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BACKGROUND OF THE INVENTION
The present invention relates to a valve construction for a "single-shot" valve intended for use in a one time operation. More particularly, the invention relates to a valve which utilizes a deformable metallic bladder and which constitutes an improvement over a previously patented valve construction described and claimed in my U.S. Pat. No. 3,890,994, issued June 24, 1975.
As discussed in my above-identified patent, "single-shot" valves and similar devices operated by pyrotechnic charges and deformable metallic bladders are quite suitable for "one-time" operations in missile systems and the like because they may be stored for long periods of time in an inactive state without severely affecting their reliability and they may be operated from remote locations by means of an electrical firing squib. Furthermore, the fluids which actuate the valves can be confined within the valve and isolated from the primary fluids controlled by the valve. Thus, contamination of the controlled fluids is avoided. While the high pressures generated by the firing squib require certain safety precautions, it has been found that the deformable metallic bladders can be safely designed to contain such pressures during actuation and that the residual pressures assist in holding the bladder in an expanded condition sealing the valve in the closed condition.
Valves utilizing a metallic bladder of the type described are generally characterized by high reliability because they eliminate sliding or rotating seals in the form of O-rings or packing glands which generally permit a limited quantity of leakage and which are always subject to deterioration caused by abrasive wear or hardening. Thus, valve using a deformable, metallic bladder for one-time operation possesses many attractive features militating in favor of its use.
In the normally open valve construction shown in my above referenced patent, the deformable, metallic bladder has a generally tubular shape and has one end in a crushed condition projecting into the fluid passageway through the valve. When the valve is actuated, the crushed portion expands and fills the passageway to obstruct fluid flow through the valve. While such a valve is suitable in many installations, the crushed portion of the bladder does provide some restriction within the fluid passageway prior to actuation of the valve, and also prevents a conventional valve plug from sharing the same seat or portion of the fluid passageway through the valve.
It is, accordingly, a general object of the present invention to provide a valve construction utilizing a deformable, metallic bladder which does not intrude into the fluid passageway through the valve in the normally open valve condition.
SUMMARY OF THE INVENTION
The present invention resides in a normally open valve for a fluid system. The valve utilizes a deformable, metallic bladder to close the valve in a one-time operation.
The valve has a housing defining first and second fluid ports and a fluid passageway extending through the housing between the ports. The deformable bladder is formed by an expandible body having a generally tubular shape which is closed at one end and which extends across the passageway between the ports in flow-obstructing relationship when in the expanded condition. The body is mounted to the housing at the end opposite the closed end, and is preferably held in a bore of the housing for alignment and reinforcement. In the non-expanded condition, the body has one tube portion folded coaxially within an adjacent portion and thusly is shortened in axial length to remove the closed end from flow-obstructing relationship with the passageway and allow unimpeded flow through the valve. In the preferred embodiments, the closed end of the expandible body is carried in close-fitting relationship with the bore of the housing.
Means are connected with the interior of the tubular bladder to force the folded tube portion outwardly of the adjacent portion and extend the body into the fluid passageway of the housing. The means for forcing may include a pyrotechnic squib, which produces a quantity of pressurized gas, or other fluid pressure systems, and a piston may be installed within the bladder to transmit pressure forces directly to the closed end while isolating the end and the passageway from the actuating fluid within the bladder. The close-fitting relationship of the bladder and the bore and the internal pressure cause the folded tubular walls of the bladder to unroll in the manner of a rolling diaphragm, and the axial length of the bladder is thus extended.
The valve construction with a tubular bladder having the folded tubular walls may be designed to cooperate with the fluid passageway without impeding fluid flow during the normally open condition of the valve. It may also cooperate with alternate valve closing means and share a common seat within the passageway. Additionally, the valve shares the reliability safety, and other operational features of the valve shown and described in my above-identified patent.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of my valve in the normally open condition with the deformable metallic bladder in the non-expanded condition.
FIG. 2 is a cross sectional view of the valve in FIG. 1 with the bladder in the expanded condition closing the passageways of the valve.
FIG. 3 is a cross sectional view showing an alternate embodiment of my valve with the bladder in the non-expanded condition.
FIG. 4 is a cross sectional view of the valve in FIG. 3 with the bladder in the expanded condition closing the passageways of the valve.
FIG. 5 is a cross sectional view illustrating still another embodiment of my valve with the deformable metallic bladder in the non-expanded condition.
FIG. 6 is a cross sectional view of the valve in FIG. 5 and shows the deformable, metallic bladder in the expanded condition closing the fluid passageways of the valve.
FIG. 7 is a cross-sectional view showing still another embodiment of my valve with the bladder in the non-expanded condition.
FIG. 8 is a cross-sectional view of the valve in FIG. 7 with the bladder in the expanded condition closing the passageways of the valve.
FIG. 9 is a cross-sectional view of still another embodiment of the valve with the bladder in the non-expanded condition.
FIG. 10 is a cross-sectional view of the valve in FIG. 9 with the bladder in the expanded condition.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 illustrate one embodiment of my normally open valve construction. The valve, generally designated 10, is comprised principally of a housing 12, a deformable, metallic bladder 14 within the housing and means such as an electrically actuated, pyrotechnic squib 16 for forcing the bladder into an expanded condition on command.
The housing 12 has three intersecting cylindrical ducts 17, 18 and 19 which define fluid passageways through the valve between ports associated with each of the ducts on the exterior of the housing. In use, the ducts are connected with a fluid system in which fluid flow is to be controlled by the valve. It will be understood that fluid may flow through the passageways in various directions. For example, fluid may enter the duct 19 and exit through the ducts 17 and 18. Also, one of the ducts, for example, the duct 18, may be omitted and fluid may flow through the two remaining ducts 17 and 19 in one direction or the other.
The housing 12 also has a cylindrical extension 20 projecting away from the intersection of the ducts 17, 18 and 19. The deformable metallic bladder 14 is mounted within the extension 20 by means of a cylindrical collar 22. The bladder 14 is welded or otherwise attached to the collar and the collar is in turn welded or otherwise sealed to the outer end of the cylindrical extension 20.
In the expanded condition of the bladder 14 illustrated in FIG. 2, the bladder has a generally tubular shape and is closed at the one end 26 which projects into the passageways defined by the ducts 17, 18 and 19. In this expanded condition, the bladder prevents flow through one or more of the ducts. In the non-expanded condition of FIG. 1, the bladder resembles the extendible, actuating member in U.S. Pat. No. 3,106,131 issued to Barr et al. The closed end 26 is plastically deformed and inverted within a limited adjacent portion of the tubular shape. In the non-expanded condition of the bladder, the passageways through the ducts are unobscured and fluid flow through the passageways is unimpeded.
To form the bladder with the hat-shaped end 26 illustrated in FIG. 1, a sheet of ductile steel may be first formed as a cup having a large flange in a spinning, deep drawing or hydro forming process. Then the flange is reverse drawn in a tubular configuration over the cup so that the bladder is finally formed with the closed end inverted within the tubular shape as shown in FIG. 1.
With the one end 26 of the deformable bladder 14 inverted, the opposite end 28 is fastened to the collar 22 and the collar is in turn fastened to the extension 20 of the valve housing 12. The collar 20 is internally threaded and the pyrotechnic squib 16 is threaded into the collar for attachment to the valve housing 12. Thus, the end 28 of the bladder 14 which would therwise be opened is sealed by the collar and the squib.
When it is desired to actuate the valve 10, the electrical leads 30 of the squib 16 are connected to a low voltage source and a pyrotechnic charge within the squib is exploded to generate a selected volume of high pressure gases within the interior of the deformable bladder 14. The high pressure gases develop forces on the inverted end 26 of the bladder and drive the inverted end outwardly into the passageways of the ducts 17, 18 and 19 as illustrated in FIG. 2. Preferably, the outside diameter of the tubular bladder 14 and the inside diameter of the bore in the cylindrical extension 20 are approximately the same so that the bore reinforces the bladder and prevents radial expansion under the internal pressures developed by the squib 16. The diameter of the bore 20 and the diameter of the duct 19 may be equal and may be larger or smaller than the diameters of the passageways through the ducts 17 and 18 depending upon the flow desired after valve closing. Fluid flow through the ducts 17 and 18 as well as the duct 19 is completely precluded and the bladder will be forced against a finite seat within the intersection of the ducts 17 and 18 if the diameters of ducts 17 and 18 are slightly smaller than the diameter of the duct 19. If the diameters of the ducts 17 and 18 are sufficiently larger than the duct 19, flow between the passageway of the ducts 17 and 18 is permitted.
The size of the pyrotechnic charge within the squib 16 should be selected to generate a quantity of high pressure gas sufficient to expand the bladder axially from the shortened to the extended condition and also provide a residual pressure to hold the bladder against the ducts 17, 18 and 19 in sealing relationship.
Of course, means other than the pyrotechnic squib 16 may be provided to develop the forces which expand the deformable bladder 14. For example, the squib 16 may be removed from the collar 22 and a suitably controlled source of pressurized gas or other fluid at a remote location may be connected by high pressure conduits to the collar 22. Thus, the source of energy which expands the bladder as well as the triggering mechanism may be located remotely of the valve 10.
An alternate embodiment of my normally open valve, generally designated 40, is illustrated in FIGS. 3 and 4. In this embodiment, parts already described and shown in connection with FIG. 1 bear the same reference numerals. The pyrotechnic squib 16 and the collar 22 attaching the squib and bladder 14 to the extension 20 are not illustrated for simplicity.
In the valve 40, the tubular bladder 14 has the closed end 26 inverted within the bladder in the non-expanded condition in the same manner as described above. However, a tapered piston 42 is mounted within the bladder adjacent to and preferably in contact with the end wall of the inverted end 26. The skirt or left portion of the piston as viewed in FIGS. 3 and 4 is substantially the same size as the inside diameter of the tubular bladder and may be provided with an O-ring to seal the piston against the inside wall of the bladder. The piston tapers inwardly from the skirt portion and the degree of taper is made to match that defined between the inner end of the extension 20 and the inner end of the duct 19.
When hot gases from the pyrotechnic squib or pressurized fluid are introduced into the deformable bladder 14 at the left of the tapered piston 42 in FIG. 3, forces developed by the pressurized gases or fluid operate against the piston and the piston pushes against the inverted end 26. The tubular walls unroll and the piston finally reaches its seated position within the extended end 26 as illustrated in FIG. 4. When seated, the piston and bladder seal the passageway within the duct 19 and, again, by appropriate selection of the diameters of the passageways within the ducts 17 and 18, fluid flow within these ducts may be permitted or terminated also. Residual pressure within the bladder 14 and friction developed by the piston and bladder wedged within the housing 12 hold the piston 42 in the seated position. Any fluid pressure developed within the passageways of conduits 17, 18 and 19 operates against the bladder but the piston within reinforces the tubular walls and the end wall to prevent the bladder from deforming and allowing leakage between the passageways. The piston also isolates the hot gases of the pyrotechnic squib from the end 26 of the bladder and fluids within the passageways.
FIGS. 5 and 6 illustrate still another embodiment of the normally open valve, generally designated 50, and in this embodiment also parts previously described and illustrated in the embodiments of FIGS. 1-4 bear the same reference numerals.
The valve 50 is similar in construction to the valve shown in FIGS. 3-4 except that a non-tapered piston 52 is mounted within the deformable metallic bladder 14 and a viscous material 54 is interposed between the piston and the closed end 26 of the bladder. The viscous material may be a maleable wax or putty that readily conforms to the space in which it is confined and yet is incompressible when placed under pressure by the piston 52.
In operation of the valve 50, the pressure is developed within the bladder 14 at the left end of the piston 52 as viewed in FIGS. 5 and 6. The pressure may be developed by means of a pyrotechnic squib or other fluid pressurizing systems connected to the valve housing 12 at the outer end of the extension 20. The piston 52 slides in close fitting relationship within the bladder 14 and may be provided with an O-ring or other seal to prevent the pressurized gases from leaking passed the piston toward the viscous material 54. Thus, pressure developed against the left hand side of the piston is transmitted by the piston to the viscous material which in turn forces the end 26 of the bladder out of its inverted condition and expands the bladder into the condition illustrated in FIG. 6. In the expanded condition, the bladder is situated in the passageways defined by the ducts 17, 18 and 19 and in engagement with the inner end of duct 19. Again, by appropriate selection of the inside diameters of the ducts 17 and 18, communication between these ducts may either be interrupted or maintained.
It will be noted that the viscous material 54 operates hydrostatically upon the closed end 26 of the bladder and forces the tubular walls and the end wall outwardly at all unsupported points. This operation of the material 54 is desirable since it insures that the bladder is properly seated in sealing relationship with the housing 12 at all desired points within the fluid passageways. The material 54 and the piston 52 also provide isolation between the pressurized fluid operating against the piston 52 and the fluid within the system controlled by the valve 50. Also, the material 54 reinforces the bladder 14 against pressures that develop in the fluids controlled by the valve. Residual pressure operating on the piston 52 and any friction developed between the piston and the bladder maintain the viscous material 54 under pressure to provide such reinforcement.
FIGS. 7 and 8 illustrate another embodiment of my normally open valve, generally designated 60. Parts previously described and illustrated in FIGS. 1-6 bear the same reference numerals.
In the valve 60, the housing 62 is comprised of one portion 64 in which the squib 16 is threadably mounted and another portion 66 defining the intersecting ducts 17, 18 and 19. The bladder 68, like the bladders in the foregoing embodiments, is comprised of an inverted metallic tube in which one tube portion is folded or drawn coaxially within an adjacent portion in axially overlapping relationship to form an inversion in the tube walls. In the present embodiment, the closed end 72 of the bladder extends coaxially through the remaining portion of the bladder and projects through the open end 74 of the bladder into the bore of an extension 70 projecting from the housing portion 66. The bore of the extension 70 is only slightly larger than the outside diameter of the closed end 72 and establishes a close-fitting guide for the bladder. The open end 74 of the bladder is captured in sealing relationship between the extension 70 and a shoulder at the inward end of the bore within the housing portion 64.
During extension of the bladder 68 from the normally open position of the valve illustrated in FIG. 7 to the closed position of the valve illustrated in FIG. 8, the tubular walls roll inwardly rather than outwardly as in the foregoing embodiments. The closed end 72 moves axially out of the bore and across the fluid passageway to close duct 18 and also ducts 17 and 18 depending upon their diameter.
Optionally, a reinforcing coil spring 76 is mounted circumaxially about the intermediate portion of the bladder between the open and closed ends. The spring 76 provides additional hoop strength for the tubular walls within, and prevents collapse of the tubular walls without, when the squib 16 is detonated. Thus, the spring 76 maintains a finite curvature at the fold in the tubular walls as the bladder is extended axially by the pressurized gases. It will be noted that the coils of the spring 76 are expanded about the intermediate portion of the bladder in FIG. 7 while the same coils in FIG. 8 are compressed due to the bladder extension. The spring may be formed from circular or rectangular section wire or a series of spaced rings may be used instead.
FIGS. 9 and 10 illustrate still another embodiment of the normally open valve, generally designated 80, in which corresponding parts previously described bear the same reference numerals. The valve 80 closely resembles the valve 60 of FIGS. 7 and 8 in that the valve housings are identical and the bladder 82 is mounted in the same manner as the bladder 68.
The bladder 82 has an inverted tubular portion 84 which is open at the end 86 and closed at the inner end 88 by means of an elongated plug 90. The plug 90 has a reduced tail section 92 which fits within the end 88 of the tubular portion 84 and is brazed or otherwise sealingly connected to the portion 84 to insure that gases emanating from the squib 16 do not escape through the bladder into the ducts 17, 18 or 19.
In operation, the plug 90 is initially in the position illustrated in FIG. 9 with the tip of the plug retracted into the extension 70 and out of the fluid passageways of the fluid ducts 17, 18 and 19. After the squib 16 has been ignited, the plug 90 is propelled axially into the fluid passageways to the position illustrated in FIG. 10 closing the duct 19 and also the ducts 17 or 18 depending upon their diameter. As the plug moves between the FIG. 9 and FIG. 10 positions, the cylindrical walls of the tubular portion 84 roll inwardly away from the housing portion 64 and confine the pressurized gases within the housing.
For lighter weight, the plug 90 forming part of the bladder 82 may have a central bore opening at the tail section 92 adjacent the squib 16. Optionally, an end burning propellant 94 may be placed in the central bore to provide a slower closing of the valve when the propellant is ignited by a small charge in the squib. The rate at which gas is generated by the propellant is limited by the sustainer grain in the propellant and the endburning effect in the bore. Preferably, a small quantity of the propellant remains in the bore when the plug reaches the valve closing position as shown in FIG. 10 so that an additional quantity of pressurized gas is generated to hold the bladder in the expanded condition closing the valve.
While the present invention has been described in several preferred embodiments, it will be understood that still further modifications and substitutions can be had without departing from the spirit of the invention. For example, the valve housing need not always be provided with three intersecting ducts. A valve seat against which the bladder expands can be located in various locations within the fluid passageways. The bladder may be integrated within a more conventional valve having a gate or mechanically actuated screw plug for opening and closing the valve. The gate may operate in conventional fashion to open and close the valve and the bladder may be reserved for closing the valve in emergency situations. The inverted bladder is particularly advantageous in such composite valves because it is normally situated out of the fluid passageway through the valve and does not interfere with the more conventional valve gates. When called upon in an emergency situation, the bladder extends rapidly across the passageway in flow-obstructing relationship. Accordingly, the present invention has been described in several preferred embodiments by way of illustration rather tham limitation.
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A normally open valve construction utilizes a valve housing defining a fluid passageway extending through the housing between at least two ports, and an expandible, metallic bladder within the housing. The bladder is mounted in non-obstructing relationship with the fluid passageway when the valve is open and is expanded across the passageway in flow-obstructing relationship when the valve is closed. The bladder in the expanded condition has a generally tubular configuration and is closed at one end. In the non-expanded condition, one portion of the tubular configuration is folded coaxially within an adjacent portion to shorten its axial length and to remove all portions of the bladder from the fluid passageway. A pyrotechnic squib or other fluid pressure generator discharges within the tubular configuration to extend the bladder into the fluid passageway and close the valve.
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FIELD OF THE INVENTION
This invention pertains to back light systems for flat-panel displays and, more particularly, to a back light system that produces high intensity, collimated light for very large flat-panel displays.
BACKGROUND OF THE INVENTION
Large flat-panel displays made in accordance with known active matrix (or TFT) liquid crystal display technologies are typically mounted in front of a back light module which contains an array of fluorescent lamps. FPDs of this type have been increasing in size by about 1 to 2 inches diagonal yearly. The median size in 1999 for use in desk top PCs is about 15 inches diagonal view area. A few very large displays are made in the range of 20 to 25 inches diagonal. Tiled AMLCD FPDs may be made in the range of 40 inches diagonal, as described in copending U.S. patent application Ser. no. 09/368,921, assigned to the common assignee and hereby included as reference. However, tiling, as described in U.S. Pat. No. 5,661,531 and also included as reference requires extremely intense light sources with substantially collimated lighting, masked optical stacks, and pixel apertures that have very low emitted light efficiency. Thus, lighting with unusually high intensity ranges of 50,000 to 150,000 nits is desirable with uniformity over very large FPD areas. Unique designs, and control features are necessary to achieve such high intensities at reasonable wattages for consumer or business applications. Maintaining a bright and uniform illumination of the display over its entire active area is difficult to do. The intensity required for some applications and, in particular, that required for a large, tiled, seamless flat-panel LCD display causes the lamps to produce a significant amount of heat. In addition, fluorescent lamps are designed to run most efficiently at an elevated temperature, so it is desirable to operate them at their ideal design temperature, which is usually about 50 to 60 degrees Centigrade.
Small, edge-lit back light modules used in notebook or laptop PCs do not produce sufficient brightness for a large area display, nor are they capable of illuminating a large area uniformly. Thus, it is necessary to illuminate the area with an array of fluorescent lamps. The number of lamps required depends on the size of the area to be illuminated and the display brightness specifications. A large area display requires multiple lamps to illuminate it properly.
Since most displays are designed to be wider than they are tall, it is advantageous, from a reliability and power perspective, to use horizontal lamps. This results in fewer lamps and less power, since less lamp cathodes are present. The resultant proffered designs orient lamp tubes horizontally, one above the other with predetermined preferred angular and spacing relationships for increasing reflective efficiency of the back wall of the cavity.
The present invention provides a mechanism for using an array of high output and efficient fluorescent lamps for producing maximum brightness. Additionally, the back light assembly cavity of the inventive apparatus is treated with a highly diffuse and efficient reflective surface. Also added are commercially available optics, such as Brightness Enhancing Films (BEFs) and a diffuser for maximizing the output of the BEFs, reflector, and back light geometry.
The invention also provides for a very uniform light field across the back light exit surface.
The invention further provides means for incorporating a sharp cut-off collimator, as described in U.S. Pat. No. 5,903,328, hereby incorporated by reference.
Additionally, when used with the invention described in copending U.S. patent applications, Ser. Nos. 09/407,619 and 09/406,977, both filed concurrently herewith and also hereby incorporated by reference, the apparatus of this invention provides a very uniform, high luminance back light system capable of maintaining display brightness under a wide range of environments over long periods of time. It is particularly suited for illuminating a large tiled, seamless flat-panel LCD.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a system for uniformly distributing luminance from a back light module for a flat-panel, liquid crystal display (LCD). Fluorescent lamps are commonly used in back light modules for LCDs due to their high efficiency. Luminance from fluorescent lamps is a function of lamp tube temperature, as is the efficacy and also lamp life. This invention provides means for achieving luminance uniformity and a high degree of collimation.
A highly efficient and diffuse reflective surface treatment is disclosed. Reflection efficiency of this invention is significantly higher than other available treatments for large areas. In particular, a constant and uniform luminance output of the back light module is obtained through appropriate selection of lamps, geometry and optical components. A preferred balance of lamps, lamp spacing, reflective light back plane, and diffuser and collimating optics are chosen to produce a high brightness back light module with very high intensity output over very large surfaces. The variations in intensity over the illuminated area are minimized using light recycling in conjunction with the collimating optics. Variations are further reduced by incorporating the invention disclosed in patent application Ser. No. 09/406,977.
This invention provides means for achieving this goal through selection of combinations of components and appropriately designed geometry. A particular application is a large, tiled, flat-panel display having visually imperceptible seams as described in the aforementioned U.S. patent application, Ser. Nos. 08/652,032, 09/368,291, and U.S. Pat. No. 5,903,328. The back light module system, with thermal enhancements such as those disclosed in Ser. No. 09/406,977 and applicable controls, such as those disclosed in Ser. No. 09/407,619 provides for an efficient, reliable, large area, high intensity light source for flat-panel displays.
Additionally, optimum geometries are determined for the purpose of maximizing light output at high efficiencies, while minimizing luminance gradients across the display. These optimum geometries are also determined for maximizing light output using BEFs and light recycling.
Finally, a precise collimator such as that disclosed in Ser. No. 09/024,481 is added which eliminates light beyond a defined angle, as required in a tiled flat-panel LCD.
BRIEF DESCRIPTION OF THE DRAWINGS
A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description, in which:
FIG. 1 graphically illustrates the temperature characteristics of a fluorescent lamp
FIG. 2 a illustrates a side view of a multiple lamp back light and a display in accordance with the present invention;
FIG. 2 b illustrates a planar view of the multiple lamp back light depicted in FIG. 2 a;
FIG. 3 a is a schematic diagram illustrating lamp and reflector spacing relationships;
FIG. 3 b graphically depicts light output as a function of lamp spacing;
FIG. 4 is a graph depicting light output as a function of the number of lamps;
FIG. 5 is a schematic view of a high efficiency reflective surface treatment;
FIG. 6 depicts a back light design with display, in accordance with the present invention;
FIG. 7 graphically illustrates the collimation attributes of the optics;
FIG. 8 shows a schematic, cross-sectional view of a tiled, color display having invisible seams;
FIG. 9 depicts a heat sink used to cool the lamp ends, in accordance with the present invention;
FIGS. 10 a and 10 b depict a back light cavity back plane with louvers;
FIG. 11 is an electrical schematic diagram illustrating the fan speed control logic of the present invention;
FIG. 12 is an electrical schematic diagram illustrating the dimming ballast control logic; and
FIG. 13 graphically illustrates temperature control operation characteristics of the back light control of the present invention.
For purposes of both clarity and brevity, like elements and components will bear the same designations and numbering throughout the figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Generally speaking, the invention features apparatus and a method for controlling the luminance uniformity and collimation of light exiting a large area back light for a flat-panel display. A back light for a large tiled, flat-panel display requires high luminance levels and a precise predetermined degree of collimation. In addition, the invention provides an optimum design for the efficiency, cooling, luminance and image quality desired in a large, flat-panel display, particularly a tiled LCD.
Now referring to FIG. 1, a typical fluorescent lamp (not shown in the FIGURE) is designed to operate most efficiently at a predetermined lamp tube wall temperature. Maximum brightness occurs near the point of maximum efficacy 11 . The ideal temperature then is said to be T o 12 . The ideal temperature 12 is determined by the lamp construction and its parameters, such as phosphors and mercury vapor pressure. The most efficient lamps are those referred to as hot cathode lamps. These lamps have a preheat cycle during which the cathodes are heated, thereby causing easier ignition of the gas.
Now referring to FIG. 2 a, , a side view of a flat-panel display 20 and its back light assembly 21 is shown. The back light assembly 21 consists of a light box cavity 22 , an array of fluorescent lamps 23 , and a light diffuser 24 . Lamps are cooled by fans 29 . Some display applications require additional optics 28 to enhance certain characteristics of the exiting light. An example is the aforementioned tiled, flat-panel LCD display, which uses highly collimated light. The additional optics 28 required to collimate the light are somewhat inefficient. This necessitates that a high luminance be produced by the back light 21 .
FIG. 2 b shows a front view of the back light assembly 21 . The lamps 23 are held in the light box cavity 22 by lamp holders 25 . The lamps 23 are wired to the ballast 26 by a wiring harness 27 . The ballast 26 supplies high frequency (usually 20-30 Khz) AC power to the lamps 23 .
FIG. 3 a illustrates an arrangement of lamps 23 and the reflecting back plane 30 of the back light cavity 22 . Lamps 23 have a diameter D and are spaced apart by dimension S. The lamps 23 are positioned at a distance H from the back plane 30 .
FIG. 3 b shows the effect of changing the ratio of S to H. The light output 31 can be calculated easily by assuming that the back plane surface 30 is 100% reflective, while the lamp tubes 23 are 100% absorbing. For a given diameter D of a lamp 23 and lamp space S, there is an optimum distance 32 for the back plane surface 30 to lamp tube 23 space H.
A first approximation analysis can easily be obtained through a consideration of the geometry in FIG. 3 a. Light leaving the lamp 23 exits forward toward the display, is absorbed by neighboring lamps, or is sent back to the back plane 30 . It is desired to have as much light possible to reflect off the back plane. A first approximation is to assume that the back plane is a mirror; in reality it is a diffusive reflector. The lamp is assumed to be a line source.
Light rays leaving the rear of the lamp will reflect back into the lamp if they leave the lamp at angles smaller than B. If the exiting angle is larger than A, the light will be absorbed by neighboring lamps. Light rays exiting the rear of lamp 23 that have exit angles between A and B will escape forward through the interlamp space S. A first approximation of angle A is A = tan - 1 ( D / 4 ) ( H + D / 2 )
A first approximation for the angle B is B = tan - 1 ( S + D / 2 ) ( H + D / 2 )
The escape angle is then
E=A−B
There is a value H, given S and D, that maximizes the light escape angle E. The maximum is found by setting the differential equal to zero. That is E H = 0 = A H - B H = H { tan - 1 D 2 ( 2 H + D ) tan - 1 ( 2 S + D 2 H + D ) }
FIG. 4 illustrates the results of an analysis to determine the number of lamps 23 to be used in a back light assembly 21 having a predetermined size. The assumptions are the same as used to generate FIG. 3 b. In addition, the optimum lamp 23 to reflective back plane 30 space H was chosen for calculation. The curve of total light output from the back light cavity 42 is shown as a function of the number of lamps installed. The desired light level 40 is also presented. It will be noted that, as the number of lamps increase, the light output increases until a maximum illumination 43 occurs prior to reaching the point of maximum lamp capacity 44 .
The lamps 23 block light reflected from the reflector surface 30 , from the rear half of the lamp tube. Also, as more lamps are used, spaced closer together, they block light from each other. The number of lamps 41 corresponding to the desired light output 40 is also shown.
A good approximation of the total light output of the back light assembly, without considering collimation and related light recirculation, can be obtained by considering the geometry. A lamp tube 23 produces light rays uniformly over 360 degrees. The light exits forward toward the display, is absorbed by neighboring lamps or it exits rearward and hits the reflective back plane 30 . The light reflecting off the back plane 30 either exits the back light through space S or is absorbed by a lamp.
The light absorbed by a neighboring lamp can be expressed by the angle of light rays leaving the lamp. Or φ 1 = sin - 1 ( D S + D )
The space S is given by the number of lamps N housed in the width W of the back light cavity, and is S = W - ND N - 1
The light exiting forward is given by its angle
φ forward =180−2φ 1
The light exiting rearward is the same as the forward, but the light then reflected out of the back light cavity from the back plane is φ back = S D + S φ forward
The total light exiting from the back light assembly is L: L = Nl 360 { φ forward + φ back }
where l is the total light output of one lamp. The results are plotted in FIG. 4 .
Since the power consumed by each lamp 23 is constant, efficiency is related to light output and the number of lamps. The curve 42 is nearly linear until the number of lamps approaches 50% of the maximum that can be installed in the allotted space. It is desirable then to choose a light output design point near this inflection point. Thus, an optimum number of lamps 41 is shown in FIG. 4 .
FIG. 5 shows a unique surface treatment for the back plane 30 of the back light cavity 22 of the back light assembly 21 . The back light cavity 22 is constructed of aluminum with a moderately high gloss finish 50 . A somewhat reflective white powder coat of paint 51 is applied to the aluminum back plane 30 . The surface texture finish of the paint 51 is chosen through experiment to best reflect diffuse light.
The texture features of peak-to-peak roughness and off-planar angularity of the microsurfaces are chosen to reflect and disperse light without imaging shadows of the texture details. Next, a white Teflon sheet is applied to the back plane 30 using an optically clear adhesive. The Teflon sheet is a commercially available product with a high loading of titanium dioxide powder filler. The film is sufficiently thick to maximize the reflected light. Specific designs use a 0.05 mm thick paint 51 and 0.25 mm of Teflon material.
Now referring to FIG. 6, there is shown a cross sectional view of a back light assembly 21 with additional optics 28 and flat-panel display 20 . The back light assembly 21 consists of a back light cavity 22 with reflecting back plane lamps 23 and a glass cover plate 61 . A diffuser is added to complete the back light assembly 21 .
Collimating optics consist of crossed BEFs 63 and 64 and a collimator 65 . The diffuser and collimating optics are sandwiched between two glass plates 61 and 62 . These plates 61 and 62 may be any optically clear, with enough stiffness to support the film optics over the expanse needed. A flat-panel display 20 is placed in front of the optics assembly 28 by a distance F, leaving an air space 66 . This air space 66 is vented to ambient air to allow for further cooling of the display 20 .
As aforementioned, the collimating optics makes use of BEFs. A BEF accepts light at high angles of incidence and sends light at near normal angles of incidence back to the back light assembly for recycling. It is desirable to have as much reflective area available as possible for the BEFs. However, more lamps produce more light output. The first pass design choice for lamp spacing S is increased slightly. Specifically, 10% fewer lamps are used. The coupling of light into the BEFs 63 and 64 is also affected by the distance B that they are placed from the lamps 23 .
The luminance output of the BEFs increases with proximity to the lamps, but luminance uniformity decreases with closeness to the lamps. For practical reasons a reasonable space is required between the lamps and the glass optics holder 61 for air flow to cool the cavity 22 .
The preferred diffuser 24 is a high transmission holographic type diffuser which is chosen to have a near Lambertian distribution in order to couple a maximum amount of light into the BEFs 63 and 64 and to permit a maximum amount of recycling in the back light cavity 22 . The diffuser 24 need not be of the holographic type, but is must have high transmission efficiency and produce a Lambertian distribution of light. The lamps are not 100% absorbing and the reflective back plane is not 100% reflecting, although reflectivity is greater than 95%. Accordingly, fine tuning is necessary in the design parameters of lamp spacing, back plane space, and BEF spacing to the lamps.
The collimator 65 , also disclosed in the aforementioned U.S. Pat. 5,903,328, consists of open hexagonal cells in a honey comb configuration, coated with a highly light-absorbing paint. The aspect ratio of cell width to cell depth determines the cut-off angle or collimation angle.
The use of a sharp cut-off collimator is preferred in a seamless, tiled, flat-panel display. Untiled, large displays do not require a sharp cut-off collimator. Unfortunately, the collimator, having a physical structure, creates a shadow image which can be seen on the display. To prevent imaging of the collimator, the display is placed further away so that cell images overlap, or are defocused, and therefore are not visible to the viewer.
FIG. 7 depicts the degree of collimation or angular distribution of light emitted from each of the optical components. The diffuser 24 emits a Lambertian distribution 71 , as stated hereinabove. The BEFs focus light forward in a distribution 72 that has a theoretical forward gain of 2.2 for the type used herein. Actual achieved forward gain is about 1.9. The BEF distribution 72 has a significant amount of light energy remaining beyond the cut-off angle (˜30° in the preferred embodiment) desired for a seamless, tiled, flat-panel display.
The collimator eliminates such unwanted light by cutting off light beyond the collimation angle, as shown by its emission distribution 73 . The surface absorption of the collimator cell must be sufficient to prevent luminance of more than 1% of normal luminance beyond the collimation angle.
Brightness levels far exceeding industry capability have been achieved. Luminance values exceeding 100,000 nits (candellas/square meter) have been reached. Reasonable designs with exceptional efficiency have been prototyped with luminance output exceeding 50,000 nits, a uniformity of luminance of 10% at an efficiency better than any commercially available unit even at lower brightness levels.
Now referring to FIG. 8, one embodiment of a seamless, tiled display is illustrated in cross-sectional view. The seamless display 150 comprises an image source plane 151 comprising a color filter layer 152 and lightvalve layer aperture areas 153 . It should be understood that the image source plane 151 can be disposed anywhere between the viewer and the source. The tiles are presented by the glass layers 154 , which are separated by a gap 155 . This gap 155 and the areas between the lightvalve areas 56 are covered by a mask 157 , in order to make the image source plane uniform. An overlaid screen surface 158 is used to project the image source plane into the image view plane. A lens surface may be used, instead of the screen surface 158 , for generating the image view plane.
When the seam 155 is blocked from the backlight source, the seam is still noticeable because of ambient light and scattered light from the sides of the tiles. However, when the seam 155 is blocked directly from above, using a mask 157 , which is aligned to the tiles and lightvalves of the display, then the seam is not perceptible when viewed directly along the surface normal. However, for sufficiently large viewing angles away from the surface normal, the seam 155 is no longer shadowed by the mask 157 , and thus becomes visible. If the view angle range for seamless appearance is unacceptably small, it can be enhanced through the use of a microlens array. The closer the screen 158 can be placed to the mask 157 , the larger the view angle range becomes for seamless appearance. The mask reduces the transmitted light flux significantly. A thin polarizer layer 159 can be placed between the image source plane 151 and the screen 158 .
FIG. 9 is an exploded view of a cathode heat sink assembly 240 in accordance with the invention. The heat sink assembly 240 serves as a lamp holder (not shown) as well. The heat sink assembly 240 covers the cathode area of the fluorescent lamps 23 (FIG. 2 b ). The heat sink assembly 240 consists of two mating parts: the heat sink body 241 and the heat sink cap 245 . Both of these two parts 241 and 245 have respective, essentially semicircular cavities 242 for receiving lamps 23 . The two mating parts 241 and 245 are held together by fasteners 248 .
Prior to placing the lamps 23 into the heat sink cavities 242 , thermally conductive elastomeric tape 246 is placed around the lamps 23 in the cathode area. The thermal tape 246 provides compliance so that the lamp tubes 23 are not overly stressed during assembly. High viscosity thermal grease can be used in conjunction with the tape 246 .
A thermal sensor 244 is mounted in the heat sink body 241 using thermal adhesive. The heat sink temperature is uniform across the lamps 23 . The temperature at the top of the heat sink 240 is the most indicative of the lamp temperatures in the back light cavity 22 (FIG. 2 b ). The temperature at the sensor 244 represents the lamp cathode heat plus some of the heat produced in the chimney of the lamp array 23 . The output of the sensor can be used to regulate the speed of cooling fans (not shown). The use of fans to cool a light box, of course, is well known to those skilled in the art.
The heat sink assembly 240 is mounted in the back light cavity 22 with cooling fins 247 protruding from the rear of the cavity 22 . This allows cool ambient air to flow convectively over the heat sink fins 247 . This additionally allows the heat sink 240 to be at a near uniform temperature. The sensor 244 is located at an optimum thermal location for use in a temperature control system.
Referring now to FIG. 10 a, there is shown an array of louvers, or open slots, dispersed behind the lamps 23 . Different sized louvers 261 , 262 and 263 are used for thermal balancing. The louvers 261 , 262 and 263 are punched into the back plane of the back light cavity 22 . This plane is a highly efficient, diffusive reflector; the louver surface is reflective as well. The louvers 261 , 262 and 263 present no visible slot to the viewer, due to the diffusive reflectivity characteristic of the back plane.
In summary, the lamp tubes 23 can be made to operate at a uniform temperature along their entire length by allowing cool ambient air pulled by fans (not shown) to enter the back light cavity 22 through louvers 261 , 262 and 263 placed behind the lamps 23 . A filter 264 is placed behind the back light cavity 22 , as shown in FIG. 10 b.
The height H and width W of the louvers 261 , 262 and 263 can be determined experimentally, guided by analysis. It is desired that the air temperature and flow rate be constant along the lamp tube length. To counterbalance the chimney effect, larger and more numerous louvers are disposed at the top of the lamp array 23 and near the horizontal center. The objective is to maintain each lamp at a uniform temperature along its length, but not necessarily to maintain the same temperature from lamp to lamp.
FIG. 11 is an electrical schematic diagram that depicts a closed loop circuit for controlling fan speeds. One type of temperature sensor 371 in this embodiment is a thermistor forming part of a voltage divider network with fixed resistors 373 and held between a reference voltage 372 and ground 374 . The divided voltage 376 is fed into a microprocessor 370 via analog-to-digital converters 375 . The temperature sensor 371 in this embodiment can be used as sensors 363 , 364 .
A microprocessor 370 uses digital temperature data 378 to adjust fan speeds. The digital output 379 of the microprocessor 370 is fed into the motor drive amplifiers 377 via digital-to-analog converters 376 . In this embodiment, motor drive amplifiers 377 then supply a DC voltage to the fans (not shown).
The simplest form of control algorithm adjusts the speed of all fans to be the same, based on the value of one sensor S 1 . Air flow is uniform across the lamps 23 . This is the most cost efficient control scheme. The adjustment to the microprocessor output 379 to changes in the input 378 is accomplished using a simple lookup table, not shown, which is empirically developed by actual test results. Only one sensor and one motor drive amplifier is needed for this simplest of controls.
A two zone air flow control system can be accomplished in two ways. The simplest is to thermally profile the unit during actual testing and determine the air speed ratios desired between the two zones. A more complex method is to use two sensors 363 and 364 of the type 371 for example, to independently control the air flow (a) up through the center of the back light assembly 21 and (b) for the sides of the back light assembly 21 . Additional sensors and motor drive amplifiers, not shown, can be added to control the temperature distribution more accurately within the back light assembly 21 . It has been found that a dual zone with one sensor is adequate for most applications.
FIG. 12 shows the control system used for dimming the lamps individually or in groups. The control again is through lookup tables in the microprocessor 370 . Lamp temperature digital data 378 is fed to the microprocessor 370 , as previously shown. Ballasts 26 have a dimming feature such that the output of a ballast 26 is proportional to a DC input voltage 384 . The digital output 382 of the microprocessor 370 is converted to the appropriate ballast voltage 384 via a digital-to-analog converter 383 . Each lamp 23 may be driven by one ballast 26 . Alternatively, the lamps 23 may be ganged, so that one ballast 26 can drive several lamps 23 .
In simplest form, the ballasts 26 are all given the same dimming voltage 384 . The dimming voltage 384 is controlled by one sensor 371 (the same one used for fan control) and the external brightness command 381 . Dimming voltage 382 and fan speed voltage 379 are determined from a lookup table, the inputs for which are temperature sensor data 378 and brightness setting 381 . Brightness increases based on input 381 , as long as the average maximum temperature does not exceed the ideal. Brightness can be decreased by external input. Microprocessor output 382 to the ballasts is decreased accordingly. In addition, fan speed data 379 is lowered to a predetermined level based on a new lower ideal temperature that has been empirically determined by actual testing.
Referring now to FIG. 13, normal operation of the back light 21 is shown along with a safe mode operation sequence of events. The normal operation of the back light module 21 begins when initially turned on. Fan speeds and dimming output data are set at predetermined initialization levels. As the unit heats up, lamp temperature follows curve 404 towards the preset brightness level 402 and upper operating temperature level 403 .
As the temperature level 403 is reached, power to the lamps 23 is reduced incrementally in steps via the dimming output data. When temperature reaches an acceptable lower operating temperature, the fan speed is incrementally increased. This area of control on the curve is the normal operation area, depicted by reference numeral 405 . In the event of an over temperature condition 406 , the lamp power is reduced via the dimming output data level to a predetermined safe power (brightness) level 401 . The lamp temperature then drops, following path 407 . When the temperature is in a safe zone, the lamp power is again increased, following curve 408 towards the normal operating area 405 . If this over temperature condition reoccurs a predetermined number of times, a shut down occurs.
Since other optical configurations can be formulated to fit particular operating specifications and requirements, it will be apparent to those skilled in the art that the invention is not considered limited to the examples chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
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The present invention features a system for uniformly distributing luminance and a high degree of collimation from a back light module for a flat-panel, liquid crystal display (LCD). A constant and uniform luminance output of the back light module is obtained through appropriate selection of lamps, geometry and optical components. An appropriate balance of lamps, lamp spacing, reflective light back plane, and diffuser and collimating optics are chosen to produce a high brightness back light module with very high intensity output over very large surfaces. Variations in intensity over the illuminated area are minimized using light recycling in conjunction with the collimating optics. Optimum geometries are determined for the purpose of maximizing light output at high efficiencies, while minimizing luminance gradients across the display. Finally, a precise collimator eliminates light beyond a defined angle, as required in a tiled, flat-panel LCD.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Application No. 60/438,564, filed Jan. 6, 2003, entitled “Lint-Free Towels” to Rajesh Mandavewala.
FIELD OF THE INVENTION
[0002] The present invention relates to processes for making towels. In particular, the invention is directed at producing lint-free towels.
BACKGROUND OF THE INVENTION
[0003] Lint is a soft material of linen or cotton which contains fluff and scraps of yarn. Many towels are made of 100% cotton yarns in the ground warp, pile loops and the interlacing weft, and therefore these towels produce a lot of lint.
[0004] The amount of twisting in the yarn affects the properties of the towel and the amount of lint that the towel produces. The pile yarn is generally a low-twist yarn. The pile loops provide maximum surface area for the absorption of water, and the low twist aids in the absorption by imparting wicking properties to the yarn. The ground warp and the weft are generally hard-twisted compared to the pile yarn. The ground and weft yarn twist factors generally range from 3.8 to 4.1, depending upon the towel construction. In contrast, the twist factor in the pile yarn generally ranges from about 3.2 to 3.6. The lower the twist factor in the pile yarn, the softer and thicker the towel.
[0005] Towels are generally thick materials. The thicker the towel, the greater the surface area, and thus a greater amount of water can be absorbed.
[0006] In the towels the normal reed varies from 56 dents/inch and 60 to 76 dents/inch, but does not exceed 76. Similarly the number of picks per inch varies from 35 to 52.
[0007] The cover factor indicates the degree of closing or cover provided by the yarns. The warp cover factor is calculated using the following formula (I):
Warp cover factor=Number of ends per inch/square root of warp count (Ne) (I)
[0008] The weft cover factor is calculated in a similar manner, using the following formula (II):
Weft cover factor=Number of picks per inch/square root of weft count (Ne) (II)
[0009] Therefore, as the number of ends per inch or picks per inch increases due to finer counts, the cover factor also increases. Generally in towels, the counts are coarse and the number of ends and picks per inch are also limited to balance the weight of the towel, measured in grams per square meter (GSM). Therefore, the cover factors in a towel are low. The typical yarn counts used in ground warp are 2/20s, 2/24s, 10s, 12s in English cotton number (Ne), which yield a warp cover factor ranging from 16 to 24. The normal weft count used in towels is Ne 12s or 16s, which yield a cover factor ranging from 8.75 to 16.75.
[0010] These cover factors are not high cover factors and the fabric contains lot of space between the yarns in the fabric. This provides a large surface area, which increases the absorbency of the towel. However, such low cover factors also produce towels with a great tendency to shed fibers and produce lint.
[0011] Another source of lint is due to the hairiness of the yarn. When the cotton fiber are twisted in the ring spinning system, the fibers follow a helical path and due to centrifugal force during twisting, the end of the fibers protrude on the yarn surface, like hairs. The more short fibers used in making the yarn, the hairier the yarn becomes. The hairier the yarn, the more fibers dislodge during washing of the towels resulting in linting.
[0012] Sometimes the cotton lint sticks to the body of a user. The lint in towels often annoys the users of the towels.
[0013] Therefore it is an object of the invention to provide towels which minimize or prevent the production of lint.
[0014] Another object of the invention is to provide a process for making towels which produce less lint than ordinary towels.
BRIEF SUMMARY OF THE INVENTION
[0015] Towels which produce little to no lint (herein referred to as “lint-free”) and methods for making such towels are described herein. The lint-free towels contain a small amount of short cotton fibers in the pile yarn and the pile yarn contains a low twist factor. In the preferred embodiment, 24% or more of the noil is removed when the pile yarn is produced. This combination of low twist factor with few short cotton yarns, results in soft, absorbent, lint-free towels. Preferably, the lint-free towels contain yarn with a hairiness index of 5 to 7.5.
[0016] The lint-free towels are produced by twisting the pile yarn with a poly vinyl alcohol (PVA) spun yarn. After weaving the yarns to form a towel, the PVA yarn is then dissolved during the production process, leaving twistless pile yarn.
DETAILED DESCRIPTION OF THE INVENTION
[0017] I. Lint-Free Towels
[0018] The lint-free towels can be made in any size, including bath, hand wash and bath sheet sizes. The lint-free towels can have a variety of different designs and counts.
[0019] A. Fibers
[0020] Terry towels are formed from three types of yarn. The first type of yarn is the ground warp. The ground warp is the longitudinal set of yarn forming the base fabric. The second type of yarn is the pile warp. The pile warp is placed in the longitudinal direction and produces the pile loops on the towel surface. The pile loops provide a large surface area for maximizing the absorption of water. The third type of yarn is the weft yarn. The weft yarns are laid perpendicular to the pile yarns, and interlace with pile or ground yarn to form the fabric of the towel.
[0021] Pile Yarns
[0022] Generally the pile yarn is 100% cotton yarn. Alternatively, the pile yarn can be Spun Silk or Modal Spun Yam. Preferred cotton yarns include Indian cotton S-6, Egyptian cotton, and Australian cotton. In the most preferred embodiment, the pile yarn is a 50/50 mixture of Egyptian Cotton Giza 70 and Australian Cotton Abas. This mix provides a fiber with a long staple and low content of short fibers. Alternatively, the cotton yarn may contain 25% Egyptian cotton and 75% Shankar cotton, 25% Australian cotton and 75% Shankar cotton, or 25% Egyptian cotton, 25% Australian cotton, and 50% Shankar 6 cotton.
[0023] Table 1 provides the characteristics of the 50/50 Mixture of Egyptian Giza 70 and Australian Abas cotton fibers.
TABLE 1 CHARACTERISTICS FOR 50/50 MIXTURE OF EGYPTIAN GIZA 70 AND AUSTRALIAN ABAS 2.5% Short Span Strength Uniformity Fiber Maturity Type of Fiber MIC Length 8/tex Ratio Index Coeff Trash % Giza 70 3.4-3.8 32-34 28-32 44-48 2.5-3.5 0.70-0.80 3.0-4.0 Egyptian Abas 4.2-4.7 28-29.5 20-22 45-47 4-6 0.68-0.72 1.5-2.0 Australian 50/50 Mix 3.8-4.2 28-32 22-24 44-47 44-47 0.68-0.75 3.0-5.0
[0024] During the processing of the yarn, the short fibers should be removed from the yarn. In the preferred embodiment, 24% or more of the noil is removed. The noil contains short fibers and is removed during the combing process. The removal of 24% of the noil generally effectively eliminates all the short fibers.
[0025] The pile yarn has a low Uster hairiness index. Suitable yarn has a hairiness index in the range of 5 to 7.5.
[0026] Polyvinyl Alcohol Yarn
[0027] Polyvinyl alcohol (PVA) yarn is a synthetic yarn which is easily dissolved by warm or hot water, without the aid of any chemical agents. Due to its ready solubility, these yarns can not be used for ordinary wear fabrics. Although PVA yarn is preferred, other materials which have the same or similar properties can also be used.
[0028] The counts for suitable PVA yarns cover a broad range, and include 31 Dtex, 40 Dtex, 44 Dtex, 62 Dtex, and 84 Dtex. As the filament becomes finer, the amount of PVA in the twisted yarn decreases. For example, 31 Dtex is the finest available filament and contains the smallest amount of PVA. The most preferred PVA filament is 84 Dtex. 84 Dtex PVA yarn improves the performance on the looms.
[0029] One type of PVA filament yarn is manufactured by NITIVY Co. (Japan) and marketed under the brand name SOLVRON®. These PVA yarns have shrinkage ranging from 35 to 60% when subjected to steaming under tension free conditions. Tables 2 and 3 list types of multifilament and monofilament SOLVRON® PVA yarns and their solubility, dissolution and shrinkage characteristics.
TABLE 2 TYPES OF PVA MULTIFILAMENT YARNS AND THEIR CHARACTERISTICS Type SH SM SL SX SS SP SF SHC** *Temp. for 95 95 70 60 30 25 55 90 Dissolution (° C.) Tenacity 3.5-4.5 1.5-2.5 3.5-6 2-4.5 3.5-4.5 3-4 3.4-4.4 4-5 (grm/d.) (Dry) Elongation 12-16 30-40 10-20 15-25 10-20 25-35 12-25 10-20 (%) Solubility 93 ± 3 90 ± 3 50 ± 5 36 ± 4 20 ± 5 15 ± 5 36 ± 5 85 ± 5 in Water (° C.) Maximum 45-50 35-40 50-60 45-60 — — 40-55 55-60 Shrinkage (%) Temp. for 85 85 25 20 20 75 Maximum Shrinkage (° C.) Shrinkage 2-7 5-10 50-60 45-60 — — — 45-50 in water at 25° C. (%) (Tension Free) Shrinking 0.05-0.1 0.05-1 0.05-1 0.05-1 — — — 0.3-0.4 Strength (grm/d) (In water at 25° C.) Sizes 28 D/9F 56D/12F 28D/9F 28D/9F 56D/18F 56D/18F 31DT 28D/9F 56D/18F 40D/12F 40D/12F 100D/30F 75D/25F 44DT 75D/24F 75D/20F 56D/18F 200D/60F 100D/30F 62DT 100D/30F 100D/30F 100D/20F 84DT 225D/100F 200D/40F 110DT 300D/50F 220DT 600D/50F 330DT 600D/100F 660DT 900D/150F
[0030] In the preferred embodiment, the PVA filament is a SL, SX, or SF type of yarn, which dissolves at a temperature within the range of 55 to 80° C. For example, the PVA filament may be: (1) 44 dtex/12 Filament SX or SF, which is soluble at 60 to 70° C. in water, with shrinkage of 45 to 60% in water at 20° C. under tension-free conditions; (2) 62 dtex/18 Filament SX or SF type soluble at 60 to 70° C. in water, with a shrinkage of 45 to 60% in water at 20° C. under tension-free conditions; or (3) 84 dtex/20 Filament SX or SF type soluble at 60 to 70° C. in water with a shrinkage of 45 to 60% in water at 25° C. under tension-free conditions.
TABLE 3 TYPES OF PVA MONOFILAMENT YARNS AND THEIR CHARACTERISTICS Type MH ML *Temp. for 95 70 Dissolution (° C.) Tenacity (Dry) 3-4 3-4 (grm/d.) Elongation 15-20 15-20 (%) Solubility in Water (° C.) 85 ± 5 60 ± 5 Maximum Shrinkage (%) 45-50 40-45 Temp. for Maximum 65 25 Shrinkage (° C.) Shrinkage in water at 25° C. 33-38 40-45 (%) (Tension Free) Shrinking Strength (grm/d) 0.1-0.13 0.1-0.13 (In water at 25° C.) Sizes 30D/1F 30D/1F 45D/1F 45D/1F 675D/15F
[0031] The preferred PVA fiber for spun yarn is 38 mm×1.4 denier PVA cut staple fibers, having a dissolution temperature of 90° C. The PVA spun yarn may be of a wide range of counts. Typical counts include Ne 30s, 40s, 50s, 60s, and 70s with a twist multiplier of 4.0.
TABLE 4 PROPERTIES OF STAPLE FIBERS FOR PVA SPUN YARN Nominal Dissolving Temp. in Cut Water Fineness length Tenacity Elongation Type (° C.) (dtex) (mm) (cN/dtex) (%) 1 20 1.7 38 5 20 2.2 51 2 40 1.2 38 7 15 1.7 38 2.2 38, 51, 75B 3 50 1.7 32, 38 7 15 2.2 32, 38, 51, 75B, 85B 4 70 1.7 38 7 12 2.2 51 5 80/90 1.4 32, 38 8 11 1.7 32, 38 2.2 51, 85B 2.2 75B 7 15 6 95 1.7 38 9 10 2.2 51, 75B
[0032] Ground and Weft Yarns
[0033] The ground and weft yarns are typically 100% cotton yarn. Alternatively, the yarn may be Spun Silk or Modal Spun Yarn. The count covers a broad range, including Ne 10s, 12s, 14s, 16s, 18s, and 2/24s. The cotton yarn may be either combed or carded.
TABLE 5 CHARACTERISTICS OF COTTON FOR GROUND AND WEFT YARNS 2.5% Short Span Uniformity fiber Maturity Type MIC Length Strength Ratio Index Coeff Trash % Shankar-6 3.8 to 4.2 27 to 29 20 to 24 45 to 47 Up to 5% 0.65 to 0.78 Up to 5% NHH 4 4.2 to 4.5 26.5 to 28.0 19 to 20 45 to 47 Up to 5% 0.70 to 0.78 Up to 5% J-34 4.2 to 4.6 26.5 to 28.0 19 to 22 45 to 47 Up to 5% 0.70 to 0.75 Up to 5%
[0034] II. Method of Producing Lint-Free Towels
[0035] A. Production of the Pile Yarn
[0036] Pile yarn is prepared according to standard procedures. First, the types of cottons are selected and mixed in their desired proportions. Then the cotton is processed in the blow room, at a speed of approximately 550 kg/hr. Next the cotton is carded, with a delivery speed of 40 kg/hr and a hank of sliver of 0.12. The cotton proceeds to breaker drawing, with 6 ends up, at a speed of 400 mpm and an output hank of 0.12. Then the unilap is formed, typically with 24 ends up and a lap weight of 70 grams/meter. Next the yarn is sent to the combers. For the pile yarn the combers process the material at 350 nips/min. During the combing process, 24% noil is removed to eliminate those short fibers which are of less than 12.5 mm in length. Combing efficiency is 65%. Short fiber removal is 65%. The hank of silver is 0.12.
[0037] Then the yarn is sent to finisher drawing. The auto leveler drawing speed is about 350 mpm for pile yarn. The hank is 0.12 and the Silver U% is up to 2.5-3.0%.
[0038] Next, the yarn is sent to roving. The speed is around 1000 rpm. The hank of roving is 0.72. The TPI for the roving is 1.4. The standard package weighs 1.8-2.0 kgs.
[0039] Next, the roving is sent to ring spinning. The average speed is 14, 500 rpm. For pile yarn, the count is 12s combed and the TM is 3.8 Z twist.
[0040] Finally, the yarn is sent to the auto coners. The clearer setting is N of 500, S of 200% at 2.5 cm, L of 40% at 40 cm, and T of 30% at 30 cm. The speed of the autoconers is around 1,100 mpm.
[0041] The process should be closely monitored during spinning to provide a yarn having a lower Uster hairiness index than would be achieved with normal combed yarn. The hairiness index should be within the range of 5-7.5. For example, for combed 50/50 Egyptian and Australian cotton yarn, the typical hairiness index is 6.95 at COP stage, while such yarn would normally have a hairiness index of 9.0.
[0042] This cotton yarn is then assembled on an Assembly Winder with the PVA spun yarn (Ne 40s, 60s or 70s). For example, 70s PVA spun yarn, with a TPI of 33.4, a TM of 4.0, a CSP of 2,850, and an RKM of 18.5 may be used. The Assembly winding speed is maintained at 450 mpm. The tension of the cotton yarn is 4, while the tension of the PVA yarn is 0. Then the yarn is doubled using a Two for One (TFO) Twister. The TPI of the resulting yarn is either 2 TPI greater or 2 TPI less than the TPI for the single yarn. The yarn is twisted in the S direction. The speed of the TFO is 10,500 rpm, which results in a package output of 1.75 to 2.0 kg. The twisted yarn is then wound onto cones and sent to Warping. Warping is carried out under normal conditions. Typically during warping the tension is 40 gms and the speed is 600 mpm so that the yarn passage is smooth.
[0043] B. Production of the Weft and Ground Yarns
[0044] Weft and ground yarns are prepared according to standard procedures, such as those described above for pile yarns. However, during combing only 10-16% of the noil is removed. Typically 10%, 12%, 14%, or 16% of the noil is removed. During ring spinning, the combed ground yarn has a count of 20 S. The TM for weft yarn and ground yarn is 3.8 Z twist. Upon leaving the autoconers, the weft and ground yarn may be dyed. The dyed or grey ground yarn is then sent to warping and then to weaving. The dyed or grey weft yarn is sent directly to weaving.
[0045] C. Weaving of Pile, Weft, and Ground Yarns
[0046] The ground, weft, and pile yarns are woven together under normal conditions. No special attention is required for weaving.
[0047] D. Dissolving the PVA Fiber
[0048] After the weaving is completed, the fabric roll is scoured and dyed in the normal fashion in a fabric dyeing machine. When the material enters the dyeing machine, the operating temperature is 120° C.
[0049] The liquor ratio is a ratio of the material (weight) to water (volume). The liquor ratio should be sufficient to facilitate prompt dissolution of the PVA, while allowing free movement of the fabric. Typically the liquor ratio is 1:30.
[0050] The material is typically wound into the shape of a rope prior to entering the fabric dyeing machine. The rotation of the material is essential to promote rapid dissolution of PVA. A continual overflow of water is also desired.
[0051] After washing, the liquor is drained and fresh water is injected for rinsing to eliminate all the dissolved PVA. The water is at a temperature ranging from 55-100° C. Preferably, the water is at a high temperature, such as 95° C. The PVA coagulates during the dissolving step and promptly dissolves in hot water if the high temperature is maintained. Therefore, the fabric is rinsed in hot water after draining to wash away any PVA residue. This rinsing step also ensures that any loose fibers drain out along with the drain water.
[0052] The washed rope is then passed through padding mangle for a resin treatment, where it is padded with dimethyl, dihydroxy ethylene urea (DMDHU) at 25 g/L, a resin with magnesium chloride as a catalyst (7.5 g/L), Soft touch Softener (5 g/L), and Turbex CAN (10 g/L) to prevent loss of fiber strength.
