the electronic governor for positioning gates 36.
From step 226, controller 120 proceeds to step 228, where a parameter error routine 400 is executed as summarized below with reference to FIG. 6C. In general, parameter error routine 400 verifies that sensed or calculated parameter values are consistent with expected ranges of variation, and determines whether adjustments to the virtual cam matrix or the optimization routine are in order (e.g., expanding the matrix to additional range segments or modifying the weighting coefficients for the optimization routine). From parameter error routine 400, controller 120 returns to main routine 200 at step 230. At step 232, controller 120 verifies whether an exit command has been received, such as from an automatic or operator commanded interrupt. If such a command has been received, the routine is exited at steps 234 and 236 as described above. Otherwise, controller 120 returns to step 214 to continue cycling through the main control routine.
Preferred flow of the present optimization technique is summarized in FIG. 6B. Optimization routine 300 is entered at step 302 from step 222 of the main control routine. At step 304, controller 120 accesses memory circuit 128 to determine whether characteristic data relating optimized parameters to wicket gate position has been identified for the current set of operating conditions (i.e., the location in the virtual cam matrix). If not, controller 120 proceeds to step 316 to generate such data as described below. If such information is found in memory circuit 128, controller 120 proceeds to step 306, where controller 120 prompts the operator to select whether optimization factors are to be changed.
In the presently preferred embodiment, a number of factors are preferably considered for selection of the desired gate position for the virtual cam matrix location being populated with a desired gate positional setting. As illustrated in FIG. 6B, these factors preferably include pumping efficiency, cavitation and vibration. Because the pumping efficiency ultimately results in real or opportunity costs for the installation, it is generally desirable to operate at the peak efficiency for the current operating conditions reflected in the cam matrix location. However, other factors, such as cavitation and vibration also ultimately result in costs to the installation, typically in terms of higher or more frequent maintenance and lost revenue during maintenance down times. Moreover, the optimal gate setting for minimizing costs resulting from such operating parameters may not, and typically is not the same setting as that resulting in peak efficiency. Thus, the present technique provides a mechanism for balancing the influences of the gate positional setting on these various parameters.
Thus, at step 308, the operator may change the parameters on which the desired gate position is selected. Additional optimization factors might include, for example, bearing temperature. At step 310, controller 120 determines the optimal gate setting for the current virtual cam matrix location by minimizing an optimization index value derived from the relationship:
Opt=(K1×EF)+(K2×CF)+(K3+VF) (1);
where Opt is the optimization index value, K1, K2, and K3 are weighting or penalty coefficients, and EF, CF and VF are a factors representative of the influence of gate position on pumping efficiency, cavitation and vibration, respectively, as described below.
It should be noted that although equation (1) is presently preferred, the present technique permits an unlimited number of parameter values to be considered in determining the optimal gate setting. In general, the technique is intended to minimize deviation from optimal gate settings for each of the optimized parameters in accordance with the relationship:
Opt= K1×(P1(o)-P1(s))!+ K2×(P2(o)-P2(s))!+. . . + Kn×(Pn(o)-Pn(s))! (2);
where P1(o), P2(o) and Pn(o) are optimum levels of first, second and nth optimized parameters at any gate setting for the current virtual cam matrix location, and P1 (s), P2(s) and Pn(s) are actual levels for the same parameters at the selected or desired gate setting. By determining the influence of gate settings on each of the optimized parameters, as described below, controller 120 may thus determine which gate setting results in the optimal level for index value Opt. The values of optimal levels of the parameters and functions relating each parameter to gate position (to determine the actual parameter levels at the selected gate position) are identified through a gate positioning test sequence described below.
It should also be noted that the optimized parameters considered at step 310 may include parameters defining the virtual cam matrix in memory circuit 128, or may be entirely different parameters. In general, as mentioned above, the virtual cam matrix will include the parameters of head, flow and power input. However, as discussed above, additional parameters, or "dimensions" may include, by way of example, seal clearance, the operating state of neighboring units in a multi-unit facility, the relative situation of the particular unit in the facility (e.g., adjacent to a stream or pond bank or near the middle of a stream) and the relative condition of upstream or downstream conduits (e.g., as indicated by sensed head losses through the conduits). While such parameters may be considered for the purposes of gate setting optimization, they are typically better suited to definition of the N-dimensional virtual cam matrix. On the other hand, parameters considered for optimization are preferably those that are more directly influenced by gate positional changes.
Once the desired gate setting has been determined, controller 120 sets the gates to the optimal point at step 312 and saves the setting in memory circuit 128 for the virtual cam matrix location. Controller 120 then returns to main routine 200 as indicated at step 314.
With reference to FIGS. 6B and 7, the influence of gate position on the optimized parameters is determined as follows. FIG. 7 represents a family of exemplary curves 500 relating optimized parameters of pumping efficiency, cavitation. and vibration to gate position. At step 304, if controller 120 does not locate such data in memory circuit 128 from previous execution of optimization routine 300, it proceeds to step 316. At step 316, a first gate test position is assigned to be a lower limit position for the gates. This lower limit position may be represented by the vertical line extending from point 508 in FIG. 7. At step 318, the gates are set to this initial position. At step 320, the sensors providing indications of the optimized parameters are polled. This procedure is preferably performed several times at step 320, and the resulting values are statistically analyzed at step 322, such as by determining mean and standard deviation values for the parameter levels. At step 324, controller 120 determines whether the pump-turbine unit has stabilized by comparing the statistical data to acceptable variances allowable for steady state operation. If steady state operation has not been reached, controller 120 returns to step 318 to await steady state conditions.
Once steady state conditions are reached, controller 120 proceeds to step 326, where elements of the optimized parameters are calculated, along with the parameters themselves. For example, in the presently preferred embodiment, the pumping efficiency value is determined from the total head across pump-turbine 28, flow rate through the unit and the power input to drive the pump-turbine, in a manner well known in the art. To allow comparison to model test data, this total head is calculated based upon the signals produced by sensors 72 and 74 plus a velocity head correction where an absolute flow rate measurement is used (e.g., from an acoustic or ultrasonic sensor). Where a relative or indirect flow rate measurement is used (such by a Winter-Kennedy type calculation), the total head may be provided by a differential pressure transducer at the location of sensors 74 and 76. At step 328, this data is stored in memory circuit 128.
At step 330, the gate position is incremented (such as by 10% of the total allowable gate movement range). At step 332, controller 120 verifies whether the new gate test position exceeds the upper limit gate position, as indicated by the vertical line extending from point 510 in FIG. 7. If the upper limit is not exceeded, controller 120 returns to step 318 where the gate is moved to the new test setting. The procedure outlined above is then repeated until the gate upper limit position is exceeded at step 332.
The data measured through steps 316-332 identifies the influence of gate position on the optimized parameters as illustrated in FIG. 7. Curves such as those shown in FIG. 7 represent data preferably obtained by a curve fitting technique, such as linear curve fitting, based on the data obtained in steps 316-332. For example, curve 502 represents the influence of gate position on pumping efficiency, which reaches a peak at a point 512. Similarly, curves 504 and 506 represent the influence of gate position on cavitation and vibration, respectively, which reach respective minima at points 514 and 516. Through subsequent incorporation of this data in the optimization determination at step 310, values of optimization index Opt may be obtained as a function of gate position, inherently taking into account both the separate optima of each optimized parameter, the shape of the parameter curve surrounding the optimal point, and the weighting coefficients for each parameter, as indicated by curve 518. As will be appreciated by those skilled in the art, depending upon the relative weighting of each parameter, the overall optimal setting, indicated by the minimum point 520 on Opt versus gate settings curve 518 may typically not correspond to any one of the individual optima for the separate operating parameters, but instead represents a balance between the gate position influence on each of the optimized parameters.
As indicated at step 228 of FIG. 6A, the present technique also provides a mechanism for determining whether sensed data is historically consistent and whether the optimization routine should be modified. As shown in FIG. 6C, parameter error routine 400 begins at step 402, and at step 404, controller 120 determines whether data sensed or calculated at step 214 above falls within the virtual cam matrix stored in memory circuit 128. If not, an error flag is generated. At step 406, circuit 124 determines whether such a flag is set. If so, circuit 124 causes an error message to be displayed on operator interface 134, and logs or stores the errors in memory circuit 128, as indicated at step 408.
Following step 408, or if no error flag is detected at step 406, at step 410 the sensed or calculated data is stored to a history data base for the matrix location. At step 412, based upon the historical data stored in the data base, circuit 124 evaluates trends in the data to determine whether a rate of change limit has been exceeded. If so, an error flag is set. Such rate of change limits are preferably set during configuration of routine 400 and are stored in memory circuit 128. Exceeding a rate of change limit is then considered to indicate that degradation in a sensed parameter is occurring as an abnormal rate. Also at step 412, circuit 124 projects or estimates the time expected for the changing parameter to exceed an allowable limit if proceeding at its current rate. At step 414, circuit 124 determines whether any error flags were set in step 414, and, if so, displays an error message on operator interface 134 and saves the errors in memory circuit 128.
At step 418, controller 120 reviews any combinations of errors logged at steps 408 and 416 to identify any known error patterns, indicative of some known system degradation or failure. At step 420, if any pattern was recognized, circuit 124 proceeds to step 422, where a pattern alert message is displayed on operator interface 134, and the trend is stored in memory circuit 128. From step 422, circuit 124 returns to the main routine as indicated at step 440. If no known pattern was recognized, circuit 124 proceeds from step 420 to step 424, where an operator may identify or label any unknown patterns in the logged parameter errors and suggest corrective action in response to the error pattern. If the operator elects not to do so, circuit 124 returns to the main control routine. If a pattern identity and corrective action are suggested by the operator, this information is entered at step 426, and at step 428, the new identity and corrective action data are stored in memory circuit 128. The newly entered information is then displayed and logged at step 430, from which point, controller 120 again returns to the main control routine.
As will be appreciated by those skilled in the art, parameter error routine 400 provides a diagnostic tool for identifying abrupt changes in sensed or calculated parameters on the basis of which the matrix and optimization techniques outlined above are executed. For example, where data outside the range of the matrix is identified, this may indicate failure or malfunction of one or more sensors, or may be symptomatic of longer term changes in the parameters. In the latter case, plant operations or engineering personnel may opt to expand or otherwise modify the matrix to accommodate the changes and determine new optimum gate settings accordingly. For example, parameters such as seal clearance defining the virtual cam matrix may gradually change to levels not originally included in the matrix, requiring modification of the matrix and population of the new matrix locations with optimal gate settings. Moreover, by identifying trends in optimized parameters, operations personnel may identify potential problem areas, such as bearings or seals, for which optimization coefficients may need to be increased to forestall maintenance costs or operational down time, or shut down the unit for emergency maintenance.
While the foregoing description has been provided for the presently preferred embodiment of the invention, the invention is not intended to be limited to any particular arrangement, but is defined by the appended claims. Various alternative configurations of the invention may occur to those skilled in the art, and to the extent such variations fall within the scope of the claims, they are intended to form a part of the claimed invention. For example, in the preferred embodiment characteristic data is identified relating optimized parameters to gate position and the optimal gate position is subsequently determined by reference to an optimization index based on the data. Alternatively, however, a similar optimization index value may be generated for each gate position tested and an iterative process used to select the gate position resulting in the minimum or optimal value of the index.
Similarly, in the above discussion, reference was made to storing values representative of the desired gate setting for each virtual cam matrix location for later use. Alternatively, data identified in the gate position test sequence indicating the influence of gate settings on the optimized parameters may be stored instead of the actual gate position. Subsequently, at step 304, controller 120 will access this influence data from the memory circuit and determine the optimal gate setting at step 310 in real time, each time the virtual cam matrix location is encountered. The latter approach has the advantage of allowing new optimal gate settings to be determined in response to changes in weighting coefficients without re-evaluating the influence of gate settings on the optimized parameters. As a further alternative, both currently preferred gate settings and influence data may be stored for each matrix location, and the gate settings updated following changes in the weighting coefficients.
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A technique is disclosed for optimizing performance of a pump-turbine unit while operating normally in the pumping mode by identifying gate positions resulting in optimization of certain parameters of interest. Influences of gate positions on the optimized parameters is determined and used to evaluate the combined effect of the gate position on the parameters. Weighting coefficients may be used to alter the relative importance of each parameter in the gate position ultimately selected. Gate positions are optimized for each location in a multi-dimensional virtual cam matrix as conditions defining the locations are encountered. A parameter error or evaluation routine is provided for evaluating the consistency of monitored parameter values and for identifying trends that may require reconfiguration of the virtual cam matrix or alterations in the optimization routine, such as changes in the weighting of various parameters. The technique may be used to identify gate positions for one parameter of interest, such as pumping efficiency, or a number of parameters simultaneously to improve productivity of the facility and avoid or delay maintenance costs caused by degradation influenced by gate settings.
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BACKGROUND OF THE INVENTION
9-volt battery supported LED flashlights have been marketed for about the last seven years. The principal advantage of these flashlights is because they are supported on and atop the 9 volt battery, they eliminate the need for a flashlight body holding the batteries, they eliminate the need for a removable bulb holding assembly, they eliminate the need for a light reflector and they eliminate the need for a lens and lens bezel.
The companies currently manufacturing battery mounted flashlights have not optimized the market for these products because: (1) their product design is not cost sensitive; (2) their product design is not durable; and (3) they have not designed and promoted the product in its optimal markets.
The first technical entry into the battery supported flashlight market is shown in the Puppo, U.S. Pat. No. 6,137,398, filed on Oct. 15, 1999, entitled “Miniature Battery Powered Beacon”. This device includes a base 12 carrying terminals 26 and 28 and a top mounted LED 14 covered by a cap 30 . There is no switch in the Puppo device and the only way to shut the Puppo “Beacon” off is to remove the flashlight from the battery. Besides the cumbersome maneuver of snapping the flashlight on and off the battery just to shut the light off, because the flashlight is so small, when it is off the battery it is frequently misplaced or lost. This is not a good design.
Benjamin Victor Duane Henry, in his U.S. Pat. No. 6,511,202 entitled “Light Emitting Diode 9-volt Battery Snap Flashlight”, came up with the idea of adding a switch to the Puppo design, but the incremental cost of the switch itself makes Henry's design non-competitive in the marketplace.
Then came John Collins (U.S. Pat. No. 6,695,459, entitled “Portable Lighting Product, Portable Lighting Product Circuitry, and Method for Switching Portable Lighting Product Circuitry), in 2002 and devised a switchless battery mounted flashlight that pivots on one of the battery terminals to engage the other battery terminal to turn the flashlight on and off. The base 40 , as seen in FIG. 8 , carries a terminal 56 that clamps on and pivots with respect to the battery terminal 22 . The wire 47 clips on the other battery terminal selectively to turn the flashlight on and off as the base pivots on a vertical, not horizontal, axis.
The biggest problem with the Collins design is stability. When the switch is off as depicted in FIG. 8 , the base 40 is solely supported on one battery contact, contact 22 , and the base is swung perpendicular to and overhanging the battery. It cannot be carried in that position because it will easily snap off the battery and damage the base terminal connection.
Furthermore, when in use the Collins device feels and appears flimsy and of low quality.
It is a primary object of the present invention to ameliorate the problems noted above in battery mounted flashlights.
SUMMARY OF THE PRESENT INVENTION
In accordance with the present invention, a 9-volt battery mounted flashlight is provided including a lower housing fixedly mounted on the battery and an upper housing carrying an LED that pivots or rocks on the lower housing to turn the flashlight on and off. The upper housing has a pair of integral pivot bosses that mount in horizontal pivot bores in the lower housing so the upper housing rocks between on and off positions.
The principal advantages of the present invention are low cost and stability. The low cost is provided by the one-piece upper and lower housings and the elimination of a self-standing switch. The rocking motion of the upper housing provides the switching function at a lower cost. The stability is provided by the lower housing which snaps onto both positive and negative terminals of the battery to lock the lower housing on the battery without relative movement therebetween such as in the Collins portable lighting product discussed above. Further stability is provided by the recess in the top of the lower housing that receives and guides the upper housing as it rocks from on to off positions in the lower housing.
This flashlight has many uses such as a home emergency light, a camping light, or with red flashing LEDs, a vehicle warning light. One ideal marketing of this product is with of 9-volt batteries at the point of sale of the batteries, either inside or outside of the battery packaging.
This flashlight, properly made and designed, can be manufactured at a cost of approximately $0.30 at a given labor rate, by far cutting the cost of currently marketed battery mounted flashlights.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present light assembly shown snapped onto the contacts of a standard 9-volt battery;
FIG. 2 is an exploded view of the light assembly and battery illustrated in FIG. 1 ;
FIG. 3 is a longitudinal section through the light assembly and battery showing the light assembly in its “off” position;
FIG. 4 is a longitudinal section of the light assembly and battery according to the present invention illustrated in the “on” position;
FIG. 5 is a circuit illustrating the LEDs, switch, and 9-volt battery and resistor in series configuration;
FIG. 6 is a lower perspective of the top housing assembly;
FIG. 7 is a bottom perspective of the bottom housing assembly, and;
FIG. 8 is a top perspective of the bottom housing assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and particularly FIGS. 1 to 4 , the present light assembly is generally designated by the reference numeral 10 , and as illustrated in FIG. 1 is releasably snapped to the top contacts of a standard 9-volt battery 11 .
As seen more clearly in the exploded view of FIG. 2 , the light assembly 10 includes a stationary bottom housing 12 carrying a positive contact or terminal 14 and a negative contact or terminal 15 that snap respectively onto positive battery contact or terminal 16 and negative battery contact or terminal 17 .
Also seen in FIG. 2 a “J” contact 27 is provided that selectively engages the negative contact 15 to turn the light assembly on and off, a resistor 28 provides the necessary voltage drop to the LEDs 19 and 21 , and a conductive wire 30 provides electrical contact between the positive contact 14 and one of the leads of resistor 28 . A coil spring may be an alternative to “J” contact 27 .
An upper housing 18 carries LEDs 19 and 21 and is pivotally mounted in lower housing apertures 23 by integral opposed circular mounting bosses 25 . The pivotal movement of the upper housing 18 within the lower housing 12 is what causes actuation and deactuation of the LEDs 19 and 21 .
The light assembly 10 is illustrated in FIG. 3 in its “off” position, with “J” contact 27 apart from the negative light assembly contact 15 .
As seen in FIGS. 3 , 7 , and 8 , the lower housing 12 is a one-piece plastic molding that is generally rectangular in construction having an upper rectangular recess 32 that pivotally receives and guides the upper housing 18 . As seen in FIG. 8 , the lower housing has a transverse wall 34 with a pair of through bores therethrough 35 and 36 , that receive the stems 39 and 40 of contacts 14 and 15 respectively. The contacts are riveted in bores 35 and 36 . As seen more clearly in FIG. 7 , positive contact 14 is hexagonal in configuration and has a bore 38 therein that snaps over battery positive terminal 16 , while contact 15 is a male member that fits within negative battery terminal 17 , as seen clearly in the sectional views of FIGS. 3 and 4 .
As seen more clearly in FIGS. 3 , 4 , and 6 , the upper housing 18 is also generally rectangular in construction and is sized to fit closely within recess 32 of the lower housing 12 so the upper housing is guided by and stable in the lower housing. The upper surface of the housing 18 has a pair of circular bosses 38 and 39 on transverse wall 40 that each have a pair of holes therein that receive the leads of the LEDs 19 and 21 . The LEDs 19 and 21 are glued in the recesses formed by the bosses 38 and 39 .
As seen more clearly in FIG. 6 , the bottom of the upper housing 18 has a rectangular recess 42 therein and has a vertical adjacent slot 43 into which the “J” contact 27 is press-fitted. Resistor 28 is glued to the bottom surface of the transverse wall 40 .
One end of the wire 30 is soldered to the right end of the resistor 28 as illustrated in FIG. 6 , while the second lead of resistor 28 is soldered to the first lead of LED 19 . The second lead of LED 19 is soldered to the right lead of LED 21 . The second lead of LED 21 is soldered to the top of the “J” contact 27 . This circuit configuration is illustrated in FIG. 5 showing the LEDs 19 and 21 in series with each other, in series with the resistor 28 , and in series with “J” contact switch 27 and 9-volt battery 11 .
It should be noted that the lower end of wire 30 is soldered to the contact 14 prior to assembly of the upper housing 18 into the lower housing 12 .
As seen in FIGS. 3 and 4 , the upper housing 18 is maintained in its on and off positions by a detent mechanism 46 that includes a pair of integral rigid prongs 47 and 48 integral with and downwardly depending from the lower reach of the upper housing 18 . The lower end of one of the prongs 47 and 48 engages and passes over a spring detent 50 formed integrally with the lower housing 12 .
As seen in FIG. 8 , the spring detent includes an upper arcuate projection 51 that is cantilevered on lower portion side wall 54 by spring portion 52 in a recess or opening 55 in lower housing transverse wall 34 . Thus, as one of the prongs 47 and 48 engages the detent projection 51 , the detent projection 51 springs downwardly and then back upwardly as the prong passes thereover securely holding the upper housing 18 in its “off” position in FIG. 3 where upper housing 18 engages the lower housing against the upper housing recess at point 58 to lock the upper housing in its “off” position.
Similarly, as the light assembly is switched or rocked to its “on” position in FIG. 4 , the detent assembly 46 locks the upper housing against the lower housing recess at point 60 thereby locking the upper housing 18 in its “on” position.
The user shifts the light assembly from its “off” position shown in FIG. 3 , to its “on” position by hand-grasping and placing the thumb against the upper reaches of the upper housing 18 adjacent the LED 21 and pushing downwardly, rotating the upper housing 18 from a position shown in FIG. 3 to the “on” position shown in FIG. 4 . Conversely, the light assembly 10 is switched from the “on” position of FIG. 4 to the “off” position of FIG. 3 by hand-grasping the battery 11 and light assembly 10 pushing downwardly with one's thumb on the upper housing adjacent the LED 19 and pushing downwardly rotating the housing assembly 18 clockwise from the position shown in FIG. 4 to the position shown in FIG. 3 .
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A 9-volt battery mounted flashlight including a lower housing fixedly mounted on the battery and an upper housing carrying an LED that pivots or rocks on the lower housing to turn the flashlight on and off. The upper housing has a pair of integral pivot bosses that mount in horizontal pivot bores in the lower housing so the upper housing rocks between on and off positions.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of this invention are generally related to safety valves. More particularly, embodiments of this invention pertain to subsurface safety valves configured to control fluid flow through a production tubing string.
2. Description of the Related Art
Safety Valves are designed to minimize the loss of reservoir resources or production equipment resulting from catastrophic subsurface events by shutting in the well. The “standard” safety valve achieves this by design with one “active control line”. The normally closed safety valves are controlled from the surface via a hydraulic control line that extends from the valve, through the wellhead to a surface controlled emergency closure system. Hydraulic pressure P C applied through the control line maintains the valve in the opened position. Removal of control line pressure returns the valve to its normally closed position. Setting depth directly affects the operational characteristics of the valve due to the hydrostatic pressures P H created from the normal control system.
Conventional safety valve design incorporates a hydraulic piston and spring to open and close the valve. The hydraulic chamber housing the piston is connected to the surface by a hydraulic control line. Pressure is applied to this control line to hold the valve in the open position. Hydrostatic or “head” pressure P H is always present in the control line due to the column of fluid between the safety valve and the surface.
Functionally, control line pressure P C actuates a piston which is mechanically linked to a “flow tube”. The flow tube traverses across a closed flapper thus opening the flow through the safety valve and its tubing. When the surface pressure is released, a return spring returns the valve back to its closed position. The nature of the design is such that the tubing pressure P T , which acts against the active control line piston effect, will assist in valve closure.
To open the valve, hydraulic pressure P C is applied to the upper end of the piston, via the control line, forcing the flow tube downward, opening the flapper.
To close the valve, the applied hydraulic pressure P C is removed from the upper end of the piston. There are two forces available now to force the flow tube upward allowing the flapper to close. The spring now furnishes an upward force F S sufficient to counteract the downward force due to the hydrostatic pressure P H of the fluid in the hydraulic control line. This causes the flow tube to move upward allowing the flapper to close. Tubing pressure P T at the safety valve will also apply an upward force on the hydraulic piston. This will assist the piston in the upward movement of the flow tube allowing the flapper to close.
In a deep set application, the active control line hydrostatic pressure P H is significant, such that a spring may not be able to overcome the hydrostatic pressure, thus not allowing the flapper to close. To compensate for the active control line's hydrostatic pressure P H , a second “balance” line is used to negate the affect of hydrostatic pressure P H from active control line. In existing balance line valves, the second line acts on the underside of the piston, to balance the hydrostatic pressure P H . However, in this design, since the underside of the piston is in fluid communication with the balance line, it is no longer in fluid communication with the tubing; thereby the beneficial effect of the tubing pressure P T is not utilized.
Therefore, there is a need for a safety valve that balances the control line hydrostatic pressure P H while still utilizing the tubing pressure P T to aid in closure of the valve.
SUMMARY OF THE INVENTION
The present invention generally relates to a subsurface safety valve configured to control fluid flow through a production tubing string. In one aspect, a safety valve for deployment beneath a surface of a wellbore is provided. The valve includes a control piston and a balance piston. The valve is configured to be connected to a controller at the surface by a control line so that the control piston is actuatable between a first position and a second position in response to receiving pressurized fluid from the controller through the control line. The balance piston is configured to compensate for hydrostatic pressure in the control line. The valve may have a bore therethrough and the control piston may be configured to utilize tubing pressure within the valve bore to urge the control piston towards the second position.
In another aspect, a subsurface safety valve is provided. The valve includes a flow tube having a bore therethrough; a control piston having two sides isolated from each other by a seal assembly and coupled to the flow tube; and a balance piston having two sides isolated from each other by a seal assembly and selectively coupled to the flow tube. The valve is configured so that the control piston will receive a control pressure on the first side and the balance piston will receive a hydrostatic pressure on the second side.
The flow tube may be actuatable between a first position and a second position and the balance piston may be selectively coupled to the flow tube so that the balance piston may urge the flow tube towards the second position but not towards the first position. The second side of the control piston may be in fluid communication with the flow tube bore. The second side of the balance piston may be in fluid communication with the flow tube bore. The valve may further include at least one housing, wherein the flow tube, the control piston, and the balance piston are disposed within the housing and the balance piston may be selectively coupled to the housing. The valve may further include a flapper coupled to the housing and a flapper spring coupled between the flapper and the housing, wherein the flapper may be actuatable by the flow tube between a first position and a second position and the flapper spring biases the flapper in the second position.
In another aspect, a subsurface safety valve is provided. The valve includes a control piston configured to open the valve by receiving pressurized fluid from a control line and means for compensating for hydrostatic pressure in a control line to the valve while utilizing tubing pressure within the valve to assist in closure of the valve.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a view illustrating a production tubing having a safety valve assembly in accordance with an embodiment of the present invention.
FIGS. 2 and 2A are cross-sectional views illustrating the valve assembly 200 in a first closed position, where the balance piston is idle.
FIGS. 3 and 3A are cross-sectional views illustrating the valve in the open position.
FIG. 4 is a cross-sectional view illustrating the valve in a closed position, where the balance piston is active.
FIGS. 5A-C are free body diagrams of the valve, which illustrate the three operational positions of the valve: closed, where the balance piston is idle; open; and closed, where the balance piston is active, respectively.
FIGS. 6A and 6B are hydraulic diagrams of alternate embodiments of the valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is generally directed to a subsurface safety valve assembly for controlling fluid flow in a wellbore. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term, as reflected in printed publications and issued patents. In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawings may be, but are not necessarily, to scale and the proportions of certain parts have been exaggerated to better illustrate details and features of the invention. One of normal skill in the art of subsurface safety valves will appreciate that the various embodiments of the invention can and may be used in all types of subsurface safety valves, including but not limited to tubing retrievable or wireline retrievable valves.
For ease of explanation, the invention will be described generally in relation to a cased vertical wellbore. It is to be understood; however, that the invention may be employed in an open wellbore, a horizontal wellbore, or a diverging wellbore without departing from principles of the present invention. Furthermore, a land well is shown for the purpose of illustration, however, it is understood that the invention may also be employed in offshore wells.
FIG. 1 is a view illustrating a production tubing 120 having a safety valve assembly 200 (hereinafter “valve”) in accordance with an embodiment of the present invention. The valve 200 is used for controlling the flow of fluid in a production tubing 120 . The valve 200 may be moved between an open position and closed position by operating a controller 150 , such as a pump, which may draw from a reservoir 155 , in communication with the valve 200 through a control line 145 A. When actuated, the controller 150 will exert a control pressure P C through the control line 145 A to the valve 200 . Due to vertical height of the control line 145 A, a hydrostatic pressure P H will also be exerted on the valve 200 through the control line. A balance line 145 B is also provided to valve 200 . The balance line 145 B provides fluid communication between the reservoir 155 and the valve 200 , thereby maintaining the outlet of the balance line 145 B connected to the valve 200 at the hydrostatic pressure P H . An inside of the valve 200 is also exposed to a tubing pressure P T which may vary with conditions within the wellbore 100 . The operation of the valve assembly 200 will first be described generally with respect to FIG. 1 , thereafter more specifically with FIGS. 2-5 .
The wellbore 100 has been lined with a string of casing 105 . A plurality of perforations 110 has been disposed through the casing 105 , thereby establishing fluid communication between a formation 115 and the production tubing 120 . Thereafter, the production tubing 120 with the safety valve 200 disposed therein is deployed in the wellbore 100 to a predetermined depth. Next, the production tubing 120 is secured in the wellbore proximate a desired zone of interest or a formation 115 . Hydrocarbons (illustrated by arrows) flow into the production tubing 120 through the safety valve 200 , through a valve 135 , and out into a flow line 130 . The flow of hydrocarbons may be stopped at any time during the production operation by switching the valve assembly 200 from the open position to the closed position as will be described in more detail in the following paragraphs.
FIGS. 2 and 2A are cross-sectional views illustrating the valve 200 in a closed position, where a balance piston 205 B is idle. A bore 260 in the valve 200 allows hydrocarbons to flow up through the valve assembly 200 during the production operation, as discussed in a previous paragraph. The valve assembly 200 includes a top sub 270 and a bottom sub 275 to sealingly connect the valve 200 to the production tubing (not shown).
The valve 200 further includes a chamber housing 255 disposed adjacent the top sub 270 and a spring housing 280 coupled to the chamber housing 255 . An annulus 240 is formed between the spring housing and a flow tube 225 . The chamber housing 255 includes a control chamber 245 A and a balance chamber 245 B. An upper end of the control chamber 245 A is in fluid communication with the control line 145 A and a lower end of the balance chamber 245 B in fluid communication with the balance line 145 B (only a port shown for the line, line not shown in this view). Routing of a passage through the chamber housing 255 from the balance line 145 B to the balance chamber 245 B may be accomplished in several ways and is not shown as it would be well within one of ordinary skill in the art. Disposed in the control chamber 245 A is a control piston 205 A. The control piston 205 A is movable between an upper position and a lower position in response to control pressure P C in the upper end of the control chamber 245 A. A seal assembly 215 A is disposed on an upper end of the control piston 205 A to isolate the upper end of the control chamber 145 A. The lower end of the control piston 205 A is exposed to pressure P T within the valve assembly 200 .
Disposed in the balance chamber 245 B is the balance piston 205 B. The balance piston 205 B is movable between a lower position and an upper position in response to hydrostatic pressure P H in the balance chamber 245 B. A seal assembly 215 B is disposed on a lower end of the balance piston 205 B to isolate the lower end of the balance chamber 245 B. A cap 211 is coupled to the chamber housing 255 to form a bottom of the balance chamber 245 B. A block 207 is coupled to an upper end of the balance piston 205 B to mate with a shoulder 214 of the chamber housing 255 and a shoulder 209 of the flow tube 225 (see FIGS. 3 and 4 ). An upper end of the balance piston is exposed to the tubing pressure P T within the valve 200 . Preferably, the balance chamber 245 B is tangentially located proximate to the control chamber 245 A, however, the balance chamber 245 B may also be located tangentially distal from the control chamber 245 A.
As illustrated in FIG. 2 , the valve 200 includes a biasing member 210 , such as a coil spring, disposed in the annulus 240 . A lower end of the biasing member 210 abuts a spacer bearing 265 that is coupled to the spring housing 280 . An upper end of the biasing member 210 abuts a shoulder of the flow tube 225 , which is coupled to the control piston 205 A. In this respect, the movement of the control piston 205 A from the upper position to the lower position compresses the biasing member 210 against the spacer bearing 265 (see FIG. 3 ).
Disposed below the spacer bearing 265 is a flapper 220 . The flapper 220 is rotationally attached by a pin 230 to a flapper mount 290 . The flapper 220 may move between an open position and a closed position in response to movement of the flow tube 225 . In the open position (see FIG. 3 ), a fluid pathway is created through the bore 260 , thereby allowing the flow of fluid through the valve assembly 200 . Conversely, in the closed position, the flapper 220 blocks the fluid pathway through the bore 260 , thereby preventing the flow of fluid through the valve assembly 200 . The flapper 220 is biased towards a closed position by a flapper spring (not shown). For the sake of simplicity and brevity, the flapper spring will not be further discussed.
Further illustrated in FIG. 2 , the flow tube 225 is disposed adjacent the flapper 220 . As discussed above, the flow tube 225 is coupled to the control piston 205 A. In this respect, the movement of the control piston 205 A in response to the control pressure P C in the control chamber 245 A also causes the flow tube 225 to move. The functions of the flow tube 225 are to hold the flapper 220 open and to minimize the potential of contaminants, such as solid particulates, from eroding critical workings of the valve assembly 200 , such as the flapper seat. As with the control piston 205 A, the flow tube 225 is movable between an open position and a closed position. In the open position, the flow tube 225 blocks the movement of the flapper 220 , thereby causing the flapper 220 to be maintained in the open position. The flow tube 225 in the closed position on the other hand allows the flapper 220 to rotate on the pin 230 and move to the closed position.
FIGS. 3 and 3A are cross-sectional views illustrating the valve 200 in the open position. Typically, the flow tube 225 remains in the open position throughout the completion operation and the production. The flow tube 225 moves to the open position as the control piston 205 A moves to the lower position and compresses the biasing member 210 against the spacer bearing 265 . Neglecting pressure P T within the valve 200 and hydrostatic pressure P H in the lines 145 A,B, controller 150 causes fluid from the control line 145 A to enter the control chamber 245 A, thereby creating the control pressure P C on the control piston 205 A. As more fluid enters the control chamber 245 A, the hydraulic pressure continues to increase until the force exerted by the hydraulic pressure on the upper end of the control piston 205 A becomes greater than an opposite force on the lower end of the piston assembly 205 created by the biasing member 210 . At that point, the force exerted by the hydraulic pressure in the control chamber 245 A causes the control piston 205 A to move to the lower position. Since the flow tube 225 is coupled to the control piston 205 A, the movement of the control piston 205 A causes the movement of the flow tube 225 . In this manner, the flow tube 225 is moved to the open position.
For the sake of simplicity, and for further discussion of the operation of the valve 200 , the tubing pressure P T within the valve 200 will be assumed to be equal to the pressure on an underside of the flapper 220 when the flapper 220 is closed so that there is no pressure difference across the flapper 220 .
FIG. 4 is a cross-sectional view illustrating the valve assembly 200 in a closed position, where the balance piston 205 B is active. Neglecting pressure P T within the valve assembly 200 and hydrostatic pressure P H in the lines 145 A,B, when controller 150 is shut off or bypassed, fluid in the control chamber 245 A exits into the control line 145 A, thereby decreasing the hydraulic pressure on the control piston 205 A. As more fluid exits the control chamber 245 A, the hydraulic pressure continues to decrease until the force exerted by the hydraulic pressure on the upper end of the control piston 205 A becomes less than the opposite force on the lower end of the control piston 205 A. At this point, the force created by the biasing member 210 causes the flow tube 225 to move to the closed position. Since the control piston 205 A is coupled to the flow tube 225 , the movement of the flow tube 225 also causes the movement of control piston 205 A to the upper position.
FIGS. 5A-C are free body diagrams of the valve assembly 200 , which have been greatly simplified for illustrational purposes. FIGS. 5A-C illustrate the three operational positions of the valve assembly 200 : closed, where the balance piston 205 B is idle; open; and closed, where the balance piston 205 B is active, respectively. Operation of the valve assembly 200 among these three positions will now be discussed for situations where P T and/or P H are substantial. It is preferred that an area A A1 of the control piston 205 A on which the control line pressure P C acts is substantially equal to an area A B1 of the balance piston 205 B on which the hydrostatic pressure P H acts; however, A B1 may be substantially greater than A A1 or the entire cross sectional area of the balance piston 205 B may be larger than that of the control piston 205 A. It is also preferred that an area A A2 of the control piston 205 A on which the tubing pressure P T acts be substantially equal to A A1 and an area A B2 on which the tubing pressure P T acts be substantially equal to A B1 . For the following analysis, it will be assumed that these four areas are equal.
FIG. 5A is a free body diagram of the valve assembly 200 in the closed position, where the balance piston 205 B is idle (P T >P H , see also FIG. 2 ). As discussed above, when the hydrostatic pressure P H is substantial, it will place a downward force on the control piston 205 A, thereby tending to open the valve assembly 200 . When the tubing pressure P T is substantial, it, along with the biasing member 210 (the force of which is denoted by F S ), will place an upward force on the control piston 205 A, thereby tending to close the valve assembly 200 . Conversely, the hydrostatic pressure P H will exert an upward force on the balance piston 205 B, thereby tending to close the valve 200 . Additionally, the tubing pressure P T will exert a downward force on the balance piston 205 B, however, this force does not tend to open the valve assembly 200 because the balance piston 205 B is structurally isolated from the flow tube 225 (and the biasing member 210 ) by interaction of the block 207 with the shoulder 214 of the chamber housing 255 . Thus, in this situation, the balance piston 205 B can never aid in opening the valve assembly 200 . Since the tubing pressure P T is greater than P H in this Figure, the balance piston 205 B is idle as it exerts no force on the flow tube 225 because a net downward force exerted by the tubing pressure P T keeps the balance piston 205 B resting on the shoulder 214 .
FIG. 5B is a free body diagram of the valve 200 in an open position (see also FIG. 3 ). To open the valve from the closed position, where the balance piston 205 B is idle, the control pressure P C is exerted on the control piston 205 A as discussed above. However, additional consideration of the tubing pressure P T and the hydrostatic pressure P H changes the analysis from the simplified analysis discussed above. The force exerted by the control pressure P C that will be applied to open the valve will now have to overcome the force generated by the tubing pressure P T as well as the force F S generated by the biasing member 210 to open the valve but will be supplemented by the force exerted by the hydrostatic pressure P H when the balance piston 205 B is idle (P T >P H ).
FIG. 5C is a free body diagram of the valve assembly 200 in a closed position where the balance piston 205 B is active (P T <P H , see also FIG. 4 ). Since the tubing pressure P T is less than the hydrostatic pressure P H , the balance piston 205 B is active as a net (the upward force exerted on the balance piston 205 B by P H less the downward force exerted by P T ) upward force on the balance piston 205 B will unseat the balance piston 205 B from the shoulder 214 of chamber housing 255 and mate with the shoulder 209 of the flow tube 225 , thereby tending to close the valve assembly 200 . Summation of the external forces acting on the flow tube 225 and cancellation of redundant terms will conclude that the only net force acting on the flow tube 225 is the force F S generated by the biasing member 210 . Therefore, the undesirable effect of the hydrostatic pressure P H exerting a downward force on the control piston 205 A, thereby tending to open the valve, is removed or negated.
To open the valve from the closed position, where the balance piston 205 B is active, the control pressure P C is exerted on the control piston 205 A as discussed above. The force exerted by the control pressure P C that will be applied will now have to overcome only F S to open the valve but without the aid of the hydrostatic pressure P H (since it is effectively cancelled by the activity of the balance piston 205 B).
FIGS. 6A and 6B are hydraulic diagrams of alternate embodiments of the valve 200 . In both figures, a device 305 enabling manual override of the valve 200 , such as a rupture disc or rupture pin has been added to the valve. In the embodiment illustrated in FIG. 6A , the override device 305 is disposed between the control line 145 A and a port (not shown) in fluid communication with the bore 260 of the valve. In the embodiment illustrated in FIG. 6B , the override device 305 is disposed between the control line 145 A and the balance line 145 B. In both embodiments, the inlet side of the override device 305 is in fluid communication with the control line 145 A. Both embodiments address the contingency of failure of the balance piston seal assembly 215 B. The actuation pressure of the override device 305 may be set significantly above the operating pressure of the control line 145 A, to avoid unintentional actuation. In the event of balance seal assembly 215 B failure, the control line pressure P C may be increased to actuate the override device 305 .
In the embodiment of FIG. 6A , actuation of the device 305 will cause the control line 145 A to be in fluid communication with the bore 260 of the valve 200 . Once the device 305 has actuated, the control pressure P C may be removed. The column of fluid in control line 145 A will then flow into the bore 260 of the valve 200 until the pressure in the control line 145 A is equal to the tubing pressure P T , thereby closing the valve. Similarly, in the embodiment of FIG. 6B , actuation of the device 305 will cause the control line 145 A to be in fluid communication with the balance line 145 B. The column of fluid in control line 145 A will then flow around the balance piston 205 B into the bore 260 until the pressure in the control line 145 A is equal to the tubing pressure P T , thereby closing the valve.
In another alternative embodiment of the valve 200 , the balance piston 205 B would be modified to receive a second seal assembly between the balance seal assembly 215 B and the block 207 . This would create an intermediate pressure chamber between the two seal assemblies. A port would be provided to this pressure chamber and the port would be connected to the control line 145 A. This would create a “fail safe” valve. The failure of balance seal assembly 215 B would then be of little consequence to valve closure since the intermediate pressure chamber would be at the hydrostatic pressure P H when attempting to close the valve 200 . Failure of the second seal assembly would have a similar result to actuation of the override device 305 in the embodiment of FIG. 6A . Failure of both seal assemblies would have a similar result to actuation of the override device 305 in the embodiment of FIG. 6B .
In yet another alternative embodiment of the valve 200 , a plurality of balance pistons would be included in the event of failure of one of the balance pistons. Additional balance lines could be run in with the valve or the additional balance pistons could be connected to the single balance line with bypass valves.
In yet another alternative embodiment of the valve 200 , the cross sectional area of the balance piston 205 B is larger than that of the control piston 205 A and the biasing member 210 is removed. The greater closing force of the larger balance piston compensates for the missing force generated by the biasing member 210 .
Although the invention has been described in part by making detailed reference to specific embodiments, such detail is intended to be and will be understood to be instructional rather than restrictive. It should be noted that while embodiments of the invention disclosed herein are described in connection with a subsurface safety valve assembly, the embodiments described herein may be used with any well completion equipment, such as a packer, a sliding sleeve, a landing nipple and the like.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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The present invention generally relates to a subsurface safety valve configured to control fluid flow through a production tubing string. In one aspect, a safety valve for deployment beneath a surface of a wellbore is provided. The valve includes a control piston and a balance piston. The valve is configured to be connected to a controller at the surface by a control line so that the control piston is actuatable between a first position and a second position in response to receiving pressurized fluid from the controller through the control line. The balance piston is configured to compensate for hydrostatic pressure in the control line. The valve may have a bore therethrough and the control piston may be configured to utilize tubing pressure within the valve bore to urge the control piston towards the second position.
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This application is a continuation of application Ser. No. 07/855,781, filed Mar. 23, 1992, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a radio telecommunication apparatus used in a radio telecommunication system such as a cellular radio system and, more specifically, to a radio telecommunication apparatus having a function of displaying whether the apparatus is present within its own service area.
BACKGROUND OF THE INVENTION
In prior art cellular radio telephone systems, a geographical area is covered and served by breaking the area into a plurality of small zones or cells. A large land area can be covered by a plurality of connected cell areas. A mobile telephone switching office (MTSO) is provided for each area and is connected to a plurality of base stations, each covering a cell within the area.
FIG. 1 is a diagram illustrating a conventional cellular radio telephone system. Referring to FIG. 1, the user of cellular radio telephone 101 usually travels within an area 102 and is assigned an identification (ID) number for the user's cellular radio telephone which is registered in a corresponding MTSO 103 which covers the area. The area is called a home area and the user is called a home area user. If the user travels out of area 102 and enters another area, the new area is called a roam area and the user is called a roamer in the new area. User fees for calls from the cellular radio telephone via the MTSO covering the roam area are higher than for calls via the MTSO covering the home area. It should be noted that, when a call is made from a cellular radio telephone, the ID number for the cellular radio telephone is transmitted to the MTSO covering the area where the cellular radio telephone is located and the MTSO can therefore distinguish roamers and home area users by checking whether the transmitted ID number is registered in the MTSO.
Similarly, the radio telephone may check within which of the home area or roam area the telephone is located on the basis of system identification (SID) information transmitted from the MTSO, and provides a display as to whether the user is presently a home area user or roamer. The display is very useful to the user because the user may know in advance whether the user fee would be higher owing to the roamer usage.
It is thus proposed to provide the radio telephone with a service area confirmation display function.
An example of the operation of the conventional radio telephone having the service area confirmation display function will now be described. When the apparatus is turned on, the operational state of the circuits in the apparatus are initialized. Then, a control channel (a paging channel, hereinafter called "P-channel") for receiving control signals, such as an incoming call signal, is selected. The P-channel is selected out of the plurality of P-channels, which are dedicated by the MTSO, by measuring the received signal strength thereof and finding the P-channel having the strongest received signal strength. Once the selection of P-channel is completed, the P-channel is set in the receiver and word synchronization is acquired. Thereafter, the reception standby state is maintained. In the reception standby state, the P-channel is reestablished at intervals of five minutes.
System information is detected out of the control signals transmitted through the P-channel, and system identification data through the P-channel (SIDp) included in the system information is stored in the apparatus. The SIDp is compared with a home system identification data (SIDH). The SIDH is a system identification of the system to which the user's apparatus belongs. The SIDH is prestored in an identification data memory (ID-ROM). When both identification data SIDp and SIDH coincide, it is determined that the apparatus is present within the home area. On the other hand, if both identification data SIDp an SIDH do not coincide, it is determined that the apparatus is present in a service area another than the home area, i.e., a roam area system, and an LCD display device displays, e.g., "ROAM", indicating that the apparatus is outside the home area. Accordingly, the user may confirm whether the user's apparatus is located within the home area.
The conventional cellular radio telephone apparatus, however, has the following problem to be solved. In the conventional apparatus, whether the user's apparatus is present within the home area is determined on the basis of the system identification data transmitted from the base station over the P-channel established in the reception standby state. Thereafter, the area display corresponding to the determination result is retained until the SIDp is updated by reestablishment of the P-channel. Consequently, even if the user's apparatus, which may be installed in a car, moves from the home area to a roam area in a short time, the area display made prior to the movement of the user is unchanged. That is, the area display indicates that the user's apparatus is present within the home area. Although the user's apparatus has been actually moved to the roam area, the user's apparatus wrongly indicates to the user that the user is a home area user and a call may be placed in this situation. This results in an undesirable situation wherein high charge is incurred unknowingly to the user.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide an improved radio telecommunication apparatus wherein the user may accurately confirm whether the user's apparatus is located within the home area, at the exact time of making a call, whereby the user may originate a call after identifying the system actually serving the apparatus.
In order to achieve the above object, according to the present invention, in a radio telecommunication system wherein one or more base units broadcast radio signals including a system identification data identifying the system over one of a plurality of control channels, the radio telecommunication apparatus includes a storage for storing a system identification data of a system to which the apparatus belongs to, and provides an indication to a user of the apparatus by the steps of: establishing a control channel in response to the user's request of call placement, receiving a system identification data through the control channel, comparing the system identification data received through the control channel with the system identification data stored in the apparatus, and providing an indication relating to a location where the apparatus is present to the user on the basis of a result of the above comparing step.
According to the present invention, at the time of call placement, an indication representative of the position of the user's apparatus is provided to a user of the apparatus on the basis of the system identification data obtained through a control channel which is established prior to establishing a speech communication link. Even if the user's apparatus moves, at the time of calling, from the home area to the roam area or from the roam area to the home area, the area confirmation data corresponding to the current position of the apparatus is accurately displayed.
Accordingly, on the basis of the updated display data, the user may exactly judge whether his/her apparatus is present within the home area. This substantially overcomes the following disadvantages of the conventional radio telephone: it is erroneously determined that the user's apparatus is present within the home area, although it is, in fact, present within the roam area, resulting in a higher speech charge. It is also possible to prevent the following undesirable situation: the user gives up calling because he/she identifies himself/herself as a roamer, although his/her apparatus is actually present within the home area.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating a conventional cellular radio system;
FIG. 2 is a circuit block diagram of a radio telephone according to an embodiment of the present invention;
FIG. 3 is a flowchart illustrating the main routine operations of the control circuit of the apparatus shown in FIG. 2;
FIG. 4 is a flowchart illustrating the reset operation in the flowchart of FIG. 3;
FIG. 5 is a flowchart illustrating the initialization operation in the flowchart of FIG. 3;
FIG. 6 is a flowchart illustrating the P-channel selecting operation in the flowchart of FIG. 3;
FIG. 7 is a flowchart illustrating the first area-display control in the flowchart of FIG. 6;
FIG. 8 is a flowchart illustrating the call placement control in the flowchart of FIG. 3;
FIG. 9 is a flowchart illustrating the second area-display control in the flowchart of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will now be described.
FIG. 2 is a circuit block diagram showing a radio telephone according to an embodiment of the present invention. This radio telephone generally comprises transmission circuitry, reception circuitry and control circuitry. Reference numeral 40 denotes a power source circuit which generates an operation voltage Vcc necessary for the apparatus, on the basis of the output from a battery 41.
The transmission circuitry comprises a microphone 11 functioning as a telephone transmitter, a speech encoder (SPCOD) 12, an error-correction encoder (CHCOD) 13, a digital modulator (MOD) 14, a multiplier 15, a power amplifier (PA) 16, a radio-frequency switching circuit (SW) 17, and an antenna 18. The speech encoder 12 encodes a speech transmission signal output from the microphone 11. The error-correction encoder 13 performs error-correction encoding of a digitized speech transmission signal output from the speech encoder 12 and a digitized control signal output from a control circuit 30 (described later). The digital modulator 14 generates a modulated signal corresponding to the digitized transmission signal output from the error-correction encoder 13. The multiplier 15 mixes the modulated signal with a local oscillation signal output from a frequency synthesizer 31. The mixed signals are frequency-converted to a radio frequency signal. The power amplifier 16 amplifies the radio transmission signal output from the multiplier 15 up to a predetermined transmission power level. The radio-frequency switch 17 is rendered operative only for a time period of a transmission time slot designated by the control circuit 30. During this time period, the radio transmission signal output from the power amplifier 16 is supplied to the antenna 18 and transmitted to a base station (not shown).
On the other hand, the reception circuitry comprises a receiver (RX) 21, a digital demodulator (DEMOD) 22, an error-correction decoder (CHDEC) 23, a speech decoder (SPDEC) 24, and a loudspeaker 25 functional as a telephone receiver. The receiver 21 performs a mixing function. That is, the receiver 21 frequency-converts a received radio-frequency signal, which was received by the antenna 18 and radio frequency switch 17, directly to an intermediate frequency signal or a base band signal. The digital demodulator 22 establishes bit-synchronization and frame-synchronism (i.e., word synchronization) for the received digital signal output from the receiver 21, and performs digital demodulation. A sync. signal obtained by the word synchronization is supplied to the control circuit 30. The error-correction decoder 23 performs error-correction decoding of the digital demodulated signal output from the digital demodulator 22. A signal obtained by the error-correction decoding consists of a digital speech reception signal and digital control information. The digital speech reception signal is input to the speech decoder 24, and the digital control information is delivered to the control circuit 30 for various control operations relating to the establishment of control and speech channels, etc. The speech decoder 24 performs decoding of the digital speech signal. An analog speech reception signal reproduced by the decoding operation is output to the loudspeaker 25.