[0053] E. Drying and Straightening the Towels
[0054] After unloading the material from the washing and rinsing vessel, the material is hydro-extracted in a Hydro-extractor in the standard manner. A rope is passed through rope opener, which is equipped with drum beaters both at feed and delivery ends, to straighten the twist in the rope. Then the material is passed two times through a hot air dryer (e.g. Alea) which is equipped with drum beaters at both the feed and delivery ends. This ensures proper lifting of the pile. The first drying is carried out at 120° C. The second drying occurs at a higher temperature, such as 150° C. for 4 to 5 minutes. The full width fabric is then passed through hot air stenter and a weft straightener to straighten the fabric and return it to its proper dimensions.
[0055] F. Shearing
[0056] The towels are then passed through the shearing machine on both the sides. The blade/laser on the shearing machine is set such that only protruding fibers are cut, but the piles are not cut. The fabric is then carried through length cutting, length hemming, cross cutting, cross hemming, checking, folding, and packing according to the standard practice.
[0057] This process produces a lint-free towel, which does not shed any fibers, even during domestic laundering.
EXAMPLES
Example 1
Production of 50/50 Egyptian and Australian Cotton/PVA Pile Yarn
[0058] A 50/50 mixture of Egyptian Cotton Giza 70 and Australian Cotton Abas, with characteristics as described by Table 1 (above), was formed. The cotton was sent to the Blow Room through a Blendomat GBR, Axiflow, Asta, MM6, CVT3, Dustex. The rate of production was maintained at 550 kgs/hr. The cotton was then carded (Truetzschler DK 760), with a delivery rate of 40 kg/hr of sliver with a hank of 0.12. The sliver is a continuous strand of loosely assembled fibers without twist. The production of the sliver is the first step in the textile operation that brings the staple fiber into a form that can be drawn and eventually twisted into a spun yarn.
[0059] The carded cotton was sent to breaker drawing (Zinser 730/1) with 6 ends up and speed of 400 rpm, producing sliver with a hank of 0.12. The Unilap had 24 ends up, with a lap weight of 70 gms/meter. Then the cotton was sent to a comber (Rieter E60H), which was run at a speed of 350 nips/min, with 5.2 mm backward feed. The comber removed 24% of the noil. This resulted in a combing efficiency of 65%, short fiber removal of 65.3% and sliver with a hank of 0.12.
[0060] Then the cotton was sent to Finisher Drawing (Truetzschler: HSR 900 with short term auto leveler). The Sliver U% was 2.5; the speed was set at 350 rpm; and the hank was 0.12. Next the cotton was sent to a Speed Frame (Toyota FL 100), which operated at a speed of 1,000 rpm and produced yarn with a hank of roving of 0.72. This step produced yarn with a TPI of 1.4. Then the yarn was sent to Ring Spinning (Toyota RXI 240) with SKF PK 2025 drafting. This produced Ne 12s combed yarn with a TPI of 13.16, and a TM of 3.8 (‘Z’ Twist). The Spindle Speed was 14,500.
[0061] Finally, the yarn was send to an Autoconer (Schlafhorst 238 with Uster Quantum), which was set at a clearer setting, N—500, S—200% at 2.5 cm, L—40% at 40 cm, T—30% at 30 cm; and a Speed of 1,100 rpm.
[0062] This process produced pile yarn with a RKm of 24.0 with RKm CV% 7.45 and 7.06% elongation having count CV % 1.02, total impurity per km of 7.6, a hairiness index on COP of 6.95, and a hairiness index on cone of 8.5. RKm stands for resistance to kilometer, i.e. the number of kilometers of yarn required to be hung from one end so that the yarn breaks due to its own weight. CV% refers to coefficient of variation of such yarn strength. The lower CV% is preferred for better performance in subsequent processes.
[0063] The 12s combed cotton yarn was assembled on PS Mettler Assembly Winder with PVA spun yarn. The PVA spun yarn had the following properties: 72 s count, 33.4 TPI, 4.0 TM, 2850 CSP, and 18.5 RKm. The spun PVA yarn was made from 1.4 denier×38 mm bright PVA fiber, which dissolved at 90° C.
[0064] The Assembly Winder ran at 450 rpm, with PVA spun yarn at a tension of 0 and 12s combed yarn at tension of 4 index. The cotton yarn and PVA yarn were twisted on a TFO Twister running at 10,500 rpm. The twist was in ‘S’ direction at 8.5 TPI. This produced a yarn with a residual positive TPI of 4.6 (i.e. 13.16−8.5). The yarn contained 85% cotton and 15% PVA, with a resultant count of 10.24. The twisted yarn was wound onto cones and sent to Warping.
[0065] Warping was carried out in normal conditions with yarn tension of 40 gms and a speed of 600 rpm.
Example 2
Production of Bath-Size, Lint-Free Towels
[0066] The PVA/cotton pile yarn produced in Example 1 was woven with 2/20s combed cotton ground warp (8.5 TPI (S); 1176 ends; and a weight of 102.64 g) and two weft yarns, a 12s combed cotton yarn (12.47 TPI (Z); 2250 picks; and a weight of 102.15 gms) and a 2/20s cotton yarn (8.5 TPI (S); 492 picks, and a weight of 26.80 gms). The loom was run at 280 rpm. Table 6 lists the specifications for the weaving process.
TABLE 6 On loom specifications Reed space for terry 87.07 cm Reed space for towel 92.07 cm Number of towels per Reed Space 3 Reed space utilization 282.20 cm Pile Ratio 6.71 Pile height 6.3 mm Warp cover factor 18.98 (ground) Weft cover factor 11.74 Reed/cm 11.81 Picks/Inch 40.64 Type of Terry 3 pick Rpm 250 Finished Reed/inch pile 34.53
[0067] The properties of the fabric when it is removed from the loom, i.e. the grey towel, are listed in Table 7.
TABLE 7 Grey Towel Specifications Grey width 84.46 cm Grey length 151.0 cm Weight of towel 785.35 g Plain portion in width 5 cm Plain portion in length 8 cm Weight of Grey Towel 785.35 g Terry portion in length 133.0 cm Selvedge to selvedge width 89.46 cm
[0068] After the weaving, the fabric roll was scoured and dyed in the normal fashion at 120° C. in the fabric dyeing machine with a liquor ratio of 1:30. This high liquor ratio was essential to ensure the complete dissolution of Spun PVA yarn. Then, the liquor was drained at 120° C. The material was rinsed a second time by pumping in water at a temperature of 95 to 100° C.
[0069] The washed rope was then passed through padding mangle and padded with DMDHU at 25 g/L, a resin with a catalyst magnesium chloride at 7.5 g/L, Soft touch Softener at 5 g/L, and Turbex CAN at 10 g/L to prevent loss of fiber strength. The padded material was hydro-extracted in the normal way.
[0070] The rope was untwisted in the rope opener. The material was then dried two times. The opened and spread material was passed through a hot air dryer (e.g. Alea), which was equipped with drum beaters at both the feed and delivery ends, to properly lift the pile. The first drying was carried out at 120° C. The second drying was carried out at 150° C. for 4 to 5 minutes. The full width fabric was then passed through a hot air stenter, which was attached with a weft straightener, to recover the dimensions of the towel.
[0071] After drying and straightening, the towels were passed through the shearing machine on both the sides. The blade was set such that only protruding fibers were cut, and the piles were not cut. The fabric was then carried through length cutting, length hemming, cross cutting, cross hemming, and folding according to standard procedures. The properties of the finished lint-free towel are listed in Table 8.
TABLE 8 Finished Towel Specifications Dimensions 76 cm × 142 cm Plain portion in width 5.0 cm Terry portion in width 74.8 cm GSM 604 Weight of finished towel 651.84 g Weight of Grey Towel 785.35 g Weight loss (%) 17% Plain portion in length 8.0 cm Design portion in length 10.0 cm Terry portion in length 133.0 cm Shrinkage % 16.4% Finished width of towel 79.60 cm
[0072] It must be noted that as used herein and in the appended claims, the singular forms “a ”, “an”, and “the” include plural reference unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods, devices, and materials are as described.
[0073] Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the following claims.
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Towels which produce little to no lint (herein referred to as “lint-free”) and methods for making such towels are described herein. The lint-free towels contain a small amount of short cotton fibers in the pile yarn and the pile yarn contains a low twist factor. In the preferred embodiment, 24% or more of the noil is removed when the pile yarn is produced. This combination of low twist factor with few short cotton yarn, results in soft, absorbent, lint-free towels. Preferably, the lint-free towels contain yarn with a hairiness index of 5 to 7.5. The lint-free towels are produced by twisting the pile yarn with a poly vinyl alcohol (PVA) spun yarn. After weaving the yarns to form a towel, the PVA yarn is then dissolved during the production process, leaving twistless pile yarn.
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FIELD OF THE INVENTION
[0001] This invention relates to welded wire corner lath or beads.
BACKGROUND OF THE INVENTION
[0002] Some building construction techniques involve the application of a coating such as stucco, plaster and the like to a building surface. This coating is the cladding or finish for such surfaces. In the following disclosure, the term stucco is used generally to apply to either cementitious or gypsum plasters as defined in applicable building codes.
[0003] When applying a stucco coating, it is generally desirable to provide a lath on the surface. The lath provides reinforcement for the stucco and also attaches the stucco to the building surface. There are a number of different metal laths being used for stucco coatings. One common type is expanded metal lath. Another group of stucco laths is wire fabric laths. Within this group, there are woven wire laths and welded wire laths.
[0004] The lath is attached to wood or metal framing by various fasteners, generally including nails, staples, self-tapping screws, or other mechanical fastening means.
[0005] At the corners, a bead is normally provided since it is either required by building codes, or the builder or contractor will require the use of corner beads to obtain a superior result. These would be installed generally on external corners, either vertically or horizontally. Vertical corners are created by the wall intersections, and around columns and posts. Horizontal corners are created when architects and designers create build-outs or reveals, or when stucco is applied to bottoms of beams, or tops of wall sections.
[0006] The most commonly used corner beads are bent into a Vee shape of approximately 70 degrees to 80 degrees. The flanges or legs of the Vee portions extend approximately 2 ½ inches. There are two general types of corner beads. The first is made from sheet metal and has expanded metal flanges and a solid metal nose that acts as the bead. The other general type is made from a grid of wires welded together, bent into a Vee shape with a continuous longitudinal wire at the nose to act as the guide to form the stucco corner.
[0007] When the corner bead is installed correctly, it becomes the depth gage or screed that will regulate the depth of stucco or plaster at the corners. Various stucco systems require stucco in depths of ⅜ inch, ½ inch, ¾ inch or ⅞ inch. Therefore, different preformed angles are required in the corner bead to obtain the correct stucco depth. For stuccos in the ⅜ to ½ inch range, beads are formed with an 80-degree Vee, whereas for stucco in the ¾ to ⅞-inch range, beads are formed in the 70 degree range. Therefore consistency of angle forming and straightness are critical factors in obtaining correct stucco thickness.
[0008] The prior art welded wire corner beads generally consist of a series of sinusoidal wires and a series of longitudinal wires resistance welded together at their intersections. Such wire beads of steel wire are generally known and are described in U.S. Pat. No. 2,645,930 by Raymond Stockton, in U.S. Pat. No. 3,175,330 by Henry Holsman, in U.S. Pat. No. 5,669,195 by Bekaert, as well as in other sources.
[0009] The prior art wire corner beads may contain 3, 4 or 5 sinusoidal wires, with 6 or 8 longitudinal wires on the shoulders of the Vee, plus the nose wire on the tip of the Vee.
[0010] The most common corner beads have 5 sinusoidal wires and 6 longitudinal wires plus the nose wire. The sinusoidal wires do not span the width of the corner bead, since they generally each have a width of 1¼ inches and a pitch of 2 inches. Therefore, a series of these sinusoidal wires is required to span the full width of the corner bead. Further, the sinusoids must be offset from each other by one-half pitch so that their points overlap to create intersections for welding. The sinusoidal wires alternate positions, with one above and the next one below across the width. The longitudinal wires can only be placed in the zones where there is a single wire thickness. The longitudinal wires must also alternate above and below the sinusoidal wires, in opposite steps from the sinusoids. This precludes all the longitudinal wires from being on one side of the product, preferably all on the surface facing outwards. To ensure that the sinusoidal wires overlay each other for welding purposes, additional wire must be used which is a waste of material. Further, the overlapping zone becomes greater which limits the positions of the longitudinal wires. These limitations and others will become more clear in the description of the drawings.
[0011] One disadvantage of the wire beads known in the prior art is that it is difficult to create a continuous series of sinusoidal shapes in multiple wires that are identical in pitch, to then offset them the correct one-half pitch, and then to position them correctly for welding. Variations as little as 1/16 inch in sinusoidal width or pitch can create production or quality problems. These variations result in high scrap rates in production because of either missed welds or quality control rejection because positioning variances exceed specifications. These variations in pitch can be the result of differences in tensile strengths between wires, slight differences in diameter, out of round variations of the wire, and differences in surface finish or lubricity of the surface. These types of differences are usually within the commercial tolerances of the wire suppliers and would be difficult and costly to tighten specifications. These variations in properties will affect the size and shape of the sinusoids, which in turn affects the phasing relationship. The other problem is in guiding these sinusoidal wires into the welding zone. The guiding system needs to have some clearance so that the wires do not bind. However, the sinusoids can then move back and forth within this clearance creating another product variance.
[0012] Another disadvantage of the prior art wire corner beads is that the density of wires is very high at the nose area. This makes it difficult to fully imbed the wires in this region with stucco or plaster, leaving voids. These voids tend to create weak areas at the corners, as well as provide cavities for water to amass creating corrosion of the adjacent wires. This corrosion leads initially to rust staining of the stucco, and ultimately to complete loss of steel. This problem has resulted in some of the prior art having to add plastic nose pieces onto the corners, or produce products from more expensive materials such as stainless steel, or to provide secondary coatings such as epoxy coatings. Each of these solutions is a disadvantage in that it adds significant cost to the product.
[0013] This high density of wires at the nose area is a greater disadvantage with the thinner stucco coatings. These thinner coatings, which are normally known as one coat systems, add glass or plastic fiber reinforcement to their stucco mix. The fibers make it more difficult to work the stucco around the wires with consequently more voids, which is more serious with the thinner stucco coatings.
[0014] A further disadvantage of the prior art wire bead is that because of its configuration, it requires more steel material for its fabrication, than what is needed for the stucco attachment and the screeding function. This additional material is not only an economic factor, but also makes cutting the product in the field more difficult. Another disadvantage is that when an overlap must be made, there is a buildup of steel wire at the joint resulting in a step in the finished stucco finish. A further disadvantage is that larger cartons must be used to fit these bulkier beads resulting in higher packaging costs, higher shipping costs, and higher storage costs.
[0015] Another disadvantage of the prior art wire bead is, that again because of its configuration, wire positions and wire sizes cannot be optimized for stucco needs.
[0016] Hence, there is a need for an improved wire bead for stucco, plaster and the like.
[0017] It is an object of this invention to provide a wire corner bead strip comprising multiple sinusoidal wires that span the full width of the strip and a series of longitudinal wires welded to the sinusoidal wires at each intersection, and in which the strip is bent at an angle around a central longitudinal wire to form a wire bead having a Vee shaped cross section.
[0018] It is further an object of this invention to provide a wire corner bead with reduced wire density without sacrificing strength, straightness and rigidity, and provides superior stucco embedment.
[0019] It is yet another object of this invention to provide a simplified wire corner bead design that is more tolerant of wire property variations and results in fewer production problems and quality rejects.
SUMMARY OF THE INVENTION
[0020] In one aspect the invention comprised of welded wire corner bead comprising at least two continuous wires in overlapping periodic wave form, bent along a longitudinal axis of the bead and including at least three parallel longitudinal wires.
[0021] In a more specific aspect, the invention comprises a welded wire corner bead being defined in two planes about longitudinal axis. The bead has a length and a lateral extent spanning the two planes. At least three parallel longitudinal wires are provided, with at least one of the longitudinal wires lying in each of the planes. At least two continuous wires are attached to each of the longitudinal wires and define a periodic waveform spanning the two planes across longitudinal axis.
[0022] In another aspect, the invention comprises a welded wire corner bead defined in two planes about longitudinal axis so as to have contiguous inside faces and contiguous outside faces of the corner bead. The bead comprises at least three parallel longitudinal wires and at least one continuous wire attached to each of the longitudinal wires. The continuous wire defines a periodic waveform. All of the parallel longitudinal wires are disposed on the outside faces.
[0023] In yet another aspect, the invention comprises a method of manufacturing the corner bead wherein the longitudinal wires are disposed in opposed spaced relation to the longitudinal axis according to a predetermined thickness of stucco for which the bead is intended to be used. In yet another aspect, the invention comprises a method of manufacturing the corner bead comprising the steps of disposing the longitudinal wires away from points of overlapping intersection between the two continuous wires and welding the longitudinal wires to the continuous wires such that the thickness of the corner bead does not exceed two wire thickness throughout the weld points.
[0024] The foregoing was intended as a broad summary only and of only some of the aspects of the invention. It was not intended to define the limits or requirements of the invention. Other aspects of the invention will be appreciated by reference to the detailed description of the preferred embodiment and to the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a plan view of the typical configuration of welded wire corner beads according to the prior art.
[0026] FIG. 2 is a cross sectional view of the wires in between welding wheels according to the prior art.
[0027] FIG. 3 is a cross sectional view of the welded wire corner bead according to the prior art after it has been formed into the V-shape and installed on a building corner.
[0028] FIG. 4 is a plan view of the improved welded wire corner bead in accordance with the preferred embodiment of the invention.
[0029] FIG. 5 is a cross sectional view of the wires in between welding wheels in accordance with the invention.
[0030] FIG. 6 is a cross sectional view of the welded wire corner bead in accordance with the preferred embodiment of the invention after it has been formed into the V-shape and installed on a building corner.
[0031] FIG. 7 is a cross sectional view of two welded wire corners according to the prior art stacked together.
[0032] FIG. 8 is a cross sectional view of two welded wire corners in accordance with the invention stacked together.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] The relative positions of the components of the prior art welded wire corner bead are shown in FIG. 1 . This configuration would represent a typical wire corner as used in the market today and as shown in Holsman U.S. Pat. No. 3,175,330. In this typical case, five sinusoidal wires ( 21 ) are arranged so that collectively, they span the width of the corner bead. Each laterally adjacent sinusoidal wire ( 21 ) is shifted by 90 degrees phase shift so that peaks of the adjacent sinusoids can overlap each other. This overlap provides intersections which are resistance welded together and which then holds the grid together.
[0034] A series of longitudinal wires are also introduced and welded to the various sinusoidal wires ( 21 ). Starting at the outside edges, two edge wires ( 22 ) are welded to the outer sinusoidal wires near the outer peak. These edge wires ( 22 ) provide stiffness and rigidity to the formed corner bead. Further, these edge wires ( 22 ) are positioned to create nailing loops ( 10 ) for attachment of the corner bead to the building structure. Next are two other longitudinal wires ( 23 ) referred to as sighting wires. These are positioned so that the installer can sight along the wall and align these sighting wires ( 23 ) with the wall in both directions. This feature then results in the corner bead being installed so that the correct stucco depth is achieved when the nose wire ( 25 ) is used as a screed or depth gage. The next two longitudinal wires ( 24 ) are shoulder wires which provide strength to the corner during handling. These shoulder wires ( 24 ) also provide additional reinforcement of the stucco in the nose region, since the corner region is always the most vulnerable to physical damage from various impacts. The last longitudinal wire is the nose wire ( 25 ). This nose wire ( 25 ) defines the corner and provides a screeding edge to obtain a sharp, straight corner with proper stucco depth on both adjoining walls.
[0035] Welded wire corner beads are normally fabricated from galvanized steel wire. The amount of zinc on the wires is classed as a ‘regular’ coating weight which is a low level of coating and which is not intended for prolonged exposure to a corrosive environment. The long term protection of the steel wire in both wire stucco laths and wire corners is the stucco itself. Stucco thickness of ⅛ inch or greater are adequate to repel majority of moisture that a wall of a building is exposed to and provide the long term life expected from these installations. However, as can be seen in FIG. 3 , the nose wire ( 25 ) and the two shoulder wires ( 24 ) and the central sinusoidal wire ( 21 c ) are at the surface or very near the surface.
[0036] There are two problems associated with this aspect of the prior art. First, there is a high risk of corrosion and rusting, especially in wetter climates, since these wires are at or near the surface and do not have an adequate covering of stucco protection. In an attempt to address this problem, efforts have been made to protect the nose wire by enclosing it in a plastic strip as disclosed in Holsman U.S. Pat. No. 3,175,330. These efforts have not been successful since the plastic tube is not bonded to the nose wire and water can be trapped within the tube and accelerating the corrosion problem.
[0037] Secondly, the plastic tube provides no protection for the shoulder wires ( 24 ) and the central sinusoidal wire ( 21 c ). The other problem with this solution is that the stucco does not adhere to the plastic portion. Therefore, the stucco terminates in very thin sections on either side of the plastic tube, and becomes even more vulnerable to physical damage. Consequently, Looverie U.S. Pat. No. 5,669,195 discloses a triangular or shaped wire at the nose (or apex) for better adhesion of the stucco. However, this solution has not improved the corner vulnerability and still has the drawback of the surface wires being vulnerable to corrosion.
[0038] As can be seen in FIG. 1 , the grid of wires is held together by welding together the overlaps of the sinusoidal wires ( 21 ). If the sinusoidal amplitude or pitch changes or varies between the five sinusoidal wires ( 21 ), there is the risk that the peaks of adjacent sinusoids may drift out of the desired phase relationship. If this happens, then the overlap is lost, welding cannot occur and the product is no longer held together. This results in lost material (scrap) and loss of productivity while the repair is made. Some of the factors that can cause variations in formation of the sinusoids is varying wire tensile strengths, varying wire sizes, varying wire backtension, and varying surface lubricity of the wire. It is difficult for the wire manufacturers to further improve on these characteristics, since there will always be a tolerance range that these wire manufacturers require.
[0039] A similar problem may arise if the sinusoidal wires drift sideways. As a result of the possible variations in sinusoid amplitude, the guides for spacing the individual sinusoidal wires are usually enlarged to cope with these variations. However, the consequence is that the sinusoidal wires can then drift sideways over a larger range. Therefore, again there is the risk that the overlap may be lost and hence the weld. Similarly, at the edge wires ( 22 ), there is the risk of the nailing loops becoming too small, or too big. There is also a potential of the edge wire ( 22 ) missing the sinusoid peak altogether and not welding.
[0040] To minimize the effects of these problems, the solution in the prior art has been to increase the amplitude of the sinusoidal wires. This has the negative result of increasing wire usage without any net benefit to the product. It also has the negative result that with the increased wire mass, it is more difficult for the applicator to force the stucco through this wire mass. This results in voids around the wires and a poor stucco job subject to cracking and subject to water intrusion. This solution has a further negative impact by decreasing the gap between adjacent sinusoidal peaks and this further limits placement options for the various longitudinal wires.
[0041] In FIG. 2 , the cross sectional view shows the positioning configuration of all the wires. The wires pass between two welding wheels, upper welding wheel 31 and lower welding wheel 32 . The wheels are driven which pulls the wires through the space between the wheels. The wheels are energized so that an electrical current passes through the various intersections of the wires in the pinch point. The upper wheel is usually spring loaded to provide a squeezing force on the wire intersections.
[0042] As can be seen in FIG. 2 , the wheels are smooth and the gap is even across the width. Therefore, the combinations of wires and wire thicknesses must be consistent across this width. Otherwise, welding can not occur at the joints where there is inadequate squeezing force, or in worst case, no squeezing force at all.
[0043] To achieve these even pressures, the sinusoidal wires ( 21 ) must alternate above and below each other to achieve even thickness of sinusoidal overlaps. The longitudinal wires ( 22 , 23 , 24 , and 25 ) must then alternate in the gaps created, and must be of the same diameter as the sinusoidal wires ( 21 ) to maintain this even thickness.
[0044] As can be seen, the prior art product design has to a large extent been dictated by the manufacturing process and there has been little ability to improve the product to be better adapted for stucco application. For example, using various wire sizes across the grid would allow the product design to be optimized by providing more size and mass where it was best required and less mass where it wasn't needed. Secondly, since the longitudinal wires must be within the gaps created by two adjacent sinusoidal wires, the ability to change longitudinal wire positions sideways is limited.
[0045] As can be seen in FIG. 3 , a further disadvantage of the prior art is that the sighting wires ( 23 ) are on the backside of the corner bead. Again this is the result of the manufacturing restrictions. It would be an advantage to have all the longitudinal wires on the outside of the corner bead, since this would improve the strength of the corner and provide less resistance to achieve full embedment of the corner with stucco.
[0046] In FIG. 4 , a preferred embodiment of welded wire corner bead 40 in accordance with the present invention is shown. The welded wire corner bead of the present invention includes, generally, the same components as prior art welded wire corner beads; namely a series of sinusoidal wires and a series of longitudinal wires, but arranged in a different manner.
[0047] The significant difference of the present invention is that each sinusoidal wire spans the full width of the corner bead. In the exemplary embodiment of FIG. 4 , the welded wire corner bead comprises three transverse sinusoidal wires 41 , 42 and 43 . In other embodiments, there may be a lesser or greater number of transverse sinusoidal wires. The number could be as low as two or up to five or more. By changing the number of sinusoidal wires, the density of the grid can be altered to achieve greater strength if desired. By welding the sinusoidal wires 41 , 42 and 43 together at their intersections, by welding these sinusoidal wires 41 , 42 and 43 to the longitudinal wires 44 , 45 , 46 and 47 , and by forming this grid into a Vee shape, a truss structure is created. This truss structure provides strength and rigidity to the improved corner. This is important during handling and during installation on the job site to ensure that the wire corner is not distorted, and that a straight stucco corner is achieved.
[0048] Although these transverse wires 41 , 42 and 43 are described as sinusoidal, they may be fashioned into other shapes. As shown in FIG. 4 , the transverse wires 41 , 42 and 43 are fashioned with straight sections as they traverse at a diagonal across the width of the corner bead 40 . Conversely, these wires could traverse along arcs or curved paths.
[0049] A feature of the preferred embodiment of the invention is that the transverse wires will always cross with the previously placed transverse wire. The advantage is that with variations in wire properties or placement of these transverse wires, there will always be a crossing point or intersection. Therefore, a weld can always be made to join the wire grid together. This will eliminate the problem associated with the configuration of the prior art wire corner bead.
[0050] Another advantage of the preferred embodiment is that there is more efficient utilization of the transverse wires. Since the wires are essentially in a straight line path, wire usage is reduced which is an economical advantage over the prior art. Further, the wire density is reduced since the overlap areas are eliminated. This has an advantage for the applicator to be able to fully embed the corner with stucco to achieve better quality stucco corners.
[0051] As shown in FIG. 4 , the welded wire corner bead may have a series of longitudinal wires attached to the transverse wires. At the outer edges, edge wires 44 a and 44 b may be provided to form nailing loops 48 . At some distance from the edges, sighting wires 45 a and 45 b may be provided. At the mid area, two shoulder wires 46 a and 46 b may be provided as well as the nose or apex wire 47 . All of these longitudinal wires are placed on only one side of the transverse wires, and do not alternate as in the prior art. As shown in FIG. 6 , the placement of these longitudinal wires will be such that they will face the outside surface when formed into a V-shape and placed on an external corner.
[0052] In the preferred embodiment, the locations of the sighting wires and the shoulder wires may be repositioned to achieve preferred locations, and no longer be limited to spaces between loops. For example, the position of the sighting wires needs to be altered for different stucco thickness designs. This has not been possible with the prior art but can be easily achieved with this embodiment.
[0053] A further advantage with the invention is that varying wire sizes may now be incorporated. This possibility is the result of the orientation of the transverse wires on one face and the longitudinal wires on the other face, and the elimination of the overlapping loops. The welding wheels will then be able to follow the various changes in wire thickness and create sound welds.
[0054] In FIG. 5 , the relationship of the welding wheels 51 , 52 and the position of the wires for the present invention is shown. The welding wheels 51 , 52 are smooth and the gap is even across the width, similar to the prior art. However, since the intersections pass through the welding zone in a sequential manner rather than a simultaneous manner as in the prior art, there are fewer intersections in the weld zone at any given point along the new corner. This is a key difference in achieving the ability to vary the combinations of wire sizes or shapes. Since there are fewer weld intersections in the weld zone, the upper welding wheel 51 can move up and down and compensate for varying thicknesses at sequential weld points and still achieve consistent welding.
[0055] A further advantage with this invention is the possibility of utilizing shaped wires. There is an advantage to use flattened wires since these wires function as scrapers and assist in pulling the stucco from the trowel and forcing it into the corner cavity. In the prior art, flattened wires could not economically be utilized since they would have to be of the same thickness as all other wires. This would then result in heavier longitudinal wires which would not be economical. However, with this invention, varying wire thickness can be incorporated and flattened wires may be utilized for some or all of the longitudinal wires.
[0056] Another benefit of utilizing flattened longitudinal wires is that the individual corners can be stacked tighter with less space in between each corner. In FIG. 7 , the prior art corner is shown stacked with another similar corner. The nose wires 25 cannot contact the adjacent sinusoidal wire 21 resulting in a spacing X of approximately 0.25 inches between corners. This has a major disadvantage when these corners are overlapped on a building corner. The installer must force or distort the overlapping corner to reduce this gap. This is difficult to achieve properly and usually results in an undesirable step in the finished stucco. The other disadvantage is that more space is required for packaging and warehousing. Presently, wire corners are packaged 40 pieces into a 10 inch carton.
[0057] In FIG. 8 , the improved wire corner 40 is shown with flattened longitudinal wires 44 , 45 , and 46 and is shown stacked with another similar corner. In this case the nose wire 47 is much closer to sinusoidal wires 41 , 42 , 43 resulting in a tighter stack. The resulting space Y between corners is approximately 0.15 inches. This results in an improved stucco corner with virtually no noticeable step at overlapping joints. Further, it will allow significant savings in packaging and warehousing costs since 50 individual corners will now be packed in the same 10 inch carton.
[0058] The same packaging and warehousing saving can be achieved with round longitudinal wires as well, since the stacking height with round wires will be approximately 0.20 inches and 50 corners will fit into the same carton.
[0059] There are other wire shapes that also could be utilized, such as spiral or helical wire. These wires would provide greater strength for a given weight or wire size. Therefore, a stronger corner may be fabricated with the use of shaped wires with the configuration of the preferred embodiment.
[0060] To enhance the corrosion resistance, it is a further feature of the preferred embodiment to provide a chromate conversion coating of the galvanized wires after the product is fabricated. Stucco corners are usually packaged in groups of 10 per bundle. To make chromate conversion coating economically viable, it is desirable to be able to batch coat the wire corners in groups of 10. With the reduced wire density of the improved wire corner of this invention, it is now possible to achieve a successful chromate coating of the wire corners. The other advantage of chromate conversion after fabrication is that the weld points, where zinc has been burned off during welding, are now provided with some corrosion protection.
[0061] In the embodiment of FIG. 4 , the transverse wire sizes and longitudinal wire sizes may range from 16 ga to 20 ga. In the preferred embodiment, the transverse wires would be 17½ ga and the longitudinal wires would be 17 ga, except for the nose wire which would be 16 ga.
[0062] The amplitude of each transverse wire could range from 3 inches to 6 inches. The preferred embodiment would have an amplitude of 5 inches. The pitch of each transverse wire could range from 2 inches to 8 inches. The preferred embodiment would have a pitch of 6 inches. In the case of 3 transverse wires as shown in FIG. 4 , nailing loops 48 would be formed every S inches, in this case every 2 inches.
[0063] It will be appreciated by those skilled in the art that the preferred and alternative embodiments have been described in some detail but that certain modifications may be practiced without departing from the principles of the invention.
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A welded wire corner bead comprising at least one and preferably two continuous wires defining a periodic wave form extending from side to side of the bead, the bead being bent lengthwise along an axis.
| 4
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to printing cellulosic articles and, more particularly, to a new and improved method of screen printing fabrics, in which the fabric article is first selectively printed with a chemical system including a dye blocking print paste and a dye enhancing print paste and subsequently dyed to bring out the print.
2. Description of the Prior Art
Traditional screen printing of garments is done by printing ink, binder, thickener and softener combinations on dyed or white prepared for print (PFP) garments. A detailed description of the screen printing process is published in the Encyclopedia of Textiles, Second Edition, 1972 Prentice-Hall, Inc., Englewood Cliffs N.J., the disclosure of which is hereby incorporated by reference in its entirety. The following discussion is taken from the above-referenced Encyclopedia of Textiles.
The screen printing method in textiles is basically a stencil process. A wooden or metal frame is covered with a bolting cloth, which may be made of silk, fine metal thread, or nylon. The fabric is covered with a film and the design areas are cut out of the film just as in stencil making. The frame is then laid on the fabric and color is brushed or squeezed through the open areas of the film by the use of a big rubber knife or squeegee.
Originally, the design was cut out of film and then adhered to the screen. Today the cutting is done mechanically by a photo-chemical process which reproduces the design exactly as it was painted in the art which is being reproduced.
In printing, one screen is used for each color and these are accurately registered one on the other by the use of fixed stops attached to an iron rail running the length of the table. The length of the table determines the number of yards which can be printed at one laying; this varies depending on the available space, though 30 yards is considered the smallest space which is practical for economic production.
While screen printing, either by hand or machine, is a slower and more expensive process than roller printing, it has several virtues. From the point of view of design, pattern repeats can be much larger than in roller printing. Also, since the process is slower, pigment colors can be laid on in heavy layers to produce a handicraft effect. From an economic point of view, it does not require as large an investment as roller printing because the runs can be shorter, especially in the hand operation. This has encouraged smaller converters to adopt the screen method and to experiment more with design than they would be able to do in the roller method, where they would be required to contract for a minimum of about 8000 yards per pattern.
One of the most important physical parameters for good screen printing is that the print paste is thick enough to stand in a gel state until it is dried and cured. This assures clean crisp definition of the print. However, the print paste still must flow readily and evenly. These two properties are defined as the rheology of the print paste and the most desirable property is called pseudo-plastic or the ability of the paste to become less viscous when moved by pump or mechanical device and to thicken or become more viscous when it stills.
Because of the nature of the print paste, screen prints are generally opaque and rubbery to the touch. In addition, these prints are not very durable especially when washed. There has been much work done in developing softer prints that do not crack and peel after washing and these softened prints are called“plastisols,” but they are still based on pigments, binder, thickener and are still a surface coating which can be “felt”.
One approach to solving this problem is disclosed in U.S. patent application Ser. No. 08/922,221, filed Sep. 2, 1997, now U.S. Pat. No. 5,984,977, which is hereby incorporated by reference in its entirety. However, some dye sites may still remain when using the teachings in this application. These sites may be sufficient to prevent multiple color dyeing since small traces of dyes may make true colors more difficult to achieve.
Thus, there remains a need for a new and improved method of screen printing in which the garment or fabric may be printed using traditional screen printing techniques while, at the same time, provides printed areas which can not be rubbed off or felt to the touch.
SUMMARY OF THE INVENTION
The present invention is directed to a dyeing system composition for use in printing articles or fabrics formed from cellulose prior to dyeing. In the preferred embodiment, the dyeing system composition includes the selective use of both a dye blocking print paste and a dye enhancing print paste to selectively decrease or increase the shade of the dyed portions of a cellulose article, such as a woven or knitted cotton or cotton/polyester article or fabric.
In the preferred embodiment, the dye blocking print paste includes a thickener and dye blocking agents. The dye blocking agents includes an ether-forming cross-linking resin, which may be pre-catalyzed, an ester-forming cross-linking resin, a reductive catalyst and a dye resist. Also, in the preferred embodiment, the dye enhancing print paste includes a thickener and an epoxy functional quaternary ammonium enhancing agent. The thickener for both print pastes, preferably, is an acid/alkali stable hydroxypropyl guar derivative, polyscaharride, dispersed in an invert emulsion.
Accordingly, one aspect of the present invention is to provide a dye blocking print paste for use in printing articles formed from cellulose prior to dyeing. The composition includes: (a) a thickener; and (b) dye blocking agents, the dye blocking agents including an ether-forming, cross-linking resin, an ester-forming, cross-linking resin, a catalyst and a dye resist.
Another aspect of the present invention is to provide a dye blocking print paste for use in printing articles formed from cellulose prior to dyeing. The composition includes: (a) a thickener; and (b) dye blocking agents, the dye blocking agents including a pre-catalyzed, ether-forming, cross-linking resin, an ester-forming, cross-linking resin, a catalyst and a dye resist.
Still another aspect of the present invention is to provide a dyeing system composition for use in printing articles formed from cellulose prior to dyeing. The composition includes: (a) a dye blocking print paste, the dye blocking print paste including: (i) a thickener and (ii) dye blocking agents, the dye blocking agents including a pre-catalyzed, ether-forming, cross-linking resin, an ester-forming, cross-linking resin, a catalyst and a dye resist; and (b) a dye enhancing print paste, the dye enhancing print paste including: (i) a thickener and (ii) an enhancing agent.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the examples.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is performed in the reverse order of traditional garment or fabric screen printing. According to the present invention, the garment or fabric is print prepared (e.g. scoured and bleached white) or griege (unprepared) with a chemical system including a dye blocking print paste and a dye enhancing print paste. The dye blocking print paste includes a wetting agent, a thickener paste; and a dye blocking agent, the dye blocking agent including a cross-linking resin and a dye resist to selectively decrease the shade of the dye. In the preferred embodiment, the dye enhancing print paste includes a wetting agent, thickener and a dye enhancing agent which is used to selectively increase the shade of the dye.
In the preferred embodiment, the thickener paste for both the dye blocking and the dye enhancing print paste is an acid/alkali stable hydroxypropyl guar derivative, polyscaharride, dispersed in an invert emulsion. Specifically, the polysaccharide concentrate includes about 35 weight percent water, 10 weight percent emulsifier, 10 weight percent polysaccharide and 45 weight of a petrol solvent.
Also, the cross-linking resin used in the dye blocking agent is preferably a pre-catalyzed glyoxal resin although it is believed that a self-catalyzed glyoxal resin might also work. In the preferred embodiment, the dye resist used in the dye blocking agent is a low molecular weight polyacrylic acid having a molecular weight of about 2000. One suitable dye resist is sold under the tradename BURCO® Dye Resist 118 by Burlington Chemical Company, Inc. of Burlington, N.C., the assignee of the present invention.
Finally, the enhancing agent used in the dye enhancing print paste is preferably an epoxy functional quaternary ammonium compound. One suitable dye enhancer is sold under the tradename BURCO® DCE by Burlington Chemical Company, Inc. of Burlington, N.C., the assignee of the present invention.
The cellulosic article, garment or fabric is then dyed to the desired shade with the blocking and enhancing print pastes selectively either reducing the amount of dye on the fabric or enhancing the dye on the fabric. If we measure the background and set it arbitrarily as 100%, the enhanced regions are 250% deeper in color and the blocked regions are 90% lighter than the background.
Further examples of the present invention can be seen in a camo print on 100% cotton knit fabric where various concentrations of the enhancer chemical are printed on and then dyed.
The present invention can be best understood by a review of the following examples:
EXAMPLES 1-2
A dye blocking print paste was prepared using both pre-catalyzed glyoxal resin and a conventional glyoxal resin according to the amounts in weight percent shown in Table 1. Cotton fabric was printed with the dye blocking print paste, the print paste was allowed to dry and cure and conventional reactive and direct dyeing were made. The results are shown in Table 1, below:
TABLE 1
Pre-
Catalyzed
Poly-
Glyoxal
Glyoxal
Acrylic
Wetting
Shade
Ex.
Pas
Resin
Resin
Acid
Agent
Difference
1
15 w
15 wt. %
—
5 wt. %
0.1 wt. %
−90%
2
15 w
—
15 wt. %
5 wt. %
0.1 wt/ %
No
Effect!
As can be seen, only the dye blocking print paste including a pre-catalyzed glyoxal resin was effective in blocking the dye.
EXAMPLES 3-6
A dye blocking print paste was prepared using pre-catalyzed glyoxal resin according to the amounts in weight percent shown in Table 2. Cotton fabric was printed with the dye blocking print paste, the print paste was allowed to dry and cure and conventional reactive and direct dyeing were made. The results are shown in Table 2, below:
TABLE 2
Pre-
Catalyzed
Poly-
Pas
Glyoxal
Glyoxal
Acrylic
Wetting
Shade
Ex.
te
Resin
Resin
Acid
Agent
Difference
3
15
15 wt. %
—
5 wt. %
0.1 wt. %
−90%
wt. %
4
15
10 wt. %
—
5 wt. %
0.1 wt. %
−60%
wt. %
5
15
5 wt. %
—
5 wt. %
0.1 wt. %
−30%
wt. %
6
15
2.5 wt. %
—
5 wt. %
0.1 wt. %
−10%
wt. %
As can be seen, the dye blocking print paste having between about 5 to 15 wt. % pre-catalyzed glyoxal resin produced a linear relationship between the weight percent of resin and the shade difference in blocking the dye.
EXAMPLES 7-10
A dye blocking print paste was prepared using pre-catalyzed glyoxal resin according to the amounts in weight percent shown in Table 3 and both with and without polyacrylic acid. Cotton fabric was printed with the dye blocking print paste, the print paste was allowed to dry and cure and conventional reactive and direct dyeing were made. The results are shown in Table 3, below:
TABLE 3
Pre-
Catalyzed
Poly-
Pas
Glyoxal
Glyoxal
Acrylic
Wetting
Shade
Ex.
te
Resin
Resin
Acid
Agent
Difference
7
15
15 wt. %
—
5 wt. %
0.1 wt. %
−90%
wt. %
8
15
15 wt. %
—
—
0.1 wt. %
−60%
wt. %
9
15
2.5 wt. %
—
—
0.1 wt. %
No
wt. %
Effect!
10
15
—
—
15
0.1 wt. %
No
wt. %
wt. %
Effect!
As can be seen, the addition of polyacrylic acid improved the effectiveness of the dye blocking print paste 50% when comparing Example 7 to Example 8. In addition, only the dye blocking print paste including a pre-catalyzed glyoxal resin was effective in blocking the dye even when the amount of polyacrylic acid was increase to 15 wt. %.
Dyeings were than made using the thickener of the present invention along with a conventional epoxy functional quaternary ammonium compound to form a dye enhancing print paste. This compound has been used in the past to react with cellulose to yield a permanent cationic site on the cellulose to improve dye yield. If we measure the background and set it arbitrarily as 100%, the enhanced regions were 250% deeper in color than the background when dyed with fiber reactive and direct dyes.
Finally, fabric was screen printed using a combination of the blocking print paste and enhancing print paste according to the present invention. Dyeing to the desired shade with the blocking and enhancing print pastes selectively either reduced the amount of dye on the fabric or enhanced the dye on the fabric. If we measure the background and set it arbitrarily as 100%, the enhanced regions were 250% deeper in color and the blocked regions were 90% lighter than the background!
In a further improved embodiment as claimed in the present invention, the dye blocking agents may include a pre-catalyzed ether-forming cross-linking resin, an ester-forming cross-linking resin, a catalyst and a dye resist. It has been discovered that the addition of an ester-forming cross-linking resin and catalyst improves the strength, the light scattering (KS value) and further reduces the excluded dye sites of the resist portion of the fabric as shown below.
EXAMPLES 11-13
Dye blocking print pastes were prepared using a thickener and different dye blocking agents and a dye resist. The dye blocking agents included only a pre-catalyzed, ether-forming, cross-linking resin; only an ester-forming, cross-linking resin and a catalyst; and the combination of a pre-catalyzed, ether-forming, cross-linking resin, an ester-forming, cross-linking resin, and a catalyst. Cotton fabric was printed with the dye blocking print paste, the print paste was allowed to dry and cure and conventional reactive and direct dyeing were made. The results are shown in Table 4, below:
TABLE 4
Fabric
Strength
(compared
Light
Dye
to
Scatter
Excluded
Blocking
untreated
(KS
Dye
Ex.
Agent
fabric)
value)
Sites
11
Pre-
60%
100%
98%
Catalyzed
(base)
Ether-
forming,
cross
linking
Resin
(only)
12
Ester-
100%
70%
97%
forming,
cross
linking
Resin
(only)
13
Both
100%
140%
99%
resins
(present
invention)
As can be seen, the dye blocking print paste including the additional cross-linking resin and catalyst is a significant improvement.
In the preferred embodiment, the ester-forming cross-linking resin are carboxylic acids. Specifically, the resin is a 50/50 mixture of polymaleic acid and butanetetracarboxylic acid at between about 5 to 15 weight percent of the total weight of the dye blocking print paste with about 8 weight percent of the total weight of the dye blocking print paste being preferred.
Also, in the preferred embodiment, the catalyst is reductive with sodium hypophosphite at a 1 to 4 ratio to the ester-forming cross-linking resin being preferred.
A cellulosic article, garment or fabric dyed to the desired shade with the improved blocking print paste further reduces the amount of dye on the fabric. If we measure the background and set it arbitrarily as 100%, the enhanced regions are still 250% deeper in color and the improved blocked regions are 98% lighter than the background.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, while the preferred embodiment of this invention is directed to printing cotton and cotton/polyester fabrics, it could be easily adapted to printing other cellulosic articles. Also, non-polymer organic acids, such as citric acid, maleic acid and BTCA, other cationics and other thickeners may work. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
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A dyeing system composition for use in printing articles formed from cellulose prior to dyeing. The dyeing system composition includes the use of both a dye blocking print paste and a dye enhancing print paste to selectively decrease or increase the shade of dyed portions of a cellulose article such as a woven cotton fabric.
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[0001] This application claims priority of European Patent Application No. 99204497.4, filed on Dec. 23, 1999 and U.S. Provisional Application Serial No. 60/178,407 filed on Jan. 27, 2000.
[0002] The invention relates to an aqueous coating composition comprising an addition polymer and a polyurethane. Preferably, this aqueous coating composition also comprises a metallic pigment, such as aluminium, or a pigment, such as a metal oxide-coated mica, so that coatings with a metallic appearance may be obtained. In this way a differential light reflection effect referred to as “flop” is obtained. A problem with coating systems having a metallic appearance is to obtain a high flop as well as a high gloss.
BACKGROUND OF THE INVENTION
[0003] To obtain a high flop, the metallic pigment on application of the coating composition should be well oriented and remain so. To obtain a high gloss, the metallic pigment-containing coating is provided with an unpigmented so-called clear coat. This system is generally called a “base coat/clear coat” system. In actual practice, the base coat will be sprayed with the clear coat, without prior curing of the base coat (“wet-on-wet”). Since the clear coat usually contains organic solvents, steps should be taken to prevent disorientation of the metallic pigment in the base coat as a result of the base coat being softened by the organic solvents in the clear coat (“strike-in”).
[0004] An aqueous base coat composition is known from EP-A-0 287 144, i.e. a non-cross-linked core-shell dispersion where the shell, when swollen, provides the desired rheological properties. A decrease in strike-in is observed. However, it has been established that this coating composition needs improvement in respect of several coating properties, such as covering power and drying times.
SUMMARY OF THE INVENTION
[0005] The present invention now provides an aqueous coating composition which may be used as base coat in a base coat/clear coat system which has good mechanical properties, a high flop, a high gloss, practically no strike-in, and a good water-resistance. Due to the fact that higher solids contents can be achieved with the aqueous coating composition of the present invention, a reduction in drying times and number of coats is obtained. In one or more of these properties the aqueous coating composition of the present invention shows improvement over the one disclosed in EP-A-0 287 144.
[0006] The aqueous coating composition according to the invention comprises 5 to 95 wt. % of at least one alkali-swellable core-shell addition polymer (I), and 95 to 5 wt. % of at least one polyurethane (II), the sum of the wt. % indicated for the polymers (I) and (II) always being 100 wt. %.
DETAILED DESCRIPTION OF THE INVENTION
[0007] Preferably, the aqueous coating composition comprises 10 to 90 wt. % of at least one addition polymer (I), and 90 to 10 wt. % of at least one polyurethane (II). More preferably, the aqueous coating composition comprises 25 to 75 wt. % of at least one addition polymer (I), and 75 to 25 wt. % of at least one polyurethane (II).
[0008] Preferably, the alkali-swellable core-shell addition polymer (I) is a copolymer prepared in two or more steps by emulsion polymerization, and is obtained by the copolymerization in a first step of
[0009] A) 60-95 parts by weight (based on 100 parts by weight of addition polymer) of a monomer mixture A consisting of
[0010] i) 65-100 mole % of a mixture of
[0011] a) 60-100 mole % of a (cyclo)alkyl (meth)acrylate of which the (cyclo)alkyl group contains 4-12 carbon atoms, and
[0012] b) 0-40 mole % of a di(cyclo)alkyl maleate and/or a di(cyclo)-alkyl fumarate of which the (cyclo)alkyl groups contain 4-12 carbon atoms,
[0013] the sum of the mole % indicated for the monomers (a) and (b) always being 100 mole %, and
[0014] ii) 0-35 mole % of another copolymerizable, monoalkylenically unsaturated monomer,
[0015] the sum of the mole % indicated for the monomers (i) and (ii) always being 100 mole %, and
[0016] by the copolymerization in a subsequent step of
[0017] B) 5-40 parts by weight (based on 100 parts by weight of addition polymer) of a monomer mixture B comprising
[0018] iii) 10-60 mole % of (meth)acrylic acid and
[0019] iv) 40-90 mole % of another copolymerizable, monoalkylenically unsaturated monomer,
[0020] the sum of the mole % indicated for the monomers (iii) and (iv) always being 100 mole %,
[0021] with the carboxylic acid groups derived from the (meth)acrylic acid being at least partially ionized; resulting in a non-cross-linked, alkali-swellable core-shell addition polymer (I).
[0022] Such alkali-swellable core-shell addition polymers are known from EP-A-0 287 144.
[0023] Preferably, the addition polymer is obtained by the copolymerization of 80-90 parts by weight of monomer mixture A and 10-20 parts by weight of monomer mixture B. Optionally, different monomer mixtures A and/or B may be used successively.
[0024] By emulsion polymerization is meant here the polymerization of an ethylenically unsaturated monomer in water in the presence of a water-soluble or water-insoluble initiator and using an emulsifier.
[0025] As examples of (cyclo)alkyl (meth)acrylates suitable for use in monomer mixture A and having a (cyclo)alkyl group with 4-12 carbon atoms may be mentioned: butyl acrylate, butyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, octyl acrylate, octyl methacrylate, isobornyl acrylate, isobornyl methacrylate, dodecyl acrylate, dodecyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, and mixtures thereof. It is preferred that monomer mixture A should contain 70-95, more particularly 80-95, mole % of the aforementioned (cyclo)alkyl (meth)acrylate. Preferred monomers are butyl acrylate, butyl methacrylate, and mixtures thereof.
[0026] As examples of di(cyclo)alkyl maleates and/or fumarates with (cyclo)alkyl groups having 4-12 carbon atoms suitable for use in monomer mixture A may be mentioned: dibutyl maleate, dibutyl fumarate, 2-ethylhexyl maleate, 2-ethylhexyl fumarate, octyl maleate, isobornyl maleate, dodecyl maleate, cyclohexyl maleate, and mixtures thereof.
[0027] As suitable copolymerizable, monoalkylenically unsaturated monomers of which maximally 35, and preferably 5-20, mole % may be used in monomer mixture A may be mentioned: alkyl (meth)acrylates having fewer than 4 carbon atoms in the alkyl group, such as methyl methacrylate, methyl acrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, and isopropyl acrylate; alkyl maleates and fumarates having fewer than 4 carbon atoms in the alkyl groups, such as dimethyl maleate, diethyl maleate, diethyl fumarate, and dipropyl maleate; (meth)acrylates having ether groups such as 2-methoxyethyl methacrylate, 2-ethoxyethyl methacrylate, 3-methoxypropyl acrylate; hydroxy-alkyl (meth)acrylates, e.g., 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, 2-hydroxypropyl methacrylate, 4-hydroxybutyl acrylate, 6-hydroxyhexyl acrylate, p-hydroxycyclohexyl acrylate, p-hydroxycyclohexyl methacrylate, hydroxypolyethylene glycol (meth)acrylates, hydroxypolypropylene glycol (meth)acrylates, and the corresponding alkoxy derivatives thereof; epoxy (meth)acrylates, such as glycidyl acrylate and glycidyl methacrylate; monovinyl aromatic hydrocarbons, such as styrene, vinyl toluene, α-methyl styrene, and vinyl naphthalene; also acrylamide and methacrylamide, acrylonitrile, methacrylonitrile, N-methylol acrylamide, and N-methylol methacrylamide; N-alkyl (meth)acrylamides, such as N-isopropyl acrylamide, N-isopropyl methacrylamide, N-t-butyl acrylamide, N-t-octyl acrylamide, N,N-dimethyl aminoethyl methacrylate, and N,N-diethyl aminoethyl methacrylate; monomers, such as vinyl chloride, vinyl acetate, vinyl pyrrolidone, and vinyl propionate, and monomers containing one or more urea or urethane groups, for instance the reaction product of 1 mole of isocyanatoethyl methacrylate and 1 mole of butylamine, 1 mole of benzylamine, 1 mole of butanol, 1 mole of 2-ethylhexanol, and 1 mole of methanol, respectively. Mixtures of these compounds may also be used. Preferred are alkyl (meth)acrylates, such as methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, and mixtures thereof, and hydroxyalkyl (meth)acrylates, such as 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, 2-hydroxypropyl methacrylate, and mixtures thereof.
[0028] Since the addition polymer (I) is non-crosslinked, the choice of the monomers in monomer mixtures A and B is such that, other than the unsaturated bonds, the functional groups present cannot react with each other under the reaction conditions for the preparation of the addition polymer.
[0029] As examples of copolymerizable, monoalkylenically unsaturated monomers which may be used in monomer mixture B in addition to the (meth)acrylic acid may be mentioned: monovinyl aromatic hydrocarbons, such as styrene, vinyl toluene, α-methyl styrene, and vinyl naphthalene; nitriles, such as acrylonitrile and methacrylonitrile; acrylic or methacrylic esters, such as methyl methacrylate, methyl acrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, isopropyl acrylate, butyl acrylate, butyl methacrylate, and 2-ethylhexyl acrylate; hydroxyalkyl (meth)acrylates, e.g., 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, 2-hydroxypropyl methacrylate, 4-hydroxybutyl acrylate, 6-hydroxyhexyl acrylate, and p-hydroxylcyclohexyl acrylate; (meth)acrylates having ether groups such as 2-methoxyethyl methacrylate, 2-ethoxyethyl methacrylate, and 3-methoxypropyl acrylate; hydroxypolyethylene glycol (meth)acrylates, hydroxypolypropylene glycol (meth)acrylates and the corresponding alkoxy derivatives thereof; ethylenically unsaturated monocarboxylic acids such as crotonic acid and itaconic acid, and compounds such as vinyl chloride, vinyl acetate, vinyl propionate, vinyl pyrrolidone, acrylamide, methacrylamide, and N-alkyl (meth)acrylamides such as N-isopropyl acrylamide, N-t-butyl acrylamide, and N-t-octyl acrylamide. Mixtures of these compounds may also be used. Preferred monomers are methyl acrylate, methyl methacrylate, butyl acrylate, and butyl methacrylate, and mixtures thereof.
[0030] It is preferred that monomer mixture B should contain 15-50 mole %, more particularly 20-40 mole % of (meth)acrylic acid and 50-85 mole %, more particularly 60-80 mole % of the copolymerizable, monoalkylenically unsaturated monomer.
[0031] Copolymerization of monomer mixture B will generally yield a copolymer having an acid number of 30-450 and preferably of 60-350, and a hydroxyl number of 0-450 and preferably of 60-300. Both the acid number and the hydroxyl number are expressed in mg of KOH per g of copolymer.
[0032] The addition polymer (I) has a Mn of from 50,000 to 2,000,000, preferably from 100,000 to 1,000,000.
[0033] The emulsifiers preferably used in the emulsion polymerization are of an anionic or non-ionic nature. Examples of anionic emulsifiers include: potassium laurate, potassium stearate, potassium oleate, sodium decyl sulphate, sodium dodecyl sulphate, sodium dodecylbenzene sulphonic acid, and sodium rosinate. Examples of non-ionic emulsifiers include: linear and branched alkyl and alkylaryl polyethylene glycol and polypropylene glycol ethers and thioethers, alkyl phenoxypoly(ethyleneoxy) ethanols such as the adduct of 1 mole of nonyl phenol to 3-12 moles of ethylene oxide; alkyl (ethyleneoxy) ethanols with 8-18 carbon atoms in the alkyl groups, such as the adduct of 1 mole of dodecanol to 3-12 moles of ethylene oxide. Examples of emulsifiers comprising anionic and non-ionic groups are the ammonium or sodium salt of the sulphate of alkyl phenoxypoly(ethyleneoxy) ethanols, such as the adduct of 1 mole of nonyl phenol to 3-12 moles of ethylene oxide, and the ammonium or sodium salt of the sulphate of alkyl (ethyleneoxy) ethanols with 8-18 carbon atoms in the alkyl groups, such as the adduct of 1 mole of C 12-14 alcohol to 3-12 moles of ethylene oxide. Preferred is the ammonium or sodium sulphate salt of the adduct of 1 mole of C 12-14 alcohol to 3-12 moles of ethylene oxide.
[0034] Also, in emulsion polymerization, the conventional radical initiators may be used in the usual amounts. Examples of suitable radical initiators include water-soluble initiators, such as ammonium persulphate, sodium persulphate, potassium persulphate, and t-butyl hydroperoxide, and water-insoluble initiators, such as bis(2-ethylhexyl) peroxydicarbonate, di-n-butyl peroxy-dicarbonate, t-butyl perpivalate, cumene hydroperoxide, dibenzoyl peroxide, dilauroyl peroxide, 2,2′-azobisisobutyronitrile, and 2,2′-azobis-2-methyl-butyronitrile.
[0035] As suitable reducing agents which may be used in combination with, e.g., a hydroperoxide may be mentioned: ascorbic acid, sodium sulphoxylate formaldehyde, thiosulphates, bisulphates hydrosulphates, water-soluble amines such as diethylene triamine, triethylene tetramine, tetraethylene pentamine, N,N′-dimethyl ethanol amine, and N,N-diethyl ethanol amine, and reducing salts such as cobalt, iron, nickel, and copper sulphate.
[0036] Optionally, a chain length regulator, for instance n-octyl mercaptan, dodecyl mercaptan, and 3-mercaptopropionic acid, may also be used.
[0037] Copolymerization of the monomer mixtures generally is carried out at atmospheric pressure at a temperature of 40-100° C., preferably 60-90° C., in an atmosphere of an inert gas, such as nitrogen. Optionally, however, copolymerization may also be carried out at elevated pressure. in any case, the reaction conditions for monomer mixtures A and B should be chosen such that, other than the unsaturated bonds, functional groups present in the monomer mixtures cannot react with each other.
[0038] According to the invention, the carboxylic acid groups derived from the acrylic acid and/or methacrylic acid are at least 40-100% neutralized by the addition of a neutralizing agent. As suitable neutralizing agents for the carboxylic acid may be mentioned ammonia and amines such as N,N-dimethyl ethanol amine, N,N-diethyl ethanol amine, 2-(dimethyl)-amino-2-methyl-1-propanol, triethyl amine, and morpholine. It is preferred that the neutralizing of the carboxylic acid groups be carried out after the polymerization.
[0039] Mixtures of alkali-swellable core-shell addition polymers may be used in (I).
[0040] An example of a dispersion comprising such an alkali-swellable core-shell addition polymer is Setalux 6801 AQ-24, ex Akzo Nobel Resins.
[0041] The polyurethane (II) may in general be prepared from polyisocyanates and polyols as known by the skilled man. Examples thereof include Neorez R970 (ex NeoResins) and Daotan VTW 2275 (ex Vianova Resins). Also included in the definition of polyurethane (II) are hybrids of polyurethane such as polyurethane acrylate hybrids. Examples thereof include Neopac E115 (ex NeoResins) and Daotan VTW 6460 (ex Vianova Resins).