The control circuitry comprises a controller (CONT) 30, a frequency synthesizer (SYN) 31, a system identification information memory (ID-ROM) 33, a control data memory (RAM) 34, a console unit (CU) 35, a display driver circuit 36, and a liquid crystal display (LCD) 37. The frequency synthesizer 31 generates local oscillation signals corresponding to channel frequencies for control and speech channels designated by the control circuit 30. The ID-ROM 33 prestores system identification data SIDH of the system to which the user's apparatus belongs. The SIDH was entered into the ID-ROM by telephone dealers when the user purchases the telephone. The RAM 34 stores control data such as a telephone number input by dial keys or system identification data transmitted from the base station over various control channels. The console unit 35 is provided with a key pad having dial keys, a call request key, etc. The LCD display 37 is driven by the display driver circuit 36 to display a dial number and information indicating whether or not the user's apparatus is located within the home area, i.e. the surface area of the system to which the apparatus belongs.
The control circuit 30 comprises, for example, a microcomputer as a main control unit. The control circuit 30 includes first area-display control means 30a and second area-display control means 30b, in addition to ordinary control functions relating to the initialization of the apparatus, call-reception, call-transmission, and speech communication link establishment.
The first area-display control means 30a detects system identification data SIDp transmitted from the base station over a P-channel set in the standby state, and causes the SIDp to be stored in the RAM 34. The first area-display control means 30a compares the detected system identification data SIDp with the system identification data SIDH which is prestored in the ID-ROM 33 and relates to the system to which the user's apparatus belongs. If the data SIDp and the data SIDH do not coincide, it is determined that the user's apparatus is present within the roam area, and the LCD display 37 displays, e.g., "ROAM". When data SIDp and SIDH coincide, it is determined that the user's apparatus is present within the home area, and the LCD display 37 does not display "ROAM".
The second area-display control means 30b detects a system identification data SIDA transmitted from the base station over an access channel (A-channel), established prior to an establishment of speech communication link, and compares the detected system identification data SIDA with the system identification data SIDH. If the SIDA and the SIDH do not coincide, it is determined that the user's apparatus is present within the roam area, the LCD display 37 displays, e.g., "ROAM". If the SIDA and SIDH coincide, it is determined that the user's apparatus is present within the home area, and the displayed indication of "ROAM" on the LCD display 37 is erased.
The operation of the apparatus having the above arrangement will now be described in accordance with the control procedure of the control circuit 30. FIG. is a flowchart illustrating the main routine of the control procedure.
When the power switch 35a is turned on, the control circuit 30 executes a reset operation in step 2a. Specifically, as shown in FIG. 4, the states of the respective parts of the circuits are reset in step 3a. In subsequent step 3b, the lock state is monitored. The lock state is set to prevent false use of the apparatus by a third party. When the lock state setting operation is performed, the apparatus is maintained in the lock state. Unless and until a specific key is operated, the apparatus cannot be used. While the lock state is set, the LCD display 37 displays "LOCK" (step 3c). On the other hand, if the lock state is not set, the LCD displays 37 displays "NO SVC" in step 3d.
When the reset is completed, the control circuit 30 executes an initializing operation in step 2b. As is shown in FIG. 5, in step 4a, a plurality of control channels (Dedicated Control Channels, hereinafter called D-channels) for initialization are scanned, thereby selecting a channel having a strongest received signal strength, and a channel having a second strongest received signal strength. In step 4b, a control operation is performed to establish bit synchronization and frame synchronization (i.e., word synchronization) for the D-channel having the strongest received signal strength. When the word synchronization is acquired in a predetermined time period by this control operation, the control routine goes to step 4c. In step 4c, system identification data SIDd is detected from control information transmitted from the base station over the D-channel. In step 4e, the SIDd is stored in the RAM 34. If the word synchronization is not acquired in the predetermined time period or the system identification data is not detected in steps 4b and 4c, the control routine goes to step 4d. In step 4d, the D-channel having the second strongest received signal strength is selected, and the control of steps 4b to 4e is executed for this D-channel.
When the initializing step is completed, the control circuit 30 executes the control of step 2c, and executes the P-channel selection control for the standby state. Specifically, as shown in FIG. 6, in step 5a, a plurality of P-channels are scanned, thereby selecting a channel having a strongest received signal strength, and a channel having a second strongest received signal strength. In step 5b, a control operation is performed to acquire bit synchronization and frame synchronization (i.e., word synchronization) for the P-channel having the strongest received signal strength. When the word synchronization is acquired in a predetermined time period, the control routine goes to step 5c. In step 5c, a system identification data SIDp (a system identification data transmitted over the selected paging channel) is detected from control information transmitted from the base station over the P-channel, and the SIDp is stored in the RAM 34. If the word synchronization is not acquired in the predetermined time period or the system identification data is not detected in a predetermined time period in steps 5b and 5c, the control routine goes to step 5d. In step 5d, the P-channel having the second strongest received signal strength is selected, and the word synchronization is acquired and a system identification data is detected for the P-channel. If the system identification data SIDp detected from the P-channel does not coincide with the system identification data SIDd detected from the D-channel at the time of initialization, the control routine returns to the initializing control (step 2b).
If the system identification data SIDp is detected in step 5c, the control of the control circuit 30 goes to step 5e, and the first area-display control is executed in the following manner. FIG. 7 shows the control steps thereof. Specifically, in step 6a, the control circuit 30 compares the system identification data SIDp detected through the P-channel with the system identification data SIDH which is prestored in the ID-ROM 33 and relates to the system to which the user's apparatus belongs. If the SIDp and SIDH coincide, it is determined that the user's apparatus is present within the home area, and "ROAM" is not displayed. On the other hand, if the SIDp and SIDH do not coincide, it is determined that the user's apparatus is present within the roam area, and the LCD display 37 displays "ROAM" in the step 6c. Accordingly, the user may confirm whether his/her apparatus is present within the home area or the roam area, on the basis of the presence/absence of indication of "ROAM". After the area identification display is performed, the control circuit 30 is set in the standby state (step 2d).
Now suppose that in the standby state an incoming call signal has come from the base station over the P-channel. In this case, the control routine of the control circuit 30 goes to step 2e, and the call-reception response control is executed. Specifically, the control circuit 30 first scans a plurality of access channels (A-channels) used to establish an access channel prior to establishing a speech communication link, and selects a channel having a strongest received signal strength and a channel having a second strongest received signal strength. Word synchronization for the selected A-channel is acquired and thereafter a call-reception response signal is transmitted to the base station over this A-channel. After the call-reception response signal is transmitted, the incoming of a speech channel designation signal from the base station is awaited. When the speech channel designation signal is received, the speech channel (SP-channel) designated by the speech channel designation signal is established. Thus, the apparatus is set in the ringing signal reception standby state (step 2f). If a ringing signal is received in this state, a lingering sound is generated, for example, from a sounder (not shown). Then, the control circuit 30 is set in the user's response awaiting state (step 2g). The user, who has recognized an occurrence of the call-reception from the lingering sound, responds by making an off-hook operation. Thus, the control circuit 30 executes the talk control in step 2h.
When a speech-finishing operation is performed in steps 2f and 2g, the control circuit 30 releases the reception state over the speech channel in step 2i, and stops the operation of the transmission circuitry in step 2j. Thereafter, the initializing operation is performed once again. In the states of steps 2f, 2g and 2h, if the received signal intensity remains lower than a predetermined level for a predetermined time period or more owing to the influence of phasing, etc., the control routine of the control circuit 30 goes on to step 2j and the control circuit 30 stops the operation of the transmission operation and performs the initializing operation once again.
Suppose that in the standby state (step 2d) a call request is made by operating a call request key or a speech dial. Then, the control circuit 30, in step 2k, executes the call request control. FIG. 8 is a flowchart showing the control procedures and the control items thereof.
In response to the user's operation on console unit 35 of entering a telephone number and depressing a send-key, the control circuit 30 starts a timer for counting a call request reception time (step 7a). This operation causes a call flag in control circuit 30 to change from `0` to `1`. The call request reception time is set at, fr example, 12 seconds. In step 7b, the control circuit 30 scans a plurality of A-channels, thereby selecting a channel with a strongest received signal strength and a channel with a second strongest received signal strength. In step 7c, it is confirmed whether the user wishes to make a call. If the user wishes to make a call, the control routine goes to step 7d, and a control is performed to establish word synchronization for the A-channel. Whether the user wishes to make a call is determined on the basis of the state of a call flag, i.e., "1" or "0". The call flag is changed to `0` when the user depresses an end-key on console unit 35. If it is determined that the user does not wish to make a call, the control routine returns to the initializing operation.
When word synchronization has been established in step 7d, the control circuit 30 confirms the user's wish to make a call once again in step 7f. Then, in control circuit 30, system-identification data SIDA is detected out of system information transmitted from the base station over the acquired access channel. Then, using the acquired access channel, a call origination signal, which contains information corresponding to a destination telephone number input by the user, is transmitted out (step 7h). If the access channel cannot be acquired within a predetermined time period, "failure" is determined in step 7i and the control routine returns to step 7f.
In the meantime, when the call signal has been transmitted, the control routine of the control circuit 30 goes to step 7j and the second area-display control is executed. Specifically, as shown in FIG. 9, in step 8a, the control circuit 30 compares the system identification data SIDA detected through the access channel with the system identification data SIDH which is prestored in the ID-ROM 33 and identifies the system to which the user's apparatus belongs. If the SIDA and SIDH do not coincide, "ROAM" is displayed on the LCD device 37 in step 8b. If the SIDA and SIDH coincide, the control routine advances to step 8c and "ROAM" on the LCD display 37 is erased.
When the area-display control is completed, the control circuit 30, in step 7k, monitors the sending-back of a call response signal. When the call response signal is transmitted back from the base station, the control routine advances to step 71. In step 71, a control is performed to capture the speech channel (SP-channel) designated by the call response signal. If the SP-channel is captured, the apparatus is set in the speech state (step 2h). If the sending-back of the call response signal is not detected in a predetermined time period or the capture of the SP-channel fails in steps 7k and 71, the control routine goes back to the initializing operation.
In the present embodiment, in the call control procedure, the system identification data SIDA transmitted from the base station over the access channel is detected. The SIDA is compared with the system identification data SIDH which is prestored in the ID-ROM 33 and identifies the system to which the user's apparatus belongs. In accordance with the comparison result, the display of "ROAM" on the LCD display 37 is updated. Thus, even if the user's apparatus moves from one area to another in the standby state and the area data (ON/OFF of "ROAM") on the LCD display 37 does not represent the area in which the apparatus is actually situated, the area data displayed on the LCD display 37 is corrected to conform to the actual position of the apparatus at the time when the access channel has been established. Accordingly, the user may exactly confirm whether the user's apparatus is located in the home area or the roam area at the time of making a call, whereby the user may have a conversation with another party over a speech channel after exactly knowing whether the user is roamer. It is therefore possible to surely prevent the undesirable situation that a higher speech fee is charged unknowingly to the user.
The present invention is not limited to the above embodiment. For example, in the above embodiment, when the user's apparatus is present within the roam area, "ROAM" is displayed, and when it is present within the home area, "ROAM" is not displayed; however, it is possible to display "HOME" when the user's apparatus is present within the home area, and not to display "HOME" when it is present within the roam area. Alternatively, it is possible to display "ROAM" when the user's apparatus is within the roam area, and display "HOME" when it is within the home area. Furthermore, it is possible to change the display mode of "ROAM" to distinguish the roam area from the home area, for example, by flickering "ROAM", changing the color of "ROAM," or accompanying "ROAM" with an alarm.
Other various modifications can be made, within the spirit of the present invention, to the structure of the apparatus, the control procedures and control items of the control circuit, and the type, structure and display mode of the display means.
Although an embodiment applied to a cellular radio telephone has been described, it is apparent to those skilled in this art that the present invention may be easily applied to any kind of radio telecommunication apparatus. For example, the invention also is applicable to a cordless telephone system wherein a plurality of zones are covered by a plurality of base units and a mobile unit is capable of communicating with another apparatus over a plurality of control channels wherever the mobile unit moves around within the zones.
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A radio telecommunication apparatus includes a storage for storing a system identification data of a system to which the apparatus belongs to and provides an indication relating to where the apparatus is present on the basis of a result of a comparison between the system identification data stored in the storage and a system identification data received through a control channel which is established immediately before a speech communication link is established. According to the present invention, even if the user's apparatus moves, at the time of calling, from the home area to the roam area or from the roam area to the home area, the area confirmation data corresponding to the current position of the apparatus is accurately displayed.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/316,585 filed on Apr. 1, 2016, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to a device and a method used in a wireless communication system, and more particularly, to a device and a method of handling a handover.
2. Description of the Prior Art
[0003] A long-term evolution (LTE) system provides high data rate, low latency, packet optimization, and improved system capacity and improved coverage. The LTE system is evolved continuously to increase peak data rate and throughput by using advanced techniques, such as carrier aggregation (CA), dual connectivity, licensed-assisted access, etc. In the LTE system, a radio access network known as an evolved universal terrestrial radio access network (E-UTRAN) includes at least one evolved Node-B (eNB) for communicating with at least one user equipment (UE), and for communicating with a core network. The core network may include a mobility management and a Quality of Service (QoS) control of the at least one UE.
[0004] A UE is connected to a first eNB in coverage enhancement (CE) via a cell of the first eNB. It is not clear how the first eNB can initiate a handover to hand over the UE in from the first eNB to a second eNB.
SUMMARY OF THE INVENTION
[0005] The present invention therefore provides a communication device and method for handling a handover to solve the abovementioned problem.
[0006] A first base station (BS) for handling a handover with a second BS comprises a storage unit for storing instructions and a processing circuit coupled to the storage unit. The processing circuit is configured to execute the instructions stored in the storage unit. The instructions comprise connecting to a first communication device; determining to hand over the first communication device to the second BS; generating a first handover request message in response to the determination, wherein the first handover request message comprises one of first system information and second system information according to whether the first communication device is in coverage enhancement (CE) or according to a type of the first communication device; transmitting the first handover request message to the second BS; receiving a first handover request acknowledgement message in response to the first handover request message from the second BS; and transmitting a first handover command to the first communication device in response to the reception of the first handover request acknowledgement message.
[0007] A second base station (BS) for handling a handover with a first BS comprises a storage unit for storing instructions and a processing circuit coupled to the storage unit. The processing circuit is configured to execute the instructions stored in the storage unit. The instructions comprise connecting to the first BS; receiving a handover request message for a first communication device from the first BS; generating a handover request acknowledgement message in response to the handover request message; generating a first configuration according to first system information and transmitting the handover request acknowledgement message comprising the first configuration to the first BS, if the handover request message comprises the first system information and the first communication device is in coverage enhancement (CE) or a type of the first communication device is a first type; and generating a second configuration according to second system information and transmitting the handover request acknowledgement message comprising the second configuration to the first BS, if the handover request message comprises the second system information and the first communication device is in not CE or the type of the first communication device is a second type.
[0008] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic diagram of a wireless communication system according to an example of the present invention.
[0010] FIG. 2 is a schematic diagram of a communication device according to an example of the present invention.
[0011] FIG. 3 is a flowchart of a process according to an example of the present invention.
[0012] FIG. 4 is a flowchart of a process according to an example of the present invention.
DETAILED DESCRIPTION
[0013] FIG. 1 is a schematic diagram of a wireless communication system 10 according to an example of the present invention. The wireless communication system 10 is briefly composed of a communication device 100 , base stations (BSs) 102 and 104 . In FIG. 1 , the communication device 100 , the BS 102 and the BS 104 and are simply utilized for illustrating the structure of the wireless communication system 10 . Practically, the BS 102 and/or the BS 104 may be BSs in a narrowband (NB) internet of things (IoT) network or in an evolved Universal Terrestrial Radio Access Network (E-UTRAN). The BS 102 and/or the BS 104 may be fifth generation (5G) BSs (e.g., gNBs) in a 5G network. In FIG. 1 , coverage areas of the BS 102 and the BS 104 may be overlapped or non-overlapped. In general, a BS may also be used to refer any of the eNB and the 5G BS.
[0014] The communication device 100 may be a user equipment (UE), a mobile phone, a laptop, a tablet computer, an electronic book, a portable computer system, a vehicle, or an airplane. For uplink (UL), the communication device 100 is the transmitter and the BS 102 and/or the BS 104 is the receiver, and for downlink (DL), the BS 102 and/or the BS 104 is the transmitter and the communication device 100 is the receiver.
[0015] The communication device 100 may be a bandwidth reduced low complexity (BL) communication device by which the maximum bandwidth for transmission and reception is operated is lower than a system bandwidth operated by the BS. For example, the BL communication device operates in any LTE system bandwidth (e.g., 3, 5, 10, 15 or 20 MHz) but with a limited channel bandwidth of 6 physical resource blocks (PRBs) (corresponding to the maximum channel bandwidth available in a 1.4 MHz LTE system) in DL and UL. The BL communication device may access a cell of the BS 102 or the BS 104 , if system information (e.g., a Master Information Block (MIB)) of the cell indicates that the access of the BL communication device is supported. Otherwise, the BL communication device considers the cell as barred.
[0016] The communication device 100 in coverage enhancement (CE) uses enhanced coverage functionality (e.g., transmit multiple repetitions of data and/or signal, and/or receive multiple repetitions of data and/or signal) to access a cell of the BS 102 or the BS 104 . The communication device 100 may access a cell using enhanced coverage techniques only if system information (e.g., MIB) of the cell indicates that access of UEs in CE is supported.
[0017] FIG. 2 is a schematic diagram of a communication device 20 according to an example of the present invention. The communication device 20 may be the communication device 100 , the BS 102 and/or the BS 104 shown in FIG. 1 , but is not limited herein. The communication device 20 includes a processing circuit 200 such as a microprocessor or Application Specific Integrated Circuit, a storage unit 210 and a communication interfacing unit 220 . The storage unit 210 may be any data storage device that stores a program code 214 , accessed and executed by the processing circuit 200 . Examples of the storage unit 210 include but are not limited to read-only memory, flash memory, random-access memory, hard disk, optical data storage device, non-volatile storage unit, non-transitory computer-readable medium (e.g., tangible media), etc. The communication interfacing unit 220 is preferably a transceiver used to transmit and receive signals (e.g., data, signals, messages and/or packets) according to processing results of the processing circuit 200 .
[0018] In the following embodiments, a UE is used to represent the communication device 100 in FIG. 1 , to simplify the illustration of the embodiments.
[0019] FIG. 3 is a flowchart of a process 30 according to an example of the present invention. The process 30 may be utilized in a first BS (e.g., the BS 102 ), to handle a handover with a second BS (e.g., the BS 104 ). The process 30 includes the following steps:
[0020] Step 300 : Start.
[0021] Step 302 : Connect to a first UE.
[0022] Step 304 : Determine to hand over the first UE to the second BS.
[0023] Step 306 : Generate a first handover request message in response to the determination, wherein the first handover request message comprises one of first system information and second system information according to whether the first UE is in CE or according to a type of the first UE.
[0024] Step 308 : Transmit the first handover request message to the second BS.
[0025] Step 310 : Receive a first handover request acknowledgement message in response to the first handover request message from the second BS.
[0026] Step 312 : Transmit a first handover command to the first UE in response to the reception of the first handover request acknowledgement message.
[0027] Step 314 : End.
[0028] According to the process 30 , the first BS connects to a first UE (e.g., the communication device 100 ), and determines to hand over the first UE to the second BS. The first BS generates a first handover request message in response to the determination, wherein the first handover request message comprises one of first system information and second system information according to whether the first UE is in CE or according to a type of the first UE. Then, the first BS transmits the first handover request message to the second BS. The first BS receives a first handover request acknowledgement message in response to the first handover request message from the second BS. Accordingly, the first BS transmits a first handover command to the first UE in response to the reception of the first handover request acknowledgement message. That is, whether a UE is in CE or a type of the UE is used for determining content of a handover request message for handing over the UE. Thus, the handover can be performed adaptively according to a state or mode of the UE or a type of the UE. Performance of the UE can be improved correspondingly.
[0029] Realization of the process 30 is not limited to the above description. The following examples may be applied to the process 30 .
[0030] In one example, the first handover request message includes the first system information when the first UE is in CE, and the first handover request message includes the second system information when the first UE is not in CE.
[0031] In one example, the first handover request message includes the first system information if the type of the first UE is a first type (i.e., a UE with the first type or a first-type UE), and the first handover request message includes the second system information if the type of the first UE is a second type (i.e., a UE with the second type or a second-type UE). In one example, the first type is a first category (e.g., category M1), and the second type is a second category (e.g. non-category M1 category, such as category x, wherein x is a number which may be 1, 2, . . . , 20). In one example, the first type is a (massive) machine type communication ((m)MTC), and the second type is an (evolved) mobile broad band ((e)MBB). In one example, the first type is an Ultra-Reliable and Low Latency Communications (uRLLC), and the second type is an (e)MBB. In one example, a first radio frequency (RF) capability of the first type and a second RF capability of the second type may have different maximum transmitting and/or receiving bandwidths. For example, a UE with the first type is capable of receiving maximum 1.4 MHz (e.g., BL UE), and a UE with the second type is capable of receiving maximum 20 MHz (e.g., not a BL UE). For example, the UE with the first type is capable of receiving maximum 20 MHz (e.g., supports bandwidth class 3), and the UE with the second type is capable of receiving maximum 100 MHz (e.g., supports bandwidth class 5).
[0032] In one example, the first handover request message comprises the first system information when the first UE is in CE or a type of the first UE is the first type. The first BS further connects to a second UE, and determines to hand over the second UE to the second BS. The first BS generates a second handover request message in response to the determination, wherein the second handover request message comprises the second system information when the second UE is not in CE or a type of the second UE is the second type. Then, the first BS transmits the second handover request message to the second BS. The first BS receives a second handover request acknowledgement message in response to the second handover request message from the second BS. Accordingly, the first BS transmits a second handover command to the second UE in response to the reception of the second handover request acknowledgement message. In other words, the process 30 can be applied to the handovers of multiple UEs.
[0033] In one example, the first handover request message includes a UE configuration of the first UE. The UE configuration includes at least one of a security configuration (e.g., security algorithm), a measurement configuration and a data radio bearer (DRB) configuration. In one example, the first handover request acknowledgement message includes the first handover command. Similarly, the second handover request message includes a UE configuration of the second UE. Further, the UE configuration includes at least one of a security configuration (e.g., security algorithm), a measurement configuration and a DRB configuration. In one example, the second handover request acknowledgement message includes the second handover command.
[0034] In one example, the first system information includes at least one first system information block (SIB) for the UE in CE or the first type UE, and the second system information may include at least one second SIB for the UE not in CE or the second type UE. In one example, the at least one first SIB includes a SystemInformationBlockType1-BR, and the at least one second SIB includes a SystemInformationBlockType1. In one example, the at least one first SIB includes a first SystemInformationBlockType2, and the at least one second SIB includes a second SystemInformationBlockType2. For example, the first SystemInformationBlockType2 may be included in SystemInformation-BR in a BCCH-DL-SCH-Message-BR transmitted by the first BS, and the second SystemInformationBlockType2 may be included in SystemInformation in BCCH-DL-SCH-Message transmitted by the first BS.
[0035] In one example, the first system information includes at least one IE which is not comprised in the second system information. In one example, the first and second system information includes an IE. The IE in the first system information and the IE in the second system information may have the same value or different values.
[0036] In one example, the first system information may be broadcasted by the first BS for the first UE with the first type and/or for the first UE in CE. The second system information may be broadcasted by the first BS for the first UE with the second type and/or for the first UE not in CE. In one example, the first system information and the second system information may be broadcasted by the first BS in different frequency resources and/or different time in a same carrier. For example, the first system information may be transmitted within 1.4 MHz bandwidth in the same carrier (e.g., 20 MHz) for a UE with the first type UE, and the second system information may be transmitted within more than 1.4 MHz bandwidth in the same carrier. For example, the first system information may be transmitted in more repetitions in the same carrier than the second system information in the same carrier.
[0037] FIG. 4 is a flowchart of a process 40 according to an example of the present invention. The process 40 may be utilized in a second BS (e.g., the BS 104 ), to handle a handover with a first BS (e.g., the BS 102 ). The process 40 includes the following steps:
[0038] Step 400 : Start.
[0039] Step 402 : Connect to the first BS.
[0040] Step 404 : Receive a handover request message for a first UE from the first BS.
[0041] Step 406 : Generate a handover request acknowledgement message in response to the handover request message.
[0042] Step 408 : Generate a first configuration according to first system information and transmit the handover request acknowledgement message comprising the first configuration to the first BS, if the handover request message comprises the first system information and the first UE is in CE or a type of the first UE is a first type.
[0043] Step 410 : Generate a second configuration according to second system information and transmit the handover request acknowledgement message comprising the second configuration to the first BS, if the handover request message comprises the second system information and the first UE is in not CE or the type of the first UE is a second type.
[0044] Step 412 : End.
[0045] According to the process 40 , the second BS connects to the first BS, and receives a handover request message for a first UE from the first BS. The second BS generates a handover request acknowledgement message in response to the handover request message. Accordingly, the second BS generates a first configuration according to first system information and transmits the handover request acknowledgement message comprising the first configuration to the first BS, if the handover request message comprises the first system information and the first UE is in CE or a type of the first UE is a first type. The second BS generates a second configuration according to second system information and transmits the handover request acknowledgement message comprising the second configuration to the first BS, if the handover request message comprises the second system information and the first UE is in not CE or the type of the first UE is a second type. The first configuration and the second configuration may be different. That is, whether a UE is in CE or a type of the UE is taken into consideration, when a configuration is generated according to system information in a handover request message for handing over the UE. Thus, the handover can be performed adaptively according to a state of the UE or a type of the UE. Performance of the UE can be improved correspondingly.
[0046] Realization of the process 40 is not limited to the above description. Examples described regarding the process 30 for the first system information and the second system information may be applied herein and not repeated. The following examples may be applied to the process 40 .
[0047] In one example, the first configuration may be for updating a first value comprised in the first system information, and the second configuration may be for updating a second value comprised in the second system information. In one example, the first configuration may be for configuring a third configuration which is not comprised in the first system information, and the second configuration may be for configuring a fourth configuration which is not comprised in the second system information.
[0048] In one example, the first configuration includes a first RadioResourceConfigCommon, and the second configuration includes a second RadioResourceConfigCommon. In one example, the first RadioResourceConfigCommon includes a first IE which is not comprised in the second RadioResourceConfigCommon. In one example, the first RadioResourceConfigCommon and the second RadioResourceConfigCommon have at least one of a second IE and a third IE. A first value of the second IE of the first RadioResourceConfigCommon and a second value of the second IE of the second RadioResourceConfigCommon may be different. In one example, a first value of the third IE of the first RadioResourceConfigCommon and a second value of the third IE of the second RadioResourceConfigCommon may be the same.
[0049] In one example, the first configuration includes a first RLF-TimersAndConstants, and the second configuration includes a second RLF-TimersAndConstants. In one example, the first RLF-TimersAndConstants includes a first IE which is not comprised in the second RLF-TimersAndConstants. In one example, the first RLF-TimersAndConstants and the second RLF-TimersAndConstants have at least one of a second UE and a third IE. A first value of the second IE of the first RLF-TimersAndConstants and a second value of the second IE of the second RLF-TimersAndConstants may be different. In one example, a first value of the third IE of the first RLF-TimersAndConstants and a second value of the third IE of the second RLF-TimersAndConstants may be the same.
[0050] Those skilled in the art should readily make combinations, modifications and/or alterations on the abovementioned description and examples. The abovementioned description, steps and/or processes including suggested steps can be realized by means that could be hardware, software, firmware (known as a combination of a hardware device and computer instructions and data that reside as read-only software on the hardware device), an electronic system, or combination thereof. An example of the means may be the communication device 20 . Any of the processes above may be compiled into the program code 214 .
[0051] To sum up, the present invention provides a device and a method for handling a handover. Whether a UE is in CE or a type of the UE is used for determining content of a handover request message for handing over the UE. Thus, the handover can be performed adaptively according to a state of the UE or a type of the UE. Performance of the UE can be improved correspondingly.
[0052] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
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A first base station (BS) for handling a handover with a second BS comprises a storage unit for storing instructions and a processing circuit coupled to the storage unit. The processing circuit is configured to execute the instructions stored in the storage unit. The instructions comprise determining to hand over a first communication device to the second BS; generating a first handover request message, wherein the first handover request message comprises one of first system information and second system information according to whether the first communication device is in coverage enhancement (CE) or according to a type of the first communication device; transmitting the first handover request message to the second BS; receiving a first handover request acknowledgement message from the second BS; and transmitting a first handover command to the first communication device in response to the reception of the first handover request acknowledgement message.
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This application is a division of copending application U.S. Ser. No. 717,296, filed Jun. 18, 1991, now U.S. Pat. No. 5,177,298.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates in general to adsorption separation processes. More particularly, this invention relates to fixed bed adsorption systems comprising multiple beds, and the integration of typical refinery streams as regenerant streams.
2. Description of the Prior Art
A variety of arrangements are known for adsorption separation processes. One type as practiced in the prior art, is shown in U.S. Pat. Nos. 4,734,199 and 4,740,631 and discloses as many as six distinct steps, namely:
(a) adsorption of one or more components from a feedstock mixture;
(b) draining the bed of unprocessed feedstock;
(c) regeneration of the bed using a heated purge fluid;
(d) cooling down the newly regenerated bed in preparation for a new adsorption step by passage into the bed of a cooling medium;
(e) draining the cooling medium from the cooled bed; and
(f) filling the void space of the cooled bed with fresh feedstock.
These steps are more fully characterized below:
Adsorption step (a): During this step the liquid phase feedstock containing the impurities to be removed is passed through a vessel containing a suitable particulate adsorbent such as a zeolitic molecular sieve. As the feed passes through the adsorbent bed the impurities (sorbates) are selectively held up by the adsorbent. The feed, now containing significantly less impurity, leaves the adsorption vessel as product. The adsorption step is continued for a fixed time interval or until the impurity levels in the product exceed specifications. At this time the feed is directed to another adsorption vessel of the system, this vessel having been previously regenerated.
Feedstock Drain Step (b): During this drain step, the feedstock remaining in the void space of the vessel at the end of the adsorption step (a) is drained by gravity or pumped out and recycled to feed. If the vessel is drained slowly then the time required for draining will constitute a significant portion of the overall cycle time. If the vessel is drained quickly then the additional flow rate due to material combining with the feed must be considered when sizing the sorbent requirement. In either case, the elimination of the drain step would be of considerable advantage in a liquid phase sorption system.
Regeneration Heat Step (d): After draining step (b), a heated regeneration medium is passed through the adsorbent bed. As the adsorbent is heated it releases the previously sorbed sorbate. The sorbate passes into the regeneration heating medium and is carried out of the system by the latter. The heating step is continued until the bulk of the impurities have been carried out of the adsorption vessel. Regeneration heating is usually carried out with a regenerating medium differing from both product and feedstock.
Regeneration-Cool Step (d): During this step a cooling medium is passes through the hot adsorption vessel to carry out the sensible heat remaining in the adsorption vessel at the end of the regeneration heat step. The cooling is continued until the bulk of sensible heat is carried out of the sorption vessel. In many instances cooling is carried out with a medium other than the feedstock. It is customary to drain this medium before proceeding to the fill step. This adds another step to the overall process cycle.
Cooling Medium Drain Step (e) the step in which the cooling medium remaining in the adsorbent bed void space at the end of Regeneration Cool Step (d) is removed from the bed either by gravity flow or by pumping.
Void Space Filling Step (f): During the fill step, either product or feedstock is used to fill the void spaces in the adsorption vessel before returning the vessel back into service. This is necessary since failure to do so will result in two phase flow and vapor lock. In large volume sorption vessels the time required for filling the vessel can be substantial especially since often the rate at which feed or product is available is often limited. Upon completion of the fill step the sorption vessel is ready to be put back into the sorption step.
In the above processes the regenerant fluid, although heated, remains in the liquid phase requiring a drain step at the end of the regeneration-cool step. It is preferred to operate the process with the regenerant in the vapor phase during the desorption step. Operation of the regeneration cycle in the vapor phase permits the processing of feedstocks with relatively small quantities of oxygen-containing compounds. The objective of the present invention is to remove trace amounts of oxygenates such as methanol, methyl tertiary butyl ether (MTBE), dimethyl ether (DME), tertiary butyl alcohol (TBA) and water from a reactor effluent stream wherein the concentration of each of these oxygenates ranges from 20 to 2000 ppm wt. and the total amount of oxygenates in the stream ranges from 1000 to 2500 ppm wt. The operation of the regeneration in the vapor phase further permits a pressure assisted drain step to drain the liquid feedstock from the bed at the beginning of the regeneration cycle. A small amount of vaporized regenerant less than 20% of the total is permitted to enter the effluent end of the adsorber bed, forcing the feedstock from the bed. This operation significantly shortens the drain step and provides some initial bed heating. When all of the feedstock has drained from the bed, the full flow of vapor regenerant can be passed over the adsorbent to desorb the oxygen-containing hydrocarbons. The vapor is recirculated and heated until the bed reaches the required temperature for desorption, typically this ranges from 200°-300° C. At the conclusion of the desorption step, the bed must be cooled to adsorption conditions, typically ranging from 25°-50° C. Typically, the bed is cooled by introducing a liquid regenerant which may be the feedstock, the product, or a separate fluid. The initial passing of liquid through the bed in an upflow manner often results in a degree of vaporization of the regenerant liquid which provides further cooling.
The ideal regenerant is a dry, sulfur-free gas. However, in a petroleum refinery there are very few sources of dry gases with a minimum of impurities such as sulfur compounds which would be suitable for this application. Impurities such as water, sulfur and heavy hydrocarbons may contaminate the adsorbent and reduce its effectiveness or shorten its useful life.
Typically, this process used lighter molecular species or the same molecular species as the product for the regenerant. It was generally believed, by those skilled in the art, that regenerant streams containing hydrocarbons that are heavier than the product would interfere with the operation of the adsorbent. Normal butane was often used for the regenerant. When this butane could be blended into gasoline, there were some gasoline octane benefits. However, current U.S. Environmental Protection Agency requirements to reduce the vapor pressure of gasoline has restricted this use for butane.
One of the major applications for this technology is in the manufacture of a high octane motor gasoline component such as methyl tertiary alkyl ethers in these processing arrangements as described in U.S. Pat. No. 4,816,607. The production of ethers by the reaction of an isoolefin with an alcohol is well known and is practiced commercially. This highly selective reaction is also used to remove olefins, especially isobutylene, from mixed hydrocarbon streams such as the C 4 streams produced in steam cracking plants which produce ethylene. Increased attention has been focused on ether production due to the rapidly increasing demand for lead-free octane boosters for gasoline such as MTBE. A detailed description of the processes, including the catalysts, processing conditions and product recovery, for the production of MTBE from isobutylene and methanol are provided in U.S. Pat. Nos. 2,720,547 and 4,219,678 and in an article at page 35 of the Jun. 25, 1979 edition of Chemical and Engineering News. The preferred process is described in a paper presented at the American Institute of Chemical Engineers 85th National Meeting on Jun. 4-8, 1978 by F. Obenaus, et al. Descriptions of integrated processes, including those which utilize butane isomerization are found in U.S. Pat. Nos. 3,726,942, 4,118,425, 4,252,541, and 4,329,516.
In U.S. Pat. No. 4,814,517 to Trubac a dual or compound adsorption bed containing silica gel and zeolite 13X is employed to first selectively remove methanol and then selectively remove dimethylether from an etherification effluent within a process scheme for the production of methyl tertiary butyl ether, MTBE. The adsorber system is regenerated in the liquid phase with normal butane as the regenerant.
BRIEF SUMMARY OF THE INVENTION
The invention provides a method of regenerating solid adsorbents used to remove oxygen-containing compounds from a process stream of an integrated etherification process. The method comprises contacting the usual sorbent with a high temperature stream comprising a hydrocarbon present in a typical petroleum refinery where the availability of suitable regenerant streams are limited.
This invention provides a solution to the problem of finding a suitable regenerant and, where beneficial, retaining the octane quality of the oxygenates for use in the gasoline pool through the use of specific vaporized regenerants. Regenerants for this invention are usually first treated by adsorption to remove sulfur compounds. In such cases, a portion of the treated desorbent is then used to desorb oxygenate compounds from an oxygenate adsorption system while another portion of the regenerant is used to desorb sulfur compounds from the sulfur adsorption zone. Saturate C 3 and C 4 hydrocarbons, commonly known as LPG and the isomerized C 5 -C 6 fraction of a crude oil stream are used as the regenerants of this invention.
It has also been discovered that the isomerized C 5 -C 6 fraction, normally called isomerate, has good gasoline blending characteristics, even though, it represents a higher molecular weight material than the feedstock processed herein. Using isomerate as a vapor regenerant permits the process to be used to effectively remove oxygenates with surprising results and still retain the benefits of recovering oxygenates for use in gasoline blending. Thus, using the isomerate as a regeneration stream has special advantages even when it is used without sulfur removal steps.
In a more complete aspect of the present invention, an LPG stream, which typically contains impurities comprising sulfur compounds and water, is employed as a regenerant to desorb oxygen-containing compounds, or oxygenates from a solid adsorbent wherein sulfur compounds and water are deleterious to the function of the solid adsorbent. A first adsorption system is positioned upstream of the adsorbent for rejecting oxygen-containing compounds. The first adsorption system selectively removes the impurities in the LPG, a portion of the treated sweet LPG is used to desorb the oxygen-containing compounds in the oxygenate removal section and a portion of the sweet LPG is used to desorb the first adsorption system returning the sulfur compounds and water to produce a sour LPG by-product stream. Both a sweet and a sour LPG by-product may be subsequently used for fuel in the refinery.
In another aspect of the invention, a hydrocarbon stream comprising isomerized C 5 -C 6 paraffins is vaporized and used as a regenerant to desorb oxygen-containing hydrocarbons from solid adsorbent. Upon condensation, the isomerate combined with the rejected oxygen-containing hydrocarbons are passed to the gasoline blending pool wherein the surprising benefit is that the isomerate now has a higher research octane and the refinery has retained the higher value use of the oxygen-containing compounds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic flow diagram for an adsorption system comprising a sulfur and water removal section and oxygen-containing hydrocarbon rejection section.
FIG. 2 is a schematic flow diagram of an adsorption system comprising two adsorbent beds with a C 5 -C 6 isomerate regenerant.
DETAILED DESCRIPTION OF THE INVENTION
The adsorption process of the present invention is carried out in the liquid phase and the desorption process of the current invention is carried out in the vapor phase.
The feedstocks suitably treated by the present process are not a narrowly critical factor, it being the principal properties of such feedstocks that are normally in the liquid phase under the pressure conditions which can reasonably be imposed on the adsorption system. Also the feedstocks must contain a constituent, preferably a minor constituent, which is selectively adsorbed by the sorbent employed. Such feedstocks include mixtures of hydrocarbons where the sorptive selectivity is based on molecular size, degree of unsaturation or degree of volatility. The selectively adsorbed impurity can be a non-hydrocarbon such as water, alcohols, sulfides, nitrogen containing compounds and organometallics. The illustration of the invention below is concerned with such a process.
The particular adsorbent involved is also not a critical feature. Any of the commonly used solid adsorbents such as activated alumina, silica gel or zeolitic molecular sieves can be employed. It has been found that a sodium zeolite X is well suited to this application. Of the zeolite adsorbents, particularly zeolite 5A, zeolite 13X and zeolite D are preferred. More preferably zeolite 13X offers particular advantages in adsorbing trace amounts of oxygenates.
The temperature and pressure conditions to be utilized are in the main dependent upon the feedstocks being treated and the adsorbent employed. In general, the temperature at which the adsorption purification step is carried out is, when possible, at near ambient temperature typically ranging from 25°-50° C. since lower temperatures favor adsorption but higher or lower temperatures can be used. Pressure conditions are chosen to maintain the feedstocks and cooling streams in the liquid phase and to move the fluids through the system at the desired rates; typically pressures range from 150 to 200 psia. The degree to which the regeneration purge streams are elevated in temperature typically ranging from 200°-300° C. is also largely dependent upon the particular adsorbate being removed from the sorbent and also the particular sorbent employed. The selection of all of these operating parameters is well within the routine skill of those familiar with the adsorption purification art.
As one of its primary functions, the process of this invention rejects oxygenates from a stream of unreacted hydrocarbons and oxygen-containing compounds. In the case of methyl tertiary butyl ether (MTBE) production, these compounds are MTBE, methanol and by-products including dimethyl ether and tertiary butyl alcohol. Other schemes (U.S. Pat. No. 4,575,565) disclose the means for removing these oxygen-containing compounds to supply a treated process stream substantially free of the oxygen-containing compounds, but are silent on their disposition.
This process is especially suited for using refinery streams that are not generally suited as regenerant fluids for oxygenate adsorption zones. Regenerant streams that pass through the oxygenate adsorption zone must be low in sulfur compounds and olefinic and aromatic hydrocarbons. Thus, the typical high sulfur content of an LPG stream makes it unsuitable as a desorbent. Most isomerate streams have a low enough concentration of sulfur and unsaturated hydrocarbons to make them suitable adsorbents. However, this low sulfur concentration is usually the result of some prior treatment steps. Thus, this invention can be incorporated into such schemes to provide the necessary treatment of the isomerate for upstream processes as well as oxygenate desorption. Moreover, some isomerate streams may still have a sulfur concentration that is unsuitable for sustained used as a desorbent. In such cases this invention has the advantage of allowing only a part of the isomerate stream to be treated for use as an adsorbent.
In most cases the oxygen-containing compounds remain in the regenerant fluid. If the fluid is a natural gas, or other light hydrocarbon stream, the oxygen-containing compounds are burned for fuel. If the regenerant fluid is, however, a gasoline blending component which does not contain unacceptable concentrations free of impurities such as olefins, sulfur compounds and water, the rejected oxygen-containing compounds can be combined with this material to provide additional octane benefits.
Looking particularly at LPG, in a typical refinery this stream may be produced from a variety of processes, but the LPG often contains total sulfur, typically ranging from 100 to 150 ppm wt., and water which could be detrimental to the operation of the adsorbent. It is preferred that the regenerant for this process be dry and contain less than 1 ppm wt. total sulfur. Thus, where needed, this invention provides a separate adsorption section for the drying and selective removal of sulfur compounds from the regenerant stream such that in the adsorption mode the regenerant stream will have a suitable composition. Again, in the case of LPG, the normally wet, sour stream is first passed to a drying and sulfur removal adsorber to produce a dry, sweet LPG which is, heated and passed to the adsorbent bed of the oxygenate removal unit during desorption. In addition, a portion of the dry, sweet LPG is returned to a different drying and sulfur removal adsorber undergoing desorption. Thus, the drying and sulfur adsorption system and the adsorption system for rejecting oxygen-containing compounds share the dry, sweet regeneration stream wherein the impurities which are potentially harmful to the second adsorption system were removed.
The practice of this invention with a wet, sour LPG stream to provide the regenerant stream for an oxygenate adsorption system is illustrated with reference to FIG. 1. The feedstock being treated in this illustrative process is the effluent from an etherification reaction to make a methyl tertiary alkyl ether following the removal of the ether and the removal of unreacted C 4 -minus aliphatic monocyclic alcohols. The alcohols are chosen from methanol, ethanol, primary and secondary propanol, the various butanols, and other alcohols. Methanol and ethanol are particularly preferred. The majority of the description of the invention is presented in terms of the reaction of isobutene with methanol since these are the preferred feed materials and this is the commercially predominant reaction. However, it is not intended to thereby lessen the scope of the inventive concept.
The other component of the etherification reaction is a C 4 -C 6 cyclic hydrocarbon or a single carbon number mixture of isomeric hydrocarbons. The hydrocarbon may, therefore, be substantially pure normal butane, normal pentane or a mixture of the corresponding isomeric and normal hydrocarbons. The preferred hydrocarbon is a mixture of isobutane and normal butane such as is available from several sources in a petroleum refinery, or as available as field butanes. This variety of possible hydrocarbon materials allows the production of a wide variety of ethers other than the preferred MTBE including methyl tertiary amyl ether, ethyl tertiary aryl ether and ethyl tertiary butyl ether.
The effluent from the etherification reaction is passed to a separation zone wherein the MTBE is separated from the effluent whereby the MTBE is taken as the bottoms product and the separation zone effluent is taken overhead to a methanol removal section. In the methanol removal section, the remaining effluent is typically water washed or passed through an adsorption process to remove the unreacted methanol which is returned to the etherification reaction. The methanol depleted separation zone effluent has the following typical amounts of oxygenates:
______________________________________Dimethylether 200-750 ppm wt.Water 500 ppm wt.Methanol 20 ppm wt.TBA 10 ppm wt.MTBE 10 ppm wt.______________________________________
and is hereinafter referred to as the feedstock. In the operation of this illustrative process, the overall cycle requires 960 minutes; i.e., the time interval required from the beginning of an adsorption-purification step in one of the adsorption beds until the beginning of the next adsorption-purification step in the same bed.
The feedstock is passed into the process via lines 1 and 2 to valve 4 and from valve 4 through lines 5 and 6 to oxygenate adsorber bed 201 containing an adsorbent such as activated alumina and/or crystalline zeolitic molecular sieves having the capacity to adsorb trace amounts of oxygenates comprising methanol, MTBE, TBA, DME and water. The preferred adsorbent for this process is a commercially available zeolite X molecular sieve known as zeolite 13X. The temperature within adsorbent bed 201 is at an initial temperature of about 38° C. Immediately prior to introduction of the feedstock into bed 201, the bed contains one bed void volume of the liquid regeneration cool-down medium as a result of the immediately prior regeneration of bed 201. This regeneration cool-down medium is a portion of the dry, sweet LPG. The bed regeneration procedure is described hereinafter with respect to oxygenate adsorbent bed 202.
The upflow of feedstock into bed 201 continues for a total of 480 minutes, during which time oxygenates are adsorbed selectively and retained in the bed. For the first 15 minutes, the effluent from bed 201 is principally the regeneration cool-down medium which filled the bed immediately prior to the beginning of the feedstock flow therein. Over this 15 minute period, the regeneration medium effluent passes up from bed 201 through lines 8 and 12, valve 13, lines 14, 23 and 24, valve 25, lines 26, 39', 35 and 34, valve 31 and lines 30 and 29 to enter the bottom of bed 202, until the void volume of bed 202 is filled with regenerant from bed 201. Thereafter, for the remaining 465 minutes of the aforesaid 480 minute flow period of feedstock into bed 201, the effluent flowing through lines 8 and 9, valve 10 and out of the system through lines 11, 16 and 94, is C 4 hydrocarbon product containing less than 10 wt. ppm of oxygenates. This stream will usually have an oxygenate concentration of between 1 and 10 wt. ppm and is suitable for subsequent processing in downstream refining processes such as butane isomerization, alkylation and dehydrogenation.
At the beginning of the passage of the feedstock into bed 201, bed 202 has completed the adsorption-purification step except that there remains in the bed void space about one bed void volume of feedstock. Flow of feedstock into bed 202 has been terminated at the point where the adsorbent therein retains sufficient capacity to adsorb the amount of oxygenates present in the void space feedstock. In conventional practice, this bed volume of feedstock would be drained from the bed using a separate draining step before the beginning of the regeneration steps. In the present process, however, the drain step is avoided by using the bed volume of the void space regeneration cool-down medium which is the effluent from bed 201 at this time to force the bed volume of feedstock in bed 202 upward over the unspent adsorbent therein and out of bed 202 via lines 19 and 18, valve 17 and lines 15, 16 and 94. If it is necessary to avoid contamination of the product with C 3 's in the regenerant, this stream is returned to separator 205. This by-pass time is 9.5 minutes, starting 10 minutes into the displacement time. This effluent moves from bed 202 through lines 19 and 18, valve 17 and lines 15, 16 and 91 to valve 92 and on to separator 205 via line 93.
During the displacement step, an LPG treater containing adsorbers 203 and 204 is on standby. At the conclusion of the displacement step, bed 202 and bed 204 must be drained of liquid regenerant in preparation for the vapor heating and desorption step. The draining is usually accomplished by a pressure assisted drain step which is effected by the introduction of a small portion of regenerant as superheated vapor. If the entire regenerant were vaporized, the resulting vapor could create high gas velocities. The LPG regenerant enters the process via line 86. A small fraction, less than 20%, of regeneration liquid entering via line 86, passes on via lines 80 and 71 to valve 69 and lines 70 and 66 to the bottom of bed 203 which is still hot from a prior regeneration. The remainder of the regenerant is by-passed via line 81 through valve 81' and lines 79 and 100 to separator 206. As the regenerant cools the bed 203, it is vaporized, passing out of the bed 203 via lines 59 and 59' to valve 56 and on to superheater 207 via lines 55, 54, 48 and 49. During this phase there is no hot spent regeneration vapor through exchanger 206'. The regeneration liquid fed to bed 203 may include at least a portion of liquid regenerant recycle from separator 205 via line 96, pump 209, line 97 and line 82 which joins the fresh regenerant flow in line 80.
The superheated regeneration vapor enters the top of bed 202 via line 50, through valve 51 to lines 52, 23, 22, 20 and 19 and through valve 21. A small fraction of the superheated vapor is also routed to bed 204 via lines 53, 64 and 62 and valve 63.
The superheated regenerant vapor heated to a temperature of between 200°-240° C., enters bed 202 and forces the liquid from the adsorbent bed to separator 205 via lines 29, 30, 34, 35, 36, 38 and 44, passing through valves 31 and 37. The superheated regenerant entering bed 204 via lines 53 and 64, valve 63 and line 62 forces the fluid drained from bed 204 into separator 206 via lines 67, 74, 76, 77, 78, and 100, passing through valve 75 and condenser 210. Once all of the liquid is drained in this manner from beds 202 and 204 the full regeneration flow can be routed through lines 86, 80, 71 and valve 69 to lines 70 and 66 to bed 203. The heating phase begins at this point.