[0042] Preferably, polyurethane (II) is a polyurethane polyurea. More preferably, the polyurethane polyurea comprises:
[0043] v) at least 200 milliequivalents per 100 g of solids of chemically incorporated carbonate groups —O—CO—O—, and
[0044] vi) a combined total of up to 320 milliequivalents per 100 g of solids of chemically incorporated urethane groups —NH—CO—O— and chemically incorporated urea groups —NH—CO—NH—.
[0045] Such polyurethane polyurea dispersions are known from DE 39 36 794.
[0046] Preferably, the polyurethane polyurea comprises at least 250 milliequivalents, per 100 of solids content, of chemically incorporated carbonate groups —O—CO—O—, and a combined total of 200 to 300 milliequivalents, per 100 g of solids content, of urethane groups —NH—CO—O— and urea groups —NH—CO—NH—.
[0047] Polyurethane polyurea may be prepared in a known manner by reacting
[0048] a) organic polyisocyanates which contain no hydrophilic groups or groups convertible into hydrophilic groups with
[0049] b) relatively high-molecular weight organic polyhydroxyl compounds which have no hydrophilic groups or groups convertible into hydrophilic groups,
[0050] c) optionally, low-molecular weight compositions containing at least two isocyanate-reactive groups but no hydrophilic groups or groups capable of conversion into hydrophilic groups,
[0051] d) optionally, non-ionic hydrophilic starting components containing at least one isocyanate group or at least one isocyanate-reactive group, and
[0052] e) optionally, starting components containing at least one ionic group or at least one group capable of conversion into an ionic group, as well as at least one isocyanate-reactive hydrogen atom,
[0053] provided that the quantities of non-ionic groups and ionic groups present in components d) and e) are sufficient to ensure the dispersibility of the polyurethane polyureas in water.
[0054] The reaction between isocyanate groups and hydroxyl groups results in urethane groups, while any urea groups present in the reaction products are formed from amine-functional starting components and/or the reaction between isocyanate groups and the dispersing water, which is always possible during the preparation of the aqueous polyurethane dispersions.
[0055] Polyisocyanate component a) includes any polyisocyanate known from polyurethane chemistry. These polyisocyanates generally have a molecular weight of 112 to 1,000, preferably 140 to 400. Suitable polyisocyanates are those which correspond to the formula Q(NCO)n, wherein Q represents an organic group obtained by removing the isocyanate groups from an organic polyisocyanate having a molecular weight of 112 to 1,000, preferably 140 to 400, and n stands for a number from 2 to 4, preferably 2 or 3 and more preferably 2. In the above formula Q preferably represents a divalent aliphatic hydrocarbon group having 4 to 18 carbon atoms, a divalent cycloaliphatic hydrocarbon group having 5 to 15 carbon atoms, a divalent aromatic hydrocarbon group having 6 to 15 carbon atoms or an araliphatic hydrocarbon group having 7 to 15 carbon atoms. Examples of suitable polyisocyanates include tetramethylene diisocyanate, 1,6-diisocyanatohexane (HDI) dodeca-methylene diisocyanate, 2,2,4-trimethylhexane diisocyanate, undecane diisocyanate-(1,11), lysine ester diisocyanate, cyclohexane-1,3- and -1,4-diisocyanate, 1 -isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (IPDI), and 4,4′-diisocyanato dicyclohexylmethane. Also suitable are aromatic diisocyanates such as 2,4-diisocyanato toluene and/or 2,6-diisocyanato toluene, 4,4″-diisocyanato diphenyl methane, and 1,4-diisocyanato isopropyl benzene. HDI, IPDI and mixtures of these diisocyanates are particularly preferred.
[0056] Component b) includes organic polyhydroxyl compounds having a molecular weight of 300 to 5,000, preferably from 500 to 3,000, and containing at least 50% by weight, preferably more than 70% by weight, of polyhydroxy polycarbonates. The polyhydroxy polycarbonates are esters of carbonic acid obtained by the reaction of carbonic acid derivatives, e.g., diphenyl carbonate or phosgene, with diols. Examples of these diols include ethylene glycol, propane-1,2- and 1,3-diol, butane-1,4- and -1,3-diol, hexane-1,6-diol, octane-1,8-diol, neopentyl glycol, 1,4-bis-hydroxymethyl cyclohexane, 2-methyl-propane-1,3-diol, 2,2,4-trimethylpentane-1,3-diol, diethylene glycol, tri- and tetraethylene glycol, dipropylene glycol, polypropylene glycols, dibutylene glycol, polybutylene glycols, Bisphenol A and tetrabromo Bisphenol A. The diol component preferably contains from 40 to 100% by weight of a hexane diol, preferably hexane-1,6-diol, and/or hexane diol derivatives preferably containing ether or ester groups in addition to terminal OH groups, e.g., the products obtained by the reaction of 1 mole of hexane diol with ≧1 mole, preferably 1 to 2 moles, of caprolactone according to DE 17 70 245 or the products obtained by the self-etherification of hexane diol to form dihexylene or trihexylene glycol according to DE 15 70 540. The polyether polycarbonate diols described in DE 37 17 060 are also very suitable.
[0057] The hydroxyl polycarbonates should be substantially linear although they may, if desired, be slightly branched by the incorporation of polyfunctional components, in particular low-molecular weight polyols such as glycerol, trimethylol propane, hexane-1,2,6-triol, butane-1,2,4-triol, trimethylol propane, pentaerythritol, quinitol, mannitol and sorbitol, methyl glycoside and 1,4,3,6-dianhydrohexitols.
[0058] In addition to the polyhydroxy polycarbonates, starting component b) may contain other known polyhydroxyl compounds having the previously described molecular weights, e.g.,
[0059] b1) dihydroxy polyesters obtained from dicarboxylic acids such as succinic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, phthalic acid, isophthalic acid, terephthalic acid, tetrahydrophthalic acid, and from diols such as ethylene glycol, propane-1,2-diol, propane-1,3-diol, diethylene glycol, butane-1,4-diol, hexane-1,6-diol, octane-1,8-diol, neopentyl glycol, 2-methyl propane-1,3-diol and the various isomeric bis-hydroxymethyl cyclohexanes;
[0060] b2) polylactones such as the polymers of ε-caprolactone initiated with the above-mentioned dihydric alcohols; and
[0061] b3) polyethers, e.g., the polymers or copolymers of tetrahydrofuran, styrene oxide, propylene oxide, ethylene oxide, the butylene oxides or epichloro-hydrin initiated with divalent starter molecules such as water, the above-mentioned diols or amines containing 2 NH bonds, in particular the polymers and copolymers of propylene oxide and optionally ethylene oxide. Ethylene oxide may be used as a portion of the total quantity of ether molecules, provided the resulting polyether diol contains not more than 10% by weight of ethylene oxide units. It is preferred to use polyether diols which have been obtained without the addition of ethylene oxide, especially those based on propylene oxide and tetrahydrofuran alone.
[0062] The optionally used starting components c) are known low-molecular weight compounds which have a molecular weight below 300, contain hydroxyl and/or amino groups, and are at least difunctional in isocyanate addition reactions. Compounds which are difunctional in isocyanate addition reactions (chain extenders), compounds which are at least trifunctional in isocyanate addition reactions (cross-linking agents), and mixtures of such compounds may be used as starting components c). Examples of these compounds include low-molecular weight polyhydric alcohols such as ethylene glycol, propane-1,2- and -1,3-diol, butane-1,4- and -1,3-diol, hexane-1,6-diol, octane-1,8-diol, neopentyl glycol, 1,4-bis-hydroxymethyl cyclohexane, 2-methyl-propane-1,3-diol, 2,2,4-trimethyl pentane-1,3-diol, glycerol, trimethylol propane, trimethylol ethane, the isomeric hexane triols and pentaerythritol; low-molecular weight diamines such as ethylene diamine, 1,2- and 1,3-diaminopropane, 1,3-, 1,4- and 1,6-diamino-hexane, 1,3-diamino-2,2-dimethyl propane, isophorone diamine, 4,4′-diamino-dicyclohexyl methane, 4,4-diamino-3,3′-dimethyldicyclohexyl methane, 1,4-bis-(2-amino-prop-2-yl)-cyclohexane, hydrazine, hydrazide, and mixtures of such diamines and hydrazines; higher functional polyamines such as diethylene triamine, triethylene tetramine, dipropylene triamine, and tripropylene tetramine; hydrogenated products of addition of acrylonitrile to aliphatic or cycloaliphatic diamines, preferably those obtained by the addition of an acrylonitrile group to a molecule of a diamine, e.g., hexamethylene propylene triamine, tetramethylene propylene triamine, isophorone propylene triamine or 1,3- or 1,3-cyclohexane propylene triamine, and mixtures of such polyamines.
[0063] The hydrophilic starting components d) are compositions containing ethylene oxide units incorporated within polyether chains, specifically:
[0064] d1) diisocyanates and/or compositions which contain isocyanate-reactive hydrogen atoms and are difunctional in isocyanate polyaddition reactions, the diisocyanates and compositions also containing polyether side chains containing ethylene oxide units, and
[0065] d2) monoisocyanates and/or compositions which are monofunctional in isocyanate polyaddition reactions and contain an isocyanate-reactive hydrogen atom, the monoisocyanates and compositions also containing terminal polyether chains containing ethylene oxide units, and
[0066] d3) mixtures of d1) and d2).
[0067] The preparation of these hydrophilic starting components is carried out by methods analogous to those described in U.S. Pat. Nos. 3,920,598, 3,905,929, 4,190,566, and 4,237,264.
[0068] The compounds used as starting component e) have at least one isocyanate-reactive group and at least one (potentially) ionic group. They include the alcohols-containing tertiary amino groups, hydroxy carboxylic acids, hydroxy sulphonic acids, amino carboxylic acids, and amino sulphonic acids disclosed in U.S. Pat. No. 3,479,310. Instead of these starting components containing potentially ionic groups, the corresponding salt type derivatives thereof may be used, i.e. ionic groups formed by the quaternization or neutralization of the potentially ionic groups. Examples of suitable quaternizing and neutralizing agents for converting the potentially ionic groups into ionic groups are also set forth in U.S. Pat. No. 3,479,310. When potentially ionic starting components are used, the at least partial conversion of the potentially ionic groups into ionic groups is carried out by quaternization or neutralization after or during preparation of the polyurethane polyureas.
[0069] Preferred starting components e) include 2,2-bis-(hydroxy-methyl)-alkane monocarboxylic acids having a total of 5 to 8 carbon atoms and/or salts thereof obtained by partial or complete neutralization with organic amines or NH 3 . 2,2-dimethylol propionic acid (2,2-bis-hydroxymethyl propionic acid) and/or salts thereof are particularly preferred for use as starting component e).
[0070] Preparation of the polyurethanes from the starting components a) to e) is carried out in a known manner in one or more stages using the reactants in such proportions that the equivalent ratio of isocyanate groups present in the starting components to isocyanate-reactive groups present in the starting components is 0.8:1 to 2:1, preferably 0.95:1 to 1.5:1, and more preferably 0.95:1 to 1.2:1.
[0071] Component d) is used in a quantity such that the polyurethane polyurea contains 0 to 30% by weight, preferably from 1 to 20% by weight, of ethylene oxide units incorporated into terminal or lateral polyether chains.
[0072] The quantity of component e) and the degree of neutralization required to form ionic groups are calculated to ensure that the polyurethane finally obtained contains 0 to 120, preferably 1 to 80 milliequivalents, of ionic groups per 100 g of solids. The total quantity of ethylene oxide units and ionic groups must be sufficient to ensure the dispersibility of the polyurethane polyureas in water.
[0073] The reaction of the starting components a) to e) may be carried out in one or more stages, optionally in the presence of an isocyanate-inert, water-miscible solvent, so that the reaction products are obtained in the form of a solution in such a solvent. In this context, the term “solution” denotes either a true solution or a water in oil emulsion which may be formed if, for example, individual starting components are used in the form of aqueous solutions. Examples of suitable solvents include acetone, methylethyl ketone, N-methyl pyrrolidone, and any mixtures of such solvents. These solvents are generally used in such quantities that the reaction products of starting components a) to e) are obtained in the form of 10 to 70 wt. %.
[0074] When the preparation of polyurethane polyureas is carried out as a single-stage reaction, the starting components containing isocyanate-reactive groups are preferably mixed together and then reacted with the starting components containing isocyanate groups. This reaction preferably is carried out initially in the absence of solvents at temperatures of 50 to 150° C., optionally in the presence of known catalysts.
[0075] The viscosity of the mixture increases during the course of the reaction and one of the above-mentioned solvents is therefore gradually added to the mixture. The polyurethane content of the organic solution finally obtained is adjusted to a concentration of 10 to 70% by weight, in particular 15 to 55% by weight.
[0076] When a two-stage process is employed, an isocyanate prepolymer preferably is first prepared solvent-free at about 50 to 150° C. from excess quantities of isocyanate-containing starting components and hydroxyl-containing starting components at an NCO/OH equivalent ratio of 1.1:1 to 3.5:1, preferably 1.2:1 to 2.5:1, with or without a solvent, and this isocyanate prepolymer is then taken up in a solvent if no solvent has been used up to this stage. The solution obtained is then further reacted with chain extenders or cross-linking agents c), which are optionally used in the form of aqueous solutions and are preferably starting components of the above-mentioned type containing primary and/or secondary amino groups. The quantity of starting components c) used in the second stage is calculated to ensure that the equivalent ratio of all the starting components used in the first and second stages conforms to the conditions previously stated.
[0077] The end products of both variations (single-stage and two-stage) are solutions of the reaction products in the above-mentioned solvent having a solids content within the ranges indicated above.
[0078] If any potentially ionic groups are present, their at least partial conversion into ionic groups by quaternization or neutralization is advantageously carried out before the addition of the dispersing water. If starting component e) contains carboxyl groups, which is preferred, in particular dimethylol propionic acid, the neutralizing agents used preferably are tertiary amines such as triethylamine, tri-n-butylamine, N,N,N-trimethyl cyclohexylamine, N-methyl morpholine, N-methyl piperazine, N,N-dimethyl ethanolamine, N-methyl piperidine, and triethanolamine. For the neutralization of carboxyl groups it is also preferred to use ammonia under the conditions set forth in EP-A-0 269 972.
[0079] After the addition of water as solvent or dispersing medium, at least the major proportion of the auxiliary solvent used is optionally removed by distillation. The water is used in a quantity which is sufficient to provide a product with a solids content of 10 to 60% by weight, preferably 20 to 45% by weight.
[0080] The polyurethane polyureas may also be prepared by other methods known in the art, for example by using hydrazine or diamines as chain extenders c) in a blocked form, i.e. in the form of the corresponding azines or ketimines, as disclosed in U.S. Pat. Nos. 4,269,748 and 4,829,122.
[0081] Alternatively, the so-called prepolymer mixing process may be used (see D. Dieterich, Angew. Makromol. Chem. 9A, 142 (1981)). In this process, an NCO prepolymer is initially prepared as described above and after the at least partial conversion of any potentially ionic groups present into ionic groups, the prepolymer is mixed with water to form an emulsion. The NCO groups of the prepolymer are then brought to reaction in the aqueous phase by the addition of amine-functional chain extenders or cross-linking agents c) and/or by a reaction with water.
[0082] One example of such a polyurethane polyurea dispersion is Bayhydrol VPLS 2952 ex Bayer.
[0083] Mixtures of polyurethanes may be used in (II).
[0084] The coating composition of the present invention, being an aqueous coating composition, consists essentially of water. However, about 20 wt. % of liquid content of the coating composition may be an organic solvent. As suitable organic solvents may be mentioned such ether group-containing alcohols as hexylglycol, butoxyethanol, 1-methoxy-propanol-2,1-ethoxy-propanol-2,1-propoxy-propanol-2,1-butoxy-propanol-2, and 1-isobutoxy-propanol-2; alcohols, such as methanol, ethanol, propanol, butanol, pentanol, and hexanol; diols, such as ethylene glycol and diethylene glycol.
[0085] The coating composition according to the present invention may be cured by physical drying. Alternatively, however, the coating compositions may be cured in the presence of a curing agent which reacts with hydroxyl and/or carboxyl groups.
[0086] Examples of suitable curing agents include N-methylol and/or N-methylol ether groups-containing aminoplasts obtained by reacting an aldehyde, for instance formaldehyde, with an amino or amido groups-containing compound such as melamine, such as Cymel 328, ex Cytec, urea, N,N′-ethylene urea, dicyanodiamide, and benzoguanamine. The resulting compounds are preferably wholly or partially etherified with alcohols having 1-6 carbon atoms, such as methanol, ethanol, n-propanol, isopropanol, n-butanol, isobutanol, amyl alcohol, hexanol, or mixtures thereof. Especially favourable results may be obtained when using a methylol melamine having 4-6 methyl groups per molecule of melamine, at least 3 methylol groups being etherified with butanol or a butanol etherified condensation product of formaldehyde and N,N′-ethylene diurea. Examples of other suitable curing agents include polyisocyanates or water-dispersible blocked polyisocyanate such as a methylethyl ketoxime-blocked, isocyanate group-containing adduct of a polyisocyanate to a hydroxycarboxylic acid, e.g., dimethylol propionic acid, and aliphatic or aromatic carbodiimides.
[0087] In addition to the alkali-swellable core-shell addition polymer (I) and the polyurethane (II), the binder composition may also comprise water-dilutable materials such as alkyd resins, polyesters, polyacrylates, and mixtures thereof.
[0088] In addition, the coating composition may contain the conventional additives and adjuvants, such as dispersing agents, dyes, accelerators for the curing reaction and rheology modifiers such as Acrysol RM 2020, Acrysol ASE 60, Coatex Rheo 3000, and Viscalex HV 30.
[0089] Applicable pigments may have an acid, a neutral or a basic character. Optionally, the pigments may be pre-treated to modify the properties. Examples of suitable pigments include metallic pigments such as aluminium and stainless steel; nacreous pigments, such as mica coated with a metal oxide such as iron oxide and/or titanium dioxide; inorganic pigments, such as titanium dioxide, iron oxide, carbon black, silica, kaolin, talc, barium sulphate, lead silicate, strontium chromate, and chromium oxide; and organic pigments, such as phthalocyanine pigments.
[0090] The solids content of the coating composition ranges from 5-60 wt. %, preferably from 10-40 wt. %. This depends on whether a metallic pigment is used or not. The presence of metallic pigments results in a lower solids content compared to when non-metallic pigments are present. However, compared to conventional aqueous base coat systems, the solids content of the coating composition of the present invention is higher in both cases.
[0091] Preferably, the coating composition according to the present invention is used as a base coat in a so-called base coat/clear coat system to provide a high gloss metallic appearance. To this end the coating composition according to the invention comprises so-called “non-leafing” aluminium paste or some other metallic pigment. Use of the coating compositions according to the invention as a base coat may prevent the base coat from being softened by the clear coat after being sprayed with it, so that the metallic effect will not be lost.
[0092] The clear coat used in the base coat/clear coat system may for instance be a clear baking lacquer of a conventional polyacrylate/melamine composition. The clear coat may also be a two-component polyester or polyacrylate/polyisocyanate composition. The polyisocyanate may be for example the trimer of 1,6-hexamethylene diisocyanate. The clear coat may also be water borne comprising hydrophilic polyisocyanates.
[0093] The coating composition according to the invention may be applied to a substrate in any desirable manner, such as by roller coating, spraying, brushing, sprinkling, flow coating, dipping, electrostatic spraying, or electrophoresis, preferably by spraying.
[0094] Suitable substrates may be made of wood, metal, and synthetic material, optionally pretreated, e.g. with a primer or filler. Curing may be carried out at ambient temperature or, optionally, at elevated temperature to reduce the curing time. Optionally, the coating composition may be baked at higher temperatures in the range of, for instance, 60 to 160° C., in a baking oven over a period of 10 to 60 minutes. The clear coat may be applied wet-on-wet on the base coat. Optionally, the base coat may be partially cured prior to the application of the clear coat. Also, the base coat may be fully cured prior to the application of the clear coat.
[0095] The compositions are particularly suitable in the preparation of coated metal substrates, such as in the refinish industry, in particular the body shop, to repair automobiles and transportation vehicles and in finishing large transportation vehicles such as trains, trucks, buses, and aeroplanes. The compositions of the present invention may also be used in the first finishing of automobiles.
[0096] The invention will be further described in the following examples, which must not be construed as limiting the scope of the present invention.
EXAMPLES
[0097] The test methods used in the examples are described below.
[0098] The spray viscosity was determined with a DIN cup no. 4. The solids content, the binder content, and the VOC were calculated theoretically. In the calculation of VOC the presence of water is disregarded. The drying time was determined visually. This time started at the moment of spraying the substrate until hiding and ended at the moment the appearance of the coating was opaque.
[0099] The following compounds were used:
[0100] PAD=Setalux 6801 AQ-24, ex Akzo Nobel Resins
[0101] PUR=Bayhydrol VPLS 2952, ex Bayer
Examples 1-9
[0102] Several colour formulae were prepared to test the coating compositions of the present invention. To this end, binders, pigments, solvents, water, and conventional additives were mixed together. The selected colour formulae are given in Table 1.
[0103] Metal panels were prepared with a conventional primer. A black and white sticker was applied to the primed panel to be able to establish the hiding properties of the coating composition. Base coat compositions of the colour formulae provided in Table 1 were sprayed on the panels. The panels were cured at ambient temperature.
[0104] As can be seen from the results in Table 2, the coating compositions of the present invention dry noticeably quickly, leading to fast application and taping times. Furthermore, only small amounts of material are needed to provide complete hiding. Finally, the ready-to-spray viscosity versus VOC is excellent.
TABLE 1 Solids Binder content content PAD* PUR* VOC Ex Colour code Type Colour (wt. %) (wt. %) (wt. %) (wt. %) P/B (g/l) 1 KIA 3002 Solid Red 23 17 37 63 0.36 321 2 KIA 9011 Pearl Red 22 16 58 42 0.34 305 3 GMA 92:84 Pearl Pink 20 16 64 36 0.27 321 4 OP 549:91 Pearl Red 20 15 71 29 0.33 310 5 VOL 324 Metallic Beige 17 17 69 31 0.19 376 6 FEU 9352 Metallic Silver 20 21 50 50 0.15 377 7 NISER 3 Pearl/ Yellow 18 16 73 27 0.27 362 metallic 8 FEU 411 Solid White 32 15 35 65 1.35 253 9 P1607:87 Solid Red 22 15 55 45 0.38 348
[0105] [0105] TABLE 2 Spray Drying Material viscosity Number time usage Ex (sec) of layers (min.) (g) 1 n.d. 2.5 13 182.5 2 n.d. 2 + mist 10.5 149.7 3 n.d. 2 + mist 11 100 4 36 2.5 + mist 11 184 5 28.5 2 + mist 8 138 6 24.5 2 + mist 9 157 7 26 2.5 + mist 14 211 8 25 4 13 204 9 26.5 4 17 231
Examples 10 to 13 and Comparative Examples A to D
[0106] Several colour formulae were prepared as mentioned in Example 1. As comparative examples the same colour formulae were prepared, except that in the binder composition instead of a mixture of Setalux 6801 AQ 24 and Bayhydrol VPLS 2952, 100% Setalux 6801 AQ 24 was used, in such a way that the pigment binder ratio stayed the same.
[0107] Conventional solvents were added to the coating compositions so that each had the same ready-to-spray viscosity and applied as explained in Example 1. The results are reported in Table 3.
Solids Number Drying Material content of time usage Time Material Ex Colour code (wt. %) P/B layers (min.) (g) saving saving Solid white 10 FEU 411 35.1 1.35 4 7 50 26% 28% A 26.7 1.35 5 9.5 70 Solid red 11 P1607:87 22 0.37 4 9.5 90 34% 10% B 18 0.37 6 14.5 100 Metallic beige 12 VOL 324 21 0.2 2 4.5 20 25% 23% C 17 0.2 3 6 26 Pearl red 13 OP 549:91 20 0.3 2 4 35 33% 40% D 18 0.3 4 6 60
[0108] As can be seen from the results in Table 3, the ready-to-spray viscosity versus the solids content is excellent. Unexpectedly, the coating compositions of the present invention have a higher solids content with the same ready-to-spray viscosity. Furthermore, the coating compositions of the present invention dry noticeably quicker, leading to fast application and taping times. Finally, only small amounts of material are needed to provide complete hiding.
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The present invention discloses an aqueous coating composition comprising 5 to 95 wt. % of an alkali-swellable core-shell addition polymer (I), and 95 to 5 wt. % of a polyurethane (II).
The present invention provides an aqueous coating composition which may be used as base coat in a base coat/clear coat system which has good mechanical properties, a high flop, a high gloss, practically no strike-in, and a good water-resistance. Due to the fact that higher solids contents can be achieved with the aqueous coating composition of the present invention, a reduction in drying times and number of coats is obtained.
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FIELD OF THE INVENTION
The present invention is related in general to semiconductor integrated circuits, and particularly to electrically erasable and programmable read-only memory (EEPROM) devices. The present invention involves the novel concepts of programming the EEPROM device with body hot-electron injection, and using the body voltage to control the drain current. The devices are specifically adapted for integration through their small footprint and low programming power consumption.
BACKGROUND OF THE INVENTION
Non-volatile memories are a large part of the microelectronics infrastructure. There is a great need for devices in which information never, or only very rarely, has to be refreshed, and are fast, small, and consume little power. Such devices, and arrays made with these devices, have been known in the art for some time. For instance, one can find information on non-volatile memories in: “Nonvolatile Semiconductor Memories, Technology, Design and Applications” Edited by Chenming Hu, IEEE Press, New York, 1991.
Electrically erasable and programmable read-only memory (EEPROM) devices are the most widely spread, and useful of all the non-volatile memories. Practically all EEPROM-s are of the floating gate type, where the presence, or absence, of a charge on a floating gate alters the threshold of the device. Thus, the information is stored in the form of charge on a floating gate. An electrically programmable device of this type has to be able to change the amount of charge on the floating gate by purely electrical means. An overview of such conventional EEPROM-s can be found in: “Endurance brightens the future of Flash, fast memory as a viable mass-storage alternative,” Kurt Robinson, Electronic Component News, “Technology Horizons”, November 1988.
EEPROM devices usually use channel hot-electron injection for programming in order to achieve a fast programming speed of less than 10 μsec. In such conventional devices, during programming operation a large drain-to-source voltage is applied and a large gate-to-source voltage is also applied. Electrons flowing from source to drain gain energy from the large drain voltage and become hot electrons. The large gate voltage attracts the hot electrons, which are confined mostly near the drain region, towards the gate electrode, thus causing a gate current to flow. This gate current charges up the floating gate, causing an increase in the threshold voltage of the floating gate portion of the EEPROM device.
Although the gate voltage and the drain voltage during programming are both large during channel hot electron programming, the voltage difference (Vgate−Vdrain) is usually almost zero, or slightly negative. That is, the electric field in the gate insulator does not favor the injection of hot electrons from near the drain region into the gate insulator. Consequently, only a small fraction of the hot electrons near the drain actually contribute to the gate current, making channel hot electron programming a very inefficient process. For a typical EEPROM device, the maximum ratio of gate current to channel current is in the range of 10 −11 to 10 −8 , depending on the details of the device design and the voltages applied. With such a low programming current efficiency, typical EEPROM device requires a channel current of about 1 mA per bit during programming in order to achieve a programming speed of less than 10 μsec. The corresponding power dissipation during programming is about 5 mW per bit, assuming a drain to source voltage of 5 volt.
With such large power dissipation during programming, conventional EEPROM devices using channel hot-electrons for programming are not suitable for low power operations, particularly to battery-powered applications, where frequent reprogramming is required. As mobile and battery-operated systems are becoming more and more prevalent, there is an urgent need for EEPROM devices that dissipate relatively little power, even during programming.
SUMMARY OF THE INVENTION
In view of the above described difficulties with the current state of the art EEPROM-s, the present invention aims for several objectives to remedy the situation.
The object of this invention is a fast, low programming power, and suitable for very large scale integration (VLSI) EEPROM device.
It is another object of the present invention to teach important steps in the manufacturing methods of such EEPROM devices.
It is a further object of this invention to teach the integration of the novel EEPROM devices into memory arrays.
It is also an object of the invention to teach the integration of such EEPROM memory arrays into systems.
A common-gate (plate) EEPROM device having a substrate hot-electron injector is put forward in this invention. Also, in the new device the body voltage, instead of the gate voltage, is used to turn on and off the device channel. The common-gate configuration is conducive to the implementation of the device in SOI, or more generally, in a thin film technology.
During programming, the device body is reverse biased, and the common control gate is positively biased, with respect to the source and drain. A charge injector attached to the body causes electron injection into the device body, or substrate. As these substrate electrons drift vertically towards the gate electrode, they gain energy from the electric field caused by the reverse bias between the device body and the source and drain. The electrons with sufficient energy to surmount the silicon-SiO 2 energy barrier are injected into the floating gate, thus changing the threshold voltage of the EEPROM device. Since substrate hot-electrons directly impinge on the gate insulator, injection efficiency can easily be orders of magnitude higher than that during channel hot-electron injection. The injection efficiency is about 1×10 −4 , and it takes about 1 μsec to inject enough hot electrons into the floating gate to cause a threshold voltage shift of about 1.4 V. This injection efficiency is about 4 to 7 orders of magnitude higher than the channel hot electron injection in conventional EEPROM devices. For the nominal write conditions, the injection efficiency is about 8×10 −5 , and the write time is 1.2 μsec with a power consumption of 20 μW per bit during programming.
During erase operation, electrons in the floating gate are removed by tunneling. Depending on the device design, electrons in the floating gate can be removed by tunneling to the control gate or plate, or by tunneling back to the device body or source and drain. For example, the plate electrode can be negatively biased relative to the device body, source and drain, causing electrons to tunnel from the floating gate into the device body and source and drain. A voltage difference of 10V between the source/drain and plate during the erase operation is adequate for such a purpose.
During standby, the device body is reverse biased relative to the source and drain, causing the device to have a high threshold voltage. To read the device memory state, the device body is held at the same voltage as the source, causing the device to have a low threshold voltage.
In the fabrication of the disclosed EEPROM device an important step is a layer transfer. In such a step the device is transferred from a first wafer to a second wafer, ending in an up-side-down orientation relative to as it was on the first wafer. This step allows standard processing on both wafers, with the result that the up-side-down device provides easy access for contacting its body region, and several, or a great many, devices can share a common gate, or plate. These aspects lead to a small cell size in memory arrays.
In a memory array of the disclosed devices, the drain is connected to the bitline, the device body is connected to the wordline, while the control gate is a plate electrode.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the present invention will become apparent from the accompanying detailed description and drawings.
FIG. 1 . shows in a cross sectional view one embodiment of the invention, a stack gate configuration EEPROM device.
FIG. 2 . shows the EEPROM device threshold voltage as a function of the device body voltage.
FIGS. 3 . to 14 . outline the process in cross sectional views for fabricating two adjacent stack gate EEPROM devices in a memory array configuration.
FIG. 3 . shows the starting material as a silicon-on-insulator (SOI) wafer.
FIG. 4 . shows the formation and patterning of the gate insulator and the floating gate.
FIG. 5 . shows the formation of the heavily doped n-type source and drain regions.
FIG. 6 . shows the formation of planarized isolation oxide.
FIG. 7 . shows the formation of an insulator layer and a polysilicon layer on top of the floating gate.
FIG. 7 A. illustrates the transferring the device structure layer from a first substrate, or wafer, to a second substrate.
FIG. 8 . show illustrates the structure after bonding to another wafer.
FIG. 9 . shows the structure in cross section in the width direction at this stage of the precessing.
FIG. 10 . shows the structure after patterning an oxide layer to expose the device body regions.
FIG. 11 . shows the formation of a polysilicon layer.
FIG. 12 . shows the structure after reactive ion etching of the polysilicon layer.
FIG. 13 . shows the structure after the deposition of a layer of oxide, planarization of the oxide layer, and doping the polysilicon sidewalls by ion implantation.
FIG. 14 . shows the structure after etching the oxide to form contacts to the source and drain regions.
FIG. 15 . shows in a cross sectional view one embodiment of the invention, a split gate configuration EEPROM device.
FIGS. 16 . to 29 . outline the process in cross sectional views for fabricating two adjacent split gate EEPROM devices in a memory array configuration.
FIG. 16 . shows the starting material comprising an SOI wafer.
FIG. 17 . shows the structure after gate polysilicon and gate insulator have been formed and patterned.
FIG. 18 . shows the structure after a shallow heavily doped n-type layer has been formed.
FIG. 19 . shows the structure after oxide is deposited and planarized to form isolation regions.
FIG. 20 . shows the structure after an insulator layer is formed on the polysilicon regions that form the floating gates.
FIG. 21 . shows the structure after a layer of polysilicon has been deposited.
FIG. 22 . shows the structure after bonding to a second SOI wafer.
FIG. 23 . shows the structure after isolation oxide regions have been formed.
FIG. 24 . shows the cross section view along the device width direction of the floating gate region at this stage of the processing.
FIG. 25 . shows the cross section view along the device width direction of the regular gate region at this stage of the processing.
FIG. 26 . shows the structure after patterning of an oxide layer and formation of a polysilicon layer.
FIG. 27 . shows the structure after reactive ion etching of the polysilicon layer.
FIG. 28 . shows the structure after the deposition of a layer of oxide, planarization the oxide layer, and doping the polysilicon regions by ion implantation.
FIG. 29 . shows the structure after etching the oxide to form contacts to the source and drain regions.
FIG. 30 . Schematically shows an electronic system containing an EEPROM array of the present invention as its component.
DETAILED DESCRIPTION OF THE INVENTION
An EEPROM device having a substrate hot-electron injector for high-speed and low-power programming is disclosed. This device is adapted for large scale integration. It fits with standard silicon technology processing, it is tightly packable on chips with each device having appropriate isolation. For a given linewidth capability, the size of the devices is state of the art. The control lines operating this device are similar in number and complexity to the current practice in EEPROM arrays. EEPROM arrays built with these devices can be incorporated in electronic systems practically by a simple “plug in”. At the same time, such arrays inherit the low-power, high-speed advantage of the disclosed devices.
In the embodiments to be described the EEPROM body is p-type, and the programming charge is consisting essentially of electrons. However, this should not be read as a limitation on the invention. It is understood that an embodiment where the body is n-type, and consequently other regions of the device are also changed in type, and the programming charge consists essentially of holes, is within the scope of the invention. Most embodiments where the body is p-type, can also be implemented in configurations where the body is n-type.
The invented EEPROM device rests on the top of an insulating layer. The insulating layer in one embodiment is SiO 2 , which in turn is on top of a silicon substrate. This embodiment is typical of an SOI technology. The disclosed devices are also compatible with a general thin film technology framework. In thin film technologies layers of various materials are deposited, which at times may not be of the same high quality as those of SOI technology. However, thin film technology can offer other advantages, such as cost of manufacturing.
The fabrication of the invented EEPROM device is benefitting from a layer transfer step. In such a step the device is transferred from a first substrate to a second substrate, ending in an up-side-down orientation relative to its orientation on the first substrate. This step allows standard processing steps on both substrates, with the result that the up-side-down device provides easy access for contacting its body region, while many devices can share a single gate, or plate. These aspects lead to a small cell size in a memory array.
The disclosed device differs from those in the art in that programming is done by charge injection through the body, and the device is turned on or off not by the gate, but through the body effect, by an appropriate bias on the source-body junction.
Charge injection into the body is accomplished by various injection means. In differing embodiments differing means may be used. Injecting minority carriers through a semiconductor p-n junction is one preferred embodiment. In another embodiment injection of electrons into the body can be achieved from a metal-semiconductor junction, a so called Schottky barrier junction. Yet another embodiment can use injection of carriers via tunneling across an appropriately biased thin insulating barrier.
FIG. 1 shows in a cross sectional view one embodiment of the invention, a stack gate configuration EEPROM device. In a stack gate structure the floating gate overlaps the device channel region completely.
The device rests on a plate 104 , which is the control gate of the device. In the memory array the plate is contacted and controlled by the plate-line 114 . In many embodiments the plate is shared by two, or by a plurality of memory cell devices. The plate is isolated from the floating gate 105 by insulator 122 . Insulator 122 in a preferred embodiment is SiO 2 . The floating gate is isolated by another insulator 121 , typically SiO 2 , from the source 103 , body 101 , and drain 102 . Insulators 61 and 81 isolate one device from another device at the gate level and at the body level, respectively. The p-type body is contacted by an n + -type electron injector 106 . This arrangement is an embodiment of injection means, namely in the form of a p-n semiconductor junction. In an EEPROM memory array, besides the plate-line 114 , further control lines are also contacting the device. The bitline 112 contacts the drain 102 . The wordline 111 contacts the body 101 , since in this device the drain current is being controlled by a voltage between the source and the body. A source-line 113 contacts the source 103 , and an injection line 116 contacts the electron injector 106 .
During programming, the device body 101 is reverse biased with respect to the source 103 and drain 102 , the control gate 104 is positively biased with respectively to the source 103 and drain 102 , and the injector 106 is forward biased with respected to the device body 101 . Electrons are injected from the injector 106 into the device body 101 or substrate. As these substrate electrons drift vertically towards the gate electrode 104 , they gain energy from the electric field caused by the reverse bias between the device body 101 and the source 103 and drain 102 . The electrons with sufficient energy to surmount the silicon-SiO 2 energy barrier 121 are injected into the floating gate 105 , thus changing the threshold voltage of the EEPROM device.
During erase operation, electrons in the floating gate 105 are removed by tunneling. Depending on the device design, electrons in the floating gate can be removed by tunneling to the control gate or plate 104 , or by tunneling back to the device body 101 or source 103 and drain 102 . For example, the plate electrode 104 can be negatively biased relative to the device body 101 , source 103 and drain 102 , causing electrons to tunnel from the floating gate 105 into the device body 101 and source 103 and drain 102 .
During standby, the device body 101 is reverse biased relative to the source 103 and drain 102 , causing the device to have a high threshold voltage. To read the device memory state, the device body 101 is held at the same voltage as the source 103 , causing the device to have a low threshold voltage.
In one embodiment the p-type silicon body 101 has a uniform doping concentration of 1×10 17 cm −3 , with an oxide thickness of 7 nm for insulator 121 , and an oxide thickness of 20 nm for insulator 122 . The operating voltages for this embodiment are given in Table 1. As a naming convention, the ‘1’ is referred to as a true state.
TABLE 1
bitline
wordline
injector-line
source-line
plate-line
read
1 V
0
V
0
V
0 V
2
V
write ‘0’
0 V
−4
V
−4
V
0 V
4.5
V
write ‘1’
0 V
−3.2
V
−4
V
0 V
4.5
V
erase
4 V
4
V
4
V
4 V
−6
V
standby
0 V
−3
V
0
V
0 V
2
V
In FIG. 2 the EEPROM device threshold voltage as a function of the device body voltage is shown for the same as embodiment that gives Table 1. FIG. 2 shows the threshold voltage in the erased state 22 (no injection charge) and in the programmed state 21 (charge injection=1.5×10 12 cm −2 ). It clearly indicates that under a common-gate voltage of 2V, the device is turned off in the standby mode by a reverse body-bias of 3V, and the device programmed state can be satisfactorily read with zero body-bias in the read mode.
FIGS. 3 . to 14 . outline the process in cross sectional views for fabricating two adjacent stack gate EEPROM devices in a memory array configuration.
FIG. 3 shows the starting material comprising a silicon-on-insulator (SOI) wafer. It has a first substrate, typically a Si wafer 31 , and an insulating layer 32 on top of the substrate, typically SiO 2 . On top of the insulator there is a high quality Si layer 33 . This Si layer, 33 , is where devices are being fabricated.
FIG. 4 . shows the formation and patterning of the gate insulator 121 and the floating gate 105 . The floating gate is formed from a layer of polysilicon.
FIG. 5 . shows the formation of the heavily doped n-type source 103 and drain 102 regions, using the patterned floating gate as a ion implantation mask. The source 103 and drain 102 are defining the body 101 region.
FIG. 6 . shows the formation of planarized isolation oxide 61 .
FIG. 7 . shows the formation of an insulator layer 122 and a polysilicon layer 104 on top of the floating gate 105 . This polysilicon layer forms the plate (control gate of the devices) 104 electrode of the memory array.
FIG. 7 A. shows an illustration of transferring the device structure layer from a first substrate 31 , or wafer, to a second substrate 83 . Device layer 999 is a multitude of layers at this point of the process, including all the processing shown in FIGS. 3 to 7 . This device layer is, by methods known in art, bonded or transferred onto a second insulting layer, typically SiO 2 82 . Once the first substrate 31 and insulator 32 are removed, the devices in layer 999 are resting on a new, second, substrate in an up-side-down position in comparison to their position on the first substrate.
There are several ways known in the art that a layer transfer can be carried out, such as the so called SmartCut (a registered trademark of SOITEC Corporation) technique, or the so called ELTRAN (Epitaxial Layer TRANsfer, a registered trademark of Canon K.K.) process, as described in U.S. Pat. No. 5,371,037 to T. Yonehara, titled: “Semiconductor Member and Process for Preparing Semiconductor Member”, and further techniques as well. For the embodiments of the present invention any known layer transferring technique or process can be used.
FIG. 8 . shows the structure after bonding to another, (second) wafer 83 , and after the substrate 31 and oxide 32 of the original SOI wafer has been removed after bonding, and after isolation oxide 81 has been formed to isolate the two memory devices from their neighbors. Thus, the silicon that forms the device regions now lie on top of the plate electrode 104 and the floating gate regions 105 . The devices are in an up-side-down position in comparison as they were on the first substrate 31 .
FIG. 9 . shows the structure in cross section in the width direction at this stage of the processing. It shows that the device body 101 and floating gate 105 of the individual devices are isolated by 61 and 81 , but in this embodiment there is a common plate electrode 104 for the memory array. This plate electrode in various embodiments can belong to individual cells, be shared by two cells, or can be shared by a large plurality of cells, for instance by a whole subarray, or even a whole array.
FIG. 10 . shows the structure after forming and patterning an oxide layer 1011 to expose the device body regions 101 .
FIG. 11 . shows the formation of a polysilicon layer 1111 . This polysilicon layer will be used to form the heavily n-type doped injector electrode and to form a heavily doped p-type contact to the device body.
FIG. 12 . shows the structure after reactive ion etching of the polysilicon layer 1111 without using a masking step, showing the polysilicon sidewalls 1112 . Alternatively, the polysilicon layer can be patterned using a masking step, but the resulting polysilicon regions will be larger than the sidewalls, leading to a larger device area.
FIG. 13 . shows the structure after the deposition of a layer of oxide 1312 , planarization of the oxide layer, and doping the polysilicon sidewalls by ion implantation. The p + polysilicon regions are the body contacts 1311 , and the n + polysilicon regions are the electron injectors 106 , the means for injecting a programming current in this embodiment.
FIG. 14 . shows the structure after etching the oxide 1312 to form contacts to the source 103 and drain 102 regions. It shows that the pair of devices share a common source 103 to minimize device area in an array.
The stack gate device configuration can have an over-erasure exposure. Over-erasure occurs when the erase process results in a net negative amount of charge in the floating gate 105 , causing the floating gate to be positively charged and the threshold voltage of the device to be smaller than intended. A split gate device structure embodiment has no exposure to over erasure. In the split gate device structure the device channel is divided into two parts in series, one part is covered by the floating gate 105 , and the other by the control gate 104 . Thus, even if over-erasure occurs, the device threshold voltage is determined by the control gate part of the device. In all other aspects the stack gate and split gate configuration devices work identically.
FIG. 15 . shows in a cross sectional view one embodiment of the invention, a split gate configuration EEPROM device. The device rests on a plate 104 , which is the control gate of the device, and in this embodiment it also extends 124 over part of the body 101 . The shallow n + -type region 125 connects the device channel of the floating gate region 105 with the device channel of the gate region 124 . Regions 104 and 124 , of course, are electrically connected. In the memory array the plate is contacted and controlled by the plate-line 114 . In many embodiments the plate is shared by two, or by a plurality of memory cell devices. The plate is isolated from the floating gate 105 by insulator 122 . Insulator 122 in a preferred embodiment is SiO 2 . The floating gate is isolated by another insulator 121 , typically SiO 2 , from the source 103 , body 101 , and drain 102 . Insulators 61 and 81 isolate one device from another device in the gate level and in the body level, respectively. The p-type body is contacted by an n + -type electron injector 106 . This arrangement is an embodiment of the injection means, namely as a p-n semiconductor junction. In an EEPROM memory array besides the plate-line 114 , further control lines are contacting the device. The bitline 112 contacts the drain 102 . The wordline 111 contacts the body 101 , since in this device the drain current is being controlled by a voltage between the source and the body. A source-line 113 contacts the source 103 , and an injection line 116 contacts the electron injector 106 .
FIGS. 16 . to 29 . outline the process in cross sectional views for fabricating two adjacent split gate EEPROM devices in a memory array configuration.
FIG. 16 . shows the starting material comprising an SOI wafer: the first substrate typically a Si wafer 31 , the insulating layer 32 on top of the wafer, typically SiO 2 , and the high quality Si layer on top the insulator 33 . This Si layer 33 is the one where devices are being fabricated.
FIG. 17 . shows the structure after gate polysilicon and gate insulator 121 have been patterned. Two polysilicon regions will be used in one device, with one polysilicon region forming the floating gate 105 and another polysilicon region forming the gate electrode 124 of the split gate device.
FIG. 18 . shows the structure after a shallow heavily doped n + -type source 103 and drain 102 regions, using the patterned floating gate as a ion implantation mask. The shallow n + -type region 125 connects the device channel of the floating gate region 105 with the device channel of the gate region 124 .
FIG. 19 . shows the structure after oxide is formed and planarized to form isolation regions 61 .
FIG. 20 . shows the structure after an insulator layer 122 is formed on the polysilicon regions that form the floating gates 105 . No insulator is formed on the polysilicon regions that form the regular gate electrodes 124 .
FIG. 21 . shows the structure after a layer of polysilicon has been deposited 104 . This polysilicon layer is in electrical connection to the gate polysilicon regions 124 , but is insulated from the floating gate regions 105 by insulator 122 . Thus, this polysilicon 104 becomes the control gate of the two split gate devices. In the memory array arrangement, this polysilicon layer functions as a plate electrode, connected to plate-line 114 .
The next step is the layer transfer, which occurs for the split gate embodiment in the same manner as for the stack gate embodiment. This step is as illustrated on FIG. 7A , and described in the discussion of FIG. 7 A.
FIG. 22 . shows the structure after bonding to another, (second) wafer 83 , and after the substrate 31 and oxide 32 of the original SOI wafer has been removed after bonding. Thus, the silicon that forms the device regions now lies on top of the plate electrode 104 , the floating gate regions 105 and gate regions 124 . The devices are in an up-side-down position in comparison as they were on the first substrate 31 .
FIG. 23 . shows the structure after isolation oxide regions 81 have been formed to isolate the pair of devices from their neighbors in the memory array.
FIG. 24 . shows the cross section view along the device width direction of the floating gate region 105 at this stage of the processing. It shows that the device body 101 and floating gate 105 of the individual devices are isolated by 61 and 81 , but in this embodiment there is a common plate electrode 104 for the memory array. This plate electrode in various embodiments can belong to individual cells, be shared by two cells, or can be shared by a large plurality of cells, for instance by a whole subarray, or even a whole array.
FIG. 25 . shows the cross section view along the device width direction of the regular gate region 124 at this stage of the processing. It shows that the device body 101 is isolated by 61 and 81 , but in this embodiment there is a common plate electrode 104 , shorted to the gate 124 , for the memory array. This plate electrode in various embodiments can belong to individual cells, be shared by two cells, or can be shared by a large plurality of cells, for instance by a whole subarray, or even a whole array.
FIG. 26 . shows the forming and patterning an oxide layer 1011 , and formation of a polysilicon layer 1111 . This polysilicon layer will be used to form the heavily n + -type doped injector electrode and to form the heavily doped p + -type contact to the device body.
FIG. 27 . shows the structure after reactive ion etching of the polysilicon layer 1111 without using a masking step, showing the polysilicon sidewalls 1112 . Alternatively, the polysilicon layer can be patterned using a masking step, but the resulting polysilicon regions will be larger than the sidewalls, leading to a larger device area.
FIG. 28 . shows the structure after the deposition of a layer of oxide 1312 , planarization of the oxide layer, and doping the polysilicon sidewalls by ion implantation. The p + polysilicon regions are the body contacts 1311 , and the n + polysilicon regions are the electron injectors 106 , the means for injecting a programming current in this embodiment.
FIG. 29 . shows the structure after etching the oxide 1312 to form contacts to the source 103 and drain 102 regions. It shows that the pair of devices share a common source 103 to minimize device area in an array.
FIG. 30 . Schematically shows an electronic system 1000 containing an EEPROM array 100 of the present invention as its component. The electronic system 1000 can be digital, such as a computing device, or computer, or it can have analog components as well, such as a communication device. Furthermore, any battery operated system, such as a cellphone, portable computer, or sophisticated toy is a system that can take advantage of the present invention. Any electronic system using EEPROM-s can benefit from the herein disclosed device. The availability of such a low powered fast EEPROM will likely spur new applications, as well.
Many modifications and variations of the present invention are possible in light of the above teachings, and could be apparent for those skilled in the art. The scope of the invention is defined by the appended claims.
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A low programming power, high speed EEPROM device is disclosed which is adapted for large scale integration. The device comprises a body, a source, a drain, and it has means for injecting a programming current into the body. The hot carriers from the body enter the floating gate with much higher efficiency than channel current carriers are capable of doing. The drain current of this device is controlled by the body bias. The device is built on an insulator, with a bottom common plate, and a top side body. These features make the device ideal for SOI and thin film technologies.
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This Application claims the benefit of Provisional Application 06/216,214 filed Jul. 6, 2000.
BACKGROUND OF THE INVENTION
In the manufacture of furniture such as tables, case goods, cabinetry, desks, shelves and related items, a wide variety of materials have been used. For instance, depending upon the desired market and price, furniture materials may range from low cost plastic molded units and particle board constructions to mid range wooden laminates to higher end premium wood or metal construction. Where a real wood or a high quality simulated wood appearance is sought, such products are difficult to find in a durable, versatile furniture. Furniture constructed from particle board is extremely heavy, has poor strength characteristics, and suffers from a loss of integrity when exposed to moisture. Laminated wood products are easily damaged and are difficult to repair since the surface features and texture of the laminate covering are not shared with the underlying wood or particle board substrate.
Accordingly, there is a need for improvements for providing finished furniture, case good products, and laminated panels which overcomes the limitations of the prior art.
SUMMARY OF THE INVENTION
It has now been discovered that a process and resulting product provides for a furniture grade, non-wood laminate which is useful in a variety of furniture constructions. The laminate comprises a thermoformable sheet which may be molded into a desired configuration. An interior cavity formed by curved edge walls formed in the thermoformable sheet is then used as part of a mold cavity into which a polyurethane foam is injected and cured. Following curing of the foam, the exposed foam surface may be covered with a decorative paper, vinyl, or fabric covering.
Typically, the resulting laminate is interconnected to other laminate pieces or, in the example of a laminated table top, legs may be attached to the laminated top. Accordingly, appropriate mounting or attachment hardware may be suspended or placed within the cavity by appropriate jig(s). The jigs hold the mounting hardware in the desired three-dimensional spacial orientation during the foaming and curing step.
Upon hardening of the structural foam, the mounting hardware is permanently attached to the laminate by the adhesive properties of the cured foam. The cured structural foam also imparts a great deal of rigidity to the resulting laminate, yet adds little additional weight. The thermoplastic molded sheet and the interior molded foam of the laminate are largely impervious to water, durable, and may be further milled, sawed, drilled or worked as needed for use as a laminate in general furniture making needs.
The resulting laminates may be made of a wide range of thicknesses to accommodate various construction needs. The thermoformable materials may be selected from extruded sheets of pigmented and wood grained poly-vinyl chloride (PVC). PVC materials have an accepted appearance within the market place and may be provided in a number of color combinations. Further, various types of texture may be molded into the PVC sheet when thermoformed. Combined with the nearly indestructible properties of PVC along with the ease of repair of scratches and other blemishes, PVC has useful attributes as a laminate component. When used as part of a rigid foam laminate, a PVC sheet having a thickness of 2-3 mm provides a laminate having excellent strength and rigidity properties. However, other thermoformable sheet material may be used in place of the PVC.
The use of a thermoplastic material, such as PVC, has advantages in that the surface of the laminate may be easily repaired by using various grades of sandpaper or steel wool and buffing with a rubbing compound to restore the surface of the damaged laminate to an attractive state. Conventional furniture laminates of pressed wood fibers or thin surface veneers are difficult to repair in a manner which restores an original appearance.
The ability to position and mold in situ the attachment hardware simplifies assembly of a finished furniture article. Further, the assembled article is stronger than similar articles made from a compressed wood or whole wood since the material integrity is not compromised by conventional hardware installation techniques. Since no cutting, drilling, or other invasive action is applied to the substrate, the material integrity is maintained. This improvement is important given that failure or weakening of attachment sites and hardware is a common occurrence in traditionally constructed furniture.
Hence, in one aspect, the invention resides in a method for making a laminate panel useful in furniture making. The laminate is formed by a process in which a sheet of a high impact wood grained PVC of about 2 mm in thickness is heated in an oven to a softening temperature. The heated PVC sheet is then stamped between a male and female mold into a form which, in one sample embodiment, may resemble a tray which defines a cavity area. The tray cavity is positioned within a foam molding station with the tray cavity being accessible to one or more jigs. The jigs are used to suspend inserts, such as mounting hardware and/or structural reinforcements, into the tray cavity area. The tray area is filled with a structural foam such as polyurethane using standard foam reagents and methods. Conventional polyurethane foam reagents and methods are well known within the art as set forth in U.S. Pat. Nos. 5,972,260 and 5,941,622 which are incorporated herein by reference.
The foam cures into a rigid structure which surrounds the insert portions positioned within the cavity. The tray is then inverted so that the tray top may form the upward-facing surface of a table top, counter top, or similar article. Legs or other attachments may then be made using the inserts or mounting hardware previously foamed in place.
In another aspect, the invention resides in the foregoing method and resulting product wherein the inserts are suspended partially within the cavity but do not make contact with the PVC molded article. The sequential foaming and curing steps thereby provides a layered structural foam between the sheet material and the insert. In accordance with this invention it has been found that by avoiding direct contact between a load bearing insert and the thermoformable sheet, a better distribution of forces occurs. As such, bulges or indentations which may otherwise occur from the transfer of forces between an insert and the laminate surface material are avoided.
In yet another aspect of this invention, it has been found that the strength of conventional inserts used in the present laminated construction may be improved by increasing the surface area and/or orientation of the insert with respect to the foam substrate. For instance, the strength between the foam and a bracket may be increased by providing an angled bend to the bracket portion within the foam. The structural integrity of the foam laminate portion may be increased by altering the three-dimensional shape of the laminate as well. Further, the incorporation of structural members having a higher rigidity than the thermoplastic laminate may be used. Such structural members may be of wood, steel, or rigid plastic. These inserts may be placed in high stress areas and may be installed in a manner similar to various attachment hardware.
These and other aspects of the invention will be described in greater detail in reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying drawings.
FIG. 1A is a perspective view of a table formed from a laminate of the present invention;
FIG. 1B is a perspective view of a folding table constructed in accordance with the present invention;
FIG. 2A is a perspective view illustrating various process steps and equipment used to form a laminate of the present invention;
FIG. 2B is a perspective view similar to FIG. 2A setting forth additional steps of the laminate making process;
FIG. 3A is a sectional view taken along line 3 — 3 of FIG. 2B;
FIG. 3B is a sectional view showing additional details of construction of a table formed from a laminate of the present invention;
FIGS. 4A-4C set forth additional details of construction of a pedestal table according to the present invention; and
FIG. 5 is a perspective view showing two laminate panels being joined together.
DETAILED DESCRIPTION OF THE INVENTION
Reference now will be made in detail to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features, and aspects of the present invention are disclosed in the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions.
In describing the various figures herein, the same reference numbers are used throughout to describe the same apparatus or process pathway. To avoid redundancy, detailed descriptions of much of the apparatus once described in relation to a figure is not repeated in the descriptions of subsequent figures, although such apparatus or process is labeled with the same reference numbers.
Referring first to FIG. 1A there is illustrated a work surface seen in the form of a table 10 . Table 10 has an upper work surface formed from a thermoplastic sheet of material such as PVC. The sheet has an exterior surface 22 seen here as the upper table surface and an interior surface best seen in reference to FIG. 2A. A curved edge 26 curves in a downward direction relative to an upper plane of surface 22 thereby forming an inverted tray-like configuration. As seen in reference to FIG. 2A, a cavity 28 is defined by the outer edge wall 26 and the interior surface 24 of the thermoplastic sheet 20 .
As best seen in reference to FIG. 2A, a jig 35 is used to suspend a plurality of inserts 40 which are suspended at least in part within the cavity 28 . Preferably, the suspended inserts 40 make no direct contact with the thermoplastic sheet 20 . A structural foam 30 , such as a polyurethane foam available from Custom Rigid Formulation, is introduced through an injection gun or similar apparatus into the mold and allowed to cure. The polyurethane foam has a density of 11 pounds per cubic foot, with component A preset at a ratio of 1 to 0.89 to component B and using water as an initiator and blowing agent. However, other structural foams may be used. While not separately illustrated, the foaming step is carried out in a foam molding unit, the upper mold half configured to accommodate the inserts and jigs while providing a platen surface which is pressed flat against the lower walls of edge 26 and the decorative layer 37 . If desired, the platen surface may be used to create depressions on other molded shapes within the surface of the cured form.
As seen in FIG. 2B, following the foaming step, the cured rigid structural polyurethane 30 has filled in cavity 28 and is substantially flush with the outer edge walls 26 . Each insert 40 is at least partially embedded within the foam in the desired three-dimensional configuration initially established by the jigs 35 . If desired, a backing layer 37 may be attached to the exposed foam surface during the foam molding step using the foam as an adhesive. Backing 37 may be in form of a decorative fabric, cardboard, or other covering and may be applied to the foam post-curing by use of a separate adhesive.
As seen in reference to FIG. 3A, the foam 30 fills the cavity defined between edges 26 and interior sheet surface 24 . Insert 40 , suspended a set distance from any wall surface of sheet 20 , is surrounded in part by the rigid foam. As best seen in reference to FIG. 3B, insert 40 may serve as an attachment point for additional accessories such as a table leg 42 . While insert 40 is illustrated as an L-shaped bracket defining a plurality of apertures, insert 40 may be provided by any conventional connectors or hardware. For example, hardware such as a folding bracket, height adjustment mechanisms, or tilt top mechanisms, may be used and secured as described above.
Additional inserts 40 may be provided in the form of reinforcing members which may be added within the cavity in high stress areas prior to foaming. Further, in some applications, it may be useful to add wooden blocks or board members within the foamed cavity. The wooden structural member may thereafter be used as an attachment area for various connectors such as screws or nails. For instance, where the laminate of the present invention is provided in the form of a rectangular countertop, a wood member may be placed within the foamed cavity. The wood member may thereafter be used to anchor traditional screws or lag bolts which position the countertop to a lower support frame.
An additional embodiment in the invention may be seen in reference to FIG. 1B which illustrates a table with four folding legs. In this embodiment, each table leg 42 is attached to conventional folding hinges seen here as insert 40 . Such folding hinges are conventionally used in the construction of folding tables and card tables. A portion of each hinge insert 40 is anchored within the rigid foam 30 . Each hinge insert 40 and attached leg 42 are adjacent a corresponding depression 32 defined within the surface of the adjacent foam 30 . Each depression 32 is preferably formed during the molding process by an appropriate shaped mold cover template associated with the molding platen and conformed to the dimensions which permits the hinge to close and thereby place the associated table leg within the confines of the depression 32 . The molded depressions may be milled following the curing of the rigid foam.
The folded table as seen in FIG. 1B offers substantial advantages in terms of strength, weight, and durability compared to conventional folding tables. For instance, a standard card table lacks strength and rigidity for supporting heaving loads. Conventional folding tables of a sturdier construction typically have a particle board construction and/or a steel support frame which increases the table's weight. A table constructed according to the present invention has the combination of high strength along with light weight which facilitates commercial shipping as well as the end use of the table.