During the heating step, hot dry, sweet regenerant is required to desorb the oxygenates removed from the feedstock and desorb the sulfur compounds removed from the regenerant liquid. Regenerant liquid comprising fresh regenerant in line 86 and recycled sweet spent regenerant from line 82 are passed to the bottom of adsorber 203 via lines 80 and 71 to valve 69 and from that point passed through lines 70 and 66. Here the regenerant liquid initially will be heated in bed 203 and exit the bed as a vapor via lines 59 and valve 56. This vapor is passed to lines 55 and 48 where it encounters cross-exchanger 206'. At the start of the heating phase there will be no heat recovery in cross exchanger 206, however, at the end of the heating phase, a major portion of the vaporization heat will be recovered. From cross exchanger 206', the regenerant is passed via line 49 to superheater 207 wherein the temperature of the regenerant is raised to about 240° C. The superheated regenerant vapor is passed via line 50 to valve 51 which splits the superheated vapor to provide a major portion to desorb oxygenates from bed 202 and a minor portion to desorb sulfur compounds and water in bed 204. To desorb oxygenates in bed 202 the superheated vapor is passed via lines 52 and 22 to valve 21 and through lines 20 and 19 to bed 202. The spent sweet regenerant flows through lines 29 and 30 and valve 31 and is passed to valve 40 via lines 34, 35, 39' and 39. From valve 40 the hot sweet spent regenerant vapor is passed to cross exchanger 206 for heat recovery to provide the partial heating of sweet liquid regenerant. The cooler sweet spent regenerant stream is passed through lines 41 and 42 to condenser 208. At condenser 208, the sweet spent regenerant is condensed and sent to separator 205 via lines 43 and 44. In separator 205 the condensed sweet spent regenerant forms a hydrocarbon phase and an aqueous phase. Each phase contains a portion of the desorbed oxygenates. Oxygenates recovered in the aqueous phase are removed from the process via line 95 and oxygenates in the hydrocarbon phase are removed via line 83, downstream of pump 209 and lines 96 and 97. This material may be used as sweet LPG by product elsewhere in the refinery as it flows from separator 205 to pump 209, via line 96 and from line 97 to line 83. A portion of the sweet spent regenerant is passed via line 82 to a point where it joins line 86 to form line 80.
The minor portion of the superheated regeneration vapor is conducted via lines 53 and 64 to valve 63 and line 62 to the top of adsorber 204, wherein the adsorbed sulfur compounds and water from the previous cycle are desorbed. The spent regenerant from this desorption is sour since it contains sulfur and must be kept apart from the remainder of the regenerant. Therefore, the sour regenerant leaving bed 204 is conducted via lines 67 and 74 through valve 75 and lines 76 and 77 to condenser 210. Condenser 210 condenses the sour regenerant vapor which is passed to separator 208 via lines 78 and 100. This sour LPG is withdrawn as a liquid by product via line 84 and raised to the required pressure by pump 211 to distribute the sour LPG to other uses in the refinery via line 85.
Following the heating step, the oxygenate bed 202 will undergo a cool down step, while the sulfur removal bed 204 will be isolated in a hot standby mode for the next cycle. In the cool/fill step, the sweet liquid regenerant moves from line 54 to line 47 and valve 46 and continues through lines 45, 35 and 34, valve 31 and is passed to the bottom of bed 202 via lines 30 and 29. As the liquid regenerant cools and fills bed 202, hot vapor will exit the top of the bed via lines 19 and 20, through valve 21 and lines 22 and 23, and further is passed via line 98 through valve 99 to lines 65 and 42. The hot vapor is condensed in exchanger 208 and collected in separator 205 via lines 43 and 44. A portion of this liquid will be recycled via lines 96 to pump 209 and lines 97 and 82 to provide sufficient regenerant for the cooling of the oxygenate adsorber bed. This cool/fill step continues for the duration of this segment of the cycle, returning bed 202 to an adsorption temperature of about 38° C. and leaving the bed 202 filled with regenerant. The process then continues in a similar manner with beds 202 and 204 in the adsorption mode while beds 201 and 203 undergo regeneration.
As will be apparent from the foregoing, a significant attribute of the present process is the ease with which the product flow rates can be maintained constant. This is due to the fact that one of the adsorber beds in either the removal of oxygenates or the removal of sulfur and water from LPG is always in operation producing a product. The production of product is maintained on a continuous basis during the drain and fill operations and during the heating and cooling steps. Other advantages will be obvious to those skilled in the art, particularly when the peculiarities of specific feedstocks and regeneration media are taken into account.
One group of components in a typical refinery which produces unleaded gasoline is an isomerized C 5 -C 6 stream or isomerate. This material is sometimes suited as a regenerant because it is often free of sulfur compounds, olefins and aromatic compounds like benzenes. Sulfur compounds and benzene were found to interfere with the selectivity of the adsorbent to adsorb the oxygen-containing compounds. Olefinic compounds often result in the formation of coke on the adsorbent during the desorption process. Many of the oxygen-containing compounds have a research octane number of 115 to 120. When even small amounts of these materials are added to an isomerized C 5 -C 6 stream, research octane of 83-91, there will be a significant benefit to the motor octane of the combination and hence a benefit to the motor gasoline pool.
It has also surprisingly been found that the heavy hydrocarbons do not appreciably interfere with the effectiveness of the adsorbent when an isomerate is used as a regenerant stream. Therefore, in the case of low sulfur isomerates, it is possible to use such streams without the integrated sulfur removal step. FIG. 2 illustrates such a process arrangement where a low sulfur isomerate is used as the regenerant stream for the same feedstock described above in conjunction with the sulfur containing regenerant stream.
With respect to FIG. 2, the feedstock enters the system through lines 101 and 102 in the liquid phase at a temperature of about 38° C. (100° F.) and under a pressure of about 150 psia. The feedstock passes through valve 211 and lines 103 and 104 to adsorbent bed 301 containing zeolitic molecular sieve adsorbent having capacity to adsorb trace quantities of oxygenates comprising methanol, MTBE, tertiary butyl alcohol (TBA), dimethyl ether (DME), and water. A preferred adsorbent for this purpose is the commercial zeolite widely known as zeolite X.
The temperature within adsorbent bed 301 is at an initial temperature of about 38° C. Immediately prior to introduction of the feedstock into bed 301, the bed contains one bed volume of the liquid regeneration cool-down medium as a result of the immediately prior regeneration of bed 301. This regeneration cool-down medium is a portion of the C 5 -C 6 isomerate in the liquid phase.
The bed regeneration procedure is described hereinafter with respect to adsorbent bed 302. The upflow of feedstock into bed 301 continues for a total of 480 minutes, during which time oxygenates are adsorbed selectively and retained in the bed. For the first 15 minutes, the effluent from bed 301 is principally the regeneration cool-down medium which filled the bed immediately prior to the beginning of the feedstock flow thereunto. Over this 15 minute period, the regeneration medium effluent passes up from bed 301 through lines 133 and 132, valve 212, lines 127, 124 and 123, valve 213, lines 122, 120, 112 and 111, valve 214 and lines 110 and 109 to enter the bottom of bed 302 until the void volume of the bed is filled with regenerant from bed 301. Thereafter for the remaining 465 minutes of the aforesaid 480 minute flow period and an additional 15 minutes during the next displacement step, product flows from bed 301 through lines 133 and 134, valve 215 and out of the system through lines 135 and 136. The product comprises C 4 hydrocarbons containing less than 10 wt. ppm of oxygenates and typically oxygenates in a range of 1 to 10 wt. ppm. This stream is suitable for subsequent processing in downstream refinery processes such as alkylation and dehydrogenation.
At the beginning of the passage of the feedstock into bed 301, bed 302 has completed the adsorption-purification step except that there remains in the bed void space about one bed volume of feedstock. Flow of feedstock into bed 302 has been terminated at the point where the adsorbent therein retains sufficient capacity to adsorb the amount of oxygenates present in the void space feedstock. In conventional practice, this bed volume of feedstock would be drained from the bed using a separate draining step before the beginning of the regeneration steps. In the present process, however, the drain step is avoided by using the bed volume of the void space regeneration cool-down medium which is the effluent from bed 301 at this time to force the bed volume of feedstock in bed 302 upward over the unspent adsorbent therein and out of bed 302 as product effluent free of oxygenates. This effluent moves from bed 302 through lines 129 and 130, valve 216 and lines 131 and 136 as C 4 hydrocarbon product. This displacement stage requires 15 minutes. At the conclusion of the displacement step, bed 302 must be drained of liquid regenerant in preparation for the vapor heating and desorption step. The fresh liquid regenerant enters via line 116. This drain step is affected by the introduction of a small portion less than 20% of the total regenerant as superheated vapor at the top of bed 302. Excess regenerant by-passes a heater via line 117, valve 217' and lines 118 and 146 to the regenerant separator 305. The remainder of the regenerant enters lines 115 and 119, passes through heat exchanger 304, line 139, line 138, and steam superheater 303 to valve 217. From line 137 the superheated regenerant flows through lines 125, 124 and 126, valve 218 and flows downward through bed 302 from lines 128 and 129. The liquid regenerant in the void space of bed 302 is forced out of the bed via lines 109 and 110, through valve 214, lines 111 and 112, lines 120 and 121, through valve 210, line 140 through the heat exchanger 304 and lines 141, lines 144, condenser 306, lines 145 and 146 to phase separator 305. This pressure assisted drain step requires 15 minutes to remove the fluid from the bed 302. Once the bed is free of fluid, the heating step begins by heating the fresh regenerant from lines 116, 115 and 119 through heat exchanger 304 and further passing the heated regenerant via line 139 to superheater 303 wherein the regenerant is heated to a temperature in the range of 200°-300° C. (400°-550°), more preferably in a range of 200°-240° C. The superheated regenerant vapor is passed from line 137, through lines 125 and 126, valve 218 and through lines 128 and 129 downward through bed 302. In passing the superheated regenerant vapor through bed 302, the regeneration medium heats the adsorbent and oxygenates are desorbed and carried out of the bed with the hot spent regenerant. The hot spent regenerant vapor is passed from bed 302 through lines 109 and 110, through valve 214 and along lines 111, 112, 120 and 121 to valve 219. From valve 210, the hot spent regenerant vapor exchanges heat in heat exchanger 304 with fresh regenerant and moves through lines 141 and 144 to condenser 306 and on to separator 305 via lines 145 and 146. The hydrocarbon phase of the condensed spent regenerant comprising regenerant and adsorbed oxygenates is removed from the separator 305 via line 147 to pump 307 to cooler 308 via line 149 which reduces the temperature of the condensed spent regenerant and conducts the material to storage or to gasoline blending via line 150. The aqueous phase of line 148 separated in separator 305 contains water and some dissolved oxygenates which may be returned to the MTBE complex for recovery of any methanol. The heating step continues for a total of 260 minutes.
At the conclusion of the heating step, bed 302 begins the cool and fill step wherein the bed 302 is filled from the bottom with liquid regenerant and cooled to adsorption conditions. Fresh liquid regenerant is passed from lines 116 and 115 through line 114 and valve 220 and lines 113, 112 and 111 to valve 214. The regenerant enters bed 302 through lines 110 and 109. As the liquid regenerant enters the hot adsorbent, a portion of the regenerant material vaporizes, providing some sensible cooling. The regenerant passes through the top of bed 302 via lines 129 and 128 and valve 218. The regenerant is then conducted via lines 126, 124, 125 and 142 to valve 221 to condenser 306 via line 143 and 144 where it is condensed. The condensed regenerant is passed to separator 305 via lines 145 and 146. This cooling process continues for 190 minutes, returning the bed 302 to a temperature of about 38° C. and filling bed 302 with regenerant.
As will be immediately apparent to those skilled in the art from the foregoing description, that the pressure assisted drain step used between the displacement step and the heat step significantly reduces the overall cycle time over a gravity assisted drain step or through the use of a mechanical pump as required in the prior known processes. Thus, the cycle times take advantage of this significant reduction.
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A process for the regeneration of oxygenate containing adsorbents uses regenerant streams such as LPG and isomerate products for the desorption of oxygenate compounds. The process discloses arrangements for the integration of regenerant treatment into the adsorption scheme and for the enhancement of the isomerate product. The integrated flowscheme can be used to remove sulfur and water from contaminated regenerants or to deliver the oxygenates into the gasoline pool.
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BACKGROUND OF THE INVENTION
In general, the present invention is directed to systems and methods of treating wastewater produced by the manufacturing processes used to produce electronic components. More specifically, the present invention is directed to systems and methods for removing various components, such as but not limited to, tetra-methyl ammonium hydroxide ((CH 3 ) 4 NOH, TMAH) from wastewater generated by the manufacture of opto-electronic components, such as thin-film transistor liquid crystal displays (TFT-LCDs).
As manufacturing processes in the opto-electronic and semiconductor industries advance, the composition of wastewater generated by such processes has become more complex. For example, such wastewater may comprise both organic carbon compounds and organic nitrogenous compounds, which may be poisonous, corrosive, and eutrophic to the environment.
Thin film transistor liquid crystal displays are a type of LCD that uses thin-film transistor technology to provide an active matrix LCD. TFT-LCDs are used in a variety of consumer products, such as television sets, computer monitors, mobile telphones, navigation systems, etc.
The production of TFT-LCDs in particular, generates significant amounts of high-strength organic nitrogen containing wastewater. Such wastewater may comprise various contaminants, such as TMAH—used as a developer in the production of TFT-LCDs), monoethanolamine (C 2 H 5 ONH 2 , MEA) and dimethyl suphoxide ((CH 3 ) 2 SO, DMSO)—used as a stripper in the production, as well as chelating agents. TMAH is often used as component of the positive photoresist developers in the photolithography process of TFT-LCD manufacturing. TMAH, MEA, and DMSO are generally seen as slow biodegradable organic compounds, which during degradation typically release ammonia, resulting in a high ammonia concentration and a potential nitrification in treated wastewater.
Historically, semiconductor and electronic component manufacturing plants discharged their wastewater to local publicly owned treatment works (POTW) systems. However, the increased loading due to the recent growth of the semiconductor industries coupled with more stringent discharge regulations imposed on POTW to remove organic and nitrogen compounds from wastewater limits the ability of any such POTW to treat adequately treat such discharge.
It has been shown in the prior art that various microorganisms are capable of degrading DMSO under certain conditions. For example, Escherichi coli, Klebsiella, Serratia, Citrobacter braakii, Cyptococcus humicolus, Hyphomicrobium species, and Rhodobacter capsulatus have shown positive results in degrading DMSO. Moreover, MEA can often be degraded through a wide variety of reactions common to amine and alcohol, and can be hydrated to ammonia and acetate. Degradation of TMAH has been particularly problematic, in that the presence of TMAH has an adverse and inhibitory impact on nitrification activity.
Very little prior art addresses the application of a biological nutrient removal process for treating such wastewater, and the prior art that makes such suggestions falls unacceptably short in terms of performance. For example, in a paper entitled Nitrification-Denitrification of Opto-electronic Industrial Wastewater by Anoxic/Aerobic Process, by Chen, et at and published in the Journal of Environmental Science and Health, Part A: Toxic/Hazardous Substances and Environmental Engineering, Vol. 38, Issue 10, (2003), reported a 92-98% COD removal from wastewater by using a two-stage anoxic-aerobic process, yet total nitrogen removal efficiencies were merely 70%. Moreover, as noted above, it has been recorded by several studies that the presence of TMAH inhibits biological processes. See, e.g., Use of Two-Stage Biological Process in Treating Thin Film Transistor Liquid Crystal Display Wastewater of Tetramethylammonium Hydroxide, by Han-Lin Lin, et al., and published in Sustainable Environment Research Journal, Volume 21(3), (2011); Biological Treatment of TMAH (tetra-methyl ammonium hydroxide) In a Full Scale TFT-LCD Wastewater Treatment Plant, by T H Hu, et al., and published in the Bioresource Technology Journal, (2012).
Accordingly, systems and methods for treating wastewater resulting from the production of TFT-LCDs that effectively remove TMAH as well as COD and total nitrogen are desired.
SUMMARY OF THE INVENTION
In accordance with some embodiments of the present invention, aspects may include a biological and chemical treatment system for treating wastewater comprising liquid and solid components, comprising: an aerobic reactor, receiving an influent comprising wastewater to be treated; a first separation module in series with the aerobic reactor, the first separation module receiving the output of the aerobic reactor as an input, the first separation module separating liquid and solid components of the wastewater; an oxidation module in series with the first separation module, the oxidation module receiving the output of the first separation module as an input, the oxidation module removing organic materials from the wastewater; and a post-anoxic reactor in series with the oxidation module, the post-anoxic reactor receiving the output of the oxidation module as an input, the post-anoxic reactor denitrifying at least a portion of the wastewater, and outputting an effluent.
Other aspects in accordance with some embodiments of the present invention, may include a biological and chemical treatment system for treating wastewater comprising liquid and solid components, comprising: an aerobic reactor, receiving an influent comprising wastewater to be treated; a membrane filtration system receiving the output of the aerobic reactor as an input, the membrane filtration system separating liquid and solid components of the wastewater; an oxidation module in series with the first separation module, the oxidation module receiving the output of the first separation module as an input, the oxidation module removing organic materials and nitrifying ammonia from the wastewater; a post-anoxic reactor in series with the oxidation module, the post-anoxic reactor receiving the output of the oxidation module as an input, the post-anoxic reactor denitrifying at least a portion of the wastewater, and outputting an effluent; and a gravity clarifier for sludge separation receiving the output of the post-anoxic reactor as an input.
Other aspects in accordance with some embodiments of the present invention may include a biological and chemical treatment method for treating wastewater comprising liquid and solid components as well as organic nitrogen compounds, comprising: receiving an influent comprising wastewater to be treated in an aerobic reactor, biologically treating the influent to convert and degrade organic nitrogen compounds; receiving at a first separation module from the aerobic reactor an output of the aerobic reactor; separating liquid and solid components of the wastewater by the first separation module; receiving at an oxidation module from the first separation module an output of the first separation module; removing organic materials and nitrifying ammonia from the wastewater by the oxidation module; receiving at a post-anoxic reactor from the oxidation module an output of the oxidation module; and denitrifying at least a portion of the wastewater by the post-anoxic reactor, and outputting an effluent.
These and other aspects will become apparent from the following description of the invention taken in conjunction with the following drawings, although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more fully understood by reading the following detailed description together with the accompanying drawings, in which like reference indicators are used to designate like elements. The accompanying figures depict certain illustrative embodiments and may aid in understanding the following detailed description. Before any embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The embodiments depicted are to be understood as exemplary and in no way limiting of the overall scope of the invention. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The detailed description will make reference to the following figures, in which:
FIG. 1 illustrates exemplary system performance results for systems and methods of treating wastewater, in accordance with some embodiments of the present invention.
FIG. 2 illustrates an exemplary TMAH correlation with total Kjehldahl nitrogen (TKN) and total organic carbon (TOC), in accordance with some embodiments of the present invention.
FIG. 3 illustrates an exemplary relationship between calculated theoretical results and experimental results for TOC in a TMAH solution, in accordance with some embodiments of the present invention.
FIG. 4 illustrates an exemplary relationship between calculated theoretical results and experimental results for TKN in a TMAH solution, in accordance with some embodiments of the present invention.
FIG. 5 depicts a system for treating wastewater, in accordance with some embodiments of the present invention.
FIG. 6 illustrates an exemplary TOC removal performance in an aerobic reactor, in accordance with some embodiments of the present invention.
FIG. 7 illustrates an exemplary TKN removal performance in an aerobic reactor, in accordance with some embodiments of the present invention.
FIG. 8 illustrates an exemplary rate of ammonia (NH 4 —N) formation during TMAH bio-degradation, in accordance with some embodiments of the present invention.
FIG. 9 illustrates an exemplary ozone demand during advanced oxidation process (AOP) oxidation of ammonia (NH 4 —H) to nitrates (NO 3 —N), in accordance with some embodiments of the present invention.
FIG. 10 illustrates an exemplary decrease of ammonia (NH 4 —N) during AOP oxidation to nitrates (NO 3 —N), in accordance with some embodiments of the present invention.
FIG. 11 illustrates an exemplary reaction time for nitrate (NO 3 —N) formation from AOP oxidation of ammonia (NH 4 —H), in accordance with some embodiments of the present invention.
FIG. 12 illustrates an exemplary nitrate (NH 4 —N) formation as a function of ozone demand during oxidation of ammonia (NH 4 —H), in accordance with some embodiments of the present invention.
FIG. 13 illustrates an exemplary results showing reduction of chemical oxygen demand (COD) during ozonation of ammonia (NH 4 —H).
FIG. 14 illustrates an exemplary overall total nitrogen system performance, for systems in accordance with some embodiments of the present invention.
FIG. 15 depicts a system for treating liquid organic wastes, in accordance with some embodiments of the present invention.
FIG. 16 illustrates results of COD performance, in accordance with some embodiments of the present invention.
FIG. 17 illustrates results of TOC performance, in accordance with some embodiments of the present invention.
FIG. 18 illustrates results of TKN performance, in accordance with some embodiments of the present invention.
Before any embodiment of the invention is explained in detail, it is to be understood that the present invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The present invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
DETAILED DESCRIPTION OF THE INVENTION
The matters exemplified in this description are provided to assist in a comprehensive understanding of various exemplary embodiments disclosed with reference to the accompanying figures. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the exemplary embodiments described herein can be made without departing from the spirit and scope of the claimed invention. Descriptions of well-known functions and constructions are omitted for clarity and conciseness. Moreover, as used herein, the singular may be interpreted in the plural, and alternately, any term in the plural may be interpreted to be in the singular.
In order to determine the efficacy of the systems and methods discussed herein, two (2) types of industrial waste streams were tested: a liquid organic waste (LOW) stream, and a stream comprising TMAH. The TMAH stream was treated in by an aerobic-AOP-anoxic system, while the LOW stream was treated using an anoxic-aerobic-AOP-anoxic system. Each will be discussed in turn.
Treatment of TMAH Stream
The systems and methods discussed herein have been tested, both through theoretical calculations and through experimentation. It has been found that by using systems and methods in accordance with some embodiments of the present invention, a combination of aerobic treatment of wastewater, coupled with an advanced oxidation process (AOP) as well as biological denitrification, efficiencies of at or around 96.3% of total nitrogen removal can be obtained.
In general, the TMAH stream was treated using an activated sludge process configured with aerobic and anoxic bioreactors and AOP within the treatment loop. The TMAH stream was diluted at 1:6 with distilled water to avoid chemical toxicity to the biological process. As is discussed in detail below, the aerobic-AOP-anoxic system efficiently removed >98% TOC and >95% TN. Moreover, the effluent showed complete, or substantially complete degradation of TMAH in the aerobic bioreactor. Even though the influent had a TMAH concentration of 4,000 mg/L, no toxicity and/or inhibition of the biological treatment was observed over the experimental duration.
Specifically, through the use of systems and methods in accordance with some embodiments of the present invention, greater than 99% of TMAH was converted to ammonia, thereby generating a free NH 4 —N for further conversion. AOP ozonation of biologically treated wastewater then completed the oxidation of ammonia into nitrates (NO 3 —N), and post-anoxic biological denitritifaction of the effluent from the AOP resulted in complete and substantially complete conversion of the nitrates into nitrogen gas.
FIG. 1 and Table 1 set forth specific exemplary results.
TABLE 1
Overall Treatment System Performance Results
Influent
Aerobic
AOP
Anoxic
Effluent
Removal
TOC (mg/L)
2800 ± 120
80 ± 20
<30
—
—
>98%
NH 4 —N (mg/L)
7 ± 1
690 ± 30
8 ± 2
—
6 ± 3
—
NO 3 —N (mg/L)
<0.4
<0.4
610 ± 30
<0.4
<0.4
—
NO 2 —N (mg/L)
<0.5
<0.5
<0.5
<0.5
<0.5
—
TKN (mg/L)
750 ± 30
715 ± 25
30 ± 5
—
26 ± 5
>95%
TMAH (mg/L)
4000
—
—
—
—
>99%
In order to best understand the application and results of the systems and methods embodied in the present invention, it may first be useful to understand the characteristics of the wastewater to be treated by such systems and methods. Industrial wastewaters, as set forth in Table 2, the Liquid Organic Wastes (LOW) stream and TMAH stream were collected from a semiconductor manufacturer in USA.
TABLE 2
Wastewater Characteristics
Parameter
LOW stream
TMAH stream
pH
>12
>12
Conductivity (mS/cm)
75
TMAH (mg/L)
45,000-50,000
20,000-25,000
TOC (mg/L)
75,000-80,000
15,000-20,000
Total Nitrogen (mg/L)
9,500-10,000
4,500-5,000
COD (mg/L)
170,000-190,000
No test method available
Systems in accordance with some embodiments of the present invention may comprise a two-zone treatment system, in which following an equalization step, the wastewater may be conditioned with various chemicals for proper biological degradation. The wastewater may then be processed through (i) an anoxic selector reactor; (ii) an aerobic activated sludge reactor; (iii) an ultrafiltration (UF) membrane for sludge separation; (iv) an anoxic post-denitrification reactor; and (v) a clarifier for sludge separation. In addition, an AOP process may be utilized to treat organics and nitrification of the wastewater.
During experimentation, in order to address higher TN and TMAH loadings wastewater dilution rations of 1:6 and 1:3 were tested through a process comprising aerobic, clarification, AOP, and post-anoxic denitrification. Specifically, an aerobic activated sludge reactor was used to degrade TMAH and generate NH 4 —N, membrane filtration to separate the sludge, an AOP system to convert NH 4 —N into NO 3 —N, an anoxic reactor to convert NO 3 —N into N 2 gas, and a gravity clarifier for sludge separation.
Design loadings for the systems employing these strategies are set forth in Table 3.
TABLE 3
Pilot Unit Design Loadings
LOW stream
TMAH stream
COD
2.4-2.7
(kg COD/m 3 /d)
Not measureable
loading
TOC
1.2-1.4
(kg TOC/m 3 /d)
0.53-0.75
(kg TOC/m 3 /d)
loading
TN
0.14-0.16
(kg TN/m 3 /d)
0.1 3-0.21
(kg TN/m 3 /d)
loading
TMAH
0.7-0.8
(kg TMAH/m 3 /d)
0.9-1.1
(kg TMAH/m 3 /d)
loading
In order to understand the systems and methods of the present invention, as well as the exemplary results set forth herein, several components of the test protocol will be discussed below in detail. Specifically, each of (i) wastewater characterization; (ii) aerobic biological treatment for TMAH breakdown into ammonia; (iii) advanced oxidation of ammonia to nitrate; (iv) combined biological and advanced oxidation for TN removal; and (v) any potential impact of pH values on TMAH decomposition and degradation, are discussed below.
Wastewater Characterization
The wastewater to be treated was analyzed for main chemical constituents, organic content parameters (COD, TOC), nitrogen containing species (ammonia, nitrite, nitrate, organic nitrogen) and pH. The major chemical constituent found in wastewater was tetramethylammonium hydroxide (TMAH). Analytical results confirmed the presence of approximately 23,000 mg/L of TMAH, 17,561 mg/L of TOC and 4,675 mg/L of TKN.
Table 4 sets forth TOC and TKN analytical values for the wastewater comprising a TMAH solution.
TABLE 4
TOC and TKN Analytical Values for TMAH Solutions
COD (mg/L)
TOC (mg/L)
TKN (mg/L)
TMAH (mg/L)
Theoretical
Experimental
Theoretical
Experimental
Theoretical
Experimental
100
211
<20
53
59
16
17
200
421
<20
105
118
31
33
300
632
<20
158
172
47
45
400
843
<20
211
233
63
64
500
1053
<20
264
283
78
84
In order to monitor TMAH from TOC and TN, correlations between TMAH and TOC, and TMAH and TN were developed. Specifically, TMAH standard solutions of 100, 200, 300, 400 and 500 mg/L were prepared using a stock solution of 25% TMAH. FIGS. 2 , 3 and 4 show theoretical and experimental correlations for TOC and TKN concentrations in a TMAH solution.
In these analytical tests, the Total Kjeldahl Nitrogen (TKN) test method was used to determine the Total Nitrogen (TN=TKN+NOx−N) content of the solution since there was no NOx−N in wastewater treated. Thus, the Total Nitrogen concentration is equivalent to the TKN value for this sample.
The high regression coefficient (R 2 =0.99) between theoretical and experimental TOC and TKN values indicates that the ratio of TOC to TMAH and TKN to TMAH can be properly used. From these correlations, the TOC content of TMAH is 0.5267 g TOC/g TMAH and the Total N content in TMAH is 0.1536 g N/g TMAH. These ratios can be used to estimate the influent and effluent TMAH concentration.
With reference to FIG. 5 , a system 50 of treating wastewater in accordance with some embodiments of the present invention will now be discussed. FIG. 5 depicts a system in accordance with Strategy 1, comprising an aerobic reactor 510 , a first clarifier/membrane bioreactor (MBR) 520 , an AOP system 530 , a post-anoxic reactor 540 , and a second clarifier/MBR 550 .
In general, the aerobic reactor 510 may convert organic compounds into carbon dioxide, and degrade organic nitrogen (such as TMAH) into ammonia. Since the aerobic reactor 510 may be a biological reactor, the reaction may be summarized as:
Organic Carbon Source+Microorganisms+O 2 →CO 2 (gas)+H 2 O+Biomass
In the case of TMAH, the degradation may be summarized as:
TMAH→Tri-methylamine→Di-methylamine→Methylamine NH 4
Or more specifically as:
(CH 3 ) 4 NOH→(CH 3 ) 3 N→(CH 3 ) 2 NH→CH 3 NH 2 →NH 4
As noted, the aerobic reactor 510 may be a biological reactor that may convert and degrade the TMAH (i.e., organic nitrogen) into ammonia (NH 4 —N). In the aerobic reactor 510 , approximately 99% of TMAH may be degraded into ammonia, and 95% of TOC may be removed. The treated effluent from the aerobic reactor 510 may be then be fed into the first clarifier/MBR 520 .
The first clarifier/MBR 520 may be a membrane filtration unit using, for example, a flat-sheet Toray UF membrane, or may be a conventional clarifier, such as for example, a settling type intermediate clarifier, where the clarifier underflow solids are recycled to the aerobic reactor 510 by lines 502 as return activated sludge (RAS) or sent to a sludge holding tank (not shown) as waste activated sludge (WAS). In the case of a membrane filtration unit, other than settling tanks and further filtration, the MBR process may utilize specialized membranes to employ ultrafiltration (UF) and micro-filtration (MF) membranes. MBR technology is commonly submerged into the bioreactor. Such a submerged configuration may rely on aeration to produce mixing and limit fouling. Aeration maintains solids in suspension, scours the membrane surface and provides oxygen to the biomass, leading to better degradability.
The AOP system 530 may be utilized to convert ammonia (NH 4 —N) into nitrates (NO 3 —N), as well as the treatment of recalcitrant organic compounds. The AOP system 530 may use ozone (O 3 ) and hydrogen peroxide (H 2 O 2 ) for the chemical oxidation of ammonia to nitrate and COD destruction by causing oxidation of most organic compounds until they are fully mineralized as carbon dioxide, thereby removing excess carbon.
Specifically:
NH 4 +Organics+O 3 +H 2 O 2 →NO 3 1− (Nitrates)+Modified Organics+CO 2 (gas)
The AOP system 530 may comprise an aqueous phase oxidation method, comprising highly reactive species used in the oxidative destruction of the ammonia in the fluid. As noted, the AOP system 530 may use ozone (O 3 ) for treatment; alternatively, the AOP system 530 may use hydroxyl radicals, a powerful secondary oxidant.
While an AOP system 530 is shown, it is also contemplated by the present invention that other methods of removing ammonia from aqueous phase may be available. For example, as discussed in more detail below, a variety of methods, such as ammonia stripping may be utilized to remove ammonia from the aqueous phase. While advanced oxidation processes are discussed, it is fully contemplated by the present invention that alternatives processes may be utilized. For example, ammonia stripping, which is relatively known in the art may be utilized. Ammonia stripping may include the addition of dilute sulfuric acid in order to recover the ammonia as ammonium sulfate, a well-known fertilizer. Other alternatives may include breakpoint chlorination, a catalytic oxidation method, and/or selective ion exchange on clinoptilolite. Regardless of the specific system selected, the primary contribution of the system is the removal of ammonia. Moreover, note that if physical footprint is not an issue, ammonia may also be biologically removed.
The post-anoxic reactor 540 may provide an anoxic stage, where nitrates are reduced to nitrogen gas via denitrification reactions. Specifically:
NO 3 1− +Carbon Source+Microorganisms→N 2 (gas)+H 2 O+Alkalinity+Biomass
As wastewater may be deficient in macronutrients required to support biological growth, the post-anoxic reactor 540 may be fed with a biodegradable nutrient blend, containing macro- and micronutrients to maintain microbial growth. Nutrients include but are not limited to supplemental carbon such as waste sugar, corn syrup, molasses or the like, or the use of commercially available carbon sources, such as MicroC (available from Environmental Operating Solutions, Inc., in Bourne, Mass.) or D-Glucose (dextrose).
From the post-anoxic reactor 540 , the fluid may flow into the second clarifier/MBR 550 , where again, clarifier underflow solids may be recycled to as an influent of the post-anoxic reactor 540 by lines 504 as return activated sludge (RAS) or sent to a sludge holding tank (not shown) as waste activated sludge (WAS).
The system 50 depicted in FIG. 5 may comprise various reactors of various sizes. For experimental purposes, the aerobic reactor 510 utilized had a volume of 27 liters, the first clarifier/MBR 520 a volume of 15 liters, the AOP system 530 a volume of 16-25 liters, the post-anoxic reactor a volume of 4 liters, and the second clarifier/MBR a volume of 0.7 liters. Note however, that while the sizes and volumes of each system 50 component impact the overall efficiency and operation of the system 50 , it is fully contemplated that various sizes of each component may be utilized without deviating from the invention.
The system 50 received influent Q inf at 501 at a rate of approximately 0.84 liters/day of wastewater, coupled with 4.2 liters/day of dilution water, resulting in a total influent of 5.04 liters/day. Note again, that such feed rates are exemplary only, and it is contemplated that substantially different feed rates may be utilized without deviating from the invention.
Other exemplary operating attributes of the system 50 may comprise a dilution water to wastewater ration of 5:1, a dilution factor of 6:1, an operating temperature maintained approximately 62-73° Fahrenheit, a mixed liquor volatile suspended solids (MLVSS) of approximately 6,375 mg/liter (+/− approximately 676 mg/liter), and a mixed liquor suspended solids (MLSS) of approximately 7,075 mg/liter (+/− approximately 701 mg/liter).
With continued reference to FIG. 5 , the influent 501 may flow into the aerobic reactor 510 , and then into the first clarifier/MBR 520 . At this point, some return activated sludge flow 502 may be returned as an influent into the aerobic reactor 510 . The influent may then travel into the AOP 530 , and subsequently into the post-anoxic reactor 540 . The post-anoxic reactor 540 may also receive an input of carbon source 503 , discussed in more detail below. From the post-anoxic reactor 540 the fluid may then flow into the second clarifier/MBR 550 , from which some return activated sludge flow 504 may be returned as an influent into the post-anoxic reactor 540 . Effluent 505 may then exit the second clarifier/MBR 550 .
Table 5 below illustrates loadings and operational parameters for system 50 at a 1:6 dilution utilizing Strategy 1.
TABLE 5
Operational Parameters at 1:6 Dilution
LOW stream
TMAH stream
Pre-
Post-
Post-
Anoxic
Aerobic
Aerobic
AOP
Anoxic
Aerobic
AOP
Anoxic
pH
7 ± 0.2
7 ± 0.2
7 ± 0.2
—
7 ± 0.2
7 ± 0.2
—
7 ± 0.2
Temp. (° F.)
70 ± 5
70 ± 5
70 ± 5
70 ± 5
70 ± 5
70 ± 5
DO (mg/L)
<0.2
>4.0
>4.0
<0.2
>4.0
<0.2
HRT (d)
0.16
0.83
0.83
0.08
5.38
0.79
ORP (mV)
200 ± 50
—
—
200 ± 50
—
200 ± 50
MLSS
7000
7000
7000
7000
7000
7000
(mg/L)
Q recycle
3 × Q inf
3 × Q inf
1 × Q inf
3 × Q inf
1 × Q inf
Aerobic Reactor Operational Conditions and Results
During use, the aerobic reactor utilized in systems and methods in accordance with some embodiments of the present invention utilized stabilization and acclimation period of approximately two (2) weeks. After approximately one (1) week of operation, most of the TMAH was being converted into ammonia (NH 4 —H). As shown below in Table 6, 98.5% of the TN in the effluent was in ammonia form. Accordingly, TMAH was successfully degraded into ammonia in the aerobic reactor.
TABLE 6
Degradation of TMAH in Ammonia
Aerobic
Aerobic
Aerobic
Aerobic
Aerobic
Influent
Influent
Effluent
Effluent
Effluent
NH 4
TMAH
NH 4
NO X
TMAH
Date/Time
(mg/L)
(mg/L)
(mg/L)
(mg/L)
(mg/L)
Day 1
10.7
3740
650
<0.4
195
Day 2
10.3
3644
662
<0.4
0
Day 3
10.1
3719
636
<0.4
352
Day 4
4.8
3893
724
<0.4
0
Day 5
9.5
3599
658
<0.4
404
Day 6
9.9
3744
648
<0.4
469
Day 7
10
3670
672
<0.4
215
Day 8
5.1
3694
698
<0.4
176
Day 9
5.4
3619
718
<0.4
176
Day 10
5.1
3522
682
<0.4
475
Day 11
4.7
3647
738
0.6
78
Day 12
5.1
3349
754
<0.4
234
Day 13
5.3
3619
764
<0.4
0
Day 14
5.1
3990
744
<0.4
202
Day 15
5.2
2634
718
<0.4
13
Day 16
3.7
3775
708
<0.4
208
Day 17
5.9
3863
748
<0.4
241
Day 18
3.9
3823
730
<0.4
195
Day 19
5.8
3026
760
<0.4
0
Day 20
5.6
3864
698
<0.4
371
Day 21
5.7
3913
716
<0.4
514
Day 22
5.2
4088
756
<0.4
91
Average
6.4 ± 2.2
3760 ± 320
700 ± 40
210 ± 150
Four influent and effluent samples from the aerobic reactor were analyzed for direct determination of TMAH concentration. As shown in Table 7 below, approximately 99% of the TMAH was biodegraded, and effluent samples showed TMAH concentrations at less than 0.5 mg/liter.
TABLE 7
Influent and Effluent TMAH Concentrations
in the Aerobic Reactor
Influent TMAH
Effluent TMAH
Date
Concentration (mg/L)
Concentration (mg/L)
Day 1
4,000
39
Day 5
4,100
<0.5
Day 6
Not available
<0.5
Day 7
3,700
<0.5
The aerobic reactor used in the systems and methods in accordance with some embodiments of the present invention was fed with wastewater at a 1:6 dilution with the concentrations set forth below in Table 8. Note that such concentrations were exemplary and non-limiting, and the systems and methods of the present invention apply to various concentrations.
TABLE 8
Influent and Effluent Parameters of the Aerobic Reactor
Aerobic Reactor
Influent
Effluent
Removal/Conversion
Parameters
(mg/L)
(mg/L)
(%)
TOC
2800 ± 120
80 ± 25
97%
TKN
750 ± 30
675 ± 70
10%
NH 4 —N
7 ± 1
635 ± 60
n/a
Organic-N
740 ± 30
40 ± 60
95%
NO 3 —N
<0.4
<0.4
n/a
TN
750 ± 30
675 ± 40
10%
The aerobic reactor effluent characteristics of 80+/−20 mg/L TOC, 635+/−60 mg/L NH 4 —N and 675+/−70 mg/L TKN may indicate robustness of the biological system to treating TMAH. Direct measurement of the TMAH concentration also confirmed a breakdown of greater than 99% of TMHA. Note that the effluent NH 4 —N concentration of 635+/−60 mg/L may be generated from the bio-degradation of TMAH. The nitrogen present in the TMAH molecule is organic nitrogen and not free ammonia as shown in the influent analysis of the feed wastewater. Moreover, an effluent TOC of 80+/−20 mg/L resulting in approximately 96.5% degradation in organic carbon may be an indication of TMAH bio-degradation in the aerobic reactor.
With reference to FIGS. 6 and 7 , the TOC and TKN removal efficiencies in the aerobic reactor are depicted. Approximately 10% of the TKN was removed in the aerobic reactor primarily for biomass synthesis. Furthermore, FIG. 8 indicates that the biodegradation of TMAH in the aerobic reactor may generate an NH 4 —N concentration of greater than 600 mg/L (85% of the influent TKN), which may be removed using the AOP or ammonium stripping technologies. Accordingly, greater than 95% of total nitrogen may be removed from the wastewater utilizing the treatment system in accordance with the present invention.
AOP Operating Conditions and Performance
Samples were analyzed to determine the characteristics of the feed to the AOP, as well as the AOP treated wastewater characteristics. Tables 9 and 10 below set out the results.
TABLE 9
Composite Biological and AOP Treated Effluent Characteristics
Bio-Effluent
TKN
AOP Effluent
NH 4 —N
NO 3 —N
(mg/
NH 4 —N
NO 3 —N
TKN
(mg/L)
(mg/L)
L)
(mg/L)
(mg/L)
(mg/L)
Batch
475
<0.4
500
0.5
430
Not
1
measured
Batch
530
<0.4
640
31
395
Not
2
measured
Batch
600
<0.4
625
10
385
Not
3
measured
Batch
670
<0.4
710
0.5
595
Not
4
measured
Batch
730
<0.4
755
10
640
Not
5
measured
TABLE 10
Influent and Effluent Characteristics of AOP Treatment
AOP Treatment
Parameters
Influent (mg/L)
Effluent (mg/L)
COD
250 ± 50
90 ± 30
NH 4 —N
635 ± 60
12 ± 10
NO 3 —N
<0.4
490 ± 100
TN
675 ± 70
Not measured
The results shown above in Tables 9 and 10 were the result of ozonation/H 2 O 2 treatment, in order to convert NH 4 —N into NO 3 —N. The AOP treatment substantially completely nitrified the ammonia in the biologically treated wastewater into nitrates. FIGS. 9-12 illustrate that the substantially complete oxidation of ammonia with ozone caused the formation of more than 400 mg/liter of nitrates. Furthermore, the AOP provided an additional reduction in the residual carbon in the wastewater by converting such carbon into carbon dioxide (CO 2 )
FIG. 9 illustrates the ozone demand during AOP oxidation of the ammonia (NH 3 —N) in the wastewater into nitrates (NO 3 —N). It can be seen from FIG. 9 that as the ozone level increases, the ammonia levels decrease, as it is converted into nitrates.
FIG. 10 sets forth the decrease of ammonia during the AOP oxidation into nitrates. It can be seen that as the exemplary test was conducted, the level of ammonia decreased from 487.0 mg/liters to 0.5 mg/liters in approximately 390 minutes.
FIG. 11 illustrates the reaction time for nitrates (NO 3 —N) to form from the AOP oxidation of ammonia (NH 4 —N). At approximately 390 minutes into the test, approximately 425 mg/liter of nitrates are formed.
FIG. 12 depicts the nitrate (NO 3 —N) formation as a function of ozone demand during oxidation of ammonia (NH 4 —N).
FIG. 13 shows the destruction of COD during ozonation of the ammonia in the wastewater.
Post-Anoxic Denitrification Reactor Performance
The post-anoxic denitrification reactor was fed with an influent comprising greater than 400 mg/liter nitrates (NO 3 —N), received from the AOP reactor, as well as a carbon source (element 503 in FIG. 5 ). Exemplary operational parameters of the post-anoxic reactor comprise a flow of approximately 5.04 liters/day, a reactor size of 4 liters, a hydraulic residence time of 0.79 days, an operating temperature of 62-73 degrees Fahrenheit, a mixed liquor volatile suspended solids (MLVSS) of approximately 5,483 mg/liter, and a mixed liquor suspended solids (MLSS) of approximately 6,113 mg/liter.
Table 11 below illustrates the performance of the post-anoxic reactor with regard to nitrogen removal. The post-anoxic reactor effluent was measured at a NO 3 —N amount of less than 0.4 mg/liter, thereby indicating complete biological denitrification of the nitrates.
TABLE 11
Influent and Effluent Characteristics of Denitrification
Post-anoxic Reactor
Parameters
Influent (mg/L)
Effluent (mg/L)
NH 4 —N
12 ± 10
10 ± 8
NO 3 —N
490 ± 100
<0.4
NO 2 —N
<0.5
<0.5
TKN
40 ± 20
25 ± 10
Overall System Performance
The combination of the aerobic treatment followed by the AOP and biological denitrification increased the overall removal efficiency of the TN from the wastewater. Table 12 below indicates the removal efficiencies of the system. Specifically, aerobic biological treatment resulted in an approximate 96.5% destruction of TOC, which thereby generated a free NH 4 —N for further conversion. The AOP ozonation of the biologically treated wastewater resulted in a substantially complete conversion of ammonia into nitrates. The post-anoxic biological denitrification provided to the AOP treated effluent resulted in substantially complete conversion of nitrates into nitrogen gas.
TABLE 12
Overall System Performance
Influent
Aerobic
AOP
Anoxic
Effluent
Removal
TOC (mg/L)
2800 ± 120
80 ± 20
—
—
—
>98%
NH 4 —N (mg/L)
7 ± 1
690 ± 30
8 ± 2
—
6 ± 3
—
NO 3 —N (mg/L)
<0.4
<0.4
610 ± 30
<0.4
<0.4
—
NO 2 —N (mg/L)
<0.5
<0.5
<0.5
<0.5
<0.5
—
TKN (mg/L)
750 ± 30
715 ± 25
30 ± 5
—
26 ± 5
>95%
TMAH (mg/L)
4000
—
—
—
—
>99%
Treatment of LOW Stream
As noted above, the LOW stream was treated with an anoxic-aerobic-AOP-anoxic process. With reference to FIG. 15 a system 1500 in accordance with some embodiments of the present invention will now be discussed. System 1500 may comprise, in general, a pre-anoxic reactor 1510 , an aerobic reactor 1520 , a first clarifier/MBR 1530 , an AOP 1540 , a post-anoxic reactor 1550 , and a second clarifier/MBR 1560 . An influent (Q INF ) 1501 may be provided to the pre-anoxic reactor 1510 , and may subsequently be provided, in serial, to each of the aerobic reactor 1520 , first clarifier/MBR 1530 , AOP 1540 , post-anoxic reactor 1550 , and second clarifier/MBR 1560 .
The first clarifier/MBR 1530 may return at least a portion of activated sludge from the first clarifier/MBR 1530 as an input of the pre-anoxic reactor 1510 . It is also contemplated that the first clarifier/MBR 1530 may return at least a portion of the activated sludge to the aerobic reactor 1520 . Similarly, the second clarifier/MBR 1560 may return at least a portion of activated sludge from the second clarifier/MBR 1560 as an input to the post-anoxic reactor 1550 .
The operation of the various biologic reactors may be much the same as discussed above with regard to the TMAH waste stream. Similarly, the post-anoxic reactor 1550 may receive a carbon source 1503 , much as discussed above.
The overall treatment system performance results are indicated below in Table 13.
TABLE 13
Overall Treatment System Performance Results (LOW Stream)
Influent
Anoxic
Aerobic
AOP
Anoxic
Effluent
Removal
COD
2600 ± 125
920 ± 190
190 ± 30
<30
—
—
>98%
(mg/L)
TOC
1300 ± 90
450 ± 200
75 ± 30
<30
—
—
>98%
(mg/L)
NH 4 —N
14 ± 4
55 ± 20
95 ± 20
<1.0
—
3 ± 1
—
(mg/L)
NO 3 —N
<0.4
<0.4
<0.4
95 ± 30
<0.4
<0.4
—
(mg/L)
NO 2 —N
<0.5
<0.5
<0.5
<0.5
<0.5
<0.5
—
(mg/L)
TKN
165 ± 10
140 ± 15
120 ± 15
30 ± 12
—
25 ± 7
>80%
(mg/L)
TMAH
830
—
—
—
—
—
—
(mg/L)
The organic rich TMAH loaded wastewater (LOW stream) was diluted at 1:60 with distilled (DI) water to avoid potential toxicity primarily due to the presence of 49,300 mg/L of TMAH. Table 14 below shows influent, anoxic reactor, aerobic reactor and final effluent characteristics.
TABLE 14
Influent and Effluent Parameters of the Anoxic-
Aerobic Reactor (LOW stream)
Anoxic-Aerobic Reactor
Influent
Effluent
Removal/Conversion
Parameters
(mg/L)
(mg/L)
(%)
COD
2600 ± 125
90 ± 30
91%
TOC
1300 ± 90
75 ± 30
94%
TKN
165 ± 10
120 ± 15
18%
NH 4 —N
14 ± 4
95 ± 20
Organic-N
150
50 ± 20
67%
NO 3 —N
<0.4
<0.4
TN
165 ± 10
120 ± 15
18%
NH 4 − N of 55 mg/L and 95 mg/L were observed in both the anoxic and aerobic reactors, respectively, at C/N ratios of 5-7 in the anoxic reactor and 1-2 in the aerobic reactor. Accordingly, the findings indicate an efficient NH 4 −N release from the organic matrix in the aerobic reactor.
Following treatment by the aerobic reactor 1520 , a clarifier/MBR 1530 may be used. Note that as discussed above, the clarifier/MBR 1530 may take one of a variety of forms (a gravity clarifier, a membrane bioreactor, or an ultrafiltration membrane).
FIGS. 16 , 17 , and 18 illustrate, in accordance with some embodiments of the present invention, that the anoxic-aerobic-aerobic/AOP-anoxic unit consistently removed greater than 90% COD, greater than 90% TOC, and greater than 90% TMAH. Approximately 25% TN removal in the anoxic-aerobic system was primarily attributed to biomass synthesis during degradation of LOW. Effluent NH 4 − N (which appears to account for more than 75% of the effluent TKNs) was removed by employing nitrification-denitrification techniques. Both biological oxidation (aerobic) and chemical oxidation (ozonation, AOP) were investigated to oxidize ammonia present in the anoxic-aerobic effluent.
The anoxic-aerobic system coupled with an extended aerobic reactor resulted effluent of NO 3 —N at less than 0.4 and NO 2 —N at less than 0.5 which confirmed the inhibition of biological nitrification in the aerobic reactor even at a C/N ratio of less than 1.0.
Given the ineffectiveness of biological nitrification of the semiconductor wastewater, chemical oxidation (AOP) was employed to oxidize the NH 4 − N released from TMAH. The AOP system utilized an external carbon source (such as, for example, Micro-C4200), which was injected in the post-anoxic reactor for denitrification. Addition of AOP and post-anoxic system followed by anoxic-aerobic process improved nitrogen removal efficiency from 25% to greater than 80%.
Table 15 below sets forth the influent and effluent characteristics of the AOP treatment of the LOW stream.
TABLE 15
Influent and effluent characteristics of AOP Treatment (LOW Stream)
AOP Treatment
Parameters
Influent (mg/L)
Effluent (mg/L)
COD
190 ± 30
<30
NH 4 —N
95 ± 20
<1.0
NO 3 —N
<0.4
95 ± 30
TN
120 ± 15
not measured
Note that as discussed above, the AOP 1540 provides oxidation of the ammonia, thereby degrading the ammonia (NH 4 − N) to nitrates (NO 3 − N). While advanced oxidation processes are discussed, it is fully contemplated by the present invention that alternatives processes may be utilized. For example, ammonia stripping, which is relatively known in the art may be utilized. Ammonia stripping may include the addition of dilute sulfuric acid in order to recover the ammonia as ammonium sulfate, a well-known fertilizer. Other alternatives may include breakpoint chlorination, a catalytic oxidation method, and/or selective ion exchange on clinoptilolite. Regardless of the specific system selected, the primary contribution of the system is the degradation of ammonia to nitrates.
As noted above, after treatment by the AOP system 1540 , the fluid is fed to the post-anoxic reactor 1550 for denitrification, to degrade the nitrates to nitrogen gas. More specifically:
NO 3 1− +Carbon Source+Microorganisms→N 2 (gas)+H 2 O+Alkalinity+Biomass
As wastewater may be deficient in macronutrients required to support biological growth, the post-anoxic reactor 1550 may be fed with a carbon source 1503 . The carbon source may comprise a biodegradable nutrient blend, containing macro- and micronutrients to maintain microbial growth. As noted above, nutrients may include but are not limited to supplemental carbon such as waste sugar, corn syrup, molasses or the like, urea or the use of commercially available carbon sources, such as MicroC (available from Environmental Operating Solutions, Inc., in Bourne, Mass.) or D-Glucose (dextrose).