An additional embodiment of a work surface is seen in reference to FIGS. 4A-4C. As seen in FIG. 4C, a pedestal mounted table 110 may be provided which is secured on a pedestal mount 142 . As seen in FIG. 4A, insert 140 is in the form of a mounting bracket having a threaded bolt for the mated engagement of a pedestal leg 142 . As seen in reference to FIG. 4B, a portion of insert 140 is positioned above the outer foam surface while other portions are encapsulated by the foam. As seen in reference to FIGS. 4A and 4B, it is useful to provide insert extensions 146 which are integral with or otherwise attached to and form a part of insert 140 . Such extensions 146 increase the surface area and hence the bond strength between the foam and the inserts 140 . Further, the extensions 146 help distribute forces throughout the laminate.
The extensions 146 may be integral with the insert 140 or may be separately attached to a conventional insert 140 using some form of permanent attachment. In either case, the extension 146 provides for an increased surface area and hence increased strength and force distribution between the insert and the structural foam.
It has further been found advantageous to suspend load bearing inserts during the foaming process so that direct contact between the insert and the thermoplastic sheet are avoided. In this manner, forces will not transfer directly from the insert to the sheet material where, if in intimate contact, distortions or buckling of the surrounding sheet material may occur.
As seen in reference to FIG. 5, the present laminates may be used to provide component parts for furniture construction. For instance, article 10 A may be the upper surface of a shelf, cabinet, or dresser. Laminate 10 B is a corresponding side panel of the above-referenced structure. A connector 46 , seen here in the form of a threaded bolt, may be used to secure laminate 10 A to 10 B via the corresponding inserts 40 .
Panels such as those seen in FIG. 5 may be provided and used in place of particle board and wooden board for consumer assembled furniture. Connective hardware may be provided at precise locations within the rigid foam. Traditional connectors such as locking cams, dowels, bolts, support clips, brackets, and other conventional hardware may be used to secure the assembled components. Further, the laminated panels of the present invention are resistant to moisture, are lightweight, have excellent strength and load-bearing characteristics, and may be easily disassembled and reassembled numerous times. Further, the rigid panels resist warping and flexing under heavy loads.
The present laminates have the exterior surface securely bonded to the inner foam core. As such, separation of the exterior surface from the lower surface is prevented. In conventional wood or plastic laminated furniture, the upper decorative or work surface will often separate from the underlying substrate. Such flaws are unsightly, and promote rapid deterioration of the laminated structure as moisture penetrates and contributes to the delamination process. Such delamination is of particular concern in the restaurant industry where separations between a laminate and the lower core material may constitute a violation of local health codes. The present laminate structure eliminates such problems. The surface of the laminate may be easily repaired by using various grades of abrasive paper or wool, along with various rubbing compounds.
Although various embodiments of the invention have been described using specific terms, devices, and methods, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit or scope of the present invention, which is set forth in the following claims. In addition, it should be understood that aspects of the various embodiments may be interchanged, both in whole or in part. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained therein.
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A method and apparatus for fabrication of foam laminates suitable for use in the construction of furniture and case goods are provided. The panel has an upper surface formed from a thermoplastic sheet of material such as PVC. A cavity formed by the interior surfaces of the sheet have suspended therein attachment or mounting hardware which is subsequently encapsulated by an in situ structural foaming step. The resulting laminated panel is useful as a table top, shelving, and as a structural component in a variety of case goods and furniture.
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RELATED APPLICATIONS
This application is a Continuation-In-Part of U.S. patent application Ser. No. 12/001,044, having a filing date 10 Dec. 2007 and is to be issued as U.S. Pat. No. 8,006,416 having an issue date of Aug. 30, 2011.
BACKGROUND OF THE INVENTION
1. Field of the Invention
These inventions relate to pants pressing machines, specifically to such pressing machines, which are used on the pants upper portion, pant legs and for creased pants.
The puffer machine available for pressing the upper portion of a pair of pants on the market place today is limited on pressing the waist area. The biggest drawback of the puffer machine is its size, it is a small sized puffer machine with a round shape, if a pair of pants are relatively large an operator has to spend more time moving the fabric around and adjusting the pants to fit over the puffer to remove wrinkles, wasting more time just on pressing the upper portion of a pair of pants. The pants still have to be brought to a second station, to complete pressing the waist.
A newer version of the upper puffer pressing machine is electrical and a high cost machine. Since the machine is operated automatically, a switch is pressed and a lot of steam releases from the machine, steam is wasted on pressing just a small area of the pants.
Another great drawback is the upper portion puffer pressing machine also removes the creases from the leg. For an operator it is difficult to spend time searching for the original crease, so as not to make a double crease. Time is wasted looking for the original crease. And still the operator must go to another station to finish pressing the upper portion of the pants. The pocket, back seam and the waist belt area have to be touched up with a hand held flat iron. So it's a two step operation, only to press the upper portion of a pair of pants completely.
Accordingly in order to press the upper portion of a pair of pants correctly, it is conventionally necessary to move to different stations and use several different pressing machines. This as it should be apparent in addition to making it a difficult and time consuming pressing operation, also requires a large space in a pressing shop.
On the market there are pants pressing machines, but there is no equipment that exists that focuses on pressing the inseams and out seams on the legs of a pair of pants. A general pressing machine is used when pressing a pair of pants.
The greatest problem when using a general pressing machine is when the pressing plate is brought down on the legs of the pants. The pressing plate makes contact with the inseams and out seams on the pants. Therefore, impressions of the inseams and out seams are left on the fabric of the pants. Pants are also left with shiny marks along the inseams and out seams on the pant fabric and the fabric is left looking dull. If a pair of pants are to be pressed without creases, an operator must press the pants with a hand held iron, making it time consuming and costly.
Prior pressing machines that are used for pressing all garments have been around for decades. An operator brings the pressing plate down on the pants 2 times per leg. Therefore the pressing plate is brought down on the pants a total of 4 times for the entire pants.
A new pant pressing machine on the market today has been designed to have a contour crotch shape on one end and a narrow shape on the other end. Allowing small size pants to be pressed but because of the small size it is more time consuming to press larger size pants.
One drawback of the pressing machine is the narrow end, if the bottom of a pair of pants are wide, the pressing plate has to be brought down 2 times per pant leg, making it a total of 4 times the pressing plate has to be brought down to press the entire pants. The finished pressed and creased pants turn out to be more time consuming and costly.
The greatest drawback is when the pressing plates are brought down on the pants, the seams on legs of the pants are left with impression marks and the fabric is left looking shiny.
2. Description of the Prior Art
There are other pressing device designed for pants. While these pressing devices may be suitable for the purposes for which they where designed, they would not be as suitable for the purposes of the present invention as heretofore described.
SUMMARY OF THE PRESENT INVENTION
It is, therefore an object of the present invention in FIG. 1B , to provide an improved pants pressing machine that can be used for pressing the upper portion of a pair of pants, this machine completes the pressing of the waist area.
It is another object, of the present invention because of its specific designed size and shape feature it will permit relatively small and large pants to be accommodated. Small and large pants will be pressed in the same amount of time.
Accordingly, the present invention due to its manual operation will provide a quick and economic method of pressing and completing the upper portion of the pants.
Yet another object of the present invention due to its manual mechanism, it will be a smaller pressing machine than prior automatic pressing machines, making the present invention a space savor in a small shop.
The operation construction, in particular is designed to connect to a hot heated steam boiler and vacuum duct. Operated manually which can easily be made and which moreover is very competitive from a mere economic stand point.
Accordingly the aim of the present invention in reference to FIG. 2B , is to over come the above mentioned drawbacks.
The present invention has been specifically designed for pressing the inseams and out seams on the legs of a pair of pants. If the pants have a crease, the pressing machine will press the pants but it will not remove the creases. Hence, when pants do not need creases, the pressing of the pants are completed at this one pressing station.
The main object of the present invention is to provide a pants pressing machine that will leave no impression marks of the inseams and out seams on the fabric of the pants.
Another object of the present invention is to provide a pants pressing machine that presses relatively small and large pants. The rear side of the invention is 6 to 10 inches wide, the length is 32 to 37 inches and the hem side is 4 to 6 inches wide. The size and shape of the pressing machine will allow pants of all sizes to be pressed.
Due to the design of the present invention the seams are also pressed. No marks are left on the seams and if pants are lined, the lining will be pressed at the same time.
The object of the present invention in reference to FIG. 3C , is to provide an improved pants pressing machine that will be used for pressing wrinkled and creased pants.
It is the primary object of this invention to provide a pants pressing machine that will not leave the inseams and out seams on a pair of pants with any impression marks or leave the fabric looking shiny. The invention has been designed with the top pressing plate to have an indention 1 to 5½ inches wide and 1 to 3 inches deep. An operator will align the pant leg seams with the indention. When the top pressing plate is brought down, the seams fit directly into the indention. The pressing plate will not hit the seams. The inseams and out seams are left untouched and unmark. Leaving the pants creased and well pressed.
The present invention has been specifically designed to have the top and bottom pressing plates to have a contour crotch shape. The contour crotch shape will make it easy for an operator to line up the pants for pressing. The other end of the top and bottom pressing plates are wide, the present invention may be used in any size situation where some pants are relatively small or relatively large. An operator pressing a large pair of pants will only need to bring the pressing top plate down 1 time per leg. To complete the pressing it will only take bringing the pressing plate down 2 times. Thus an operator will bring the pressing plate down fewer times and spend less time to complete pressing a pair of pants. The crotch side and the hem side are the same size. So if a pair of pants is wider at the leg, the pants will still be pressed bringing the pressing plate down only once on the pants.
Yet another object of the present invention solves the problem of the fabric being left flat and looking faded. The pants pressing machines top plate has an indention, the indention area does not release steam, so the inseams and out seams on the pants are never touched, therefore the fabric of the pants are left fluffy and in its original state.
The present invention provides a pants pressing machine which will make the job of an operator quicker and easier. The invention is a manually operated machine, thus making it an economically lower cost operating pants pressing machine.
An additional object of the present invention is to provide a longitudinal framework pressing plate having a triangular shape with a transverse curvilinear surface.
Another object of the present invention is to provide a longitudinally tapered rectangular steam and vacuum framework pressing plate having a substantially co-planar top and bottom surface.
A further object of the present invention is to provide a longitudinal trough within the top plate preferably 1 to 5½ wide and 1 to 3 inches in depth so that when the top plate is moved into engagement with the bottom plate the seam will be with the trough thereby eliminating the seam having pressing marks thereon.
A yet further object of the present invention is to provide a laser projecting a line along the bottom plate as an alignment tool for the operator to place the seam of the pants leg thereover so that when the top plate having the longitudinal trough therein is moved into engagement with the bottom plate the seam will reside within said trough thereby eliminating and pressing marks on the pants leg seam.
Additional objects of the present invention will appear as the description proceeds.
The present invention overcomes the shortcomings of the prior art by providing three pressing steam apparatuses wherein one of the steam apparatus is used in pressing an upper portion of a pants, another steam apparatus is used in pressing the legs of a pair of pants and the other steam apparatus is used to form a crease in the legs of the pants.
The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying drawings, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawings, like reference characters designate the same or similar parts throughout the several views.
The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
In order that the invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawing in which:
In the drawings, closely related figures have the same number but different alphabetic suffixes. Further characteristics and advantages of the present inventions will become more apparent from the following detailed disclosure of the pants pressing machines to be used for pressing the upper portion, the legs and the creases of a pair of pants.
FIG. 1A is a front view of the upper portion pressing machine, illustrating a plurality of tiny steam outlet holes.
FIG. 1B is a further perspective rear view of the upper portion pressing machine, illustrating in particular the steam, drain and vacuum valve connections.
FIG. 2A is a front side view of the pressing machine, illustrating the pants size range means for pressing the legs of a pair of pants.
FIG. 2B is a further perspective rear view, illustrating the steam, vacuum connections and the manual foot pedals.
FIG. 3A is a front side view of the creasing pants pressing machine, illustrating the opening and closing means on the pressing machine.
FIG. 3B is a further perspective front view, illustrating the pressing plates and clearly showing the seam indention on the top pressing plate.
FIG. 3C is a further perspective side rear view, illustrating the steam, drain and vacuum valves connections on the top and bottom pressing plates.
FIG. 3D is a further perspective side rear view, illustrating the laser light alignment device for aligning a seam thereover.
DESCRIPTION OF THE REFERENCED NUMERALS
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the figures illustrate the Pants Pressing Machine of the present invention. With regard to the reference numerals used, the following numbering is used throughout the various drawing figures.
10 Pants Pressing Machine of the present invention
11 framework pressing plate
12 steam outlet holes
13 pin release
14 vacuum valve
15 drain valve
16 boiler valve
17 vacuum valve connection
18 wire spool
19 wheel
20 wheel
21 top base supporting structure
22 steam release valve
23 metal wired string
24 vertical side support base structure
25 wheel
26 wheel
27 cylinder
28 wheel
29 bottom base support structure
30 wheel
31 wheel
32 right foot pedal
33 left foot pedal
34 wheel
35 cylinder
36 metal wire string
37 steam pin release
41 steam outlet holes
42 framework pressing plate
43 wire spool
44 drain valve
45 boiler valve
46 vacuum valve
47 vacuum valve
48 pin release
49 wheel
50 side support base structure
51 metal wire string
52 wheel
53 wheel
54 cylinder
55 wheel
56 left foot pedal
57 right foot pedal
58 wheel
59 wheel
60 wheel
61 cylinder
62 metal wire string
63 wheel
64 steam pin release
65 top base support structure
66 steam valve
67 bottom base support structure
70 steam outlet holes
71 bottom framework pressing plate
72 back board
73 top framework pressing plate
74 longitudinal trough
75 steam outlet holes
76 open lever
77 steam release lever
78 close handle
79 top boiler valve connection
80 top drain valve connection
81 contour crotch shape
82 contour crotch shape
83 drain valve
84 boiler valve
85 vacuum valve connection
86 vacuum valve
87 vacuum pin release
88 metal wire string
89 wheel
90 left foot pedal
91 middle foot pedal
92 right foot pedal
93 bottom base support structure
94 table structure
95 laser device
96 laser generated alignment line
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following discussion describes in detail one embodiment of the invention (and several variations of that embodiment). This discussion should not be construed, however, as limiting the invention to those particular embodiments, practitioners skilled in the art will recognize numerous other embodiments as well. For definition of the complete scope of the invention, the reader is directed to appended claims.
One embodiment of the pressing machines rear view is illustrated in FIG. 1B . The framework pressing plate 11 has a plurality of tiny steam outlet holes 12 . In the preferred embodiment, the rear of the framework pressing plate 11 consists of having several valve connections and two release pins.
Starting from the left side of the embodiment is the first connection, a drain valve 15 . The drain valve 15 connects to a drain pipe. The second valve is a boiler valve 16 ; the boiler valve 16 connects to a boiler. There is also a vacuum valve 14 , one end of the vacuum valve 14 has a vacuum valve connection 17 and the other end of the vacuum valve 14 has a pin release 13 that pulls the vacuum valve 14 . To the far right of the framework pressing plate 11 are the steam release valve 22 and the steam pin releaser 37 .
The framework pressing plate 11 connects to the top support base structure 21 . The top support base structure 21 has a wire spool 18 . Toward the edge of the top base support structure 21 are two wheels, wheel 19 and wheel 20 . The top base supporting structure 21 has a vertical side support base structure 24 . The vertical side support base structure 24 towards the far right near the bottom has two wheels, wheel 25 and wheel 26 . Directly underneath wheel 25 and wheel 26 are two holes. Metal wired string 23 and metal wired string 36 which will be passing through the two holes. Holding the vertical side supporting base structure 24 is the bottom base support structure 29 .
The bottom base support structure 29 has two cylinders. The cylinder 35 to the left has two wheels, wheel 34 and wheel 31 . Cylinder 27 to the right has two wheels, wheel 28 and wheel 30 . Attached to wheel 31 by a metal wired string 23 is left manual foot pedal 33 . Attached to wheel 30 by a metal wired string 36 is the right manually operated foot pedal 32 .
The manner of using the upper portion pressing machine is as such one, one places the waist side of a pair of pants draped over the framework pressing plate 11 . Due to the specifically designed size and shape of the framework pressing plate 11 relatively small and relatively large pants may be placed easily and pressed. The drain valve 15 is connected to a drain pipe; the boiler valve 16 is connected to the boiler. The vacuum valve 17 is connected to a vacuum.
The upper portion pants pressing machine is operated manually, one steps on the left foot pedal 33 . When the left foot pedal 33 is stepped on, it pulls the metal wire string 36 . The metal wire string runs through four wheels, wheel 31 , wheel 34 , wheel 26 and wheel 20 . The metal wired string 36 pulls the steam pin release 37 which opens the steam valve 22 , which opens a plurality of tiny steam outlets holes 12 . Steam leaves the framework pressing plate 11 through the plurality of tiny steam outlet holes 12 through the fabric of the pants.
One then steps on the right foot pedal 32 , when the right foot pedal 32 is stepped on; it pulls the metal wire string 23 . The metal wired string 23 runs through four wheels, wheel 30 , wheel 28 , wheel 25 and wheel 19 . The metal wired string 23 pulls the vacuum pin release 13 , which opens the vacuum valve 14 . The vacuum valve 14 pulls the steam through the tiny steam outlet holes 12 and pulls the air through the pants, cooling down the fabric. Thus leaving the upper portion of a pair of pants pressed, if pleats are needed a hand held flat iron may be applied.
One embodiment of the leg pressing machine is illustrated in FIG. 2B . The long framework pressing plate 42 rear side is wide and narrow on the end of the framework pressing plate 42 . The framework pressing plate 42 has a plurality of tiny steam outlet holes 41 all over the framework pressing plate 42 . On the rear view of the embodiment of the framework pressing plate 42 are the valve connections and the pin releases.
Starting from the left side of the embodiment is the first connection, a drain valve 44 . The drain valve 44 connects to a drain pipe. The second valve is a boiler valve 45 , the boiler valve 45 connects to a boiler. There is also a vacuum valve 47 , one end of the vacuum valve 47 has a vacuum valve connection 46 and the other end of the vacuum valve 47 has a pin release 48 . To the far right of the framework pressing plate 42 is the steam release valve 66 and on the end of the steam release valve 66 is the steam pin releaser 64 .
The framework pressing plate 42 connects to the top support base structure 65 . The top support base structure 65 has a wire spool 43 . Toward the right edge of the top base support structure 65 are two wheels, wheel 49 and wheel 63 .
The top base supporting structure 65 has a vertical side support base structure 50 . The vertical side support base structure 50 has two wheels near the bottom on the right side, wheel 52 and wheel 53 . Directly underneath wheel 52 and wheel 53 are two holes. Metal wired string 51 and metal wired string 62 both which run through the two holes when pulled. Holding the vertical side supporting base structure 50 is the bottom base support structure 67 .
The bottom base support structure 67 has two cylinders. The cylinder 54 to the left has two wheels, wheel 55 and wheel 58 . Cylinder 61 to the right has two wheels, wheel 60 and wheel 59 . Attached to wheel 58 by a metal wired string 62 is left manual foot pedal 56 . Attached to wheel 59 by a metal wired string 51 is right manual foot pedal 57 .
The manner of using the leg presser as shown in FIG. 2B is as such one places one leg of a pair of pants through the framework pressing plate 42 . Due to the specifically designed size and length of the framework pressing plate 42 relatively small and relatively large pants may be easily draped on the framework pressing plate 42 and pressed.
The drain valve 44 is connected to a drain pipe, the boiler valve 45 is connected to the boiler. The vacuum valve 46 is connected to a vacuum duct. One steps on the left foot pedal 56 . When the left foot pedal 56 is stepped on, it pulls the metal wire string 62 . The metal wire string 62 runs through four wheels, wheel 58 , wheel 55 , wheel 53 and wheel 63 . The metal wired string 62 pulls the steam pin release 64 which opens the steam valve 66 which opens the plurality of tiny steam outlet holes 41 . Steam leaves the framework pressing plate 42 through the plurality of tiny steam outlet holes 41 through the fabric of the pants, removing the wrinkles.
One then steps on the right foot pedal 57 , when the right foot pedal 57 is stepped on, it pulls the attached metal wire string 51 . The metal wired string 51 runs through four wheels, wheel 59 , wheel 60 , wheel 52 and wheel 49 . The metal wired string 51 pulls the vacuum pin release 48 , which opens the vacuum valve 47 . The vacuum valve 47 pulls the air through the plurality tiny steam outlet holes 41 and pulls the air through the pant leg, cooling down the fabric, leaving the pant leg pressed. If pants need to be creased a pants creasing pressing machine may be used.
One embodiment of the pants pressing machine a side view is illustrated in FIG. 3C . The pants pressing machine has two framework pressing plates. The top framework pressing plate 73 has a plurality of tiny steam outlet holes 75 . The top framework pressing plate also has a longitudinal trough 74 preferably 1 to 5½ inches wide and 1 to 3 inches deep without the aforementioned steam out holes. On the top framework pressing plate 73 towards the middle is a close handle 78 . Next to the close handle 78 are two levers. To the left is the steam release lever 77 , to the right is the open lever 76 . To the far left on the top framework pressing plate 73 are two valve connections. The top drain valve connection 80 and the top boiler valve connection 79 . The left side of the top framework pressing plate 73 has a contour crotch shape 81 .
The top framework pressing plate 73 is supported by a table structure 94 . On top of the table structure 94 is the bottom framework pressing plate 71 . The bottom framework pressing plate 71 also has a plurality of tiny steam outlet holes 70 . The far left of the bottom framework pressing plate 71 also has a contour crotch shape 82 . Behind the bottom framework pressing plate 71 is a back board 72 .
The table structure 94 is supported by the bottom base support structure 93 . To the side of the bottom support base structure 93 has three valves used for the bottom framework plate 71 . To the far left by the bottom framework pressing plate 71 is the first valve, the drain valve 83 . The second valve is the bottom framework pressing plate 71 boiler valve 84 . The third valve is the bottom framework pressing plate 71 vacuum valve 86 , the vacuum valve 86 has a vacuum valve connection 85 . On the other end of the vacuum valve 86 is the vacuum pin release 87 . To the far right is a wheel 89 , the wheel 89 has a metal wire string 88 , that attaches to the vacuum pin release 87 . Near the front bottom base support structure 93 are three foot pedals. The left foot pedal 90 , the middle and bigger manual foot pedal 91 and the right manual foot pedal 92 .
The manner of using the pants pressing machine as shown in FIG. 3C is as such. The pant leg is placed on the bottom framework pressing plate 71 . The crotch side of the pant leg is aligned with the contour crotch shape 82 . The seam of the pant leg is aligned with the indention 74 of the top framework pressing plate 73 .
To close the framework pressing plate 73 an operator must step on the close pedal 91 and bring down the close handle 78 at the same time. An operator then presses the steam release lever 77 . Steam releases through the top framework pressing plate 73 , via the plurality of tiny steam outlet holes 75 through the pant leg fabric removing wrinkles. One then steps on the left foot pedal 90 . When the left foot pedal 90 is stepped on it pulls the metal wire string 88 . The metal wired string 88 runs through wheel 89 , which is on the side of the bottom base support structure 93 . The metal wired string 88 pulls the vacuum pin release 87 , which then opens the vacuum valve 86 . The vacuum valve 86 opens the plurality of tiny steam outlet holes 75 on the top framework pressing plate 73 and it also opens the plurality of tiny steam outlet holes 70 on the bottom framework pressing plate 71 .
The vacuum 86 pulls the air from the top framework structure 73 and the bottom framework structure 71 through the pant leg and cools the fabric down. One then presses the open lever 76 down to open the pressing machine.
The pant leg is left well pressed and due to the indention 74 on the top framework pressing plate 73 . The seams on the pant leg are left unmarked and no impressions are left.
When a different garment is being pressed and extra steam is needed one would step on the right foot pedal 92 . When stepping on the right foot pedal 92 , steam is released into the bottom framework pressing plate 71 via the plurality tiny steam outlet holes 70 . The steam leaver 77 is pressed at the same time allowing steam to enter the top framework pressing plate 73 via the tiny steam out let holes 75 into the garment. Leaving a garment fluffy and steam pressed.
The manner of using the pants pressing machine as shown in FIG. 3D provides for the user of a laser 94 generating a seam alignment light 95 as a guide so that when the pants leg is placed is placed is placed on the bottom framework pressing plate 71 with the crotch side of the pant leg is aligned with the contour crotch shape 82 . The seam of the pant leg is placed over the alignment light and therefore in alignment with the longitudinal trough 74 of the top framework pressing plate 73 thereby eliminating any pressing marks on the pant seam. The rest of the pressing sequences is the same as described in FIG. 3C .
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The present invention relates to a pressing machine to be used for pressing the upper portion of a pair of wrinkled pants. The pressing machine has the contour shape of the upper portion of a pair of pants. The shape of the pressing machine makes it easier for an operator to drape a pair of pants over the machine for pressing. The shape of the pressing machine allows pants of all sizes to be pressed. The pressing machine is operated manually by pressing on two foot pedals.
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CLAIM OF PRIORITY
This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. § 119 from my application entitled SIGNAL SUPPLY APPARATUS FOR PUBLIC AND PRIVATE MOBILE COMMUNICATION SYSTEM filed with the Korean Industrial Property Office on 27 Sep. 2001 and there duly assigned Serial No. 2001-59972.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mobile communication system, and more particularly to a signal supply apparatus in a system that can provide both public and private mobile communication services.
2. Description of the Prior Art
In a general mobile communication system, a base station controller (BSC) receives a reference clock signal from a satellite, and synchronizes its internal equipment. For instance, the BSC provides a link between the BSC and a mobile switching center (MSC), a link between the BSC and a base transceiver subsystem (BTS), and a vocoder. In order to receive the reference clock from the satellite, a global positioning system receiver (GPSR) is mounted in the respective BSCs and BTSs, respectively. The GPSR receives GPS information that includes the reference clock and time of day (TOD) information from the satellite, and provides the GPS information to the corresponding equipment.
As described above, in order to receive the reference clock, the GPSR should be mounted on the respective BSCs and BTSs. However, if it is possible to supply the GPS information including at least the reference clock to the respective BTSs that belong to the BSC in a state that the GPSR is mounted only in the corresponding BSC, the system cost can be reduced. Also, if it is possible to supply the GPS information including at least the reference clock to the BSC and BTS using the existing lines, the cost of system installation can be reduced.
U.S. Patent Application Publication No. 2001/0046215 to Kim pertains to a public/private mobile telephone system where only pBSC 203 has a GPS receiver. However, Kim '215 does not teach relaying the date and time information received by the GPS receiver over a LAN cable to a large plurality of Internet protocol private base transceiver subsystems to run a clock in these Internet protocol private base transceiver subsystems, thereby avoiding the need of many GPS receivers.
U.S. Patent Application Publication No. 2001/0024455 to Thaler et al. teaches distributing a reference time signal throughout a IEEE 1394 network. Thaler '455 contemplate receiving the reference signal from GPS. Non 1394 networks are also contemplated. Thaler '455 teaches that the network may be wired or wireless. An 8 kHz clock is contemplated in FIG. 4 . Thaler '455 also teaches distribution of the time reference signal over a LAN.
U.S. Patent Application Publication No. 2002/0072381 to Becker et al, teaches transmission of time synchronization signals from one base station to another in a mobile telephone communication system. Becker '381 seeks to do this to reduce the costs of having numerous GPS receivers in a mobile phone system. The synchronization signals are transmitted by wireless communications.
However, I have not seen the transmission of time and date signals received from a GPS receiver to a large number of private base transceiver subsystems in a public/private mobile communications system. Further, I have not seen the transmission of GPS time and date information over a LAN cable to a large number of private base transceiver subsystems. Further, I have not seen the transmission of GPS time and date signals to recipient private base transceiver subsystems to generate a plurality of internal clocks in these private base transceiver subsystems where the private base transceiver subsystems do not have a GPS receiver or a GPS antenna.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a signal supply apparatus for a public and private mobile communication system that enables a base station controller to receive GPS information and to supply a reference clock and TOD information to the base station controller and base transceiver subsystems.
It is also an object of the present invention to provide a signal supply apparatus that enables a base station controller to supply a reference clock and TOD information to the base station controller and base transceiver subsystems using the existing lines.
It is further an object of the present invention to distribute to a large number of private base transceiver subsystems GPS time and date information over a LAN cable.
It is still yet another object of the present invention to generate internal clocks in a large number of private base transceiver subsystems using GPS information sent over a cable.
It is yet also another object of the present invention to generate internal clocks in a large number of private base transceiver subsystems from GPS time and date signals where the private base transceiver subsystems do not have either a GPS receiver or a GPS antenna.
In order to accomplish these objects, there is provided a signal supply apparatus for a public and private mobile communication system including a plurality of Internet protocol base transceiver subsystems each having a plurality of Internet protocol private base transceiver subsystems which can be connected by an Internet protocol, respectively; and a private base station controller that controls the plurality of Internet protocol base transceiver subsystems and checks their status, the private base station controller receiving a reference clock and time of day (TOD) information from a satellite, and transmitting to the plurality of Internet protocol base transceiver subsystems various kinds of signals including the TOD information and a sync clock having a frequency that can be transmitted through a local area network (LAN) cable; wherein each of the Internet protocol base transceiver subsystems comprises the plurality of Internet protocol private base transceiver subsystems that can be connected by the Internet protocol through the LAN cable, and generate various kinds of clocks internally required using the sync clock; and collective base transceiver subsystems, connected to the plurality of Internet protocol private base transceiver subsystems through the LAN cable, for performing a function of the base station controller with respect to the plurality of Internet protocol base transceiver subsystems and performing a function of one base transceiver subsystem with respect to the private base station controller, the collective base transceiver subsystems performing a conversion and inverse conversion of a call service signal from the private base station controller into the Internet protocol, and transmitting various kinds of signals including the sync signal and the TOD information transmitted by the private base station controller and the call service signal converted into the Internet protocol to the plurality of Internet protocol base transceiver subsystems through the LAN cable.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
FIG. 1 is a block diagram of a network for explaining the concept of a public and private mobile communication service;
FIG. 2 is a block diagram of the public and private communication service equipment according to an embodiment of the present invention;
FIG. 3 is a view illustrating a connection state of signal lines for supplying signals from a pBSC to IP-pBTSs;
FIG. 4 is a block diagram of a cBTS matching section constructed for internal or external mounting of cBTSs in a system; and
FIG. 5 is a timing diagram of sync clock signals.
DETAILED DESCRIPTION OF THE INVENTION
The mobile communication network is classified into a public mobile communication network and a private (or intra-office) mobile communication network, and if the mobile communication service is provided with the interlocking of the two networks, it will be much convenient to users. This is called a public and private mobile communication system. FIG. 1 shows the construction of a public and private mobile communication system that can provide both a public mobile communication service and a private mobile communication service. In order to provide both the public and private mobile communication services, the public and private mobile communication system, as shown in FIG. 1 , has a public/private shared cell area 14 that is a public and private shared communication service area, and is provided with a public/private communication service equipment 12 . It is preferable that the public/private shared cell area 14 is allocated for the convenience of a specified group (company, institution, school, etc.) in providing a communication service. For instance, if it is assumed that a specified company uses a building, an area to which the building belongs may be allocated as the public/private shared cell area 14 . It is preferable that allocation of the public/private shared cell area 14 is made in agreement with a public mobile communication service provider in advance. In this case, a private base transceiver subsystem (private BTS: 8 - k ) in the public/private shared cell area 14 can be recognized as a public BTS from a viewpoint of the public mobile communication system. In the description, in order to discriminate the BTSs belonging to the public mobile communication system, i.e., the BTSs 6 - 1 to 6 - k , and 8 - 1 illustrated in FIG. 1 , from the private BTS 8 - k in the public/private shared cell area 14 , the private BTS 8 - k is called “pBTS”. The pBTS 8 - k is in radio communication with a mobile station (MS) 24 located in the public/private shared cell area 14 , and performs a function of managing radio resources. The pBTS 8 - k is connected to a base station controller (BSC) of the public mobile communication system, for instance, BSC 4 - m illustrated in FIG. 1 , through the public/private communication service equipment 12 . The public/private communication service equipment 12 is connected to the BSC 4 - m of the public mobile communication system, a public switch telephone network/integrated services digital network (PSTN/ISDN) 16 , and an Internet protocol network 18 . The public/private communication service equipment 12 performs the mobile communication service so that the public mobile communication service and the private mobile communication service can be selectively provided to mobile stations (MSs) in the public/private communication shared cell area 14 , for example, an MS 24 of FIG. 1 . If the MS 24 is registered in the public/private communication service equipment 12 so that it can receive the private mobile communication service, the MS 24 can receive the private mobile communication service in addition to the public mobile communication service. However, if the private mobile communication service of the MS is not registered in the public/private communication service equipment 12 , the MS 24 can receive only the public mobile communication service. Also, the public/private communication service equipment 12 performs a wire communication service with the PSTN/ISDN 16 and the IP network 18 .
Meanwhile, the public mobile communication network is typically called a public land mobile network (PLMN), and includes, as illustrated in FIG. 1 , a plurality of mobile switching centers (MSCs) 2 - 1 to 2 - n , a plurality of base station controllers (BSCS) 4 - 1 to 4 - m , a plurality of base transceiver subsystems (BTSs) 6 - 1 to 6 - k , and 8 - 1 to 8 - k , mobile stations (MSs) 20 and 22 , and a home location register/visitor location register (HLR/VLR) 10 . The plurality of MSCs 2 - 1 to 2 - n are connected to the plurality of BSCs 4 - 1 to 4 - m , respectively, and the plurality of BSCs 4 - 1 to 4 - m are connected to the plurality of BTSs 6 - 1 to 6 - k , and 8 - 1 to 8 - k , respectively. Especially, the pBTS 8 - k among the plurality of BTSs 8 - 1 to 8 - k is connected to the BSC 4 - m of the public mobile communication system. The respective MSCs 2 - 1 to 2 - n controls the connection of the respective BSCs 4 - 1 to 4 - m to the PSTN/ISDN or another MSC in the public mobile communication network. The respective BSCs 4 - 1 to 4 - m perform a wireless link control and a handoff function, and the respective BTSs 6 - 1 to 6 - k , and 8 - 1 to 8 - k constitute wireless communication paths along with the MS 20 , 22 , and 24 which belong to their own communication service areas, i.e., which belong to their cell areas, and manage the wireless resources. In the HLR/VLR 10 , the HLR performs a function of registering subscriber locations and a database function of storing subscriber information, and the VLR is a database for temporarily storing information of the MS existing in the cell area of the corresponding MSC among the plurality of MSCs 2 - 1 to 2 - n . If the MS moves to a cell area that is managed by another MSC, the information stored in the corresponding VLR is deleted. In the description, in order to discriminate from the public/private shared cell area 14 , the communication service areas of the BTSs 6 - 1 to 6 - k , and 8 - 1 to 8 - k of the public mobile communication system are called public dedicated cell areas. As an example, the communication service area of the BTS 8 - 1 among the BTSs 6 - 1 to 6 - k , and 8 - 1 to 8 - k of the public mobile communication system is marked as the public dedicated cell area 15 in FIG. 1 . Typically, the public dedicated cell area 15 is much wider than the public/private shared cell area 14 determined for the convenience of a specified group in providing a communication service.
In FIG. 1 , an E 1 line 30 connects the public/private communication service equipment 12 to the pBTS 8 - k , and thus whenever a new pBTS is added, a new E 1 line should be installed. This causes an increase of the installation cost and inconvenience in system installation.
In the embodiment of the present invention, considering that the place where the private mobile communication service is to be used is a building of a specified group and the typical LAN cables have already been installed in the building, the existing LAN cables are used instead of new E 1 lines.
FIG. 2 is a block diagram of the public and private communication service equipment according to an embodiment of the present invention. In FIG. 2 , collective base transceiver subsystems (cBTSs) 46 - 1 to 46 - 5 in Internet protocol base transceiver subsystems (IP-BTSs) 44 - 1 to 44 - 5 are connected to corresponding Internet protocol private base transceiver subsystems (IP-pBTSs) 48 - 1 to 48 - 6 , respectively, through LAN cables 64 .
Referring to FIG. 2 , an Internet protocol private branched exchange (IP-PBX) 32 is a private exchange having a voice over Internet protocol (VoIP) function. The IP-PBX 32 accommodates intra-office wire subscribers 34 by connecting to a PSTN/ISDN 16 , and can connect to an intra-office dedicated digital telephone 36 . Also, the IP-PBX 32 has a VoIP card mounted therein, and supports the VoIP function. In case of connecting to a private base station controller (pBSC) 38 , the IP-PBX is also used as a switching system. That is, the IP-PBX 32 switches a private mobile communication service (i.e., intra-office call), which is not the public network connection, under the control of the pBSC 38 . The IP-PBX 32 is connected to the pBSC 38 by the E 1 line, and has a LAN port for the VoIP support.
The pBSC 38 is abase station controller that controls the lower IP-BTSs 44 - 1 to 44 - 5 and checks their status. If the public mobile communication service is requested from the MS located in the public/private shared cell area 14 , the pBSC 38 serves to directly bypass the request to the public BSC 4 - m of FIG. 1 without passing through the IP-PBX 32 . The pBSC 38 is divided into 4 parts: a system clock supply section 50 , an asynchronous transfer mode (ATM) switching and pBSC main control section 52 , a public network BSC and IP-BTS connection section 54 , and an IP-PBX connection section 56 .
The system clock supply section 50 includes a GPSR and a master clock distribution board assembly (MCDA). The system clock supply section 50 receives GPS information including a reference clock and TOD information from a satellite, and supplies various kinds of signals required for respective blocks and sync clocks to the blocks. In the embodiment of the present invention, signals transmitted from the system clock supply section 50 to the IP-BTSs 44 - 1 to 44 - 5 include the TOD information and the power supply voltage, and the sync clocks includes sync clocks having a frequency of 8 KHz, which can be transmitted through the LAN cable 64 , and an even second signal Even_Sec.
The ATM switching and pBSC main control section 52 includes an ATM switch, an alarm signal collection section, and a main control section. The ATM switch performs an ATM switching function, and the alarm signal collection section collects alarm signals applied by the respective blocks. The main control section performs the whole control of the respective blocks of the pBSC 38 , and is connected to the call management section 40 by an optical cable to inform the alarm signals collected by the alarm signal collection section to the call management section 40 . The public BSC and IP-BTS connection section 54 is a block for connecting to a public network PLMN (i.e., BSC 4 - m in the embodiment of FIG. 1 ). The IP-PBX connection section 56 converts an audio compressed signal received from the MS into a pulse code modulation (PCM) signal, and transfers the PCM signal through the E 1 lines. The respective blocks of the pBSC 38 communicate with one another through a multiplexer and demultiplexer for multiplexing and demultiplexing the ATM cells. The multiplexer and demultiplexer multiplexes the ATM cells coming out of respective sources, and transfers the multiplexed ATM cells to a destination. The multiplexer and demultiplexer also performs a demultiplexing operation opposite to the above multiplexing operation.
An IP network connection section 42 is a block for connecting to an IP network 18 , and is composed of a hub and a router. The call management section 40 is the pBSC management equipment that provides to the users operation status of the pBSC 38 and the IP-BTSs 44 - 1 to 44 - 5 and various kinds of alarms generated during operation in a graphic user interface (GUI) environment. Also, the call management section downloads a program required by the respective blocks during the system operation through the pBSC main control section in the pBSC 38 , and automatically updates the program when it is changed. The call management section 40 also performs a remote control of the pBSC 38 and the IP-BTSs 44 - 1 to 44 - 5 so that the environment or operation of the pBSC 38 or the IP-BTSs 44 - 1 to 44 - 5 can be changed during the system operation.
The IP-BTSs 44 - 1 to 44 - 5 are parts that allocate the wireless resources, and interface with the MS located in the public/private shared cell area (i.e., 14 in FIG. 1 ) by sending an actual radio frequency (RF) signal. Also, the respective IP-BTSs 44 - 1 to 44 - 5 receives audio data from a public network BSC and IP-BTS connection section 54 of the pBSC 38 , converts the audio data into an RF signal, and then transmits the RF signal through an antenna. In the opposite operation, the respective IP-BTSs also receives an RF signal from the MS, converts the RF signal into a digital compressed signal, and then sends the digital compressed signal to the pBSC 38 . Specifically, each of the respective IP-BTSs 44 - 1 to 44 - 5 is composed of one cBTS and 6 IP-pBTSs at maximum, and from the viewpoint of the pBSC 38 , they are managed and operated as one BTS.
The IP-BTS 44 - 1 among the IP-BTSs 44 - 1 to 44 - 5 is composed of one cBTS 46 - 1 and 6 IP-pBTSs 48 - 1 to 48 - 6 . The pBSC 38 and the cBTS 46 - 1 are connected through an ATM-E 1 line 62 in the same manner as the connection between the existing BSC and the BTS, but the connection among the 6 IP-pBTSs 48 - 1 to 48 - 6 corresponding to the cBTS 46 - 1 is made through a LAN cable 64 . As the cBTS 46 - 1 and the 6 IP-pBTSs 48 - 1 to 48 - 6 are connected through the LAN cable 64 , transmission control protocol (TCP) and user datagram protocol (UDP) communications can be performed between the cBTS 46 - 1 and the 6 IP-BTSs 48 - 1 to 48 - 6 . Since the LAN cable 64 is typically installed wherever the public and private mobile communication service is received, a plurality of IP-pBTSs can be installed using the LAN cable 64 with the installation cost of the system reduced. Also, the additional installation of the IP-pBTSs can be conveniently performed.
The cBTS 46 - 1 in the IP-BTS 44 - 1 that is one among the blocks constructed to accommodate the plurality of IP-BTSs and the LAN cable 64 is located between the IP-pBTSs 48 - 1 to 48 - 6 and the pBSC 38 . The cBTS 46 - 1 performs a function of a base station controller with respect to the IP-pBTSs 48 - 1 to 48 - 6 , and performs a function of a base transceiver subsystem with respect to the pBSC 38 . That is, the cBTS 46 - 1 performs various kinds of functions for enabling the 6 IP-pBTSs 48 - 1 to 48 - 6 at maximum provided in the IP-BTS 44 - 1 to be regarded as one BTS from the viewpoint of the pBSC 38 . The various kinds of functions of the cBTS 46 - 1 will be explained in detail below.
wireless resources management, call control, statistics, status, alarm, etc. status management of the IP-pBTSs 48 - 1 to 48 - 6 and information providing to the pBSC 38 IP-to-ATM mapping function ATM/inter-processor communication (IPC) control function (ATM adaptation later (AAL) 0/2/5) real-time transport protocol (RTP) control function with the IP-pBTSs handoff control function among the lower corresponding IP-pBTSs 48 - 1 to 48 - 6 connected to the cBTS 46 - 1 itself (at this time, ATM path information is not changed.) base station controller identifier (ID) control function for handoff with other IP-pBTSs (including cBTS). Different base transceiver subsystem IDs are given to the respective IP-pBTSs 48 - 1 to 48 - 6 , but the cBTS 46 - 1 is controlled by the base transceiver subsystem ID which is known to the network.
The respective IP-pBTSs 48 - 1 to 48 - 6 connected to the cBTS 46 - 1 through the LAN cable 64 perform the following function. Each of the IP-pBTSs 48 - 1 to 48 - 6 is composed of a wireless channel control section, a modem section, a radio frequency/intermediate frequency (RF/IF) section, an IP connection section, an antenna section (distributed antenna), etc., and accommodates 32 channels for an audio subscriber and 4 channels for a data subscriber (based on 144 kbps). Also, the channel control section performs an IP connection for a bi-directional accommodation and a status control of the IP-pBTS in consideration of a channel management performance. The antenna section is composed of 1-8 distributed antennas to accommodate an attenuation of 0-9 dbm. The respective IP-pBTSs 48 - 1 to 48 - 6 perform the RTP control function with the cBTS 46 - 1 .
Though the IP-BTS 44 - 1 and its internal blocks have been explained as above, it should be understood that the remaining IP-BTSs 44 - 2 to 44 - 5 and their internal blocks perform the same operation as the IP-BTS 44 - 1 and its internal blocks.
FIG. 3 is a view illustrating a connection state of signal lines for supplying signals from the pBSC 38 to the IP-pBTSs 48 - 1 to 48 - 6 corresponding to the cBTSs 46 - 1 to 46 - 5 . FIG. 3 shows two cBTSs 46 - 1 and 46 - 2 among 5 cBTSs 46 - 1 to 46 - 5 and 6 IP-pBTSs 48 - 1 to 48 - 6 corresponding to the cBTSs 46 - 1 and 46 - 2 .
It is preferable that the pBSC 38 and the cBTSs 46 - 1 to 46 - 5 are mounted together on a shelf. Various kinds of signals and the sync clock provided from the system clock supply section 50 of the pBSC 38 are supplied to the cBTSs 46 - 1 to 46 - 5 through a clock supply cable 62 . As shown in FIG. 3 , the various kinds of signals and the sync clock are a sync clock of 8 KHz, an even second signal Even_Sec, a TOD signal, and a power supply voltage of −48V. The timing of the sync clock of 8 KHz and the even second signal Even_Sec is illustrated in FIG. 5 . Referring to FIG. 5 , the even second signal Even_Sec has a pulse width corresponding to one period of a 4.096 MHz signal, and the 8 KHz signal has a pulse width corresponding to two periods of the 4.096 MHz signal. However, the phase of a 1.544 MHz signal is not consistent with that of the even second signal Even_Sec.
Referring again to FIG. 3 , the TOD signal among the various kinds of signals and the sync clock is applied to the cBTS 46 - 1 , cBTS 46 - 2 , and cBTSs 46 - 3 to 46 - 5 in order. Between the public BSC and IP-BTS connection section 54 of the pBSC 38 and the cBTSs 46 - 1 to 46 - 5 is connected an ATM-E 1 line 60 , and an ATM E 1 signal is transmitted/received through the ATM-E 1 line 60 . Also, between the cBTSs 46 - 1 to 46 - 5 and the corresponding IP-pBTSs 48 - 1 to 48 - 6 is connected the LAN cable 64 . The LAN cable 64 is composed of 4 lines of the E 1 signal and 4 lines of the reference clock, and can be installed with a length as long as 200 meters at maximum.
The cBTSs 46 - 1 to 46 - 5 located between the pBSC 38 and the IP-pBTSs 48 - 1 to 48 - 6 are in an ATM-E 1 connection with the pBSC 38 , and in an IP connection with the IP-pBTSs 48 - 1 to 48 - 6 through an Ethernet port. That is, the respective cBTSs 46 - 1 to 46 - 5 receive the ATM-E 1 signal from the pBSC 38 , convert the ATM-E 1 signal into an IP signal, and then transfer the IP signal to the IP-pBTSs 48 - 1 to 48 - 6 . The respective cBTSs 46 - 1 to 46 - 5 supply the even second signal Even_Sec that is the sync clock required by the IP-pBTSs 48 - 1 to 48 - 6 , the 8 KHz signal, and the TOD signal to the lower IP-pBTSs 48 - 1 to 48 - 6 . The clock signals required by the IP-pBTSs 48 - 1 to 48 - 6 are, for example, a 10 MHz signal, 29.4912 MHz signal, 4.096 MHz signal, 1.544 MHz signal, even second signal Even_Sec, etc. However, since the high-frequency signals in the range of about several to several tens of MHz cannot be sent far (i.e., 200 m at maximum), only the even second signal Even_Sec that is the sync clock and the 8 KHz signal are supplied. In this case, the respective IP-pBTSs 48 - 1 to 48 - 6 provide the sync clock to their internal phase locked loop (PLL) logic as the reference signal, and the required clocks (for example, the 10 MHz, 29.4912 MHz, 4.096 MHz, and 1.544 MHz) synchronized by the PLL logic are generated.
One cBTS is designed to control 6 IP-pBTSs at maximum. Accordingly, if it is assumed that 5 cBTSs are mounted, each cBTS accommodates 6 IP-pBTSs at maximum, and thus 30 IP-pBTSs are connected from the viewpoint of one pBSC 38 . If 30 IP-pBTSs 48 - 1 to 48 - 6 are directly connected to one pBSC 38 , the corresponding number of E 1 lines (i.e., 30 E 1 lines) is required. Also, the capacity that can be processed by the pBSC 38 is limited. Thus, in the embodiment of the present invention, the cBTSs 46 - 1 to 46 - 5 are mounted between the pBSC 38 and the IP-pBTSs 48 - 1 to 48 - 6 , so that the cBTSs process the signals which are not required to pass through the pBSC 38 .
FIG. 4 is a block diagram of a cBTS matching section 100 constructed for the internal or external mounting of 5 cBTSs 46 - 1 to 46 - 5 in the system. The cBTS matching section 100 to be explained later is provided with connectors and slots installed therein in order to support all the internal and external mounting of the cBTSs 46 - 1 to 46 - 5 in the system.
Referring to FIG. 4 , The ATM-E 1 signal received from the pBSC 38 through the ATM-E 1 cable is connected to a connector 70 illustrated in FIG. 4 , and then connected to an IP-pBTS connector 78 through patterns. Between the IP-pBTS connector 78 and cBTS slots 84 - 1 to 84 - 5 for mounting the cBTSs 46 - 1 to 46 - 6 are connected backboard patterns (in case of built-in cBTS) or cables (in case of armored cBTS). The sync clock signal of 8 KHz and the even second signal Even_Sec received from the pBSC 38 through the clock supply cable 62 are connected to a connector 72 through the clock supply cable 62 , and then connected to an IP-pBTS clock connector 80 through the patterns. Between the IP-pBTS clock connector 80 and cBTS slots 84 - 1 to 84 - 5 for mounting the cBTSs 46 - 1 to 46 - 5 are connected backboard patterns (in case of built-in cBTS) or cables (in case of armored cBTS). The TOD signal received from the pBSC 38 through the clock supply cable 62 is connected to a clock driving section 76 through a connector 74 . The TOD signal is driven by the clock driving section 76 , and connected to the IP-pBTS clock connector 80 . The TOD signal transmitted from the system clock supply section of the pBSC 38 is received only through a pre-provided port, and since it is required for the cBTS to receive the TOD signal through 5 ports, the clock-driving section 76 is provided. The clock driving section 76 provides the TOD signal to the IP-pBTS clock connector 80 and to the system clock supply section 50 of the pBSC 38 through a connector 82 by allocating one port.
The signal lines connected to the CBTS slots 84 - 1 to 84 - 5 through the backboard patterns (in case of built-in cBTS) and the cables (in case of armored cBTS), as shown in FIG. 4 , are 4 ATM-E 1 signal lines ATM-E 1 , and 6 clock signal lines 8 KHz+/−, Even_Sec +/−, and TOD TX+/TOD TX−. The respective cBTS slots 84 - 1 to 84 - 5 are connected through patterns to 6 connectors 86 - 1 to 86 - 6 and 88 - 1 to 88 - 6 provided for the connection to the 6 IP-pBTSs 48 - 1 to 48 - 6 .
The transfer of the E 1 signal and the sync clock from one cBTS to 6 IP-pBTS 48 - 1 to 48 - 6 using the LAN cable 64 according to the embodiment of the present invention has the following advantages.
Typically, the clock signals required by the BTS are generated using the GPSR mounted in the BTS. That is, the GPSR mounted in the BTS receives the reference clock from the satellite, and generates clocks required by the respective blocks through the internal PLL logic based on the reference clock. In the embodiment of the present invention, since it is not easy in cost, installation, maintenance and repair to mount the GPSR for each IP-pBTS in a structure that can accommodate 30 IP-pBTSs at maximum, an 8-wire LAN cable is used. The existing LAN cable can be used as they are, or a new LAN cable may be installed. The newly installed LAN cable is used not only for the transmission of the E 1 signal, sync clock, and TOD information according to the embodiment of the present invention, but also for the data transmission in a network terminal using an Ethernet port. In the embodiment of the present invention, among the 8 wires of the LAN cable, 4 lines are used for the transmission of the E 1 signal Tx+/Tx− and Rx+/Rx−, and the remaining 4 lines are used for the transmission of the sync clock of 8 KHz and the even second signal Even_Sec. Since the 8 KHz signal and the even second signal Even_Sec (0.5 Hz) are low-frequency signals of several to several tens of Hz, the loss due to the length of line is small. Accordingly, the IP-pBTS that received the 8 KHz signal and the even second signal Even_Sec (0.5 Hz) through the LAN cable can reproduce the required clocks through the PLL logic based on the 8 KHz signal and the even second signal Even_Sec. Also, the TOD signal received from the satellite by the system clock supply section 50 is provided to the respective IP-BTS under the control of the pBSC main control section of the ATM switching and pBSC main control section 52 in the pBSC 38 . Since the IP-pBTSs 48 - 1 to 48 - 6 according to the embodiment of the present invention do not mount the GPSR therein, the TOD signal is directly transmitted from the system clock supply section 50 to the respective IP-pBTSs 48 - 1 to 48 - 6 . The TOD signal is a message having a specified format, and thus can be outputted from the system clock supply section 50 to the respective IP-BTSs through the cBTS.
In the embodiment of the present invention, an unshielded twisted pair (UTP) cable represented as a high-speed and extremely high-speed information communication cable is used as the LAN cable 64 provided between the cBTSs 46 - 1 to 46 - 5 and the IP-pBTSs 48 - 1 to 48 - 6 , respectively.
As described above, according to the present invention, the GPSR is not mounted in the BSC and the pBTS, respectively, and thus the system cost can be reduced. Also, the required signals and the sync signal are supplied to the pBTS through only one line of the LAN cable, and thus the cost for system installation can be reduced with the convenience in construction greatly increased. Also, the present invention can support both the internal mount and the external mount of the cBTS in the system to provide convenience to users.
Although a preferred embodiment of the present invention has been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
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A signal supply apparatus for a public and private mobile communication system. The apparatus has Internet protocol base transceiver subsystems, and a private base station controller that controls the Internet protocol base transceiver subsystems. Instead of having a global positioning system receiver (GPSR) in each of the Internet protocol base transceiver subsystems to receive time of day (TOD) signals, the TOD signals are relayed to each of the Internet protocol base transceiver subsystems via a LAN cable. It is only the base station controllers that have the GPSR that receives the TOD signals. Then, these TOD signals are relayed from the base station controller to respective collective base station transceivers and then from each collective base station transceiver to their respective Internet protocol base transceiver subsystems via a LAN cable.
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[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/089,979, filed on Aug. 19, 2008, which is incorporated herein by this reference.
TECHNICAL FIELD
[0002] The present invention relates to methods of randomly accessing wireless communication networks.
BACKGROUND
[0003] Mobile communication systems enable a mobile terminal (a.k.a., user equipment (UE)) to access a network via a network node (e.g., a base station). In some systems, before the UE begins transmitting traffic to the network via the network node, the UE performs a random access (RA) procedure to request access to the network. For example, the UE transmits an access burst to the network node using a random access channel.
[0004] To distinguish between different UEs performing RA, the access burst transmitted by the UE contains a preamble randomly chosen by the UE that the network node may use to identify the UE. Generally, the UE will uniformly, randomly select a preamble from a set of preambles (e.g., 64 preambles) that was derived from one or more root sequences (e.g., Zadoff-Chu sequences) associated with the network node.
[0005] A set of one or more preambles may be derived from a root sequence by cyclic shifting of the root sequence. The number of preambles that can be derived from a root sequence depends on the maximum expected round trip time between the UE and the network node. For instance, if a root sequence had a length of 800 μs and a very short maximum expected round trip time, then 64 preambles could be derived from the root sequence if the cyclic shift length was less than or equal to 800/64 μs, or 12.5 μs. The maximum expected round trip time is not always short. Indeed, sometimes it may be rather large. Because the cyclic shift length must be large enough to avoid any ambiguity in preamble detection due to propagation round trip time, in some instances, multiple root sequences (e.g., 64 root sequences) are required to generate 64 unique preambles.
[0006] According to some standards, a number of root sequences are available to derive the preambles. For instance, according to the 3G Long-Term Evolution (LTE) standard, a total of 838 root sequences are available for use. Each network node in the network is typically associated with a subset of the 838 root sequences. While different nodes may have the same root sequences associated with them, it is generally advisable to assign different root sequences to nodes that are physically near each other to avoid ambiguity.
[0007] Not all root sequences have the same properties. For instance, different root sequences can have different power back-off metrics (PBM) (e.g., different cubic metric (CM), peak-to-average power ratio, out-of-band emissions, etc.). All preambles derived from a particular root sequence inherit the PBM properties of the particular root sequence. While it may be desirable for a UE to select a preamble having the “best” PBM characteristics when randomly accessing a network node, all UEs should not use the preamble with the best PBM characteristics because this would result in an increase in collisions. Thus, there exists a need in the art for a method of selecting a preamble with desirable PBM characteristics while at the same time not exacerbating the collision problem.
SUMMARY
[0008] In one aspect the present invention provides a method performed by a UE for randomly accessing a network node. In some embodiments, the method includes the following steps: (A) receiving from the network node sequence information for defining a set of sequences (e.g., a sequence index and a cyclic shift length where the sequence index is specific to a set of one or more network nodes of which the network node is a member), where each sequence in the set is associated with a power back-off metric (e.g., a cubic metric, a peak to average power ratio, or an out of band emission related metric); (B) selecting a sequence from the set of sequences; and (C) using the selected sequence or a sequence derived from the selected sequence to access the network node, wherein the step of selecting a sequence from the set of sequences comprises randomly selecting a sequence from the set of sequences using a non-uniform selection process such that the probability that a particular sequence is selected is a function of the power back-off metric associated with the particular sequence.
[0009] In some embodiments, the step of using the selected sequence or the sequence derived from the selected sequence to access the network node comprises transmitting to the network node the selected sequence or a preamble derived from the selected sequence.
[0010] In some embodiments, the step of selecting a sequence from the set of sequences comprises randomly selecting a sequence from the set of sequences using a non-uniform selection process such that the probability that a particular sequence is selected is a function of (i) the power back-off metric associated with the particular sequence and (ii) a value representing an amount of path loss experienced by the UE, such that if the value representing the amount of path loss experienced by the UE is greater than a threshold the non-uniform selection process favors certain sequences from the set, and if the value representing the amount of path loss experienced by the UE is less than a threshold the non-uniform selection process favors other sequences from the set of sequences wherein each other sequence is associated with a power back-off metric that is higher than the average or median power back-off metric of said certain sequences.
[0011] In some embodiments, the step of randomly selecting a sequence from the set of sequences using a non-uniform selection process is performed only if one or more certain events are detected. The one or more certain events may include a path loss exceeding a threshold, the receipt of a hand off command, the UE being located at a cell edge, and/or the nth successive failure of a random access attempt, where n>1. In some embodiments, the method also includes receiving a path loss threshold transmitted from the network node, wherein the one or more certain events comprises determining that a measured path loss exceeds the path loss threshold.
[0012] In some embodiments, the step of selecting a sequence from the set of sequences comprises randomly selecting a sequence from the set of sequences using a non-uniform selection process that favors certain sequences from the set of sequences, wherein each of said certain sequences is associated with a power back-off metric that is lower than an average or median power-back off metric for the set of sequences.
[0013] In some embodiments, the step of randomly selecting a sequence from the set of sequences using a non-uniform selection process comprises: forming a second set of sequences; and randomly selecting a sequence from only the second set of sequences. The step of forming the second set of sequences may include: for each sequence included in the first recited set of sequences, determining whether the sequence should be added to the second set of sequences, wherein the determination is based on, at least in part, the power back-off metric associated with the sequence, and adding the sequence to the second set of sequences in response to determining that the sequence should be added to the second set of sequences.
[0014] In some embodiments, the step of determining whether the sequence should be added to the second set of sequences comprises determining whether the power back-off metric associated with the sequence is below a threshold, wherein if the power back-off metric associated with the sequence is below the threshold, then the sequence should be added to the second set of sequences such that the second set of sequences contains only those sequences that are associated with a power back-off metric that is relatively small.
[0015] In some embodiments, the step of randomly selecting a sequence from the second set of sequences is performed such that each sequence in the second set of sequences has an equal probability of being randomly selected.
[0016] In some embodiments, the set of sequences is a set of root sequences, and the UE stores a set of power back-off metrics, wherein each power back-off metric is associated with a root sequence.
[0017] In another aspect, the present invention provides an improved communication device. In some embodiment, the improved communication device includes a receiver operable to receive sequence information; a data processing system configured to define a set of sequences, where each sequence in the set is associated with a power back-off metric, and select a sequence from the set of sequences; and a transmitter operable to transmit to a network node the selected sequence or a sequence derived from the selected sequence, wherein the data processing system is operable to randomly select a sequence from the set of sequences using a non-uniform selection process such that the probability that a particular sequence is selected is a function of the power back-off metric associated with the particular sequence.
[0018] The above and other aspects and embodiments are described below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate various embodiments of the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention. In the drawings, like reference numbers indicate identical or functionally similar elements
[0020] FIG. 1 illustrates a portion of a mobile communication system.
[0021] FIG. 2 is a flowchart depicting a method for randomly accessing a wireless network according to embodiments of the present invention.
[0022] FIG. 3 is a flowchart depicting a method of randomly selecting a sequence from a set of sequences using a non-uniform selection process according to embodiments of the present invention.
[0023] FIG. 4 is a flowchart depicting a method, according to embodiments of the present invention, of determining whether a sequence with a low power back-off metric is preferred.
[0024] FIG. 5 is a flowchart depicting a method, according to embodiments of the present invention, of determining whether a sequence with a low power back-off metric is preferred.
[0025] FIG. 6 schematically depicts a UE according to embodiments of the present invention.
DETAILED DESCRIPTION
[0026] Referring now to FIG. 1 , FIG. 1 illustrates a portion of a mobile communication system 100 . As depicted in FIG. 1 , mobile communication system 100 may comprise a plurality of network nodes 102 a, 102 b (e.g., base stations) for enabling a mobile terminal 104 (a.k.a., user equipment (UE) 104 ) to access network 110 .
[0027] As described above, in some communication systems, UE 104 must transmit to a network node 102 a request to access network 110 prior to transmitting traffic to network 110 . This request may be transmitted as an access burst on a random access channel (e.g., a Physical Random Access Channel (PRACH)). As also discussed above, when UE 104 transmits a message (e.g., an access burst) to a network node 102 using the random access channel, UE 104 should select a preamble to include in the message. As further discussed above, it would be advantageous if UE 104 can intelligently select a preamble without significantly increasing the likelihood of a preamble collision.
[0028] Referring now to FIG. 2 , FIG. 2 is a flow chart illustrating a process 200 , according to some embodiments, performed by UE 104 for randomly accessing a network node 102 .
[0029] Process 200 may begin in step 202 , where UE 104 determines whether it needs to randomly access a network node 102 . If it does, the process proceeds to step 204 , otherwise process 202 may be repeated again.
[0030] In step 204 , UE 104 obtains sequence information. For example, in step 202 UE 104 may receive the sequence information from a network node 102 . In some systems, each network node periodically broadcasts sequence information. For example, in some systems, each network node broadcasts a logical sequence index and a cyclic shift length. Additionally, in some systems (e.g., LTE) a high speed flag is also transmitted.
[0031] In step 206 , UE 104 uses the received sequence information to define a set of sequences. For example, in some embodiments, the set of defined sequences may consist of all of the root sequences that correspond to the received sequence information. In other embodiments, the set of defined sequences may consist of sixty four (64) preambles, where each preamble was derived from a root sequence included in the set of root sequences that correspond to the received sequence information. For instance, if the set of root sequences that correspond to the received sequence information consists of a single root sequence, then each of the 64 preambles are derived from that one root sequence. As another example, if the set of root sequences that correspond to the received sequence information consists of 64 root sequences, then each of the 64 preambles is derived from a different one of the root sequences.
[0032] In step 208 , UE 104 determines whether it should use a non-uniform or uniform selection process to select a sequence from the set of sequences (e.g., UE 104 determines whether it should select a sequence with a low power back-off metric or a high power back-off metric). Process 200 proceeds to step 210 if UE 104 determines it should use a non-uniform selection process, otherwise it proceeds to step 212 .
[0033] In step 210 , UE 104 randomly selects a sequence from the set of sequences defined in step 206 using a non-uniform selection process. In some circumstances, in step 210 , UE 104 randomly selects a sequence from the set of sequences defined in step 206 using a non-uniform selection process that favors sequences having a low power back-off metric. For example, if UE 104 determines that it is at a cell edge or has a high path loss, then UE 104 will select a sequence from the set of sequences using a selection process that favors sequences having a low power back-off metric (e.g., sequences associated with a power back-off metric that is lower than the average or median power back-off metric associated with the set of sequences).
[0034] In other circumstances, in step 210 , UE 104 randomly selects a sequence from the set of sequences defined in step 206 using a non-uniform selection process that favors sequences having a high power back-off metric. For example, if UE 104 determines that it is not at a cell edge or does not have a high path loss, then UE 104 may select a sequence from the set of sequences using a selection process that favors sequences having a high power back-off metric (e.g., sequences associated with a power back-off metric that is higher than the average or median power back-off metric associated with the set of sequences).
[0035] In step 212 , UE 104 randomly selects a sequence from the set of sequences defined in step 206 using a uniform selection process such that no sequences are favored in the selection process.
[0036] In step 214 , UE 104 transmits to the network node from which UE 104 received the sequence information a message containing the selected sequence (i.e., the selected preamble or a preamble derived from the selected root sequence depending on whether the set of sequences consists of preambles or root sequences).
[0037] In step 216 , UE 102 determines whether there was a transmission failure (e.g., whether the network node to which the message was transmitted successfully received the message). If there was no transmission failure, process 200 may end (or return back to step 202 ). If there was a transmission failure, process 200 proceeds to step 220 .
[0038] In step 220 a counter that keeps track of the number of transmission failures is incremented (this counter may have been initialized to zero prior to performing step 214 ).
[0039] Referring now to FIG. 3 , FIG. 3 is a flow chart illustrating an exemplary process 300 for performing step 210 . Process 300 may begin in step 302 where a set of candidate sequences is initialized. A sequence is then selected from the set defined in step 206 and “removed” from the set (step 304 ). A sequence may be “removed” from the set by, for example, setting a flag indicating that the sequence has been selected.
[0040] At step 306 , the power back-off metric (PBM) associated with the selected sequence is determined. If the PBM of the selected sequence is identified as being below a certain pre-defined threshold value (T 2 ) at step 308 , then the selected sequence is added to the set of candidate sequences (step 310 ), otherwise process 300 proceeds to step 312 . In step 312 , UE 104 determines whether the set of sequences defined in step 206 is “empty” (i.e., whether all of the sequences in the set have been selected). If the set is not empty, the process loops back to step 304 . If, the set is empty, then a sequence can be randomly selected from the set of candidate sequences using, for example, a uniform selection process (step 314 ). In this manner, UE 104 randomly selects a sequence from the set of sequences defined in step 206 using a non-uniform selection process that favors sequences having a lower power back-off metric.
[0041] Process 300 is an example process for performing step 210 . Other processes for performing step 210 are contemplated. For example, step 210 may be implemented by randomly selecting a sequence from the set defined in step 206 such that the probability that a particular sequence is selected is function of the PBM associated with the sequence (e.g., sequences with a low PBM may be weighted more heavily in the selection process than sequences that do not have a low PBM such that the sequences with a low PBM are selected more of the time than sequences with high PBM). Additionally, the probability that a particular sequence is selected may also be function of a value representing an amount of path loss.
[0042] Referring now to FIG. 4 , FIG. 4 is a flow chart illustrating an exemplary process 400 for performing step 208 . Process 400 may begin in step 402 where it is determined whether UE 104 is being handed off from one node to another node. If the UE is being handed off, then the method proceeds to step 210 , which prefers sequences with low power back-off metrics. The reason that the method goes to step 210 during a hand off is because, when a UE is being handed off from one network node to another, it is normally on the edge of the node's transmission radius and, therefore, it is important to have a sequence with a low power back-off metric. If the UE is not being handed of (i.e., if it is just being turned on of has been in standby mode for an extended period of time), then the UE determines whether the measured path loss is greater than a certain pass loss threshold value (shown here as T 2 ) at step 404 . If the path loss is greater than the threshold, then the method advances to step 210 . If, however, the path loss is less than the threshold value, then the method determines whether the counter incremented in step 220 , which is indicative of the number of transmission attempts to the network node, is greater than a certain threshold T 1 (step 406 ). If the counter is greater than T 1 , then the method advances to step 210 . However, if the counter is below T 1 , then the method advances to step 212 . The path loss threshold value T 2 may be a configuration parameter stored in UE 104 prior to UE 104 performing process 200 and/or it may be communicated to UE 104 by a network node 102 .
[0043] Referring now to FIG. 5 , FIG. 5 is a flow chart illustrating an exemplary process 500 for performing step 208 . Process 500 may begin in step 502 where UE 104 determines whether its is being handed off or not. If it is, then the path loss is determined and if the path loss is greater than a certain threshold T 2 as determined at step 504 , then the method advances to step 210 . If, however, the path loss is less than the threshold value, then the method determines whether the counter incremented in step 220 is greater than the threshold T 1 (step 506 ). If the counter is greater than T 1 , then the method advances to step 210 . However, if the counter is below T 1 , then the method advances to step 212 .
[0044] Referring now to FIG. 6 , FIG. 6 is a functional block diagram of UE 104 according to some embodiments of the invention. As shown, UE 104 may comprise a data processing system 602 (e.g., one or more microprocessors), a data storage system 606 (e.g., one or more non-volatile storage devices) and computer software 608 stored on the storage system 606 . Data 610 (e.g., the above mentioned threshold values and root sequences) may also be stored in storage system 606 . UE 104 also includes transmit/receive (Tx/Rx) circuitry 604 for transmitting data to and receiving data from network nodes 102 .
[0045] Software 608 is configured such that when data processing system executes software 608 , UE 104 performs steps described above (e.g., the steps described above with reference to the flow charts shown in FIGS. 2-5 ). For example, software 608 may include: (1) computer instructions configured to obtain sequence information for defining a set of sequences (root sequences or preambles) and (2) computer instructions configured to randomly select a sequence from the set of sequences using a non-uniform selection process such that the probability that a particular sequence is selected is a function of a power back-off metric associated with the particular sequence.
[0046] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above described exemplary embodiments.
[0047] Additionally, while the processes described above and illustrated in the drawings are shown as a sequence of steps, this was done solely for the sake of illustration. Accordingly, it is contemplated that some steps may be added, some steps may be omitted, the order of the steps may be re-arranged, and some steps may be performed in parallel.
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The present invention relates to methods for establishing a connection between a user equipment and a wireless network. More particularly, the present invention relates to methods for selecting a preamble based on its power back-off metric in order to randomly access a wireless network while avoiding collisions with other user equipments attempting to access the network at the same time.
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BACKGROUND OF THE INVENTION
This invention relates to a training aid which is readily attached to and detached from the handle of any golf club to assist the golfer in determining an optimum grip pressure. It is important to maintain a fairly light, even grip throughout the golf swing. A proper grip should generate a feeling of controlling the club and a sensing of the weight of the club head. The grip pressure should remain constant at all times during the set-up, back-swing and follow-through.
An excessively tight grip stiffens the forearms causing a retardation of the swing. An excessively loose grip creates other problems such as overswinging or brushing the ground prior to hitting the ball. Golfing experts recognize that a good grip is essential for any strategy to improve a player's golfing game.
A number of training aids for measuring a golfer's grip have been invented as typified by U.S. Pat. No. 4,138,118, issued Feb. 6, 1979 to David R. A. Budney; U.S. Pat. No. 4,103,896, issued Aug. 1, 1978 to Walter R. Lorang and U.S. Pat. No. 3,323,367, issued June 6, 1967 to R.W. Searle. The patent to Budney shows a golf grip employing strain gauges fixedly mounted on selected locations of the handle. The strain gauges are connected to a remote recorder which provides a series of graphs which can be compared to the graphs produced by an expert golfer. Lorang shows a golf grip training apparatus having a switch lever mounted on one side of the golf club handle. Excessive pressure exerted by the middle fingers of the off-target hand causes the lever to close a circuit to activate a signalling device mounted on the club. Searle shows a plurality of pressure sensitive sensors mounted on the handle of a golf club to respond to the grip pressure of both hands. The sensors are part of a bridge circuit which indicates grip pressure information on a meter attached to the club.
While the above mentioned patents do teach pressure responsive grips, the prior art does not teach a grip training device having the flexibility of attachment, the wide application and the feature of adjustability found in the instant invention.
SUMMARY OF THE INVENTION
The overall object of the present invention is to improve upon the prior art golf grip training devices by increasing the flexibility of usage and the range of application.
It is a specific object of the invention to provide a golf-grip training device that can be readily attached and removed from a golfer's own set of clubs. Although the invention may be permanently integrated into a golf club, it is primarily designed as a removable attachment for use at the option of the golfer. The fact that the invention can be attached to the golfer's own clubs makes it useable both for right-handed and left-handed golfers.
It is another object of the invention to provide a pressure grip indicator responsive to at least two specific pressures. The change in grip pressure response is brought about by means of an electrical switch in series circuit with a battery, a pressure sensor and an audible signalling device. The change in grip pressure range enables use by golfers with different degrees of muscular strength and different levels of proficiency and experience.
It is yet another object of the invention to provide an audible self-analysis of the pressure used to grip the club. An audible signal mounted on the golf club is to be preferred over a visual signal in that the golfer can keep his eye on the ball without distraction while the gripping pressure is monitored.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the apparatus of the invention mounted on a golf club;
FIG. 2 is an enlarged view of the handle portion of FIG. 1 golf club with the apparatus of the invention removed and in position for attachment;
FIG. 3 is a perspective view of the pressure sensitive switch of the invention with the outer cover removed to expose the inner details;
FIG. 4 shows a portion of the FIG. 3 switch in the normal unstressed condition;
FIG. 5 shows the FIG. 3 switch in the first lighter grip stressed condition;
FIG. 6 shows the FIG. 3 switch in the second heavier grip stressed condition;
FIG. 7 is a circuit diagram illustrating the electrical operation; and
FIG. 8 is a top view of the signalling device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in general to the drawings and in particular to FIGS. 1-3, the novel golf-grip training device 1 of this invention comprises a grip pressure sensing element 2 secured to the underside of the handle 3 of a golf club 4. The grip pressure sensing element 2 comprises a multi-level strip switch 5 encased in an elastomeric housing 6 to seal out dirt and moisture. Another important function of the elastomeric housing 6 is to provide the requisite flexibility to enable the pressure generated by the gripping fingers of the hands to be passed on to the internal strip switch 5. The housing flexibility also enables it to conform to the handle 3 of the golf club without creating any bulkiness.
Velcro straps 7 and 8 are mounted on end portions of the housing 6 of the pressure sensing element 2 to secure it in place on the golf club grip 3. As best seen in FIG. 2, the Velcro straps are permanently bonded to outside portions of housing 6 with the free ends of the straps in position to encircle the grip. The pressure sensing element 2 is then held against a bottom portion of the club grip and the Velcro straps tightly wrapped in locking arrangement around the handle 3 as shown in FIG. 1.
A signalling device 9 is mounted on the top side of the golf club 4 between the golf club head and the pressure sensing element as close to the sensing element as practical to conveniently electrically connect the two. The details of construction and operation of the signalling device 9 will be explained below in connection with FIGS. 7 and 8. It is sufficient to note at this time that the signalling device 9 is strapped to the golf club by means of a Velcro strap 10 clamped to the bottom of the signalling device by a clamping plate 11 fastened to the bottom plate of the signalling device. A half-cylindrical section of spongy material 12 of a length approximately equal to the length of the signalling device is bonded to the lower surface of the clamping plate 11. The purpose of spongy section 12 is to frictionally secure the signalling device to the golf club under pressure from Velcro strap 10.
After the pressure sensing element 2 and the signalling device 9 are mounted on the golf club the two are electrically connected by means of a quick connect electrical coupling. Although a wide variety of quick connect couplings may be used it is preferred to employ a modular phone jack as used in telephone service. A modular spade line cord 13 is connected to the output terminals of pressure sensor 2. A modular jack 14 is recessed in one end of signalling device 9 to receive the modular spade line cord 13 thereby completing the circuit. The connection can be easily disconnected when detaching the golf grip training device from the golf club.
Referring now to FIG. 3, the multi-level strip switch 5 is shown exposed to view after the elastomeric housing 6 has been removed. The switch 5 comprises an outer contact strip 15, a middle contact strip 16 and a bottom contact strip 17 separated by a number of blocks 18 of compressible material. The blocks 18 are made of a plastic foam with the opposed wide surfaces provided with an adhesive coating for bonding to the metal strips 15, 16, and 17. The foam blocks are adhesively bonded between the metal strips at spaced intervals to form a two-layer sandwich construction.
In a normal unstressed position the blocks 18 maintain the three resilient contact strips 15, 16 and 17 in spaced apart insulated relation. When pressure is applied to outer switch contact 15 electrical contact is made between 15, 16 and 17 depending upon the amount of applied pressure.
Although there is nothing critical in the precise dimensions of the parts or the materials employed, for the sake of explanation some exemplary dimensions and materials of construction will be given. The resilient contact strips 15, 16 and 17 are made of stainless steel and are about 8 inches long, 1/4 inch wide and 0.005 inch thick. The compressible foam blocks 18 are 1/4 inch wide, 3/8 inch long and 1/8 inch thick. The blocks are cut from foam strip material with adhesive on both sides. Different material from different manufacturers have differing resistance to compression. Through experimentation, a material with the desirable compressibility factor is selected to yield the desired pressure response. The blocks 18 are mounted in a partial overlapping relationship with each block in a sandwich being spaced approximately 1/2 inch apart. The last space in each sandwich layer at the butt end location is somewhat less than 1/2 inch as determined by experimentation.
At the strip switch 5 end remote from the butt end a series of terminals 19, 20, 21 are provided on contact strips 15, 16, 17, respectively. The exposed wires of modular spade line cord 13 are attached to these terminals. The terminals 19-21 and the line cord 13 attached thereto are sealed at an end portion 22 of elastomeric housing 5 where the line cord exits to prevent entry of dirt and moisture. The other end of line cord 13 is inserted in modular jack 14 of the signalling device 9 to complete the circuit.
The electrical operation will be explained in connection with FIG. 7. Terminals 19, 20, 21 of contact strips 15, 16, 17 respectfully, are connected by spade line 13 to contacts 23, 24, 25 in modular jack 14 when the spade line is inserted into the modular jack located in the housing of the signalling device 9. A battery 26 mounted within housing 9 supplies voltage to a two position grip pressure selector switch 27 having output terminals 28 and 29. Switch terminal 28 is connected to middle contact strip 16 via terminals 24, 20. Switch terminal 29 is connected to bottom contact strip 17 via terminals 25, 21. Outer contact strip 15 acts as a common line and is connected to a buzzer 30 via contacts 23, 19. Buzzer 30 is connected to battery 26 to complete the circuit.
In the switch 27 position shown in FIG. 7, voltage is supplied to middle contact strip 16. Gripping pressure applied to outer contact 15 beyond the compressibility level of blocks 18 will cause contact strip 15 to make contact with middle strip 16 to energize buzzer 30. This will signal the golfer that he has exceeded a first presettable gripping pressure. When switch 27 is set to energize terminal 29, a voltage is supplied to bottom terminal 17. Gripping pressure applied to outer contact 15 beyond the compressibility of blocks 18 in both switch levels will cause contact strip 15 to make contact with strip contacts 16 and 17 to energize buzzer 30. This will signal the golfer that he has exceeded a second higher presettable gripping pressure. The manner of gripping pressure switch actuation will be further explained below in connection with FIGS. 3-6.
Most golfing experts agree that there is an optimum gripping method for holding a golf club. For a right-handed golfer it involves holding the butt end of the handle in the left hand and applying the right hand so that the club shaft lies across the first joint of the four fingers. Reference is made to FIG. 1 of U.S. Pat. No. 4,138,118 to Budney for a showing and description of the preferred grip. In further analyzing the optimum grip it can be seen that gripping pressure on the golf club handle is supplied mainly by the last three fingers of the left hand and the two middle fingers of the right hand.
The important fingers controlling the grip are schematically shown as circles in FIG. 3 where 31 and 32 represent the middle fingers of the right hand and 33, 34, 35 represent the last three fingers of the left hand. Tightening of the grip fingers exerts gripping pressure in the direction of the arrows to compress the multi-level strip switch 5 against the golf club handle, not shown in FIG. 1. Also not shown in FIGS. 3-6 is the thin elastomeric housing which covers switch element 5.
FIGS. 4-6 illustrate the three contact positions for multi-level switch 5. FIG. 4 shows a partial section of switch 5 with two gripping fingers operating thereon. A portion of the golf club handle 3 is shown for providing a reaction force. In the FIG. 4 position, no force is applied by the fingers and the switch is in an idle condition.
In FIG. 5, the two fingers shown apply a gripping pressure to outer contact strip 17 compressing blocks 18 and allowing deflection of strip 17 to contact middle contact strip 16. Assuming switch 27 is set on contact 28 for a low gripping pressure setting, the buzzer will sound indicating that the desired gripping pressure has been exceeded. The switch 5 has been designed to react to a low gripping pressure of 5 to 6 pounds.
In FIG. 6, a single gripping finger is shown applying a strong gripping pressure to outer contact 17 compressing blocks 18 at both levels and allowing deflection of outer strip 17 to contact middle strip 16 which in turn is deflected to contact bottom strip 15. Assuming switch 27 is set on contact 29 for a higher gripping pressure setting, the buzzer 30 will sound indicating that the desired higher gripping pressure has been exceeded. The switch 5 has been designed in this mode to react to a gripping pressure of 14 to 15 pounds.
The undulations 36 shown in strip contacts 15 and 17 are formed by a slight permanent set in the strips across the open unsupported areas. They serve as convenient indexing recesses for the gripping fingers.
FIG. 8 shows the top portion of signalling device 9. All the components are mounted in a generally rectangular plastic housing 37 approximately 2 inches long, 15/8 inches wide and 5/8 inch high. Grip pressure selector switch 27 is mounted on the top surface along with the output grille of buzzer 30. Modular jack 14 is situated on an end portion facing the golf club grip 3.
It is not intended to limit the present invention to the details of illustration or terms of description of the single preferred embodiment shown above. It will be appreciated by those skilled in the art that various modifications and alterations therein may be made within the scope of the present invention.
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A golf grip training device designed to be readily attached and removed from the handle of a golf club. An elongated pressure sensitive switch is mounted on the underside of the handle and is responsive to the grip pressure of the golfer. The switch is formed of three resilient conducting strips adhesively secured to a number of spaced compressible foam blocks forming two sandwich layers. The switch is responsive to two distinct grip pressures. A signalling device containing a battery, a buzzer, and a grip pressure selector switch is mounted on the golf club and electrically connected to the pressures sensitive switch to emit an audible signal when a predetermined grip pressure is exceeded. The grip pressure selector switch can select either of the two grip pressure ranges built into the pressure sensitive switch.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to a hydrogen storage technology for new energies, and particularly to a method and apparatus for manufacturing high-purity hydrogen storage alloy Mg 2 Ni.
BACKGROUND OF THE INVENTION
[0002] Owing to substantial growth of usage in fossil energy while which energy is drying up gradually, to pernicious substances harmful to human bodies produced by extensive application of fossil energy, such as SO 2 —CO—NO x , and to global climate changes caused by the greenhouse effect due to considerable quantity of exhausted CO 2 , the world is devoted to the development of new energy technologies. In particular, hydrogen energy is planned to be one of the major energies in the future by the International Energy Agency (IEA), because the byproduct thereof is water only, without CO 2 , which completely prevents pollution and the greenhouse effect. However, in practical applications, due to the light molecular weight of hydrogen, the storage volume will be immensely huge. Though super-high pressure can be adopted for storage, safety will be another issue.
[0003] The problems of storage density and safety of hydrogen are not solved until 1980 when the hydrogen storage alloys that can stores hydrogen in solid state is introduced. Nevertheless, the hydrogen storage density of current commercial hydrogen storage alloys, including transition-metal-based hydrogen storage alloys AB 2 or rare-earth-metal-based hydrogen storage alloys AB 5 , is still too low, less than 2.0% in weight. Thereby, the research and development of high-capacity hydrogen storage alloys is the current international trend. Particularly, magnesium-based hydrogen storage alloys are regarded as potential hydrogen storage alloys due to their low costs in raw materials. However, because pure magnesium is very active, the surface thereof tends to form an oxidation layer that can block absorption of hydrogen molecules, and hence affect diffusion rate of hydrogen atoms on the surface of alloys. As a result, pure magnesium is difficult to be activated and has bad hydrogen absorption-desorption dynamics. In addition, the temperatures of hydrogen absorption and desorption are too high. Accordingly, it cannot be developed to be a practical hydrogen storage alloy.
[0004] Regarding to the issue of bad hydrogen absorption-desorption dynamics of pure magnesium, by many researches, it is discovered that by adding nickel with catalyzing effect, the reaction rate of hydrogen absorption-desorption in the hydrogen storage alloy Mg—Ni can be improved, and the initial activation properties is catalyzed as well. In the Mg—Ni-based hydrogen storage alloys, Mg 2 Ni in the γ-phase has the fastest activation reaction rate and the best hydrogen absorption-desorption property.
[0005] Because the melting points of magnesium (649° C.) and nickel (1455° C.) differ greatly, melting tends to be ununiform, which would result in ununiformity in composition of the hydrogen storage alloy. In addition, the vapor pressure of magnesium is high, thereby magnesium is easy to vaporize during melting, which causes severe deviation in initial composition, and excess eutectic structure and formation of the β-phase MgNi 2 , which is incapable of absorbing hydrogen. In order to solve the problem the severe deviation in composition during melting as described above, next-generation vacuum induction furnaces are introduced. However, although the vacuum induction furnaces are equipped with in-situ inspection, for the hydrogen storage alloy Mg—Ni, owing to its natural characteristic in the phase diagram, the melt liquid of Mg—Ni still cannot give 100%-pure γ-phase Mg 2 Ni after solidification, even the composition of magnesium and nickel are controlled to be accurately 2:1 via the most precise in-situ inspection function. This is because according to the binary equilibrium phase diagram of magnesium and nickel, in such a composition, far above the melting point 761° C. of the γ-phase Mg 2 Ni, the β-phase MgNi 2 , which has a meting point of 1147° C. and is incapable of absorbing hydrogen, has solidified and precipitated first. Besides, because the composition of the β-phase MgNi 2 has much more nickel than the γ-phase Mg 2 Ni, the residual Mg—Ni melt liquid yet solidified deviates from the original composition of the γ-phase Mg 2 Ni with a magnesium-to-nickel atomic ratio of 2:1, and becomes a magnesium-rich state. The Mg—Ni melt liquid in the magnesium-rich state, according to the binary equilibrium phase diagram of magnesium and nickel, not only will form the γ-phase Mg 2 Ni if the temperature is lower than 761° C. in the present composition, but also will give an eutectic structure including the pure-magnesium phase at the eutectic temperature of 507° C. That is to say, even the macroscopic composition complies with the proportion of the γ phase, the microscopic structure thereof includes the β-phase MgNi 2 and the solid solution phase of pure-magnesium in the γ-phase Mg 2 Ni. Thereby, the smelt method according to the prior art cannot be used for preparing high-purity hydrogen storage alloy Mg 2 Ni with fast activation reaction rate and with excellent hydrogen absorption and desorption properties.
[0006] Accordingly, the authors of the present invention make advantage of the segregation principle in physical metallurgy, in a broad range of composition and in low temperatures (far lower than the melting point of pure nickel), and propose a simple apparatus for continuously manufacturing high-purity hydrogen storage alloy Mg 2 Ni.
SUMMARY
[0007] An objective of the present invention is to provide a method and apparatus for manufacturing high-purity magnesium-nickel hydrogen storage alloy without the need of precisely controlling the composition of magnesium and nickel in the magnesium-nickel alloy.
[0008] Another objective of the present invention is to provide a method and apparatus for manufacturing high-purity magnesium-nickel hydrogen storage alloy, which can recycle the residual magnesium-rich liquid after the precipitation reaction and continuously manufacture high-purity magnesium-nickel hydrogen storage alloy according to the method provided by the present invention.
[0009] In order to achieve the objectives described above, the present invention provides a method and apparatus for manufacturing high-purity magnesium-nickel hydrogen storage alloy. The apparatus comprises a vacuum chamber with a material feeding tube, a first crucible, a heating device, a stirring device, and a second crucible. First, put the raw material of pure magnesium into the first crucible, and place the first crucible into the vacuum chamber gassed with an inert gas. Then, use the heating device to heat the magnesium raw material until it melts completely into a magnesium liquid. Next, use the material feeding tube to add slowly pure nickel powders to the first crucible with the magnesium liquid, and use the stirring device to stir unceasingly while using the heating device to heat up, so that the nickel powders are melt completely and mixed with the magnesium liquid to become a uniform magnesium-nickel liquid. It is not necessary for the apparatus and method according to the present invention to install delicate in-situ inspection, nor to control precisely the composition of the magnesium-nickel liquid. It is only required that the weight percentage of the amount of the added nickel to the whole magnesium-nickel melt is between 23.5 and 50.2, then it is guaranteed to give pure γ-phase Mg 2 Ni hydrogen storage alloy with composition of Mg-54.6 wt % Ni (that is, the atomic ratio between magnesium and nickel is 2:1) without other phases.
[0010] The next step is to control the heating temperature of the heating device to be within a temperature range, which is between 507° C. and 761° C. According to the segregation principle of physical metallurgy and to the Mg—Ni phase diagram, high-purity magnesium-nickel hydrogen storage alloy will be formed and precipitated automatically, and the purity thereof is independent of the precipitation temperature within said temperature range. Thereby, according to the present invention, it is not necessary to adopt accurate and costly temperature control systems. In addition, the precipitated quantity (weight) of the hydrogen storage alloy Mg 2 Ni depends on the composition of the magnesium-nickel liquid and the precipitation temperature. In general, within the broad ranges of composition and temperature conditions according to the present invention, the higher the proportion of nickel and the lower the precipitation temperature, the more the precipitated quantity of high-purity γ-phase Mg 2 Ni. The exact precipitated quantity (weight) can be calculated according to the level rule of phase diagram in physical metallurgy.
[0011] Because the nickel composition (54.6 wt %) of the precipitated high-purity γ-phase Mg 2 Ni according to the present invention is higher than that of the original magnesium-nickel composition (that is, the weight percentage of nickel is between 23.5 and 50.2), with the progress of precipitation reaction, according to the law of conservation of mass, the composition of the residual magnesium-nickel liquid will become more and more magnesium-rich. The density of nickel (8.9 g/cm 3 ) is much greater than that of magnesium (1.74 g/cm 3 ), therefore, the precipitated high-purity magnesium-nickel hydrogen storage alloy will sink at the bottom of the crucible given that the density of solid-state magnesium-nickel hydrogen storage alloy is much greater than the specific weight of the magnesium-nickel liquid. Thereby, pour the residual liquid in the first crucible after the precipitation reaction into the second crucible, draw out the first crucible loaded with the precipitated magnesium-nickel hydrogen storage alloy from the heating device, and cool the first crucible. After cooling, pick out the magnesium-nickel hydrogen storage alloy from the first crucible, and repeat the procedure described above for the second crucible loaded with the residual liquid. Then high-purity magnesium-nickel hydrogen storage alloy is given continuously.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a flowchart according to a preferred embodiment of the present invention;
[0013] FIG. 2A shows a schematic diagram of the apparatus in the steps S 10 and S 11 according to a preferred embodiment of the present invention;
[0014] FIG. 2B shows a schematic diagram of the apparatus in the step S 12 according to a preferred embodiment of the present invention;
[0015] FIG. 2C shows a schematic diagram of the apparatus in the step S 13 according to a preferred embodiment of the present invention;
[0016] FIG. 2D shows a schematic diagram of the apparatus in the step S 14 according to a preferred embodiment of the present invention;
[0017] FIG. 2E shows a schematic diagram of the apparatus in the step S 15 according to a preferred embodiment of the present invention;
[0018] FIG. 2F shows a schematic diagram of the apparatus in the step S 16 according to a preferred embodiment of the present invention; and
[0019] FIG. 3 shows a schematic diagram of the apparatus according to another preferred embodiment of the present invention.
DETAILED DESCRIPTION
[0020] In order to make the structure and characteristics as well as the effectiveness of the present invention to be further understood and recognized, the detailed description of the present invention is provided as follows along with preferred embodiments and accompanying figures.
[0021] FIG. 1 and FIG. 2A show a flowchart and a schematic diagram of the apparatus in the steps S 10 and S 11 according to a preferred embodiment of the present invention. As shown in the figure, the present invention provides a method and apparatus for manufacturing high-purity magnesium-nickel hydrogen storage alloy. The apparatus comprises a vacuum chamber 10 with a material feeding tube 104 , a first crucible 12 , a heating device 14 , a stirring device 16 , and a second crucible 18 . By using the apparatus, the step S 10 is executed for putting a raw material of magnesium 11 into the first crucible 12 , where the raw material of magnesium 11 is a magnesium metal bulk, and the material of the first crucible 12 is a metal material with melting point greater than that of the magnesium metal. Then, gas an inert gas 13 into the vacuum chamber 10 , and put the first crucible 12 with the raw material of magnesium 11 into the vacuum chamber 10 . Before gassing the inert gas 13 into the vacuum chamber 10 , the inert gas 13 is first used to purge the vacuum chamber 10 . Finally, seal the vacuum chamber 10 , and let the inert gas 13 be maintained in the vacuum chamber 10 . After the first crucible 11 loaded with the raw material of magnesium 11 is put into the vacuum chamber 10 , the step S 11 is executed for setting the first crucible 12 in the heating device 14 , which is used for heating the raw material of magnesium 11 in the first crucible 12 to be totally melt and become a magnesium liquid 110 . The heating device 14 is a resistive heater with a temperature adjustment function.
[0022] FIG. 2B shows a schematic diagram of the apparatus in the step S 12 according to a preferred embodiment of the present invention. As shown in the figure, after the raw material of magnesium 11 in the first crucible 12 is melt into the magnesium liquid 110 , the step S 12 is executed for adding nickel powders 15 slowly to the magnesium liquid 110 in the first crucible 12 by using the material feeding tube 104 , and stirring the magnesium liquid 110 and the nickel powders 15 loaded in the first crucible 12 by using the stirring device 16 . Besides, the heating device 14 is used for heating the first crucible 12 with the magnesium liquid 110 and the nickel powders 15 so that the temperature of the magnesium liquid 110 is heated above 770° C. Thereby, the nickel powders 155 are melt completely in the magnesium liquid 110 and a uniformly mixed magnesium-nickel liquid 112 is produced. The stirring device 16 includes a motor 161 and a paddle 163 . In addition, the stirring device 16 can be elevated. When the stirring device 16 is used for stirring, the paddle 163 can elevated to a proper position, and the motor 161 will drive the paddle 163 for stirring. Furthermore, an oar-shaped blade 165 is adapted on one end of the paddle 163 for increasing stirring area and speed. When stirring is performed, the paddle 163 of the stirring device 16 is retracted. The weight percentage of the nickel element in the magnesium-nickel liquid 112 is between 23.5% and 50.2%, which represents the composition of the added nickel powders. Thereby, the composition ratio of the magnesium and nickel elements in the final precipitated high-purity solid-state magnesium-nickel hydrogen storage alloy is 2:1 without other phases.
[0023] FIG. 2C shows a schematic diagram of the apparatus in the step S 13 according to a preferred embodiment of the present invention. As shown in the figure, when the magnesium-nickel liquid 112 is produced, the step S 13 is executed for controlling the temperature of the heating device 14 to fall within a temperature range. Thereby, the temperature of the magnesium-nickel liquid 112 will be within the temperature range, which is above the solidification temperature and below the liquification temperature of the magnesium-nickel liquid 112 . That is, between 507° C. and 761° C. According to the segregation principle of physical metallurgy and to the Mg—Ni phase diagram, high-purity magnesium-nickel hydrogen storage alloy 114 will be formed and precipitated from the magnesium-nickel liquid 112 automatically, and the purity thereof is independent of the precipitation temperature within said temperature range. Thereby, according to the present invention, it is not necessary to adopt accurate and costly temperature control systems. In addition, the precipitated quantity (weight) of the hydrogen storage alloy 114 depends on the composition of the magnesium-nickel liquid and the precipitation temperature. In general, within the broad ranges of composition and temperature conditions according to the present invention, the higher the proportion of nickel and the lower the precipitation temperature, the more the precipitated quantity of high-purity magnesium-nickel hydrogen storage alloy 114 . The exact precipitated quantity (weight) can be calculated according to the level rule of phase diagram in physical metallurgy.
[0024] FIG. 2D shows a schematic diagram of the apparatus in the step S 14 according to a preferred embodiment of the present invention. As shown in the figure, the solid-state magnesium-nickel hydrogen storage alloy 114 is precipitated from the magnesium-nickel liquid 112 . The nickel composition of the magnesium-nickel hydrogen storage alloy 114 is greater than that in the magnesium-nickel liquid 112 . With the progress of precipitation reaction, according to the law of conservation of mass, the composition of the residual magnesium-nickel liquid 116 will become magnesium-rich. The density of nickel (8.9 g/cm 3 ) is much greater than that of magnesium (1.74 g/cm 3 ), therefore, the solid-state magnesium-nickel hydrogen storage alloy 114 will sink at the bottom of the first crucible 12 . After the magnesium-nickel liquid 112 precipitated the solid-state magnesium-nickel hydrogen storage alloy 114 , the step S 14 is executed for separating the residual liquid 116 in the first crucible 12 from the solid-state magnesium-nickel hydrogen storage alloy 114 suck at the bottom of the first crucible 12 by pouring the residual liquid 116 in the first crucible 12 into the second crucible 18 . In order to pour the residual liquid 116 in the first crucible 12 into the second crucible 18 easily, an inclinable base 19 is adapted in the vacuum chamber 10 with the first crucible 12 and the heating device 14 set thereon. When the base 19 inclines, the first crucible 12 and the heating device 14 incline with the base 19 , and the residual liquid 116 will be poured into the second crucible 18 . Finally, the solid-state magnesium-nickel hydrogen storage alloy 114 will be left at the bottom of the first crucible 12 .
[0025] FIG. 2E shows a schematic diagram of the apparatus in the step S 15 according to a preferred embodiment of the present invention. As shown in the figure, the step S 15 is executed. Draw out the first crucible 12 from the heating device 14 , and cool the first crucible 12 loaded with the solid-state magnesium-nickel hydrogen storage alloy 114 . In or to draw out the first crucible 12 from the heating device 14 conveniently, a hoist mechanism 17 is further adapted in the vacuum chamber 10 . The hoist mechanism 17 includes a plurality of twisted ropes 171 , which is fixed on the first crucible 12 . Thereby, the hoist mechanism 17 can draw out the first crucible 12 from the heating device 14 . In addition, in order to secure the connection between the hoist mechanism 17 and the first crucible 12 , a plurality of hanging ears (not shown in the figure) is adapted at the periphery of the opening of the first crucible 12 . A hanging hook (not shown in the figure) is adapted on one end of the plurality of twisted ropes 171 of the hoist mechanism 17 , respectively. Thereby, the hanging hooks are hooked on the plurality of hanging ears of the first crucible 12 . Thus, the connection between the hoist mechanism 17 and the first crucible 12 is secured.
[0026] Another significant technological breakthrough of the present invention is to recycle the residual liquid, and thereby a method and apparatus for continuously manufacturing high-purity magnesium-nickel hydrogen storage alloy is developed. FIG. 2F shows a schematic diagram of the apparatus in the step S 16 according to a preferred embodiment of the present invention. As shown in the figure, after the first crucible 12 is drawn out from the heating device 14 , the step S 16 is executed for putting the second crucible 18 loaded with the residual liquid 116 into the heating device 14 by using the hoist mechanism 17 . Then, the steps S 10 through S 16 are executed repeatedly for continuously manufacturing high-purity magnesium-nickel hydrogen storage alloy 114 . The first and the second crucibles 12 , 18 are used alternately owing to continuous manufacturing.
[0027] While manufacturing continuously, the second and thereafter manufacturing cycles differ from the first manufacturing cycle in that, in the second and thereafter manufacturing cycles, in order to increase productivity of high-purity magnesium-nickel hydrogen storage alloy 114 , the amount of added nickel powders can be increased from the preset range of 23.5% and 50.2% up to 54.6%. The condition still gives high-purity magnesium-nickel hydrogen storage alloy 114 without other phases. Because the residual liquid 116 is a magnesium-rich liquid, which is an excellent composition adjuster, the nickel composition of the magnesium-nickel liquid 112 can be maintained within the range of 20 to 55 wt % without precise and accurate control of chemical composition.
[0028] FIG. 3 shows a schematic diagram of the apparatus according to another preferred embodiment of the present invention. As shown in the figure, the present invention provides an apparatus for manufacturing high-purity magnesium-nickel alloy and comprising a vacuum chamber 10 , a first crucible 12 , a heating device 14 , a stirring device 16 , a second crucible 18 , a hoist mechanism 17 , a water-cooled copper base 100 with recycling cooling water, and a material feeding tube 104 . The vacuum chamber 10 according to the present preferred embodiment is divided into a precipitation chamber 101 and a crucible in/out chamber 103 . One or more isolation valves 102 are adapted between the precipitation chamber 101 and the crucible in/out chamber 103 , so that the precipitation chamber 101 can be maintain in vacuum or in the inert gas no matter separation or crucible in/out is undergoing.
[0029] The first crucible 12 , the heating device 14 , the stirring device 16 , the hoist mechanism 17 , the water-cooled copper base 100 , and the material feeding tube 104 are set in the precipitation chamber 101 of the vacuum chamber 10 . The first crucible is set on the heating device 14 . The stirring device is set on top of precipitation chamber 101 of the vacuum chamber 10 , and facing the first crucible 12 . The hoist mechanism 17 is also set on top of precipitation chamber 101 of the vacuum chamber 10 . The water-cooled copper base 100 is set on one side of the first crucible 12 . The material feeding tube 104 penetrates the vacuum chamber 10 .
[0030] According to the present invention, place a raw material of magnesium to the first crucible 12 on the crucible in/out chamber 103 of the vacuum chamber 10 , and gas an inert gas to the vacuum chamber 10 . Use the hoist mechanism 17 to put the first crucible 12 loaded with the raw material of magnesium to the precipitation chamber 101 filled with the inert gas and into the heating device 14 . The heating device 14 heats the first crucible 12 loaded with the raw material of magnesium, melts the raw material of magnesium to a magnesium liquid. Then, through the material feeding tube 104 penetrating the vacuum chamber 10 , nickel powders are added into the first crucible 12 loaded with the magnesium liquid. By using the heating device 14 , the first crucible 12 loaded with the nickel powders and the magnesium liquid. Besides, the stirring device 16 is used for stirring, so that the nickel powders are melt in the magnesium liquid to produce a magnesium-nickel liquid. Next, control the temperate of the heating device 14 to fall within a temperature range for the magnesium-nickel liquid to precipitate a solid-state magnesium-nickel hydrogen storage alloy. Finally, separate the residual liquid in the first crucible from the precipitated solid-state magnesium-nickel hydrogen storage alloy. First, place a raw material of magnesium in the second crucible 18 and put it to the precipitation chamber 101 of the vacuum chamber 10 . Use the hoist mechanism 17 , which is capable of inclining, to put the first crucible 12 loaded with residual liquid to the second crucible 18 , and put the first crucible 12 on the water-cooled copper base 100 in the precipitation chamber 101 . The water-cooled copper base 100 cools the solid-state magnesium-nickel hydrogen storage alloy in the first crucible 12 . After cooling, use the hoist mechanism 17 to pick the first crucible 12 out, and take the solid-state magnesium-nickel hydrogen storage alloy from the first crucible 12 . The water-cooled copper base 100 is adapted in the precipitation chamber 101 . Because the activity of magnesium-nickel hydrogen storage alloy is very high, it tends to react with oxygen or even ignite, deteriorating its characteristics and producing dangers, it is necessary to cool sufficiently before drawing out from the precipitation chamber 101 in vacuum or filled with the inert gas. In mass production, for example, smelt above hundreds of kilograms or tons, the cooling rate of nature cooling is insufficient, and thus limiting the production efficiency. Thereby, the water-cooled copper base is equipped in the precipitation chamber 101 . By taking advantage of the excellent heat-sinking characteristic of copper, the first crucible loaded with high-purity solid-state magnesium-nickel hydrogen storage alloy can be quenched rapidly.
[0031] To sum up, the present invention provides a method and apparatus for manufacturing high-purity magnesium-nickel hydrogen storage alloy, which can be used for manufacturing high-purity magnesium-nickel hydrogen storage alloy with superior hydrogen absorption-desorption dynamics without the need of adopting costly and delicate equipments. In addition, the residual liquid after precipitation reaction can be recycled and high-purity magnesium-nickel hydrogen storage alloy with superior hydrogen absorption-desorption dynamics can be manufactured continuously.
[0032] Accordingly, the present invention conforms to the legal requirements owing to its novelty, non-obviousness, and utility. However, the foregoing description is only a preferred embodiment of the present invention, not used to limit the scope and range of the present invention. Those equivalent changes or modifications made according to the shape, structure, feature, or spirit described in the claims of the present invention are included in the appended claims of the present invention.
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The present invention provides a method and apparatus for manufacturing high-purity hydrogen storage alloy Mg 2 Ni applicable to industry and capable of manufacturing continuously. First, raw materials of magnesium-nickel with weight percentage of nickel between 23.5 and 50.2 are heated, melt, and mixed uniformly. Cool the magnesium-nickel liquid and control the temperature to be above the solidification temperature and below the liquification temperature in the phase diagram of magnesium-nickel. By making advantage of segregation principle in phase diagrams, solid-state high-purity γ-phase Mg 2 Ni hydrogen storage alloy is given. The residual waste magnesium-rich liquid in the crucible is poured to another independent crucible, and switch with the position of the crucible originally containing the γ-phase Mg 2 Ni hydrogen storage alloy. Then, new raw materials of magnesium and nickel are added and heated. Repeat the smelt steps described above continuously, and a continuous manufacturing method is introduced. After the original crucible is cooled, the solid substances at the bottom of the crucible can be tapped down without further special treatments. Then high-purity γ-phase Mg 2 Ni hydrogen storage alloy with atomic ratio of 2:1, no other phases, and with excellent hydrogen absorption-desorption dynamics is given.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This Application is a Divisional of prior application Ser. No. 10/413,962 filed on Apr. 15, 2003, currently pending, to Paul S. Westbrook. The above-listed Application is commonly assigned with the present invention and is incorporated herein by reference as if reproduced herein in its entirety under Rule 1.53(b).
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates to a method and apparatus for measuring the polarization of light.
BACKGROUND OF THE INVENTION
[0003] High-speed optical fiber communication systems operate by encoding information (data) onto lightwaves that typically propagate along optical fiber paths. Most systems, especially those used for medium to long distance transmission employ single mode fiber. As implied by the name, single mode fibers propagate only one mode of light below cutoff. The single mode typically includes many communications channels. The communications channels are combined into the one transmitted mode, as by wavelength division multiplexing (WDM) or dense wavelength division multiplexing (DWDM).
[0004] While only one mode is transmitted, that mode actually comprises two perpendicular (orthogonal) polarizations. The polarization of these two components varies undesirably as the waves propagate along a fiber transmission path. The distortion of the optical signals caused by the varying polarization is called polarization mode dispersion (PMD). PMD can be corrected through a combination of measurements of the PMD and the control of active corrective optics.
[0005] Polarimeters measure the polarization of light. Polarimeters can generate signals representing a measured degree of polarization that can be useful for diagnostic purposes. The signals can also be advantageously used for polarization correction using feedback techniques to minimize PMD.
[0006] Polarimeters generally employ one or more photodetectors and related electro-optical components to derive basic polarization data. The raw photodetector signal measurements are typically transformed by mathematical techniques into standard polarization parameters. In the prior art, the photodetector outputs are generally averaged, as by some electronic time constant, and then multiplied as part of the signal processing and transformation process. The problem with averaging at detection is that instantaneous temporal information lost through averaging cannot be retrieved later.
[0007] What is needed for more accurate polarization measurements is a polarimeter that instantaneously measures polarimeter photodetector outputs without averaging, multiplies the unaveraged signals early in signal processing, and then averages and transforms the signals into polarimetry parameters.
SUMMARY OF THE INVENTION
[0008] An improved method and apparatus for the measurement of the polarization of light uses nonlinear polarimetry. The higher order moments of the E field are measured and then transformed into standard polarimetry parameters yielding the polarization of the light. In a first embodiment, the light to be measured is transmitted through a rotating retarder capable of rotating at a plurality of angles with at least two retardances Δ. The retarder is optically coupled to a fixed analyzer. The light from the analyzer is then detected by linear and nonlinear photodetectors. The spectra from the detectors is calculated and transformed, to obtain the polarization. In a second embodiment, the light to be measured is received by an optical fiber comprising a plurality of fiber birefringences to retard the light. Polarization sensitive gratings along the length of the fiber scatter the light, and photodetectors detect the scattered light. The signals from the photodetectors can then be transformed to obtain the polarization.
[0009] Apparatus in two preferred embodiments can perform the inventive method. In the first embodiment, nonlinear and linear photodetectors are preceded by a rotating retarder, rotating at a plurality of angles with a retardance, and an analyzer, such as a fixed polarizer. In the second preferred apparatus, a plurality of photodetectors are located adjacent to polarization sensitive gratings situated in a birefringent optical waveguide located between each of the polarization sensitive gratings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The advantages, nature and various additional features of the invention will appear more fully upon consideration of the illustrative embodiments now to be described in detail in connection with the accompanying drawings. In the drawings:
[0011] FIG. 1 shows an apparatus to perform the method of nonlinear polarimetry;
[0012] FIG. 2 shows an alternative apparatus to perform the method of nonlinear polarimetry using optical fiber and polarization sensitive gratings;
[0013] FIG. 3 shows an apparatus as in FIG. 1 , including a linear and a nonlinear detector;
[0014] FIG. 4 shows a detector arrangement comprising a linear and a nonlinear detector;
[0015] FIG. 5 shows a first preferred embodiment of an apparatus to perform the method of nonlinear polarimetry; and
[0016] FIG. 6 shows a second preferred optical fiber apparatus to perform the method of nonlinear polarimetry.
[0017] It is to be understood that the drawings are for the purpose of illustrating the concepts of the invention, and except for the graphs, are not to scale.
DETAILED DESCRIPTION
[0018] This description is divided into two parts. Part I describes the inventive method for polarimetry and two embodiments for making polarization measurements according to the inventive method. For those skilled in the art, Part II further develops, defines, and introduces the concepts of invariance, state of polarization and degree of polarization, and the foundation equations governing nonlinear polarimetry as best understood by applicants at the time of the invention.
[0000] Part I: Nonlinear Polarimetry
[0019] Standard polarimeters use linear detectors and thus measure terms quadratic in the E field. These can be considered 2 nd order moments of the E field and are related to the power and the Stokes parameter of the E-field. A detector measuring intensity squared, though would measure 4 th order moments of the E field. Such higher order moments can have more information about the E-field. Simply put, a higher order moment of some time varying quantity is simply the time average of a higher power of the quantity. The first power is always just the mean. The second power is the standard deviation and so on.
[0020] Nine moments of the E field can be measured with apparatus 10 as shown in FIG. 1 . Incoming light 11 is retarded by retarder 12 at angle C, with a retardance of Δ. Analyzer A 13 is a polarizer that precedes the nonlinear detector as represented by photodiode 14 . This apparatus can be accomplished using bulk optics or integrated electro-optical techniques.
[0021] Retarder 12 is an optical component that retards one polarization with respect to the orthogonal polarization. In terms of E fields, the retarder gives one of the polarizations a phase with respect to the other orthogonal E component. Examples are ½ λ or ¼ λ retarders.
[0022] A ¼ λ wave retarder causes a
π 2
delay difference:
Δ = ( 1 4 λ λ ) 2 π = π 2
[0023] Similarly, a ½ λ wave retarder causes a delay difference of π:
Δ = ( 1 2 λ λ ) 2 π = π
[0024] Here, the retarder 12 is a generic retarder. It has an arbitrary angle and arbitrary phase retardance. The angle C sets the two linear states of polarization on which the phase difference Δ is applied.
[0025] Analyzer 13 is a polarizer. It passes the light of polarization A, and suppresses all other polarizations. By rotating analyzer 13 , light of polarization A is a continuous sampling of all 2π polarizations. A detector viewing the light output of a continuously rotating analyzer registers a periodic waveform. The Fourier spectra of that waveform contains a DC component (near 0), and all other components of the spectra.
[0026] A preferred alternative version of this embodiment rotates retarder 12 , with a fixed analyzer 13 to generate the sine and cosine quadrature components of the Fourier spectra of the detector output. These components yield the nine E field higher order components.
[0027] The response of the nonlinear detector is:
V detector = I optical 2 = [ E x 2 + E y 2 ] 2
A linear detector would measure:
I = 1 2 [ S 0 + [ S 1 cos 2 C + S 2 sin 2 C ] cos 2 ( A - C ) + [ S 2 cos 2 C + S 1 sin 2 C ] sin 2 ( A - C ) cos Δ + S 3 sin 2 ( A - C ) sin Δ ) ]
[0028] The nonlinear detector would measure I 2 , and the filter in the DC electronics would determine an averaging time, as in the linear case:
V detector = ∫ T RC ⅆ tI 2 = ⋯ 〈 S 0 S 1 〉 T RC ⋯
[0029] All nine components can be measured if one rotates both analyzer A and retarder C in a manner analogous to the linear Stokes case. By performing measurements at the different sum and difference frequencies proportional to nine linearly independent superpositions of S i S j , a 9×9 inversion matrix may then be applied to calculate the nine moments.
[0030] For the nonlinear polarimeter one would toggle between:
A = π 4 + ɛ 1 , Δ = π 4 + ɛ 2 where ɛ 1 and ɛ 2 are small
and
A = π 4 and Δ = π 4
and rotate C at a fixed rate. Then the nine moments can be extracted from the nine (quadrature) components: 1 (DC), cos2C, sin2C, cos4C, sin4C, cos6C, cos8C, sin8C. However, it can be advantageous to have more oscillating components, since it is less desirable to measure at a frequency that appears in the DC or non-oscillating response as this would be subject to DC noise.
[0031] A static measurement of the moments can also be done with apparatus 20 as shown in FIG. 2 , but with polarization sensitive gratings 22 and fiber birefringences 23 for the retarder. Here nonlinear detectors 24 detect the light scattered by polarization sensitive gratings 22 . Birefringent optical fiber 23 causes the birefringences. In the limit of weak scattering for each grating, the scattered E-field is the same as in the case of the retarder and the analyzer. As before, there are nine detectors and a resultant 9×9 matrix to connect the detector values to the moments.
[0032] Here each grating with its nonlinear detector 24 will generate an output signal which is proportional to a linear transformation of the Stokes parameters. Each detector 24 signal is linearly related to a Stokes tensor component. Therefore with proper grating 22 alignments, the nine detector 24 outputs have a linear relationship with the nine Stokes tensor components. Gratings 22 are each aligned in different directions. Gratings 22 are each aligned azimuthally about the axis of the optical fiber. Both the grating 22 alignments and birefringences are aligned such that the 9×9 calibration matrix is invertible.
[0033] The measured moments have several uses. The degree of polarization (DOP) is most useful with the Stokes vector because it does not depend on the SOP. That is you can bump the fiber, and the DOP will not change. In other words, the DOP is invariant (see definition of invariant later in Part II) under unitary or lossless transformations. This makes it valuable as a monitoring quantity since a fiber bump does not change it, at least not as much as a bump causes a change in S 1 or S 2 . The higher order moments also have invariants. To understand the invariance of S i S j , remember that S 1 S 2 S 3 is a vector and unitary transformations correspond to a rotation on the Stokes sphere R ij . With the higher order moments then, ( S 0 S 1 , S 0 S 2 , S 0 S 3 ) transforms as a vector. Therefore their magnitudes are fixed and:
∑ 1 3 〈 S 0 S i 〉 〈 S 0 S i 〉
is invariant.
[0034] But, there are more terms, since S i S j =T ij is a tensor
∑ i = 1 3 ∑ j = 1 3 T ij T ij
is also invariant.
A proof of this is shown as follows (All duplicate indices are summed from 1 to 3):
Rotation of the Stokes tensor: T ij ′R im R jn =T mn , invariant:
T ij T ij = T ij ′
R im R jn T kl ′
R k m R i n = T ij ′ T kl ′ R im R mk - 1 R jn R nl - 1 =
R mk - 1 R nl - 1 ( these are 3 ⨯ 3 rotation matrices )
= ɛ ij T ij ′ T ij ′
Another invariant is:
∑ 1 3 T ii T ii ,
and one can also get invariants from the determinants: det(T ij ), where i,j=1,2,3. Therefore a list of some invariants is:
∑ i , j = 1 3 T ij 2 , ∑ j = 1 3 T 0 j 2 , ∑ j = 1 3 T jj 2 ,
and det(T ij ) where i,j=1,2,3. These invariants can all represent useful monitoring quantities. Since higher moments are usually most interesting when combined with the lower moments to give fluctuations of the E-field, it would be useful to build in the same linear measurement done in normal polarimetry.
[0035] FIG. 3 shows an apparatus to accomplish this measurement comprising incoming light 31 retarded by retarder 32 at angle C, with retardance Δ. Analyzer A 33 comprises coupler 36 , and nonlinear and linear photon detector 34 and 35 . The response of detectors is V l =k l I for detector 34 , and V l =k l I 2 for detector 35 . By building four more gratings into the device of FIG. 3 , for a total of 13 gratings, the averages can be subtracted from higher order moments.
[0036] Using such an embodiment, one can measure aV l 2 −V l , where a is such that when the signal is constant, aV l 2 −V n =0, then V n −aV l 2 ≧0, since intensity fluctuations always make I 2 > I 2 . DOP=0 gives the extreme case, since the linear detector is constant in this case.
[0037] An important advantage to having both a linear and nonlinear detector is that the nonlinear detector can be “nonlinearized” by subtracting out the linear part. This is illustrated by FIG. 4 , where the response to light 41 of detector 34 is V l =CI, and the response of detector 35 is V n =aI 2 +bI. Thus:
V nonlinear quadratic = cV n - bV 1 aacI 2 .
This would allow for lower powers to be used with the nonlinear detector. Of course the noise would still be as large as it is for one detector, but one could extend the nonlinear concept previously discussed and measure the linear and nonlinear moments simultaneously. This embodiment of the invention needs nine nonlinear (quadratic) and four linear detectors. The 13 detectors would have a linear relationship to the 13 linear and quadratic moments as related by a 13×13 matrix. Rotating polarizers or static birefringence can be used.
Examples
[0038] FIG. 5 shows a first preferred embodiment of the nonlinear polarimeter. Here, rotating retarder 52 receives light 31 . Fixed polarizer 53 is optically coupled to rotating retarder 52 and coupler 36 . Coupler 36 splits the light from fixed polarizer 53 to the two photodetectors, linear detector 34 and nonlinear detector 35 . This embodiment can be accomplished in bulk optics or by using integrated electro-optics fabrication techniques.
[0039] FIG. 6 shows a second preferred embodiment of a nonlinear polarimeter to accomplish static measurement of the moments. Here, fiber 23 receives light 31 . The light from polarization sensitive gratings 22 is detected by four linear detectors 34 and nine nonlinear detectors 35 . Each polarization sensitive gratings 22 has a different scattering angle. Birefringent optical fiber 23 causes the birefringences. In the limit of weak scattering for each grating, the scattered E-field is the same as in the case of specific retarder and the analyzer positions. As before, there are nine detectors and a resultant 9×9 matrix to connect the detector values to the moments. This embodiment can be fabricated with optical fibers and fiber components or by integrated electro-optic fabrication techniques. Here the additional four detector outputs yield a 13×13 calibration matrix. The polarization sensitive gratings' 22 scattering angles and the sections of birefringent optical fiber 23 are set such that the 13×13 calibration matrix is invertible.