TABLE 16
Influent and Effluent Characteristics of De-Nitrification (LOW Stream)
Post-anoxic Reactor
Parameters
Influent (mg/L)
Effluent (mg/L)
NH 4 —N
<1.0
3 ± 1
NO 3 —N
95 ± 30
<0.4
NO 2 —N
<0.5
<0.5
TKN
30 ± 12
25 ± 7
Following treatment by the post-anoxic reactor 1550 , a second clarifier/MBR 1560 may be used. Note that as discussed above, the clarifier/MBR 1560 may take one of a variety of forms (a gravity clarifier, a membrane bioreactor, or an ultrafiltration membrane. It is contemplated that the second clarifier/MBR 1560 may be a gravity clarifier for sludge separation.
PH Variations
It was noted during experimentation that the pH of the wastewater had an impact on the decomposition of TMAH and/or NH 4 —N formation.
Full-Scale Treatment System
Utilizing the systems and methods of the present invention, parameters for a full-scale treatment system can be set forth. Note that the following parameters are exemplary only, and variations in the sizes, rates, coefficients, and efficiencies may vary while still being taught by the present invention.
A full-scale aerobic biological reactor may have the following exemplary characteristics: a TOC removal rate of 3.13+/−0.19 g TOC/kg MLVSS/hr; a TMAH removal rate of 4.86 g TMAH/kg MLVSS/hr; a TKN assimilation rate of 0.1613+/−0.12 g TKN-N/kg MLVSS/hr; and a TKN or TMAH conversion rate to free ammonia of 0.8123+/−0.089 g TKN-N/kg MLVSS/hr. Additional characteristics (such as biomass yield coefficient or chemicals consumption rates) may also be provided.
A full-scale AOP treatment system may have characteristics such as an influent NH 4 —N of approximately 600 mg/liter (0.6 g/liter), an effluent NH 4 —N of less than 2 mg/liter, and a flow rate of 180 gpm (682 liters/min). Ozone amounts may vary: at NH 4 —N of 2 mg/liter, the ratio of O 3 to NH 4 —N may be approximately 10.2, yielding 250.4 kg/h O 3 . However, in order to allow for some off gas, a full scale design of approximately 270 kg/O 3 /hr may be desired.
In addition, the AOP treatment system may comprise an oxidation tank, which may allow for recirculation for more than 60 minutes. Accordingly, the working volume can be up to two (2) times the expected hourly flow of 10,800 gallons. Ozone may then be applied for more than 60 minutes if needed, or can be applied for less than 60 minutes if the oxidation is complete. A TOC/TN analyzer may provide a determination when the oxidation is complete.
A full-scale post-anoxic biological denitrification reactor may have exemplary characteristics such as a nitrate conversion rate of 0.828+/−0.0098 kg/NO 3 —N/kg MLVSS/day; and a chemicals consumption rate of 6 mg COD/mg NO 3 —N of carbon source.
It will be understood that the specific embodiments of the present invention shown and described herein are exemplary only. Numerous variations, changes, substitutions and equivalents will now occur to those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is intended that all subject matter described herein and shown in the accompanying drawings be regarded as illustrative only, and not in a limiting sense, and that the scope of the invention will be solely determined by the appended claims.
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The invention is directed to systems and methods of biological and chemical treatment of wastewater comprising organic nitrogen compounds. Systems may include: an aerobic reactor, a first separation module for separating liquid and solid components of the wastewater; an oxidation module for removing organic materials from the wastewater; and a post-anoxic reactor for denitrifying at least a portion of the wastewater. Systems may include a second separation module and various feedback recycle lines between the components. Methods may include: degrading by the aerobic reactor more than 95% of organic compounds to ammonia, oxidizing by the oxidation module at least a portion of the ammonia to nitrates, and degrading by the post-anoxic reactor at least a portion of the nitrates to nitrogen gas and water. Systems and methods may reduce total organic carbon of the wastewater by more than 90%, and total nitrogen of the wastewater by more than 90%.
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RELATED APPLICATION
This application claims priority to and all the benefits of co-pending U.S. Provisional Patent Application Ser. No. 60/119,741 entitled “Anti-Scratch Coating For Automotive Fasteners”, which was filed on Feb. 12, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to automotive fasteners. More particularly, the present invention pertains to automotive fasteners having a parabolic shaped coating adhered to the tip of the fastener to prevent scratching during installations and the process of producing the same.
2. Prior Art
There exists the need for an automotive fastener that can be used to attach automotive components to a vehicle without damaging the decorative coating that has been applied to the body of the vehicle.
During the assembly process, fasteners of the general type disclosed in this invention are welded to a bracket, such as a bumper mounting bracket, to allow attachment of various components to a vehicle body. The mounting bracket assemblies are commonly treated to prevent corrosion by processing with caustic and acid washes, with a subsequent electrodeposited paint coating.
During installation of the bracket assembly, the tips of the fasteners have been known to damage the decorative coating of the vehicle body. The damage is predominantly caused when a person attempts to install the bracket assembly at an angle other than perpendicular to a mounting hole. When attempting to install the bracket assembly at an angle, the fastener tip may be dragged across the vehicle body thereby scratching the decorative coating.
It is an object of this invention to provide a fastener having a parabolic shaped coating applied to the tip of the fastener to prevent scratching of the decorative coating of a vehicle during installation. It is a further object of this invention to provide a fastener having a parabolic shaped coating applied to the tip of the fastener, where the coating can withstand the welding and corrosion treatment outlined above.
Various fasteners having coatings are known, U.S. Pat. No. 4,692,080 entitled “Self Drilling Fasteners And Process For Making The Same”, discloses a self-drilling screw having a frangible polymer coating on the screw tip. The coating is applied prior to applying a corrosion resistant plating to the screw for preventing the plating from being deposited upon the tips of the fasteners. The coating comprises a triallyl cyanurate which is ultra-violet or infrared curable. The coating breaks away from the fastener during the installation process, to expose the sharp self-drilling tip of the disclosed fastener.
The fastener of the above referenced patent does not provide a fastener having a parabolic shaped coating on the tip that will not break off during the installation process, thereby preventing the scratching of the decorative coating of the vehicle body.
U.S. Pat. No. 4,713,855 entitled “Process For Making Self-Drilling Fasteners”, discloses a process for manufacturing the fasteners outlined in the previously referenced U.S. Pat. No. 4,692,080. The patent discloses a process for applying the frangible coating to the self-tapping screw tip which includes dipping the tip into a triallyl cyanurate polymer bath and subsequently curing the polymer using ultra-violet or infrared light.
The process of the above referenced patent does not provide a process for applying a coating to the tip of a fastener, to produce a parabolic shaped coating on the tip.
It is therefore, the purpose of the present invention to cure those deficiencies outlined above by providing a fastener and the process for producing the same, whereby the tip of the fastener has a parabolic shaped coating adhered to the tip of the fastener to prevent scratching of the decorative coating of a vehicle during installation.
SUMMARY OF THE INVENTION
Thus, in accordance with the present invention, there is provided a process for making a fastener having a shank with a head and a flat tip. A polymeric coating is applied to the flat tip to form a parabolic bubble on the tip of the fastener. The bubble is cured to prevent the tip of the fastener from damaging a decorative coating on a vehicle, such as during installation of the fastener.
The invention includes the several steps and the relationship of the several steps with respect to each other. The invention also includes the article produced by the process and its properties as disclosed in the following Detailed Description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a fastener having a parabolic shaped coating on a tip;
FIG. 2 is a side view of the fastener with an applicator for applying a paint bubble to the tip.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a fastener for securing a component to a vehicle (not shown) is generally illustrated at 10 in FIG. 1 . The component may be any suitable exterior trim piece or body panel which is secured to the vehicle. In addition, the component may be formed of plastic or metal as is desired.
The fastener 10 comprises a shank 12 having first 14 and second 16 ends. The shank 12 may be of any desired length or diameter as needed for a particular application. A head 18 is disposed on the first end 14 with the second end 16 terminating at a flat tip 20 . The head 18 may be of any suitable shape and size such as circular or oval.
A majority of the shank 12 has a plurality of threads 22 extending between the head 18 and the tip 20 . The threads 22 work in concert with a bolt or other like device (not shown) to secure the component to the vehicle. The entire fastener 10 is preferably formed of a metal material, such as steel, which can withstand typical oven temperatures. As appreciated, the threads 22 may be substituted for locking projections or the like. The important feature is that the fastener 10 adequately secures the component part to the vehicle.
The fastener 10 is characterized by a polymeric coating 24 disposed on the flat tip 20 . The polymeric coating 24 forms a parabolic bubble 24 on the flat tip 20 for preventing scratching of the vehicle by the fastener 10 during installation of the component. In particular, the parabolic shaped coating 24 prevents the tip 20 from contacting the decorative coating of a vehicle body. The decorative coating is primarily the painted exterior body panel of the vehicle.
The thickness (or height) of the parabolic shaped coating 24 is directly proportional to the angle the fastener 10 can approach the vehicle body without the tip 20 scratching the decorative coating. For example, a 0.5 mm coating thickness prevents the tip 20 from contacting the vehicle body at a 24.5 degree approach, while a 2.5 mm thickness prevents the tip 20 from contacting the vehicle body at a 66.3 degree approach. A range of coating thickness can be applied to obtain a desired approach angle, whereby the tip 20 will not contact and scratch the decorative coating. The determined range includes:
Thickness
Approach angle
0.5 mm
24.5 degrees
0.75 mm
34.5 degrees
1.0 mm
42.4 degrees
1.5 mm
53.8 degrees
2.0 mm
61.2 degrees
2.5 mm
66.3 degrees
The parabolic shaped coating 24 is formed from a paint mixture comprising at least four components. The first component is a high solid polyurethane polymer dispersed in dispersing solvents Methyl ethyl Ketone, N-Butyl Acetate, and Methyl Amyl-Ketone. However, other dispersing solvents may be used as required. The polyurethane polymer can be purchased from Cardinal Industrial Finishes and is sold as High Solids Polyurethane.
The second component is a polyurethane catalyst. The catalyst comprises Hexamethane Diisocyanate, a free monomer, dispersed in dispersing solvent N-butyl acetate. However, other dispersing solvents may be used as required. The Hexamethane Diisocyanate causes the polyurethane to crosslink while curing in a bake oven. The catalyst can be purchased from Cardinal Industrial Finishes and is sold as 340 HP Catalyst.
The third component is a pigment paste for adding color and inhibiting corrosion. Various pigments have been contemplated for use to meet various color requirements. A pigment known to meet color and corrosion requirements is Zinc Oxide. Zinc Oxide is wetted with Toluene and Aliphatic Naphtha forming the third component. This pigment can be purchased from Tremulad.
The fourth component is a hardening agent having Isopropanol. A higher concentration of the hardening agent in the final product hardens the coating and improves adhesion. The hardening agent reduces the affect of gravitational forces which cause the paint to flow during curing. Thus, a higher concentration of the hardening agent will yield a thicker (higher) coating. The hardening agent can be purchased from Sheffield Bronze Inc., and is known as Japan Dryer.
The preferred composition range for the four components is:
Component
Range
One
46%-66%
Two
18%-34%
Three
10%-20%
Four
2%-8%
The preferred target for operation for each component is:
Component
Range
One
65%
Two
20%
Three
10%
Four
5%
Another example of a target composition for the four components is:
Component
Amount
One
70%
Two
15%
Three
12%
Four
3%
Still another example of a target composition is:
Component
Amount
One
60%
Two
25%
Three
10%
Four
5%
Still another example is:
Component
Amount
One
55%
Two
20%
Three
20%
Four
5%
The paint mixture requires a three part blending process prior to application to the tip 20 . First, components three and four are mixed together forming a first pre-mix. Second, components one and two are mixed together forming a second pre-mix. Shortly thereafter, the first pre-mix is blended with the second pre-mix over a two to five minute period under medium speed agitation forming the paint mixture.
Referring to FIG. 2, an applicator 26 for applying the coating 24 is shown. The applicator 26 includes an infeed line 28 leading from an application tank (not shown). The applicator has a hole through 30 which is formed in a flat base 32 . The applicator 26 preferably has a closed cylindrical configuration with the hole 30 disposed at the opposite end of the infeed line 28 .
During application, the paint mixture is loaded into the application tank and maintained under agitation. A plurality of paint lines 28 lead from the application tank.
Each paint line 28 connects with a corresponding applicator 28 having a hole 30 through a flat base 32 . While under pressure, the paint mixture is forced through the hole 30 which is in close proximity to the tip 20 forming a bubble on the tip 20 . Prior to application, the tips 20 are cleaned via a solvent wipe. A plurality of fasteners 10 are held in a processing fixture (not shown) during paint application.
After application, the processing fixture is installed into a preheated oven for curing the paint and forming the bubble shaped coating 24 . The oven curing cycle ranges from two hours at 450 degrees Fahrenheit to eight hours at 300 degrees Fahrenheit. While in the oven, the paint bubble cures into the parabolic shape of the coating 24 . A higher oven temperature will yield a harder coating 24 . The preferred oven curing cycle associated with the preferred range of operation includes oven curing for four hours at 425 degrees Fahrenheit.
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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A process for making a fastener having a shank with a head and a flat tip. A polymeric coating is applied to the tip of the fastener. The coating forms a parabolic bubble and is subsequently cured. The bubble prevents damage to a decorative coating of a vehicle during installation of a component in which the fastener is utilized. The disclosure is further directed to the fastener which is produced by the process.
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This is a continuation of application Ser. No. 329,262 filed Dec. 9, 1981, now abandoned, which was a continuation-in-part of Ser. No. 129,588, filed on Mar. 12, 1980, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to an instrument for generating an alarm when a resting patient's heart rate or respiratory rate varies from previously established values. This device is useful in monitoring patients with fluctuating heart and respiratory rates which may be indicative of potential life threatening emergencies, such as Sudden Infant Death Syndrome (SIDS), nocturnal apnea, suffocation, and certain diseases of the heart which causes rapid or diminished cardiac rates.
Present instruments used to monitor apnea and bradycardia rely on two separate sensors that attach physically to the patient. These devices restrict the patient's movements, and are very uncomfortable especially when used on neonatal infants. In addition, the complexity of obtaining positive mechanical probes attached to the patient and the electrical connections required, make the use of these sensors cumbersome and ineffective due to the danger of separation of the probes from the patient. The complexity of these instruments also requires professional operators for best results to operate the device.
In a previous patent application, Ser. No. 129,588, I have described a device that is non-invasive and is placed on any part of a conventional bed or crib where the patient rests to monitor the heart and breathing functions. The present invention describes a single sensor which is sensitive to both the heart beat and breathing functions. An improved electronic circuit has been achieved which takes advantage of the dual sensor capabilities to detect deviations of these functions. The electronic circuit is capable of producing an alarm when a deviation from present limits occurs.
SUMMARY OF THE INVENTION
Available electronic heart and breathing monitors employ two separate transducers to obtain data, one for the heart and one for the breathing functions. These sensors, Re: Harway, Jr. et al., U.S. Pat. No. 4,033,332; Bashman, U.S. Pat. No. 3,898,981, are coupled to the patient by mechanical means. Heart monitors employ electronic probes attached to the patient. Breathing monitors use special mechanical devices to activate the sensors. The monitoring control device produces an alarm when there is a deviation of heart or breathing function different from the norm set by the attending nurse or the operator of the instrument. In many instances, in the presently available devices, a signal processing circuit converts the signal produced by the sensors in a format manageable by the operator and compatible with the overall electrical circuit of the device. In monitoring the heart signal, for example, the circuit is designed to detect the heart beat rate and uses this digital data to activate an electronic counter which is sensitive to a time period. When a deviation of the heart beat rate varies from a predetermined value, the circuit that senses the rate, triggers an alarm signal. The sensor for detecting and monitoring breathing employs a similar circuit. These techniques are very useful for obtaining certain diagnostic data of cardiac functions and the breathing mechanism. In my invention, however, the diagnostic application is not of primary consideration except for detecting SIDS. My invention is concerned with monitoring deviations of these functions from a predetermined norm which may be indicative of the onset of SIDS. For this application, my invention may be fabricated with less sophistication to achieve a more versatile use, resulting in an instrument which is reliable and easily operable by an inexperienced operator.
My invention utilizes a single transducer to detect both the heart beat and breathing rates. These signals are combined electronically and the circuit detects the integrated energy of the two signals. A simple electronic circuit detects deviation of the combined integrated power. A deviation from a normal integrated energy is sensed, and when it is more or less, an alarm signal is generated to alert an attendant. The transducer and associated circuitry for the complete functioning of the device is housed in an apparatus of approximately 16 cubic inches. The apparatus can contain, in addition to the transducer, the electronic battery power supply, a radio transmitter or a direct line to transmit the alarm signal to a remote station. This apparatus is placed on the normal bed or normal crib of the patient without physical coupling to the patient. A small radio receiver can be placed away from the apparatus to receive the alarm signal and produce an audible or visual alarm.
In the application of my invention, where it is necessary to obtain or display individual data of only the heart beat rate, or the breathing rate, the apparatus provides these outputs. These functions are accomplished by employing electric filtering to separate the two different signals.
The literature teaches that there are transducers available that are able to detect very minute movements of the body produced by the acceleration of the blood as it moves in the circulatory system. Data from these transducers can only be obtained when the body is freely suspended and can move uninterrupted by friction. Cunningham and Danders, Bibliography Cardial, 19, pages 1-6, 1967, constructed a bed-like structure which floated on air bearings to detect the blood movement and obtained ballistocardiogram (BCG) readings of the heart function. The air bearing construction allowed the bed-like structure to be freely suspended and isolated from ambient mechanical movement of the pavement. An accelerometer was used to detect the heart functions.
According to Starr and Nordergroad, American Heart Journal, 64, pages 79-100, 1962, ballistocardiographic techniques require that the mass of the bed be extremely small. The body weight of the patient being observed should be at least ten times greater than the bed on which he lays. Other workers in this field have concluded that if ballistocardiography is used as a non-invasive technique for obtaining heart data, the bed or other structures, such as chairs, tables, or platform used by the patient, must be considered as part of the special equipment required by the system. This limitation has made the use of ballistocardiography expensive and impractical.
The most successful transducers employed in ballistocardiograms have been those used to detect acceleration by means of piezo-resistive techniques. Transducers of this type have a natural frequency range above that which can detect heart beat, about 1.2 Hertz. This characteristic makes their use cumbersome, and require sophisticated electronic circuitry for adopting them for the low frequency necessary to detect heart rates. I have also found that available transducers are not effective to produce a signal of the heart beat in combination with the breathing rate of a patient for monitoring these two functions at the same time. In addition, Re: Starr, in The Harvey Lectures, page 199, delivered January 1947 and Curtis, H. J., The Design of the Ballistocardiograph, Am J Physiol 142: 1-11, 1944, concluded that breathing functions have a deleterious effect on heart monitoring in ballistocardiography.
In conjunction with the present invention, I have invented a new type of transducer capable of detecting these two functions simultaneously in an efficient manner. The transducer consists of a small cylindrical magnet which is surrounded by an electrical coil so that when the coil is made to move, it produces an electrical current proportional to the movement of the body, and generates a voltage proportional to the frequency of the relative movement between the coil and the magnet assembly. The magnet and associated pole pieces are held fixed to the transducer container or case, which rests on the patient's bed. A thin cylindrical rigid structure is filled with liquid which rests on a flexible liquid seal or membrane which is attached to the coil assembly. The liquid forms an incompressible medium which produces a force on the surface of the movable membrane and hence also on the coil assembly. This transducer, in which the vertical liquid column loads the coil assembly, efficiently senses vertical movement. I have found experimentally that this characteristic is very effective in detecting the body movements caused by the heart beat and breathing, since heart and breathing functions mainly produce vertical movement of the bed and mattress on which a subject lies. This transducer is placed on a conventional bed where the patient lies, attached only by gravity. The transducer can be placed away from the patient for example at rear of the patient's feet. The bed need not be isolated from the floor. Thus the bed is not a component part of the system as it is in the case of ballistocardiogram devices and thus the transducer and its associated circuitry and other types of monitors can be placed on any bed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing illustrating the novel heart and breathing rate transducer.
FIG. 2 is a schematic diagram of the novel electronic circuitry of the invention used to amplify and process the electrical signal produced by the heart and breathing rate transducer to obtain an alarm signal.
FIG. 3 is a schematic diagram of the unprocessed wave form produced by the heart and breathing rate transducer.
FIG. 4 is a schematic diagram of the wave shape of FIG. 3 after it has been rectified.
FIG. 5 is a curve indicating the various triggering voltage points to produce an alarm signal.
FIG. 6 is a representative view of the invention as may be used for a general application to monitor the heart and breathing functions of a patient.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is an illustrative drawing of a Motion Detection Transducer which I have invented to detect the minute movements of a patient lying in a conventional bed. The patient's natural coupling with the mattress where he rests produces a movement throughout the mattress which is sensed by the transducer. The design of the transducer enhances sensitivity in one direction, namely the vertical direction, which is the direction of most of the mattress movement due to heart and respiratory action of a person lying on the mattress. This design allows for an improved signal-to-noise ratio compared to sensors that have omnidirectional sensitivity, as it is evident in Hawley, et al., U.S. Pat. No. 3,270,565.
The physical and mechanical aspects of this sensor may be described as follows: Given a narrow cylindrical column of liquid hermetically enclosed. Let the column stand vertically on a platform freely movable in all three axes. Apply a force on the platform along the vertical axis. This force in turn accelerates the column of liquid in the upward direction. However, since the liquid is enclosed, the upward acceleration creates an increase in pressure at the lower end of the thin column while producing a lower pressure at the top of the column. The pressure produced is proportional to the height of the column and the density of the liquid. The change in pressure produces a force which may be detected by an electromagnetic device. When a force is applied to the platform in the horizontal direction, it creates in turn an acceleration in the thin column of liquid in a sideways direction. The force produced by this action is similar to that obtained by having the force in the vertical direction, except that the pressure produced in the horizontal direction is much less because the configuration of the liquid in the horizontal direction is only the result of the effective diameter of the thin column of liquid. I have found experimentally that the thinner the column is made, the greater is the directional sensitivity in the direction of the column. I also have found experimentally that the sensor I have invented enhances signals produced by the vertical movement of a person resting in bed, and attenuates those signals that are off vertical. Ambient mechanical noises which affect the movement of the bed omnidirectionally are suppressed. Therefore, the resultant signal-to-noise ratio of my sensor is improved.
A better understanding of the construction of the transducer may be obtained by referring to FIG. 1.
The case or container 1, which can be constructed of such material as aluminum, encloses the sensor mechanism and provides terminal electrical connections 2. The sensor mechanism consists of an enclosure 3 which houses a magnet 4 mounted in a magnetic flux conducting pole piece 8. Coil 5 is supported by cylindrical tube 5a which surrounds magnet 4. The cup-shaped pole piece 8 forms part of the magnetic circuit to produce a radial magnetic flux in the air gap in which the coil and its support 5a are mounted, so that the flux lines are cut when the coil and its support move vertically in the air gap. The structure described thus far is similar to the magnetic and voice coil system of a loudspeaker. Flexible elements 6 and 6a are connected to wires 7 and 7a which bring the output electrical signal to terminals 2. Cylindrical tube 5a is attached to flexible membrane 9, which may be constructed of a very thin material such as Mylar having a thickness of about 0.001 inches. Membrane 9 centers coil 5 around the magnet and prevents contact with the magnet during operation. Membrane 9 also makes a hermetical seal with enclosure 3 and the vertical column 10. Column 10, which can be a hollow tube made of a suitable material such as aluminum, is sealed at the top by a mechanical fixed seal or cap 11. Column 10 is totally filled with liquid 12. The liquid employed may be water, aqueous solutions of salt for increased specific gravity, organic solutions, or other substance such as mercury, which is more efficient because of its higher specific gravity. Cylindrical tube 13 is attached to the top of pole piece 8, which in turn is attached to membrane 9 and column 10 to produce a rigid assembly. The attaching medium may consist of a suitable cement such as an epoxy compound. Tube 5a is attached to membrane 9 using the same type cement.
During the operation of my motion detector transducer, the device is placed on a conventional mattress, which may be covered by a conventional sheet or blanket, where a patient is resting. The patient's heart and breathing functions create a rhythmic movement on the mattress. The mattress movement produces a force in liquid 12 perpendicular to the surface of the mattress. The force of the liquid is transmitted through the rigid column 10 and reacts with the flexible membrane 9, which in turn creates a movement of coil 5 resulting in the generation of a current which is proportionate to the amplitude of the movement of the mattress and exhibits the same frequency as the combined frequencies of the heart and breathing functions. The current generated by the transducer is fed to an electronic circuit for processing.
An alternate explanation of the mode of operation is that the weight of the liquid column resting on the movable coil assembly represents a mass loading of the system which lowers the natural resonant frequency thereof to the vicinity of the frequency of the signals of interest. These frequencies are approximately 1-2 Hz for heart signals and approximately 0.3 Hz for respiration signals.
Also the mass loading of the moving coil tends to hold the coil stationary if the case 1 is moved by an external force such as the aforementioned body functions. The resultant relative movement between the magnet assembly and the coil assembly will produce an output signal at terminals 2.
Turning to FIG. 2, which is an electrical schematic diagram of the invention, motion detection transducer 14 is connected to a low frequency amplifier 15 to amplify the A.C. voltage signal produced by transducer 14 when monitoring a patient. Diode 16 rectifies the signal so that only the positive element is reproduced. Bias network 17 supplies a positive bias voltage to the anode of diode 16 such that very low D.C. signals are blocked. The bias network 17 thus acts as an adjustable threshold regulator to block low amplitudes caused by ambient noises which may be picked up by transducer 14. The output of diode 16 is fed to a low pass filter 18 which allows only frequencies of about 4 Hertz or less pass and cuts off frequencies much above 4 Hertz. Attenuator 19 is used as a sensitivity control to set the signal output at a manageable level for the remaining circuit. Light indicator 20a is a light emitting diode which is energized to the proper voltage to indicate proper signal output. Indicator 20a can also be used to indicate that the monitor is in operation since it flickers at the heart beat frequency of the patient. Inverting amplifier 20 is a low frequency amplifier which acts as a low power amplifier to distribute this signal to different circuits. Diode 21 allows minus potential only to flow to the succeeding circuitry. Control 22 serves as a bias regulator for diode 21 and permits minus polarity potential above the setting of control 22 to enter integrator 23 through switch 46 and also prevents leakage of the stored charge on storage capacitor 24. Integrator 23 consists of resistors 25, 25a and 25b, and storage capacitor 24. Capacitor 24 is charged negatively at every D.C. pulse produced by the action of the heart beat and breathing functions sensed by transducer 14. The sum of the pulsed voltages is related to the frequency of the pulses, e.g., the higher the pulse frequency the higher is the voltage stored in capacitor 24. Resistors 25, 25a and 25b limit the buildup of this voltage for any given time depending on the RC time constant of this circuit. The negative voltage generated in integrator 23 is fed to a low voltage detector 26. Detector 26 consists of an operational amplifier, non-inverting op-amp 27 of the 741 type which has been biased positive by variable resistor 28 to balance the output voltage of integrator 23 and produce a negative voltage output of op-amp 27 during a steady state frequency sensed, nominally 72 heart beats and 14 breathings per minute, by transducer 14. Resistors 29, 30 and 31 form a feedback signal network voltage divider and reduce the effect of a large offset current of op-amp 27. Low voltage detector 26 achieves gain higher than 5,000 and goes to an overload condition by a very small voltage input differential. This feature makes this circuit able to trigger relay 32 when there is a very small decrease in the absolute value of the negative voltage stored on capacitor 24 of integrator 23. The decrease in absolute negative voltage is due to the reduction of the frequency of the heart beat and breathing sensed by transducer 14. For instance, if the heart beat decreases to about 40 beats and the breathing rate to about 8 beats per minute, the voltage integration resulting in capacitor 24 is reduced to a critical point of about 2 volts to trigger op-amp 27 from a minus potential output to full power plus potential output. Diode 33 allows flow of the positive potential to activate relay 32. Relay contacts 34 are activated by relay 32 and closes the circuit of terminal 35 and 36.
High gain inverting amplifier 37 is also fed by integrator 23. Variable resistor 38 and voltage divider resistors 39, 40 and 41 are chosen to maintain op-amp 42 at a plug bias potential of about +6 volts. If the heart beat and breathing functions increase, for instance, to about 110 and 25 respectively, the voltage integrated is increased and capacitor 24 obtains an absolute voltage in excess of the minus 6 volts which obtains under normal heart and respiration rates. For example with increased heart and respiration rates, the negative voltage on capacitor 24 may go to 7 or 8 volts. This action changes the bias voltage of op-amp 42 negatively which results in a positive output voltage. This triggering action causes a flow of positive current through diode 43 which activates relay 44. Switch 45 is activated by relay 44 and closes the circuit to terminals 35 and 36.
The circuitry of the two detectors 26 and 37 is similar except that in the case of the low voltage detector 26, the integrator voltage is applied to the positive input terminal of op-amp 27 from adjustable resistor 25a and in the high voltage detector 37 the integrator voltage from adjustable resistor 25b is applied to the negative input of op-amp 42. This difference in inputs is what produces the difference in function of these two otherwise similar circuits.
It should be noted that the circuit of FIG. 2 can be easily modified to accommodate positive voltages on storage capacitor 24. If diode 21 is reversed in polarity, positive voltage pulses would be applied to the integrator. The two detector circuits would then be modified to detect changes in the positive integrator voltage.
Also, other types of detectors could be used instead of those shown. One other type would be Schmitt trigger circuits. These circuits could be designed to trigger and actuate the alarms when the critical high and low voltages on integrator 23 obtain.
The values indicated in FIG. 2 for the capacitor and the resistors are only for explanatory purposes. These values can vary to conform with parameters chosen for the application of the device. The value of heart beat and breathing indicated are also to show some practical limits. For instance, adjusting the value of resistance 25b and 38 allows adjustment for triggering op-amp 42 at different frequency rates of heart and breathing actions which are above those of the patient at rest. Adjusting resistor 25a and 28 allows triggering points of op-amp 27 below those of the patient at rest. FIG. 5 shows this application in a graph form.
The use of the very high gain non-inverting op-amp 27 and inverting op-amp 42 are electronic circuits that employ single op-amps to accomplish comparator functions combined with the triggering action to gate and amplify small signals. For instance, the change over from negative output to positive output of op-amp 27 and 42 is caused by a very small voltage differential on the input going from a positive to a less positive voltage of about 0.001. This small voltage differential is gated and amplified over 5,000 times at high slew triggering rates.
The negative current that goes through diode 21 is channeled through switches 46, 47 and 48 to integrator 23. Band pass filter 50 allows to pass only frequencies associated with the heart beat. These may be of the order of from 45 to 250 beats per minute. Band pass filter 49 allows to pass only frequencies associated with breathing. These may be of the order of 6 to 40 breathing cycles per minute. If switch 46 is closed and all other switches are open the two bandpass filters are out of the circuit and the output of diode 21 comprising both heart and respiration signals is applied to the integrator 23. Switches 47 and 51, when in the closed position and switch 46 in the open position, inserts respiration bandpass filter 49 between the diode 21 and integrator 23. Similarly if switches 48 and 52 are closed and switch 46 in the open position the heart bandpass filter 50 will be inserted between the diode 21 and the integrator, allowing only heart frequency signals to enter integrator circuit 23. This arrangement of switches allows the instrument to be used as a monitor for the combination of heart and breathing functions; heart function only or breathing function only. The control of these switches may be done from the outside of the alarm device. A visual monitor 53 which may consist of an oscilloscope or a strip chart recorder is connected by means of switch 53a to examine the wave shape produced by transducer 14 after being electronically processed. Visual monitor 53 can monitor the combined frequencies of the heart and breathing functions when switch 46 is conducting; the heart beat only when switches 48 and 52 are conducting; and the breathing only when switches 47 and 51 are conducting. Radio transmitter 54 can be connected to terminals 35 and 36 to transmit the alarm signals generated by amplifiers 27 and 42. In applications where the heart and breathing monitor is to be used in a private house, it may be more advantageous to eliminate from FIG. 2 the circuits associated with bandpass filters 49 and 50 and the visual monitor 53. These features may make the device unnecessarily more complex and expensive for such applications. However these features may be advisable for hospital applications.
The dc power supply needed to operate the monitor device has not been shown in the schematic diagram. This can be obtained from a conventional ac power source which has been rectified and the voltage adjusted to conform with the electronic component used. A battery power supply can also be used. In this manner the instrument which is placed on the bed where the patient rests is self-powered and eliminates power wiring to be attached to the bed structure. The battery can also be of the rechargeable type which can be recharged using house current without taking the battery out of the enclosure.
Turning to FIG. 3, it is a schematic of the unprocessed wave form from transducer 14. The high frequency wave form contains heart beat pulses 55 and ambient noises 56. In noises 56 there is also some signal that is related to the diagnostic condition of the heart function. However, this information is not the object of this invention, and is not discussed here. The breathing rate, low frequency 57 is shown by a dotted line with enclosed pulses 55.
Turning to FIG. 4, it is a schematic of the wave shape shown in FIG. 3 after it has been rectified by diode 16. Rectified wave 58 corresponds to the unrectified wave 55. Rectified wave, shown in dotted lines 60 corresponds to the unrectified wave 57. Rectified wave 59 has a lower amplitude than the corresponding wave 56. This is a result of adjusting bias network 17 of FIG. 2 and setting the threshold of the rectified voltage to a suitable level.
Turning to FIG. 5, it is curve of the various triggering voltage points to produce an alarm signal for the circuit of FIG. 2. The negative voltage generated by integrator 23 is shown by curve 61. The curve 61 between the voltages -V2 and -V3 is generated by the voltage integrated by integrator 23 when transducer 14 is placed on the bed where the patient is resting. The patient's normal heart beat and breathing actions may fluctuate slightly during time t3 without causing a triggering action on amplifiers 27 and 42. This condition may last for an indefinite time if the patient'activity remains normal. The portion of the curve designated by -V1 and -V2 shows a period t2 during which time the absolute value of the voltage is declining due to the onset of apnea or bradycardia, or both. This condition slows the heart beat and the breathing period, resulting in a diminished voltage integration, as shown. If this condition continues for a period designated as t2, the triggering voltage -V1 is reached and amplifier 27 goes to the triggering mode producing a signal in terminals 35 and 36. The time interval t2 is normally adjusted to be 10 to 20 seconds. The adjustment of the time interval t2 is accomplished by adjusting the bias voltage of amplifier 27 with variable resistor 28. This adjustment is done by the operator of the alarm device in accordance with the needs of the patient. For instance, if the patient is a small child with suspected SID syndrome, it is advisable to adjust the variable resistor 28 so that the alarm triggers about 10 seconds after the attack of apnea. The knob operating resistor 28, not shown in the drawing, may be calibrated in units of time to guide the operator.
If the patient has an increase in the action of the heart beat or breathing, integrator 23 charges to a higher absolute voltage designated by -V3. At this point, amplifier 42 will go to the triggering mode and produce an alarm signal to terminal 35 and 36.
The alarm signal of the low activity and high activity of the patient are shown in FIG. 2 to terminate at the same point, i.e., terminals 35 and 36. However, these two signals, not shown in FIG. 2, may be separated if so desired. Amplifier 42 will also trigger an alarm signal if the high activity is caused by a physical movement of the patient which generates sufficient voltage in integrator 23. The curve portion designated as t4 indicates the time interval required for integrator 23 to reach the required triggering voltage. This time interval is also varied, similarly as t2, by the operator of the alarm device who can adjust variable resistor 38 which controls the bias triggering voltage of amplifier 42. The curve designated as t5 shows that the alarm stays on for an indefinite time until the alarm device is deactivated.
Turning to FIG. 6, conventional bed 62 depicted as a conventional double size bed, supports a conventional mattress 63. Patient 64 rests on a portion of mattress 63. Heart and breathing monitor 65 is placed on one extreme portion of the mattress, which may be covered by a conventional sheet or blanket. Monitor 65 contains the electronics of FIG. 2 as well as the transducer of FIG. 1 to detect apnea and bradycardia, excessive heart and breathing rates and high activity physical movements that can cause damage to the patient. Radio transmitter 54 transmits, through antenna 66, an alarm signal when the above conditions are sensed by transducer 14 located within monitor 65. Radio receiver 67 receives the alarm signal and produces an audible sound which is generated in speaker 68. Electrical lights 69 may be made to flash to give a visual display that the alarm has been tripped. The number of light indicators can vary depending on the application of the instrument. Using conventional electrical circuitry, not shown in FIG. 6, radio transmitter 54 can transmit a coded signal identifying the location of the bed. This coded information may be decoded by conventional circuitry, not shown in FIG. 6, in receiver 67 and the proper light will flash to indicate the location of the patient requiring attention. This feature can be used in locations where more than one patient is being monitored and the radio receiver is located at a central point.
The double size conventional bed 62 has been depicted to indicate the large area of sensitivity of monitor 65. It further depicts that monitor 65 does not require body coupling with the patient in order to sense the heart and breathing functions. Therefore, it can operate within large areas of mattresses. Mattress areas of conventional double and single bed sizes, hospital beds, baby cribs, incubator cribs and the like are within the scope of this invention and monitor device.
While the invention has been shown and described with reference to a specific embodiment and electronic processing, it is not limited to the configuration of electronic circuitry and components used for the specific circuits shown in the preferred embodiment, since other alternate electronic circuits and mechanical construction can produce satisfactory results. It should be obvious to those skilled in the state-of-the-art that various changes and modifications can be made to this specific embodiment without departing from the spirit and scope of this invention.
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A device for sensing heart and breathing rates in a single transducer and having electronic and filtering circuits to process the electrical signal generated by the transducer. The transducer is an electromagnetic sensor constructed to enhance sensitivity in the vertical direction of vibration produced on a conventional bed by the action of patient's heart beat and breathing functions and achieves sufficient sensitivity with no physical coupling between the patient resting in bed and the sensor placed on the bed away from the patient. The electronic circuits integrates the electrical energy generated by the sensor that pertains to cardiac and breathing informations and sets off an alarm when pre-set circuits of these functions have been surpassed. The device has applications in monitoring SID Syndrome and non-ambulatory patients.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for the distribution of particulate material onto a surface, in particular to an apparatus for the distribution of glass beads onto a line of paint and/or polymeric material previously applied to the surface of a road or the like, to produce retro-reflective traffic markings.
2. Description of the Related Art
In the application of traffic markings to road surfaces, it is generally desirable to apply a reflectorised material in the form of small glass spheres or beads to the marking for increasing night-time visibility and further extending the life of the marking. The glass beads may be applied with a paint binder in a single operation. An alternative method of application is to apply the paint binder separately from a paint application machine and then immediately follow the paint binder with an application of the glass beads from a distribution apparatus associated with the machine, from which the beads are dispensed by gravity flow.
It is important to dispense the glass beads at a uniform rate and evenly over the width of the marking, without spillage of the beads onto unwanted areas which can be both wasteful and may be damaging to the environment.
In U.S. Pat. No. 3,289,899 (Miller et al) there is described an apparatus for the distribution of glass beads onto a road surface in which the apparatus comprises a housing, an upper chamber within the housing for the receipt of glass beads, a lower chamber within the housing having a downwardly directed opening, and a distribution control valve positioned between the upper and lower chambers to allow the glass beads to pass in a controlled manner into a lower chamber, from where they fall through the downwardly directed opening onto the road surface. The distribution control valve is in the form of a conically-shaped spreader which is movable in a vertical direction from a position closing an opening between the upper and lower chambers to a position in which this opening is partially open. The glass beads then fall through an annular space between the surface of the spreader and the inside surface of the lower chamber and fall primarily in the form of a ring onto the road surface. The disadvantage of the apparatus described in U.S. Pat. No. 3,289,899 is that there is an accumulation of beads at the edges of the marking line and a shortage of beads at the centre of the marking line. Thus with this apparatus it is difficult to achieve uniform distribution of the beads on the road surface.
In European Patent EP129551-B (Road Construction Authority), there is described a glass bead applicator in which glass beads are stored in a pressurised hopper and fed to a nozzle from which they are projected, by means of compressed air, directly on to the road surface. This arrangement does not however result in a uniform distribution of the glass beads; there is a tendency for the beads to accumulate at the centre of the marking line. Further, the glass bead hopper must be pressurised and it is necessary to provide means for dehydrating the compressed air used to pressurise the hopper if one is to avoid condensation of moisture on the beads which could generate problems in their discharge from the nozzle.
It is an object of the present invention to provide an apparatus for sprinkling glass beads or other particulate material onto a surface, such as onto a line of freshly applied paint and/or polymer material applied to a road surface, in a manner which enables more uniform distribution to be achieved over a defined area in a simple and reliable manner.
SUMMARY OF THE INVENTION
According to the invention, there is provided an apparatus for the distribution of particulate material onto a surface, characterised in that the apparatus comprises a chamber having a downwardly directed opening and feeding control means positioned above said chamber to allow the particulate material to pass in a controlled manner to said chamber and in that, positioned in said chamber, is at least one distribution grid, through which substantially all the particulate material passes to the downwardly directed opening to be applied to said surface.
Thus, the invention provides an apparatus which enables glass beads to be deposited onto a material to be solidified, such as paint or a polymerisable material, by uniform and reliable distribution onto the surface before the complete hardening of the material. The distribution grid plays an essential role in obtaining the beneficial results of the invention. It is indeed surprising that such a simple construction is able to achieve a uniform distribution of the glass beads onto the marking line material.
The principal application of the process concerns the formation of reflective traffic markings on the ground. Usually, the apparatus according to the invention will be associated with a paint and/or polymer application machine, such as being fixedly coupled thereto or integral therewith. A paint or polymer coating is applied to the ground, ie to the road surface, in the form of a line of desired width and the glass beads are dispersed thereon from the dispensing apparatus before the hardening of the paint or the coating. In practice, a line of constant width is formed by the continuous deposition of paint and then the glass beads are applied in a desired width. The glass beads penetrate the fresh paint to a greater or lesser extent, depending upon the type of glass beads which are used and the treatment of the surface.
One specific application for which the apparatus according to the invention is particularly useful is the formation of reflective traffic markings based on polymerisable paint, where the initiator for the polymerisation reaction, generally a peroxide, is carried on the surface of the glass beads. It is important that these glass beads are uniformly distributed over the paint to allow for uniform hardening thereof and to obtain a uniform retro-reflection. Further, it is important that the glass beads do not fall outside the width limits of the paint line in order to avoid pollution of the immediate environment by the peroxide.
The particulate material which can be used in the apparatus according to the invention is, for example, glass or other vitreous material, in spherical form, ie in the form of beads. For example, glass beads having a size of from 100 μm to 700 μm have been found to be suitable. As an alternative, glass beads having a size of from 1 to 2.4 mm have also been found to be suitable. The beads may be surface treated to modify the physico-chemical properties of their surfaces. British patent specification GB 2 208 078 (Glaverbel) discloses beads which are suitable for incorporating in a polymer matrix, the beads carrying an initiator or catalyst for the polymerisation of the matrix. For example, glass beads having a nominal diameter of from 150 to 250 μm are coated with benzoyl peroxide and a silane from a toluene solution and are suitable for incorporation in an acrylic resin matrix. British patent specification GB 2 214 915 (Glaverbel) discloses glass beads whose surfaces have been treated to control the surface tension thereof, thereby to ensure the good dispersion thereof in a polymer matrix. For example, glass beads treated with a methanol/water solution of β-(p-chlorophenyl) ethylsilane at a level of 0.1 g/Kg to reduce the surface tension to 45 mN/m are suitable for incorporation in a high viscosity acrylic matrix. British patent specification GB 2 175 224 (Glaverbel) discloses a method of modifying the wettability of glass beads by coating with a hydrophobic material and an oleophobic material. For example, glass beads having a size of from 200 μm to 600 μm are coated with gamma-aminopropyltriethoxysilane at a level of 0.04 to 0.08 g/Kg and with potassium fluoroalkyl sulphonate at a level of 0.008 to 0.020 g/Kg.
Any of the glass beads disclosed in the above mentioned patent specifications can be used with advantage in the apparatus according to the present invention.
Preferably, the chamber is constituted by a lower chamber located within a housing having an upper chamber for the receipt of particulate material, the feeding control means being positioned between the upper and lower chambers to allow the particulate material to pass in a controlled manner from the upper chamber to the lower chamber.
The feeding control means may comprise a vibrating inclined surface which is used to control the feeding of the glass beads from the upper to the lower chambers. The quantity of the glass beads which fall from the inclined surface onto the distribution grid may be a function of the intensity of vibration of the inclined surface. As an alternative, a rotating disc with a scraper may also be used as the feeding control means, where the speed of rotation of the disc may be used to control the quantity of glass beads which are fed to the distribution grid. It is also possible to use, as the feeding control means, a spreading cone of the type described in U.S. Pat. No. 3,289,899 (Miller et al) referred to above. As a further alternative, the feeding control means may comprise means for projecting the beads towards the distribution grid, such as a compressed air nozzle positioned above the distribution grid. Where the supply of glass beads is under pressure, control of the quantity fed to the distribution grid may be controlled by controlling the degree of pressure applied.
Preferably, the feeding control means comprise a rotatable distribution roller. Such a roller achieves in a simple manner a precise dosage of the glass beads falling onto the paint.
Where in the apparatus according to the invention, a rotatable distribution roller is used as the feeding control means, this may be formed with scoops or pockets which pick up the glass beads from the upper chamber and feed them to the lower chamber as the roller rotates. For example there may be used a roller having a number of cavities provided on its surface as described in French Patent publication FR 2552702 (Walter Hofmann GmbH). Preferably the rotatable distribution roller is a grooved dosing roller. This may be cylindrical or conical and may have a length equal to the smallest width of line upon which the particulate material is to be deposited, for example 15 cm. The speed of rotation of the dosing roller determines the amount of particulate material which is deposited. By linking the rotation of the dosing roller with the movement of the apparatus, it is ensured that a constant quantity of particulate material is deposited per unit length of the marking line, irrespective of the speed of movement of the apparatus. This linking can be achieved in a convenient manner where the apparatus is provided with ground engaging means, which enable the apparatus to be moved over the ground in a direction generally perpendicular to the axis of the dosing roller. The ground engaging means may be constituted by one or more ground engaging wheels, which are linked to the rotatable distribution roller to cause the latter to rotate at a speed dependent upon the speed of the apparatus over the ground. Usually the ground engaging means will be such as to restrain the dispensing apparatus to follow exactly the path of the paint application device, that is to constrain the machine with the distribution apparatus associated therewith to one direction of movement only. We prefer that the rotatable distribution roller is driven from a ground engaging wheel via a gear-box, such that the rotational speed of the roller is proportional to the linear speed of the apparatus over the road surface. By the provision of an adjustable gear-box it is possible to control the rate of deposition of the particulate material according to the width of the marking line, as will be explained in further detail below, according to the diameter of the glass beads and according to the desired retro-reflective effect.
The dosing roller may be formed of any suitable material such as metal (especially stainless steel) or a plastics material such as a fluoro-elastomer, in particular "Viton" (Trade Mark ex Dupont de Nemours or an anti-adherent material like "Teflon" (Trade Mark ex Dupont de Nemours). Some types of glass beads may adhere to a metal dosing roller causing its performance to be unreliable. Also, some metal rollers may be subject to corrosion resulting from condensation of moisture thereon, which may occur if the ambient temperature falls below the dew point. In these cases a plastics material dosing roller is preferred.
The glass beads fall from the dosing roller into the lower chamber wherein is positioned one or more distribution grids. We have found that more than two distribution grids are preferred, such as four. The glass beads fall through the openings in the grids, from one grid to the next and ultimately onto the paint freshly applied to the ground. The distribution grids preferably are in a generally horizontal disposition, generally parallel to the axis of the dosing roller. The passage of the glass beads through the mesh openings in the distribution grids is aided by any vibration inherent in the use of the apparatus, such as may be picked up from an uneven road surface or such as may be inherent in any motor mounted on the apparatus, such as for example a drive motor or compressor motor where the glass beads are fed to the upper chamber by pneumatic means, or associated with the paint applicator mounted on the same machine. A small electric motor, such as an eccentric motor or a motor having inherent instability, may also be used specifically to generate further vibration. The mesh openings in the distribution grids are preferably from 750 μm to 400 μm, most preferably from 1000 μm to 1800 μm for the range of smaller glass beads and from 2 to 8 mm, most preferably from 3 to 6 mm for the range of larger glass beads. The mesh openings in the distribution grids should be greater than the maximum diameter of the glass beads, such as preferably from 2 to 3 times as large. If the openings are too large, however, such as more than 4 times as large as the maximum diameter of the glass beads, uniform distribution of the beads over the whole surface of the distribution grid may not be assured. If, on the other hand, the mesh openings in the distribution grid are too small, such as less than 1.5 times as large as the maximum diameter of the glass beads, blockages may occur leading to non-uniform distribution. However, the optimum size of the mesh openings will depend on the number of distribution grids used, larger mesh openings being suitable the greater the number of distribution grids.
Preferably the distribution grids are mounted in a removable manner, enabling the mounting of a grid with an appropriate mesh size, according to the size of glass beads which are being used and also for ease of cleaning. A convenient manner of achieving this is to provide each distribution grid, or a group of such grids, in the form of a rectangular drawer which may be slid into and out of position in the lower chamber of the apparatus.
According to a particularly preferred embodiment of the invention, the second chamber comprises support means for distribution grids of a number of sizes, in particular enabling distribution grids having a length greater than the axial length of the dosing roller to be mounted therein. Thus, where the dosing roller has a length of 15 cm, distribution grids having any length from 15 cm to say 35 cm may be provided, according to the desired width of the marking line. It is indeed surprising that with a dosing roller shorter than the width of the desired marking line, uniform distribution of the glass beads over the surface of such larger distribution grids and thus, ultimately, over the road surface can be achieved. Uniformity of distribution is assisted in this case, where the dosing roller is positioned centrally with respect to the distribution grids. Where a wider distribution grid is used, it will be necessary to adjust the gear ratio in the drive to the dosing roller to thereby increase the amount of glass beads which are dosed to the distribution grids, ie the rotational speed of the dosing roller should be increased. One or more deviation plates may be positioned in the lower chamber to assist the distribution of the glass beads over the whole surface of the distribution grids.
By means of the apparatus according to the invention, a uniform distribution of the glass beads is achieved in an amount required for the marking line, within the limits of that line and without significant spillage onto other parts of the road surface. The distribution grids are conveniently mounted in a static position relative to the housing, thereby avoiding any problems of wear and maintenance which arise with moving parts. The distribution grids serve to distribute the glass beads uniformly without the consumption of energy, save for the vibration which is present in any case. In contrast to some prior art devices, the use of compressed air to distribute the glass beads is avoided. A simple, efficient and relatively maintenance-free apparatus is thereby provided.
If one desires to deposit two or more different types of glass beads (for example, having different diameters or carrying different coatings) onto the same marking line, it is preferred to provide an apparatus according to the invention for each type of glass bead, these apparatus being mounted on a common machine which also carries the paint and/or polymer application devices, mounted ahead of the glass bead distribution apparatus.