[0040] Actual fabrication forms and techniques suitable for constructing the inventive apparatus in general, includes, but is not limited to, bulk optical components, optical fibers and optical fiber components, and integrated techniques, including planer waveguides, and other integrated optical components.
[0000] Part II: Theoretical Development of Nonlinear Polarimetry Including the Definition of Invariance
[0041] Invariance: A polarization transformation is said to be invariant when there is a polarization transformation in which the two principle states are delayed by less than the coherence length of the light. This is an invariant transformation. In mathematical terms:
[0042] ∫dtE 1 (t)E 2 (t+τ c )≠0, τ c =correlation time, E 1 , E 2 are principal states, and τ invariant <<τ c . In short: Invariant=unitary with τ<τ c where τ is the maximum time delay between polarization components. Also the ratio of the two principle states must remain fixed, i.e., the “fiber touch” cannot be before a large PMD element such as a fiber link, since changing the launch polarization into a fiber with PMD will change the ratio of the two principle states and hence alter the output pulse shape and its higher order moments. The “fiber touch” that we wish to avoid being sensitive to through the use of invariants is that directly before the polarization monitor. With standard polarimeters the only invariants are the total power and the DOP.
[0043] State of polarization and Degree of Polarization: It is useful to provide a clear definition of “state of polarization” (or SOP), with respect to an optical signal propagating through a fiber. In general, if the core-cladding index difference in a given optical fiber is sufficiently small, then the transverse dependence of the electric field associated with a particular mode in the fiber may be written as:
E ( z,t )= {circumflex over (x)}A x exp ( iφ x )+ ŷA y exp ( iφ y )
where A x and A y define the relative magnitude of each vector component and the phases are defined as follows:
φ x =βz−ωt+φ 0 , and
φ y =βz−ωt+φ 0 −δ,
where β defines the propagation constant, ω defines the angular frequency, φ 0 defines an arbitrary phase value, and δ is the relative phase difference between the two orthogonal components of the electric field.
[0044] In accordance with the teachings of the present invention, the state of polarization (SOP) of an optical fiber will be described using the Jones calculus and the Stokes parameters, since these are both complete and commonly used. The Jones vector J that describes the field at any location z or point in time t is given by the following:
J= ( A x exp ( iφ x ), A y exp ( iφ y ))= exp ( iφ x )( A x ,A y exp (− i δ)).
In practice, the factor exp(iφ x ) is ignored, so that the state of polarization is described by the three main parameters: A x , A y and δ. The physical interpretation of these three parameters is most commonly based on the polarization ellipse, which describes the path traced out by the tip of the electric field vector in time at a particular location, or in space at a particular time. It should be noted that the Jones vector description is valid only for monochromatic light, or a single frequency component of a signal.
[0045] A more complete description of the state of polarization is based on the defined Stokes parameters, since this method also accounts for the degree of polarization (DOP) of a non-monochromatic signal. In terms of the Jones vector parameters, the four Stokes parameters are defined by:
S 0 =A x 2 +A y 2
S 1 =A x 2 −A y 2
S 2 =2 A x A y cos δ
S 3 =2 A x A y sin δ,
and the degree of polarization (DOP), 0≦DOP≦1, is defined to be:
DOP = S 1 2 + S 2 2 + S 3 2 S 0 .
A partially polarized signal can be considered to be made up of an unpolarized component and a polarized component. The DOP is used to define that fraction of the signal which is polarized, and this fraction may be described by either the polarization ellipse or Jones vector. It is to be noted that, in strict terms, there are four parameters that fully describe the elliptical signal: (1) the shape of the ellipse; (2) the size of the ellipse; (3) the orientation of the major axis; and (4) the sense of rotation of the ellipse. Thus, four measurements can unambiguously define the signal. These four parameters are often taken to be A x , A y , the magnitude of δ, and the sign of δ. The four Stokes parameters also provide a complete description of fully as well as partially polarized light. The Jones vector may be derived from the Stokes parameters according to:
A x =√{square root over ( S 0 +S 1 )}/√{square root over (2)}
A y =√{square root over ( S 0 −S 1 )}/√{square root over (2)}
δ=arctan( S 3 /S 2 )
It is to be noted that the last equation above does not unambiguously determine δ. Most numerical implementations of θ=arctan(x) define the resulting angle such that −π/2<θ<π/2. Thus, for S 2 ≧0, the expression δ=arctan(S 3 /S 2 ) should be used, where as for S 2 <0, the expression δ=arctan(S 3 /S 2 )±π should be used. Therefore, with the knowledge of the four Stokes parameters, it is possible to fully determine the properties of the polarized signal.
[0046] It has been recognized in accordance with the teachings of the present invention that the full state of polarization (SOP) cannot be determined by merely evaluating the signal passing through a single polarizer. Birefringence alone has also been found to be insufficient. In particular, a polarimeter may be based on a presumption that the optical signal to be analyzed is passed through a compensator (birefringent) plate of relative phase difference Γ with its “fast” axis oriented at an angle C relative to the x axis (with the light propagating along the z direction). Further, it is presumed that the light is subsequently passed through an analyzer with its transmitting axis oriented at an angle A relative to the x axis. Then, it can be shown that the intensity I of the light reaching a detector disposed behind the compensator and analyzer can be represented by:
I ( A,C,Γ )=½{ S 0 +S 1 [cos(2 C )cos(2[ A−C ])−sin(2 C )sin(2[ A−C ])cos(Γ)]+ S 2 [sin(2 C )cos(2[ A−C ])+cos(2 C )sin(2[ A−C ])cos(Γ)]+ S 3 sin(2[ A−C ])sin(Γ)}.
In this case, S j are the Stokes parameters of the light incident on the compensator, such that S 0 is the incident intensity. If the compensator is a quarter-wave plate (Γ=π/2), then the intensity as defined above can be reduced to:
I ( A,C,π/ 2)=½{ S 0 +[S 1 cos(2 C )+ S 2 sin(2 C )]cos(2[ A−C ])+ S 3 sin(2[ A−C ])}
whereas if the compensator is removed altogether (Γ=0), the equation for the intensity I reduces to:
I ( A,−, 0)=½−{ S 0 +S 1 cos(2 A )+ S 2 sin(2 A )}.
This latter relation illustrates conclusively that it is impossible, without introducing birefringence, to determine the value of S 3 , and hence the sense of rotation of the polarization ellipse.
[0047] Following from the equations as outlined above, a polarimeter may be formed using a compensator (for example, a quarter-wave plate), a polarizer, and a detector. In particular, the following four measurements, used in conventional polarimeters, unambiguously characterize the Stokes parameters:
1) no wave plate; no polarizer→I(−,−,0)=S 0 2) no wave plate; linear polarizer along x axis→I(0,−,0)=½(S 0 +S 1 ) 3) no wave plate; linear polarizer at 45°→I(45,−,0)=½(S 0 +S 2 ) 4) quarter-wave plate at 0°; linear polarizer at 45°→I(45,0,π/2)=½(S 0 +S 3 ).
In a conventional polarimeter using this set of equations, the measurements may be performed sequentially with a single compensator, polarizer and detector. Alternatively, the measurements may be performed simultaneously, using multiple components by splitting the incoming beam of light into four paths in a polarization-independent fashion.
Nonlinear Polarimeters:
[0052] Standard polarimeters measure the degree of polarization (DOP), or Stokes parameters that represent the polarization, by taking time averaged measurements of the x and y components of the E-field as represented by:
S 1 =E x E x *−E y E y *
But, higher order moments can be measured as well as:
E x E x *E x E x * or E y E y *E y E y *
[0053] A nonlinear polarimeter is a device that measures the higher order moments. These measurements can provide extra information about the bit stream or any polarized or partially polarized signal.
[0054] The number of moments that can be measured can be determined in two ways. The E-field representation as mentioned above is one way:
[0000] Define (m, n) where m=#E x 's and n=#E y 's
[0000] This gives 1×(4,0)+1×(0,4)+2(1,3)+2(3,1)+3(2,2)=9 or
E x E x *E x E x * E y E y *E y E y * E x E y *E y E y * E y E x *E y E y * E x E x *E y E x * E x E x *E x E y * E x E y *E x E y * E y E x *E y E x * E x E x *E y E y *
[0055] Alternatively, the un-averaged Stokes products S i S j can be constructed. These are the 2 nd order moments before averaging:
S 0 S 1 =( E x E x *+E y E y *)( E x E x *−E y E y *)
They are linear superpositions of the four product E field averages. The independent quantities are: S 0 S 1 , S 0 S 2 , S 0 S 3 , S 1 S 1 , S 2 S 2 , S 3 S 3 ,S 1 S 2 , S 2 S 3 , S 3 S 1 . Again there are nine higher order moments. Note that these are not the same as Stokes parameters:
S 1 S 2 ≠ S 1 S 2
Also, S 0 S 0 is not independent, because before averaging DOP=1, therefore, before time averaging, S 0 S 0 =S 1 S 1 +S 2 S 2 +S 3 S 3 .
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A method of nonlinear polarimetry for measuring higher order moments of the E field of an optical signal is provided. The method includes imposing a phase delay on a first polarization of a received optical signal with respect to a second polarization of the optical signal to produce an intermediate optical signal having a time varying polarization. A polarization of the intermediate optical signal is suppressed. The intermediate optical signal is detected with a plurality of photodetectors, with at least one photodetector configured to be responsive to a nonlinear optical process. Spectra of the photodetector outputs are calculated to determine higher order moments of the E field, and the moments are transformed to obtain the polarization measurement.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a divisional of U.S. application Ser. No. 08/529,014, filed on Sep. 15, 1995, now U.S. Pat. No. 5,972,223, the disclosure of which is incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to methods and apparatus for preparing solutions for medical purposes. More particularly, the present invention relates to such methods and apparatus for preparing dialysis solutions and/or replacement solutions for use in hemodialysis, hemodiafiltration or hemofiltration, as well as other liquids for medical use, such as infusion solutions, peritoneal dialysis solutions, nutritional solutions, and the like. Still more particularly, the invention relates to methods for disinfecting such apparatus and vessels intended for use in such apparatus.
BACKGROUND OF THE INVENTION
In dialysis clinics for hemodialysis, large numbers of patients are treated simultaneously. Each patient is thus connected to a dialysis machine, a so called monitor, which prepares the dialysis solution and administers the solution to a dialyzer, which is connected to the patient.
In monitors which are presently in use, such as the GAMBRO AK-100 monitor, preparation of the dialysis solution normally takes place by mixing two dialysis concentrates to produce a desired composition and concentration.
The dialysis concentrate can be an A-concentrate, which consists of acetic acid, sodium chloride, potassium chloride, calcium chloride and magnesium chloride, and a B-concentrate, consisting of bicarbonate. Reference is made to European Patent No.
B1-0 278 100 for further details thereof.
These concentrates are diluted with water, which is normally obtained from a particular water outlet at each treatment location. The water must be specially treated so that it contains as few impurities as possible, and is normally prepared by the so-called RO (reverse osmosis) process. Such a process is described, for example, in European Patent Nos. B1-0 058 303 and BI-0 058 304.
The water is usually purified at a central location, and is conducted to each patient location in a particular conduit system which is constructed with the intention of reducing the possibilities of bacterial contamination. Furthermore, the conduit system is regularly disinfected by feeding warm water, at a temperature above 90° C., through the system.
German Patent No. A1-34 43 911 describes a method and an apparatus for the batchwise preparation of a dialysis solution consisting of common salt, magnesium, calcium, potassium and glucose by mixing with so-called "zero-conductivity water," i.e., purified water, in a large tank. The thus-prepared dialysis solution is then drained into containers of about 10 liters each, and placed at the dialysis clinic's disposal to form the above-mentioned A-concentrate after the addition of acid (which can take place in the monitor itself). The disadvantage with this process is that heavy concentrate-containing containers must be physically handled by the personnel and transported or carried to each patient location.
German Patent No. C2-42 03 905 describes the distribution of a centrally prepared dialysis solution by means of a conduit system. The disadvantage with such central distribution of dialysis solution is that the dialysis solution is a very good nutritional medium for many bacteria. According to German Patent No. C2-42 03 905, a sterile filter is employed, though this can become quite expensive. Furthermore, very effective disinfection of the conduit system is required. The conduits must first be rinsed clean to remove the dialysis solution, after which hot water or other disinfecting agents are circulated through the conduits.
SUMMARY OF THE INVENTION
One object of the present invention is to propose a practical and useful method and apparatus for centrally preparing solutions or concentrates intended for dialysis or similar medical purposes.
A saturated concentrate solution of sodium chloride, common salt, is a very poor nutritional medium for bacteria, and only a small number of bacteria are known which can survive in such an environment, i.e., so-called halo bacteria.
In addition, a saturated common salt solution may be heated to high temperatures without its properties or solubility being altered.
It has also been shown to be possible to continuously prepare a saturated common salt solution starting from a large quantity of common salt in powder form by means of passing water through the quantity of powder. If the grain size of the common salt crystals lies within a predetermined range, no formation of lumps of common salt occurs even with very large quantities of salt, something which otherwise could be expected. (See European Patent No. B1-0 278 100).
In accordance with the present invention, these objects have now been realized, and the characteristics discussed above have now been utilized by the invention of a method for the central preparation and distribution of a concentrate to a plurality of medical treatment devices comprising supplying a liquid stream comprising substantially only water to a central container including substantially only a single salt composition at least partially in solid form therein, producing a substantially saturated solution of said salt composition in said central container, and distributing said salt solution to a distribution conduct, the distribution conduct including a plurality of concentrate connectors whereby the salt solution can be distributed to the plurality of medical treatment devices.
In accordance with one embodiment of the method of the present invention, the method includes preparing a medical treatment solution from the salt solution in each of the plurality of medical treatment devices. Preferably, the medical treatment solutions include dialysis solutions and replacement solutions for hemodialysis, hemofiltration and hemodiafiltration.
In accordance with another embodiment of the method of the present invention, the method includes heating the liquid stream or the substantially saturated solution of the salt composition to an elevated temperature whereby the salt solution is distributed to the distribution conduit at that elevated temperature.
In accordance with another embodiment of the method of the present invention, the method includes adding a separate substance to the salt solution, preferably acetic acid.
In accordance with one embodiment of the method of the present invention, the medical treatment solution comprises a dialysis solution and the plurality of medical treatment devices comprises a plurality of dialysis machines, and the method includes diluting the substantially saturated salt solution and adding carbon dioxide gas to the substantially saturated salt solution prior to distributing the salt solution to the distribution conduit.
In accordance with another embodiment of the method of the present invention, the method includes distributing the salt solution to the distribution conduit at an elevated pressure.
In accordance with another aspect of the present invention, a method of disinfecting an apparatus for the central preparation and distribution of a concentrate to a plurality of medical treatment devices has been devised, comprising a central concentrate container for preparation of a substantially saturated solution of substantially only a single salt composition and distribution means for distributing the salt solution to a plurality of concentrate connectors whereby the salt solution can be distributed to the plurality of medical treatment devices, the method comprising circulating the salt solution in a recirculation circuit including the distribution means and heating the salt solution to an elevated temperature in order to disinfect the recirculation circuit thereby. Preferably, the method includes recirculating the salt solution in the recirculation circuit at an elevated pressure.
In accordance with the apparatus of the present invention, apparatus for the central preparation and distribution of a concentrate to a plurality of medical treatment devices has been devised, comprising central concentrate preparation means for preparing a substantially saturated solution of substantially only a single salt solution from the salt at least partially in solid form and a supply of water, inlet means for supplying the water to the central concentrate preparation means, and conduit means for supplying the salt solution to a distribution conduit for distribution to the plurality of medical treatment devices. In a preferred embodiment, the central concentrate preparation means comprises at least one container for the salt at least partially in solid form.
In accordance with another embodiment of the apparatus of the present invention, the plurality of medical treatment devices comprises a plurality of dialysis machines, and preferably the at least one container includes salt in an amount of at least about 10 kg, preferably greater than about 20 kg, and more preferably greater than about 40 kg.
In accordance with another embodiment of the apparatus of the present invention, the salt comprises sodium chloride in a particulate form, and preferably the particles of sodium chloride have a particle size of between about 50 and 200 μm.
In accordance with another embodiment of the apparatus of the present invention, the central concentrate preparation means includes a water tank, and the inlet means includes a water supply conduit for supplying the water from the water tank to at least one container for the salt, return conduit means for returning the salt solution to the central concentration means, and pump means for pumping the salt solution to the conduit means. In a preferred embodiment, the apparatus includes pressure means for measuring the pressure downstream of the at least one container and upstream of the pump means. In another embodiment, the apparatus includes concentrate meter means for measuring the concentration of the salt in the salt solution upstream of the conduit means, and valve means for selectively diverting the salt solution for disposal based upon the reading of the concentrate meter means.
In accordance with another embodiment of the apparatus of the present invention, the apparatus includes metering means for metering an additional substance into the water or the substantially saturated salt solution in the central concentrate preparation means. In a preferred embodiment, the additional substance is an acid, preferably acetic acid, or carbon dioxide.
In accordance with another aspect of the present invention, a container is provided for use in an apparatus for the central preparation and distribution of a concentrate to a plurality of medical treatment devices comprising central concentrate preparation means for preparing a substantially saturated salt solution of substantially only a single salt composition from the salt at least partially in solid form and a supply of water, inlet means for supplying the water to the central concentrate preparation means, and conduit means for supplying the salt solution to the distribution conduit for distribution to the plurality of medical treatment devices, the container for incorporation into the central concentrate preparation means including sodium chloride in particle form in a quantity of at least about 10 kg, the container including inlet means for the water and outlet means for the substantially saturated salt solution, the inlet means including first connecting means and the outlet means including second connecting means, the first and second connecting means being compatible with each other. In a preferred embodiment, the container includes more than about 20 kg of the sodium chloride in particulate form, and more preferably more than about 40 kg of the sodium chloride in particulate form. In another preferred embodiment, the first connecting means comprises male connecting means and the second connecting means comprises female connecting means.
In accordance with another aspect of the present invention, apparatus is provided for disinfecting a device for the central preparation and distribution of a concentrate to a plurality of medical treatment devices comprising a central concentrate container for preparation of a substantially saturated solution of substantially only a single salt composition, distribution means for distributing the salt solution to a plurality of concentrate connectors whereby the salt solution can be distributed to the plurality of medical treatment devices, and recirculation means for recirculating the salt solution, the recirculation means including distribution means, heating means for heating the salt solution to an elevated temperature to disinfect the recirculation circuit, a pressure meter for measuring the pressure in the recirculation circuit, and a concentrate measuring means for measuring the concentrate of the salt solution. Preferably, the concentration measuring means comprises a conductivity meter. In another embodiment, the apparatus includes bypass means for bypassing the concentrate container during the disinfecting. In a preferred embodiment, the recirculation means comprises a closed system, whereby an elevated pressure can be maintained within the recirculation means.
In accordance with the present invention, there is thus provided a method for centrally preparing and distributing a concentrate of substantially only one salt in water for preparation of a medical solution starting from the concentrate. This includes medical solutions such as dialysis solutions and/or replacement solutions for hemodialysis, hemofiltration or hemodiafiltration. In accordance with this invention, the method includes supplying primarily water to a container containing the salt at least partially in solid form, removing a substantially saturated concentrate of the salt in water from the container, and distributing the concentrate to a distribution conduit and concentrate connectors arranged thereon, for preparation of the medical solution. The concentrate and/or water may be heated to a high temperature for distribution of the concentrate at said temperature to the distribution conduit. It is also possible to add a substance such as acetic acid to the concentrate or the water.
In an alternative embodiment of this invention, the concentrate is diluted to a suitable concentration for the dialysis solution, and carbon dioxide gas may be added before distribution to the distribution conduit.
In accordance with the present invention, there is also provided apparatus for carrying out the above-mentioned method for centrally preparing and distributing a concentrate of substantially only one salt in water, for preparing a medical solution starting from the concentrate, for example dialysis solution and/or replacement solution for hemodialysis, hemofiltration or hemodiafiltration. This apparatus comprises a concentrate generator provided with an inlet for purified water and at least one distribution conduit for distribution of the concentrate to at least one concentrate connector, and further comprising at least one container for the salt which is at least partially in solid form, a conduit for supplying primarily water to the container to form a substantially saturated concentrate of the salt in water in the container by partially dissolving the salt in the water, and a conduit for feeding the concentrate to the distribution conduit. It is preferable that the container contain the salt in a quantity of at least 10 kg, preferably more than 20 kg, and most preferably more than 40 kg. Preferably, the salt is sodium chloride in particle form, which particles have a size between about 50 and 200 μm.
In a preferred embodiment of the apparatus of the present invention, the concentrate generator includes a water tank to which primarily water is fed through an inlet, a conduit for supplying water from the water tank to one of the containers, a return conduit for returning substantially saturated concentrate form the container to the concentrate generator, and a pump for feeding the concentrate solution to the distribution conduit. Furthermore, a pressure meter is preferably arranged in association with the inlet to the pump to detect a pressure downstream of the container, a concentration meter is included for measuring the concentration of the salt in the concentrate before it is fed to the distribution conduit, and a valve for directing the concentrate to a drain should an error arise.
The present invention also relates to a method for disinfecting the above-identified apparatus for the central preparation and distribution of a concentrate of substantially one salt in water, and consisting of a concentrate generator and at least one distribution conduit for distribution of the concentrate to at least one concentrate connector, wherein the concentrate is recirculated in a recirculation circuit comprising at least the distribution conduit, and in which the concentrate is heated to a high temperature, and preferably at an overpressure, to attain disinfection of the recirculation circuit.
Finally, the present invention also comprises a container intended for use in the above-mentioned apparatus and containing sodium chloride in particle form in a quantity of at least 10 kg, preferably more than 20 kg, and most preferably more than 40 kg, and being provided with an inlet for water and an outlet for concentrate, which inlet and outlets preferably have different connecting means, for example of the male and female type, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in the following in greater detail by way of reference to preferred embodiments of the invention and with reference to the attached drawings, in which:
FIG. 1 is a schematic diagrammatic representation, partially in perspective, of one embodiment of the present invention;
FIG. 2 is a more detailed schematic diagrammatic representation of another embodiment of the present invention;
FIG. 3 is a schematic, partially perspective view of an inner bag intended for use according to the present invention;
FIG. 4 is a front, perspective view of a container provided with an inner bag for use in the embodiment according to FIG. 3;
FIG. 5 is a plan view of a blank which is intended to form the container according to FIG. 4; and
FIG. 6 is a front, perspective view of a container of the present invention without the inner bags.
DETAILED DESCRIPTION
Referring to the Figures, in which like reference numerals refer to like elements thereof, FIG. 1 shows a first embodiment of the present invention. The apparatus according to this invention comprises a concentrate generator 1 with two salt containers, 2 and 3, for containing, e.g., sodium chloride (NaCl) in powder form connected thereto. In addition, a water inlet 4 and a concentrate outlet 5 (preferably for substantially saturated concentrated sodium chloride solution) are provided. The invention can be used with other salts or electrolytes, but for the sake of simplicity it will be described herein when used with NaCl, or common salt.
In addition, a distribution conduit 6 for the concentrate is provided which is preferably arranged in the form of a closed loop connected between the concentrate outlet 5 and return inlet 7 on the concentrate generator 1.
The distribution conduit 6 is provided with a plurality of concentrate connectors 8 to which one or more dialysis machines 9 for preparing and administering a dialysis solution are connected. In principle, any type of dialysis machine can be connected, though the dialysis machine should, of course, be adapted, and provided with an inlet, for substantially saturated NaCl solution.
By way of example, one such dialysis machine is GAMBRO AK-100, the construction of which is apparent from, for example, European Patent No. B1-0 278 100. This dialysis machine prepares a ready-to-use dialysis solution starting out from a dry powder (such as bicarbonate powder) and other concentrate with predetermined compositions. A further example is apparent from European Patent No. A1-0 443 324. In the dialysis machine according to any one of these patent documents, the particular preparation of NaCl concentrate is replaced by the connection to the concentrate connector 8 according to the present invention.
Each salt container, 2 and 3, is connected to the concentrate generator 1 by means of two conduits, 10 and 11. Conduit 10 supplies water to the upper region of the container, and conduit 11 returns saturated concentrate of NaCl solution from the lower region of the container. The concentrate is thereafter fed to the distribution conduit 6 through outlet 5, which is shown in greater detail in FIG. 2. Of course, such feeding can take place in the lower region of the container, and removal in the upper region, if so desired. Other variations are also possible.
The principle behind the arrangement according to the invention is shown in more detail in FIG. 2. As is apparent in FIG. 2, water enters the concentrate generator 1 through inlet 4 to a water tank 20. The water level in the tank 20 is controlled by a level sensor 21 which controls an inlet valve 22. The tank 20 can include a heat source 23 for heating the water and/or for regulating the water temperature by means of a temperature sensor.
The incoming water should be purified in a suitable manner, for example using filters of various types (ion exchange filters) and reverse-osmosis processes. The water is thus free from impurities, such as salts, particles and bacteria.
The water is conducted from the tank 20 to a first valve 24 and from there to a water outlet 25 for connection to a container 2 with NaCl powder through conduit 10. Saturated NaCl solution is returned form the container 2 through conduit 11 to a concentrate inlet 27, which leads to a second valve 29. A second container 3 is connected between a water outlet 26 associated with the first valve 24 and a concentrate inlet 28 which is connected to the second valve 29. It will be apparent that by switching the valves 24 and 29, the first container 2 or the second container 3 can alternatively be connected to the concentrate generator 1. It will further be apparent that more than two containers can be connected in parallel if so desired by arranging more water outlets and concentrate inlets to the valves 24 and 29, respectively. While one of these containers is connected, the other container can be exchanged and prepared for use, in which manner continuous supply can be assured.
The concentrate flows from the second valve 29 through a pressure meter 30, a pump 31, a conductivity meter 32 and a third valve 33 to the concentrate outlet 5 for further transport to the distribution conduit 6 and the concentrate connectors 8, and then back to the return inlet 7.
From the return inlet 7, the returned concentrate is fed through a fourth valve 36 back to a mixing point 34 upstream of the pump 31 for recirculation in the distribution conduit 6. The third valve 33 is arranged to direct the concentrate to a drain 35 if the conductivity meter 32 provides a value which does not lie within a predetermined range substantially corresponding to concentrated sodium chloride solution. It will be apparent that other types of meters other than conductivity meters can be used, such as ion-selective meters, etc.
The above-mentioned meters 30 and 32, and devices 33, 34 and 36 are not completely necessary for the system (with the possible exception of the pump 31), but the use of these devices does improve the safety thereof. It is to be noted that corresponding safety features are normally provided in the dialysis machine.
It should be mentioned that it is not necessary to recirculate the saturated concentrate, but instead the return inlet 7 and the recirculation can be omitted in certain applications. Furthermore, it is not always necessary to have the tank 20 for water. The water can instead thus be fed directly to the containers, 2 and 3. The water tank 20 can also be smaller in size and in principle may only contain the heating source 23 for on-line heating of the incoming water. Thus, the term "water tank" is meant to include all different sizes from, in principle, merely a widening of a conduit to rather large storage tanks.
The containers 2 and 3 contain sodium chloride in powder form in a large bag or sack. One embodiment of the bag is shown in more detail in FIG. 3, and consists of a six-sided inner bag 40 made from polyethylene or polypropylene, or similar such materials. The inner bag can be totally or partially stiff or self-supporting so that it adopts the shown shape, or alternatively, it can be flexible.
An inlet 41 for water for connection to the conduit 10 is provided at the upper end of the bag. In addition, particle filter 42 and an outlet 43 in the form of a tube 44 are provided at the lower end of the bag, the tube opening out into a connector 45 which forms the outlet for saturated concentrate. The tube 44 and the connector 45 correspond to the conduit 11 in FIG. 1.
The connector 45 and the inlet 41 are differently shaped, such as male and female connectors respectively, to avoid incorrect coupling. Furthermore, the connector 45 can be directly connected to the inlet 41 to seal the bag during transport or when the bag is not in use.
It is also possible to connect several bags in series to extend the operating time. Since water is supplied to the first of the series-connected bags, the powder in the first bag will be consumed first, and thereafter the powder in the next bag will be consumed. Since concentrate is removed from the last bag of the series-connected bags, the powder in all of the series-connected bags will be consumed successively.
At least the lower region 46 of the bag is conical, which facilitates the utilization of all the sodium chloride in the bag.
The inner bag is housed in a protective casing 50, as shown in FIG. 4. The casing is manufactured from cardboard or hard plastic, or a similar such material. The casing 50 is shown in FIG. 4 with the inner bag arranged therein. As is apparent from FIG. 4, an upper chamber 51 is created above the inner bag in which the tube 44 and the connector 45 can be accommodated during transport.
The casing can be made from a blank which is shown in detail in a flat condition in FIG. 5, and in an erect condition in FIG. 5. Suitably, handles 52 are stamped out in the side. Alternatively, carrying means such as straps can be provided to facilitate transport thereof.
The inner bag 40 is filled by the manufacturer with sodium chloride in powder form and is then transported to the user, who may be a dialysis clinic, etc. The shape of the casing is selected so that it can be easily transported by conventional means, for example on load pallets of standard 800×1200 mm size.
It is already known per se to use common salt (NaCl) in cartridges, and to allow water to flow through the cartridge and dissolve the common salt on-line as is required. In the above-mentioned European Patent No. B1-0 278 100, a cartridge is described containing about 1000 g of common salt, where it has been determined that a particle size between about 50 μm and 200 μm is suitable.
It has surprisingly been shown that such a cartridge can be made very large without the risk of lump formation of the common salt during operation with the granule sizes which are mentioned above. According to the present invention, this discovery is used to produce "cartridges" on the order of tens of kilograms in weight for central preparation of NaCl concentrate "on-line," whereby the common salt is dissolved during use. In this manner, batchwise preparation of the NaCl concentrate in large mixing vessels having a volume of tens of cubic meters is avoided.
By using common salt bags of this size, transport of large quantities of water which was previously required is avoided, thereby leading to large savings. Furthermore, large quantities of salt can be transported in one and same bag and prepared online in a central system according to the present invention. No reloading is thus necessary, but instead the container can be used in the form in which it arrives at the clinic.
Preparation of the concentrate takes place by supplying water, preferably purified water, to the common salt in powder form in the container or the inner bag. Water is supplied in such a quantity that the water level in the bag is above or level with the level of the common salt in the bag, which need not be all the way up to the upper end of the bag.
When the water is supplied to the powder, a mass of common salt particles is created which can move around each other in a manner similar to small stones in water. The particles are continuously dissolved so that the water becomes saturated with common salt. Thereafter, no further continued dissolving takes place. Instead, the saturated common salt solution and the common salt particles are in equilibrium.
When concentrate is removed through conduit 11, the same quantity of water is supplied via the conduit 10 and the common salt is dissolved anew, so that the incoming water becomes saturated with common salt. Thus, the common salt particles are continuously consumed during withdrawal of concentrate. In between, no consumption of common salt particles takes place since the solution is saturated. Agglomeration is avoided, as mentioned above, by selection of the particle size of the common salt particles. As soon as the NaCl powder is completely wetted, a mass or slurry of common salt powder and water is formed which exhibits no tendency to lump together but instead remains as a shapeless mass, with the common salt powder in solid form and water substantially saturated with dissolved common salt.
In order to take full advantage of the invention, it is suitable that the inner bag be so big that it is advantageous from a transportation point of view. Accordingly, it is preferred that the bag contain at least about 10 kg of salt, and preferably more than about 20 kg of salt. A preferred size is about 40 kg of salt, above which size the bag can become difficult to handle. Bags of around 65 kg and up to about 100 kg can still be possible.
As mentioned above, saturated NaCl solution is a very poor growth medium for bacteria. Despite this fact, the distribution conduits 6 and the concentrate connectors 8 must still be disinfected at regular intervals.
For this purpose, another positive property of NaCl solution, namely that the solubility is substantially temperature independent, is exploited. It is therefore possible to heat saturated NaCl solution to a high temperature suitable for disinfecting without the risk of precipitation or crystal formation or that the properties of the concentrate be changed. Accordingly, the conduits 6 and the connectors 8 can be disinfected by the concentrate itself without having to first flush them clean of concentrate.
During disinfecting, the fourth valve 36 is first switched to a disinfecting position for recirculation of the concentrate to the water tank 20.
A bypass conduit 37 between the first valve 24 and the second valve 29 bypasses the containers 2 and 3, since the plastic material in the containers otherwise might potentially be damaged by the high temperature, and the time required for the heating up would also be extended. In this manner, the entire concentrate generator, including the water tank 20, is filled with concentrate. Alternatively, the water in the water tank 20 can be used to dilute the concentrate in the conduit 6 so that this solution, which is used for disinfecting, is not totally saturated. As an alternative, only water, or water including only a small portion of salt, can also be so utilized.
The heating source 23 is now activated to gradually heat the concentrate to such a temperature that disinfecting takes place, for example a temperature above about 90° C., preferably abut 98° C., or up to about 105° C., and the circulation is allowed to continue for a suitable period of time, for example at least 30 minutes. Thereafter, the system is allowed to cool and the valves are switched to normal operation.
If the system is closed, even higher temperatures can be used, for example up to about 121° C., at which sterilization is achieved. In this manner, an overpressure of about one atmosphere is attained in the system.
The above-described disinfecting can be executed entirely automatically, for example at night, when the dialysis clinic is not normally in operation.
It is possible to operate the concentrate generator 1 at a continuously high temperature, whereby disinfecting is achieved during operation. For reasons of safety, it can be suitable to maintain this temperature at about 60° C., but it is also possible to use temperatures in the order of just over 90° C. In the latter case, it should be ensured that the connectors to the dialysis machine have safety means so that scalding cannot occur.
As an alternative, or complementary to the particular by-pass conduit 37, the conduit 10 can be disconnected from the container 2 and connected directly to the corresponding concentrate inlet 27 so that the concentrate can flow along this path during disinfecting.
It will be appreciated that disinfecting agents other than saturated common salt concentrate can be used in the system according to the present invention.
It can be suitable to fill the common salt containers 2 and 3 with water at the same time that they are connected to the concentrate generator 1 according to the present invention, i.e., so-called priming. The reasons for this are many, such as the fact that the common salt powder should be moistened before use, and for purposes of flushing out particles which may have lodged in the tubes or the connectors. During this priming step, the third valve 33 is set so that the concentrate is fed to the outlet 35, and the pump 31 pumps water from the tank 20, through the tubes 10 and 11 to the drain. After a short period of time, and when the conductivity meter 32 provides correct measured values, the priming step is discontinued by switching the third valve 33 to its normal position.
Priming of one container can take place while the other container is in use. Necessary valves and conduits for this purpose are not shown in the drawings, though these are evident for a skilled person. Moreover, separate pumps and conductivity cells can be arranged for each container to facilitate simultaneous priming. This also applied to means for emptying the entire concentrate generator.
In FIGS. 1 and 2, two containers 2 and 3 are shown connected in parallel. It will be apparent, however, that the second container can be connected when the first container is empty so that a longer operating time can be achieved, which occurs with valves 24 and 29. An indication that one container is empty is thus obtained by means of the conductivity meter 32. Alternatively, the pressure meter 30 can be used, which indicates a lower pressure as the container is emptied, or visual indication on the NaCl containers can be employed. Further pressure meters can be placed in other positions in the system, for example in outlets 25 and 26, for controlling the filling of each container.
The containers and the system hereof are particularly suitable for preparation of saturated common salt solution for use in hemodialysis, hemofiltration or hemodiafiltration. The other constituents of the dialysis solution are prepared by the monitor, such as bicarbonate solution via a BICART® cartridge, a product of GAMBRO AB, and remaining electrolytes by means of a bag containing such electrolytes in concentrated dissolved form, for example in a concentration of 1:400. These electrolytes can be potassium chloride, calcium chloride, magnesium chloride and possibly glucose. In addition, acetic acid is normally added to adjust the pH value to from about 7.2 to 7.4 in the final dialysis solution.
The composition of the prepared dialysis solution is determined by the dialysis machine. The concentration of the substantially saturated common salt solution is measured by the dialysis machine, and the measured value controls a pump or valve so that the correct quantity of common salt is mixed into the dialysis solution.
Salts other than common salt can also be prepared centrally according to the present invention. One such salt is potassium chloride, which has substantially the same properties as common salt. However, such small quantities of potassium chloride are used in the dialysis solution that the economic benefits of central preparation of potassium chloride concentrate rarely justifies such an investment. Those salts which can be prepared according to this invention should be such salts in which bacteria growth is minimal.
It is possible to prepare several salts in parallel and to distribute these concentrates in separate parallel distribution conduits to the dialysis machine. It is to be noted that with this invention, two parallel distribution conduits are used, one for the concentrate according to the invention, and one for purified water which must also be supplied to the dialysis machine.
It can also be possible to mix two of the ingredients during the course of central preparation of the concentrate according to the present invention. Normally, however, only one salt is included in the concentrate because of the difficulty of dosing the concentrate in the dialysis machine and achieving the correct composition. It can, however, be possible to add an acid to the water tank 20. The acid can be acetic acid, and is used in the dialysis solution to adjust the pH value to avoid precipitation of calcium carbonate and other such impurities.
It is to be noted that the term "water" which is used above can also include water with certain additions, such as acid, etc. In addition, this water can, for example after a disinfection treatment, contain common salt or other electrolytes.
It can also be possible to dilute the common salt concentrate so that it is not saturated when it is fed to the distribution conduit 6. In this manner, the use of two parallel distribution conduits can be avoided, i.e., one for the common salt concentrate and the other for water. Instead, these can be combined in one and the same distribution conduit. In this manner, it is necessary that the solution which is fed to the distribution conduit have the lowest expected concentration for sodium, and a final adjustment of this concentration is made in the dialysis machine according to individual requirements. In this embodiment, carbon dioxide gas can be added to the mixture of water and NaCl, whereby a sufficient quantity of carbon dioxide can dissolve in the mixture so that necessarily low pH values are obtained in the prepared dialysis solution without additional mixing of carbon dioxide or other acids. Since the solubility of carbon dioxide in water is proportional to the pressure, additional quantities of carbon dioxide can be dissolved if the concentrate generator is operated at an overpressure of, for example, about one atmosphere.
During disinfection, it can be suitable to use saturated common salt concentrate to obtain as efficient a disinfection as possible, particularly with regard to the fact that saturated common salt concentrate can be heated to about 107° C. before it boils.
A plurality of distribution conduits 6 which are connected in parallel or in series can be used.
It is preferred to remove the substantially saturated concentrate from the lower portion of the container. It is also possible, however, to remove the concentrate from the upper portion of the container, or from some other intermediate position. It is to be noted that the common salt solution may stratify, particularly when the container includes smaller quantities of common salt in solid form at the end of the container's use. When removing concentrate from the upper portion of the container, the concentrate can thus have a lower concentration than that when it is saturated. Even though common salt has a high solubility, and dissolves quickly in water, under certain operating conditions with high flow velocity of water through the container it may occur that the removed concentrate is not saturated. The expressions "substantially saturated concentrate" and "substantially saturated solution" are intended to include these departures from the concentrated condition, either permanently, for example because of stratification, or constant high flow velocity, or temporarily because of deviations which can exceptionally arise, such as at the end of the use of a container. Normally, monitoring takes place to ensure that the concentrate is sufficiently concentrated or saturated by means of the conductivity meter 32. If concentrate with a concentration which is too low should reach a dialysis machine, the machine will emit an alarm signal to indicate that sufficient final concentration in the dialysis solution cannot be attained.
The invention has been described with reference to a preferred embodiment of the invention. However, it is to be understood that the invention can be modified in many ways by a skilled person reading this description, and the intention is that such modifications which are evident to a skilled person are to be included within the scope of this invention. The various described components can be combined in other ways than those shown in the drawings.
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Methods for the central preparation and distribution of a concentrate to a plurality of medical treatment devices are disclosed comprising supplying a stream of substantially only water to a central container which includes a single salt composition at least partially in solid form, producing a substantially saturated solution of the salt composition in the central container, and distributing the salt solution to a distribution conduit which includes a plurality of concentrate connectors whereby the salt solution can be distributed to the plurality of medical treatment devices. Methods for disinfecting this apparatus, the apparatus itself, and containers for use in the apparatus are also disclosed.
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FIELD OF THE INVENTION
[0001] The present invention relates to a lockable box for pre-recorded media, notably a DVD box.
BACKGROUND TO THE INVENTION
[0002] Pre-recorded storage media such as digital versatile discs (DVDs) are usually put up for sale in a plastic box which carries information about the DVD as well as carrying sales promotional material or artwork to attract a purchaser. To prevent theft of the DVD from a store various lockable display containers have been proposed which house the DVD in its box and prevent a thief gaining access to the DVD without breaking the container or removing the container from the shop. The container can be fitted with alarm means so that it cannot be removed from the shop without actuating an alarm. Examples of such lockable containers are described in EP 0 312 172, EP 0 541 733, EP 0 666 954 and WO 00/61899. These display containers are effective but they increase the bulk of the product on display.
[0003] Known products provide a locking member which is externally applied to the box, With such products, the box cannot be shrink-wrapped for “sell-through”, as there is then no means of removing the locking member without damaging the packaging. The locking members are also subject to being tampered with. Once the locking member has been removed in order to unlock the box (in a rental situation) it has to be safely stored for re-use later on. If the locking member is lost, the box can no longer be secured.
[0004] The present invention seeks to provide an improved lockable disc box.
SUMMARY OF THE INVENTION
[0005] The present invention provides a lockable box for a DVD or other pre-recorded data carrier. The box has at least two releasably interengageable locking members which, when interengaged, prevent the box from being opened. The locking members are entirely contained within the box when the box is closed, and they can be disengaged only with the use of a special tool.
[0006] It is preferred that the box is a DVD box, and the invention will be described with reference to this embodiment. However, it will be understood that the invention is also applicable to other pre-recorded data carriers, for example compact discs (CDs), videos and tape cassettes.
[0007] The DVD box may be supplied to Record Label and Film Studio Companies as original packaging, filled with product and then sent to a retailer in either a locked or an unlocked state.
[0008] Unlike existing products, which require a manual action to insert (lock) or remove (unlock) the locking member, the disc box of the present invention can be locked and unlocked in a hands-free manner. By incorporating a ferrous element in a movable locking member, the box may be locked and unlocked by swiping it against a suitable strong magnet.
[0009] The box comprises a first box member and a second box member which are adjustable between a closed position in which they co-operate to define a substantially closed box, and an open position in which the inside of the box is accessible to permit a disc to be inserted into or removed from the box. Each box member has a locking member, and at least one of the locking members is adjustable between a locked position in which, when the box members are in the closed position, the locking members interengage so as to prevent the box from being opened, and an unlocked position in which the locking members permit the box members to be moved from the closed position to the open position. The two co-operating locking members comprise a locking mechanism.
[0010] The locking member on each box member could be movable relative to the box member. However it is preferred that one locking member is movable and the other is fixed relative to its box member. In a preferred embodiment, the movable locking member is pivotable between the locked and unlocked positions.
[0011] One of the locking members may be provided with a hole or recess in which the other locking member is disposed when the box is locked.
[0012] In another preferred embodiment, the movable locking member is slidable between the locked and unlocked positions. By providing each end of the slidable locking member with a ferrous element, locking and unlocking may be carried out means of a single swipe along an appropriate edge of the box.
[0013] Although the invention may employ only one locking mechanism, it is preferred that more than one locking mechanism, preferably two locking mechanisms, are provided. This preferred embodiment permits all three free edges of a conventional hinged DVD box to be locked.
[0014] In the preferred embodiment where one locking member of a pair is fixed and the other is movable, both movable locking members may conveniently be provided on the same box member. However, it would also be possible to provide one movable locking member on each box member.
[0015] The interior of the box may be provided with an electronic tag of a type known per se which activates an alarm system if an attempt is made to remove the DVD box from the store. It is particularly preferred that the tag may be remotely deactivated by electronic means. This permits the DVD box to be sold in shrink wrapping and to be both unlocked and alarm-deactivated at the point of sale without removing the wrapping. Suitable electronic tags are known in the art.
[0016] Other aspects and benefits of the invention will appear in the following specification, drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention will now be further described, by way of example, with reference to the following drawings in which:
[0018] [0018]FIG. 1 shows a first embodiment of a lockable DVD box in accordance with the invention;
[0019] [0019]FIG. 2 is a fragmentary cutaway view of part of the box shown in FIG. 1, with the box closed and locked;
[0020] [0020]FIG. 3 is a fragmentary cutaway view similar to that of FIG. 2, with the box unlocked and partially open;
[0021] [0021]FIG. 4 shows a second embodiment of a lockable DVD box in accordance with the invention;
[0022] [0022]FIG. 5 is a fragmentary view of part of the locking mechanism of the DVD box shown in FIG. 4;
[0023] [0023]FIG. 6 shows a third embodiment of a lockable DVD box in accordance with the invention;
[0024] [0024]FIG. 7 is an elevational view of a resilient retaining member as shown in FIG. 6;
[0025] [0025]FIG. 8 is an elevational view of a receptacle of FIG. 6 with the sliding locking member in the locked position;
[0026] [0026]FIGS. 9 and 10 are cross sections of a receptacle of FIG. 6 when the box is, respectively, open and closed; and
[0027] [0027]FIG. 11 is an elevational view of the receptacle of FIG. 8 with the sliding locking member in the unlocked position.
DETAILED DESCRIPTION
[0028] The DVD box 2 comprises a first box member 4 and a second box member 6 , of substantially similar dimensions, connected together by a hinge 8 . The box members 4 , 6 are hollow shells, for example of polypropylene, which co-operate to form a closed box when pivoted about the hinge 8 in known manner. The first box member 4 is provided with an annular disc-receiving member 24 with a resilient mount 26 in the middle, for releasably securing a DVD (not shown) as is well known in the art. The disc-receiving member 24 and mount 26 could additionally or alternatively be provided on the second box member 6 , or on an intermediate mounting member between the box members.
[0029] Two locking members 10 are pivotally mounted on the inner surface of the first box member 4 by means of pivot pins 12 . The friction between the pivot pin 12 and its locking member 10 is such that the locking member 10 cannot be pivoted by shaking of the box; a greater force is required.
[0030] Upstanding lugs 18 are provided on the inner surface of the first box member 4 adjacent the distal ends 14 and proximal ends 16 of the pivotable locking members 10 . The second box member 6 is provided with locking members comprising upstanding lugs 20 on the inner surface. Each upstanding lug 18 , 20 has a hole, and when the box 2 is closed pairs of lugs 18 , 20 are located face to face with the holes in alignment. The arrangement is such that, with the box members 4 , 6 in the closed position, pivoting of the locking member 10 from the unlocked position shown in FIG. 3 to the locked position shown in FIG. 2 brings the ends 14 , 16 into disposition through the holes in both the aligned lugs 18 , 20 in the pair. In this position, the box members 4 , 6 are locked together.
[0031] With the box 2 closed, the locking members 10 are pivotable only with the use of a special tool. It is preferred that the proximal 14 and distal 16 ends of the locking member 10 are formed from a ferrous material or are provided with a ferrous insert or attachment. This permits the locking member 10 to be pivoted by means of a strong external magnet device. A suitable magnetic device is described in WO 00/61899.
[0032] To lock the box, the box is closed, and then each short edge 28 is swiped in turn against the magnet. The magnet attracts the ferrous insert of the distal end 16 , causing the locking member 10 to pivot and both ends to engage in holes in the associated pair of lugs 18 , 20 .
[0033] To unlock the box, the long edge 30 is swiped against the magnet so that the magnet attracts the distal ends 14 of the locking members 10 and reverses the locking process.
[0034] In practice, the magnet may be mounted on a checkout desk at the point of sale or rental.
[0035] Although the above arrangement is preferred for ease of unlocking, it will be appreciated that the opposite arrangement could also be used, whereby locking is achieved by a single swipe along the long edge of the box, and unlocking by a swipe along both short edges.
[0036] In an alternative embodiment, the locking member 10 could be accessible via a hole 22 in an edge of the box. As illustrated in the drawings, the box could be locked by a user inserting a long thin tool through the hole 22 in the long edge 30 so as to push the proximal end 14 and cause the locking member 10 to pivot to the locked position. It would be possible for unlocking to be carried out by the same tool through a similar hole adjacent to the distal end 16 of the locking member 10 . However it is preferred that exclusively magnetic means are used for unlocking and, preferably, for locking, the box because the use of a suitable magnet is quicker and permits the DVD box to be locked and unlocked while shrouded in shrink-wrap material.
[0037] In another embodiment, the proximal ends 14 are provided with permanent magnets with like poles facing towards the long edge 30 . This permits the box to be locked with a single swipe of a suitable magnet with a like pole adjacent the long edge 30 so that the permanent magnets in the proximal ends 14 are repelled. The box can be unlocked with a single swipe of a suitable magnet with the opposite polarity adjacent the long edge. Both types of magnets could be mounted at the point of sale or rental, one for locking and the other for unlocking.
[0038] It would be possible not to provide the lugs 18 on the first box member 4 so that the locking member 10 engages only with the lugs 20 on the second box member 6 when the box is locked. However, this would require the locking member 10 to be relatively rugged and robust because it would need to resist upward force exerted by an attempt to prise the box members apart. In the preferred embodiment the ends of the locking members are disposed through lugs on both the first box member 4 and the second box member 6 , so that the lugs 18 on the first box member 4 prevent force from the second box member 6 being transmitted to the pivot pin 12 .
[0039] The entire locking member 10 and its mount may be provided as a removable insert to enable its removal either at point of sale or by a customer. Alternatively, the pivot pin 12 could be made releasable by exerting an upward force on the pivotable locking member 10 .
[0040] Referring now to FIGS. 4 and 5, an alternative embodiment of the invention employs a locking member 110 which is slidably mounted on the first box member 4 . The second box member 6 is provided with a plurality of fixed locking members comprising upstanding L-shaped hooks 120 . For each hook 120 there is a corresponding hole 34 in the slidable locking member 110 . Under each hole 34 there is a space 36 , as best shown in FIG. 5, for receiving a corresponding hook 120 . The proximal 114 and distal 116 ends of both slidable locking members 110 are provided with ferrous inserts (not shown) so that they are attractable by a magnet. By swiping a first long edge 30 of the box against a suitable magnet, the slidable locking member moves in the direction of arrow 38 to an unlocked position in which the hooks 120 can enter and leave the spaces 36 via the holes 34 . With the box 2 in the closed position and the slidable locking member 110 in the unlocked position, the box 2 may be locked by swiping the opposite long edge 32 against a magnet so as to move the slidable locking member 110 to the locked position in the direction of arrow 40 . Here, the hooks 120 are trapped in the slidable locking member 110 , and the box is locked.
[0041] In this embodiment, the DVD box 2 can be locked and unlocked with a single swipe against a suitable magnet along the appropriate edge.
[0042] [0042]FIG. 6 shows a third embodiment of the invention including a sliding locking member 210 mounted in the first box member as in FIGS. 4 and 5. The sliding locking member is disposed between retaining pillars 50 that retain the slidable locking member 210 in the correct alignment. A wall 52 separates the sliding locking member 210 from the disc-receiving member 24 .
[0043] The sliding locking member 210 is shown in the locked position for illustrative purposes, although the second box member is not in the closed position. The sliding locking member is provided with holes 234 through which hooks 220 formed on the second box member 6 may pass. The first box member 4 includes receptacles 54 aligned through the holes 234 for receiving the hooks 220 . The arrangement of the hooks 220 , sliding locking member 210 and the receptacles 54 is more clearly shown in FIGS. 9 and 10. A receptacle 54 is shown in greater detail in FIG. 8.
[0044] The sliding locking member 210 also includes a resiliently biased detent 56 that co-operates with a pillar 58 on the first box member 4 to prevent the sliding locking member 210 from moving easily to the unlocked position. This prevents the box 2 from being unlocked by tapping or knocking. The resiliently biased detent is shown in greater detail in FIG. 7.
[0045] The sliding locking member also includes ferrous inserts 68 on opposite long edges of the box 2 to enable magnetic locking and unlocking of the box 2 as described above.
[0046] [0046]FIG. 7 shows an elevation view of the resiliently biased detent 56 of FIG. 6. The detent 56 comprises an elongate body 60 with an enlarged circular head 62 . A pillar 58 on the first box member 4 protrudes upwardly adjacent to the detent 56 . In the locked position (as shown) the pillar 58 is located in a recess 64 between the body 60 and head 62 of the detent 56 .
[0047] To unlock the box 2 the sliding locking member 210 must be moved in the direction shown by arrow 66 causing the head 62 of the detent 56 by the pillar 58 . The body of the detent 56 is resiliently deformable such that the head 62 of the detent 56 may move slightly from side to side in the plane of the sliding locking member 210 . For the head 62 to pass by the pillar 58 the body 60 of the detent 56 must deform to allow the head 62 to move aside.
[0048] The force required for such a deformation prevents the sliding locking member 210 from moving to an unlocked position when the box 2 is shaken, tapped or hit sharply. The force required should be such that the sliding locking member 210 can be moved when desired by unlocking means such as a magnet as discussed above. The force required can be adjusted as needed by changing the dimensions of the body 60 or head 62 of the detent or by altering the material from which it is made during manufacture. Additionally, or alternatively, the pillar 58 could be made releasably moveable so that its position can be laterally adjusted to increase or decrease the force needed for the head 62 of the detent 60 to pass by.
[0049] [0049]FIGS. 8 and 11 show an elevation view of a receptacle 54 of FIG. 6. The receptacle 54 is formed by a back wall 70 and two side walls 72 , 74 upstanding from the first box member 4 to form a “U” shape. The receptacle 56 passes through a hole 234 in the sliding locking member 210 . When the sliding locking member is in the locked position (as shown in FIG. 8) it engages in cutout portions 76 of the two side walls 72 , 74 . When the sliding locking member is in the unlocked position (as shown in FIG. 11) it allows a hook 220 to enter the receptacle 54 and pass through the hole 234 .
[0050] [0050]FIGS. 9 and 10 show cross sectional side views of a receptacle 54 , sliding locking member 210 and hook 220 of FIG. 6. FIG. 9 shows the arrangement in an unlocked position and FIG. 10 shows the arrangement in a locked position.
[0051] In the unlocked position, the sliding locking member does not engage with the cutouts 76 and the receptacle 54 is unobstructed so a hook 220 can enter into the receptacle 54 and align with the cutouts 76 as shown in FIG. 10.
[0052] In the locked position, with a hook 220 in the receptacle 54 , the sliding locking member 210 engages with both the cutout portions 76 of the side walls 72 , 74 of the receptacle 54 and a shoulder 80 of the hook 220 . The sliding locking member 210 couples the hook 220 to the receptacle 54 and hence couples the first box member 4 to the second box member 6 in a closed position.
[0053] In all three embodiments, the locking members 20 , 120 , 220 on the inner surface which does not carry the mount 26 for the DVD (in these examples, the second box member 6 ) are arranged to as to permit literature pertaining to the DVD to be inserted and removed. One or more clips (not shown) may be provided on the inner surface of the second box member 6 to releasably retain such literature, in a manner well known in the art.
[0054] It is appreciated that certain features of the invention, which are for clarity described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for the sake of brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination.
[0055] While the present invention has been described with reference to specific embodiments, it should be understood that modifications and variations of the invention may be constructed without departing from the scope of the invention defined in the following claims.
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A lockable box ( 2 ) for a DVD or other disc has at least two releasably interengageable locking members ( 10,20 ) ( 110,120 ) which, when interengaged, prevent the box from being opened. The locking members are entirely contained within the box when the box is closed, and they can be disengaged only with the use of a special tool.
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CONTRACTUAL ORIGIN OF THE INVENTION
The United States Government has rights in this invention pursuant to Contract No. W-31-109-ENG-38 between the U.S. Department of Energy and The University of Chicago representing Argonne National Laboratory.
BACKGROUND OF THE INVENTION
This application is a continuation-in-part application of U.S. patent application Ser. No. 830,719, filed Feb. 4, 1992, now U.S. Pat. No. 5,340,668, which was a continuation-in-part application of application Ser. No. 774,204, filed Oct. 10, 1991, now abandoned.
This invention relates to an electrochemical cell and to methods of fabricating the cell and improving its capacity and/or power and capability of operating at low temperatures. The invention also relates to a new positive electrode or cathode during discharge for electrochemical cells and method of fabricating same, and more particularly, relates to electrochemical cells and positive electrodes for metal chloride batteries having lower internal impedance and greater discharge capacity with a higher specific energy and power.
According to the invention, an electrochemical cell comprises an alkali metal, and preferably, a sodium negative electrode or anode during discharge which is molten at operating temperatures of the cell, an alkali and preferably, a Na + ion conducting solid electrolyte/separator, a molten salt liquid electrolyte in the positive electrode compartment which is compatible with the positive electrode, and which is also at least partially molten at the operating temperature of the cell, and a positive electrode which is impregnated by the liquid electrolyte and which comprises, as the electrochemically active positive electrode substance of the cell, a transition metal chloride which preferably is selected from the group consisting or iron chloride, nickel chloride, chromium chloride, cobalt chloride and manganese chloride or mixtures thereof. Since the cell with a Na electrode has received the major development effort, a shorthand method of referring to these cells is (Na/MCl 2 ) battery or electrochemical cell, wherein M is one of the transition metals identified above. Batteries of this type are disclosed in U.S. Pat. No. 4,288,506 issued Sep. 8, 1981, to Coetzer et al. and U.S. Pat. No. 4,546,055 issued Oct. 8, 1985 to Coetzer et al. and U.S. Pat. No. 4,592,969 issued Jun. 3, 1986 to Coetzer et al. The batteries or electrochemical devices of the type herein discussed are useful as a power source alternative to petroleum engines and are being developed commercially, not only for electrically powered vehicles, but also for load leveling in electrical utilities.
An ideal electrochemical cell or battery should exhibit a number of characteristics, including low resistance and high discharge rates, operation over a wide temperature range, a capability to operate over a large number of cycles, and high energy on a volume, weight and cell basis. Generally, these types of electrochemical cells or batteries consist of two dissimilar metals in an ionically conductive medium, with the ionization potential of one metal sufficiently higher than the other metal to yield a voltage upon reduction/oxidation redox (coupling) over and above that needed to break down the electrolyte continuously at the positive electrode.
Metal typically goes into solution at the negative electrode or anode, releasing electrons to travel in the external circuit to the positive electrode, or cathode, doing work in transit. Material which will go through a valency drop on electrochemical discharge is included in the positive electrode. In essence, this material, the oxidizer, accepts electrons coming from the negative electrode and serves as the depolarizer. The depolarizer or cathode is positioned, in one embodiment, in the positive electrode in combination with some electrolyte-containing matrix, and should be porous to allow access of the electrolyte to the enlarged area of the depolarizer or cathode. Porosity of the cathode provides a surface at which the redox reaction may take place.
The economic and social advantages of powering automobiles from batteries are considerable as the vehicles could operate at relatively high efficiencies, such as 30-40%, and be non-polluting. Two important characteristics are considered in seeking an energy storage system for a vehicle. One of the characteristics or variables, specific power, designed in watt per kilogram (W/kg), determines to a large extent, acceleration and speed capabilities. The other consideration or variable of specific energy is designated as watt hours per kilogram (Wh/kg), determines vehicle range. The capacity density of a cell, or how much electrochemical energy the electrode will contain per until volume is designated as ampere hours per cubic centimeter (Ah/cm 3 ).
It is generally seen, therefore, that increasing the cell capacity available during discharge and the cell power by lowering the internal impedance of the cell are both important attributes in the consideration of how and when and to what extent electrochemical cells will be placed in the vehicle as a significant portion of the vehicle propulsion systems.
Sodium/Metal chloride cells of the type disclosed in the patents hereinbefore identified use a sodium anode, a β" alumina solid electrolyte and a cathode designated as Mcl 2 with a molten electrolyte of sodium chloroaluminate, NaAlCl 4 .
Metal halide batteries exploit the higher electrolysis threshold values of the electrolyte constituents. In charging, the positive electrode becomes poor in sodium salt with sodium metal being deposited on the negative electrode and the halogen electrochemically reacting with the metal to form a metal halide. Among halides, the fluorides and chlorides exhibit higher electrolysis thresholds than bromide and iodides, and therefore are preferred and generally used. As such, metal chloride and metal fluoride systems exhibit relatively higher energy densities and lighter mass than systems using bromides and iodides. Because of the better electrochemical properties and low price, the metal chloride systems are preferred.
As with other electrochemical cells, metal halide batteries generate electricity by transporting electrons from the fuel constituent to the oxidizer, with concomitant oxidation and reduction occurring at the negative electrode or anode and the positive electrode or cathode, respectively. The following reaction occurs:
MX.sub.2 +2 Na⃡2 NaX+M
where M is a transition metal and preferably is one or more of nickel, iron, cobalt, chromium and manganese and X is a halogen, preferably chlorine. The left hand side of the above equation depicts a charged state, before reduction of the metal halide, with the right hand side of the equation depicting a discharged state with reduced transition metal.
Utilization of the metal/chloride system is usually expressed on the basis of the ratio of the reacted NaCl to the total quantity of NaCl used to fabricate the positive electrode. This practice is convenient for the Na/MCl 2 cell because they are fabricated in the discharge state and the MCl 2 active material is formed electrochemically, as noted in the above cell reaction. As used hereinafter, weight percent of a constituent in the positive electrode refers to the positive electrode in the dry state, as the electrodes exist prior to being placed in the electrochemical cell and cycled to charge the cell.
One of the significant problems in the sodium metal halide batteries is the limited battery capacity, due to the chloride of the positive electrode metal which forms a layer of low conductivity on the positive electrode. Since this metal chloride has limited conductivity, after it reaches a certain thickness on the order of one micrometer, it practically terminates further charge uptake of the cell. It has also been noted that cell capacity may be lowered after repeated charge and discharge cycles. Previous efforts to improve cell performance have involved the addition of sulfur to the liquid electrolyte or the addition of sulfide to the porous positive electrode. Neither of these solutions has been totally satisfactory.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a positive electrode and electrochemical cell including same which overcomes the limited capacity of prior cells and permits enhanced charge uptake.
Another object of the invention is to provide an electrochemical cell of the alkali/metal transition metal halide type which has increased specific energy and power output due to lower internal impedance.
One feature of the present invention is the use of bromide and/or iodide containing additives in the positive electrode compartment to increase cell capacity and power.
Another object of the invention is to use certain pore formers in the cathode in combination with the bromide and/or iodide additions as described herein providing improved electrode morphology and lower impedance resulting in lower cell operating temperatures.
Yet another object of the invention is to provide improved cell capacity and specific energy and power particularly with lower internal impedance due to the use of a bromide and/or iodide additives, pore formers in the cathode and sulfur present either in the electrolyte or in the cathode or both.
In brief, the objects and advantages of the present invention are achieved by providing electrochemical cells with various combinations of additives including bromide and/or iodide and sulfur containing materials and pore formers for electrode fabrication.
The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its construction and operation, and many of its advantages should be readily understood and appreciated.
FIG. 1 is a schematic view of one embodiment of the invention in the form of an electrochemical cell.
FIG. 2 is a graphical illustration of the relationship between the area-specific impedance and the discharge capacity of the cell for cells with no additives and cells with a 2 weight percent sulfur additive;
FIG. 3 is a graphical illustration of the relationship between the area-specific impedance and discharge capacity like FIG. 2 for various combinations of additives to for the basis of the invention;
FIG. 4 is a graphical illustration of the relationship between cell voltage and discharge capacity for a cell without additives and a cell with additives;
FIG. 5 is a graphical illustration of the relationship between the cell discharge energy and charged time; and
FIG. 6 is a graphical illustration of the relationship between cell volumetric capacity and cell operating temperature.
DETAILED DESCRIPTION OF THE INVENTION
While the invention is primarily described with respect to a sodium-transition metal chloride cell, it is to be understood that the invention includes cells from other alkali metals, such as lithium and potassium, with the electrolyte being changed to correspond to the particular alkali metal.
Referring now to FIG. 1 of the drawings, there is disclosed a sodium/metal chloride cell in schematic illustration. A single cell 10 is illustrated, it being understood that a plurality of such cells may be connected in series, as well as in parallel, to provide the required voltage and battery capacity for any specific use such as powering an electric car, or the like. The electrochemical cell 10 includes an outer casing 11 of any suitable container which can act as a negative electrode, the container may be steel or any other suitable electron conducting material. Alternate metals may be nickel or stainless steel, it being understood that any good electrical conductor which does not react with the negative electrode material, which in this case is sodium, may be used as an outer casing. The outer casing has a negative buss or terminal 12 electrically connected to the casing positioned at the top of the cell 10. A positive electrode or cathode 13 includes a solid rod of a transition metal and preferably nickel or iron or chromium or cobalt or manganese or any combination of alloys thereof which acts as a current collector and leads to a positive buss 14 at the top for connection as desired. The solid rod 13 is surrounded by positive electrode material 15 which is a combination of the chloride of the solid rod 13 and in the partially discharged state sodium chloride and an electrolytic material, such as sodium chloroaluminate, NaAlCl 4 . With lithium or potassium as the negative electrode, the electrolyte would be LiAlCl 4 or KAlCl 4 , respectively.
For illustrative purposes, the positive electrode may contain nickel, nickel chloride, sodium chloride and sodium chloroaluminate which is also liquid at cell operating temperatures which are generally in the range of from about 200° C. to about 400° C., but normally prior art cells operate in the range of from about 250° C. to about 335° C. A β" alumina electrolyte solid tube 16 is positioned to contain the rod 13 and the positive electrode material 15 consisting of the chloride of the rod 13 along with the sodium chloroaluminate. Outwardly of the β" alumina electrolyte 16 is the negative electrode 17 of sodium metal, which is liquid at cell operating temperatures. Finally, the cell 10 is closed by an alumina header 18 in the form of a disc. The cell reactions for a positive electrode of NiCl 2 or FeCl 2 as hereinbefore stated are:
NiCl.sub.2 +2 Na⃡2 NaCl+Ni 2.59 V
FeCl.sub.2 +2 Na⃡2 NaCl+Fe 2.35 V
As hereinbefore stated, the positive electrode may be of a variety of materials or transition metals, specifically the materials may include iron, nickel, cobalt, chromium, manganese, or alloys thereof. While one transition metal is normally used for the positive electrode, combinations may have some advantages. As an illustration, iron powder may be used with a nickel rod as a current collector with FeCl 2 as the metal chloride in the molten electrolyte. For purposes of example only, and without limiting the scope of the invention, the nickel/nickel chloride positive electrode will be described. In all cases, the negative electrode or anode was sodium metal, liquid at cell operating temperatures. In addition, sodium chloroaluminate was used with the β" alumina as the electrolyte material 16. To provide enough capacity and form sufficient quantity of nickel chloride, sodium chloride must be added to the positive electrode during fabrication. Up to 0.66 gNaCl/gNi ratio and high surface area of the nickel particles are required to achieve high capacity density (mAh/cm 3 ). With the 0.66 gNaCl/gNi ratio, up to 33-50% electrochemical utilization of nickel is possible. For cells with lithium or potassium electrodes, the salt would be LiCl or KCl.
Also, as hereinbefore stated, the nickel/nickel chloride positive electrode has a capacity and specific power which is limited by the nickel chloride layer formation on the surface of the nickel particles, which nickel chloride layer forms when the cell is charged. After the nickel chloride reaches a thickness on the order of about one micrometer, further charge uptake is terminated. In order to remedy this inherent limitation and improve the capacity and power characteristics of the nickel/nickel chloride cell, the following additives and preparation techniques were examined.
In general, the additives found beneficial contained bromide, iodide, sulfur, and various pore formers. More specifically, it was found that bromide could be present in the range of 1 to 25 wt % expressed on the basis of the weight of the positive electrode and as equivalent to NaBr on the basis of halogenoid content, and/or iodide could be present in the range of 0.05 to 25 wt % expressed on the basis of the weight of the positive electrode and as equivalent to NaI on the basis of the halogenoid content. The preferred amounts of NaBr and NaI or their equivalents on halogenoid basis used were 5-10% and 5-12% by weight, respectively, but in any event, the total amount of halide should not exceed about 30% by weight. It is to be understood that other sources of the bromide and iodide may be used, such as AlBr 3 , AlI 3 , NiBr 2 and PbI 2 , with the preferred amounts being in the above ranges based on the sodium salts.
Sulfur can be added to the positive electrode as elemental sulfur or sulfide, such as Na 2 S; the useful range for sulfur is 0.05 to 10 wt % with about 2% by weight being preferred. Where various combinations of halide and sulfur are used as additives, preferably the combination should not exceed about 30% by weight.
The pore former may be any material which decomposes to gases during fabrication. The preferred pore formers are the ammonium salts of carbonic acid or other weak organic acids, such as formic, acetic or oxalic or these weak organic acids themselves since these do no cause undesirable reactions with the materials of the cell. Other materials such as oxamide or methylcellulose may also be used as pore formers, but the preferred pore former is (NH 4 ) 2 CO 3 . The pore former may be present in the range of from about 5% to about 20% by weight, the preferred range being about 5% to about 15% and the best results being about 10% by weight.
It is believed that the superior results reported herein are due, in part, to the modification of the chloride coating and to the controlled pore distribution during positive electrode fabrication, thereby increasing cell performance. This increased performance is primarily evidence in capacity and/or power which may occur by a result of decreased impedance or by increasing the amount of active electrode material during the charge cycles. While the other alkali and transition metals may be used for cells of the invention, the results are particularly favorable for the Na/NiCl 2 cell.
Where nickel felt or foam was used instead of nickel powder, the felt could be used alone or additional nickel powder sintered to the felt could be used. The pore former was always used with a sintered nickel electrode, and weight percents for the pore former relate to the amount of the pore former before sintering.
Referring now to FIG. 2, the relationship between cell impedance and discharge capacity is illustrated for a sodium/nickel chloride cell having no additives and no pore formers, it is seen that the cell impedance of curve A in FIG. 2 sharply rises at relatively low discharge capacities to provide a relatively unsatisfactory cell. Curve B of FIG. 2 shows the slightly improved results when sulfur (2 wt %) is added to the liquid electrolyte but the impedance is still very high at a relatively low discharge capacity.
In the examples as described below, positive electrodes were fabricated as described for each example and installed in a cell as illustrated in FIG. 1 with a sodium negative electrode, solid electrolyte, and a NaCl and NaAlCl 4 electrolyte which is molten at the operating temperature of 300° C. A voltage of up to 3.1 V was applied to charge the cell with the capacity, power and/or impedance measured as illustrated in FIGS. 3-4 or for the charging time illustrated in FIG. 5. Performance during discharge was also measured. Repeated cycles of charge, and discharge were carried out.
EXAMPLE 1
7 wt % NaBr+10 wt % Pore Former
This examples illustrates the typical fabrication of Ni/NiCl 2 electrode with the performance shown in FIG. 3, plot 1. The weight of the materials are relative to the dry electrode weight 4.3 g nickel powder (0.68 M 2 /g BET area, 0.55 g/cm 3 bulk density, 1.74 g sodium chloride powder with mesh size -270+325, 0.605 g sodium chloride with mesh size -325+400, and 0.500 g sodium bromide (325+400 mesh size) were mixed together thoroughly. To this mixture of the salts a 0.7145 g of the pore former, ammonium bicarbonate was added and thoroughly mixed. The mixture was then placed in a stainless steel die and pressed to obtain an electrode with 2.85 cm diameter and 0.5 cm thickness. This electrode as described above was then placed in a tube furnace and heated first at 250° C. for 30 minutes under a hydrogen containing atmosphere (5% hydrogen+95% helium) in order to remove pore former as ammonia, water, and carbon dioxide gases and finally to 700° C. for one hour for sintering. The electrode was removed from the furnace and placed in the cell in the positive electrode compartment. The cell was charged and discharged with the discharge performance being measured and illustrated in FIG. 3, plot 1. A comparison of FIG. 3, plot 1 with FIG. 2, curve A, reveals the improvement in performance provided by the addition of the bromide additive and use of the pore former.
EXAMPLE 2
7 wt % NaBr+1 wt % Vapor--Phase Sulfidation
The positive electrode was fabricated by the same procedure as described in Example 1. The amounts of the chemical used was also exactly as in Example 1, except that no pore former was used for this electrode and, therefore, the electrode was not heated at 250° C. Rather, the electrode was heated directly at 700° C. for one hour. After removing the electrode from the furnace it was sulfidized to 1.0 weight percent by sulfur vapor. The performance of this cell system is shown in FIG. 3, plot 2. A comparison of FIG. 3, plot 2 with FIG. 2, curve A, reveals the improvement in performance provided by the addition of the bromide addition and the/wt % sulfur.
EXAMPLE 3
7 wt % NaBr+10 wt % Pore Former+0.5 wt % Vapor Phase Sulfidation
NaBr (0.5 g) and pore former (1.45 g) were introduced in the electrode as described above for Example 1 and the electrode was sintered and then sulfidized by 0.035 g of sulfur. Tests on the cell demonstrated that this combination produced better capacity, cycle life and lower impedance than the combination described in Example 2. More specifically, the curve for this Example would be between FIG. 3, plot 1 and plot 2.
EXAMPLE 4
7 wt % NaBr+2 wt % S in Electrolyte
NaBr (0.5 g) was introduced in the electrode as described and 2 wt % sulfur by the electrode weight (7.145 G) was incorporated to the liquid NaAlCl 4 electrolyte. This combination produced lower cell impedance and higher capacity than the cell in Example 3. These results demonstrated that the addition of sulfur to the electrolyte also resulted in an improvement in cell performance.
EXAMPLE 5
7 wt % NaBr+10 wt % Pore Former+2 wt % S in the Electrolyte
The positive electrode was fabricated in accordance with the procedure described in Example 1. A 2 wt % sulfur by the electrode weight (7.145 g) was mixed very thoroughly to the liquid NaAlCl 4 electrolyte by slowly and carefully increasing the temperature to 200° C. After mixing the sulfur with the NaAlCl 4 electrolyte, the positive electrode was placed in the positive electrode assembly of a Na/NiCl 2 cell. The performance of this cell system is shown in FIG. 3, plot 5. A comparison of FIG. 3, plot 5 with plot 1, reveals the improvement in performance provided by the combination of the bromide addition, the pore former and sulfur.
EXAMPLE 6
0.5 wt % NaI+10 wt % Pore Former+2 wt % Sulfur
Pore former was introduced in the electrode during electrode fabrication. NaI (0.035 g) and sulfur (0.1429 g) were added to the electrode or electrolyte. The combination produced better cell capacity and impedance than the cell in Example 5. More specifically, the curve for this example would be between the curves for FIG. 3, plot 5 and plot 8, and would reveal that the small addition of the iodide was very effective compared to the bromide addition of Example 5.
EXAMPLE 7
7 wt % NaBr+2 wt % NaI+10 wt % Pore Former
This combination was incorporated in the nickel chloride electrode during fabrication. The incorporation was achieved with or without the pore former, but the inclusion of pore former produced better results.
EXAMPLE 8
7 wt % NaBr+10 wt % Pore Former+5 wt % NaI in the Electrolyte
The positive electrode was fabricated in accordance with the procedure described in Example 1 except lower sintering temperature of 550°-650° C. was used. The amounts of the chemical used was exactly the same as in Example 1. Before placing the electrode in the positive electrode assembly, sodium iodide (0.3573 g) was added to the electrolyte. After this step, the positive electrode was placed in the cell assembly. The performance of this cell system is shown in FIG. 3, plot 8.
EXAMPLE 9
7 wt % NaBr+10 wt % NaI+10 wt % Pore Former+5 wt % Sulfur
The positive electrode Ni/NiCl 2 was fabricated in accordance with the procedure described in Example 8. Before placing the electrode in cell assembly, a 5 wt % sulfur (0.3572 g) and 10 wt % sodium iodide (0.7145 g) by the electrode weight (7.145 g) were added to the NaAlCl 4 electrolyte. The electrode was then placed in the positive electrode compartment of Na/NiCl 2 cell. The performance of this cell system is shown in FIG. 3, plot 9. A comparison of the curves for FIG. 3, plot 9 and plot 8, reveals the improvement provided by the combination of additive plus the pore former.
EXAMPLE 10
10 wt % NaI+20 wt % Pore Former
1.36 g Ni (15 vol %), 0.552 g NaCl (-270+325 mesh size), 0.259 g NaCl (-325 mesh size), and 0.231 g NaI (-325 mesh) were mixed together thoroughly. To this mixture of the salts a 0.4804 g of the pore former ammonium bicarbonate was added and thoroughly mixed. The mixture was then placed in a stainless steel die and pressed to obtain an electrode with 1.15 cm diameter and 1.0 cm long. This electrode, as described above, was then placed in a tube furnace and heated first at 250° for 30 minutes, under a hydrogen-containing atmosphere (5% hydrogen+95% helium) in order to remove pore former as ammonia, water, and carbon dioxide gases and, finally, to 600° C. for one hour for sintering. The electrode was removed from the furnace and placed in a cell having the positive electrode within the β"-alumina tube and sodium negative electrode outside the tube. A 2 wt % NaI (0.048 g) relative to the dry electrode weight was added to the liquid NaAlCl 4 electrolyte. The cell was charged and discharged and the performance of the cell provided data for a curve between curve 1 and curve 5 in FIG. 3.
EXAMPLE 11
1 wt % NaI+20 wt % Pore Former
The positive electrode was fabricated by the same procedure as described above in Example 10. In this example, however, 1 wt % NaI was used. The electrode was sintered in the same way as described in the example. The performance of this electrode was lower than the electrode described in Example 10, but was improved over the performance by FIG. 3, curve 1.
FIG. 3 correlates to the various examples above reported and shows the continued improvement in lowering impedance and expanding the capacity of the cell for each addition of additives. For instance, curve 1 relates to the cell made as reported in Example 1 and the other curves, 2, 5, 8, and 9 each corresponds to the same number Example. It is clear that the Example 9 which includes 10 wt % sodium bromide, 2 wt % sodium iodide, 3 wt % sulfur with the use of the ammonium bicarbonate pore former in the amount of about 10% by weight of the dry positive electrode provided the best results for the tests. In all cases, percentages of additives expressed as weight percentages of the positive electrode relates to the weight of the positive electrode in the dry state, that is before being soaked with the electrolyte and changed through cycling.
FIG. 4 shows the relationship between cell voltage and discharge capacity for curve C representing a cell without any additives and curve D representing a cell made according to Example 9. As can be seen, the capacity is much improved using the cell of the invention compared to an electrochemical cell without additives whatsoever.
FIG. 5 shows the relationship between the charging time in hours and the discharged energy in mWh/cm 2 (milliwatt hours per centimeter square), the curve representing an electrode made according to Example 9. As can be seen from FIG. 5, a cell made according to the present invention can be charged up to 20 mWh/cm 2 in about one half hour and by about 3 hours 600 mWh/cm 2 can be charged, representing almost 90% of the final charge attainable even after 12 hours of charging time. This is a significant advantage over the prior art presently known wherein charging times for the prior art automobile batteries are in the neighborhood of 8-15 hours. Recharging a battery for an electric car in half an hour as opposed to 8 hours is an extraordinary improvement.
FIG. 6 shows the relationship between the volumetric capacity in milliamp hours per centimeter cubed (mAh/cm 3 ) and the operating temperature of the battery. It can be seen from FIG. 6, which represents the battery with a positive electrode made according to Example 9, that such a battery can operate at 150° C. compared to the usual 250° C.-335° operating temperatures for batteries presently being used. The advantage of low operating temperatures and the batteries in the environment are significant. By operating the battery at lower temperatures reduces the heat management problems inherent with any battery of this type. Operating at temperatures of 335° C. increases the solubility of the nickel chloride present in the battery and when nickel ions exchange for sodium ions in the electrolyte, the internal impedance of the battery rises and hence, the heat given off during discharge rises. Moreover, lowering the operating temperature of the battery increases the battery life by reducing the glass seal corrosion. The glass seals usually used in these batteries between the metal and ceramics of the cell tend to corrode and the lower the battery operating temperature, the slower the corrosion reaction, thereby extending the life of the battery.
There is a difference in morphology for electrodes made in accordance with Example 9 characterized as ANL 92 and an electrode without the pore formers or halide additives which is designated ANL 90. The high surface area of about 10.3 m 2 /cm 3 of the Example 9 electrode (ANL 92) includes the existence of micro pores in the range of between about 0.005 and 0.5 micrometers as well as macro pores in the range of from about 1 to about 80 micrometers. The simultaneous presence of both micro pores and macro pores, referred to as bimodal pore distribution, results in an improved morphology of the nickel chloride electrode resulting in a high BET area. The macro pores in the nickel matrix do not get blocked by the formation of sodium chloride crystals during the discharge reaction which gives easy access of the active material to the electrode which would have been blocked if the macro pores were not there. The existence of the micro pores increases the high surface area of the electrode which apparently results when combined with the macro pores in increased specific capacity and volumetric capacity as illustrated in TABLE I.
TABLE I______________________________________NICKEL CHLORIDE ELECTRODE CAPACITY CHAR-ACTERISTICS FOR VARIOUS NICKEL SUBSTRATES BET Area Specific VolumericNickel Area Capacity Capacity CapacityElectrode cm.sup.2 /g mAh/cm.sup.2 mAh/g mAh/cm.sup.3______________________________________Nonporous ˜3.8 ˜1.7 × 10.sup.-1 ˜6.3 × 10.sup.-1 --wireFelt 3 × 10.sup.3 1.8 × 10.sup.-1 56 30ANL-90 1.8 × 10.sup.4 7.0 × 10.sup.-3 142 200(Sintered)ANL-92 7.7 × 10.sup.4 6.0 × 10.sup.-3 399 551(Sinteredwith Pore-former)______________________________________
TABLE I shows that the ANL 92 (Example 9) electrode is approximately 250% better in both specific capacity and volumetric capacity than is the prior ANL 90 electrode without the pore former and halide additives. Because the volumetric capacity determines the available miles a car can operate before charging and is related to the power output of the battery, it is volumetric capacity which is the most telling statistic when judging performance of electric automobile batteries.
Another feature of the invention is that batteries presently available for electric car use have an initial power in the neighborhood of 100 watts per kilogram (W/kg) but by the end of the discharge cycle, the presently available batteries are usually operating at about 60 W/kg. The battery of Example 9 has an initial power of about 200 W/kg and a final power, that is at the end of discharge, of about 170 W/kg demonstrating not only the 100% increase in battery initial power but just as important almost a 300% increase in power at the end of the discharge cycle. This feature provides a significant advantage for electric car operation because the battery power at the end of the discharge cycle is within about 15% of initial power, a substantial improvement over batteries which are presently available.
Accordingly, it is seen with the battery of the present invention, specific capacity, volumetric capacity and specific power are all greatly increased with respect to the best known prior art batteries of this type.
By reversing the physical position of the positive electrode or cathode and the negative electrode or anode illustrated in FIG. 1, more power can be generated. In such an example, the nickel chloride would be outside the β" alumina tube and the outer container would be preferably nickel, whereas the inner rod would be any good electrical conductor such as iron or steel or any other metal which would not chemically react with the liquid sodium positioned inside the tube.
It is also known that the thickness of the electrode has an effect on cell operation and varying the thickness of the electrode, will vary the impedance within the cell; however, it is believed that the addition of the additives described herein, these being bromide, iodide and sulfur containing materials and use of a suitable pore former enhances the discharge capacity of the cell and lowers the impedance.
Although the cell voltage of the Na/FeCl 2 cell (2.32 V) is somewhat lower than its counterpart Na/NiCl 2 (2.58 V), the Na/FeCl 2 cell system does offer some unique advantages. One of the major advantages of the Na/FeCl 2 battery system is that the iron chloride positive electrode can utilize scrap iron, table salt, and recycled aluminum cans as the materials of fabrication that will reduce the cost of the commercial full size battery by a significant amount. The use of these materials may also help the environment in a variety of ways. The performance of the present batteries, however, is severely limited due to the problem of overcharging of the cells, which results in the oxidation of iron (II) to iron (III) chloride in the positive electrode. The Fe (III) thus formed is exchanged with the sodium ions of the β"-alumina electrolyte. The exchange of the Na + by Fe 3+ causes the impedance of the β"-alumina and thus the cell to rise by a significant amount. Ion exchange also severely damages the integrity of the β"-alumina. Due to these effects the power, and thus the life of the Na/FeCl 2 cell declines rapidly with cycling to unacceptable values.
It was unexpectedly discovered that overcharge protection of the iron chloride was obtained by modifying the chemistry of the iron chloride electrode by the use of the chemical additives such as NaI and S, which prevent the oxidation of FeCl 2 to FeCl 3 and hence improve the cell performance. In addition to the overcharge protection, these additives significantly enhanced the capacity and power performance of the iron chloride electrode due to the modification of the electrode chemistry during the charge and discharge of the cell. The electrode fabricated with these additives has shown excellent overcharge protection, energy, power, and cycle life. This new chemistry would save nickel for the cell component fabrication. In our experiments we observed that even at the high charge voltage of 2.9 V vs. Na, there were no indications of FeCl 3 formation. At this charge voltage a cell without the additives would disintegrate. The suppression of FeCl 3 formation during the charge reaction is due to the preferred electrochemical oxidation of NaI to I 2 at the potentials where Fe(II) otherwise would oxidize to Fe(III) hence suppressing the formation of Fe(III). Iodine thus formed reacts with iron metal to form Fe(II). In addition, a redox reaction (2 NaI+2 FeCl 3 →2 FeCl 2 +I 2 +2 NaCl) probably also takes place very rapidly to convert any FeCl 3 , if formed, to give FeCl 2 . The details of the incorporation of these chemical additives in the FeCl 2 electrode are provided in the following examples.
EXAMPLE 12
2 wt % S+10 wt % Pore Former+10 wt % NaI
This example illustrates the typical fabrication of Fe/FeCl 2 electrode with additives to provide overcharge protection. The weight of the materials are relative to the dry electrode weight 3.87 g iron powder (7.86 g/cm 3 bulk density), 1.73 g NaCl powder with mesh size -270+325, and 0.905 g sodium chloride with mesh size -325+400 were mixed together thoroughly. To this mixture of the salts, 0.65 g of the pore former (ammonium bicarbonate) was added and thoroughly mixed. The mixture was then placed in a stainless steel die and pressed to obtain an electrode with a 2.85 cm diameter and an 0.5 cm thickness. This electrode was then placed in a tube furnace and heated first at 250° C. for 30 minutes under a hydrogen containing atmosphere (5% hydrogen+95% helium) in order to remove pore former as ammonia, water, and carbon dioxide gases and finally to 700° C. for one hour for sintering. Before placing the electrode in the cell assembly, 2 wt % sulfur (0.13 g) and 10 wt % sodium iodide (0.65 g) were added to the NaAlkCl 4 electrolyte. The electrode along with this electrolyte mixture was then placed in the positive electrode compartment of the cell.
EXAMPLE 13
5 wt % S+10 wt % Pore Former+10 wt % NaBr+10 wt % NaI
The combination of 10 wt % pore former, 10 wt % NaBr, and 5 wt % NaI was introduced in the electrode during electrode fabrication as described in Example 12. The remaining 5 wt % NaI and 5 wt % S were mixed thoroughly with the liquid electrolyte by slowly and carefully increasing the temperature to 200° C. After mixing the sulfur and NaI with the NaAlCl 4 electrolyte, the positive electrode was placed in the positive electrode assembly of a Na/FeCl 2 cell.
Both the electrodes of Examples 12 and 13 were repeatedly cycled without the expected disintegration due to Fe(III) formation, and upon examination no Fe(III) was detected, such that the final discharge power of the cell is at least 80% of the initial power of the cell.
While there has been disclosed what is considered to be the preferred embodiment of the present invention, it is understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
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An electrochemical cell having a bimodal positive electrode, a negative electrode of an alkali metal, and a compatible electrolyte including an alkali metal salt molten at the cell operating temperature. The positive electrode has an electrochemically active layer of at least one transition metal chloride at least partially present as a charging product, and additives of bromide and/or iodide and sulfur in the positive electrode or the electrolyte. Electrode volumetric capacity is in excess of 400 Ah/cm 3 ; the cell can be 90% recharged in three hours and can operate at temperatures below 160° C. There is also disclosed a method of reducing the operating temperature and improving the overall volumetric capacity of an electrochemical cell and for producing a positive electrode having a BET area greater than 6×10 4 cm 2 /g of Ni.
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RELATED APPLICATION
[0001] The present Application claims priority from U.S. Provisional Application Serial No. 60/404,098, filed on Aug. 15, 2002.
FIELD OF THE INVENTION
[0002] The present invention is related generally to iridescent films, and particularly to holographic embossing of such films.
BACKGROUND OF THE INVENTION
[0003] There is a need in the art for methods to produce thin gauge holographic iridescent film with a high refractive optical index. The film should be capable of producing both iridescent colors and holographic/prismatic information that is visible under various types of light. The development of such prismatic effects generated by holographic methods will enable information in the film to be used for both decorative and document/product authenticity. Similar effects can be achieved when applying the film in cut up, particle form.
SUMMARY OF THE INVENTION
[0004] The present invention is directed to a method for producing iridescent holographic optically enhanced decorative and or security film. A multi-layered iridescent film is print treated to accept a thermo-set embossing resin. The resin coating is holography embossed and then thermo-set (hardened). The film is then treated with a high refractive optical enhancement.
[0005] The process is economically advantageous in that it produces the advantage effects of four different films into one in-line processed film. The film is also colorfast/fade resistant, solvent resistant, water based and non-metallic. The film is easy to cut, laminate, combine with resins, print, vacuum treat or otherwise convert. Because one film can replace a variety of heavier and more costly film combinations, it is ideally suited for a variety of applications.
BRIEF DESCRIPTION OF THE DRAWING
[0006] [0006]FIG. 1 is a block schematic illustration of an apparatus used to produce holographic iridescent film according to one embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0007] According to the present invention, Iridescent Holographic Film is produced by a process comprising coating a poly-plastic multi-layered iridescent web with a holographic embossing, which can later be further optically enhanced.
[0008] Specific embodiments of the present invention will now be described in detail. These embodiments are intended to be illustrative only, and the invention is not limited to the materials, conditions or process parameters set forth in these embodiments.
[0009] According to the present invention the multi-layered poly-plastic web or iridescent film includes, but is not limited to corona or plasma treated polyester, polypropylene, acrylic, polyvinyl chloride (PVC), or cellulose acetate. Required untreated base film is available from Englehard Industries Inc. (series 8861 , 8601 , 8181 , 8511 , 4221 , 3181 ). In various embodiments, the web or film has a thickness of about 0.00045 inch to about 0.020 inch thick. Preferably the web is about 0.0012 inch thick. Some multi-layered iridescent films are available from Taiwan, and 3M.
[0010] In various embodiments, the size and shape of the iridescent web or film can be any suitable size roll as desired for the particular processing equipment. However, a roll of such film material about 40 inches wide and several thousand feet in length permits the material to be continuously drawn through the in-line production equipment 10 (see FIG. 1) described below by a pair of rollers 15 with tension clutch brake located downstream of the bulk roll 12 of iridescent film 13 . It is believed that one of ordinary skill in the art will be able to alter the size and variety of the iridescent film in view of the present disclosure to suit particular uses or process conditions. An adhesion coating 14 is applied to the iridescent web 13 .
[0011] The adhesion coating/treatment 14 allows the subsequent embossing thermo-set resin coating 16 to be applied evenly. In one embodiment, the thickness of the adhesion coating 14 is about 0.00005 inch. In various embodiments, this treatment can be applied as a solvent (ethyl alcohol), or resin (PVC/styrene reduced to 10% resin) resin, with a flexographic or gravure roller. A plasma treatment in a vacuum system or a water based and UV cured print treatment system can also be used. The plasma treatment is the preferred embodiment.
[0012] The adhesion coating 14 is then coated with a resin embossing coating 16 . The resin embossing coating 16 can be either thermo-set or thermoplastic. Thermo-set gives added solvent resistance and heat stability. Thermo-set systems include but are not limited to vinyl resins and epoxy resins which are cross-linked by heat. Thermoplastic urethane and water-based resins or combinations thereof are cured by ultraviolet (UV) light and lower temperature.
[0013] Optical clarity of the resin will affect the viewable color spectrum and holographic information intensity. In various embodiments, a pigment or plurality of chemicals or elements can be mixed with a clear, cured or semi-cured resin. The pigment may be present in the resin in any effective amount. The resin thermo-set embossing coating 16 is applied with a flexographic or gravure roller, to fill in the spectrum stretches in the iridescent film 13 . An optically flat surface is necessary for embossed holograph.
[0014] Next, the uncured or semi-cured resin and adhesion coated iridescent web 17 is passed through a set of holographic embossing roller(s) 18 . In various embodiments, the iridescent film 13 can be coated on one or both sides simultaneously or after curing one side of the film 13 .
[0015] Next, the thermo-set resin is cured (baked, dried, cross-linked) in an oven 20 to achieve maximum solvent resistance. Curing time in the oven varies with the type and thickness, ex. (0.0005 to 0.0015 inch thick) of the selected resin, ex. (150-350 deg. F.), for ex. (5 to 25 seconds). Thermoplastic and water based systems are cured in accordance with the manufacturer's protocol. The unenhanced processed film 24 can in one embodiment be fed via pull rollers 21 to a takeup roll 23 .
[0016] In other embodiments, after curing the resin, a metallic or non-metallic high-resolution index coating 22 can be applied via pull rollers 21 to rollers 25 with a tension clutch brake, and therefrom to the holographic surface side of the film to further enhance the overall spectral effect. This enhancement, high-resolution index (HRI), can be applied to the film 24 either by vacuum deposition (aluminum, gold, silver, bismuth, etc.), or by using a bath of (silver halide, nickle), or by solution coating as demonstrated above with the adhesion coating 14 . In this example the enhanced film 26 is fed via pull rollers 27 to a takeup roll 28 .
[0017] The finished film 24 , 26 can now be converted by slitting, sheeting, laminating, die cutting, folding, shaping or molding, printing or further color coating, or spraying as cut up particles.
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A method of producing holographic iridescent film includes the steps of applying an adhesion coating upon a corona or plasma treated iridescent film, holographically embossing the adhesion coating, thermosetting the holographically embossed adhesion coating, and applying a high-resolution index (HRI) coating to the thermo-set holographically embossed adhesion coating.
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[0001] This application claims the benefit of U.S. Provisional Application No. 60/653,736, filed Feb. 17, 2005.
FIELD OF THE INVENTION
[0002] This invention is in the field of chemical processes; more specifically, an improved process for preparing (disubstitutedpropenyl) phenylalkyl substituted dihydrobenzofurans.
BACKGROUNDS
[0003] (Disubstitutedpropenyl) phenylalkyl substituted dihydrobenzofurans, such as:
[0000]
[0000] wherein R 1 , R 2 , R 3 , R 4 , R 5 and R 6 are independently selected from halogen or alkyl and x is 2, 3, 4, 5 or 6; are useful insecticides and have been described in U.S. Pat. No. 6,987,194, the disclosure of which is incorporated herein by reference. Disadvantages of processes to produce these compounds include less than optimal yields, less than optimal cycle times and high catalyst loadings. Compounds represented by formula I:
[0000]
[0000] wherein R 3 , R 4 , R 5 , R 6 and x are as defined above; are key intermediates in the process for preparing (disubstitutedpropenyl) phenylalkyl substituted dihydrobenzofurans.
SUMMARY OF THE INVENTION
[0004] The present invention improves the process for preparing compounds of formula I. As a result of the present invention, overall yield, cycle times and catalyst loading are improved for the production of (disubstitutedpropenyl) phenylalkyl substituted dihydrobenzofurans. Specifically, it has now been found that a compound of formula I:
[0000]
[0005] wherein
R 3 and R 4 are selected from halogen; R 5 and R 6 are independently selected from halogen or alkyl; and x is2, 3, 4, 5 or 6;
can be prepared in excellent yield and purity by a process comprising:
[0009] a) reacting a compound of formula ( A ):
[0000]
[0010] wherein R 7 and R 8 are independently selected from hydrogen, alkyl, aryl or R 7 and R 8 taken together with an alkyl or aryl, forming a cyclic ester;
[0011] with a halogenating agent in the presence of a base to form a compound of formula II:
[0000]
[0012] wherein
R 3 and R 4 are as defined above; and R 7 and R 8 are as defined above;
[0015] b) reacting a compound of formula ( B ):
[0000]
[0016] wherein R 5 and R 6 are as defined above;
[0017] with a compound of formula ( C ):
[0000]
[0018] wherein
R 9 and R 10 are independently selected from halogen, hydroxyl or —OSO 2 R 11
wherein R 11 is alkyl or aryl; and
x is 2, 3, 4, 5 or 6;
[0022] in the presence of a base to form a compound of formula III:
[0000]
[0023] wherein
R 5 , R 6 R 10 and x are as defined above;
[0025] c) reacting a compound of formula II with a compound of formula III in the presence of a base to form a compound of formula IV:
[0000]
[0026] wherein
R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and x are as defined above; and
[0028] d) reacting a compound of formula IV to form a compound of formula I.
Definitions
[0029] The modifier “about” is used herein to indicate that certain preferred operating ranges, such as ranges for molar ratios for reactants, material amounts, and temperature, are not fixedly determined. The meaning will often be apparent to one of ordinary skill. For example, a recitation of a temperature range of about 120° C. to about 135° C. in reference to, for example, an organic chemical reaction would be interpreted to include other like temperatures that can be expected to favor a useful reaction rate for the reaction, such as 105° C. or 150° C. Where guidance from the experience of those of ordinary skill is lacking, guidance from the context is lacking, and where a more specific rule is not recited below, the “about” range shall be not more than 10% of the absolute value of an end point or 10% of the range recited, whichever is less.
[0030] As used in this specification and unless otherwise indicated the substituent terms “alkyl”, “alkoxy”, and “haloalkyl”, used alone or as part of a larger moiety, includes straight or branched chains of at least one or two carbon atoms, as appropriate to the substituent, and preferably up to 12 carbon atoms, more preferably up to ten carbon atoms, most preferably up to seven carbon atoms. “Halogen”, “halide” or “halo” refers to fluorine, bromine, iodine, or chlorine. The term “ambient temperature” refers to a temperature in the range of about 20° C. to about 30° C. Certain solvents, catalysts, and the like are known by their acronyms. These include the acronyms “DMAC” meaning N,N-dimethylacetamide, “DMF” meaning N,N-dimethylformamide, “THF” meaning tetrahydrofuran. The term “glymes” refers to a class of solvents comprised of monoglyme, diglyme, triglyme, tetraglyme, and polyglyme. The term “GC” refers to gas chromatography or gas chromatographic methods of analyses.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention relates to a process for preparing a compound of formula I:
[0000]
[0032] wherein
R 3 and R 4 are selected from halogen; R 5 and R 6 are independently selected from halogen or alkyl; and x is 2, 3, 4, 5 or 6;
[0036] said process comprising:
[0037] a) reacting a compound of formula ( A ):
[0000]
[0038] wherein R 7 and R 8 are independently selected from hydrogen, alkyl, aryl or R 7 and R 8 taken together with an alkyl or aryl, forming a cyclic ester;
[0039] with a halogenating agent in the presence of a base to form a compound of formula II:
[0000]
[0040] wherein
R 3 and R 4 are as defined above; and R 7 and R 8 are as defined above;
[0043] b) reacting a compound of formula ( B ):
[0000]
[0044] wherein R 5 and R 6 are as defined above;
[0045] with a compound of formula ( C ):
[0000]
[0046] wherein
R 9 and R 10 are independently selected from halogen, hydroxyl or —OSO 2 R 11
wherein R 11 is alkyl or aryl; and
x is 2, 3, 4, 5 or 6;
[0050] in the presence of a base to form a compound of formula III:
[0000]
[0051] wherein
R 5 , R 6 R 10 and x are as defined above;
[0053] c) reacting a compound of formula II with a compound of formula III in the presence of a base to form a compound of formula IV:
[0000]
[0054] wherein
R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and x are as defined above; and
[0056] d) reacting a compound of formula IV to form a compound of formula I.
[0057] The reaction of step b) can be conducted in the presence of a catalyst; at elevated temperature. The catalyst can be polyethylene glycol, dimethylaminopyridine, triethylamine, p-toluenesulfonic acid, phosphorous pentoxide, pyridine, phase transfer catalysts such as quaternary ammonium salts or quaternary phosphonium salts or mixtures thereof. The catalyst can be present in a concentration of from about 0.1% by weight to about 15% by weight. The elevated temperature can be in the range of 30° C. to 120° C.
[0058] The reaction of step c) can be conducted in the presence of a solvent; in the presence of a catalyst; at elevated temperature. The solvent can be tetrahydrofuran, toluene, xylene, acetone, acetonitrile, 1,2-dichloroethane, triethylamine, p-dioxane, N,N-dimethylacetamide, N,N-dimethylformamide, glymes, methyl isobutyl ketone, dimethylsulfoxide or mixtures thereof. The catalyst can be polyethylene glycol, dimethylaminopyridine, triethylamine, p-toluenesulfonic acid, phosphorous pentoxide, pyridine, phase transfer catalysts such as quaternary ammonium salts or quaternary phosphonium salts or mixtures thereof. The catalyst can be present in a concentration of from about 0.1% by weight to about 20% by weight. The elevated temperature can be in the range of 30° C. to 110° C.
[0059] The reaction of step d) can be conducted with a base; as a hydrolysis in the presence of an acid; in the presence of a solvent; in the presence of a catalyst. The solvent can be tetrahydrofuran, toluene, xylene, 1,2-dichloroethane, triethylamine, p-dioxane, N,N-dimethylacetamide, N,N-dimethylformamide, glymes, methyl isobutyl ketone, dimethylsulfoxide or mixtures thereof. The catalyst can be polyethylene glycol, dimethylaminopyridine, triethylamine, p-toluenesulfonic acid, phosphorous pentoxide, pyridine, phase transfer catalysts such as quaternary ammonium salts or quaternary phosphonium salts or mixtures thereof. The catalyst can be present in a concentration of from about 0.1% by weight to about 20% by weight.
[0060] Another embodiment of the present invention is a process for preparing a compound of formula I:
[0000]
[0061] wherein
R 3 and R 4 are selected from halogen; R 5 and R 6 are independently selected from halogen or alkyl; and x is 2, 3, 4, 5 or 6;
[0065] said process comprising:
[0066] a) reacting a compound of formula II:
[0000]
[0067] wherein
R 3 and R 4 are as defined above; and R 7 and R 8 are independently selected from hydrogen, alkyl, aryl or R 7 and R 8 taken together with alkyl or aryl, forming a cyclic ester;
[0070] with a compound of formula ( C ):
[0000]
[0071] wherein
R 9 and R 10 are independently selected from halogen, hydroxyl or —OSO 2 R 11
wherein R 11 is alkyl or aryl; and
x is 2, 3, 4, 5 or 6;
[0075] in the presence of a base to form a compound of formula V:
[0000]
[0076] wherein
R 3 , R 4 , R 7 , R 8 , R 10 and x are as defined above;
[0078] b) reacting a compound of formula V with a compound of formula ( B ):
[0000]
[0079] wherein R 5 and R 6 are as defined above;
[0080] in the presence of a base to form a compound of formula IV:
[0000]
[0081] wherein
R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and x are as defined above; and
[0083] c) reacting a compound of formula IV to form a compound of formula I.
[0084] The reaction of step a) can be conducted in the presence of a catalyst; at elevated temperature. The catalyst can be polyethylene glycol, dimethylaminopyridine, triethylamine, p-toluenesulfonic acid, phosphorous pentoxide, pyridine, phase transfer catalysts such as quaternary ammonium salts or quaternary phosphonium salts or mixtures thereof. The catalyst can be present in a concentration of from about 0.1% by weight to about 15% by weight. The elevated temperature can be in the range of 30° C. to 100° C.
[0085] The reaction of step b) can be conducted in the presence of a solvent; in the presence of a catalyst; at elevated temperature. The solvent can be tetrahydrofuran, toluene, xylene, 1,2-dichloroethane, triethylamine, p-dioxane, N,N-dimethylacetamide, N,N-dimethylformamide, glymes, methyl isobutyl ketone, dimethylsulfoxide or mixtures thereof. The catalyst can be polyethylene glycol, dimethylaminopyridine, triethylamine, p-toluenesulfonic acid, phosphorous pentoxide, pyridine, phase transfer catalysts such as quaternary ammonium salts or quaternary phosphonium salts or mixtures thereof. The catalyst can be present in a concentration of from about 0.1% by weight to about 20% by weight. The elevated temperature can be in the range of 30° C. to 110° C.
[0086] The reaction of step c) can be conducted with a base; as a hydrolysis in the presence of an acid; in the presence of a solvent; in the presence of a catalyst. The solvent can be tetrahydrofuran, toluene, xylene, 1,2-dichloroethane, triethylamine, p-dioxane, N,N-dimethylacetamide, N,N-dimethylformamide, glymes, methyl isobutyl ketone, dimethylsulfoxide or mixtures thereof. The catalyst can be polyethylene glycol, dimethylaminopyridine, triethylamine, p-toluenesulfonic acid, phosphorous pentoxide, pyridine, phase transfer catalysts such as quaternary ammonium salts or quaternary phosphonium salts or mixtures thereof. The catalyst can be present in a concentration of from about 0.1% by weight to about 20% by weight.
[0087] Another embodiment of the present invention is a compound of formula II:
[0000]
[0088] wherein
R 3 and R 4 are selected from halogen; and R 7 and R8 are independently selected from hydrogen, alkyl, aryl or R 7 and R 8 taken together with an alkyl or aryl, forming a cyclic ester.
[0091] Another embodiment of the present invention is a compound of formula III:
[0000]
[0092] wherein
R 5 and R 6 are independently selected from halogen or alkyl; R 10 is selected from halogen, hydroxyl or —OSO 2 R 11
wherein R 11 is alkyl or aryl; and
x is 2, 3, 4, 5 or 6.
[0097] Another embodiment of the present invention is a compound of formula IV:
[0000]
[0098] wherein
R 3 and R 4 are selected from halogen; R 5 and R 6 are independently selected from halogen or alkyl; R 7 and R 8 are independently selected from hydrogen, alkyl, aryl or R 7 and R 8 taken together with an alkyl or aryl, forming a cyclic ester; and x is 2, 3, 4, 5 or 6.
[0103] Yet another embodiment of the present invention is a compound of formula V:
[0000]
[0104] wherein
R 3 and R 4 are selected from halogen; R 7 and R 8 are independently selected from hydrogen, alkyl, aryl or R 7 and R 8 taken together with an alkyl or aryl, forming a cyclic ester; R 10 is selected from halogen, hydroxyl or —OSO 2 R 11
wherein R 11 is alkyl or aryl; and
x is 2, 3, 4, 5 or 6.
[0110] The following examples illustrate processes for preparing compounds of formulae I, II, III, IV and V.
Example 1
[0111]
[0112] In the first step (a) of Example 1, dialkyl 4-hydroxybenzenephosphate (A), for example diethyl 4-hydroxybenzenephosphate, was reacted with a halogenating agent, for example sulfurylchloride, in the presence of a base at reduced temperature to form dialkyl 3,5-dihalo-4-hydroxybenzenephosphate, a compound of formula II, for example diethyl 3,5-dihalo-4-hydroxybenzenephosphate.
[0113] In step (b) of Example 1,2,2-dialkyl-2,3-dihydrobenzo[b]furan-7-ol (B) was reacted with a 1,4-dihaloalkane (C), for example 1,4-dihalobutane, in the presence of a base and a catalyst at elevated temperature to form a 1-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))-4-haloalkane, a compound of formula III, for example 1-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))-4-halobutane.
[0114] In step (c) of Example 1, dialkyl 3,5-dihalo-4-hydroxybenzenephosphate, a compound of formula II, for example diethyl 3,5-dihalo-4-hydroxybenzenephosphate, was reacted with a 1-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))-4-haloalkane, a compound of formula III, for example 1-(2,2- dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))-4-halobutane, in the presence of a base, a solvent and a catalyst at elevated temperature to form a dialkyl 4-[4-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))alkoxy]-3,5-dihalobenzenephosphate, a compound of formula IV, for example diethyl 4-[4-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))butoxy]-3,5-dihalobenzenephosphate.
[0115] In step (d) of Example 1, a dialkyl 4-[4-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))alkoxy]-3,5-dihalobenzenephosphate, a compound of formula IV, for example diethyl 4-[4-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))butoxy]-3,5-dihalobenzenephosphate, was reacted with a base at ambient temperature to form a 4-[4-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))alkoxy]-3,5-dihalophenol (I), for example 4-[4-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))butoxy]-3,5-dihalophenol.
Example 2
[0116]
[0117] In the first step (a) of Example 2, dialkyl 3,5-dihalo-4-hydroxybenzenephosphate, a compound of formula II, for example diethyl 3,5-dihalo-4-hydroxybenzenephosphate, can be reacted with a 1,4-disubstitutedalkane (C), for example 1,4-disubstitutedbutane, in the presence of a base and a catalyst at elevated temperature to form dialkyl 4-(4-substitutedalkoxy)-3,5-dihalobenzenephosphate, a compound of formula V, for example diethyl 4-(4-substitutedbutoxy)-3,5-dihalobenzenephosphate.
[0118] In step (b) of Example 2, a dialkyl 4-(4-substitutedalkoxy)-3,5-dihalobenzenephosphate, a compound of formula V, for example diethyl 4-(4-substitutedbutoxy)-3,5-dihalobenzenephosphate, can be reacted with 2,2-dialkyl-2,3-dihydrobenzo[b]furan-7-ol (B) in the presence of a base, a solvent and a catalyst at elevated temperature to form a dialkyl 4-[4-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))alkoxy]-3,5-dihalobenzenephosphate, a compound of formula IV, for example diethyl 4-[4-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))butoxy]-3,5-dihalobenzenephosphate.
[0119] In step (c) of Example 2, a dialkyl 4-[4-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))alkoxy]-3,5-dihalobenzenephosphate, a compound of formula IV, for example diethyl 4-[4-(2,2-dialkyl(2,3-dihydrobenzo[2,3-b]furan-7-yloxy))butoxy]-3,5-dihalobenzenephosphate, can be reacted as in Example 1 to produce the expected product (I).
[0120] While this invention has been described with an emphasis upon preferred embodiments, it will be obvious to those of ordinary skill in the art that variations of the preferred embodiments may be used and that it is intended that the invention may be practiced otherwise than as specifically described herein. Accordingly this invention includes all modifications encompassed within the spirit and scope as defined by the following claims.
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An improved process is described for preparing (disubstitutedpropenyl) phenylalkyl substituted dihydrobenzofurans. This improved process is focused on steps to produce key intermediates, namely disubstitutedphenolylalkyl substituted dihydrobenzofurans of formula I:
where R 3 , R 4 , R 5 , R 6 and x are defined herein.
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FIELD AND BACKGROUND OF THE INVENTION
This invention relates to construction or excavating equipment and, more particularly, to modifying equipment such as a front end loader or bucket loader with a hoisting gin or boom member so that equipment may be used for lifting or lowering objects in construction work, in addition to such normal work as trenching or excavating.
Equipment, such as bucket loaders, have been modified in the past to mount or carry boom members or cranes for special lifting applications. Normally such loaders are utilized for excavating and loading. With the addition of the boom attachment, the equipment is utilized for lifting objects such as pipe in the construction of sewers and drainage systems. The boom or crane attachments in the past have required a significant number of connections to the bucket or support such that the installation of the same is time consuming. More importantly, there is no provision on such construction equipment for storing the attachment when it is not in use. Consequently, a problem exists of having the attachment available and in proximity at a work site in order to facilitate connection and disconnection of the same. This contributes to time delays and adds to the cost of usage and operation of the equipment. Examples of such prior constructions are shown in the United States Patents to Swanson U.S. Pat. No. 3,092,259; Foster, U.S. Pat. No. 3,249,245 and DeCarli, U.S. Pat. No. 3,587,887.
SUMMARY OF THE PRESENT INVENTION
The present invention is directed to a hoisting gin or boom attachment for construction equipment in which the gin or boom member is storable on the equipment so that it is available for usage at all times. Further, it may be set into a position of usage in the minimum amount of time, significantly reducing the cost of operation of the same. The improved boom attachment or gin pole is specifically adapted to be mounted on the bucket of a front end loader. The bucket of the loader is modified to provide a pair of supports on the upper side of the bucket adjacent the sides thereof. Each support includes a pivot member and a retaining flange with the pivot member being positioned rearwardly of the retaining flange. The boom member may be selectively attached to either support and is coupled to the pivot member through a pivot pin extending through the pivot member and fitted through an aperture in one end of the boom member to secure the same to the support. The pins are removable to provide for interchange of the boom member in one or the other of the supports. The retaining flange of the support is a generally right angle bracket with a removable pin which is adapted to extend vertically through the end of the flange alongside of the boom member and retain the same therein, holding the boom member to prevent pivotal movement of the same within the support. The boom member extends beyond the forward edge of the bucket and may be formed of telescopic parts to adjust the length of the same. Suitable apertures and pins in the boom member will adjust and retain the length of the same. The end of the boom member mounts a universal swivel with a piece of cable attached thereto, the cable having a safety lifting hook on the end of the same. The cable is adapted to connect objects, such as pipes, to the end of the boom member for lifting or lowering purposes, and the boom member will be moved with the bucket to which it is attached through a tilting and elevating motion conventional with front end loaders or bucket loaders.
When the boom member is not in use, it may be collapsed and stored on the upper edge of the bucket by removing the pin in the retaining flange and pivoting the boom member to the opposite support where it may be connected to either the retaining flange or the pivot member of the opposite support. A U-shaped bracket is positioned on the upper edge of the bucket intermediate the supports to aid in supporting the boom member in a stored position.
The boom member also includes a loop welded to the side of the same to which the lifting hook of the cable may be attached to dispose the cable along the side of the boom member in the stored position when not in use.
The invention will be best understood in connection with the attached drawings wherein:
IN THE DRAWINGS
FIG. 1 is a side elevation view of a construction machine, such as a front end loader, with a boom member or gin pole attachment thereon;
FIG. 2 is a top perspective view of the bucket of a front end loader with a boom member thereon;
FIG. 3 is a top elevation view with the boom member in a stored position; and,
FIG. 4 is a sectional view of the boom attachment of FIG. 2 taken along the lines 4--4 therein.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a construction machine, such as a front end loader or bucket loader, to which the storable boom member or gin pole is normally attached. The front end loader, indicated generally at 10, may take varying forms. The front end of the machine mounts a bucket 20 which is coupled to the front end of the machine through various linkages 25 and actuators, indicated generally at 30, to enable the bucket to be pivoted about an axis transverse to the extent of the machine and elevated or lowered on the linkages. Such machines are normally used for excavation-type work or loading since the bucket may be elevated and pivoted for loading purposes and lowered so that the edge of the bucket bites into or moves along the ground surface for excavation purposes. To extend the usage of such a machine, a boom member 40 or hoisting gin pole may be coupled to the bucket, enabling the machine to lift articles and lower the same in varying construction type operations. It has a swivel 42 mounted at the end of the same with a suitable cable 44 attached to the swivel, the cable having a safety lifting hook 45 at the end of the same, enabling the cable to be attached to a sling or choker (not shown) or to be secured around an object to lift or lower the same.
As will be seen in FIGS. 1 and 2, the bucket 20 is normally formed with an inclined upper or top side 51 and a lower bottom side 52 surface with sides 53 joined thereto. It includes a rear surface 54, leaving an open front face which has a greater area then the rear side of the bucket.
As will be seen in FIG. 2, the supports for the gin pole or boom member are mounted on the forward edge of the upper side of the bucket. Thus, as is indicated in FIG. 2, supports 60 and 65, which are similar in construction, are mounted on the forward edge of the upper side of the bucket adjacent the sides thereof. Each support is comprised of a base plate 61 generally square or rectangular in section, which is welded to the top side of the bucket. The base plate mounts a pivot flange 62 on the rear edge of the plate 61 and a retaining flange 64 forward of the same and adjacent the front edge of the bucket. The pivot flange is preferably formed of two upstanding right angle sides which are common to the outside edge of the bucket and the rear edge of the base plate, the sides being welded to the base plate and to a top plate overlying the sides.
As will be seen in FIG. 4, a suitable pivot pin 70 is positioned through an aperture in the top of the pivot flange and extends to an aperture 71 in the base plate aligned therewith. The pivot pin has a T-shaped handle 72 on the top side of the same and a suitable rib 74 welded to the top side of the pivot flange has an aperture therethrough by means of which a suitable nut and bolt 75 may pass through the rib and an aperture in the pin to retain the pin on the top of the pivot flange. The retaining flange 64 or locking member is generally an L-shaped member welded to the base plate to give a U-shaped configuration with a closed side common to the edge of the bucket and open toward the center, front and rear of the bucket. A suitable retaining pin 77 extends through an aperture in the flange and into an aperture 78 in the base plate to hold the pin therein. The retaining flange similarly has a rib 79 at the top edge of the same through which a bolt 80 is positioned and through an aperture in the pin to secure the pin to the retaining flange. Pin 77 is positioned near the open face of the retaining flange such as to extend vertically along the side of the boom member, as will be hereinafter defined.
Boom member or gin pole 40 is a generally elongated structure formed of telescopic parts 41, 43 which may be square or round in cross-section and slidable one within the other. Suitable apertures 47 in the extent of the gin pole or boom permit the boom member to manually be extended or retracted and retained in position by pins 46 which pass through the apertures. The pivot end of the boom member 40 or the telescopic part 41 as shown in FIGS. 1 and 2 has an aperture 85 extending therethrough by means of which the boom member may be mounted in the pivot flange 62 of the support. The pivot pin 70 extends through the pivot flange and the aperture 85 in the telescopic part 41 of the boom member or gin pole to secure the same to the support. The pin may be removed and the boom member selectively positioned in one or the other of the supports 60 or 65. The retaining flange 64 serves as a locking member to hold the boom in a forward extended position with respect to the bucket when in use. The boom will fit within the U or L-shaped configuration of the retaining flange and the pin 77 extends therethrough will hold the boom member in a locked position.
The end of the boom member or gin pole mounts the swivel 42 which is preferably universally mounted in the telescopic part 43. The cable 44 is attached thereto and the safety lifting hook 45 at the end of the same will enable the cable to be secured to a sling or choker placed around the object, such as a pipe, to secure the same to the cable for lifting and lowering the pipe, such as in a sewer construction. The length of the boom part 41 or the boom member when collapsed is basically the same as the width of the bucket or the distance between the pivot members 62 on the supports 60 and 65. When the boom member or gin pole is not in use, the pin 77 of the retaining flange 64 will be removed, allowing the boom to be pivoted into alignment with opposite support. The swivel 42 at the end of the same may be secured by the pin of the opposite retaining flange or the pin of the opposite pivot flange to secure the boom or gin pole in a stored position. An intermediate support flange 102 is also mounted on the center of the bucket on the top side thereof between the supports 60, 65 which support flange is generally U-shaped in form and open facing forward to receive the boom in the stored position and aid in securing the same to the bucket. The safety lifting hook 45 in the stored position is connected to a loop 100 mounted on the top of the gin pole or boom member to store the cable when the boom is folded onto the upper surface of the bucket.
The improved hoisting gin pole or storable boom member may be readily removed from its mounting in one support and positioned in the other support, depending upon the desired location of the same with respect to the bucket. Similarly, the boom may be moved from the stored position and retained in a forward working position by the respective retaining flanges. The boom may be extended or retracted as desired, and the cable thereon will connect to the object which may be raised or lowered through pivot of the bucket by the linkages connecting the bucket to the machine.