BRIEF DESCRIPTION OF THE DRAWING
The invention will now be further described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a side elevational cross-sectional of an apparatus according to the invention;
FIG. 2 is a front elevational cross-sectional of the apparatus shown in FIG. 1;
FIG. 3 is a view similar to FIG. 2, of a modified apparatus according to the invention;
FIG. 4 is a plan view of the distribution grid suitable for use in the apparatus shown in FIG. 1;
FIG. 5 is a side cross-sectional view of a distribution grid shown in FIG. 4, taken on the line V--V in FIG. 4;
FIG. 6 is a cross-sectional view of part of the distribution grid shown in FIGS. 4 and 5, taken on the line VI--VI in FIG. 4; and
FIG. 7 is a view of the apparatus shown in FIG. 1 forming part of a road marking machine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 of the drawings, the apparatus 10 comprises a housing 12 defined by a front primary wall 14, a rear primary wall 16 and side primary walls 18, 20. Within the housing 12 and supported in a generally horizontal disposition by bearings 21a, 21b carried in the side primary walls 18, 20 is positioned a grooved dosing roller 22 dividing the housing 12 into an upper chamber 24 and a lower chamber 26. The housing 12 includes upper front, rear and side walls 28, 30, 32 and 34 which are so shaped as to define a hopper 36 for the receipt of glass beads or other particulate material which is desired to distribute onto the road surface. The lower part of the apparatus 10 is constituted by a distribution grid support assembly 37 formed of front, rear and side support walls 38, 40, 42 and 44 which support a number of distribution grids 46, in the case of the embodiment shown in these drawings, four such grids 46a, 46b, 46c and 46d. The support walls 38, 40, 42 and 44 at their lower extremity define a downwardly directed opening 48 of the housing 12.
The dosing roller 22 acts as a feeding control means for feeding the glass beads from the upper chamber 24 to the lower chamber 26. Mounted on the front and rear primary walls 14, 16 of the housing 12 are deflector plates 49a, 49b set at an angle of 30° to the horizontal to deflect the glass beads from the hopper 36 towards the dosing roller 22. The dosing roller 22 has grooves 50 extending in a direction parallel to the axis 52 of the dosing roller 22. The number of grooves 50, and their dimensions, are determined by the desired rate of distribution of the beads over the road surface and by the diameter of the beads. We have found that 20 equally spaced grooves, each having a width of 4 mm to be convenient. The plates 49a, 49b also serve to retain the rubber contact strips 51a, 51b in position.
The distribution grids 46 are positioned in parallel, one above the other in the lower chamber 26. The front and rear support walls 38, 40 and one side support wall 42 are formed with support grooves 54 on the inwardly facing surfaces to support the front rear and one side edge of the distribution grids 46. The other side support wall 44 has slots 56 formed therein, through which the distribution grids 46 may be inserted and which, in the in-use position, serve to support the remaining side edge of the distribution grids. The upper pair of distribution grids 46a, 46b are coupled together as a single unit by means of a connecting plate 58a. Similarly, the lower pair of distribution grids 46c, 46d are coupled together as a single unit by means of a connecting plate 58b. The connecting plates 58a, 58b are are fixed to the support wall 44 by bolts (not shown).
In the embodiment shown in FIG. 3, identical reference numbers are used for features similar to those seen in FIGS. 1 and 2. However, this embodiment differs in that the lower side support plates 42, 44 are coupled to the primary side plates 18, 20 by way of intermediate plates 60, 62. Thus, the sideways dimension of the lower chamber 26 and the downwardly directed opening 48 in the embodiment shown in FIG. 3 is greater than that of the upper chamber 36 and is greater than the length of the grooved dosing roller 22. The intermediate plates 60, 62 may be secured to the primary side plates 18,20 in any suitable manner, in particular in a releaseable manner, enabling the distribution grid support assembly 37 to be removed and replace with an assembly with distribution grids of a different dimension. A rectangular distribution plate (not shown) may be added above the upper distribution grid 46a, at the centre thereof, to cause the glass beads reach the extremities of the upper distribution grid more rapidly. The dimensions of this distribution plate may be related to the size of the distribution grids.
Referring to FIGS. 4 and 5, there is shown a single distribution grid 46, which comprises a peripheral frame 62 made up of front, rear and opposite side frame members 64, 66, 68 and 70 disposed in the shape of a rectangle. The frame 62 supports a stainless steel wire mesh grid 72, consisting of lateral 74 interwoven with longitudinal wires 76 in the manner indicated in FIG. 6. FIG. 6 also shows that the frame members of the distribution grid 46 are U-shaped in cross-section, having an inwardly directed channel 78, in which the edge of the wire mesh grid 72 is located. One side frame member has attached thereto a handle 80, by means of which the distribution grid 46 may be inserted and withdrawn from the apparatus 10. Where the distribution grids 46 are coupled in pairs, as in the embodiments shown in FIGS. 1 to 3, the handle 80 is positioned on the same side of the distribution grid 46 as the connecting plate 58, and may be integral therewith.
Referring to FIG. 7, the apparatus 10 is carried as part of a road marking machine 82, only part of which is shown. The machine 82 comprises a main frame 84 supported for movement over a road surface on a number of wheels 86, some of which may be driven by means not shown. A side arm 88 of the frame 84 projects beyond the tracking line of the wheel 86 and carries at its remote end a paint spraying head 90 and the glass bead distribution apparatus 10. The paint spraying head has associated therewith a paint feed device and a compressor (not shown) to enable the paint to be sprayed from the spraying head 90 in a current of compressed air, these items being mounted on the main frame 84. By mounting the apparatus 10 directly on the machine 82, an advantage is achieved in that vibration from the compressor mounted on the main frame is transmitted to the apparatus 10 to aid in the uniform distribution of glass beads therefrom. The disposition of the apparatus 10 on the machine 82 is such that, as the machine moves forward, the apparatus 10 moves in a direction generally at right angles to the axis of the dosing roller 22, following the paint spraying apparatus exactly. The wheel 86 is linked, by means not shown, to the dosing roller 22 so that as the machine moves forward the roller 22 rotates at a rotational speed proportional to the linear speed of the machine. The amount of glass beads delivered to the distribution grids 46 is thus proportional to the distance covered by the machine 82. This link can be achieved in a convenient manner if the shaft 92 of the roller 22 is extended to carry a sprocket wheel or the like (not shown) which by means of a chain drive can be connected to the drive means for the machine. The means whereby the wheel 86 is linked to the roller 22 also preferably includes a gear box of known construction having an adjustable gear ratio, such that the quantity of beads applied to the road surface per linear unit distance is adjustable.
In use, the machine 82 is driven forward by motive power or manually. The paint spraying head 90 applies paint to the road surface to form a paint line 94. The apparatus 10 then applies the glass beads uniformly to the freshly applied paint line 94, so as to complete the formation of the marking line 96.
The invention will now be illustrated by the following non-limiting example.
EXAMPLE
In a practical example, a 600 μm thickness coating of acrylic paint (density 1.5) was applied to a road surface in a line having a width of 30 cm (about 900 g/m 2 of paint). For adjustment of the retro-reflectivity of the marking line in rainy conditions, about 200 g/m 2 of Vialux (Trade Mark) glass beads having a diameter between 1 and 2 mm were initially deposited upon the freshly applied paint. Thereafter, from 1.4 to 1.6 Kg/m 2 of Tecnoperl (Trade Mark) glass beads was applied. The weight ratio of paint to Tecnoperl glass beads was between 1.5 and 2. The Tecnoperl glass beads have a granulometry of between 100 and 700 μm and carry a peroxide as initiator for the polymerisation of the paint. Following the application of the glass beads, the thickness of the marking line had increased to 2 mm. In order to carry out this process, a distribution apparatus for the Vialux beads is disposed on a paint applicator machine just behind the paint spraying head. The dosing roller of the distribution apparatus has a length of 15 cm and an external diameter of 5 cm. Four distribution grids were used, each having a length of 30 cm, corresponding to the width of the marking line. The mesh opening in the distribution grids was about 1.4 mm. Mounted behind the Vialux distribution apparatus was a Tecnoperl distribution apparatus similarly constructed, except that the mesh opening in the distribution grids was 3.0 mm.
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An apparatus for the distribution of particulate material including glass beads onto one of freshly applied paint or polymer material applied to a surface, includes a housing having defined therein an upper chamber for the receipt of particulate material and a lower chamber including a downwardly directed opening. The housing additionally has feeding control means positioned between the upper chamber and the lower chamber to allow the particulate material to pass in a controlled manner from the upper chamber to the lower chamber. At least one distribution grid is positioned in the lower chamber through which substantially all of the particulate material to be applied onto the surface passes to the downwardly directed opening.
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[0001] This invention claims the benefit of U.S. Provisional Application No. 62/364,077 titled, “Inverse Hall Effect Energy Generation Device” filed on Jul. 19, 2016, and which is hereby incorporated by reference. Applicant claims priority pursuant to 35 U.S.C. Par 119(e)(i).
FIELD OF THE INVENTION
[0002] The present invention relates to thermoelectric devices that exploit an inverse or reciprocal version of the Hall Effect or quantum Hall Effect.
BACKGROUND
[0003] The Hall Effect is a well known phenomenon: a current moving through a conductor perpendicular to a magnetic field generates a voltage perpendicular to both the current and the field. The Hall resistance is defined as the ratio of the generated voltage to the current. The longitudinal resistance is understood to be the resistance along the direction of the current. In other words, if a given voltage difference is produced at the two ends of the conductor, the longitudinal resistance is the ratio of this voltage difference to the current.
[0004] The quantum Hall Effect is typically observed at low temperature even though some recent experiments notably in graphene have shown it to be possible near room temperature. When certain materials are subjected to a magnetic field, electrons move in circular orbits in the material and can only acquire discrete energy values. This electronic quantization results in the Hall resistance being a step-wise function of the magnetic field. Corresponding to each step of the Hall resistance, the longitudinal resistance falls to near zero.
SUMMARY OF THE INVENTION
[0005] This invention describes an energy generation device based on a reciprocal version of the Hall Effect. When a magnetic field is applied parallel to a layer of thermoelectric material, and an electric field is applied perpendicular to the layer, electrical carriers in the layer follow cyclotron orbits interrupted by one of the layer's surfaces. These interrupted orbits produce a drift current along the layer and perpendicular to both fields. Therefore, the inputs are a magnetic field and an electric field, and the output is a current. The phenomenon differs from the classical Hall Effect in which the inputs are a magnetic field and a current and the output is a voltage.
[0006] This drift current is spontaneous and can only occur near one of the surfaces of the layer where the statistics of the carriers are biased by the combination of magnetic field, electric field and surface.
[0007] This reverse Hall Effect can be explained as follows: the magnetic field causes free carriers to follow circular orbits inside the thermoelectric layer. However, near the surface, these orbits are interrupted in an asymmetric manner, giving rise to surface drift currents. In the absence of an electric field, drift currents on opposite sides of the layer have equal amplitudes but opposite directions, and therefore cancel each other out. When an electrical field is applied perpendicular to the layer and perpendicular to the magnetic field, an imbalance is created in the carrier density between the two sides, resulting in one of the surface currents being depleted or pinched off. The surface drift currents on the two sides are not balanced. Therefore, a net current becomes observable and can be exploited for energy production. This energy can be used immediately, stored for later use, converted to another form, or transmitted to a different location.
[0008] The effect can be produced by applying a magnetic field perpendicular to a layer or by using materials (such as ferromagnetics) capable of exhibiting the anomalous Hall Effect. The effect can also occur by replacing the thermoelectric material with an oven containing plasma.
[0009] Many implementations are envisioned. The first utilizes insulated capacitor plates positioned on the floor and ceiling of a flat-shaped vacuum oven. A magnetic field is applied horizontally, parallel to the plates and an electric field is generated vertically, perpendicularly to the plates by applying a voltage across the plates. The electric field shifts the carriers and associated thermionic activity to one of the plates where, in the presence of the magnetic field, the thermionically emitted carriers follow partial orbits starting and ending at the surface of the plate. The asymmetrical motion of the carriers generates a current that flows along the surface of the plates, and that can be captured by two electrodes located at the edges of the plates.
[0010] Implementations can also use the electric field produced in thermoelectric junctions, either N-doped or P-doped. A thin layer of the material is placed between insulated capacitor plates. The layer is thin enough and the doping, moderate enough, to prevent the formation of space charges that would cancel the electric field.
[0011] Implementations can also utilize N/intrinsic or P/intrinsic junctions, to produce the electrical field. Implementations can also produce the electric field produced by electrets or ferroelectric materials.
[0012] Layers can be stacked together in a manner that the electric fields in the layers mutually reinforce each other and such that the currents produced by the layers add up (parallel connection) or such that the voltages add up (series connection).
[0013] Applications of this technology include heating, cooling, electrical energy production and lighting. Power supplies and coolers can be fabricated as integral subcomponents of semiconductor chips or modules.
[0014] This invention is therefore, an energy generator which comprises a layer of semiconductor material. The semiconductor material can be thermoelectric material with a preferably large ZT factor, for example greater than 0.5, greater than 1.0, greater than 1.5 or greater than 2. The ZT factor is a figure of merit for thermoelectric defined as ZT=σS 2 T/K, where σ is the electrical conductivity, S is the Seebeck coefficient, T is the temperature, and κ is the thermal conductivity.
[0015] The thermoelectric material can comprise Bismuth chalcogenides such as Bismuth Telluride or Bismuth Selenide. The thermoelectric material can also comprise Lead Telluride or Lead Selenide or Tin Telluride or Tin Selenide. The thermoelectric layer can also comprise inorganic clathrate, magnesium with group IV compounds such as Silicon, Germanium or Tin). The thermoelectric material can also include Skutterudite. The thermoelectric material can also include half Heusler alloys. The thermoelectric material can also include graphene. The readier is referred to the vast literature on thermoelectric materials.
[0016] The layer holds electrical carriers which can be electrons or holes. A magnetic field is applied parallel to the layer, the magnetic field can be produced by a permanent magnet or an electro-magnet. An electric field is applied perpendicular to the layer. This field can be produced by insulated capacitor plates, a semiconductor junction, electrets or ferroelectric material.
[0017] In accordance with this invention, a voltage is generated between two opposite ends of the layer, along an axis in the plane of the layer and perpendicular to the magnetic field and to the electric field. Electrodes connected to the two ends of the layer capture this voltage, allowing a current to flow. The voltage and current represent useful electrical energy that can be used immediately, stored for later use, converted to a different form or transmitted to be used at a different location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates the motion of an electrical carrier near a surface, when subjected to a magnetic field.
[0019] FIG. 1A shows that the Hall Effect generates surface drift currents on opposite surfaces of a layer. These currents have equal amplitudes but opposite directions.
[0020] FIG. 1B shows that an electric field can pinch off one of the surface currents on either side of a layer, resulting in a net current along the layer.
[0021] FIG. 2 shows the movement of carriers near the surface of a layer, in the quantum Hall Effect.
[0022] FIG. 2A shows the conventional interpretation of the quantum Hall Effect as a step function in the Hall resistance and a near zero (or zero) resistance in the longitudinal resistance.
[0023] FIG. 3 illustrates the basic idea in this invention. The Hall Effect generates two antiparallel Hall currents on opposite sides of a layer. These two Hall currents cancel each other out exactly. Pinching off one of the Hall currents by means of an electric field results in a net current out of the layer.
[0024] FIG. 3A illustrates the basic idea of the invention when the magnetic field is replaced by magnetization of the material.
[0025] FIG. 4 shows an implementation of this invention using electrons or ions between insulated capacitor plates in a vacuum chamber.
[0026] FIG. 5 shows an implementation of this invention using a thermoelectric material in a sandwich between insulated capacitor plates.
[0027] FIG. 6 shows an implementation of this invention using a thermoelectric material forming a junction between an N-doped and an intrinsic material.
[0028] FIG. 7 shows an implementation of this invention using a thermoelectric material forming a junction between a P-doped and an intrinsic material.
[0029] FIG. 8 shows how the output of the device can be increased by stacking individual devices.
[0030] FIG. 9 shows a stack of N material in a sandwich between capacitor plates and connected in series.
[0031] FIG. 10 provides an orthogonal view of FIG. 9 , also showing a stack of N material in a sandwich between capacitor plates and connected in series.
[0032] FIG. 11 shows a stack of N/intrinsic junctions connected in series.
[0033] FIG. 12 shows a stack or N/intrinsic and P/intrinsic junctions connected in parallel.
DETAILED DESCRIPTION
[0034] The description of this invention includes a first section covering the theory and a second section covering physical implementations.
Theory
[0035] A theory is presented herewith for a better understanding of the invention, but it is understood that the invention is not tied to the theory. A semi-classical method shall be used to calculate the drift current produced as shown in FIG. 1 on the surface of a thermoelectric layer 1 .
[0036] Thermoelectrics are remarkable semiconductor materials because of the relatively low coupling between the electrical carriers—electrons or holes—and the supporting crystal lattice. These materials owe their properties to a high conductivity σ of the electrical carriers and low thermal conductivity κ of the heat phonons. Their thermoelectric efficiency is described by the figure of merit Z=S 2 σT/κ where S is the Seebeck coefficient. Remarkably, electrical carriers in these materials can be considered to be in a gas phase. Both heat phonons in the crystal lattice and electrical carriers transport heat but because of their mutual low coupling these two sets of heat carriers may have different temperatures. In other words, electrical carriers can have a temperature different from the lattice.
[0037] The thermoelectric material 1 is assumed to be highly conductive, that is mostly transparent to electrical carriers but operating in depletion mode that is mostly devoid of electrical carriers. Let the thermoelectric material be N-doped. Consider an electron with charge q, mass m and subjected to a magnetic field B 2 parallel to the surface of the layer 1 . The question being asked is how much current is produced along the length L of the layer by this carrier as it bounces near the surface.
[0038] Let the carrier colliding against the insulator surface be thermalized and re-emitted. At first let us assume that the re-emitted carrier only travels as shown in FIG. 1 , in a vertical plane perpendicular to the field B 2 , with velocity v along a circular s arc that begins and ends at the surface of the thermoelectric layer 1 . If the charge is negative and the magnetic field points into the plane of the drawing, the carrier always travels clockwise. On the bottom surface, the endpoint is always to the right of the starting point generating a surface drift current to the left and vice versa, on the top surface the endpoint is always to the left of the starting point and the surface drift current is to the right.
[0039] The clockwise movement of the carrier along arc s produces a current along the chord a on the surface of the layer. Let the carrier leave the surface at a tangential angle α. The length of the arc is then s=2αr where α can range from 0 for a zero-length arc to π for a full orbit. The travel time from the starting point to the ending point along the arc is
[0000]
t
=
2
α
r
v
[0000] which is also the travel time of the charge along the chord a. The surface drift current along a is
[0000]
I
a
=
q
t
.
[0000] The current I(α) over the entire length L of the layer needs to be scaled accordingly by a/L:
[0000]
I
(
α
)
=
a
L
q
t
=
a
L
qv
2
α
r
.
(
1
)
[0040] Since a=2r sin(α):
[0000]
I
(
α
)
=
qv
L
sin
(
α
)
α
.
(
2
)
[0041] Now assuming a carrier density n at the surface, the current becomes
[0000]
I
(
α
)
=
nq
2
L
sin
(
α
)
α
v
.
(
3
)
[0042] As mentioned above, this current represents only the contribution of carriers moving in a plane perpendicular to the field. To get the total surface drift current, we integrate equation (3) using a half Maxwell-Boltzmann distribution expressed in polar coordinate form:
[0000] I=∫ −π/2 π/2 ∫ 0 π/2 ∫ 0 ∞ I ( a ) f (θ,φ, v ) dvdθdφ. (4)
[0043] However, v is constant over the domain of integration i.e., f(θ,φ,v)=f(v). Hence, we can treat each integral in equation (4) separately. Substituting equation (3) into equation (4) yields:
[0000]
I
=
∫
-
π
/
2
π
/
2
∫
0
π
/
2
∫
0
∞
nq
2
L
sin
(
α
)
α
vf
(
θ
,
ϕ
,
v
)
dv
d
θ
d
ϕ
.
(
5
)
[0044] Since
[0000]
θ
=
π
2
-
α
,
[0000] we can express
[0000]
∫
-
π
/
2
π
/
2
sin
(
α
)
α
d
θ
as
-
∫
0
π
sin
(
α
)
α
d
α
Hence
[0045]
I
=
-
nq
2
L
∫
0
π
sin
(
α
)
α
d
θ
∫
0
π
/
2
d
ϕ
∫
0
∞
vf
(
v
)
dv
.
(
6
)
[0046] from equation 21 in [1]:
[0000]
v
_
=
∫
0
∞
vf
(
v
)
dv
=
∫
0
∞
(
m
2
π
k
B
T
)
3
/
2
exp
(
-
mv
2
2
k
B
T
)
4
π
v
3
dv
.
(
7
)
[0047] and using ∫ 0 ∞ x exp(−x)dx=Γ(2)=1 we can solve the integral in equation (7)
[0000]
v
_
=
∫
0
∞
vf
(
v
)
dv
=
(
8
π
)
1
/
2
(
k
B
T
m
)
1
/
2
.
(
8
)
[0048] The other two integrals in equation (6) are easy to solve, i.e.,
[0000]
∫
0
π
sin
(
α
)
α
d
α
=
Si
(
π
)
=
1.85
and
∫
0
π
/
2
d
ϕ
=
π
2
.
Therefore:
[0049]
I
=
-
1.85
nq
2
L
π
2
(
8
π
)
1
/
2
(
k
B
T
m
)
1
/
2
=
-
1.85
(
π
2
)
1
/
2
nq
L
(
k
B
T
m
)
1
/
2
.
(
9
)
[0050] As shown in FIG. 1A , the current 3 flowing on the bottom surface is moving left, and the one 4 on the top surface is moving right. The currents have equal magnitudes but opposite directions resulting in a zero net observable current.
[0051] Let us now apply an electric field E 5 produced by applying a voltage V across the capacitor plates 5 and 6 insulated from the thermoelectric layer by insulators 8 and 9 as shown in FIG. 1B . If the magnetic force is significantly larger than the electric force (qvB>>qE) we can assume that the carriers still follow mostly circular orbits and that the calculations above are correct except that the electric field shift modifies the concentration of carriers by shifting them from one side of the layer 1 to the other. It shall be assumed that the doping is low to moderate and that the layer is thin enough that the number of carriers shifted by the electric field is insufficient to significantly alter the electric field across the thermoelectric material. In other words, the layer is operated in the depletion zone and the electric field E is not canceled by the shift in the carriers. In Filed Effect Transistor terminology, the electric field “pinches off” the carries on one side of the layer and enriches them on the other side.
[0052] The shift in carriers results in a difference Δn in carrier concentration between the two sides of the layer. Let the thermal interaction between the carriers and the insulator surface define the carriers' statistics as maxwellian. The change in carrier concentration between the top and bottom of the layer can be written as
[0000]
n
top
=
n
bottom
exp
(
-
q
V
z
k
B
T
)
.
(
10
)
[0053] The difference Δn is then
[0000]
Δ
n
=
n
bottom
(
1
-
exp
(
-
q
V
z
k
B
T
)
)
.
(
11
)
[0054] The net current for the top and bottom surfaces of the layer is obtained by combining equations (9) and (11), yielding
[0000]
Δ
I
=
-
1.85
(
π
2
)
1
/
2
nq
L
(
k
B
T
m
)
1
/
2
exp
(
qV
k
B
T
)
.
(
12
)
[0055] which is a measurable current.
[0056] Remarkably the only contribution of the magnetic field to equation (12) is the sign indicating that the current at the bottom of the layer flows to the left, and the one at the top of the layer, flows to the right. One must recognize that the equation represents a simplified model of the overall process and that the size of the magnetic field is actually important. In a weak field, the current at the top of the layer and the one at the bottom move away from their respective surfaces and into the bulk, and cancel each other. It is therefore important for the field to be strong enough that the orbits of the carriers have a radius significantly smaller than the thickness of the layer. The radius can be obtained by equating the Lorentz force to the centrifugal force.
[0000]
F
=
q
vB
=
mv
2
r
.
(
13
)
[0057] and solving r yields:
[0000]
r
=
mv
qB
.
(
14
)
[0058] Hence
[0000]
mv
qB
<<
Thickness.
(
15
)
[0059] Using the average value for v obtained from equation (8) we get
[0000]
(
8
π
)
1
/
2
1
qB
(
mk
B
T
)
1
/
2
<<
Thickness.
(
16
)
[0060] Equation (12) indicates that a current can be spontaneously generated. How much voltage can be produced? If the current path is open circuit, electrical charges are shifted in the plane of the layer and accumulate, giving rise to a counter voltage that eventually equals V stopping any more charge displacement.
[0061] The well know quantum Hall Effect illustrated in FIGS. 2-2A can also operate in inverse or reciprocal mode. The quantum Hall Effect relies on surface carriers as already explained in FIG. 1-1B . For certain values of the magnetic field, Hall resonance states become observable and correspond to the quantization of the electronic energies as shown in FIG. 2A . The Hall resistance becomes a step-wise function of the magnetic field. In addition, when an electron flowing along the surface encounters an obstacle in its path, the reflected wave destructively interferes with itself because of the ½ spin and the wave nature of the electrons. No reflection occurs and the electron goes through or around the obstacle unimpeded, resulting in zero resistance. The surface drift currents 3 and 4 become supercurrents 11 and 12 , manifesting themselves as a drastic lowering of the longitudinal resistance.
[0062] As the magnetic field is varied, each resulting quantum energy state of the electrons corresponds to a step in the Hall conductivity and a dip in the longitudinal resistance of the layer. A drift supercurrent 12 is carried by the top surface in one direction, and another drift supercurrent 11 is carried by the bottom surface in the opposite direction, the current sum being zero. Conventionally, the quantum Hall properties are not expressed in terms of currents which are not readily measurable, but of Hall resistance 13 and longitudinal resistance 14 . The Hall resistance is the ratio of Hall voltage to current and is a step function because of quantization effects. The longitudinal resistance is the ratio of longitudinal voltage to current and drops to nearly zero or to zero for each step of the Hall resistance function. In analogy to the reciprocal Hall Effect described above in this invention, the reciprocal quantum Hall Effect produces spontaneous supercurrents on each side of a layer supporting a quantum Hall Effect. When an electric field is applied perpendicularly to the layer, one of the supercurrents 11 and 12 currents is pinched off and the other current becomes observable.
[0063] FIG. 3 illustrates the basic idea of this invention. If an electrical field 5 is applied perpendicularly to the top and bottom surfaces of the layer 1 and to the magnetic field 2 , then the electrical carriers, (e.g., electrons) are pushed to one side of the layer, leaving the other side depleted of carriers. In Field Effect Transistors technology, this phenomenon is called pinching off. The net imbalance of carriers between the two surfaces results in a net output current 3 . The electric field 5 can be produced in several ways, for example by insulated capacitor plates 6 and 7 as shown in the drawing, or by electrets or junctions as shall be explained further below.
[0064] As can be appreciated, this effect can be produced by the Hall Effect or the quantum Hall Effect, but, for this effect to be observable, the number of carriers needs to be limited. If the number of carriers is too large, the shift in carriers produced by the electric field generates space charges that cancel the electric field in the bulk of the material. In other words, the layer needs to operate in depletion mode. In conventional Hall Effect experiments the effect is not observed because the material usually has a high conductivity.
[0065] The preceding discussion describes the reciprocal Hall Effect produced by charged carriers behaving in a gas phase in a thermoelectric material. The same effect can also be generated by a plasma enclosed in an oven and having thermionic interaction with the walls of the oven. The same effect can also be produced by a topological insulator in which carriers are free to move on the surface.
[0066] In FIG. 3A , the magnetic field is replaced by magnetization 15 of the material, relying on the anomalous Hall Effect, thereby allowing a reduced magnetic field or the elimination of the field altogether.
[0067] Another interesting and useful phenomenon produced by the reciprocal Hall Effect is the temperature gradient along a layer capable of carrying a reciprocal Hall current. This temperature gradient occurs as an Onsager reciprocal of the current.
Implementation
[0068] This effect can be produced in many different ways as shown in FIGS. 4 to 12 .
[0069] FIG. 4 shows this effect operating at high temperature. Insulated capacitor plates 6 and 7 are positioned on opposite walls of a flat oven 17 . The plates 6 and 7 are conductive and covered by insulators 8 and 9 . A magnetic field 2 is applied parallel to the plates 6 and 7 and produced either by an electromagnet or by a permanent magnet. An electric field 5 is produced perpendicularly to the plates 6 and 7 by applying a voltage across the plates by means of electrodes 21 and 22 . The temperature is high enough to enable thermionic (either electrons or ions, but preferably electrons) emission. The ionic density or electronic density should be low enough as not to cause a significant charge displacement between the opposite walls of the oven 17 , which would cancel the electric field produced by the capacitor plates 6 and 7 . Electrical carriers bouncing off the floor and ceiling of the oven 17 produce a flow along the surface of the insulator and a current can be generated between two electrodes 23 and 24 located at the edges of the insulator. Thermionic emission can be facilitated by fabricating a sprinkling of quantum dots in the insulator 8 .
[0070] FIG. 5 shows a low temperature or room temperature implementation using a structure very like the one already discussed above except that it utilizes a thermoelectric layer 1 (for example N-doped) in a sandwich between two insulated capacitor plates 6 and 7 connected to electrodes 21 and 22 respectively. The current is captured by electrodes 23 and 24 . The material in FIG. 5 is N doped and the carriers are electrons but the same applies to P doped material carrying holes, with the polarity of the magnetic and electric field appropriately reversed. The layer 1 should be thin enough and its doping, moderate enough for the layer to operate in the depletion zone. In other words, the carrier density should be low enough that no significant space charge accumulates on either side of the layer, which would cancel the electrical field 5 across the layer 1 .
[0071] FIG. 6 is a thermoelectric implementation in which the electric field 5 is produced by a semiconductor junction between N doped material 30 and intrinsic material 31 . The electrons are pulled toward the insulator 8 by the field 5 across the junction.
[0072] FIG. 7 shows an implementation identical to the one shown in FIG. 6 except that the N material is replaced by P material 32 and the carriers are holes. The electric field 5 , the magnetic field 2 and the polarity of the electrodes 23 and 24 are reversed.
[0073] It is possible to stack the devices of FIGS. 3 to 7 . The example in FIG. 8 shows interleaved layers including insulator 50 , negative capacitor plate 51 , insulator 52 , N material 53 , insulator 54 , positive capacitor plate 55 , insulator 56 , N material 57 , these layers repeating an arbitrary number of times. Clearly, stacks of devices shown in FIGS. 3-7 can also be built made of either N material or P material.
[0074] FIGS. 9 and 10 show how multiple layers can be connected together. These two figures are perpendicular cross-section views of the layers. In FIG. 9 the magnetic field 2 is perpendicular to the plane of the drawing, and in FIG. 10 the magnetic field 2 is parallel to the plane of the drawing. In FIG. 9 the electric current 61 is parallel to the plane of the drawing and in FIG. 10 the current 61 is perpendicular to the plane of the drawing.
[0075] FIG. 11 shows how layers formed of N material 70 and intrinsic material 71 can be stacked and electrically connected in series. Clearly the same can be done with P material.
[0076] FIG. 12 illustrates how N/intrinsic and P/intrinsic junctions can be stacked together. The outputs can be connected either in parallel or in series. Junctions can also be formed by joining N+ and N material and by joining P+ and P material.
[0077] In addition, material (such as ferromagnetics) capable of anomalous Hall Effect or anomalous quantum Hall Effect can also be used. These materials have the special property of enabling the Hall Effect in the presence of a weak magnetic field or even in the absence of a magnetic field altogether. The devices described in FIGS. 3-12 could utilize such materials.
[0078] Furthermore, the electric field can be produced by ferroelectric or by electrets.
Materials
[0079] Materials suitable for this application include those with good thermoelectric properties, those with strong Hall Effect, anomalous Hall Effect, quantum hall Effect, anomalous quantum Hall Effect, and those recognized as topological insulators. There is a long list of such materials mentioned in the technical literature.
[0080] While the above description contains many specificities, the reader should not construe these as limitations on the scope of the invention, but merely as exemplifications of preferred embodiments thereof. Those skilled in the art will envision many other possible variations within its scope. Accordingly, the reader is requested to determine the scope of the invention by the appended claims and their legal equivalents, and not by the examples which have been given.
REFERENCES
[0000]
1. G. Levy, Quantum Game Beats Classical Odds—Thermodynamics Implications, Entropy 2015, 17, 7645-7657; doi:10.3390/e17117645.
2. Levy, G. S., The Reciprocal Hall Effect, CPT symmetry and the Second Law. The Open Science Journal of Modern Physics, 2017 (in press).
3. Levy, G. S., The Faraday Isolator, Detailed Balance and the Second Law. Journal of Applied Mathematics and Physics, 5, 889-899. (2017) doi: 10.4236/jamp.2017.54078.
4. Levy, G. S., Playing Rock, Paper, Scissors in Non-Transitive Statistical Thermodynamics. Journal of Applied Mathematics and Physics, 5, [TBD]
|
When a magnetic field is applied parallel to a layer of thermoelectric material, and an electric field is applied perpendicular to the layer, electrical carriers in the layer follow cyclotron orbits interrupted by one of the layer's surfaces. These interrupted orbits produce a drift current along the layer and perpendicular to both fields. Therefore, the inputs are a magnetic field and an electric field, and the output is a current. The phenomenon differs from the classical Hall Effect in which the inputs are a magnetic field and a current and the output is a voltage. The output current produces electrical energy which can be used immediately, stored for later consumption, converted to another form or transmitted to another location. Layers can be stacked, each layer of the stack mutually reinforcing the electrical field in the adjacent stack layers. Stacked layers can be connected in series or parallel.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from PCT Application No. PCT/AT2005/000246 filed Jun. 30, 2005, in turn claiming priority from Austrian Patent Application A 1151/2004 filed Jul. 7, 2004.
[0002] 1. Field of the Invention
[0003] The invention relates to a bowl-shaped or plate-shaped component, and more particularly a structural element, consisting of a first layer, a second layer, and an intermediate layer therebetween.
[0004] 2. Background of the Invention
[0005] Components of this type, also known as structural elements, are used specifically in vehicle manufacture. Known construction methods involve so-called sandwich constructions in which a first layer of sheet metal or a metal profile imparts the major portion of strength to the construction. This first layer is usually the outer layer in vehicles such as railroad cars. The next layer is the intermediate layer, which serves mainly as a heat insulating and/or sound insulating layer. The inner layer serves mostly as an inner lining, and its function is often primarily decorative. The individual layers are firmly bonded to each other with, say, adhesives.
[0006] It is known that adhesive bonds tend to delaminate due to chemical and/or physical aging—a process that often does not occur until many years later. In railroad vehicle construction, where the life of the vehicles is 30 years or longer, the structural elements known in the prior art lead to problems that make it necessary to resort to other, more expensive structural elements, which frequently do not possess the desired heat insulating properties between the inner layer and the outer layer.
[0007] It is desired to provide a light-weight and/or thin-walled structural element, for example for railroad vehicles, having strength and insulating properties resistant to aging.
BRIEF SUMMARY OF THE INVENTION
[0008] This object is achieved with a structural element of the aforementioned type in which, according to the invention, the first and second layers are profiles with anchorage couplers projecting into the intermediate layer, which regionally interlock with the anchorage couplers associated with the respective opposite layer, and the space between the profiles and their anchorage couplers is filled with a material that is rigid and cohesive per se.
[0009] The invention provides a structural element with multifunctional applications and in which insulation and inner coverings can be integrated without the disadvantages of an exclusively firmly-bonded connection. By means of the interlocking of the anchorage couplers, a particularly good connection between the first and the second layers is achieved without the formation of thermal bridges by the anchorage couplers.
[0010] Very good interlocking is achieved if the anchorage couplers of the profiles have inwardly-projecting base bars that have interlocking retention bars on their inside ends, and it is expedient if the retention bars project outwardly from both sides of the inner ends of the base bars.
[0011] With regard to the inherent durability of the structural element, the metal profile can be an open profile with essentially smooth and/or plane outer surfaces, ie, there is no need to resort to expensive hollow profiles.
[0012] Very good insulation properties are achieved if a plastics foam is introduced into the space between the profiles and allowed to cure therein.
[0013] On the other hand, good strength values and low weight can alternatively be achieved if a foamed aluminum is introduced into the space between the profiles and allowed to harden therein.
[0014] With regard to the strength standards generally desired in vehicle construction, it is advisable for at least one of the profiles to be a metal profile, and especially for at least one of the profiles to be a stainless steel profile.
[0015] In another variant that is advantageous in many cases due to its cost effectiveness and light weight, at least one of the profiles is composed of aluminum or an aluminum alloy. Especially in vehicle construction, it can be advantageous if the profile of the first layer is composed of a material different from that of the profile of the second layer, and in most cases, but not obligatorily so, the outer layer will a metal layer and the inner layer a layer of plastics material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate the presently preferred embodiments of the invention, and, together with the general description given above and the detailed description given below, serve to explain the features of the invention. In the drawings:
[0017] FIG. 1 shows a first embodiment of a plate-shaped structural element of the invention in a partial perspective view;
[0018] FIG. 2 shows a second embodiment of the invention having a bowl-shaped design in a view similar to that of FIG. 1 ; and
[0019] FIGS. 3 to 7 show other embodiments of structural elements of the invention, all as partial cross sections.
DETAILED DESCRIPTION OF THE INVENTION
[0020] In the drawings, like numerals indicate like elements throughout. Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. The embodiments illustrated below are not intended to be exhaustive or to limit the invention to the precise form disclosed. These embodiments are chosen and described to best explain the principle of the invention and its application and practical use and to enable others skilled in the art to best utilize the invention.
[0021] The structural element shown in FIG. 1 is basically composed of three layers, namely, a first layer A, a second layer B, and an intermediate layer C disposed between said first and second layers.
[0022] The first layer A is designed as a profile 1 a of, say, an aluminum alloy, and it has a smooth and plane outer surface and inwardly-projecting anchorage couplers 2 a . The latter consist of base bars 3 a , which project outwardly from the base of the profile 1 a and which have retention bars 4 a on their inner ends, each anchorage coupler having an overall T-shape.
[0023] The layer B opposite the first layer A is also a profile 1 b and is mirror-inverted relative to the first profile 1 a , and in this embodiment it is identical to the latter, ie, it has the same anchor elements 2 b consisting of base bars 3 b and retention bars 4 b.
[0024] An essential feature of the present invention is the positive interconnection of the three layers A, B, and C, whereby the structural element is not dependent on the adhesive properties of the layer C with regard to the outer layers A and B, said layer C being usually composed of plastics material. This does not mean, however, that such adhesive properties should not or may not be present in the embodiment of the invention. Strains occurring transversely to the structural element, as created by compressive stress zones in this embodiment, can be optimally absorbed by the mutually interlocking sections of the anchorage couplers and the plastics material disposed between them. In most cases, the intermediate layer C should, of course, provide heat insulation and frequently also sound insulation. Thermal bridges will not form if plastics material is present between the anchorage couplers 2 a , 2 b of the inner and outer layers.
[0025] The material used for the intermediate layer C can be selected according to the field of application, preference being given to plastics foams that can be easily introduced into the interspace and allowed to cure therein. Examples of such foams are polymethane foam, as well as other materials such as foamed aluminum. Examples of known foamed aluminum products are marketed under the brand name ALULIGHT® (supplied by Alulight International GmbH). Non-foamed synthetic resins, etc., are also possible.
[0026] The embodiment according to FIG. 2 shows a section of a bowl-shaped structural element, wherein the outer profile 1 a and the inner profile 1 b are curved in one direction. The anchorage couplers 2 a and 2 b also have base bars 3 a , 3 b . However, in this case the retention bars 4 a , 4 b are curved, giving the anchorage couplers a mushroom shape.
[0027] In general, it should be noted at this juncture that the two profiles 1 a , 1 b can differ from each other in every respect. Although in most cases both of the profiles 1 a , 1 b will be composed of metal, for example, aluminum or stainless steel, with the outer profile 1 a usually having the main supporting function, the inner profile, in particular, may alternatively be composed of a plastics material, say, a glass fiber-reinforced or carbon fiber-reinforced material.
[0028] Other variants with regard to the configuration of the retention bars are shown in FIGS. 3 to 5 . The retention bars 4 a , 4 b in FIG. 3 are comparable to those in FIG. 2 ; however, they have a pitched roof shape.
[0029] FIG. 4 shows that the anchorage couplers 2 a associated with the first layer A can be configured differently than the anchorage couplers 2 b associated with the second layer B. The anchorage couplers 2 a resemble those illustrated in FIG. 3 . However, the retention bars 4 a only extend to one side. The anchorage couplers 2 b in FIG. 4 resemble those illustrated in FIG. 2 . The anchorage couplers 2 a , 2 b represented in FIG. 5 have retention bars 4 a , 4 b that can be described as thickened regions or heads, or enlargements, of the base bars 3 a , 3 b.
[0030] FIG. 6 illustrates that the anchorage couplers do not have to be formed on the first or second layer A or B. An outer wall 5 a is equipped by, say, welding with a separate component having a U-shaped profile 6 a , the shanks of which form the base bars 3 a and the ends of which are bent over to form retention bars 4 a . The second layer B is designed in a similar manner, namely as an outer wall 5 b with a separate component having a C-profile 6 b welded onto its inner side, the ends of said C-profile being bent over to form retention bars 4 b . The base bars 3 a interlock with the retention bars 4 b so that the retention bars 4 a , 4 b again mutually interlock.
[0031] The profiles 1 a , 1 b of the embodiment in FIG. 7 comprise integrated anchorage couplers 1 a , 1 b that are curved in opposite directions and face each other in such a way that their end sections mutually interlock.
[0032] It should be clear that only a limited number of possible embodiments has been described above, and that, within the spirit and the scope of the protection claimed, without departing from the broad inventive concept thereof, there are many other possible variants of the invention that can be produced by persons skilled in the art within the scope of their technical skills.
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A bowl-shaped or plate-shaped structural element, consisting of a first layer (A), an intermediate layer (C), and a second layer (B), wherein the first layer (A) and the second layer (B) are profiles ( 1 a, 1 b ) having anchorage couplers ( 2 a, 2 b ) projecting into the intermediate layer (C), which couplers regionally interlock with the anchorage couplers ( 2 a, 2 b ) associated with the respective opposite layer (A, B), and the space between the profiles and their anchorage couplers is filled with a material that is solid and cohesive per se.
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This application is a divisional of commonly-owned U.S. patent application Ser. No. 08/058,120, entitled "OFF-AXIS POWER BRANCHES FOR INTERIOR BOND PAD ARRANGEMENTS," filed May 5, 1993, by Michael D. Rostoker, Nicholas F. Pasch and Joe Zelayeta.
TECHNICAL FIELD OF THE INVENTION
The invention relates to integrated circuit fabrication techniques, and more particularly to techniques for forming electrical connections with an integrated circuit die.
BACKGROUND OF THE INVENTION
As used herein, the term "semiconductor device" refers to a silicon chip or die containing circuitry, and the term "semiconductor device package" refers to the semiconductor device and associated packaging containing the chip, including leads such as for connecting to a socket or a circuit board, and internal connections, such as bond wires or solder bump (e.g., micro-bump) connections, of the chip to the leads.
In a typical modern semi conductor device package, a semiconductor die (device) is disposed within a package and is connected to conductive leads of the semiconductor device package (assembly) by means of bond wires or "solder bump" (micro-bump) connections. The connections to the semiconductor die are accomplished via metallic connection points or "bond pads" (I/O pads) disposed on a planar surface of the die, around the periphery (along the edges) thereof in a "peripheral area". The peripheral area is a ring-shaped area on the surface of the die, essentially a narrow band between the edges of the die and the "interior area" of the die. The conductive leads of the semiconductor device package may be provided by a leadframe, such as in a molded plastic or TAB (Tape Automated Bonding) semi conductor device package, or by printed traces, such as in a ceramic or overmolded printed circuit board package. The conductive leads approach the semiconductor die within the semiconductor device package in a generally radial pattern. They may also approach the die in parallel ranks, from one or more edges of the die.
Typically, a leadframe is stamped (or etched) from a sheet (foil) of conductive material, simultaneously forming all of the conductive leads of the leadframe. Often, the leadframe is held together by sacrificial "bridges" between the leads, which are removed after the leadframe is assembled to a die and a package body is formed. The leads are then effectively separate. However, by virtue of their common mounting within a package body, they continue to behave, in many respects, as a unit.
As the circuitry on a die operates, it dissipates power and heats up. Often, there is a mismatch between the thermal coefficients of expansion (TCE) of a semiconductor die and the leadframe (and package body) to which it is attached. This is especially troublesome where solder bump (micro-bump) connections are used to connect the die to the leadframe. (It is assumed that the heating of the die as it operates is fairly uniform). The die expands about its "centroid" (center of mass) as temperature rises, as do the leadframe and package body. However, the die expands at a different rate than the leadframe and package body, causing a great deal of mechanical stress at the interface between the leadframe and the bond pads (the solder bump connections). This stress creates a tendency of the bond pads to tear away from the die.
On any thermally expanding body, the further a point on the body is from the centroid, the greater the absolute distance it travels (displaces) during expansion. Since semiconductor dies are typically rectangularly shaped and the bond pads are typically disposed along the edges of the rectangular shape (in the peripheral area), the bond pads undergo a fairly large absolute displacement as compared to points located closer to the center of the die. Any bond pads located at the corners of the die, being furthest from the centroid, undergo the greatest displacement during thermal expansion. As a consequence of the absolute thermal displacements that any two different points undergo on the surface of the die, they undergo differential thermal displacements relative to one another. The further from one another that any two points on the surface of an expanding die are, the greater the differential thermal displacement between them. The leadframe and package body combination also expands about its centroid, albeit at a different rate. The center of expansion of the leadframe/package body combination is generally located fairly close to the centroid of the die, since the die is the heat source which causes the expansion. As a result, any differential thermal displacement causing mechanical stress at the bond pads of a semiconductor device is greatest at the corners of the die. The common practice of disposing bond pads along the edges of the die, therefore, would seem to create the worst possible circumstances from the point of view of thermal expansion.
Although the thermal expansion problem is most severe with micro-bump (solder bump) connections to a relatively rigid leadframe assembly, the same expansion characteristics apply to the die and leadframe/package body even if bond wires are used to connect the bond pads on the die to the leadframe. While bond wire connections are considerably more flexible and resilient than are solder bump connections, thermal flexing of bond wire connections can create long-term reliability problems.
One of the most significant reasons that bond pads are typically disposed about the edges (periphery) of a die is that the peripheral location of bond pads permits a relatively large number of connections to the die without causing connections (e.g., bond wires) to cross over one another. Current trends are towards providing smaller bond pads so that even greater numbers of I/O (and power) connections to the die may be accommodated. Unfortunately, these smaller bond pads are even more fragile than "ordinary" (larger) size bond pads, making such techniques even more prone to thermal stress problems.
Another problem with locating bond pads along the periphery of a die is that many of the connections are made to circuitry that lies well within the interior area of the die, requiring that the signals to and from that circuitry (and, in some cases, power to the circuitry) travel a relatively great distance within the die along the die's minute wiring structures (conductive lines) before they reach the bond pad connection. Hence, a "pad buffer" circuit is usually provided at or near a bond pad associated with an output signal to buffer the output signal at the bond pad. These factors can contribute to timing "skew", or differences in signal timing due to different wiring delays, particularly for very high speed circuits, which presents additional challenges to the circuit designer. The wiring structures (interconnections, or conductive lines) on the die are extremely small and exhibit relatively high (i.e., non-trivial) resistance. Even a tiny bond wire is a massive conductor compared to the relatively tiny interconnection lines on a die.
Power distribution to the chip is also hampered to some degree by the location of bond pads in the peripheral area. Circuits located close to the centerline (centrally located circuits) of the die receive power from the pads at the periphery of the die, usually along a branched "bus" structure formed in the wiring layers of the die. Power is distributed to other circuits between the pads and the centrally located circuits before it reaches the center of the die. While the power "bus" structure is typically routed in a fairly direct fashion, some branches of the power distribution bus can become fairly tortuous in reaching certain circuits. Many circuits located within the interior area of the die, particularly centrally located circuits, may receive power along a wiring path the length of which is greater than one half of the distance across the die. As a result, line losses and electrical noise problems may be experienced by those circuits which are most distant from the power distribution (bond) pads, particularly the centrally located circuits.
In order to minimize such line losses and electrical noise, it is common practice to provide multiple bond pads distributed about the periphery of the die for each power supply voltage. However, this does not solve the problem of the length of the power distribution path in the internal wiring layers of a die required to reach centrally located circuits.
Attention is directed to the following U.S. Patents, incorporated herein by reference, and of general interest with respect to leadframe-type semiconductor device packages and methods for manufacture thereof: U.S. Pat. Nos. 4,701,999 issued Oct. 27, 1987 to Palmer, 4,774,635 issued Sep. 27, 1988 to Greenberg et al., 4,894,704 issued Jan. 16, 1990 to Endo, 4,897,602 issued Jan. 30, 1990 to Lin et al., and 5,051,813 issued Sep. 24, 1991 to Schneider et al.
Attention is further directed to the following U.S. Patents, incorporated herein by reference, and of general interest with respect to micro-bump (e.g., solder bump) bonding: U.S. Pat. Nos. 3,429,040 issued Feb. 25, 1969 to Miller, 3,811,186 issued May 21, 1974 to Larnerd et al., 3,871,014 issued Mar. 11, 1975 to King et al., 3,984,860 issued Oct. 5, 1976 to Logue, 4,190,855 issued Feb. 26, 1980 to Inoue, 4,772,936 issued Sep. 20, 1988 to Reding et al., 4,803,546 issued Feb. 7, 1989 to Sugimoto et al., 4,825,284 issued Apr. 25, 1989 to Soga et al., 4,926,241 issued May 15, 1990 to Carey, and 4,970,575 issued Nov. 13, 1990 to Soga et al.
Other information relating to microbump bonding techniques may be found in Japanese Patent number 61-145838A issued on Jul. 3, 1986 to Kishio Yokouchi, and in "LED Array Modules by New Technology Microbump Bonding Method," by Natada, Fujimoto, Ochi, and Ishida, IEEE Trans. Comp., Hybrids, and Manuf. Tech., Volume 13 no. 3, September 1990, incorporated by reference herein.
DISCLOSURE OF THE INVENTION
It is therefore an object of the present invention to provide an improved technique for distributing power to circuits of (circuitry within) a die.
It is a further object of the present invention to provide a technique for shortening the maximum length of power distribution wiring paths (conductive lines, in the die) to circuits on a semiconductor die.
It is a further object of the present invention to provide a technique for minimizing line losses in distributing power to various circuit elements in a semiconductor (integrated circuit) die.
It is a further object of the present invention to provide a technique for minimizing electrical noise resulting from power distribution to a semiconductor die, by providing a technique that more directly supplies power to the circuitry on a die via substantially direct (non-tortuous) paths.
It is a further object of the present invention to accomplish the foregoing objects in the context of both bond wire and micro-bump connections to semiconductor dies.
It is a further object of the present invention to accomplish the foregoing objects in the context of minimizing thermally created stresses at bond pad interfaces to semiconductor dies.
Hereinafter, the planar surface area of a semiconductor die in the immediate vicinity of the edges of the die will be referred to as the "peripheral area", and bond pads disposed in this peripheral area will be referred to as "peripheral bond pads". Also, the planar surface area of the die located inside of (surrounded by) the peripheral area will be referred to as the "interior area" of the die, and bond pads disposed within the "interior area" will be referred to as "interior bond pads".
According to the invention, it is posited that differential thermal displacements between points on a body due to thermal expansion of the body are proportional to the distance between the points. It is further posited that the absolute thermal displacement of a point on a body relative to the thermal center of expansion is proportional to the distance between the point and the thermal center of expansion. Also, if two bodies have different thermal coefficients of expansion and are thermally coupled at a point near their respective centroids, then differential thermal displacement and absolute thermal displacements between points on the different bodies will behave similarly.
It is further posited that leadframe fingers and/or bond wires are considerably stiffer relative to end displacement in a longitudinal direction (along their length) than to end displacement in a lateral direction (perpendicular to their length). Therefore, lateral thermal displacements of the ends of bond wires or leadframe fingers due to differential expansion create less mechanical stress on bond pad interfaces than do longitudinal thermal displacements. Accordingly, the present invention seeks to place signal-carrying bond pads along an "axis" of a semiconductor die. The "axis" is an imaginary line which passes over (or near) the centroid (center of mass and/or center of thermal expansion) of the die. Since the axis lies over the centroid of the die, bond pads placed along the axis experience only longitudinal displacement (along the axis), and little or no lateral thermal displacement (away from the axis). On-axis bond pads do, however, displace thermally along the length (longitudinally along) the axis. Since bond wires and/or leadframe fingers will approach the bond pads from a direction substantially perpendicular to the axis, this longitudinal thermal displacement of bond pads along the axis translates to lateral end displacement of the bond wires and/or leadframe fingers. Since lateral displacement of the bond pads relative to the axis is minimal, longitudinal end displacements of the leadframe fingers and/or bond wires are correspondingly small. In this manner, by orienting the bond pads along a line substantially perpendicular to the leadframe fingers (or bond wires), problems associated with thermally-induced migration of the bond pads can be minimized.
According to a feature of the invention, in order to better distribute power to the semiconductor die, power-carrying bond pads are disposed in an off-axis configuration in an area centered about the axis (centerline) equal to about one half of the total die area.
In one embodiment of the invention, a semiconductor device with off-axis interior bond pads for power distribution comprises a semiconductor die, circuitry formed within the die, a first plurality of bond pads disposed on the die in a linear configuration along an axis of the die, and a second plurality of bond pads disposed on the die, within an interior area of the die and spaced away from the axis (e.g., centerline). Signal connections (to a leadframe or to bond wires) are formed between the first plurality of bond pads and the circuitry, and power connections (to a lead frame or to bond wires) are formed between the second plurality of bond pads and the circuitry.
According to one aspect of the invention, a first limit line and a second limit line are defined on the surface of the die, located on opposite sides of the axis, parallel to the axis and located a distance from the axis equal to one-quarter of the width of the die. A placement area is defined on the surface of the die between the first limit line and the second limit line. The second plurality of bond pads is disposed entirely within the placement area.
According to another aspect of the invention, at least two of the bond pads in the second plurality of bond pads are disposed in a collinear arrangement, on opposite sides of the axis, along a line perpendicular to the axis.
According to another aspect of the invention, at least two of the bond pads in the second plurality of bond pads are disposed in a collinear arrangement, on a common side of the axis, along a line perpendicular to the axis.
Other embodiments of the invention are directed to forming the semiconductor device arrangements described above.
Both the first (signal-carrying) and the second (power-distributing) pluralities of bond pads are preferably "interior" bond pads, located in an interior (non-peripheral) area of the die.
Further, according to the invention, if circuits on a semiconductor die are located distant from the desired "interior" bond pad locations, that existing and/or extra wiring (metallization) layers may be employed to provide connection between these circuits and bond pads at the desired locations. This is particularly useful in applying the present inventive technique to semiconductor dies which were originally laid out for bond pads in the peripheral area. Existing and/or additional wiring layers may be employed to route signals from the original (designed) bond pad positions to the new (desired, according to the inventive technique) interior bond pad positions.
Other objects, features and advantages of the invention will become apparent in light of the following description thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a semiconductor die with an off-axis bond pad pattern for power distribution, according to the present invention.
FIG. 2a is a top view of a semiconductor die with a compound off-axis bond pad pattern for power distribution, according to an alternate embodiment of the invention.
FIG. 2b is a side view of a leadframe finger connection to an off-axis compound pair of bond pads, according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
According to the invention, it is posited that if an array of bond pads on a semiconductor die is tightly (closely) grouped (arranged or clustered), then the amount of differential thermal expansion between those bond pads will be correspondingly small, and that if such a small array of bond pads is located close to the centroid of the die, then the absolute thermal displacement of the bond pads will be correspondingly small.
Similarly, if the ends of the conductive leads of a leadframe (or bond wires) connecting to the die form a small pattern, the differential thermal displacement of the ends of the leads will be correspondingly small. Also, if the small pattern formed by the ends of the conductive leads is located close to the center of expansion of the leadframe, then the absolute thermal displacement of the ends of the conductive leads will be correspondingly small. According to the invention, these principles may be used to great advantage in the packaging of semiconductor dies.
While the industry trend is largely towards increasing the number of connections to a semiconductor die, certain types of semiconductor devices, despite great complexity, do not require large numbers of I/O connections. One example of this type of semiconductor device is any type of memory device (e.g., ROMs, RAMs, including dynamic RAM and static RAM, etc.) Memory devices are highly repetitive arrays of circuitry with a relatively small number of I/O connections thereto. In cases such as these, there is no need to use the large bond pad capacity of the periphery of the die. In fact, according to the invention, it is extremely advantageous (from a thermal expansion point of view) to locate the bond pads in a relatively small array, preferably, but not necessarily, towards the centroid of the die.
Leadframe fingers and, to a lesser degree, bond wires are stiffest (most rigid and unbending) along their length, since any displacement of the end of the leadframe finger or bond wire tends to put it in compression. Although bond wires are considerably more tolerant of any kind of end displacement than are leadframe fingers, the path of bond wires is typically kept fairly flat (no significant "loft" or high arc in the path of the bond wire), resulting in a certain amount of stiffness along the length of the bond wires (longitudinally) because of the tendency of end motion in a flat configuration to put the bond wire in compression until an arc is formed. This flat bond wire configuration is used to minimize to possible of short-circuits between adjacent bond wires. However, bond wires and leadframe fingers are both considerably more tolerant of lateral displacement of their ends since the lateral displacement is distributed along the entire length of the leadframe finger or bond wire (i.e., there is some sideways "springiness" of bond wires and leadframe fingers). Accordingly, then, a linear bond pad arrangement along a longitudinally oriented centerline of a semiconductor die with bond wires or leadframe fingers approaching from the sides takes greatest advantage of this feature. That is, an arrangement of bond pads in a straight line along a path through (or over) the centroid of a semiconductor die will experience little or no lateral (relative to the line of bond pads, longitudinal relative to the bond wires or leadframe fingers) thermal displacement of bond pads.
Unfortunately, such a solely linear arrangement of bond pads provides little or no improvement in power distribution, since the distance from a "centerline" bond pad to the most distant circuits can still be on the order of one half of the distance across the die.
According to the invention, bond pads for signal connections are disposed in an interior area of the die along a line approximately through (over) the centroid of the die, to minimize lateral thermal displacement (relative to the line). This line through the centroid is an "axis" of the die, and the linear configuration of bond pads along the "axis" is an "on-axis" bond pad configuration. Additional bond pads for power supply connections are disposed in the interior area of the die in an "off-axis" location (i.e., off of the centerline). These bond pads are kept within the approximately half of the area of the die which is distributed about the centerline (i.e., their distance from the axis is no greater than one quarter of the distance across the die as measured perpendicular to the axis).
By positioning the power distribution pads off-axis, the maximum distance of power wiring paths is reduced by as much as half. With this reduction in power wiring length (within the die) comes a resultant reduction in line losses and in power-induced electrical noise. Further, by constraining the locations of the bond pads to one half of the die area distributed about the centerline (an "inner" half of the die area), lateral thermal displacements of bond pads (relative to the axis, longitudinal relative to the leadframe fingers or bond wires) are less than half of those experienced in peripheral bond pad configurations, creating considerably less thermally induces stresses on the bond pads.
FIG. 1 is a top view of a semiconductor die 100 having an "interior" bond pad arrangement, according to the invention. A plurality of "signal" bond pads 120 (sixteen shown) are disposed on a planar surface 110 of the die 100 along an axis 150 of the die 100. The axis 150 is preferably centered on the die. "Power" bond pads 130a, 130b, 140a, and 140b, are disposed in an off-axis location relative to the signal bond pads 120. Typical leadframe finger positions 135a, 135b, 145, for leadframe fingers connecting to the power bond pads are indicated with dashed lines. Power bond pads 130a and 130b are located off-axis (off of the centerline or axis 150), on opposite sides of the centerline (axis) 150 and are non-collinear but are positioned fairly close to the centerline 150. Power bond pads 140a and 140b are located off-axis, approximately halfway between the centerline 150 and the edges of the die 100, are on opposite sides of the centerline 150, and are collinear (along a line perpendicular to the centerline).
A first leadframe finger 135a is shown as a dashed line approaching the die 100 from one side of the centerline and extending over the surface 110 of the die 100 and over power bond pad 130a. A second leadframe finger 135b, also shown as a dashed line, approaches from the opposite side of the centerline 150, and extends over the surface 110 of the die 100 and over the power bond pad 130b. Typically, micro-bump connections are formed between the bond pads 130a and 130b and the leadframe fingers 135a and 135b, respectively.
A single leadframe finger 145 (also shown as a dashed line), approaching the die 100 from one side of the centerline 150, extends over the surface 110 of the die 100 and over both power bond pads 140a and 140b. Micro-bump connections are formed between both power bond pads 140a and 140b and the single leadframe finger 145.
The leadframe fingers 135a, 135b and 145 described with respect to FIG. 1 are for carrying power to the die. Hence, they connect to the power-distributing, off-axis bond pads 130a, 130b and 140a/b, respectively.
Not shown in FIG. 1 are additional leadframe fingers which connect to the signal-carrying bond pads 120. Such additional leadframe fingers would enter the surface of the die parallel to the power-carrying leadframe fingers 135a, 135b, 145, from one or both sides of the die (top or bottom as viewed in the Figure). These additional signal-carrying leadframe fingers are omitted from the figure for illustrative clarity. However, it is evident that the off-axis power bond pads (130a, 130b and 140a/b) must be disposed at longitudinal (with respect to the axis 150) positions whereat there are no signal-carrying bond pads 120. Hence, as shown in FIG. 1, there are discontinuities in the array of signal-carrying bond pads 120 along the axis 150--"blank" (no pad) positions corresponding to the longitudinal coordinates of the laterally offset power bond pads. No power bond pad is collinear (longitudinal coordinate the same) as any signal bond pad. However, the two (pair of) power bond pads 140a and 140b occupy the same longitudinal coordinate (and are on opposite sides of the axis).
FIG. 1 also illustrates that there are leadframe fingers (one shown, can be more) 135c extending from one edge (top, as viewed) of the die to a portion of the signal-carrying bond pads 120, and that there are leadframe fingers (one shown, can be more) 135d extending from an opposite edge (bottom, as viewed) of the die to another portion of the signal-carrying bond pads 120. This dedication of certain leadframe fingers for signals (and for connection to signal pads 120) and other leadframe fingers for power (and for connection to power pads, e.g., 130a, 130b, 140a, 140b) is also applicable to the embodiment shown in FIG. 2a.
FIG. 2A is a top view of a semiconductor die 200 having an arrangement of interior bond pads similar to that of FIG. 1, but this time employing a "compound" off-axis power bond pad arrangement. (A "compound" off-axis bond pad arrangement is one where two or more bond pads are disposed in a collinear arrangement along a line perpendicular to the centerline of a die on one side of the centerline, or axis.) A plurality of "signal" bond pads 220 (sixteen shown; similar to those 120 of FIG. 1) are disposed on a planar surface 210 of the die 200 along an axis 250 of the die 200. Compound (pairs of) power bond pads 230a, 230b, 240a, and 240b, are disposed in an off-axis location relative to the signal bond pads 220 (and at longitudinal coordinates corresponding to `missing` bond pads 220, as was the case in FIG. 1). Typical leadframe finger positions are indicated with dashed lines. A first pair of compound power bond pads 230a is located in collinear off-axis arrangement perpendicular to the centerline 250 on one side of the centerline. A second pair of compound power bond pads 130b is located in a collinear off-axis arrangement, on the opposite side of the centerline (axis) 250 and is non-collinear with the first pair 230a. Two pairs of compound power bond pads 240a and 240b are located in a collinear off-axis configuration on opposite sides of the centerline 250.
A first leadframe finger 235a (shown as a dashed line) approaches the die 200 from one side of the centerline (the same side of the centerline as the bond pads 230a) and extends over the surface 210 of the die 200 and over both compound power bond pads 230a. The leadframe finger 235a is connected (by microbumps, or the like) to both of the bond pads 230a.
FIG. 2B shows the connection of the leadframe finger 235a to the pair of bond pads 230a (designated 231a in this figure), including raised features 232a of the connection effected between the leadframe finger and the bond pad. This type of connection is exemplary, and is also applicable to the arrangements of FIG. 1.
A second leadframe finger 235b (also shown as a dashed line) approaches from the opposite side of the centerline 250, and extends over the surface 210 of the die 200 and over both compound power bond pad 230b. The leadframe finger 235b is connected (by microbumps, or the like) to both of the pair of compound bond pads 230b.
Notably, with regard to the bond pads 230b and leadframe finger 235b connecting to the pads, the bond pads 230b are disposed at an axial (longitudinal) position that is coincident with a one of the bond pads 220, which bond pad 220 would be connected to by a lead frame finger (not shown) entering the die from the opposite side of the axis. In the other cases shown (e.g., 230a, 240a, 240b, 130a, 130b, 140a, 140b), the off-axis power bond pads are disposed at longitudinal positions whereat there is an absence of a signal bond pad (120, 220) in the linear signal bond pad array.
A third leadframe finger 245a extends from one side of the die, across the surface of the die, over (and connects to) the pair of compound bond pads 240a, which are on the same side of the centerline 250. A fourth leadframe finger 245b extends from an opposite side of the die, across the surface of the die, over (and connects to) the pair of compound bond pads 240b, which are on the same side of the centerline. The leadframe fingers 245a and 245b enter the die from opposite sides of the centerline 250, across the surface 210 of the die 200 and over the compound bond pads 240a and 240b, respectively. In this case, the pair of compound bond pads 240a are not only collinear with one another, but are also collinear with the pair of bond pads 240b, and both pairs 240a and 240b are located at longitudinal positions whereat there is no signal bond pad 220.
As illustrated in FIG. 2a, all of the power bond pads are disposed within and area between two outer limit lines 250a and 250b. These limit lines 250a and 250b indicate a constraint on the location of the power bond pads to a fractional (e.g., one half) area of the die that is preferably centered about the centerline 250. The limit lines 250a and 250b are positioned approximately halfway between the centerline and the edge of the die 200, on opposite sides of the centerline. That is, they are positioned parallel to the centerline 250 and are a distance away from the centerline 250 equal to approximately one-quarter (25%) of the distance across the die, as measured perpendicular to the centerline 250. By observing the constraints imposed by the limit lines 250a and 250b, it can be ensured that the conductive paths within the die, from a power bond pad to a given circuit element, can be minimized. This is in marked contrast to the sometimes rather long, tortuous paths required to be taken by conductive lines in the die when connecting to power bond pads disposed about the periphery of the die. Further, as noted hereinabove, by locating all of the bond pads within a central (interior) area of the die, the undesirable effects of thermally-induced bond pad migration can be minimized, which will alleviate stress-related failures (e.g, relatively immobile lead fingers pulling out bond pads).
In the embodiments shown and described hereinabove with respect to FIGS. 1, 2a and 2b, while circuitry on the die is not shown to avoid illustrative clutter, and the additional lead fingers connecting to the signal-carrying bond pads (120, 220) are omitted, it will be readily apparent to one of ordinary skill in the art that signal connections are formed in wiring layers of the die between the on-axis (signal) bond pads and the circuitry, and that power connections are formed in wiring layers of the die between the off-axis (power) bond pads and the circuitry.
It will also be readily apparent to one of ordinary skill in the art that the present inventive techniques are also applicable to bond wire connections to the bond pads.
Connections between circuits in the die and bond pads on the die may be accomplished by means of either existing or additional wiring layers, either within the die (under the surface of the die) or on the surface of the die. This is particularly advantageous in circumstances where either:
a) the design of the circuitry on the die was optimized for bond pad placement at the periphery of the die, and re-routing of existing signal (or power) lines is necessary to apply the present inventive techniques; or
b) the circuitry on the die cannot be laid out optimally for the desired interior bond pad locations and it is necessary to route signals to bond pads from relatively distant positions on the die.
It is within the spirit and scope of the present invention that any of the techniques described hereinabove may be used in combination. For example, single and compound power bond pads may be mixed on a single die. In other words, there may be, on a given die, some combination of the various embodiments shown in FIGS. 1 and 2.
Further, the inventive techniques may be applied to raised bump mounting to printed traces on substrates, such as printed circuit board (e.g., FR4, BT resin, etc.) substrates, in a flip-chip configuration. Such printed circuit boards often have a thermal coefficient of expansion significantly different from that of silicon. Evidently, interior bond pads can be used to great advantage in such configurations.
By segregating the power bond pads (e.g., 130a) from the signal bond pads (e.g., 120), overall bond pad layout can be optimized for signal delay and noise, as well as for minimizing thermally-induced bond pad tearout problems.
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A technique for improving power distribution to an semiconductor die while simultaneously reducing thermally-induced mechanical stresses on bond pads in semiconductor device assemblies is accomplished by providing the signal-carrying bond pads in a collinear arrangement along an axis of the die, and providing power-carrying bond pads in an off-axis location. The on-axis configuration of signal-carrying bond pads minimizes lateral thermal displacements of the bond pads relative to the axis, which minimizes any longitudinal, compressive end displacements of leadframe fingers or bond wires, thereby minimizing thermally induced mechanical stresses of the bond pad interfaces to the die. The positioning of the power-carrying bond pads off-axis reduces the length of internal (to the die) wiring required to connect circuitry on the die to the power-carrying bond pads. Constraining the location of the power-carrying bond pads to an interior area of the die approximately one half of the die area, and substantially centered about the axis, keeps longitudinal thermal displacements of the ends of leadframe fingers or bond wires connected to the power-carrying bond pads relatively small compared to those experienced in peripheral bond pad placement (at the die edges), and ensures shorter, more direct internal paths to circuitry on the die.
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BACKGROUND OF THE INVENTION
The invention relates to an apparatus intended for drilling holes, which are generally but not necessarily vertical, in the ground, for example to enable stakes to be implanted or foundation piles to be erected.
In order to drill regular holes in the ground more easily, rotating tools have been used which served to cut the ground and collect the debris so that it can be conveniently removed; examples of such tools include augers or drilling cylinders and bells.
SUMMARY OF THE INVENTION
The apparatus of the invention comprises a cylindrical hole-drilling tool having, at one open end, an attacking edge capable of penetrating into the ground and cutting a borehole.
It is an object of the invention to provide an apparatus of this kind which is capable of drilling holes in very different types of ground, from hard, resistant ground to soft ground with a tendency to crumble, by means of which the drilled material can readily be withdrawn from the hole and can also easily be removed from the drilling tool even if the ground is firm and cohesive.
According to the present invention there is provided apparatus for drilling holes in the ground comprising a cylindrical drilling tool having an upper end and a lower end, a drilling edge being provided at the lower end of said drilling tool, a motor assembly for rotating said drilling tool, a rotatable elongate sleeve coupling said motor assembly to said drilling tool, said sleeve being interposed between the motor assembly and the drilling tool and being keyed to the upper end of said drilling tool, a hydraulic jack disposed for rotation with said sleeve, the hydraulic jack having a piston rod which extends through the upper end of the drilling tool into the drilling tool and is longitudinally movable relative to said drilling tool, and means for closing and filling the drilling tool provided on the free end of said piston rod.
In a preferred embodiment of the invention, the elongate sleeve is formed, at least in its upper part, by the cylinder of the jack. The cylindrical tool is closed off at its upper end by a base which is fixedly connected to the rotational drive sleeve and has, in its centre, a guide aperture of suitable dimensions to ensure the longitudinal guiding of the piston rod of the jack.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will hereinafter be described, by way of example, with reference to the accompanying drawings, wherein:
FIG. 1 is an elevation of apparatus of the invention with the lower part in partial section through a plane which passes through the axis, so as to show the interior of the drilling tool;
FIG. 2 is a partial view from above, in the direction of the arrow F of FIG. 1, of a valve-action member of the apparatus;
FIG. 3 is a partial section of a further embodiment of the invention showing the drilling tool and the valve-action member;
FIG. 4 is a partial section, analogous to FIG. 3, showing an alternative construction of the drilling tool and valve-action member.
DESCRIPTION OF PREFERRED EMBODIMENTS
Apparatus of the invention may be constructed as an accessory for an existing, preferably hydraulic, machine such as a mobile crane, a hydraulic shovel, a drill with articulated or telescopic arms, etc. For this reason, there is provided, at its upper end, a fixing means 1 below which is attached the body of a hydraulic motor 2, or any other suitable motor, followed by a speed reducer 3. This reducing motor assembly serves to rotate a drilling tool 4 so as to drill a borehole as will be explained hereinafter.
One of several known means may be used for coupling the drilling tool 4 to the output shaft of the speed reducer 3. It is generally preferable to use a sleeve 5 which extends from one to the other and the length of which depends on the desired depth of the holes to be drilled.
The drilling tool 4 comprises a cylinder which is open at its lower end, where it terminates in an attacking edge 6 provided with teeth 7 which are preferably easy to replace when they wear out. The sleeve 5 may be coupled to the drilling tool 4 by various means. For example, the cylindrical wall 4 A of the tool 4 could be connected directly to the sleeve 5. However, as will become apparent, it is more convenient to provide the tool 4 with a base 8 opposite its attacking edge 6 and to fix the sleeve 5 to this base 8 by means of a flange assembly.
According to the invention, a member 9 acting as a valve is arranged inside the drilling tool 4 so as to be longitudinally movable therein from the base 8 to a point outside the tool 4, beyond the attacking edge 6. In order to provide this longitudinal translation of the member 9, the valve-action member 9 is mounted on the end of a rod 10 which in turn slides within the tool 4. When a base 8 is provided, the rod 10 passes through it and is thus guided in its movement.
The rod 10 may be manoeuvred by any known means, and is preferably the longitudinally extending piston rod of a hydraulic jack 11 arranged above the drilling tool 4. Of course, the jack 11 may be housed within the sleeve 5 but it is preferable for the jack 11 itself to form part of the sleeve 5. For this purpose, the cylinder 12 of the jack 11 is provided with flanges 13 at both ends so as to be mounted to provide an extension of the sleeve 5. This jack 11 is a double-action jack, with a simple action or a telescopic action, as required. When the jack 11 is mounted coaxially with the drilling tool 4, as has just been explained, its cylinder 12 serves to effect rotational driving of this tool. For this reason, a rotary joint 14 is interposed between the jack 11 and the speed reducer 3 so as to ensure an unobstructed supply of fluid under pressure.
It is not essential for the valve-action member 9 to be rotated, the present invention is also applicable to embodiments where this member 9 is only movable in translation. However, it is more advantageous, as in the embodiment shown in FIG. 1, for the member 9 to rotate at the same time as the drilling tool 4. In this embodiment, rotation of the member 9 is caused by rotation of the jack 11. However, it is preferable for the rod 10 which passes through the base 8 to have a cross sectional profile which is circular, e.g. to have an hexagonal profile as shown in FIG. 2, so that rotation of the base 8, which has a corresponding aperture for the passage and guiding of the rod 10, rotates the said rod.
The valve-action member 9 may be constructed in several ways which the man skilled in the art can adapt to suit the special nature of the ground which is to be drilled. The essential function of the member 9 is to allow fragments and particles of the drilled material to enter inside the drilling tool 4 whilst the tool 4 is being plunged into the ground and to prevent this material from accidentally falling out when the tool is withdrawn from the hole. Subsequently, outside the hole, the member 9 allows or positively causes this material to be discharged from the drilling tool 4.
The valve-action member 9 shown in FIG. 2 comprises a hub 15 from which a plurality of radial arms 16 spaced in a circle extend. Each arm 16 carries a flap 17 disposed in the space between two adjacent arms. Each flap 17 is pivotally mounted at 18 to its respective arm 16 and may be pivoted from a blocking position in which it extends transversely of the drilling tool 4 upwardly towards the base 8. Thus, as the drilling tool 4 is operating fragments of the material being drilled push back the flaps 17 and pass into the drilling tool 4 but cannot escape therefrom. The jack 11 enables the material within the tool 4 to be compressed so as to ensure better filling of the tool 4. In the embodiment illustrated in FIG. 2, the flaps 17 do not completely fill the spaces between the arms 16. The need for more or less total blocking of these spaces depends on the nature of the material being drilled. Sandy soil may require almost total blocking.
Instead of being pivotally mounted by means of one of their radially extending edges, the flaps 17 could be pivotally mounted by their circumferential edge 19 close to the hub 15. Pivotal mounting of the flaps is not obligatory; fixed but flexible blades could be used to achieve the same result. It should be understood that the invention covers all possible equivalents in this respect.
In a second embodiment of the valve-action member 9 shown in FIG. 3, there are again radial arms 16 extending from the hub 15, but the flaps are replaced by a spiral 20 extending helically from each arm 16 towards the interior of the drilling tool 4. Each spiral 20 covers the entire radial length of the arms 16 and is developed over a fraction of the circumference, e.g. a quarter when four arms are provided.
Of course, the invention does not impose any restrictions on the size of the spiral 20. As shown in FIG. 4, it may be developed over a number of turns and in this case starts from only one of the arms 16. During rotation of the valve-action member 9, the drilled material may penetrate inside the drilling tool 4; in fact the material is actually driven into the tool 4 by the screwing action of the spiral 20 and is compressed therein, thus ensuring that the tool 4 is properly filled. When rotation of the member 9 ceases, the drilled material cannot fall out, of the tool 4, particularly if the spiral 20 has a shallow pitch. To empty the tool 4, rotation of the member 9 in the reverse direction may be effected by means of the motor 3, so that the spiral 20 drives the material out of the tool 4, or else the member 9 may be pushed downwards by means of the jack 11 beyond the attacking edge 6 and outside the drilling tool 4.
It will be apparent that the valve-action member 9 has to be adapted to the nature of the ground being drilled; the spiral 20 in FIG. 4 is highly suitable for sandy soils. If the ground in question is clay and tends to compact, the apparatus according to the invention may be used by placing the member 9 within the drilling tool 4 adjacent the base 8, as shown in FIG. 1. With a sticky material, the material drilled adheres to the inside of the tool 4 without having to be held in place. To make this soil fall out at the proper time, the member 9 is used as a piston by pushing it towards the edge 6 of the tool 4 by means of the jack 11.
The construction of the member 9 with radial arms is not essential, as has already been stated; however, it is advantageous to provide these arms 16, since they each have an outer surface, i.e. a surface facing the outside of the drilling tool 4. Teeth 21 for penetrating into the ground to be drilled may be attached to this outer surface. Thus, if the ground is stoney or rocky or simply very compact, the teeth 21 on the member 9 break it up by rotation and the debris is conveyed and compressed by the spiral 20 inside the drilling tool 4 whilst the tool is entering the ground. The hub 15 preferably terminates in a lower point 22 which ensures that the drilling tool 4 is centred.
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The present invention relates to an apparatus for drilling holes in the ground. The apparatus comprises a cylindrical drilling tool having one end coupled to a motor assembly for rotating the tool by way of an elongate rotatable sleeve. A hydraulic jack is disposed in the sleeve for rotation therewith. The piston rod of the jack extends longitudinally of the drilling tool and carries a valve-action member arranged to allow drilled material to enter the drilling tool and to retain the material therein. The piston rod is movable longitudinally relative to said tool for the discharge of said material.
The apparatus of the invention is able to drill holes rapidly in a large variety of soils.
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FIELD OF THE INVENTION
The invention relates to an ultrasonic vibrational system that alleviates tooth pains and discomfort, particularly when the tooth is under a dental treatment, such as drilling, filling, reaming, cutting, and anesthetic injection, by applying ultrasonic vibrations directly to a tooth.
BACKGROUND OF THE INVENTION
Even though various theoretical and technical developments have been made in the attempt to reduce or eliminate pains and discomfort during a dental treatment, there remains the fact that no pain transmission mechanism has yet been proved, which might have paved the way to a reliable and safe system. Therefore the process to alleviate the pains consists firstly in the understanding of how pain could be sensed in a diseaded tooth.
Experiments directed to that end, have indicated that tooth pain is connected somehow with the dynamic movement of the dental pulp fluid which is more active in a diseased tooth and less active in a healthy one. Then, the practical method to alleviate the pains during a particular dental treatment, will be to reduce and possibly eliminate those dynamic factors consisting primairly of movement of the dental pulp fluid, that stimulates the nerves. Therefore it is imperative to control this dynamic movement, which has an erratic course, in order to achieve a reduction or elimination of pain, without the use of anesthesia; and in the event that anesthesia is needed, the amount is limited to a small fraction of what is normally used. However, the control of the dynamic movement of the dental pulp fluid requires essentially that the fluid within the dental pulp be saturated, and one way of accomplishing this, is to apply mechanical energy in the form of ultrasonic vibrations, which creates the proper conditions for cavitation to occur.
SUMMARY OF THE INVENTION
The present invention is directed toward a new and improved system to alleviate the pains and discomfort during dental treatment of a tooth, such as a tooth with beginning or advanced caries or other, without or with limited use of anesthesia which can not be used on a great number of patients for a great number of reasons. The apparatus excites a tooth to a frequency and amplitude that create a cavitation effect on the dental pulp fluid, forcing it to the extend that no apparent dynamic movement is experienced within it, thus inducing a partial or total loss of the sense of pain, and consequently a dental treatment can be performed without, or with limited use of anesthesia.
In accordance with the invention, several experiments have been conducted, consisting in applying ultrasonic vibrations directly to a tooth, within the range of frequencies from 40 kHz to 65 kHz. These experiments have clearly indicated that the cavitation effect, a phenomenon well known in physics and engineering, created by the ultrasonic vibration on the dental pulp fluid, causes a saturation and collapse of those microscopic gas bubbles within the fluid, and therefore stabilizing and limiting the erratic dynamic movement of this fluid. As cavitation develops, the gas bubbles, which are apparently responsible for the erratic dynamic movement, collapse as they move into a higher pressure region and this generates powerful local forces, which are affected by the character of the fluid and the gas in it. As a result, the apparent density of the dental pulp fluid increases to a degree where it would not appreciably yield to any change, thus limiting the erratic dynamic movement; it can be viewed also as a tendency of the fluid to remain in its position, similar to the inertia of matter that offers resistance to any change and that remains in the same state unless affected by some outside force. Furthermore, once the dental pulp fluid has been stabilized by the cavitation effect, even though the ultrasonic vibrational energy is removed, it has the tendency to remain in this state, thus prolonging those conditions acting in alleviating pains and discomfort, and it will remain in this state until the gas bubble energy of the dental fluid will dissipate and will return to the previous conditions.
It has been observed in patients a difference in behaviour and in responses to ultrasonic stimulation, because they are affected by the density of the dental pulp fluid, which varies from person to person. It can be said that there is a resemblance to the well known concept for the regulation of human equilibrium, where a denser liquid within a cavity would be causing less dizziness than a lighter one when subjected to motion, such as sea motion. Even though it would be extremely difficult to measure physically and individually the dynamic movement of the dental pulp fluid using the state of the art technology, nevertheless the fundamental concept of the cavitation effect is proven by several lateral ways that lead to its acceptance.
Experiments conducted using frequencies within the range of 40 kHz up to 65 kHz, and amplitudes within 1 um and 10 um, have indicated that tooth pain starts alleviating when a tooth, subject to forced ultrasonic vibration, vibrates at a frequency ranging from 40 kHz to 50 kHz with an amplitude ranging from 3 um to 4 um similarly, the same alleviation effect is found at 60 kHz with amplitude between 1 um and 2 um. However, at a frequency of 60 kHz with amplitude of 3 um to 4 um, and in some cases even up to 9 um, the pain is drastically reduced and can be considered in most cases almost imperceptible. Furthermore, as mentioned previously, the tooth pain is not sensed after removing the horn tip, or at a lesser degree than it was sensed before. It is evident that even though the source of excitation is removed, some of those vibrational forces which acted on the dental pulp fluid, are still present, demonstrating that the cavitation effect does not end with the removing of the vibrational excitation, but it does continue until those forces return to their previous conditions, which are typical for each individual. It must be clear however, that the cavitation effect occurs in a closed space only, that is in a closed area with no connection with the outside, such is the area enveloping the dental pulp fluid.
As mentioned previously, in the event that anesthesia is to be used, because of different patients behavior, the amount of anesthesia would be limited to an amount consisting of only a small fraction of what is commonly used, in many cases only one-tenth of a normal dose, because the narcotic used by injection to relieve pain, is by far more effective when it is subject to ultrasonic vibrational forces. It is evident that the pulsating ultrasonic vibrations, acting on the needle of a syringe or on a diseased tooth after the injection, force the anesthestic fluid to disperse and scatter in all directions, increasing the rate of diffusion, passing into and through, affecting and penetrating those parts which are hard to reach and require exstensive length of time and a large amount of anesthetic fluid to be effective. Furthermore, the anesthetic fluid is attracted by the dynamic center, being the diseased tooth, in which originates the ultrasonic vibrations, thus increasing the permeability of those sensitive parts having pain sensation. In addition, the effectiveness of the anesthetic fluid increases when the horn probe tip is moved around in a circular motion, with light pressure, right on the injection point, similar to massaging and rubbing as to stimulate circulation and penetration of the anesthetic fluid. As a consequence, the time that normally is required for the anesthesia to be effective, which is extensive and varies greatly from person to person, is reduced to only few seconds, and for practical purposes it can be stated that the effectiveness is almost immediate, and the dulling effect, which usually continues and persists for a length of time after a dental treatment, is drastically reduced to sensation so slight as not to be easily perceived. Furthermore, experiments have demonstrated in several instances, that few drops of anesthetic fluid dropped into the dental pulp and applying right after ultrasonic vibrations, were extremely effective, thus avoiding the use of painful injection needles. The benefits those obtained are of inestimable value to human health.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal view in cross section of the invention.
FIG. 2 is a schematic view showing the electronic control system.
FIG. 3 is a view similar to FIG. 1 but showing a diseased tooth.
FIG. 4 is a view showing an anesthetic injection.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will be best understood by reading the following description in connection with the drawings.
FIG. 1 shows an ultrasonic longitudinal vibrator, enclosed in a hand piece 1, disposed on a node of vibration, where electrical vibrational energy is converted into mechanical vibrational energy, which is composed of a vibrator 4, a horn probe 3, shaped in a way to have a tip 2, rounded at the end, that comes into contact with a tooth 12, for imparting ultrasonic vibrations. FIG. 2 shows a control unit 8, which is composed of an impedance measuring circuit 5, an impedance memory 6, an amplitude control 7, an ultrasonic control 9, a power supply control 10, and a display switch control 11. The hand piece 1 is held in a manner that the horn probe tip 2 is being gently pressed against a tooth 12, as indicated by a double-ended arrow 13, so that the ultrasonic vibration is transmitted to the tooth.
Referring to FIG. 3, a small hole 17, created by some form of decay, is shown going through one side of a tooth 12, reaching the upper part of the dental pulp 14, thus allowing a passage between the outside area and the dental pulp in this case, even though ultrasonic vibrations are applied through the horn tip 2 pressed against a tooth 12, the cavitation effect does not occur because the vibrational forces, responsible for the cavitation, cannot create a higher pressure region where gas bubbles are collapsing, being the area open to atmosphere. Therefore tooth pain remains substantially the same, and even with amplitudes varying from 2 um up to 9 um, no appreciable alleviation is experienced, and pain is sensed when air is blown through hole 17. Thus, it is of primordial importance for creating cavitation in a closed area, to control the ultrasonic vibration right on the tooth, which does not vibrate properly if the horn tip 2, imposing the forced vibration, is pressed against the tooth with a force greater or lesser than required. More so, when teeth are drilled, cut, or other, using tools and instruments such as a micromotor characterized by low rpm and high torque requiring generally higher amplitude, the control and the fine adjustment of the amplitude values on the tooth are essential for effective alleviation of pain, because the forces imposed by the cutting instrument being a source of external exitation, cause unbalance which appears and even disappears under certain conditions. It is evident that the amplitude on the tooth is to be tuned to the proper desired performance, similar in a way to a tuner to adjust a radio or television receiver to a specified station.
With reference to FIG. 2, the control unit 8, is composed of a circuitry and instrumentation necessary to control the sympathetic vibration on a tooth. Being the maximum voltage V1 a function of the amplitude, it is calculated from constant current I and impedance Z, and set into the memory 6 of the impedance measuring circuit 5. As the ultrasonic vibrations are forced onto a tooth 12 by the horn probe tip 2 along the direction indicated by the double-ended arrow 13, the tooth starts vibrating with an amplitude controlled by the amplitude control 7. Then the actual impedance Z in the vibrator 4 is measured through the impedance measuring circuit 5, where the actual maximum voltage V is then determined by the well known formula: V2=I×Z. This measured maximum voltage V2 is thereafter compared to V1 set previously in memory 6, and the result indicates that, whenever V1 is equal to V2 the tooth 12 is vibrating sympathetically with the preset amplitude; however, whenever V1 is not equal to V2 the tooth is not vibrating sympathetically in accordance with the preset value in memory. In this case, in order to evidentiate the difference in amplitude value, the amplitude control 7 activates a warning red lamp 15, located on the hand piece 1, and in addition a leveling LED 16 which offers a vision of the value of deviation, which allows proper adjustment for tuning the amplitude.
As shown in FIG. 4, an hypodermic syringe 18 with a hollow metal needle 19, are subject to ultrasonic vibrations during an anesthetic injection, through a horn probe tip 2 being gently pressed, as indicated by a double-ended arrow 13, in order to increase the rate of diffusion and penetration of the anesthetic fluid. The horn probe tip 2 is then moved around with light pressure right on the injection point of the gingiva 20, similar to massaging and rubbing as to stimulate circulation and penetration of the anesthetic fluid.
The invention described above is the result of the ascertainment of the cavitation phenomenon within the dental pulp fluid when it is subject to forced ultrasonic vibrations, the value of which are defined and controlled by an electronic system. The invention is beneficial to human health in alleviating toothaches and reducing drastically the use of narcotic for anesthetic purposes related to dental diseases.
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A method to improve infusion and diffusion of local anesthesia into the gum surrounding a decayed tooth by the application of ultrasound vibration to the hypodermic syringe and needle as local anesthesia is being injected into the gum.
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BACKGROUND OF THE INVENTION
The present invention relates to improvements in or relating to switching devices and is more particularly concerned with a technique for transmitting control information across a switching device.
Data is transferred over the Internet by means of a plurality of packet switches in accordance with a standard protocol known as Internet Protocol (IP). IP is a protocol based on the transfer of variable sized portions of data known as packets. All network traffic involves the transportation of packets of data. Packet switches are devices for accepting incoming packets; temporarily storing each packet; and then forwarding the packets to another part of the network. A packet switch receives packets of data on a plurality of input ports and transfers each packet to a specific one of a plurality of output ports. The packets of data can be of variable length or of fixed length. A packet switch may include a router, or routing device, or a circuit switch.
Traffic volume in the Internet is growing exponentially, almost doubling every 3 months, and the capacity of conventional IP routers is insufficient to meet this demand. There is thus an urgent requirement for products that can route IP traffic at extremely large aggregate bandwidths in the order of several terabits per second. Such routing devices are termed “terabit routers”.
Terabit routers require a scalable high capacity communications path between the point at which packets arrive at the router (the “ingress”) and the point at which the packets leave the router (the “egress”).
The packets transferred in accordance with IP can (and do) vary in size. Within routers it has been found useful to pass data in fixed sized units. In routers then data packets are partitioned into small fixed sized units, known as cells.
One suitable technique for implementing a scalable communications path is a backplane device, known as a cell based cross-bar. Data packets are partitioned into cells by a plurality of ingress means for passage across the cross-bar.
The plurality of ingress means provide respective interfaces between incoming communications channels carrying incoming data and the cross-bar. Similarly a plurality of egress means provide respective interfaces between the cross-bar and outgoing communications channels carrying outgoing data.
A general terabit router architecture bears some similarity to conventional router architecture. Packets of data arrive at input port(s) of ingress means and are routed as cells across the cross-bar to a predetermined egress means which reassembles the packets and transmits them across its output port(s). Each ingress means maintains a separate packet queue for each egress means.
The ingress and egress means may be implemented as line interface cards (LICs). Since one of the line functions regularly undertaken by the ingress and egress means is forwarding, LICs may also be known as ‘forwarders’. Further functions include congestion control and maintenance of external interfaces, input ports and output ports.
In a conventional cell based cross-bar, each ingress means is connected to one or more of the egress means. However, each ingress means is only capable of connecting to one egress means at any one time. Likewise, each egress means is only capable of connecting to one ingress means at a time.
All ingress means transmit in parallel and independently across the cross-bar. Furthermore, cell transmission is synchronized with a cell cycle, having a period of, for example, 108.8 ns.
The ingress means simultaneously each transmit a new cell with each new cell cycle. The pattern of transmissions from the ingress means across the cross-bar to the egress means changes at the end of every cell cycle.
A cross-bar controller is provided for efficient allocation of the bandwidth across the cross-bar. It calculates the rates that each ingress means must transmit to each egress means. This is the same as the rate at which data must be transmitted from each packet queue. The calculation makes use of real-time information, including traffic measurements and indications from the ingress means. The indications from the ingress means include monitoring the current rates, queue lengths and buffer full flags. The details of the calculation are discussed more rigorously in the copending British Patent Application Number 9907313.2 (docket number F21558/98P4863).
The cross-bar controller performs a further task; it serves to schedule the transfer of data efficiently across the cross-bar while maintaining the calculated rates. At the end of each cell cycle, the cross-bar controller communicates with the ingress and egress means as follows. First, the cross-bar controller calculates and transmits to each ingress means the identity of the next package queue from which to transmit. Secondly, the cross-bar controller calculates and transmits to each egress means the identity of the ingress from which it must receive.
The architecture described above gives rise to two requirements:
(i) the need for a means for each ingress means to transmit traffic measurements and indications to the cross-bar controller; and
(ii) the need for a means for the cross-bar controller to send configuration information to each ingress and each egress means.
It is possible to provide dedicated communications paths to meet these requirements. However such a solution requires additional hardware, which is expensive in terms of increased power consumption, installation and materials.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to obviate or at least mitigate the aforementioned problems.
In accordance with the present invention, there is provided a switching device for user data in the form of cells, the switching device comprising:
a backplane;
a plurality of ingress means connected to an input side of the backplane;
a plurality of egress means connected to an output side of the backplane;
for each ingress means, associated slicing means for converting cells into slices for transfer across the backplane;
for each egress means, associated de-slicing means for reforming the slices into cells; and
backplane control means for controlling the backplane in accordance with control slices which are interspersed with slices carrying the user data.
Advantageously, the control slices are spaced in time.
Preferably, the control slices are located in predetermined timeslots.
The present invention has the advantage that it is faster and more efficient, as the use of slices rather than the significantly larger cells allows relatively low data rates for control channels without the consequent increase in latency of control traffic that use of cells would impose. Also, it removes the need for separate control hardware for the backplane.
In one embodiment of the present invention, there is provided a router device having a plurality of ingress line function means, a plurality of egress line function means, a backplane and a controller means, wherein the transmission of signals from the plurality of ingress line function means to the controller means and signals from the controller means to each of the ingress line function means and each of the egress line function means takes place across the backplane.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a terabit router architecture;
FIG. 2 illustrates a switching device in accordance with the present invention; and
FIG. 3 illustrates the operation of the slices in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a conventional terabit router architecture 100 in which packets arrive at ingress forwarders 102 , 104 , 106 via their input port(s) (not shown) and are routed across a cross-bar 110 to a correct egress forwarder 120 which transmits them across its output port(s) (not shown). Each ingress forwarder 102 , 104 , 106 maintains a separate packet queue for each egress forwarder 120 .
Ingress forwarder 102 has three queues q 11 , q 12 , q 13 of data packets ready for transfer to three separate egress forwarders (only egress forwarder 120 being shown). Data in q 11 is destined for egress forwarder 120 via the cross-bar 110 . Similarly, three queues q 21 , q 22 , q 23 and q 31 , q 32 , q 33 are formed respectively in each of the ingress forwarders 104 , 106 . Although three queues are shown in each ingress forwarder 102 , it will be appreciated that any number of queues can be present in each ingress forwarder 102 , 104 , 106 .
Generally speaking, each queue may be defined such that j represents the ingress, k represents the egress, and q jk represents the packet queue at the ingress j for the packets destined for egress k.
It will be appreciated that although only one egress forwarder 120 is shown in FIG. 1 , the number of egress forwarders will normally be the same as the number of ingress forwarders.
By way of explanation, a cell based cross-bar is characterised as follows:
a) Each ingress line function may be connected to any egress line functions.
b) Each ingress line function may only be connected to one egress line function at a time.
c) Each egress line function may only be connected to one ingress line function at a time.
d) All ingress line functions transmit in parallel across the cross-bar.
e) Data is transmitted across the cross-bar in small fixed sized cells, for example, a cell size is typically 64 octets.
f) Cell transmission is synchronised across all the ingress line functions. This means that for each cell cycle, each ingress line function starts transmitting the next cell at the same time.
g) The cross-bar is reconfigured at the end of every cell cycle.
As shown in FIG. 1 , packets of data arriving at the ingress forwarders 102 , 104 , 106 via their input port(s) (not shown) and are routed across the cross-bar 120 to the correct egress forwarders 120 which transmits them across its output port(s) (also not shown). Each ingress forwarder 102 , 104 , 106 maintains a separate packet queue for each egress forwarder 120 , for example q 11 , q 12 , q 13 , q 21 , q 22 , q 23 , q 31 , q 32 , q 33 .
A cell based cross-bar arrangement 200 in accordance with the present invention is shown in FIG. 2 . The arrangement 200 comprises a plurality of ingress forwarders 210 and a plurality of egress forwarders 220 connected to a cross-bar or backplane 230 . Here, each ingress forwarder 212 , 214 , 216 , 218 may be connected to one or more of the egress forwarders 222 , 224 , 226 , 228 . However, as mentioned above, each ingress forwarder 212 , 214 , 216 , 218 may only be connected to one egress forwarder 222 , 224 , 226 , 228 at a time and each egress forwarder 222 , 224 , 226 , 228 may only be connected to one ingress forwarder at a time 212 , 214 , 216 , 218 .
The cross-bar arrangement 200 is controlled by a cross-bar controller 240 which is physically connected to the backplane 230 via connection 232 . The cross-bar controller 240 is also logically connected to each ingress forwarder 212 , 214 , 216 , 218 via logical links 242 , 244 and to each egress forwarder 222 , 224 , 226 , 228 via logical link 246 . The cross-bar controller 240 coordinates the transmission and reception of cells, via links 242 , 244 , 246 .
The term ‘logical link’ means that there is no physical connection between the cross-bar controller 240 and the ingress and egress forwarders 212 , 214 , 216 , 218 , 222 , 224 , 226 , 228 , and all transfer of control information either from or to the cross-bar controller 240 is made via the backplane 230 .
Each ingress forwarder 212 , 214 , 216 , 218 communicates traffic measurements and notifications for the use of the cross-bar controller 240 , via logical link 242 . The cross-bar controller 240 communicates to each ingress forwarder 212 , 214 , 216 , 218 which cell it is to send next, via logical link 244 . The cross-bar controller 240 also communicates to each egress forwarder 222 , 224 , 226 , 228 information indicating from which ingress forwarder 212 , 214 , 216 , 218 to receive data, via logical link 246 . The cross-bar controller 240 allocates connections between ingress forwarders 212 , 214 , 216 , 218 and egress forwarders 222 , 224 , 226 , 228 and informs the respective forwarders accordingly for each cell cycle in turn.
In accordance with the present invention, the backplane 230 is configured such that data is transmitted thereacross in slices. A slice is a fixed size portion of a cell—typically each cell is subdivided into eight slices.
Each ingress forwarder 212 , 214 , 216 , 218 includes slicing means 252 , 254 , 256 , 258 for dividing cells into slices for transmission across the backplane 230 . Each egress forwarder 222 , 224 , 226 , 228 includes de-slicing means 262 , 264 , 266 , 268 for receiving slices from the backplane 230 re-forming the original cells. The backplane 230 deals only with slices and not cells.
Cells are input to ingress forwarders 212 , 214 , 216 , 218 , the cells are sliced in the slicing means 252 , 254 , 256 , 258 and transmitted across the backplane 230 to de-slicing means 262 , 264 , 266 , 268 in the egress forwarders 222 , 224 , 226 , 228 and the output from each egress forwarder 222 , 224 , 226 , 228 is in the form of cells.
The ingress and egress forwarders 212 , 214 , 216 , 218 , 222 , 224 , 226 , 228 are synchronised so that they each send or receive slices simultaneously. At each slice time, each ingress forwarder 212 , 214 , 216 , 218 will transmit a slice which can be received by one or more egress forwarders 222 , 224 , 226 , 228 . Likewise, at each slice time, each egress forwarder 222 , 224 , 226 , 228 can receive a slice from one and only one ingress forwarder 212 , 214 , 216 , 218 . Each egress forwarder 222 , 224 , 226 , 228 is responsible for selecting the correct slice.
As the backplane 230 only operates on slices, the cross-bar controller 240 includes a slicing means 270 for providing control information in the form of slices. In accordance with the present invention, the control information from the cross-bar controller 240 is interleaved with user data across the backplane 230 .
User data is conveyed across the backplane 230 as cells consisting of some fixed integral number of slices. This is described in more detail with reference to FIG. 3 .
In FIG. 3 , slice timeslot patterns 302 , 304 , 306 , 308 for each of the ingress forwarders 212 , 214 , 216 , 218 of FIG. 2 are shown. Each slice timeslot pattern 302 , 304 , 306 , 308 is different and comprises a control slice timeslot 312 , 314 , 316 , 318 for carrying control information from the associated ingress forwarder 212 , 214 , 216 , 218 to the cross-bar controller 240 , a control slice timeslot 322 , 324 , 326 , 328 for carrying control information from the cross-bar controller 240 to each ingress forwarder 212 , 214 , 216 , 218 , and a control timeslot 332 , 334 , 336 , 338 for carrying control information from the cross-bar controller 240 to the egress forwarders 222 , 224 , 226 , 228 . As shown, for each ingress forwarder 212 , 214 , 216 , 218 , the position of its control slice timeslots 312 , 314 , 316 , 318 , 322 , 324 , 326 , 328 , 332 , 334 , 336 , 338 is different to each other ingress forwarder.
Data to be transferred across the backplane 230 in the form of slices are fitted into slice timeslots around the control slice timeslots. For example, if ingress forwarder 212 has eight data slices to transmit, it will place the first slice in the first timeslot before control slice timeslot 312 , six slices in the next six timeslots following the control slice timeslot 312 and the last slice in the timeslot following the control slice timeslot 322 . Similarly, for ingress forwarder 214 having eight data slices to transmit, the first three slices will be placed in the three timeslots prior to the control slice timeslot 314 and the remaining five timeslots will be in the five timeslots following the control slice timeslot 314 , and so on.
If ingress forwarder 216 has fifteen slices to transmit, then the first five slices are placed in the first five timeslots, the next six slices are placed in the six timeslots following the control slice timeslot 316 , the next two slices are placed in the two timeslots following the control slice timeslot 326 , and the remaining two slices are placed in the two timeslots following the control slice timeslot 336 . Similarly, for ingress forwarder 218 having fifteen slices to transmit, the first seven slices will be placed in the first seven timeslots, the next six slices will be placed in the six timeslots following the control slice timeslot 318 , and the last two slices will be placed in the two timeslots between the control slice timeslots 328 and 338 .
For transmission of control information from ingress forwarders 212 , 214 , 216 , 218 to the cross-bar controller 240 , each ingress forwarder 212 , 214 , 216 , 218 is assigned a dedicated slice timeslot which it uses to send information to the controller 240 . The timeslots do not overlap. When the timeslot assigned to a given ingress forwarder 212 , 214 , 216 , 218 is reached, that ingress forwarder transmits a slice of control information, interrupting its transmission of user data. The cross-bar controller 240 selects the ingress forwarder 212 , 214 , 216 , 218 from which to receive control information according to the current timeslot number.
When receiving user data from a given ingress forwarder 212 , 214 , 216 , 218 , an egress forwarder 222 , 224 , 226 , 228 ignores information in a slice timeslot if that timeslot is assigned to the given ingress forwarder for transmission of control information. The position of the control slice timeslot is determined by fixed global information, for example, the position of a forwarder in a physical rack of forwarders or LICs. This makes it simple for each forwarder to determine which slice timeslot is used by each forwarder for this purpose.
For transmission of control information from the cross-bar controller 240 to ingress and egress forwarders 212 , 214 , 216 , 218 , 222 , 224 , 226 , 228 , the same technique is used except that each forwarder is assigned a dedicated timeslot on which to receive.
Where the backplane 230 supports broadcast traffic, that is, the transmission of information to all ingress and/or egress forwarders simultaneously, this can be achieved by using a single control slice timeslot. All recipients would receive information using this timeslot. Such a control slice timeslot may be in addition to the control slice timeslots 312 , 314 , 316 , 318 , 322 , 324 , 326 , 328 , 332 , 334 , 336 , 338 , or it may replace one or more of such timeslots in accordance with a particular application.
It will be readily understood that although the preceding discussion has been in terms of optical terabit routers, the apparatus of the present invention are capable of implementation in a wide variety of routing devices, including switches and routers, and that these routing devices can be either purely electronic, part electronic/part optical or optical in nature.
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A router device has a plurality of ingress line interface cards (LICs), a plurality of egress LIC's, a backplane and a controller. Transmission of signals from the ingress LICs to the controller, and from the controller to each of the ingress and egress LICs takes place across the backplane. Each ingress LIC is provided with a dedicated timeslot in which it can send information to the controller via connection. Information is sent in a slice within the dedicated timeslot and each egress LIC ignores data sent by a given ingress LIC within the timeslot assigned to said ingress LIC. A similar system is used for transmission of communications from the controller to the LICs. It is thus possible to avoid provision of additional, dedicated communications paths between the LICs (ingress and egress) and the controller.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of copending application Ser. No. 385,695, filed on July 26, 1989, now U.S. Pat. No. 4,995,783, entitled "Material Handling Platform For Material Transport Vehicle".
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a material handling platform that may be installed on a material transport vehicle for carrying material on the platform and for rotating material relative to the longitudinal axis of the material transport vehicle. The material handling platform is particularly adapted for use in underground mining operations but the platform has applications other than for underground mining.
2. Description of the Prior Art
Various types of vehicles have been provided with turntables on the vehicles for one purpose or another. U.S. Pat. No. 4,553,893 discloses a rotary turntable that may be placed in a production line to move the products to various locations.
U.S. Pat. No. 1,966,866 discloses a vehicle on endless tracks which has a turntable onto which a cement mixer may be driven. The turntable can be turned to permit the cement mixer to discharge cement to the sides of the vehicle.
U.S. Pat. Nos. 1,349,012 and 1,663,832 also show vehicles having turntables which may be utilized in paving and roadbed construction. U.S. Pat. No. 817,434 and U.S. Pat. No. 3,583,328 disclose turntables mounted on railway type vehicles. U.S. Pat. No. 3,830,385 discloses a baggage cart which has a turntable mounted on its top surface. U.S. Pat. No. 2,572,776, U.S. Pat. No. 3,190,475, U.S. Pat. No. 1,384,077 and U.S. Pat. No. Re. 15,976 all show various types of portable turntables on vehicles.
None of the foregoing prior art shows a platform having a turntable wherein the platform may be both raised and lowered and also tilted and which may be readily secured to or removed from a material transport vehicle as the requirements of a particular job may require.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a material handling platform for a material transport vehicle wherein the platform has a forwardly extending base member with a top surface and a lower surface that is movably connected to a tilt frame so that the base member can be moved vertically relative to the tilt frame between a position at ground level and various positions substantially above ground level. First actuating means are connected to the base member and the tilt frame to move the base member vertically relative to the tilt frame upon actuation of the first actuating means and to maintain base member in a fixed position relative to the tilt frame when not actuated. A horizontal pivot is fixed to the material transport vehicle and the tilt frame is pivotally secured to the vehicle pivot means. A second actuating means connected to the vehicle and to the tilt frame pivots the tilt frame relative to the vehicle about the horizontal pivot means upon actuation of a second actuating means and maintains the tilt frame in a fixed position and relative to the vehicle when not actuated. A turntable which forms a portion of the area of the top surface of the base member is rotatably supported by the base member for movement with the base member and for rotation relative to the base member. A third actuating means is connected to the turntable and to the base member to turn the turntable relative to the base member when actuated and to maintain the turntable in a fixed position relative to the base member when not actuated.
Further, in accordance with the present invention, a material handling platform for a material transport vehicle is provided which has a forwardly extending base member that has a material handling top surface movably connected to a tilt frame. The base member may be moved vertically relative to the tilt frame between a position at ground level and positions substantially above ground level. A first actuating means which includes a double action hydraulic piston and cylinder is connected to the base member and to the tilt frame to move the base member vertically relative to the tilt frame upon actuation of the first actuating means and to maintain the base member in a fixed position relative to the tilt frame when not actuated. A horizontal pivot means is fixed to the front end of the vehicle to pivotally receive the tilt frame. A second actuating means, including a double action hydraulic piston and cylinder, is connected to the vehicle and to the tilt frame to pivot the tilt frame relative to the vehicle about the horizontal pivot means upon actuation of the second actuating means and to maintain the tilt frame in a fixed position relative to the vehicle when not actuated. A turntable forming more than fifty percent (50%) of the area of the material handling top surface of the base member is provided with the turntable being rotatably supported by the base member for movement with the base member and for rotation relative to the base member. A third actuating means, including a double action rotary vane hydraulic motor is connected to the turntable and to the base member to turn the turntable relative to the base member when actuated and to maintain the turntable in a fixed position relative to the base member when not actuated. A source of fluid under pressure is located on the material transport vehicle and hydraulic control lines and valves connect the hydraulic fluid source with the first actuating means, with the second actuating means, and with the third actuating means so that the actuating means may be selectively actuated to control the position of the base member and the turntable.
Still further in accordance with the present invention, there is provided a method of placing an additional roof support in position adjacent the long wall of an underground mine. The method includes placing a roof support to be transported on the material handling platform of a material transport vehicle having a device that enables the load on the platform to be rotated relative to the longitudinal axis of the vehicle. The roof support is rotated so that the longest dimension of the roof support is aligned with the longitudinal axis of the vehicle and the vehicle is moved along the long wall to the position where the transported roof support is to be placed. The roof support is then rotated on the material handling platform 90° so that the longest dimension of the roof support is at a right angle to the vehicle longitudinal axis and thereafter the transported roof support is removed from the vehicle material handling platform onto the floor of the underground mine.
Accordingly, a principal object of the present invention is to provide a material handling platform for a material transport vehicle which has a rotatable turntable on the top surface of the platform and wherein the platform may be lifted vertically relative to the vehicle and may be tilted relative to the vehicle.
Another object of the present invention is to provide a material handling platform for a material transport vehicle that may be readily controlled to perform a variety of tasks.
A further object of the present invention is to provide a method of placing an additional roof support in position adjacent to the long wall of an underground mine in an efficient manner.
These and other objects of the present invention will become apparent as this description proceeds in conjunction with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the material handling platform of the present invention in position on a material transport vehicle.
FIG. 2 is a top plan view of the material handling platform.
FIG. 3 is a view in side elevation of the material handling platform of the present invention showing the platform in an elevated position in phantom lines.
FIG. 4 is an end elevation view of a material handling platform as viewed from the left side of FIG. 2.
FIG. 5 is a sectional view of the base member of the material handling platform taken along line 5--5 of FIG. 4.
FIG. 6 is an elevational view of the base member as viewed from the right side of FIG. 5.
FIG. 7 is an elevational view of the material handling platform as viewed from the right side of FIG. 3 with certain parts removed for clarity.
FIG. 8 is a sectional view taken along line 8--8 of FIG. 7 showing details of the lifting actuator for the material handling platform base member.
FIG. 9 is a fragmentary sectional view showing details of the horizontal rollers and the ring guide for the turntable.
FIG. 10 is a fragmentary diagrammatic illustration of the tilt mechanism of the present invention showing the material handling platform in different tilted positions.
FIG. 11 is a side elevational view of the material handling platform of the present invention with a mine roof support being transported thereon.
FIG. 12 is a fragmentary top plan view of an underground mine with a long wall mining machine therein showing the material handling platform of the present invention being utilized in placing the roof supports.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, and particularly to FIG. 1, there is shown a perspective view of a material handling platform indicated generally by the numeral 10 which is affixed to and carried by a material transport vehicle indicated generally by the numeral 12. The material transport vehicle 12 is preferably the type of vehicle disclosed in U.S. Pat. No. 4,199,299 and U.S. Pat. No. 4,411,583, both of which are assigned to the assignee herein. It should be understood that the vehicle disclosed in the aforesaid patents is the preferred type of material transport vehicle 12 but that the material handling platform 10 of the present invention may be utilized with equal facility on other types of material transport vehicles such as back hoes, front end loaders, tractors and general utility vehicles. When utilized with the vehicles disclosed in U.S. Pat. No. 4,199,299 and U.S. Pat. No. 4,411,583, the material handling platform 10 is attached directly to the vehicle body and the boom arrangement shown in the aforesaid U.S. patents is removed from the vehicle body prior to installation of the material handling platform 10 of the present invention.
Referring to FIGS. 2, 3 and 4, the material handling platform 10 is formed from a base member 14 having a top wall 16 and a bottom wall 18 that are generally parallel to each other. The top wall 16 has an angled end portion 20 which permits material to slide up onto the top wall 16 of the platform. The base member 14 also has a vertical upstanding wall 22 that extends upwardly from base member 14. Wall 22 has a rectangular opening 24 formed therein so that a winch cable 25 may be passed through opening 24 from a winch 27 on the vehicle 12, as shown in FIG. 1.
FIGS. 5 and 6 illustrate the base member 14 of the platform 10 in greater detail. As seen in FIGS. 2, 5 and 6, the base member 14 has a pair of guides 26 formed at the rear of upstanding vertical wall 22. The guides 26 guide the base member 14 for vertical movement relative to a pair of mating receiving guides 28 that are formed on tilt frame 30 (FIGS. 2 and 3).
As may best be seen in FIGS. 2, 3, 7 and 8, the tilt frame 30 slidingly receives guides 26 of base member 14 within receiving guides 28, respectively, so that base member 14 may be moved vertically relative to tilt frame 30. The tilt frame 30 has a pair of yokes 32 which extend to the rear of the tilt frame. The yokes 32 have pivot apertures or bores 34 formed therein to receive a pivot pin 35 secured to the front end of the vehicle as shown in FIG. 11 so that tilt frame 30 may pivot relative to the vehicle 12 about the pivot means that passes through pivot apertures 34 in yokes 32.
As best seen in FIGS. 7 and 8, a pair of piston brackets 36 are fixed to the tilt frame 30 within receiving guides 28. The pair of piston brackets 36 each receive a pin 40 that is attached to piston 38 of a piston-cylinder hydraulic actuator. The cylinder 42 of the hydraulic actuator is secured to a bracket 26a that is fixed to guides 26, as the case may be, that is part of base member 14. With such an arrangement, the double acting hydraulic actuator formed of piston 38 and cylinder 42 may raise and lower base member 14 relative to tilt frame 30 as illustrated in FIG. 3. With the double acting arrangement, the base member 14 may be stopped in any number of vertical positions relative to tilt frame 30 by closing all valves and trapping fluid at a specified level within the cylinder 42.
The tilt frame 30 has an elongated opening 44 formed to admit the winch cable 25 through the tilt frame 30. The opening 44 in tilt frame 30 registers with opening 24 in vertical wall 22 of base member 14. Because of the elongation of the openings, the winch cable 25 may readily pass through both the base member 14 and tilt frame 30 without being pinched no matter what vertical position the base member 14 is in relative to tilt frame 30. The winch cable 25 includes a hook 45 which may be attached to a load to be carried on the platform 10 as shown in FIG. 11. The load may be pulled onto platform 10 over inclined end 20 of the base member 14 by actuating the winch 27 on the vehicle 12.
As best seen in FIGS. 2, 3 and 7, the tilt frame 30 has brackets 46 formed thereon so that pistons 48 may be pinned by pins 50 to the brackets 46. The pistons 48 are part of a double acting piston-cylinder actuator which includes cylinder 52. Cylinder 52 has a bracket with an aperture 54 which attaches to a pivot means (not shown) that is fixed to the material transport vehicle 12. As may be seen in FIG. 10, when the piston 48 and cylinder 52 are actuated they force the tilt frame 30 to pivot about pivot apertures 34 that are pivotally secured to vehicle 12. FIG. 10 shows, in phantom lines, an alternate position of the tilt frame 30. Shown in FIG. 10, tilt frame 30 may pivot about aperture 34 a total amount equal to angle A. In most cases, angle A will be a total of 12° so that the base number 14 may pivot 6° below the horizontal and 6° above the horizontal position shown in FIG. 3.
The piston 48 and cylinder 52 provide a double acting hydraulic piston-cylinder actuator which not only serves to tilt the tilt frame 30 relative to vehicle 12 but which also may fix the position of the tilt frame 30 relative to vehicle 12 while the piston 38 and cylinder 42 are not actuated.
As best seen in FIGS. 2 and 5, the top wall 16 of base member 14 has a turntable 56 positioned therein. Turntable 56 covers in excess of fifty percent (50%) of the total area of the top wall 16 of base member 14. The turntable 56 is supported by a center column 58 and by rollers 60 so that it may support heavy loads and be rotated relative to the base member 14 with the heavy weight thereon. The center column 58 is journaled for rotation relative to the base member 14. Rollers 60 are supported on brackets 62 fixed to base member 14. A circular flange 64 is fixed to the bottom of turntable 56 and extends around the periphery of turntable 56. Circular flange 64 rides upon the rollers 60 to support the weight of the turntable 56 and any material that is carried on turntable 56. As seen in FIGS. 3 and 5, the upper surface of turntable 56 extends above the top wall 16 of base member 14. A vane type hydraulic motor (not shown) is secured to center column 58 to rotate turntable 56 upon actuation of the hydraulic motor. The hydraulic motor is double acting so that it may be utilized to rotate the turntable in either direction and it may also be utilized to fix the turntable in a fixed position when the hydraulic motor is not actuated. The turntable 56 is constructed to rotate a total of 190° relative to base member 14.
The rollers 60 on brackets 62 are positioned in relatively closely spaced relation around the periphery of turntable 56. There are 12 sets of brackets 62 and rollers 60 to provide vertical support for the turntable, where desired, additional brackets 62 and rollers 60 may be utilized to provide additional support for the turntable 56. The turntable 56 is guided horizontally by horizontal rollers 66 that are rotatably journaled over posts 68 (FIG. 9). Posts 68 are fixed to bottom wall 13 of base member 14. A guide ring 70 is fixed to turntable 56 and rides against rollers 66 to maintain turntable 56 in proper horizontal position. There are four posts 68 and rollers 66 located around turntable 56. As seen in FIG. 2, access ports 72 provide access to rollers 66 through the top wall 16 of base member 14.
When positioned on a material transport vehicle 12, the material handling platform 10 of the present invention may be raised and lowered by actuating pistons 38 in cylinders 42 to raise and lower the base member 14 relative to the tilt frame 30 as shown in FIG. 3. When pistons 48 in cylinders 52 are actuated, the tilt frame may be pivoted about pivot aperture 34 relative to vehicle 12 through a total angle A as shown in FIG. 10. When the vane type motor actuator for turntable 56 is actuated, turntable 56 may be rotated through 190° relative to base member 14.
In the foregoing description, the actuators for the various elements of the material handling platform 10 have been described as hydraulic motor type actuators and hydraulic piston-cylinder type actuators. It will be appreciated that the actuators will have appropriate control lines and appropriate control valves to control the hydraulic fluid that actuates the various actuators. The control lines, control valves and actuators themselves are conventional units and form no part of the present invention. The control lines and control valves will pass through the operator's station located on the material handling transport vehicle so that the operator of the vehicle can control the various positions of the material handling platform. The typical material transport vehicle 12 will have a source of hydraulic fluid under pressure to operate the various actuators required for controlling the material handling platform 10.
While actuators for the positioning of the material handling platform 10 have been described as hydraulic type actuators, it will be appreciated that other types of actuators such as screw type actuators driven by electric motors could be substituted for piston-cylinder hydraulic type actuators and a worm gear drive powered by an electric motor could be utilized to drive the turntable of the present invention.
The material handling platform of the present invention has many uses in material handling and haulage. It is particularly useful, however, when utilized to position roof supports in an underground mine that is using long wall mining apparatus. In long wall mining, a shear is moved along the face of the mineral being mined and dislodges the mineral from the face. The mineral is deposited upon a conveyer belt immediately behind the face and is removed from the mine in a direction parallel to the face. Typically, hydraulically controlled roof supports are positioned to protect the long wall machine and the conveyer arrangement from the roof which collapses behind the face as the face advances into the seam. As shown in FIGS. 1 and 11, a long wall roof support or jack 74 is carried on the material handling platform 10 of the present invention. In FIG. 11, the roof support is positioned on the platform 10 so that the long dimension of the roof support is aligned with the longitudinal axis of the material transport vehicle 12. In FIG. 1, the roof support 74 for illustrative purposes is illustrated as positioned on platform 10 so that the long dimension of the roof support is perpendicular or at 90° to the longitudinal axis of the material transport vehicle 12.
FIG. 12 is a diagrammatic illustration of a portion of a mine in which the mineral is dislodged by a long wall type mining machine. In FIG. 12, roof supports 76, 78 and 80 are in position at a short distance from the face 82. The conveyer 84 conveys mineral which is mined from the face to an entry located at the end of the mine.
The material transport vehicle 12 with the material handling platform 10 has an additional roof support 74 on the turntable of material handling platform 10. Ordinarily, the vehicle 12 is driven under the roof supports 76, 78 and 80 that are already in position within the mine. As the material transport vehicle 12 is moved under the existing roof supports, the new roof support 74 is positioned on turntable 56 of material platform 10 so that the long dimension of support 74 is aligned with the longitudinal axis of vehicle 12. The roof support 74 is carried with the base member 14 of material handling platform 10 raised from the ground while the vehicle is in motion and the base member 14 is not tilted but is parallel to the ground.
When the vehicle arrives at the place where roof support 74 is to be positioned, the turntable 56 of material handling platform 10 is rotated 90° so that the long dimension of the roof support 74 is at right angles to the longitudinal axis of vehicle 12. The base member 14 of material platform 10 is then tilted and lowered so that the front end of the base member 14 at the angled end 20 touches the ground. The roof support 74 is then slid from the material handling platform 10.
Prior to the use of the above-described method, it was difficult to position the roof support in its proper position within the long wall mining system since turning of the roof support was difficult. With the present method and the material handling platform of the present invention, placing a roof support within a long wall mine is greatly facilitated.
According to the provisions of the patent statutes, we have explained the principle, preferred construction and mode of operation of our invention and have illustrated and described what we now consider to represent its best embodiment. However, it should be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically illustrated and described.
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A material handling platform is pivotally attached to the front of the material transport vehicle. Actuator means raise and lower the platform. The platform is arranged to tilt relative to the vehicle about a horizontal pivot at the front of the vehicle. A turntable is mounted on the platform. The material handling platform positions roof supports in an underground mine adjacent a long wall mining machine. The roof supports are transported by the material transport vehicle carrying the material handling platform with the longest dimension of the roof support aligned with the longitudinal axis of the vehicle. After the roof support reaches the position where it is to be installed, the roof support is turned relative to the vehicle by turning the turntable of the material handling platform so that the longest dimension of the roof support is at right angles to the longitudinal axis of the vehicle. The roof support is then removed from the vehicle by lowering and tilting the platform relative to the vehicle.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and apparatus for measuring the position of a ferrule of a laser module, particularly to a method and apparatus for measuring the position of a ferrule of a laser module for compensating the shift of the ferrule after the laser module is welded.
2. Description of the Related Art
There are many types of laser module packaging, and the co-axial type and the box type are broadly used. The greatest challenge for the co-axial type of laser module packaging is to use a reliable and accurate jointing process. During the welding process, the rapid solidification of the welded region and the associated material shrinkage often cause a postweld shift (PWS) between the welded components. For a typical single-mode-fiber application, if the PWS-induced fiber alignment shift by the laser-welding-jointing process is even only a few micrometers, up to 50% or greater loss in the couple power may occur. During the solidification, shrinkage causes many different levels of shift, and there are many factors affecting the shift, such as the input welding energy, the joint geometric design and material's conditions. Since the solidification- shrinkage-induced PWS is a nonlinear behavior, it is a difficult task to analyze the PWS.
For the present laser module packaging, there is still not a quantitative measurement or a compensation principle for welded shift. In a conventional skill, it is measured by using hands to estimate the direction and level of the PWS. However, the sensitivity of the PWS for a coupled efficiency is smaller than 1 μm, and thus the measurement by using hands is not a quantitative measurement and is not accurately estimated, so that the additional welding process is inefficient, and the efficiency and yield of laser module packaging cannot be effectively improved.
Consequently, there is an existing need for a method and apparatus for measuring the position of a ferrule of a laser module.
SUMMARY OF THE INVENTION
One objective of the present invention is to provide a method and apparatus for measuring the position of a ferrule of a laser module. By utilizing the method and apparatus of the invention, the quantitative measurement and correction to the effect of the postweld-shift (PWS) on the fiber alignment shifts in laser-welded laser module packaging is achieved. Therefore, the reliable laser modules with high yield and high performance used in low-cost lightwave transmission systems may be developed and fabricated.
Another objective of the present invention is to provide a measuring apparatus for measuring the position of a ferrule of a laser module. The measuring apparatus comprises an XYZ stage, a base, a receiving portion and a laser displacement meter (LDM). The base has a first slot, and the base is connected to the XYZ stage by a first fixing device and the first slot. The first slot extends along a vertical direction. Whereby, the base can be fixed in different positions of the XYZ stage. The receiving portion is connected to the base and has a second slot. The laser displacement meter is used for measuring the distance between the ferrule and the laser displacement meter. The laser displacement meter is connected to the receiving portion by a second fixing device and the second slot. The second slot extends along a horizontal direction. Whereby, the laser displacement meter can be fixed in different positions of the receiving portion.
Still another objective of the present invention is to provide a method for measuring the position of a ferrule of a laser module. The method of the invention comprises the steps of:
(a) providing a laser module having a ferrule; (b) measuring the distance between the ferrule and the laser displacement meter by utilizing a laser displacement meter; (c) rotating the ferrule by a plurality of times and measuring the distance between the ferrule and the laser displacement meter of different angles respectively; (d) changing the corresponding height between the ferrule and the laser displacement meter; (e) measuring the distance between the ferrule and the laser displacement meter by utilizing the laser displacement meter; (f) rotating the ferrule by a plurality of times and measuring the distance between the ferrule and the laser displacement meter of different angles respectively; and (g) obtaining the position of the center of the ferrule according to the above measurements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a measuring apparatus for measuring the position of a ferrule of a laser module according to the present invention;
FIG. 2 shows a flowchart of the process of a method for measuring the position of a ferrule of a laser module according to the present invention;
FIG. 3 shows a ferrule of the present invention;
FIG. 4 shows the ferrule in three-dimensional coordinates of the present invention;
FIG. 5 shows a flowchart of the process of compensating the shift of the ferrule after the laser module is welded according to the present invention; and
FIG. 6 shows the ferrule after welding of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , it shows a measuring apparatus for measuring the position of a ferrule of a laser module according to the present invention. The measuring apparatus 1 of the present invention comprises an XYZ stage 11 , a base 12 , a receiving portion 13 , two sidewalls 14 and a laser displacement meter (LDM) 15 . The base 12 is connected to the XYZ stage 11 , and the base 12 can move in three-dimensional directions (x-direction, y-direction and z-direction) on the XYZ stage 11 .
The base 12 has a first slot 121 , and the base 12 is detachably connected to the XYZ stage 11 by a first fixing device (for example a screw) (not shown in the FIG. 1 ) and the first slot 121 . The first slot 121 extends along the vertical direction (i.e. z-direction), and the length of the first slot 121 is about 0.1 cm to 10 cm. Whereby, the base 12 can be fixed in different positions of the XYZ stage 11 , i.e., the base 12 can be adjusted to a predetermined position after the first fixing device is loosened, and then the base 12 is fixed on the XYZ stage 11 by using the first fixing device through the first slot 121 . Since the XYZ stage 11 can just move by a limited shift, by utilizing the first slot 121 of the base 12 , the shift of the laser displacement meter 15 in the vertical direction increases. In the embodiment, the base 12 is plate-shaped and extends along the vertical direction.
The laser displacement meter 15 is used for measuring the distance between the ferrule and the laser displacement meter 15 . The laser displacement meter 15 is a conventional structure. In the embodiment, the laser displacement meter 15 is product of KEYENCE Company, and its type number is LC2430. The advantage of the laser displacement meter 15 is of a resolution of 20 nm and of immediate measurement.
The receiving portion 13 is connected to the base 12 and is used to carry the laser displacement meter 15 . The receiving portion 13 has a second slot 131 . The second slot 131 extends along the y-direction, and the length of the second slot 131 is about 0.1 cm to 10 cm. In the embodiment, the receiving portion 13 is plate-shaped and extends along the horizontal direction (y-direction), and the receiving portion 13 is perpendicular to the base 12 . The laser displacement meter 15 is detachably connected to the receiving portion 13 by a second fixing device (for example a screw 132 ) through the second slot 131 . Whereby, the laser displacement meter 15 can be fixed in different positions of the receiving portion 13 , i.e., the laser displacement meter 15 can be adjusted to a designated position after the second fixing device 132 is loosened, and then the laser displacement meter 15 is fixed on the receiving portion 13 by using the second fixing device 132 through the second slot 131 . Since the XYZ stage 11 can only move by a limited shift, by utilizing the second slot 131 of the receiving portion 13 , the shift of the laser displacement meter 15 in the horizontal direction (y-direction) increases.
The sidewalls 14 are located at two sides of the receiving portion 13 respectively and extend upwards. Each sidewall 14 has a third slot 141 , and the sidewalls 14 extend along the y-direction by about 0.1 cm to 10 cm. In the embodiment, the sidewalls 14 are plate-shaped and are perpendicular to the receiving portion 13 . A third fixing device (for example a screw 142 of which the length is longer than the distance between the third slots 141 and a nut 143 ) (not shown in FIG. 1 ) is used for enhancing the connection between the third slots 141 to prevent the laser displacement meter 15 from rotating. The width of the laser displacement meter 15 is equal to the distance between the sidewalls 14 so that the sidewalls 14 can hold the laser displacement meter 15 securely. The laser displacement meter 15 contacts with the screw 142 and is fixed by the screw 142 .
Referring to FIG. 2 , it shows a flowchart of the process of a method for measuring the position of a ferrule of a laser module according to the present invention. The operation method and measuring method of the measuring device 1 are described as follows. Referring to FIG. 1 and FIG. 2 , firstly, in step S 201 , a laser module 2 is provided. The laser module 2 comprises a ferrule 21 , a fiber 22 and a housing 23 . The ferrule 21 carries the fiber 22 , and the ferrule 21 is disposed on the housing 23 . The housing 23 is then disposed at a clip 31 of a welding machine 3 .
Referring to FIG. 3 , it shows the ferrule of the present invention. The principle of the present invention is described as follows. In the present invention, the position of the ferrule 21 is represented by the position vector {right arrow over (C 1 C 2 )}, wherein C 1 and C 2 are the centers of the high position Z 1 and the low position Z 2 respectively. Circles S 1 and S 2 are corresponding to Z 1 and Z 2 respectively. The circles S 1 and S 2 are obtained by rotating the welding machine 3 with an angle of 30 degrees, then by quantitatively measuring the distance between the laser displacement meter 15 and the ferrule 21 , and finally by matching with curves.
Referring to FIG. 4 , it shows the ferrule in three-dimensional coordinates of the present invention. Actually, it is impossible for the origin of the position vector {right arrow over (C 1 C 2 )} to be the same as that of the origin of the coordinates O 0 . As shown in FIG. 4 , the origin of the position vector {right arrow over (C 1 C 2 )} moves from O 0 to O 1 on the X-Y plane. The shift of the origin is represented by the angle α between the horizontal axis r of the polar coordinates and the horizontal axis X of the coordinates. In addition, the ferrule 21 circuits round the Z′-axis with a rotating angle θ and circuits round the Y′-axis with an angle of inclination ψ. Therefore, the position vector {right arrow over (C 1 C 2 )} of the ferrule 21 can be described as a function of the above four parameters (r, α, θ and ψ), and the shift of the ferrule 21 after welding can be calculated by the position vectors before and after welding.
Referring to FIG. 1 and FIG. 2 again, according to the above principle, after the housing 23 is mounted on the clip 31 , the laser displacement meter 15 is roughly adjusted to a suitable position by utilizing the first slot 121 and the first fixing device to cooperate with adjusting the vertical height of the base 12 . The detecting light spot of the laser displacement meter 15 focuses on 1500 μm high above the bottom of the ferrule 21 , and the position is defined as the low position Z 1 . Referring to step S 202 , the distance between the ferrule 21 and the laser displacement meter 15 is measured, and at the same time, the XYZ stage 11 must be finely tuned to make the distance between the laser displacement meter 15 and the ferrule 21 closest, and the distance is recorded.
Referring to step S 203 , the clip 31 of the welding machine 3 is used to rotate the ferrule 21 , and the distance between the ferrule 21 and the laser displacement meter 15 of different angles are measured respectively and are recorded. The distances and the angles corresponding to the distances can be used to calculate the center C, of the ferrule 21 at the low position Z 1 . In the embodiment, the closest distance between the ferrule 21 and the laser displacement meter 15 is measured every 30 degrees.
Referring to step S 204 , the corresponding height between the ferrule 21 and the laser displacement meter 15 is changed, and this can be achieved by vertically moving the ferrule 21 , the laser displacement meter 15 or both of the ferrule 21 and the laser displacement meter 15 . In the embodiment, the laser displacement meter 15 is moved upwards to make the detecting light spot of the laser displacement meter 15 focus on 3000 μm high above the bottom of the ferrule 21 , and the position is defined as the high position Z 2 . Referring to step S 205 , the distance between the ferrule 21 and the laser displacement meter 15 is measured, and at the same time, the XYZ stage 11 must be finely tuned to make the distance between the laser displacement meter 15 and the ferrule 21 closest, and the distance is recorded.
Referring to step S 206 , the clip 31 of the welding machine 3 is used to rotate the ferrule 21 , and the closest distance between the ferrule 21 and the laser displacement meter 15 of different angles are measured respectively and are recorded. The distances and the angles corresponding to the distances can calculate the center C 2 of the ferrule 21 at the high position Z 2 . In the embodiment, the closest distance between the ferrule 21 and the laser displacement meter 15 is measured every 30 degrees.
Finally, referring to step S 207 , by utilizing the above measurements, the four parameters (r, α, θ and ψ) for describing the center of the ferrule 21 can be calculated. Since the center of the fiber 22 is the same as the center of the ferrule 21 , the center of the fiber 22 is calculated.
Referring to FIG. 5 , it shows a flowchart of the process of compensating the shift of the ferrule after the laser module is welded according to the present invention. The steps S 301 to S 307 of the compensating method are the above steps S 201 to 207 , and the compensation method is used to calculate the center of the ferrule 21 before welding. The step S 308 shows the welding steps. The bottom surface of the ferrule is welded on the top surface of the housing by a plurality of welding spots 40 by utilizing the laser beam providing by the laser welding machine 3 , as shown in FIG. 6 . Generally, the number of the welding spots 40 is three.
The step S 309 repeats steps S 302 to S 306 to calculate the center of the ferrule 21 after welding. Referring to step S 310 , the level and direction of the shift of the center of the ferrule 21 is calculated by comparing the center of the ferrule before welding in step S 307 and the center of the ferrule after welding in step S 309 .
Finally, referring to step S 311 , an additional welding spot is welded for compensating the shift according to the level and direction of the shift. In the embodiment, the additional welding spot is welded in the direction against the lateral of the ferrule 21 , so that the ferrule 21 has a after-welding shift with a direction against the direction of the antecedent after-welding shift. Those shifts in opposite directions countervail each other so that the final shift becomes smaller.
Referring to list 1 , it shows the measurements of the four parameters (r, α, θ and ψ) by using the compensation method. There are eight modules in the list 1 , wherein the second column is for the before-welding position of the ferrule 21 ; the third column is for the after-welding (not compensated) position of the ferrule 21 ; and the fourth column is for the after-compensating position of the ferrule 21 . The level and direction of the after-welding can be calculated by comparing the second column and the third column. By comparing the second column and the fourth column, the after-compensating position of the ferrule 21 is closer to the original position (the second column) than the uncompensated (the third column) position of the ferrule 21 , i.e., welding an additional welding spot effectively reduces the after-welding shift and reduces the power loss.
While the embodiments have been illustrated and described, various modifications and improvements can be made by those skilled in the art. The embodiments of the present invention are therefore described in an illustrative but not restrictive sense. It is intended that the present invention may not be limited to the particular forms as illustrated, and that all modifications that maintain the spirit and scope of the present invention are within the scope as defined in the appended claims.
List 1: Measurements of the four parameters (r, α, θ and ψ) before
welding, after welding and after compensating
Module
Before welding (μW)
After welding (μW)
After compensating (μW)
number
r(μm)
α(°)
ψ(°)
θ(°)
r(μm)
α(°)
ψ(°)
θ(°)
r(μm)
α(°)
ψ(°)
θ(°)
1
2.93
81.78
0.12
−34.11
3.82
59.67
−0.84
−29.91
3.37
66.73
−0.54
34.25
2
2.96
13.01
0.23
3.64
4.20
−7.18
0.10
−1.20
3.58
−15.22
0.13
5.17
3
1.90
−55.66
0.01
19.21
2.12
−74.30
0.08
30.16
2.01
−64.93
0.02
24.73
4
3.28
209.35
0.06
7.23
3.38
192.16
0.02
2.79
3.33
181.77
0.09
−1.36
5
2.15
36.42
0.07
193.56
2.23
13.46
0.04
188.17
2.19
21.83
−0.01
176.94
6
2.09
355.94
−0.14
17.54
2.51
345.53
−0.02
15.22
2.30
337.29
0.06
20.64
7
1.54
310.72
0.07
−56.32
1.98
288.23
−0.17
−69.13
1.76
274.15
0.11
74.36
8
3.55
77.69
−0.13
−6.47
5.08
50.50
−0.06
−3.57
4.31
59.23
0.16
−7.82
List 2: Power before welding, after welding and after compensating
Coupled
Coupled
Module
power before
power after
Coupled power after
number
welding (μW)
welding (μW)
compensating (μW)
1
524
416
467
2
741
506
597
3
892
759
798
4
912
864
880
5
934
856
875
6
1026
730
802
7
1103
796
897
8
1198
812
1002
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The present invention relates to a method and apparatus for measuring the position of a ferrule of a laser module. The apparatus comprises an XYZ stage, a base, a receiving portion and a laser displacement meter (LDM). The XYZ stage is used for moving in three-dimensional directions. The base has a first slot by which the base is detachably connected to the XYZ stage. The receiving portion is fixed to the base and has a second slot. The laser displacement meter is used for measuring the distance between the ferrule and the laser displacement meter. The laser displacement meter is detachably connected to the receiving portion in the second slot. Whereby, the quantitative measurement and correction to the effect of the postweld-shift (PWS) on the fiber alignment shifts in laser-welded laser module packaging is achieved. Therefore, the reliable laser modules with high yield and high performance used in low-cost lightwave transmission systems may be developed and fabricated.
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Reference is made to a microfiche appendix to this application consisting of one sheet of microfiche bearing thirty-one frames.
The present invention is directed to equipment for maintaining refrigeration systems, and more particularly to a service station for charging automotive air conditioners and like refrigeration equipment.
BACKGROUND AND OBJECTS OF THE INVENTION
Service apparatus for automotive air conditioning systems and like refrigeration equipment heretofore proposed in the art typically include a vacuum pump, a source of lubricant under pressure and a source of refrigerant under pressure, all adapted for selective connection to the equipment under service. In automated service apparatus, the service apparatus is first connected to refrigeration equipment to be charged, and then vacuum time, and oil and refrigerant quantities are set by the operator. The latter are typically accomplished by manipulation of calibrated dials on the apparatus operator panel. Vacuum time depends upon the capacity of the refrigeration equipment under service and the efficiency of the apparatus vacuum pump. For automotive air conditioning system, vacuum time may be on the order of twenty to thirty minutes. Oil and refrigerant charges also depends on system capacity and are specified by the manufacturer. One to ten ounces of oil and two and three-quarters pounds of refrigerant are typical for automotive systems.
When an automatic mode of operation is initiated, the vacuum pump is first operated for the time set to evacuate the refrigeration system under service. The pressurized oil source is then connected to the system for feeding thereto the quantity of oil set by the operator, and the pressurized refrigerant source is then connected to the system for feeding thereto the quantity of refrigerant set by the operator. Typically, the operator is not advised of progress during the successive stages of operation and, in the event of malfunction, is not apprised of the source of such malfunction. Furthermore, in the event of such malfunction or depletion of the oil or refrigerant supplies during a charge cycle, it is typically necessary to rebegin the entire process. Another problem in many prior art devices is difficulty of simply adding an incremental refrigerant charge when equipment under service simply has low refrigerant pressure but does not require a complete recharge. Thus, prior art apparatus are generally characterized by an absence of versatility and by difficulty of operation in use.
A general object of the present invention is to provide apparatus for servicing refrigeration equipment in which the charge variables--i.e. vacuum time, and oil and refrigerant quantities--may be readily programmed by the operator; which implements an automatic mode of operation wherein operating sequence and status is continually indicated to the operator at each stage of operation; which, in the event of malfunction, not only interrupts operation at the stage in which malfunction occurred, but also provides to the operator an error code indicative of the malfunction which occurred; which may either resume operation at the point at which malfunction occurred or rebegin the entire cycle, depending upon the nature of the malfunction; which includes facility for a manual mode of operation for testing apparatus operation; and which includes a multiplicity of self-test and diagnostic features.
A further object of the invention is to provide refrigeration equipment service apparatus of the described character which is economical to manufacture, and which may be easily used by unskilled or semi-skilled operators.
Yet another object of the invention is to provide apparatus of the described character in which a predetermined or preset quantity of refrigerant may be added to refrigeration equipment attached thereto independently of the automatic mode of operation and without requiring that the equipment be completely recharged.
SUMMARY OF THE INVENTION
In accordance with the present invention, a self-contained service station for charging refrigeration equipment includes a vacuum pump, a pressurized oil source and a pressurized refrigerant source adapted for selective connection by electronically controlled valves to refrigeration equipment under service. The oil and refrigerant sources are mounted on a scale which provides electronic signals to a microprocessor-based controller indicative of quantities of oil and refrigerant transferred to the refrigeration equipment. The controller is also coupled to display lamps separately indicative of vacuum, oil and refrigerant stages during each of the automatic, manual and programming modes of operation, to an alphanumeric display at which the operator can observe the charge variable during programming and decrementing variables during each stage of operation, to an operator keypad having separately labeled numeric and sequence control keys, and to a labeled sequence display for indicating mode of operation to the operator.
In the programming mode of operation selectable by an operator using the sequence control keys, time of operation of the vacuum pump and quantities of oil and refrigerant to be transferred to the refrigeration equipment are set using the numeric keys and displayed at the alphanumeric display, and then entered and stored in the controller if satisfactory. In an automatic service cycle, which is initiated by entering the automatic mode of operation, the programmed time of operation of the vacuum pump is initially shown at the alphanumeric display, and then decremented during pump operation to indicate actual progress of the vacuum stage to the operator. Likewise, during each of the oil and refrigerant transfer stages, the programmed quantities are initially shown on the alphanumeric display and decremented responsive to scale output signals to indicate actual oil and refrigerant transfer. In the event of malfunction, automatic operation is terminated and a corresponding error code is indicated at the alphanumeric display.
The sequence display indicates to the operator the mode of operation of the apparatus and is coordinated with the sequence control keys of the operator keypad to indicate the manner in which other operating modes may be initiated. In a manual mode of operation, each of the vacuum and refrigerant operating stages may be selectively sequenced by the operator for testing operation thereof. The operator may initiate transfer of a predetermined quantity of refrigerant at the sequence control keys independently of the automatic mode of operation and independently of the programmed quantity of refrigerant to be transferred to the refrigeration equipment during such automatic mode of operation. A scale test mode of operation may be initiated by the operator in which weight sensed by the scale is directly indicated at the alphanumeric display.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with additional objects, features and advantages thereof, will be best understood from the following description, the appended claims and the accompanying drawings in which:
FIG. 1 is a perspective view of an automatic air conditioning service station embodying the principles of the present invention;
FIG. 2 is an enlarged fragmentary view of a portion of the control panel of the station of FIG. 1;
FIG. 3 is a schematic diagram of the vacuum and fluid transfer plumbing of the apparatus of FIG. 1 coupled to exemplary refrigeration equipment;
FIG. 4 is a functional block diagram of the automatic service station electronics in accordance with the present invention; and
FIGS. 5-15 are composite flow charts which illustrate operator activity and programmed operation of the automatic service station system in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates a presently preferred embodiment 20 of service station apparatus in accordance with the invention as comprising a generally rectangular cabinet 22 mounted on the casters 24 for translation along the floor of a service center. A pair of hinged doors 26 provide access to the internal pumps and tanks (FIG. 3), and a pair of drawers 28 may hold suitable tools or other equipment. An electronics enclosure 30 is mounted on cabinet 22 and has a sloping front panel 32 with operator displays and switches mounted thereon. A pair of hoses 34,36 extend from a side wall of enclosure 30 for respective connection to the high pressure side and low pressure side of refrigeration equipment to be serviced. High side hose 34 includes a manual valve 38. Operator panel 32 has mounted thereon a LOW SIDE compound gage 40 (FIGS. 1 and 3) coupled to hose 36 for indicating low-side system pressure, and for indicating vacuum level during the vacuum stage of a charging cycle (to be described). Likewise, a HIGH SIDE pressure gage 42 is coupled to hose 34 for indicating high-side pressure of equipment under service. Three lamps 44,46 and 48 laterally spaced from each other between gages 40,42 respectively indicate VACUUM, OIL and REFRIGERANT stages of operation of the internal control circuitry, and are so labeled on panel 32. An EXHAUST switch 50 and a MAIN POWER switch 52 are also mounted on panel 32 beneath gage 42. A complete set 53 of printed operating instructions is mounted on panel 32 beneath gage 40.
Referring now to both FIGS. 1 and 2, operator panel 32 further includes a four-digit seven-segment alphanumeric display 54, and an LED 56 beneath display 54 for indicating a LOW REFRIGERANT WARNING. A control keypad 58 beneath display 54 includes a plurality of numeric keys successively labeled "1" through "0", and a series of individually labeled sequence control keys. An operating sequence display 60 laterally adjacent to keypad 58 includes an LED 62 for indicating that the apparatus control electronics is in a PROGRAM mode of operation, a second LED 64 for indicating an AUTOMATIC mode of operation and a third LED 66 for indicating a HOLD status. Each LED 62-66 is positioned adjacent to printed indicia indicating the associated mode of operation. A three-function key 68 in keypad 58 is coordinated with functional indicia 68a,68b and 68c printed in sequence display 60 for changing modes of operation. More particularly, when the control electronics is in the PROGRAM mode and LED 62 is illuminated, depression of key 68 functions to START the AUTOMATIC mode of operation. When in the AUTOMATIC mode of operation with LED 64 illuminated, depression of key 68 functions to HOLD such AUTOMATIC operation and transfer the system to a HOLD or standby mode. In such HOLD or standby mode with LED 66 illuminated, depression of key 68 functions to CONTinue or return to the AUTOMATIC mode. A separate RESET CYCLE key 70 in keypad 58 transfers the control electronics from the HOLD mode to the PROGRAM mode. Keypad 58 further includes an ENTER key 72 for entering numeric data and a REVIEW PROGram key 74 for indexing to the next operating stage to review previously loaded data. A key 76 in keypad 58 functions (in the manner to be described) to ADD a predetermined amount of refrigerant, specifically 0.2 pounds, to the refrigeration equipment under test independently of the AUTOMATIC mode of operation. A further key 78 is employed during a setup operation to PRESSurize the oil reservoir.
FIG. 3 illustrates the "plumbing" of station 20 connected to exemplary refrigeration equipment 80. In such equipment 80, a compressor 82 has a high pressure output connected through a condenser 84, a capillary tube 86 and an evaporator 88 to a low pressure return compressor input. (The preferred embodiment of the invention herein described is constructed and adapted specifically to service and recharge conventional automotive air conditioning equipment. However, it will be appreciated from the foregoing and following discussions that the principles of the invention apply equally as well to other types of refrigerant equipment 80, and the invention is not limited to any specific type of equipment or application.) Within cabinet 22, a bulk tank 90 containing refrigerant under pressure is connected through a solenoid-operated valve 92 and through a low pressure cut-out switch 94 to low side hose 36. A reservoir 96 of oil under pressure is likewise connected through an associated solenoid valve 98 to switch 94, and a vacuum pump 100 is connected through an associated solenoid valve 102 to switch 94. Switch 94 prevents operation of vacuum pump 100 without first exhausting refrigeration equipment 80. An oil catch bottle 104 is connected through a solenoid-operated exhaust valve 106 and through a high pressure cut-out switch 108 to high-side hose 34. Switch 108 has contacts connected to all valves 92,98,102,106 to prevent operation if the high-side pressure exceeds a preselected maximum level, such as three hundred seventy psig. It will be noted that gages 40,42 are connected directly to hoses 34,36 for observation of the pressures therein independently of cut-outs 94,108. Refrigerant tank 90 and oil reservoir 96 are mounted on a platform 110 which is carried by a scale 112, such as a strain gage or moving core scale. Scale 112 provides a d.c. output signal as a function of the weight of platform 110 with tank 90 and reservoir 96 carried thereon.
FIG. 4 illustrates the control electronics 114 of station 20 as comprising a microprocessor 116 having an associated EPROM 118 with microprocessor programming stored therein. Microprocessor 116 receives the output of scale 112 (FIGS. 3 and 4) through an a/d converter 120. Keypad 58 (FIGS. 1, 2 and 4) is likewise coupled to microprocessor 116. A series of solenoid and lamp drivers 122 receive associated control signals from microprocessor 116 and provide outputs to vacuum solenoid valve 102, oil solenoid valve 98 and refrigerant solenoid valve 92 (FIGS. 3 and 4), to VACUUM lamp 44, OIL lamp 46 and REFRIGERANT lamp 48 on operator panel 32 (FIGS. 1 and 4), and to a sonic alert and a vacuum pump relay (not shown). A panel display driver 124 receives control inputs from microprocessor 116 and provides corresponding display drive outputs to alphanumeric display 54, PROGRAM LED 62, HOLD LED 66, AUTOMATIC LED 64 and LOW REFRIGERANT WARNING LED 56 (FIGS. 1, 2 and 4). POWER switch 52 (FIGS. 1 and 4) applies a.c. power from a suitable utility power source (not shown) to a power supply 126 which powers the remainder of the control circuitry. Switch 52 also applies a.c. power to the pump relay (not shown), to solenoid valves 92,98,102, and through EXHAUST switch 50 (FIGS. 1 and 4) to exhaust solenoid valve 106 (FIG. 3).
In a working embodiment of the invention herein disclosed, microprocessor 116 includes a Motorola MC146805E2P microprocessor chip, together with a National Semiconductor 74LS139 decoder and a Motorola 74LS373 latch between the microprocessor chip and a/d converter 102. Drivers 122 include a Motorola MC1413 driver, together with suitable solenoid-drive solid state relays. EPROM 118 comprises a TI TMS2732AJL-35 4K×8 bit EPROM. Converter 120 is an Intersil ICL7109 twelve bit converter. Display driver 124 is a National Semiconductor MM5450 module, and alphanumeric display 54 is a Panasonic LN516RA seven-segment display. The remaining elements of FIG. 4 may be of any suitable type. A program in machine language for operating control circuitry 114 in the manner to be described is provided in the appendix which forms part of this application.
In general, operation of automatic service station apparatus 20 hereinabove described proceeds by first connecting hoses 34,36 to the high pressure and low pressure sides of compressor 82 (FIG. 3) using couplings on the compressor provided for that purpose and any necessary adapter fittings. Gages 40,42 may be employed to determine whether the refrigeration system under service requires repair or recharging. Assuming that some additional charge or a complete recharge is required, power is then applied to station 20 by activation of switch 52 (FIGS. 1 and 4). If only some additional refrigerant charge is required to bring the equipment up to manufacturer specifications, and in accordance with a feature of the invention, key 76 (FIGS. 1 and 2) may be depressed one or more times while observing gages 40,42 until the specified pressures are obtained. Each depression of key 76 functions to ADD 0.2 pounds of refrigerant to the equipment.
If a complete recharge of refrigeration equipment 80 is required, switch 50 is first depressed by the operator to energize exhaust valve 106 and depressurize equipment 80. Programmed vacuum time and oil and refrigerant quantities are then reviewed and reprogrammed as required. (Microprocessor 116 has a battery backup for retaining stored data when POWER switch 52 is off.) Such review and reprogramming is accomplished in the PROGRAM mode of operation, necessitating depression of RESET CYCLE key 70 if required to place the system in the PROGRAM mode. If VACUUM lamp 44 (FIG. 1) is not illuminated, REVIEW PROGram key 74 is repeatedly depressed until lamp 44 is illuminated. Display 54 will then indicate vacuum time last stored in microprocessor 116. If such time is not that desired, the numeric data keys of keypad 58 are depressed in the appropriate sequence to set the desired vacuum time in minutes, which is simultaneously shown on display 54, and key 72 is depressed to ENTER the new vacuum time data. Display 54 will flash once to indicate that the reprogrammed data has been accepted. REVIEW PROGram key 74 is again depressed to extinguish VACUUM lamp 44 and illuminate OIL lamp 46, and the above process is repeated to set oil quantity in ounces. REVIEW PROGram key 74 is again depressed to extinguish OIL lamp 46 and illuminate REFRIGERANT lamp 48, and the process is again repeated to set refrigerant quantity in pounds. The data so entered may again be reviewed, if desired, by repeatedly depressing REVIEW PROGram key 74 to sequentially progress through the vacuum, oil and refrigerant stages, each of which is indicated in turn at lamps 44-48 with the corresponding data being shown at display 54.
When the operator is satisfied with the stored variables, and with EXHAUST switch 50 off, three-function key 68 is depressed to initiate or START the AUTOMATIC mode of operation from the PROGRAM mode. VACUUM lamp 44 is then illuminated and, after a slight delay, solenoid valve 102 (FIG. 3) is energized and pump 100 is activated. Vacuum pump operating time is simultaneously displayed at 54, initially at the programmed time and thereafter decrementing or counting down to zero, at which point pump 100 is deenergized and valve 102 is closed. Apparatus 20 then automatically assumes a HOLD mode, during which LOW SIDE pressure gage 40 may be observed by the operator for loss of vacuum, indicating a leak in refrigeration equipment 80. If the gage reading is satisfactory, key 68 is depressed to CONTinue the AUTOMATIC mode of operation. (As will be described in detail hereinafter, the automatic HOLD feature after the vacuum stage may be overridden by depression of the "1" key of pad 58 during the vacuum stage, in which event the system will proceed immediately to the oil charging stage following termination of the vacuum stage.) Upon return to the AUTOMATIC mode of operation, the oil charging stage begins, OIL lamp 46 is illuminated and the oil charge quantity in ounces is indicated at display 54. This charge display is decremented as charging proceeds as a function of weight loss at scale 112. Apparatus 20 then proceeds automatically to the refrigerant charging stage, at which REFRIGERANT lamp 48 is illuminated and the refrigerant charge quantity in pounds is indicated and decremented at display 54. The end of the AUTOMATIC mode is signaled by a display of "CPL" at display 54, and apparatus 20 automatically enters a HOLD mode wherein LED 66 (FIG. 2) is illuminated and all lamps 44-48 are extinguished.
If problems are encountered during the AUTOMATIC mode of operation, the operator may enter the HOLD mode at any time by depressing key 68. Either or both refrigerant tank 90 and oil reservoir 96 (FIG. 3) may be changed or filled in the HOLD mode. Depression of key 68 functions to return to or CONTinue the AUTOMATIC mode where the operator was interrupted. In the event of malfunction at apparatus 20, microprocessor 116 (FIG. 4) diagnoses the cause or source of such malfunction and indicates at display 54 an error code which corresponds to such malfunction. These error codes are also listed on panel instruction set 53 (FIG. 1) and may be employed by the operator for correcting or repairing the source of error. The error codes and corresponding malfunctions are listed in the following table:
TABLE I______________________________________Error Code Cause______________________________________ERR 1 Low Memory BatteryERR 2 Power InterruptionERR 3 Invalid Oil EntryERR 4 Invalid Refrigerant EntryERR 5 Overloaded or Broken ScaleERR 6 Low Side Manifold Pressure too high (above 25 psig)ERR 7 High Side Manifold Pressure too high (above 370 psig)______________________________________
FIGS. 5-15 together comprise a composite flow chart which illustrates detailed operation of the preferred embodiment of the invention hereinabove disclosed. FIG. 5 illustrates the main operating routine, while FIGS. 6-15 illustrate operation of subroutines. In FIGS. 5-15, operator action away from service apparatus 20 is illustrated in dashed or phantom lines, while operator action on or relating directly to the apparatus of the invention, as well as steps taken by the internal control microprocessor, are illustrated in solid lines. It will be appreciated, of course, that FIGS. 5-15 do not attempt to teach the art of refrigeration system service or repair. Rather, operator actions indicated in the flow chart are by way of example only.
Turning to FIG. 5, with the unit power cable (not shown) plugged into a suitable source of utility power and with EXHAUST switch 50 (FIG. 1) turned off, MAIN POWER switch 52 is activated and operation transfers to an initialization Subroutine A (FIG. 6). Within the initialization subroutine, an internal routine within microprocessor 116 performs a variables checksum and, if a checksum error results, displays error code ERR 1 to indicate low memory battery power. The memory battery is replaced in the event of a low battery power error code. If the checksum initialization routine yields no error, microprocessor 116 then automatically checks to see if power was lost during a charging cycle. In the event that such interruption did occur, error code ERR 2 is indicated at display 54. Upon depression of any key in pad 58, the cycle stage at which power was interrupted, i.e. the vacuum, oil or refrigerant stage, is identified. The corresponding lamp 44,46,48 is energized, and vacuum time, oil quantity or refrigerant quantity remaining when the power was lost is indicated at display 54 as is appropriate. The unit then automatically enters the HOLD mode and energizes LED 66 (FIG. 2). Depression of key 68 in pad 58 will then CONTinue the AUTOMATIC mode of operation at the stage in which the cycle was interrupted--i.e. the automatic vacuum, oil or refrigerant subroutine of FIGS. 9, 10 or 11. If power was not interrupted during a service cycle, the last-entered vacuum, oil and refrigerant variables are shown in sequence at display 54, coupled with illumination of corresponding lamps 44,46,48. The internal program then automatically initializes at the vacuum stage of the PROGRAM mode, displays the last-entered programmed vacuum time in minutes, and returns to the main routine (FIG. 5).
FIG. 7 illustrates Subroutine B which must be performed by the operator before charging refrigeration equipment 80 (FIG. 3), specifically an automotive air conditioner or a/c system in the exemplary implementation. Hoses 34,36 (FIG. 1) are appropriately connected to the a/c system as hereinabove described. If the a/c system is newly installed or has been opened or breached for repair purposes, further repair may not be necessary and the operator may proceed with the main service routine. On the other hand, the operator must decide if system diagnosis and possible repair are required. If not, EXHAUST switch 50 is activated until the pressure at LOW SIDE gage 40 indicates that the a/c system has been fully exhausted, at which time switch 50 is turned off and operation returns to the main routine. When system repair is required, the operator diagnoses the problem and takes appropriate action. If the required repair does not involve breach of the a/c system, such as repair of the fan, replacement of the compressor belt or cleaning of the condenser, no further action need be taken on the system, and operation branches to final system check and hose disconnect Subroutine G (FIG. 12). Alternatively, the required repair action may necessitate partial or complete recharge, whereby operation returns to the main routine (FIG. 5).
Returning to FIG. 5, when a partial or incremental charge is to be added, which is an operator decision based upon a/c system pressures, key 76 (FIG. 2) of pad 58 is depressed, and control electronics 114 (FIG. 4) automatically opens refrigerant solenoid 92 and adds 0.2 pounds of refrigerant (subroutine F, FIG. 11). The operator may then observe the resulting pressures at gages 40,42 (FIG. 1) and, if the new pressure readings remain low, repeat the charge addition cycle. On the other hand, if the charge is now satisfactory, RESET CYCLE key 70 is depressed, hoses 34,36 are disconnected and the system is ready for servicing the next car. If the a/c system under service requires a complete recharge, i.e., not a mere partial charge, the operator must then determine whether the required vacuum time and oil and refrigerant charge quantities are the same as those for the last-serviced car. This may be accomplished by entering the PROGRAM mode of operation and depressing key 74 of pad 58 to review the stored variables, which are to be compared with manufacturer's specifications for the system under test. If the variables are to remain unchanged, key 68 is depressed to START the AUTOMATIC mode of operation. On the other hand, if the required variables are not the same as for the last-serviced car, operation branches to Subroutine C of FIG. 8.
Turning to FIG. 8, with the system in the PROGRAM mode, REVIEW PROGram key 74 (FIG. 7) is depressed until VACUUM lamp 44 is illuminated and the previously-stored vacuum time in minutes is indicated at display 54. If the time so displayed is incorrect, appropriate numerical data keys of pad 54 are depressed and ENTER key 72 is then depressed to enter the new vacuum time. Display 54 flashes momentarily and the sonic alarm beeps to indicate acceptance of the new data. REVIEW PROGram key 74 is then again depressed to illuminate OIL lamp 46 and display last-programmed oil charge quantity in ounces at display 54. If this amount is incorrect, appropriate numeric keys of pad 58 are depressed, ENTER key 72 is depressed, the display blinks and the sonic alarm beeps to indicate entry of the new oil quantity. If the entered quantity is greater than a twenty ounce maximum limit, error code ERR 3 is shown at display 54. Depression of any key on pad 58 will exit the error display mode, and desired oil quantity may then be re-entered. If the entered or re-entered quantity is not over the twenty ounce limit, REVIEW PROGram key 74 is depressed, REFRIGERANT lamp 48 is illuminated and the last-programmed refrigerant charge quantity in pounds is displayed. If this amount is incorrect, the refrigerant charge quantity is reprogrammed in the manner previously described. In the event that the newly-entered charge quantity is over a thirty pound maximum limit, error code ERR 4 is displayed. The newly-entered data may be reviewed, or operation returned to the main routine of FIG. 5.
With all variables entered or confirmed as previously described, and upon depression of key 68 to START the AUTOMATIC mode of operation, operation automatically branches from the main routine of FIG. 5 to vacuum Subroutine D of FIG. 9. AUTOMATIC LED 64 and VACUUM lamp 44 are illuminated, and the programmed vacuum time in minutes is indicated at display 54. If the low-side pressure indicated at gage 44 is greater than twenty-five psig, indicating that equipment 80 (FIG. 3) has not been fully exhausted, error code ERR 6 is indicated at display 54. Equipment 80 may then be exhausted by depression of switch 50. Depression of any key on pad 58 returns the system to the PROGRAM mode and to the main routine of FIG. 5, requiring redepression of key 68 to reSTART the AUTOMATIC mode of operation. If low-side pressure is not greater than twenty-five psig (FIG. 9), vacuum solenoid valve 102 and vacuum pump 100 (FIG. 3) are energized. Vacuum time is indicated on display 54 initially at the programmed level and thereafter decremented as a function of time as pump operation continues. If the operator notes any operating problems, depression of key 68 will HOLD the AUTOMATIC mode of operation and enter the HOLD mode, wherein repairs or changes may be affected per Subroutine H of FIG. 13. If no such problems are encountered, vacuum operation continues until vacuum time is decremented to zero, at which point solenoid valve 102 and pump 100 are deenergized. If numeric key "1" of pad 58 was depressed during the automatic vacuum stage, operation immediately returns to the main routine of FIG. 5 for initiation of the automatic oil subroutine. If key "1" was not so depressed, operation automatically enters the HOLD mode in which gages 40,42 may be observed to confirm that the a/c system under service holds a vacuum. If such is the case, depression of key 68 returns to or CONTinues the AUTOMATIC mode of operation. If vacuum is not held, appropriate repairs are effected and RESET CYCLE key 70 is depressed and then key 68 is depressed to reSTART the AUTOMATIC mode.
Automatic oil charge Subroutine E is illustrated in FIG. 10. AUTOMATIC LED 64 and OIL lamp 46 are illuminated. An initial reading Wi in pounds is obtained from scale 112 (FIG. 3) and a final weight Wf is computed by subtracting the programmed charge quantity Wp from the initial scale reading Wi. (The programmed charge Wp in ounces is divided by sixteen.) A variable quantity Ws, indicative of oil charge remaining to be transferred, is initialized at the programmed quantity Wp, oil solenoid valve 98 (FIG. 3) is opened and charge time t is initialized at zero. The remaining charge quantity Ws is shown at display 54. Time t is incremented and scale weight Wt is again read. In the event that the new scale reading is not less than the scale reading at the preceding time interval, indicating either a problem with the equipment under test or an empty oil reservoir 96, the sonic alert is activated. If the system under service has been evacuated, key 68 is depressed to HOLD the AUTOMATIC mode, and operation branches to Subroutine H of FIG. 13. If the system under test was not evacuated, the system is started to see if it will then accept oil charge. If the sonic alert continues, key 68 is depressed to HOLD AUTOMATIC operation. However, if the system now accepts charge, the sonic alarm is extinguished and operation remains AUTOMATIC. The amount of oil remaining to be transferred Ws is appropriately decremented and operation continues. When the weight of charge transferred equals the initially programmed amount, i.e., when Ws equals zero, oil solenoid valve 98 is closed and operation returns to the main routine of FIG. 5. At any time during the automatic oil charging subroutine, key 68 may be depressed to HOLD the AUTOMATIC mode and branch to Subroutine H (FIG. 13).
Upon successful completion of oil charge Subroutine E of FIG. 10, the main routine of FIG. 5 branches to Subroutine F of FIG. 11 for automatic implementation of the refrigerant charge subroutine. Charge quantity Wp is set at the preprogrammed level in the AUTOMATIC mode and at 0.2 pounds in the partial charge mode. During the automatic refrigerant charge subroutine, each scale reading Wt is checked to insure that the scale reading is not over forty-one pounds. In the event that the scale reading is over forty-one pounds, error code ERR 5 is indicated at display 54, and the scale must then be replaced by the operator. Depression of any key on pad 58 returns operation to the main routine (FIG. 5) from which the entire automatic operation must be restarted, if appropriate. As a modification, which would eliminate a need to start the a/c system if refrigerant is not accepted, a heater or mechanical pump could be used to elevate pressure in the refrigerant tank, as is currently done in some applications. Otherwise, the automatic refrigerant charge subroutine of FIG. 11 is substantially the same as the automatic oil charge subroutine of FIG. 10 hereinabove described, and will not be described further. Upon successful completion of refrigerant charge Subroutine F, operation is returned to the main routine of FIG. 5, and completion code CPL is indicated on display 54. Operation branches to Subroutine G (FIG. 12) wherein the operator performs a final check on the serviced equipment. If problems are noted, appropriate action is taken, which may include incremental addition of charge, or exhaust and complete recharge of the entire a/c system. If correct operation is observed by the operator, the hoses 34,36 are disconnected from the serviced equipment and operation returns to the main routine of FIG. 5.
FIG. 13 illustrates operation of Subroutine H in the event of a HOLD or interrupt of the AUTOMATIC operating mode in any of the vacuum, oil or refrigerant cycles of FIGS. 9-11. In general, the oil and refrigerant supplies are checked by the operator, and replaced or refilled as required. If the oil reservoir 96 is refilled, it must be repressurized by operation of key 78 on pad 58. This is accomplished by first branching to Subroutine D (FIG. 9) for a preset time to pull a vacuum on oil reservoir 96, and then branching to Subroutine F (FIG. 11) to charge the oil reservoir with a selected quantity of refrigerant. With the oil and refrigerant containers checked and replaced or filled as required, the programmed variables may be reconsidered and reprogrammed if desired. The operator then either presses RESET CYCLE key 70 to restart the entire AUTOMATIC cycle, or presses key 68 to CONTinue and return operation to the Subroutine H branch point.
FIG. 14 illustrates operation of the manual diagnostic Subroutine J, which is entered by simultaneously depressing the "0" and RESET CYCLE keys of pad 58. If operation of vacuum pump 100 is to be tested, the numeric "1" key is depressed. If low-side pressure is in excess of twenty-five psig, error code ERR 6 is indicated at display 54, and the refrigeration equipment under test must be exhausted to continue operation. When low-side pressure is not greater than twenty-five psig, VACUUM lamp 44 is illuminated, and vacuum solenoid valve 102 and vacuum pump 100 are energized. Redepression of the "1" key closes the vacuum pump and solenoid valve, and extinguishes the VACUUM lamp. Depression and release of the numeral "2" key similarly energizes OIL lamp 46 and oil valve 98 for test purposes, while depression and release of the "3" key of pad 58 performs a similar check on refrigerant solenoid 92 and lamp 48. Key "5" tests all lamps 44-48, all LEDs 62-66 and all segments of display 54. Key "6" likewise enables test of scale 112 by directly indicating scale weight at display 54. The operator may test scale function by adding thereto a known weight and observing the result at display 54. If such result is in error by more than three percent, the scale should be replaced. When the manual diagnostic test has been completed, depression of RESET CYCLE key 70 returns the apparatus to the PROGRAM mode of operation.
FIG. 15 illustrates operation of the low refrigerant and high pressure warning subroutines. Scale weight is constantly monitored during operation to determine if a low refrigerant warning is indicated, and high-side pressure is likewise continuously monitored. When the scale reading indicates that less than five pounds of refrigerant remains, LOW REFRIGERANT WARNING LED 56 is energized. Complete emptying of the tank is permitted while the lamp is lit. If the operator wishes to change refrigerant tank 90, key 68 is depressed to HOLD further operation, and operation branches to Subroutine H previously described. Likewise, a high-side pressure greater than three hundred seventy psig disables further operation and results in an error code ERR 7 at display 58. The sonic alert is continuously activated to advise the operator of an error indication. When the cause of the over-pressure condition has been corrected, depression of any key on pad 58 returns operation to the main routine of FIG. 5 wherein automatic operation must be reinitiated.
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Apparatus for service and recharge of refrigeration equipment, with particular application to automotive air conditioning equipment. A vacuum pump, and oil and refrigerant charge containers are housed within a portable enclosure and configured for selective connection by electrically operated solenoid valves to refrigeration equipment under service. The refrigerant and oil containers are carried by a scale which provides electrical outputs signals as a function of weight of refrigerant and oil remaining in the containers. A microprocessor-based controller receives the scale signals and control signals from an operator panel for automatically cycling through vacuum, oil charge and refrigerant charge stages in a programmed mode of operation. The microprocessor-based controller includes facility for operator programming of the vacuum time and oil and refrigerant charge quantities, and for self- or operator-implemented diagnostics. Operating conditions and stages are displayed at all times to the operator.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to new organic compounds and processes for the synthesis of the compounds. More specifically, the invention relates to bromine-containing 2,4-diaminotriazines and to esters used as intermediates in the synthesis of said compounds. The bromine-containing 2,4-diaminotriazines can be used to reduce the flammability of cotton.
2. Description of the Prior Art
Chance and Timpa reported an example of a brominated diaminotriazine (Chance, L. H.; Timpa, J. D., J. Chem. Eng. Data 1977, 22, 116, and Chance L. H. and Timpa, J. D., U.S. Pat. No. 4,055,720, 1977). They prepared 2,4-diamino-6-(3,3,3-tribromo-1-propyl)-1,3,5-triazine by the reaction of ethyl γ-tribromobutyrate with biguanide. Ostrogovich reported 2,4-diamino-6-tribromomethyl-1,3,5-triazine prepared by the direct bromination of 2,4-diamino-6-methyl-1,3,5-triazine. (Ostrogovich, A. Chem. Zentrabl. 1905, 2, 1358). Chance reported the preparation of the compounds of the present invention. (Chance, L. H., J. Chem. Eng. Data 1980, 25(4), 402).
SUMMARY OF THE INVENTION
The main object of the invention is to synthesize new bromine-containing 2,4-diaminotriazines.
A second object of the invention is to synthesize the appropriate esters to be used as intermediates in the synthesis of the said bromine-containing 2,4-diaminotriazines.
A third object of the invention is to demonstrate that said bromine-containing 2,4-diaminotriazines can be used to reduce the flammability of cotton.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In this invention compounds Ia-d were prepared by the reaction of biguanide with the appropriate ester YCO 2 Et, as shown by the following equation: ##STR1##
The ester required for Id, ethyl N-(2,4,6-tribromophenyl)glycinate (IV), was prepared by the reaction of ethyl N-phenylglycinate with bromine in a mixture of water and acetic acid. IV reacted with ammonia in ethanol solution to form N-(2,4,6-tribromophenyl)glycinamide (V).
Compounds Ia-c were then allowed to react with bromine in aqueous media to form diaminotriaizines IIa-c. ##STR2##
Crystalline methylol derivatives of IIc and Id, viz. III and VI, respectively, were prepared by reaction with aqueous formaldehyde.
Compounds I b,d, IIa-c, III, IV, V and VI are new compositions of matter.
Biguanide was prepared fresh by refluxing anhydrous biguanide sulfate in a methanol solution of freshly prepared sodium methylate by the method of Slotta et al. (Slotta, K. H., Tschesche, R., Ber. Dtsch. Chem. Ges. 1929, B62, 1390-1398). The biguanide was used in solution as prepared for all of the reactions. Because sodium sulfate formed in the preparation of biguanide did not interfere with subsequent reactions, it was not necessary to separate it from the biguanide. Ethyl malonamate used in the preparation of Ib (see Example I below) was prepared as follows by methods of Galat and Marguery (Galat, A., J. Am. Chem. Soc. 1948, 70, 2596 and Marguery, M. F., Bull. Soc. Chem. France 1905, 33, 541; J. Recherces Centr. Nalt. Recherche Sci., Labs. Bellevue (Pairs) 1959, 47, 147), through Chem. Abstr. 1962, 56, 4744g.): Diethyl malonate was converted to the mono-potassium salt of the half-ester. The latter was converted to ethyl malonyl chloride, which in turn was reacted with anhydrous ammonia in ice-cold ether to form ethyl malonamate.
Compounds IIa, IIb, III, V, and VI were applied to cotton flannelette fabric by padding and drying procedures conventionally used in the finishing of cotton textiles. The said compounds were applied to the fabric from dimethylformamide solution. The fabrics had reduced flammability as indicated by oxygen index. The oxygen index values for cotton fabric treated with compounds IIA, IIb, III, V, and VI were 33.8, 31.0, 22.1, 23.0, and 22.1, respectively. An untreated control fabric had an oxygen index of 18.5, indicating that all treated fabrics were less flammable than the control. All of the treated fabric samples contained approximately 8% bromine. The oxygen index analyses were carried out on a Stanton Redcroft instrument using the procedure set forth in ASTM D 2863-70.
The following examples illustrate procedures that have been successfully used in carrying out the invention.
EXAMPLE 1
2,4-Diamino-6-carbamoylmethyl-1,3,5-triazine (Ib). Ethyl malonamate (34.7 g, 0.26 mole) and methanol (100 ml) were placed in a flash equipped with a dropping funnel, a stirrer, and a soda lime trap (to exclude CO 2 ). The flask was cooled to about 15° C. in an ice-water bath. Freshly prepared biguanide (26.3 g, 0.26 mole, in 250 ml methanol) was added, with stirring, over 35 min at 15°-20° C. A white precipitate began to form within 8-9 min. The mixture was allowed to stir overnight at room temperature. It was then cooled to 15° C., and the white precipitate was filtered, washed with cold water to remove sodium sulfate, and finally washed with cold methanol. A crude yield of 32.7 g (76%) was obtained. A pure sample recrystallized from water had a mp of 295°-96° C. (dec.) when placed in a preheated bath at 295° C. Anal. calcd. for C 5 H 8 N 6 O: C, 36.59; H, 4.91; N, 48.76. Found: C, 36.73; H, 5.08; N, 48.51.
EXAMPLE 2
2,4-Diamino-6-(dibromocyanomethyl)-1,3,5-triazine (IIa). Ia(15.0 g, 0.1 mole) and 250 ml water were placed in a flask equipped with a reflux condenser, stirrer, and dropping funnel. Bromine (32.0 g, 0.2 mole) was added dropwise to the resulting slurry with vigorous stirring over 20 min. The mixture was stirred at room temperature for 1.5 h and then placed in a refrigerator overnight. The light-gray precipitate was filtered and washed with cold water. A crude yield of 26 g (83%) was obtained. A pure sample was obtained by dissolving 3 g of IIa in 5 ml of dimethylformaldehyde, filtering, and pouring the solution into 75 ml water. The resulting precipitate was washed with cold water and finally with cold methanol. The grayish crystals had a mp of 238°-40° C. (dec.) when placed in a bath preheated to 238° C. Anal. calcd. for C 5 H 4 Br 2 N 6 : C, 19.50; H, 1.31; Br, 51.90; N, 27.29. Found: C, 19.70; H, 1.24; Br, 51.69; N, 27.37.
EXAMPLE 3
2,4-Diamino-6-(dibromocarbamoylmethyl)-1,3,5-triazine (IIb). Ib (16.4 g, 0.1 mole) and 250 ml water were placed in a flask equipped with a reflux condenser, stirrer, and dropping funnel. Bromine (32.0 g, 0.2 mole) was added dropwise over 2.5 h. The temperature reached a maximum of only 30° C. during the addition. The reaction mixture was cooled in ice water and the crystals were filtered. They were washed with ice water, and then with cold methanol. The cream-colored crystals weighed 11.9 g. A second crop of crystals (13.2 g) was obtained by adjusting the pH of the filtrate to 7.1 by adding 29% ammonium hydroxide (25.7 g 0.44 mole). The total yield of crude IIb was 25.1 g (78%). A purer sample of white crystals was obtained by recrystallization from water. The mp was 219°-20° C. (dec.) when a sample was placed in a bath preheated to about 215° C. Anal. calcd. for C 5 H 6 Br.sub. 2 N 6 O: C, 18.65; H, 1.88; Br, 49.03; N, 24.86. Found: C, 18.83; H, 1.99; Br, 48.24; N, 25.72.
EXAMPLE 4
2,4-Diamino-6-(3,5-dibromo-4'-aminophenyl)-1,3,5-triazine (IIc). Ic (10.0 g, 0.05 mole), 150 ml conc. hydrochloric acid, and 450 ml water were placed in a flask equipped with a reflux condenser, stirrer, and dropping funnel. Ic was dissolved by heating the stirred mixture to 65° C. on a water bath. Bromine (16.5 g, 0.1 mole) was added dropwise over 10 min. A precipitate began to form as soon as the bromine addition was begun. Heating and stirring at 65° C. was continued for 3 h. The mixture was cooled to room temperature and allowed to stand overnight. After the mixture was cooled in ice water the crystals were filtered, slurried with cold acetone, and filtered again. The pale-yellow crystals weighed 17.3 g. They were placed in distilled water (450 ml) and adjusted with good stirring to pH 7.8 with conc. ammonium hydroxide to neutralize any amine hydrochloride salts that may have been present. The resulting thick slurry was filtered, and the precipitate was washed with water and pressed as dry as possible on the filter. After being air dried the cream-colored crystals weighed 15.5 g, a crude yield of 88% of IIc. A pure sample was obtained by dissolving 1.5 g in DMF (5.0 g) at 125° C. While the solution was kept hot, water (1.2 g) was added dropwise with stirring until a slight turbidity appeared. The white crystals that separated upon cooling were filtered and washed with a DMF/H 2 O mixture. They were finally washed with ethanol and dried at 110° C. The mp was 289° C. (dec.) when placed in a bath preheated to 289° C. Anal. calcd. for C 9 H 8 Br 2 N 6 : C, 30.03; H, 2.24; Br, 44.39; N, 23.34. Found: C, 29.89; H, 2.25; Br, 44.23; N, 23.56.
EXAMPLE 5
2,4-Bis[di(hydroxymethyl)amino]-6-(3,5-dibromo-4'-aminophenyl)-1,3,5-triazine (III). IIc (8.0 g, 0.22 mole) and 37% aqueous formaldehyde (110 g) were placed in a flask and adjusted to pH 7.8 by the addition of 5% NaOH (0.7 g). The mixture was refluxed for 20 min. The clear solution was cooled to room temperature and allowed to stand for 3-4 h. The white precipitate obtained was filtered and washed with 25 ml of 37% formaldehyde. It was then slurried with 100 ml of water, filtered, and washed again with 50 ml of water. After being thoroughly air dried, it weighed 8.4 g (89% yield). The crystalline compound had a mp of 165°-66° C. (dec.) when placed in a bath preheated to 165° C. Anal. calcd. for C 13 H 16 Br 2 N 6 O 4 : C, 32.52; H, 3.36; Br, 33.29; N, 17.50. Found: C, 31.93; H, 3.41; Br, 32.74; N, 17.46.
EXAMPLE 6
Ethyl N-(2,4,6-tribromophenyl)glycinate (IV). Ethyl N-phenylglycinate (20.0 g, 0.11 mole), water (500 ml), and acetic acid (100 ml) were placed in a 1-L flask equipped with a reflux condenser, a stirrer, and a dropping funnel. Bromine (52.7 g, 0.33 mole) dissolved in acetic acid (100 ml) was added dropwise with good stirring over 2 h. At first, a viscous material formed and adhered to the walls of the flask. Eventually it solidified. The solid was scraped off the walls as the bromine addition progressed. The mixture was stirred for an additional 2 h. At this point the bromine color had disappeared. The mixture was cooled in ice water. The crude pale-gray crystals were filtered and recrystallized from 500 ml of boiling methanol. The yield was 31.4 g (68.5%) of white needles, mp 81°-82° C. Anal. calcd. for C 10 H 10 Br 3 NO 2 : C, 28.88; H, 2.42; Br, 57.64; N, 3.37. Found: C, 28.80; H, 2.46; Br, 57.42; N, 3.32.
EXAMPLE 7
N-(2,4,6-tribromophenyl) glycinamide (V). IV (7.5 g, 0.018 mole) and absolute ethanol (300 ml) were placed in a flask and warmed slightly to dissolve all of the crystals. Then the solution was saturated with anhydrous ammonia while the flask was cooled in ice water. White needles separated after the clear solution stood at room temperature for 3 days. The mixture was cooled in ice water, and the crystals were filtered and washed with a small amount of cold ethanol. A second crop of crystals, 1.1 g, was obtained by evaporating the filtrate to a volume of 35 ml and cooling in ice water. The total yield was 6.1 g (89%), mp 185°-185.5° C. Anal. calcd. for C 8 H 7 Br 3 N 2 O: C, 24.84; H, 1.82; Br, 61.96; N, 7.24. Found: C, 24.83; H, 1.87; Br, 61.82; N, 7.26.
EXAMPLE 8
2,4-Diamino-6-(2',4',6'-tribromoanilinomethyl)-1,3,5-triazine (Id). Freshly prepared biguanide (6.1 g, 0.06 mole) in methanol (700 ml) was placed in a flask equipped with a stirrer and a soda lime trap to exclude CO 2 . IV (25.0 g, 0.06 mole) was added all at once through a powder funnel. After the solution was stirred for 10 min at room temperature, a white precipitate began to form. After being stirred for 7.5 h, the mixture was allowed to stand overnight. The crystals were filtered and washed with fresh methanol. They were then slurried with water (250 ml), filtered again, and washed with methanol. A crude yield of 21.9 g (81%) was obtained. It was recrystallized by dissolving 21.8 g in 80 ml of hot DMF (125° C.) and then adding 9 ml of water dropwise. When the solution cooled, white crystals separated. A second crop of crystals was obtained from the filtrate. The total recovery was 15.5 g, a yield of 57% based on the theoretical yield of 27.2 g. An analytical sample with mp of 250°-51° C. was obtained by recrystallizing again from hot DMF and finally washing with cold methanol. Anal. calcd. for C 10 H 9 Br 3 N 6 : C, 26.52; H, 2.00; Br, 52.93; N, 18.55. Found: C, 26.52; H, 2.02; Br, 52.71; N, 18.59.
EXAMPLE 9
2,4-Bis[di(hydroxymethyl)amino]-6-(2',4',6'-tribromoanilinomethyl)-1,3,5-triazine (VI). Id (25.0 g, 0.055 mole) and 37% aqueous formaldehyde (250 ml) were placed in a 500-ml flask and adjusted to pH 9.2 by the addition of 10 drops of 25% NaOH. It was refluxed for 10 min with stirring. During the reflux period, 4 drops more of 25% NaOH were added. After the solution was cooled to room temperature, the pH was readjusted to 9.1 by adding 4 drops more of 25% NaOH. A white precipitate formed as the mixture cooled. After several hours the mixture was cooled in ice water and diluted with ice water to a volume of about 600 ml to complete precipitation. It was filtered, the precipitate was slurried with cold water, filtered again, and washed on the filter with more cold water. After being thoroughly air dried, the white crystals weighed 30.3 g, a 96% yield, mp 137°-8° C. (dec). Anal. calcd. for C 14 H 17 Br 3 N 6 O 4 : C, 29.34; H, 2.99; Br, 41.83; N, 14.67; Found: C, 29.01; H, 3.31; Br, 40.49; N, 14.12.
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The following new compounds, useful in flame retardant compositions for cotton, are disclosed in the invention:
2,4-diamino-6-carbamoylmethyl-1,3,5-triazine (Ib),
2,4-diamino-6-(dibromocyanomethyl)-1,3,5-triazine (IIa),
2,4-diamino-6-(dibromocarbamoylmethyl)-1,3,5-triazine (IIb),
2,4-diamino-6-(3,5-dibromo-4'-aminophenyl)-1,3,5-triazine (IIc),
ethyl N-(2,4,6-tribromophenyl)glycinate (IV),
N-(2,4,6-tribromophenyl)glycinamide (V),
2,4-bis[di(hydroxymethyl)amino]-6-(3,5-dibromo-4'-amino-phenyl)-1,3,5-triazine (III),
2,4-diamino-6-(2',4',6'-tribromoanilinomethyl)-1,3,5-triazine (Id), and
2,4-bis[di(hydroxymethyl)amino]-6-(2',4',6'-tribromoanilinomethyl)-1,3,5-triazine (VI).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a facsimile apparatus capable particularly of transmitting two-side original.
2. Related Background Art
In the conventional facsimile apparatus capable of transmitting two-side original, in case the two-side reading is selected, the original information of the front side is transmitted with designation of the transmission of the top side (or front side), irrespective of the sub scanning length of the original information, and then the original information of the back side is transmitted with designation of the back side.
In the above-described method, the two-sided original, is read and the read data is transmitted with designating the front or back side. However, since in the receiving unit (or station), the recording sheet is often available only in a fixed size, there is encountered a major drawback that the control for the two-sided recording in the receiving unit becomes difficult if a long-sized original is transmitted from the transmitting unit.
SUMMARY OF THE INVENTION
In consideration of the foregoing, the object of the present invention is to provide a facsimile apparatus capable of smooth transmission without causing a trouble in the receiving side, even in case a long-sized two-sided original is read.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an embodiment of the present invention; and
FIGS. 2, 3 , 4 , 5 , 6 , 7 , 8 , 9 and 10 are flow charts showing the control sequence in the above-mentioned embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a block diagram showing the configuration of a facsimile apparatus, constituting an embodiment of the present invention.
Referring to FIG. 1, an NCU (network control unit) 2 is connected to a terminal of a telephone network for utilizing the same for data communication and executes connection control for the telephone network, switching to a data communication path, and retaining of a loop. The NCU 2 connects a telephone line 2 a to a telephone set 4 or a facsimile apparatus according as the signal level on a signal line 20 a from a control circuit 20 is “0” or “1”. In the normal state, the telephone line 2 a is connected to the telephone set 4 .
A hybrid circuit 6 separates transmission signals and reception signals, and transmits the transmission signal from an adder circuit 12 to the telephone line 2 a through the NCU 2 and receives the signal from a partner station through the NCU 2 for supply to a modem 8 through a signal line 6 a.
The modem 8 executes modulation and demodulation based on the ITU-T recommendations V.8, V.21, V.27 ter, V.29, V.17 and V.34, and each transmission mode is designated by a signal line 20 c . The modem 8 receives a signal outputted on a signal line 20 b and outputs modulated data to a signal line 8 a , and also receives a reception signal outputted on the signal line 6 a and outputs demodulated data to a signal line 8 b.
An ANSam send-out circuit 10 , for sending out an ANSam signal. This circuit sends out the ANSam signal or none to a signal line 10 a according as the signal on a signal line 20 d is at a level “1” or “0”. The adder circuit 12 receives the signals of the signal lines 8 a and 10 a and outputs the result of addition to a signal line 12 a.
A reading circuit 14 reads the original image for example with a CCD, and outputs the read data to a signal line 14 a . The reading circuit 14 reads the front side or back side of the original according as the signal on a signal line 20 i is at a level “0” or “1”.
A recording circuit 16 records, line by line, the information outputted on a signal line 20 e . A memory circuit 18 is used for storing the original or encoded information of the read data, and the received or demodulated information.
An operation unit 22 is provided with a one-touch dial, a contracted number dial, numeral keys, “*” and “#” keys, a start key, a set key, a stop key, a registration key for a memory circuit 30 and other function keys, and outputs the information of a depressed key to a signal line 22 a.
A both side reading selection button 24 is to be depressed in case of selecting the two-side reading (both side reading), and, upon depression, generates a depression pulse on a signal line 24 a.
A both side reading display circuit 26 , for displaying the selection of the two-side reading assumes a state of “no display” upon generation of a clear pulse on a signal line 20 f , and thereafter repeats states of “display” and “no display” in response to depression pulses generated on the signal line 24 a . The display circuit 26 outputs a signal of a level “1” or “0” on a signal line 26 a respectively in the “display” or “no display” state.
An original length (sub scan length) detection circuit 28 serves to detect, in the original reading, the length of the original in the sub scanning direction. When the resolution in the sub scanning direction is designated by a signal line 20 g (“0” for 3.85 line/mm, “1” for 7.7 line/mm or “2” for 15.4 line/mm) and a sub scanning length measurement start pulse is subsequently generated on a signal line 20 h , the detection circuit 28 determines the original length (sub scanning length) from the read line information outputted on the signal line 14 a and the resolution on the signal line 20 h and outputs the original length to a signal line 28 a.
A registration circuit 30 stores “transmission as one-sided original” or “transmission as two-sided original” for selecting the transmitting operation for the long-sized two-side original.
More specifically, in the present embodiment, in case the reading of a two-sided original is selected Band the original is long in size, the information on the original is read in succession from the front side and the back side. In transmitting thus read information, if “transmission as one-sided original is selected, the information of the read two-sided original is divided into a sub scanning length of a fixed sheet size corresponding in the main scanning direction to the read original size, and all the original information, both of the front and back sides, is transmitted as the information of the front side.
On the other hand, if “transmission as two-sided original” is selected, the information of the two-sided original is divided into a sub scanning length of a fixed sheet size corresponding in the main scanning direction to the read original size, and at first the original information of the front side is transmitted as the front side, and then remainder of the original information of the front side is transmitted as the back side. If the original information of the front side still remains, the above-described procedure is repeated until no remainder is existent. Then the original information of thus divided back side is transmitted as a side that is opposite to the side assigned to the immediately preceding final portion of the original information of the front side (namely if the immediately preceding transmission (final portion of the original information of the front side) is designated as “front” side, the initial portion of the original information of the back side is designated as “back” side, while if designated as “back” side, it is designated as “front” side), and then remainder of the original information of the back side is transmitted as a side opposite to the side thus assigned to the initial portion of the original information of the back side. If the original information of the back side still remains, the above-described procedure is repeated until no remainder is existent.
The “transmission as one-side original” or “transmission as two-side original” is registered in the registration circuit 30 through a signal line 30 a.
The control circuit 20 controls the entire facsimile apparatus of the present embodiment capable of two-side original reading, and, particularly in the present embodiment, in case the reading of the two-sided original is selected, executes the following control of detecting the sub scanning length and varying the transmission based on such sub scanning length.
More specifically, in the present embodiment, there is contemplated the original information of A4 size only in the main scanning direction, and, if the reading of two-sided original is selected, the sub scanning length of the original information not exceeding 330 mm is transmitted with compression to 297 mm. If the sub scanning length of the original information exceeds 330 mm, the information read from the front side and the back side of the original is respectively divided into 297 mm, and, if “transmission as one-side information” is selected, the original information of the front side and that of the back side are both transmitted under the designation of the front side.
On the other hand, if “transmission as two-sided original” is selected in the registration circuit 30 , the information of the two-sided original is divided into a sub scanning length of a fixed sheet size corresponding in the main scanning direction to the read original size, and at first the original information of the front side is transmitted as the front side, and then remainder of the original information of the front side is transmitted as the back side. If the original information of the front side still remains, the above-described procedure is repeated until no remainder is existent. Then the original information of thus divided back side is transmitted as a side that is opposite to the side assigned to the immediately preceding final portion of the original information of the front side (namely if the immediately preceding transmission (final portion of the original information of the front side) is designated as “front” side, the initial portion of the original information of the back side is respectively designated as “back” side), while if designated as “back” side, it is designated as “front” side, and then remainder of the original information of the back side is transmitted as a side opposite to the side thus assigned to the initial portion of the original information of the back side. If the original information of the back side still remains, the above-described procedure is repeated until no remainder is existent.
FIGS. 2 to 10 are flow charts showing the control sequence of the control circuit 20 in the present embodiment.
Referring to FIG. 2, a step SO starts the control sequence, and a step S 2 generates a clear pulse on the signal line 20 f , whereby the two-side reading display circuit 26 does not execute display.
A step S 4 outputs a signal of a level “0” on the signal line 20 i , thereby designating the reading of the front side of the reading circuit 14 . A step S 6 registers, through the signal line 30 a , “transmission as two-side original” in the transmission type registration circuit 30 .
A step S 8 outputs a signal of a level “0” to the signal line 20 a , thereby turning off the CML. A step S 10 outputs a signal of a level “0” to the signal line 20 d , thereby not sending out the ANSam signal.
A step S 12 discriminates whether transmission is selected, and a step S 14 discriminates whether reception is selected. The sequence proceeds to a step S 40 or S 18 according as the transmission or reception is selected. But, if neither is selected, the sequence proceeds to a step S 16 for other processes, and then to a step S 178 .
A step S 18 outputs a signal of a level “1” to the signal line 20 a , thereby turning on the CML. A step S 20 executes a pre-procedure for informing that the two-side recording is possible and the front or back side can be designated by an MPS signal. The next page is judged as the front side or back side according as a signal MPS 1 or MPS 2 is received. Also the first page is judged as the front side.
A step S 22 discriminates whether the two-side recording (both side recording) is designated from the transmission unit, and the sequence proceeds to a step S 28 or S 24 according as the two-side recording is designated or it is not.
A step S 24 executes reception of the image signal of all the pages and recording thereof on the front side, and a step S 26 executes a post procedure, whereupon the sequence proceeds to the step S 8 .
A step S 28 executes reception of the image signal of one page and recording thereof on the front side, and a step S 30 executes a post procedure. A step S 32 discriminates whether the pages is the last page, and, if so, the sequence proceeds to a step S 34 for the post procedure and then to the step S 8 .
If not the last page, the sequence proceeds to a step S 36 for discriminating whether the MPS 1 signal is received, and the sequence proceeds to the step S 28 if the MPS 1 signal is received, but, if the MPS 2 signal is received, the sequence proceeds to a step S 38 for receiving the image signal of a page and recording the same on the back side of the recording sheet and then to the step S 30 .
A step S 40 enters the information of the signal line 26 a for discriminating whether the two-side reading is selected, and the sequence proceeds to a step S 50 or S 42 according as the two-side reading is selected or not.
A step S 42 outputs a signal of a level “1” to the signal line 20 a , thereby turning on the CML. A step S 44 executes a pre-procedure, designating the one-side recording. Then a step S 46 executes reading of the image signal of the front side of all the pages and transmission thereof. Then the sequence proceeds to a step S 48 for post procedure and then to the step S 8 .
A step S 50 sets “1” in a page counter. A step S 52 sets the front side as the page side, then a step S 54 outputs the reading line density to the signal line 20 g , and a step S 56 generates the original length measurement start pulse on a signal line 20 h . A step S 58 reads the original information corresponding to the page counter and the page side, encodes and stores the information in the memory. A step S 60 memorizes the sub scanning length, corresponding to the page counter and the page side.
A step S 62 judges the content of the page side, and, if it is front side, the sequence proceeds to a step S 64 for setting the back side as next page side and then to the step S 54 . If it is back side the sequence proceeds to a step S 66 for discriminating whether a next page exists, and the sequence proceeds to a step S 52 or S 68 according as the next page exists or not.
A step S 68 discriminates whether an original exceeding 330 mm is present among the read information, and the sequence proceeds to a step S 122 or S 70 according as such original is present or it is not.
A step S 70 outputs a signal of a level “1” to the signal line 20 a , thereby turning on the CML. A step S 72 makes a call to the designated destination, and a step S 74 executes a pre-process.
A step S 76 discriminates whether the partner unit has the function of two-side recording and side control by the MPS 1 /MPS 2 signal, and the sequence proceeds to a step S 78 or S 100 according as the result of discrimination is affirmative or it is negative.
A step S 78 executes the remaining pre-procedure, thereby informing the designation for two-side recording and the execution of designation for the page side by the MPS 1 /MPS 2 signal. A step S 80 sets “1” in a transmission page counter, then a step S 82 sets the front side as the transmission page side, and a step S 84 transmits the information of one page, of the side set above, designated by the transmission page counter.
A step S 86 discriminates whether the transmitted page side has been the front side or the back side, and the sequence respectively proceeds to a step S 88 or S 92 .
A step S 88 executes an intermediate procedure (transmitting the MPS 2 signal), then a step S 90 sets the back side as the transmission page side and the sequence proceeds to the step S 84 .
A step S 92 discriminates whether a next page is present, and the sequence proceeds to a step S 94 or S 98 according as the next page is present or it is absent.
A step S 94 increases the value of the transmission page counter by one, then a step S 96 executes an intermediate procedure (transmitting the MPS 1 signal) and the sequence proceeds to the step S 82 . A step S 98 executes a post procedure and the sequence proceeds to the step S 8 .
A step S 100 executes the remaining pre-procedure. The two-side recording is not designated in this case. A step S 102 sets “1” in the transmission page counter, then a step S 104 sets the front side as the transmission page side, and a step S 106 transmits the information of a page, of the side set above, designated by the transmission page counter.
A step S 108 discriminates whether the transmitted page side has been the front side or the back side, and the sequence respectively proceeds to a step S 110 or S 114 .
A step S 110 executes an intermediate procedure (transmitting the MPS signal), then a step S 112 sets the back side as the transmission page side and the sequence proceeds to the step S 106 .
A step S 114 discriminates whether a next page is present, and, if absent, the sequence proceeds to a step S 120 for executing a post procedure and then to the step S 8 . On the other hand, if the next page is present, a step S 116 increases the value of the transmission page counter by one, then a step S 118 executes an intermediate procedure (transmitting the MPS signal) and the sequence proceeds to the step S 104 .
A step S 122 divides the transmission information, corresponding to the page counter and the page side, by 297 mm. More specifically, at first the front side of the first page is divided at 297 mm and thus divided information is represented as “1” by a divided page counter. The remaining information of the front side of the first page, if not exceeding 297 mm, is represented as “2” by the divided page counter. The back side of the first page is similarly divided at 297 mm and the divided portions are represented as “3” and “4” in the divided page counter. Similar operations are thereafter repeated, and the number of pages in the divided page counter is determined.
A step S 124 then outputs a signal of a level “1” to the signal line 20 a , thereby turning on the CML. A step S 126 makes a call to the designated destination, and a step S 128 executes a pre-procedure.
A step S 130 discriminates whether the partner unit has the function of two-side recording and side control by the MPS 1 /MPS 2 signal, and the sequence proceeds to a step S 132 or S 156 according as the result of discrimination is affirmative or it is negative.
A step S 132 enters the information of the signal line 30 a for checking the transmission mode of the registration circuit 30 , and the sequence proceeds to a step S 134 or S 156 according as “transmission as two-side original” or “transmission as one-side original” is registered.
A step S 134 executes the remaining pre-procedure, thereby informing the designation for two-side recording and the execution of designation for the page side by the MPS 1 /MPS 2 signal. A step S 136 sets the front side for the page side, then a step S 138 sets “1” in the divided page counter, and a step S 140 transmits the information of a page of the divided page counter.
A step S 142 discriminates whether the transmitted page side has been the front side, and the sequence respectively proceeds to a step S 144 or S 148 according as the front side or the back side has been designated.
A step S 144 executes an intermediate procedure (transmitting the MPS 2 signal), then a step S 146 sets the back side as the page side and the sequence proceeds to the step S 140 .
A step S 148 discriminates whether a next divided page is present, and, if absent, the sequence proceeds to a step S 155 for executing a post procedure and then to the step S 8 .
On the other hand, of a next divided page is present, the sequence proceeds to a step S 150 for increasing the value of the divided page counter by one. Subsequently a step S 152 executes an intermediate procedure (transmitting the MPS 1 signal), then a step S 154 sets the front side as the designated side and the sequence proceeds to the step S 140 .
A step S 156 executes the remaining pre-procedure. The two-side recording is not designated in this case. A step S 158 sets “1” in the divided page counter, then a step S 160 sets the front side as the designated side, and a step S 162 transmits the information of a page of the divided page counter.
A step S 164 discriminates whether the side designation has been the front side, and the sequence proceeds to a step S 166 or S 170 according as the front side or back side is designated.
A step S 166 executes an intermediate procedure (transmitting the MPS signal), then a step S 168 sets the back side as the side designatio, and the sequence proceeds to the step S 162 .
A step S 170 discriminates whether a next divided page is present, and, if present, the sequence proceeds to a step S 172 , but, if absent, the sequence proceeds to a step S 176 for executing a post procedure and then to the step S 8 .
A step S 172 increases the value of the divided page counter by one, and-a step S 174 executes an intermediate procedure (transmitting the MPS signal).
A step S 178 enters the information of the signal line 22 a for discriminating whether the registration in the registration circuit 30 is selected, and, if selected, the sequence proceeds to a step S 180 to register, in the registration circuit 30 , “transmission as two-side original” or “transmission as one-side original” to the receiving unit, and the sequence then proceeds to the step S 8 . On the other hand, if not selected, the sequence directly proceeds to the step S 8 .
In the foregoing explanation, the functions of the control circuit are executed by a CPU therein based on a program stored in a ROM or a RAM therein, but the present invention may also be attained by storing such program in an external memory medium such as a floppy disk, a hard disk, an optical disk, a CD-ROM or a memory card, fetching such program into the control circuit by an exclusive reading device and executing it by the CPU in the control unit.
Also the foregoing embodiment has been explained by a facsimile apparatus of stand-alone type, but the present invention is not limited to such embodiment and is likewise applicable to the control of data communication in a comprehensive data processing system in which copying function, electronic filing function, data processing function etc. are combined with the communicating function.
Furthermore, the original information of A4 size alone is contemplated in the foregoing embodiment, but similar control is possible for other sizes. Besides, the specific numerical values mentioned in the foregoing embodiment are merely an example and may be suitably altered.
As explained in the foregoing, in case of selecting the two-side reading for a long-sized original, the present invention allows to select whether to transmit the information of the two-sided original as a one-sided original by a predetermined length or to transmit the information of the two-sided original as a two-sided original by a predetermined length, to the receiving unit, thereby enabling the transmission matching the actual situation of the receiving unit and ensuing the smooth transmitting operation.
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The invention provides a facsimile apparatus capable of smooth transmission without trouble in a receiving unit, even in case of two-side reading of a long original.
According to the invention, in case the reading of two-side original is selected, the sub scanning length of the original is detected an the transmission control is modified according to the sub scanning length. In case the sub scanning length of the original exceeds a predetermined length, the user is caused to select either to (1) transmit such original as a one-sided original to the receiving unit with informing the receiving unit of that, or (2) to transmit the original information corresponding to a predetermined length on the front side of the original as the front side information and transmit the remaining original information on the front side as the backside. In case such one-side transmission is selected, after the transmission of the original information of the front side, the original information of the back side is subsequently transmitted as a one-sided original to the receiving unit with informing the receiving unit of that, but, in case such two-side transmission is selected, after the transmission of the original information of the front side, the original information on the back side corresponding to a predetermined length is subsequently transmitted as the front side and the remaining original information on the back side is transmitted as the back side.
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