In usage, the improved front end loader or bucket loader may be readily modified or set up to perform lifting operations with a boom member merely by placing the boom in an extended position and coupling the same through the retaining flange. Objects may be raised or lowered by moving the bucket and the storable boom may be readily stored on the machine when not in use so that it is readily available for usage at any time. It may be placed into operation with a minimum amount of effort and time to significantly enhance the overall performance of the machine.
In considering this invention, it should be remembered that the present disclosure is illustrative only and the scope of the invention should be determined by the appended claims.
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This invention relates to a storable hoisting gin or boom member attachment for bucket loaders which provides an arrangement for quickly and easily moving a boom member or gin pole into working relationship with respect to a bucket loader so that this type of construction vehicle may be used for lifting and lowering objeccts in construction work. The attachment consists of supports welded to the top side of the bucket, each support including a pivot flange and a retaining flange to which the boom or gin is attached. Each pivot flange permits pivoting of the boom member to a collapsed position on an opposite support on the top side of the bucket for storage purposes.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is related to the commonly owned, concurrently filed application, Ser. No. 11/428,725, entitled “METHOD AND SYSTEM FOR DYNAMICALLY CREATING AND MODIFYING RESOURCE TOPOLOGIES AND EXECUTING SYSTEMS MANAGEMENT FLOWS”, incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to the field of workflow transformation, and in particular to a method and system for transforming orders for executing them in a standard Workflow Engines.
Motivation
Today's data center management world is becoming more and more complex due to the growing complexity of multi-tier applications being run in a data center. Especially the instantiation of new applications instances and the modification of those instances has become very difficult.
There are approaches addressing the problem of growing complexity in terms of instantiating, modifying and configuring such applications. Due to their special problem domain, these approaches do not leverage standard, activity-based workflow languages. The present invention proposes a solution for transforming the descriptions being optimized for the instantiation, modification and configuration of resource graphs into standard-compliant, activity-based workflows. This allows leveraging the advantages of both worlds: The instantiation, modification and configuration of resource graphs can be described in a comfortable manner by using the description language being optimized for this domain. And for executing what is defined by this description it is possible to leverage the qualities provided by existing products being able to process standard workflows, which are for example implemented based on the Business Process Execution Language (BPEL).
BACKGROUND INFORMATION
This chapter will provide information on the background of this invention proposal. The first part of this chapter is concerned with the technical field of this invention proposal in general. After that the initial problem is described. Finally, the residual problem is addressed, which consequently provides the motivation for this invention proposal.
1. Technical Field
Today's IT infrastructures are composed of a large number of heterogeneous, distributed stateful resources. That is, complex multi-tier applications typically comprise or are hosted by several heterogeneous IT resources (e.g. servers, operating systems on those servers, databases, application server software, etc.). For each of those resources several resource-specific management functions are available for controlling the operation of a resource, i.e. for creating (provisioning), destroying (de-provisioning) and controlling the operation and configuration of a stateful resource. Resource management functions of a resource may also control other stateful resources—for example, a resource that acts as a resource manager may offer a service to create/provision a new instance of a certain other resource.
With regard to the notion of “Systems Management Flows” we also use the term “systems management tasks” for resource management functions (see the concurrently filed application cross-referenced above).
In order to perform systems management in the scope of a whole IT system (in contrast to single resources), an integration of single systems management tasks (for specific resources) into a systems-wide Systems Management Flow is necessary in order to treat a system as a whole and keep it in a consistent state.
The key to managing heterogeneous, distributed IT resources in an efficient and consistent way is to have common, standards-based interfaces to IT resources. In particular, the single systems management tasks providing management access to resources have to be accessible using common, standards-based interfaces. A common way for accessing distributed resources is using stateful Web services interfaces. This issue is addressed by several open Web Services standards (such as the Web Services Resource Framework (WS-RF), Web Services Distributed Management (WSDM), WS-Transfer, WS-Enumeration, etc.). Consequently, within the scope of this document it is assumed that systems management tasks for managing IT resources provide a stateful Web services interface and can thus be accessed by a management system in a uniform way.
The modeling of relationships between resources is another important aspect for managing heterogeneous distributed IT resources. For example, a resource may use or host another resource. Relationships between stateful resources are covered by open standards like WSDM.
Initial Problem
EP 1636743A1 describes an approach for the proper instantiation, modification, and configuration of resource graphs representing complex multi-tier applications by using so-called order documents. Order documents are XML documents, which are tailored to the area of resource graph operations—with special focus on the comfortable modification of existing resource topologies. Although order documents have the advantage of comfortable means in the systems management area, there is the disadvantage that there is a special runtime environment needed in order to process these order documents. Since the processing of order documents has pretty much the character of traditional workflow processing, it would be desirable to process the semantics expressed by the order document in combination with the existing resource topology that is to be modified, in a standard workflow container (e.g. the IBM WebSphere Process Server being able to process Business Process Execution Language (BPEL) compliant process definitions). This would help to avoid the duplicate implementation of typical qualities of services for such runtime environments (e.g. security, error handling, scalability, etc.).
2. Prior Art
Traditionally, the provisioning of resources is supported by dedicated provisioning products. These software applications normally define their view of the data center within a database. This database is normally populated by some discovery mechanisms. Based on the information, which is stored in the database, another component of the provisioning product, a deployment engine, drives provisioning workflows in order to change the data center infrastructure as desired by the administrator. An example for such a provisioning product is IBM's Tivoli Provisioning Manager (TPM). Although TPM uses its own (proprietary) workflow description today, it could also be envisioned that there is some industry-standards based workflow description language used, like for example the Business Process Execution Language (BPEL).
Residual Problem
Each of the technologies described in the previous section have certain drawbacks, which will be elaborated in the following.
The traditional approach of “workflow-driven systems management” (as it is today for example available via IBM's Tivoli Provisioning Manager) has the drawback that the used workflows are very inflexible, i.e. each time the desired deployment topology changes (e.g. for a multi-tier application from single-node deployment to distributed deployment), the workflows have to be adapted as well. This is due to the fact that the workflows assume a certain resource topology underneath. Once this resource topology changes slightly, the workflows break. As already indicated in the previous chapter, this kind of drawback is not limited to a specific product. This kind of drawback applies to all approaches being based on the concept of performing systems management actions by using plain activity-based workflow technology.
The concept of orders overcomes the aforementioned drawback of the strong dependency of the description for systems management actions on underlying resource topology. This is achieved by combining the knowledge about the information required by resources with the knowledge about the actual resource topology. The drawback of this approach is in turn that it is not possible to leverage existing products supporting traditional workflows. That means, it would be required to build the kind of tooling that is today for example available in the BPEL area (Process Modeling Tools, Debugging Tools, etc.) again for order documents. Furthermore, it would be required a special runtime infrastructure for order documents with all the qualities of service, which are today already available in standard process engines (e.g. IBM WebSphere Process Server). These qualities of service refer to security, scalability, error recovery, transactional behavior, etc.
So the residual problem in this area is the problem of needing a combination of the flexibility of order documents and the robustness and industry support of standardized workflow languages. Therefore, this patent describes an approach for transforming order documents, which can be regarded as very dynamic interpreter-based workflows into static, activity-based processes, like for example BPEL processes. This allows being very flexible in terms of the description of systems management actions while using enterprise-level tooling and runtime support.
OBJECTS OF THE INVENTION
It is an object of this invention to provide a method and system for transforming orders for executing them in standard workflow engines.
SUMMARY OF THE INVENTION
The invention is based on Orders specifically developed for and processed by an Order Processing Environment for creation or modification of resource topologies. The Order Processing Environment is partly replaced by a combination of an Order Transformation Environment and standard Workflow Engines in order to execute the Order by standard Workflow Engines.
The Order Transformation Environment needs to get two inputs.
The first input is the resource topology which is retrieved by using the Relationship Registry of the Order Processing Environment.
The second input is the Order. Orders are resource topology independent and include resource specific tasks without arranging those in a sequence. Tasks provide actions for creating and/or modifying resource topologies.
The transformation is based on above two inputs resulting in a static standard based workflow. The static, standards-based workflow (e.g. BPEL-based) can then be executed by standards-based process/workflow engines. This enables users to exploit the flexibility of orders while still being able to leverage the broad set of tooling and runtime products available across the IT industry.
DESCRIPTIONS OF DRAWINGS
FIG. 1 shows the Order Processing Environment on which the present invention is based,
FIG. 2 shows the Order Processing Path within the Order Processing Environment,
FIG. 3 shows the structure of an initial Order,
FIG. 4 shows an example of a Topology Subsection,
FIG. 5 shows an Order Processing Loop of Container—Request Path,
FIG. 6 shows an Order Processing Loop of Container—Response Path,
FIG. 7 shows a Subroutine CreateOHC chain,
FIG. 8 shows a Subroutine CreateNextOPC,
FIG. 9 shows the basic structure of the present invention,
FIG. 10 shows the basic components of the present invention, and
FIG. 11 shows the inventive method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is based on orders which are processed within an Order Processing Environment which includes Order Processing Container, Relationship Registry, and Factory Registry (see detailed description on page 8 to 10).
At first the Order Processing Environment is described in more detail in Section 1 and then the Order Transformation Environment for which patent protection will be sought is described in section 2.
Section 1
The order definition is strongly focused on improving and simplifying the process of instantiating, modifying and configuring resource graphs in general (whereas they are of course mainly targeted to be used in the systems management field). This goal is achieved by combining the knowledge about the infrastructure, which will be modified by the order with the information that is conveyed by the order itself. This is in significant contrast to traditional approaches, where the flow of activities of a system management flow is directly defined by the hard-coded sequence of activities within the flow.
Resources in the Context of Order Processing
In the following description of the order concept the term “asynchronous operation” is used. In the context of this invention an asynchronous operation is defined as an operation that immediately returns to the caller of the operation without a result. The called operation is executed later at same point in time. In this sense, implementation examples for asynchronous operations are one-way web service operations, or operations that are called via messages which are delivered by a messaging system like JMS (Java Messaging System).
Resources that take part in Order Processing implement the asynchronous operation processOrder. The only parameter of this operation is the Order that is handed over to the resource by the Container. When being called by processOrder the resource interprets the input parameters of its associated Task section in the Order and executes the Task (refer to section “Structure and Semantics of Orders” for more details regarding Order structure). A Task can perform any operation. Typically, the resource calls components of the Systems Management Layer in order to fulfill the Task. There is no specification for the interfaces of the components in the Systems Management Layer. The resource has to cover the interfacing by itself, the Order Processing Environment does not provide any support for this issue. While executing the Task, the resource may write results to its Task section in the order. Finally, the resource calls the Container of the Order Processing Environment by its asynchronous operation delegateOrder and hands over the (updated) Order back again.
There are two roles defined for resources in the context of Order Processing: role Order Processing Component and role Order Handling Component. Order Processing Components represent the base nodes of the Resource Topology. Each resource with role Order Processing Component has a related chain of resources with role Order Handling Component. Instead of using the terms “resources with role Order Handling Component” and “resources with role Order Processing Component” we simplify our wording and use “Order Handling Components” and “Order Processing Components”, respectively, in the following text. The Order Handling Component chain may also be empty for a Order Processing Component. For example, resource Subscription in FIG. 1 has an associated chain of two Order Handling Components (MeterEventLog and ReportManager), resource ODS has no associated Order Handling Components (in other words, the associated chain of Order Handling components is empty for ODS). The Container calls each Order Processing Component before and after all Order Handling Components that are contained in its associated chain. Furthermore, after all resources have been called, the Container reverses Order Processing and calls all resources again that it has called before in reverse order. As a consequence, each Order Processing Component is called four times by the Container by its processOrder operation, while each Order Handling Component resource is called twice by the Container by its processOrder operation. The example in FIG. 2 shall help to clarify the way how Orders are processed. In the example, Order Processing starts at the Subscription resource. The fact that resources get the Order from the Container and hand over the Order back to the Container again after the execution of their associated Task is not shown FIG. 2 . Instead, the sequence of the involved resources that process the order is depicted: the path starts with the Subscription resource that gets the Order handed over from the Container (i.e. the Container calls the processOrder operation of Subscription), processes the task and returns the Order back again (by calling the delegateOrder operation of the Container). The MeterEventLog resource is the second resource in the path (section “Order Processing Container” describes how the Container determines the resources along the processing path). The Container hands over the Order to the MeterEventLog, which in turn processes and then returns the Order back again to the Container. Then the path continues with the ReportManager resource. The Subscription resource is the next resource in the path. This is the second time that the Subscription resource is called by its processOrder operation. Each Order Processing Component is called before and after its related Order Handling Component chain by the Container by its processOrder operation. In contrast to this, each Order Handling Component in the chain is only called once by the Container. The processing path then continues with the ODS resource. Although the Order Handling Component chain of ODS is empty, ODS is called twice (before and after the empty Order Handling Component chain). The path continues with Application, WebApplication, etc.. Finally, the path ends up with the WebAppSry resource. The Container detects the end of the path if it cannot find any related successor resource that it could hand over the Order (see “Order Processing Container” how the Container determines the resources along the processing path). At this point in time the Container reverses the order processing path and calls each resource again that it has called before in reverse order. In the example of FIG. 2 , the Container starts the reverse path (which is also called Response Path in contrast to the Request Path that has been discussed so far) with the WebAppSry resource. The WebAppSry resource is called twice (before and after its empty Order Handling Component chain). Then the reverse path continues with the OSContainer resource, followed by the Server resource, the OSContainer resource again, the Application Tier resource, etc. The reverse path finally ends up with the Subscription resource. This also ends Order Processing for that Order.
As a result (as mentioned earlier), each Order Processing Component is called four times by the Container by its processOrder operation, while each Order Handling Component is called twice. As a consequence each Order Processing Component can subdivide the execution of its Task into four parts, while each Order Handling Component can subdivide the execution of its Task into two parts. It depends on the purpose of the Order and the individual Task how this subdivision must be done and it is up to the resource developer to make these decisions. Furthermore, all resources must keep an internal state in order to detect how often they have been called by its processOrder operation. There are no hints they get from the Order Processing Environment.
Finally, each resource must implement the operation destroy. This operation is called by the Container when it removes a resource from the Resource Topology. This is the last call the Container performs towards the resource. Then the Container removes the relationship to that resource from the Relationship Registry. From that point on the resource is treated by the Order Processing Environment as being removed and thus not existent when being called with destroy the resource should remove all of its instance data.
Relations Between Resources
Relations between resources are stored in the Relationship Registry component of the Order Processing Environment (refer to section “Relationship Registry” for more details). As the term “Relation” indicates, a relation connects two resources with each other in order to reflect a relationship between these resources with regard to the Resource Topology. Each edge in the Resource Topology graph is represented by a relation between two resources.
For the purpose of the present invention, each relation comprises of five attributes:
1. sourceHandle (a Resource Handle pointing to the first resource) 2. targetHandle (a Resource Handle pointing to the second resource) 3. sourceRole (role of the first resource) 4. targetRole (role of the second resource) 5. relationName (optional, can be used as name or stereotype for the relation).
In the context of this invention a Resource Handle is a pointer to a resource—either a direct reference to a resource or an indirect reference to a resource that must be resolved into a direct reference (the notion of direct and indirect references is, for example, mentioned in the Global Grid Forum Open Grid Service Infrastructure (OGSI)—direct references are called Grid Service References (GSR), and indirect references are named Grid Service Handles (GSH)). Another example for direct references are End Point References as defined in the WS-Addressing standard. In the context of this invention we assume that Resource Handles are unique for a resource instance so that they can be directly compared for the sake of simplicity of this description. But this does not restrict the generality of this invention. Comparisons, meaning the decision whether two Resource Handles point to the same resource instance, can be enhanced in a straightforward way since stateful resources have a unique resourceId: query the resources for the resourceId where the two Resource Handles point to. Then compare these two values,
The attributes sourceRole and targetRole define the roles of the related resources. There are two roles defined: Order Handling Component (H) and Order Processing Component (P). Valid combinations of (sourceRole, targetRole) include (P, P), (P, H) and (H, H). The combination (H, P) is invalid.
Relations are interpreted as directed connections between two resources. The direction of a relation expresses a parent-child relationship between two resources with regard to the underlying Resource Topology. The sourceRole attribute expresses the parent role of the resource that is defined by attribute sourceHandle, while the targetRole attribute expresses the child role of the resource defined by attribute targetHandle. The attribute relationName is optional and has no further purpose in the context of this patent.
Structure and Semantics of Orders
The Order is a document (e.g., XML) which includes a number of tasks for each involved resource without arranging those tasks in a sequence. The Task sequence is derived from the Resource Topology as described in section “Order Processing Container”. This differentiates Orders from workflow definitions used by standard workflow engines.
There are three types of Orders:
1. Initial Orders 2. Modification Orders 3. Termination Orders
Initial Orders contain Tasks for building up an initial Resource Topology. Modification Orders can be processed on Resource Topologies that have been initialized by an Initial Order (e.g., a Modification Order includes Tasks for provisioning a new server to the existing system). A Termination Order is the last Order that can be applied to a Resource Topology. The purpose of this Order is to terminate all management actions, to clean up any storage that keeps state information which is not required anymore, and then remove all resources of a given Resource Topology.
In addition to the Order type, each Order has an Order name which identifies the specific Order. The resources interpret the Order type and the Order name in addition to their input parameters for deriving the Task that has to be performed. Each resource has an internal list of known Orders, identified by the Order type and the Order name. If a resource is called with an unknown Order then the resource shall perform no action and return the Order immediately to the Container.
FIG. 3 shows an example of an Initial Order with the Order name “Create System”. The Order is intended to build up a base Resource Topology as depicted at the top of the figure. The Order contains eight sections, one for each resource. A resource identifies its associated section in the Order by the section name which is the resource type identifier of the resource (e.g., section Subscription refers to the Subscription resource). Each section in the Order contains two subsections: the parameters subsection and the topology subsection. Both subsections can be empty.
A topology subsection defines a set of relationships and resources to be created or removed from the current Resource Topology starting from the current resource. The topology subsection includes:
1. A hint for the Container whether the mentioned relations and resources are to be created or removed by the values “create” and “remove”, respectively. 2. A list of entries, one for each resource and relation that are to be created or removed. Each entry includes: the resource type of the resource that is to be created or removed, and definitions for the relation attributes “name”, “sourceRole”, and “targetRole”.
All relations and resource definitions in a topology subsection of a resource X are interpreted relative to resource X. In the case that the resources and relations of the topology subsection shall be added to the Resource Topology, the topology subsection has following semantics: all listed Order Handling Components are appended via relations to the Order Handling Component chain of resource X in the same sequence as they appear in the list of entries which is mentioned in point 2. above. The listed Order Processing Component (if any) is directly connected to resource X via a relation. The mentioned relations are added to the Relationship Registry according to the definitions of the relation attributes in the topology subsection entries. The role of the new resources that are listed in the topology subsection entries is derived from the definition of the corresponding relation attribute targetRole since the listed new resources are always the targets of the relations that are defined in topology subsections.
FIG. 3 shows an example of an Initial Order that contains a section for resource Subscription. The related topology subsection for Subcription is repeated here:
Topology.create: (meaning the topology below is to be created and connected to Subscription)
1. resource type: meter event log, relationship (name=uses, sourceRole=OPC, targetRole=OHC) 2. resource type: report manger, relationship (name=chainsTo, sourceRole=OHC, targetRole=OHC) 3. resource type: ODS, relationship (name=delegates, sourceRole=OPC, targetRole=OPC) with OHC and OPC being short forms for Order Handling Component and Order Processing Component, respectively.
The semantics of the mentioned topology subsection example is that three new resources (Meter Event Log, Report Manager, and ODS) are to be created and added to the Subscription resource in the following way:
1. From point 1. in the list above can be derived that Meter Event Log shall act as an Order Handling Component since the relationship targetRole attribute is OHC. So the Meter Event Log will be appended to the Order Handling Component chain of the Subcription resource by a relation with name=uses, sourceRole=Order Processing, and targetRole=Order Handling Component, sourceHandle=Resource Handle of Subscription, and targetHandle=Resource Handle of Meter Event Log (see also FIG. 4 ). Meter Event Log is the first resource in the Order Handling Component chain of Subscription. 2. From point 2. in the list above can be derived that Report Manager shall act as an Order Handling Component since the relationship targetRole attribute is OHC. So the Report Manager will be appended to the Order Handling Component chain of the Subcription resource by a relation with name=uses, sourceRole=Order Processing, and targetRole=Order Handling Component. Since Meter Event Log has been listed before Report Manager, the Report Manager will appended to the Meter Event Log, in other words: sourceHandle will point to Meter Event Log, and targetHandle will point to Report Manager (see also FIG. 4 ). 3. From 3. in the list above can be derived that ODS shall act as an Order Processing Component since the relationship targetRole attribute is OPC. So ODS will be connected directly to the Subscription via a relation with name=delegates, sourceRole=Order Processing, and targetRole=Order Processing Component, sourceHandle=Resource Handle of Subscription, and targetHandle=Resource Handle of ODS (see also FIG. 4 ).
Topology subsections that refer to removal of resources and relations are indicated by the hint “remove”. The Container identifies the existing resources and relations that are to be removed by interpreting the topology subsections in much the same way as described above for creating new resources and relations. Topology sections for removal may have less information for identifying relations and resources as long as the definition of each entry leads to a unique result. Otherwise, the Container flags an error and refuses to apply the topology subsection to the current Resource Topology. Error handling is not part of this invention and is not discussed any further.
Relationship Registry
The Relationship Registry is part of the Order Processing Environment and stores relations between resources. The semantics and structure of relations is described in section “Relations between Resources”.
Section “Container” describes how relations are used for the derivation of correct sequences for Tasks that are contained in Orders—in other words, how relations are used for the step-wise derivation of Systems Management Flows from the underlying Resource Topology while processing an Order.
In the following the interface of the Relationship Registry is summarized.
addRelationship(relation) Adds a new relation to its internal storage. removeRelationships(resourceHandle) Removes all relations with relation.sourceHandle=resourceHandle or relation.targetHandle=resourceHandle from its internal storage. In the context of this invention we assume that Resource Handles can be compared directly as discussed in section “Relations between Resources”. findRelatedTargetsByRole(startHandle 1 targetRole): ResourceHandle[ ] Retrieves all relations that are contained in the internal storage with relation.sourceHandle=startHandle and relation.targetRole=targetRole and returns the value of relation.targetHandle for all relations that have been found as an array of Resource Handles. The length of the array may be zero if no relations can be found for the requested criteria.
Factory Registry
The Factory Registry is part of the Order Processing Environment and stores for each resource type one Resource Handle that points to a resource factory for that resource type. In the context of this invention it is assumed that each resource factory provides a create operation without parameters which instantiates a new resource instance for the given resource type and which returns the Resource Handle of the new resource. In order to take part in Order Processing the new resource must support Order Processing as defined in section “Resources in the Context of Order Processing”.
Section “Order Processing Container” describes the interaction of the Container with the Factory Registry for instantiating new resources.
This section summarizes the interface of the Factory Registry.
We define a resource factory as a resource that provides an operation create which creates a new resource instance of a fixed resource type each time when being called. The create operation has no arguments and returns the Resource Handle to the new resource instance that has been created. This can be compared to a simplified view of factories in real life: assume we have a set of car factories where each factory can only produce one model. Compared to this picture the Factory Registry is a list of car factories where each entry contains the location information of the factory and the related model that the factory produces. For ordering a new model X car we query the Factory Registry in order to find out which factory produces this model, go this factory, and finally request the assembly (or “creation”) of a new model X car. If the company decides to add new or remove old car models then the list of factories is updated accordingly. The company could also decide to move production of an existing model to a different factory. This situation can also be handled by simply updating of the factory list.
The Factory Registry provides following operations:
registerFactory(resourceType, factoryHandle) Adds a new Resource Handle factoryHandle that points to a resource factory to its internal storage together with the associated resource type resourceType. deRegisterFactory(resourceType) Removes the resource factory for resource type resourceType from its internal storage. getFactoryForResourceType(resourceType): ResourceHandle This section summarizes the interface of the Factory Registry.
Order Processing Container
The Order Processing Container (in short, “Container”) is part of the Order Processing Environment and drives Order Processing. Order Processing starts when the Container is called by its asynchronous operation startOrder It is outside of the scope of this invention how Orders are generated and which system calls the startOrder operation. The startOrder operation has two parameters: the Order and the Resource Handle that points to the first resource in the Resource Topology where Order Processing is to be started. Order Processing always assumes an existing resource acting as an Order Processing Component as the starting point. This resource might be created by earlier Orders or it is created by an external system.
In order to simplify the description of the Container actions, following terms and background information are used:
1. Term: “Container connects resource Y to resource X according to the current topology subsection entry”, meaning: the Container adds a new relation as specified by the relation attributes of the topology subsection entry to the Relationship Registry by calling its addRelationship operation. The new relation connects resources X and Y where resource Y is the target resource of the relationship. Topology subsections are described in section “Structure and Semantics of Orders”. 2. Term: “Container removes resource X from Resource Topology”, meaning: the Container calls operation removeRelationships of the Relationship Registry with a Resource Handle that points to resource X in order to remove all relationships with resource X. Then the destroy operation of resource x is called by the Container. 3. Term: “Container instantiates a new resource of resource type T”, meaning: the Container queries the Factory Registry for a Resource Handle that points to the resource factory for resource type T by calling the operation getFactoryForResourceType of the Factory Registry. Then the Container calls the create operation of this factory. The create operation creates a new resource instance of resource type T and returns a Resource Handle that points to the new resource. 4. Term: “Container traverses to the next Order Processing Component”, meaning: based on a “current” resource X the Container searches for the next resource with role Order Processing Component in the Resource Topology by querying the Relationship Registry with a call findRelatedTargetsByRole and passing a Resource Handle that points to resource X as startHandle parameter for the search and passing role “OrderProcessingComponent” as targetRole parameter. The Relationship Registry responds with an array of Resource Handles that reflects the search result. If exactly one resource is found then the Container treats this resource from now on as “current” resource. Finding no resources is a valid result and is treated by the Container as described in the explanation of the Order Processing loop in the text below. In order to simplify the description of the Container actions it is assumed that if there is more than one resource found then the Resource Topology is treated as being built up incorrectly (see also section “Extension of the Order Processing Environment” for dealing with these situations correctly) and the Container would stop Order Processing. Error handling is not part of this invention and is not discussed any further. 5. Term: “Container traverses to the next Order Handling Component”, meaning: like point 4 above but using target role “OrderHandlingComponent” instead of using target role “OrderProcessingComponent”.
FIGS. 5 to 8 depict the flow charts of the Container actions during Order Processing. Order Processing is started by calling the startOrder operation of the Container with two parameters: the Order that is to be processed and the Resource Handle that points to the first resource in shows the Request Path and depict the flow charts of subroutine CreateOHCChain and CreatNextOPC, repectively.
Comments to FIG. 5 : The flow chart starting point correlates to the call of the startOrder operation of the Container. The Container calls the asynchronous operation processOrder of the current resource (as defined by the Resource Handle parameter of the startOrder operation). The resource in turn processes the Order as described in section “Resources in the Context of Order Processing” and finally hands over the (updated) Order back to the Container again by calling its asynchronous operation delegateOrder. This is not depicted in the flow chart—we treat the situation in the flow chart as if processOrder would be a synchronous call that finally returns the (updated) Order. The Container saves the Resource Handle of the current resource now to its variable handleOfLastOPC and then calls the subroutine CreateOHC chain. This subroutine creates and adds all Order Handling Components to the Order Handling Component chain of the current resource. Then the Container traverses to all available Order Handling Components in the Order Handling Component chain and calls their processOrder operations subsequently in the sequence that is given by the Order Handling Component chain. In the next step the Container restores the Resource Handle of the last Order Processing Component that the Container has called before traversing the Order Handling Component chain and treats this resource as the “current” resource. The Container now calls the current resource a second time by its processOrder operation. When finished the Container calls the subroutine CreateNextOPC which connects the next Order Processing Component to the current resource if the Container can find an entry for it in the topology subsection of the current resource and traverses to that resource it has found. Otherwise, if the Container cannot find another Order Processing Component in the topology subsection, the Request Path is terminated. In addition to the described actions, the Container stores the Resource Handle of each called resource into its internal stack. This stack is used during the Response Path for traversing thought all resources the Container has called before in reverse order.
Comments to FIG. 6 : this flow chart depicts the Container actions for processing the Response Path of Order Processing. The Container queries its internal stack for traversing through all resources the Container has called before in reverse order. In each iteration of the loop the topmost stack entry is read and removed from the stack. The stack contains the Resource Handles of all the resources that have been called in the Request Path. The fact that each Order Processing Component has been called twice during the Request Path is reflected accordingly by two stack entries for Order Handling Components (one before and the other after the entries for the Resource Handles of the resources of the Order Handling Component chain)
Comments to FIG. 7 : This flow chart depicts the actions of subroutine CreateOHCChain for building up the Order Handling Component chain for the current resource which is always an Order Processing Component. The Container instantiates and then connects the Order Handling Components to the last Order Handling Component in the chain (or directly to the current resource at the beginning) according to the entries in the topology subsection of the current resource.
Comments to FIG. 8 : This flow chart depicts the actions of subroutine CreateNextOPC. The Container reads the topology section of the current resource which is always an Order Processing Component. It the Container finds on entry for a new Order Processing Component then the Container instantiates the Order Processing Component according to the topology subsection entry for that component and connects it to the current resource. At the end of the Request Path the Container will not find a next Order Processing Component in the topology section of the current resource anymore.
Extension of the Order Processing Environment
In order to keep the description of the Order Processing Environment simple we made the restriction that branching points in the Resource Topology where more than one Order Processing Component is connected to another Order Procssing Component are not allowed. This is an unacceptable restriction for real applications which is resolved in this section.
In order to allow for the mentioned branching points, the delegateOrder operation of the Container is enhanced by an additional parameter targetOPCHandle which is set by the resource that calls the operation and which determines the next resource to be called by the Container for Order Processing. In that manner, a resource can determine where to go next at a branching point. Only resources that are Order Processing Components are allowed to redirect Order Processing to other Order Processing Components in this way. If the new parameter targetOPCHandle is left empty, then delegateOrder acts as before.
Furthermore, the Container functionality is enhanced in the following way: if the Order Processing is already processing the Response Path, then a call of delegateOrder with a defined Resource Handle for targetOPCHandle instructs the Container to switch back to the Request Path traversal mode again and to traverse the new path starting with the resource where targetOPCHandle points to. In this manner, Order Processing can traverse through multiple sub-paths starting from a branching point.
Additionally, Order Processing can also “jump” from one resource to another (even if they are not related in the Resoure Topology) since targetOPCHandle can be any Order Handling Component in the Resource Topology.
Section 2
The following section describes the invention for which patent protection is sought.
This invention embraces various functional components. Each of those functionalities is provided by certain components as depicted in FIG. 10 .
The following sections give a detailed description of each of these components, namely the Resource Topology Interpreter, the Static Workflow Builder, the Transformation Manager and the Deployment Manager embraced by the present invention.
As depicted in FIG. 10 the Transformation Manager is the entry point for the overall transformation process. Therefore, a client wanting to trigger the transformation of an order into a standards-based workflow definition must provide the order document and the information about the current resource topology as input for the Transformation Manager (step 1 , see FIG. 9 ).
Once the Transformation Manager has received that input, it first passes it along to the Resource Topology Interpreter (step 2 ), which then performs the actual transformation process in collaboration with the Static Workflow Builder (step 3 ) The details of this transformation process are described precisely in the section “Static Workflow Builder and the Resource Topology Interpreter”. Once the workflow generation process is completed, the workflow is then returned to the Transformation Manager (step 4 ). In order to be able to actually run the generated workflow, it must be deployed in a corresponding workflow engine. So the Transformation Manager passes the generated workflow definition to the Deployment Manager (step 5 ) and the Deployment Manager deploys this workflow definition into the appropriate runtime environment (step 6 ), which makes it possible to execute the semantics of the order as a standard workflow.
Transformation Manager
Transformation Manager has the responsibility for coordinating the overall transformation process. It acts as the entry point for starting the transformation process, i.e. each time a new transformation shall be started only the Transformation Manager has to be called. The Transformation Manager requires the order document to be transformed as input. Furthermore, it requires information about the resource topology, on which the order document will be processed as input. The current invention is independent of the representation format of this resource topology. An example implementation could for example be some XML format describing all resources of the resource topology and the relationships existing between them. This leads to the description of the actual data, which is required within the resource topology information: In accordance what is defined in the “Relations between Resources” section the handles for all resources are required and in terms of the relationships described as part of the resource topology information there is also the sourceHandle, the targetHandle, the sourceRole, the targetRole and the relationName required in order to represent the relationships between the resources appropriately.
Static Workflow Builder and the Resource Topology Interpreter
The Static Workflow Builder and the Resource Topology Interpreter are main parts of the present invention. The Static Workflow Builder is responsible for creating the static workflow in form of a sequence of activities depending on information from the Resource Topology and the Order document. The Resource Topology Interpreter is responsible for interpreting the incoming resource topology which is an in memory representation of the resource model. This interpretation must be performed in such a way that the underlying resource tree is traversed as defined in the previous chapter. Additionally, the Resource Topology Interpreter updates the in-memory resource topology according to the each interpretation step. Overall, the goal of this invention is to propose an approach for realizing the functionality of the Order Processing Container with standards-based workflow technology.
The following description shows the algorithm how the sequence of activities of the static workflow is built during transformation step and how these two components, Static Workflow Builder and Resource Topology Interpreter, interact. This description corresponds to FIG. 11 .
Before starting the step-by-step description of the transformation process, the assumptions are depicted next. One assumption is—as already said before—that the transformation process will get two inputs: The order and the in memory representation of the current Resource Topology. The in-memory representation of the resource topology could for example be rendered in some XML format. The specifics of such a format are not in the scope of this invention. The information about the resource topology itself must be determined by client initiating the transformation process. Therefore, the client retrieves information about the relevant resources and relationships between those resources by querying the Relationship Registry.
A further assumption is that the subscription already exists before the transformation described here starts (for example, it could have been created by a client calling the subscription factory). The subscription is always the top resource of the in-memory Resource Topology and is therefore normally used as entry point for order processing.
In step 1 the Resource Topology Interpreter has to find the first resource node to visit in the Resource Topology based on the incoming in-memory representation of the resource topology. Based on the above assumption the subscription will be the first node which is found by the Resource Topology Interpreter. In the case of an initial order which triggers the initial creation of a set of resources, only the subscription node is found as the only resource being part of the resource topology. The Resource Topology Interpreter will pass the information about this resource to the Static Workflow Builder.
In step 2 the Static Workflow Builder uses the information about the passed in resource to search the corresponding section in the order (document). If this resource section can be found, the flow proceeds with step 3 next. If no corresponding resource section exists step 5 is executed directly.
In step 3 the newly found resource section in Order Document is scanned if additional resources should be created related to the current resource. There are so-called Topology subsections within each resource section of the Order Document. These sections control the creation of resources and relationships to them. So if additional resources should be created based on the information defined within the Topology section, then the Static Workflow Builder adds activities for creation of resources in the static workflow, i.e. for each resource to be created an activity is added, which triggers the creation of the resource by executing a call to the Create operation of the corresponding resource factory. If no creation of resources is necessary then step 5 is executed directly.
In step 4 the newly created resources are added to the in-memory representation of Resource Topology by the Resource Topology Interpreter, so that this in-memory resource topology always represents the current status of the resource topology, as if the order would have been processed in reality. The Resource Topology needs to be updated to determine which resource needs to be visited next in Resource Topology as it is required in step 7 .
In step 5 the Static Workflow Builder adds one activity to the static workflow which invokes the process order operation of the resource found in step 1 and step 7 respectively. The order document contains more information which needs to be processed by this process order operation.
In step 6 the Static Workflow Builder adds one additional activity to the response path which invokes the process order operation again of the resource found in step 1 and step 7 respectively. For that the resource handle information being part of the resource topology information is used. This has to be done since each resource has to be visited on the request phase and the response phase. In the response phase, the order document is processed and updated by the resources in the reverse order of the request path.
In step 7 the Resource Topology Interpreter has to find next resource to visit in the updated in memory representation of Resource Topology. Which resource is next to visit is determined by specific relation types between resources like “delegates”, “uses” and “chains”. If a resource is found then step 2 is performed again until all resources are visited found in in-memory representation of the Resource Topology. If no resource is found the static workflow is created successfully and can be passed to the next component.
Deployment Manager
Once the workflow definition consisting of a set of activities was generated by the Static workflow Builder in combination with the Resource Topology Interpreter the workflow definition must be deployed into its runtime for being able to actually execute this workflow definition. In order to achieve that, the Transformation Manager passes the workflow definition returned from the Transformation process to the Deployment Manager. The Deployment Manager encapsulates the knowledge about what has to be done in order to bring workflow definitions into their corresponding process engine (this term is equivalent with the term workflow engine). The Deployment Manager communicates with the process engine, deploys the workflow definition into it and consequently makes it available to the outside world, so that it can be executed.
workflow engines as used by the present invention are commercially available workflow engines which are based on standard workflow description languages, e.g. bpel, fdml.
Glossary
IT Service
collection of resources and a set of
Environment
behaviour conditions that altogether
define a specific IT service
IT Service
A service in the context of information
technology, e.g. providing an ERP system
to an external customer
Systems
A logical and/or functional unit that
Management Task
performs some action in the context of
underlying IT Service Environments.
System Management Tasks may refer to one
or more resource management functions.
Task
Short form for Systems management task
Systems
A sequence of Tasks.
Management Flow
Order
The Order is a document (e.g., XML) which
includes a number of tasks for each
involved resource without arranging those
tasks in a sequence. This differentiates
Orders from workflow descriptions used by
standard workflow engines.
OrderID
A unique ID that is assigned to an
instance of an Order when being
processed.
Order Document
A document (preferably in XML) that
represents an order instance
Order Document
One section within the Order Document
Section
containing information for one specific
Task. During Order Processing (see below)
the respective Task reads its required
input data from its section in the Order
Document and writes back response data to
this section.
Order Processing
The processing of an Order Document by
the Container and Tasks. During
processing the Order Document is passed
from resource to resource; during
transitions between two consecutive
resources in the Systems Management Flow
the Order Document is passed to the
Container.
Systems
An environment for executing Systems
Management Flow
Management Flows based on the resource
Execution
topology, on the information in the Order
Container
Document, and on the responses of the
involved resources.
Container
Short form for Order Processing Container
Resource
A set of resource instances and relations
Topology
between these resource instances with the
primary purpose of reflecting the
underlying instantiated IT Service
Environment.
Resource Handle
A pointer to a resource - either a direct
reference to a resource or an indirect
reference to a resource that must be
resolved into a direct reference (the
notion of direct and indirect references
is, for example, mentioned in the Global
Grid Forum Open Grid Service
Infrastructure (OGSI) —direct references
are called Grid Service References (GSR),
and indirect references are named Grid
Service Handles (GSH)). Another example
for direct references are End Point
References as defined in the WS-
Addressing standard.
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The invention is based on Orders specifically developed for and processed by an Order Processing Environment for creation or modification of resource topologies. The Order Processing Environment is partly replaced by a combination of an Order Transformation Environment and standard Workflow Engines in order to execute the Order by standard Workflow Engines. The Order Transformation Environment needs to get two inputs. The first input is the resource topology which is retrieved by using the Relationship Registry of the Order Processing Environment. The second input is the Order. Orders are resource topology independent and include resource specific tasks without arranging those in a sequence. Tasks provide actions for creating and/or modifying resource topologies. The transformation is based on above two inputs resulting in a static standard based workflow. The static, standards-based workflow (e.g. BPEL-based) can then be executed by standards-based process/workflow engines. This enables users to exploit the flexibility of orders while still being able to leverage the broad set of tooling and runtime products available across the IT industry.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of driving a door of an automatic door assembly and more particularly, to a method of driving the door by a linear motor mounted within the automatic door assembly.
2. Description of the Prior Art
Automatic door assemblies having a linear motor as a prime mover are advantageous in that the linear motor can drive the door linearly without any special driving power transmission mechanism, the motor is simple and durable in construction, and it can be manufactured less costly. However, they also have disadvantages such that when the propulsion force of the linear motor is too small, the door is retarded and tends to stop before it reaches the end of its stroke, and when the propulsion force is too great, the door is driven so rapidly that the door frame is subjected to the full impact of the moving door. Various attempts have heretofore been made to stop the door exactly at the ends of the door stroke by retarding the door during its stroke, thereby preventing the door from striking the outer frame. One such attempt has been to reduce the speed of the door electrically by giving an opposite propulsion force to the linear motor during a final portion of the door stroke. However, this attempt has led to a drawback in that various intricate control devices such as a speed detecting device and a position detecting device which must be adjusted precisely need to be added to the automatic door assembly. Another such attempt has been to provide a pair of cushioning devices such as self-returning type air cylinders at the ends of stroke of the movable door so as to dampen the door speed mechanically.
A problem with the automatic door assembly having the cushioning devices is that the propulsion force of the linear motor must be held at all times to a level sufficiently large to overcome frictional resistance of the door and linear motor and reaction force of the cushioning device. Thus, when the linear motor, especially its reaction rod, is subjected to a voltage decrease (arising from fluctuation of a power supply) and a temperature rise (due primarily to frequent opening and closing of the door), the propulsion force of the linear motor is decreased, and the door tends to be stopped by the reaction force of the cushioning device before reaching the end of the door stroke. This result is disadvantageous especially when the door is to be closed.
One solution to the above shortcoming would be to provide a feedback control device whereby the voltage fluctuation of the power supply and the temperature rise of the linear motor are detected to automatically correct the reduction of the propulsion force of the motor. This solution is however also disadvantageous because the overall structure of the automatic door assembly becomes much more complicated.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a method of driving a door of an automatic door assembly.
It is another object of the present invention to provide a method of the type described which is capable of opening and closing the door completely even if the propulsion force of the linear motor becomes reduced due primarily to a downward fluctuation of voltage and a temperature rise caused by frequent openings and closings of the door.
According to the invention, there is provided a method of driving a door of an automatic door assembly, the method comprising the steps of driving the door by a normal propulsion force of the linear motor and driving the door by a propulsion force which is greater than the normal propulsion force, at least during a final portion of the stroke of the door, thereby overcoming the reaction force of cushioning devices provided near the ends of the door stroke.
Many more advantages and features of the present invention will become manifest to those versed in the art upon making reference to the detailed description and the accompanying sheets of drawings in which preferred embodiments incorporating the principles of the present invention are shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary front elevational view with parts cut away of an automatic door assembly driven in accordance with a method of the present invention;
FIG. 2 is a graph showing the relation between time and propulsion force of a linear motor actuated according to a conventional driving method;
FIGS. 3A through 3D are graphs each showing the relation between time and propulsion force of the linear motor actuated according to a method of the present invention; and
FIGS. 4 through 6 are circuit diagrams for controlling the linear motor in according with the invention.
FIG. 7 is a control diagram.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, an automatic door assembly 10 generally comprises an outer frame 11 to be mounted in a portal in a building and a pair of doors 12, 13, the door 12 being fixed to the frame 11 and the door 13 being horizontally movable within the frame 11 in order to open and close the portal. Each of the doors 12, 13 has an inner frame including a pair of stiles 14, 15, a top rail 16, and a glass pane 17 surrounded and held in place by the inner frame. The outer frame 11 has a pair of side jambs 18, 19 and a head 20 interconnecting the top ends of the side jambs 18, 19.
The head 20 contains therein a linear motor 21 having a reaction rod 22 extending horizontally between the side jambs 18, 19 and a movable member 23 in the form of a hollow cylinder fitted over the rod 22 with a clearance therebetween, the movable member 23 having a pair of coils for providing a shifting magnetic field. A power cable 24 extends from one of the side jambs, here the jamb 19, around the reaction rod 22 to the movable member 23 where it is connected to the windings. The head 20 also has a pair of air cushion cylinders 25, 26 of the self-returning type mounted therein and spaced apart a distance substantially equal to the stroke of the movable door 13, the cylinders 25, 26 serving to dampen the movement of the movable door 13 at the ends of its opening and closing strokes.
Each of the air cushion cylinders 25, 26 has a piston rod 27 normally urged to its projecting position by a coil spring, not shown, in the cylinder. The movable member 23 of the linear motor 21 is provided with a downwardly extending bar 28 fixed thereto and having its lower end connected with the central portion of the top rail 16 of the movable door 13. The piston rods 27 have at their distal ends rubber members 29 with which the bar 28 becomes engageable when the door 13 reaches its opened or closed position.
Conventionally, the movable door of the automatic door assembly has been driven by a normal propulsion force F 0 from the linear motor during its opening and closing time intervals. By the term "normal propulsion force" is meant a force which is sufficiently large to overcome the frictional resistance of the movable door including the linear motor and which is sufficiently small to prevent the stile 15 of the door 13 from striking the side jamb 19 when the door 13 is closed.
According to a method of the invention, as shown in FIG. 3A, an additional propulsion force F 1 that is greater than the normal propulsion force F 0 is provided at a final portion T of the door closing time interval, thereby completely closing the door 13 against the reaction force of the air cushion cylinder 26 even if the normal propulsion force of the linear motor 21 becomes reduced due to a voltage decrease and a temperature rise of the motor 21 while the door 13 is opened and closed frequently.
In FIG. 3B, the additional propulsion force F 1 is also applied at an initial portion T 1 of the door opening interval to overcome the reaction force of the air cushion cylinder 25, so that the door 13 can be fully opened.
FIG. 3C shows the application of an additional propulsion force F 1 to the pattern of FIG. 3B at initial portions T', T' 1 of the closing and opening intervals, respectively, whereby the linear motor 21 is driven to move the door 13 rapidly against the inertia by which door 13 remains at rest, when the latter starts to be opened and closed. With this pattern of operation, the door 13 can be driven at maximum speed.
Since the door 13 is permitted to stop short of its fully opened position, it may be driven in accordance with an operation pattern of FIG. 3D in which the additional propulsion force F 1 is removed from the final portion of the door opening interval.
FIG. 4 illustrates an electric circuit 30 provided for effecting the method according to this invention. The circuit 30 includes an autotransformer 31 connected at its end terminals to a single-phase a.c. source 32. A main switching relay 33 has contacts connected between one of the end terminals of the autotransformer 31 and a common terminal of a pair of parallel-connected first and second coils 34, 35 mounted within the movable member 23 of the linear motor 21. There is provided a first relay 36 of the single-pole double-throw type having a movable pole 37 and two contacts 38, 39, the contact 38 being connected to the other end terminal of the autotransformer 31 and the contact 39 to a tap 40 of the autotransformer 31. The first relay 36 is normally de-energized during which time the pole 37 contacts the contact 38. A second relay 41 of the single-pole double-throw type is provided which has a movable pole 42 coupled with the movable pole 37 of the first relay 36. A contact 43 of the second relay 41 is connected to the first winding 34 and a contact 44 is connected to the second winding 35. The second relay 41 is normally de-energized during which time the movable pole 42 contacts the contact 43. Connected across the contacts 43, 44 of the second relay 41 is a capacitor 45 serving as a phase-advancer for one of the windings 34, 35 which is selected by the second relay 41.
Assuming that the contacts of the main relay 33 are closed and the first and second relays 36, 41 are de-energized, the full voltage of the power source 32 is applied to the winding 34 and, through the capacitor 45, the winding 35, when the door 13 is driven by the propulsion force F 1 which is greater than the normal propulsion force F 0 . When the first relay 36 is actuated to shift the movable pole 37 to the contact 39, a voltage which is produced by dropping the power supply voltage through the autotransformer 31 is applied to the winding 34 and, through the capacitor 45, the winding 35, whereupon the door 13 is driven by the normal propulsion force F 0 . The direction of movement of the movable member 23 of the linear motor 21 can be changed by shifting the movable pole 42 from the contact 43 to the contact 44 or vice versa, the switching of the relay 41 being the switching of direction of the shifting magnetic field formed by the windings 34, 35. The autotransformer 31 may be a variable-ratio autotransformer whereby its output voltage across the common line can be varied continuously.
With the circuit construction of FIG. 4, a mode of operation of the automatic door assembly 10 according to the pattern of FIG. 3C is described below. There are provided four timers or timer switches 54 (FIG. 7) operatively associated with the circuit components. More specifically, a first timer switch serves to determine a time interval during which the door is opened. That is, when a switch 53 under a door mat, on the floor is activated, the first timer switch connected to the relay 41 sets a time interval after which the door starts closing. A second timer switch is energized when the main relay 33 is actuated and, after the lapse of a preset time interval which is slightly longer than the door opening interval, the second timer turns the main relay 33 off. A third timer switch is actuated at the same time as the second timer switch and, after the lapse of a time interval of the initial portion T' 1 , energizes the first relay 36 and, after the lapse of a preset time interval, de-energizes the first relay 36. A fourth timer switch is energized when the second relay 41 is actuated and, after the lapse of a preset time interval which is longer than the door opening interval, de-energizes the second relay 41 again.
When a person steps on the door mat, the switch under the mat is thrown to actuate the main relay 33 and the second relay 41, the first relay 36 remaining de-energized. The door 13 starts opening and is driven by the additional propulsion force F 1 during the initial portion T' 1 of the opening interval. After the lapse of the initial time interval T' 1 , the third timer switch actuates the first relay 36 to apply a dropped voltage to the first and second coils 34, 35, thereby propelling the door 13 by the normal propulsion force F 0 . Upon lapse of a preset time interval, the first relay 36 is de-energized again by the third timer switch, so that the door 13 is driven by the propulsion force F 1 . Simultaneously with the lapse of the door opening interval, the second timer switch de-energizes the main relay 33 thereby completing the opening of the door 13. After the switch under the door mat has opened in response to passage of the person through the door, the first timer switch is operated, after a preset time interval, to actuate the main switching relay 33 so as to initiate the door closing operation. The second relay 41 is de-energized by the fourth timer switch anywhere between the opening time interval and the closing interval. The sequence of switching of the relays 33 and 36, and operation of the second and third time switches during the door closing operation is completely identical to that during the door opening operation.
FIG. 5 illustrates a linear motor control circuit 10a constructed in accordance with another embodiment, wherein a variable resistor 46 is used instead of the autotransformer 31 in the circuit 30 shown in FIG. 4.
According to still another embodiment shown in FIG. 6, a control circuit 30b includes a single-pole double-throw type relay 47 having a movable pole 48 connected to one terminal of the power supply 32 and a pair of contacts 49, 50, the contact 49 being coupled to the first coil 34 and the contact 50 to the second coil 35. There is provided another relay 51 connected in series with a capacitor 52, the relay 51 and the capacitor 52 being connected in parallel with the capacitor 45. The relay 47 is used to change the direction of the shifting magnetic field formed by the windings 34, 35. The relay 51 serves to vary the strength of the propulsion force of the linear motor.
Although various minor modifications may be suggested by those versed in the art, it should be understood that I wish to embody within the scope of the patent warranted hereon, all such embodiments as reasonably and properly come within the scope of my contribution to the art.
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A method of driving a door of an automatic door assembly by a linear motor mounted within the automatic door assembly. The method comprises the steps of driving the door by a normal propulsion force of the linear motor and then driving the door by an added propulsion force which is greater than the normal propulsion force, at least during a final portion of the stroke of the door thereby overcoming the reaction force of cushioning devices provided near the ends of the door stroke.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 62/281,916, filed on Jan. 22, 2016 and entitled “Sealing Closure for Swimming Pool Skimmer”, and U.S. Provisional Application No. 62/281,935, filed on Jan. 22, 2016 and entitled “Sealing Closure for Swimming Pool Skimmer”, the disclosures of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates generally to swimming pools and, more particularly, to a sealing apparatus for closing a skimmer opening to prevent water from entering the skimmer when the pool is closed for the season.
Brief Description of the Prior Art
[0003] It is common to employ one or more skimming devices in the sidewalls of swimming pools, hot tubs, and the like to permit surface water to be drawn off by a pump, to be filtered at a remote location and then optionally heated, and returned to the pool through one or more return ports. While the present disclosure focuses on skimming devices for swimming pools, it is to be understood that various other water structures, including, without limitation, hot tubs, spas, jet tubs, and the like can have similar or identical skimming devices. These skimming devices have a skimmer opening in a side wall of the pool for drawing the surface water to the pump. During normal use of the pool, the surface level of the water in the pool is at the same level as the skimmer opening such that water from the surface can enter the skimmer opening. When the pool is closed, for example during the winter season, it is sometimes desirable to maintain a lower level of water in the pool for structural purposes. Even if completely drained, the water level in the pool will naturally rise during the closed season due to rainwater and melting snow, such that the water level oftentimes rises to a level of the skimmer opening or above. In such cases, it is necessary to close off the skimmer opening to prevent backflow of water through the skimmer opening and the conduits that connect the skimmer opening to the filter, pump equipment, and heater so as to prevent damage to these components due to freezing.
[0004] Within the prior art, one way of closing the skimmer opening is to employ an elongated, plug-like element. The plug element is threadably secured within the floor of the skimmer body to seal the conduit communicating with the pump and filtration equipment. Several other devices for sealing the skimmer opening are disclosed in U.S. Pat. Nos. 4,913,810; 5,285,538; and 5,937,453. Each of these devices has a detachable cover plate or panel that is removably attachable to the skimmer opening. Some of these existing devices either require a retrofit of the skimmer faceplate in order to make sealing contact with a closure member. Other known devices require the use of a polymeric flexible sealing member which snaps over the skimmer opening. Such faceplate seals may lose their effectiveness due to weathering of the polymeric material, and also may require special retrofitting of the skimmer opening member to provide better sealing between the skimmer and the flexible snap-on faceplate. In addition, the existing faceplate seals may crack or be otherwise compromised due to temperature-related shirking and/or contact with ice. Furthermore, due to the conventional square or rectangular shape of the skimmer opening, the existing devices for closing the skimmer opening may not provide an adequate seal in the corners of such skimmer openings. Accordingly, there is a need in the art for an improved sealing closure for the skimmer opening that overcomes the deficiencies of the prior art.
SUMMARY OF THE INVENTION
[0005] In view of the existing need in the art, it would be desirable to develop a sealing closure assembly for a swimming pool skimmer opening that overcomes the deficiencies associated with the existing devices.
[0006] In accordance with some preferred and non-limiting embodiments or aspects of the present disclosure, a sealing closure assembly for closing a skimmer opening of a swimming pool may have a closure faceplate having a sidewall with a central opening shaped to correspond to the skimmer opening. The closure faceplate may have a flange protruding from the sidewall to overlap a peripheral area of the skimmer opening, and a lip protruding from the flange and extending around an inner perimeter of the flange. The sealing closure assembly may further have a cover removably connectable to the closure faceplate to seal the central opening of the closure faceplate. The cover may have a cover plate with a monolithic sealing gasket fitted around an outer perimeter of the closure faceplate, a wedge plate member for engaging an inside sidewall of the sealing gasket, and a closure member for exerting a force between the cover plate and the wedge plate to pull the cover plate and wedge plate together between a locked position and an unlocked position. In the locked position, an outer sidewall of the sealing gasket may engage the flange (1) proximate to the sidewall of the closure faceplate, (2) at the lip of the flange, and (3) by wrapping around a terminal edge of the flange.
[0007] In accordance with other preferred and non-limiting embodiments or aspects of the present disclosure, movement of the wedge plate member against the sealing gasket may cause the outer sidewall of the sealing gasket to flex outwardly and engage the flange of the closure faceplate to prevent water leakage into the skimmer opening. The closure member may have a stud member for attachment to the cover plate. The stud member extending rearwardly from the cover plate and having a hook portion at a distal end. The closure member may also have the wedge plate member having a bore hole formed therethrough to allow passage of the hook portion of the stud, and a cam lock fitted on a rear surface of the wedge plate member for attachment to the hook portion of the stud. Movement of the cam lock may force the wedge plate member into engagement with the sealing gasket.
[0008] In accordance with other preferred and non-limiting embodiments or aspects of the present disclosure, the closure faceplate, cover plate, wedge plate, and cam lock may be made of an injection molded plastic material. The sealing gasket may be made of a thermoplastic elastomer material. The flange may have one or more locking elements on the flange for connecting to a peripheral flange on the skimmer opening. Each of the one or more locking elements may be formed on an outer periphery of the flange. The closure faceplate may have one or more radiused corners defining the central opening. A radius of the one or more radiused corners may be between 0.25 inches and 1 inches.
[0009] In accordance with other preferred and non-limiting embodiments or aspects of the present disclosure, a sealing closure assembly for closing a skimmer opening of a swimming pool skimmer may have a closure faceplate having an integral sidewall with a central opening in a shape of the skimmer opening. The closure assembly may further have a cover element configured for being removably connected to the closure faceplate. The cover element may have a cover plate having a top surface opposite a bottom surface and a plurality of openings extending between the top surface and the bottom surface around an outer periphery of the cover plate. A sealing gasket may extend around the outer periphery of the cover plate. At least a portion of the sealing gasket may extend through at least one of the plurality of openings on the cover plate.
[0010] In accordance with other preferred and non-limiting embodiments or aspects of the present disclosure, the sealing gasket may have a peripheral recess for receiving the peripheral lip of the closure faceplate when the cover element is connected to the closure faceplate. The closure faceplate may have a peripheral lip extending around an outer periphery of the closure faceplate, and a flange that overlaps a peripheral area of the skimmer opening. The closure faceplate may be made from an ABS plastic resin, while the sealing gasket may be made from a thermoplastic elastomer material. The sealing gasket may be molded over the cover plate such that the sealing gasket is monolithically formed with the cover plate.
[0011] In accordance with other preferred and non-limiting embodiments or aspects of the present disclosure, a cover element for closing a skimmer opening of a swimming pool skimmer may have a cover plate having a top surface opposite a bottom surface and a plurality of openings extending between the top surface and the bottom surface around an outer periphery of the cover plate. The sealing assembly may further have a sealing gasket monolithically formed around the outer periphery of the cover plate. At least a portion of the sealing gasket may extend through at least one of the plurality of openings on the cover plate. The sealing gasket may have a peripheral recess for receiving a peripheral lip of a closure faceplate when the cover element is connected to the closure faceplate. The sealing gasket may be monolithically formed with the cover plate.
[0012] In accordance with other preferred and non-limiting embodiments or aspects of the present disclosure, the sealing closure assembly may be defined by one or more of the following clauses:
[0013] Clause 1: A sealing closure assembly for closing a skimmer opening of a swimming pool, the sealing closure assembly comprising:
[0014] a closure faceplate having a sidewall with a central opening shaped to correspond to the skimmer opening, the closure faceplate comprising:
[0015] a flange protruding from the sidewall to overlap a peripheral area of the skimmer opening; and
[0016] a lip protruding from the flange and extending around an inner perimeter of the flange; and
[0017] a cover removably connectable to the closure faceplate to seal the central opening of the closure faceplate, the cover comprising:
a cover plate with a monolithic sealing gasket fitted around an outer perimeter of the closure faceplate; a wedge plate member for engaging an inside sidewall of the sealing gasket; and a closure member for exerting a force between the cover plate and the wedge plate to pull the cover plate and wedge plate together between a locked position and an unlocked position,
[0021] wherein, in the locked position, an outer sidewall of the sealing gasket engages the flange ( 1 ) proximate to the sidewall of the closure faceplate, ( 2 ) at the lip of the flange, and ( 3 ) by wrapping around a terminal edge of the flange.
[0022] Clause 2: The sealing closure assembly of clause 1, wherein movement of the wedge plate member against the sealing gasket causes the outer sidewall of the sealing gasket to flex outwardly and engage the flange of the closure faceplate to prevent water leakage into the skimmer opening.
[0023] Clause 3: The sealing closure assembly of clause 1 or clause 2, wherein the closure member comprises:
[0024] a stud member for attachment to the cover plate, the stud member extending rearwardly from the cover plate and having a hook portion at a distal end;
[0025] the wedge plate member having a bore hole formed therethrough to allow passage of the hook portion of the stud, and
[0026] a cam lock fitted on a rear surface of the wedge plate member for attachment to the hook portion of the stud, whereby movement of the cam lock forces the wedge plate member into engagement with the sealing gasket.
[0027] Clause 4: The sealing closure assembly of clause 3, wherein the closure faceplate, cover plate, wedge plate, and cam lock are made of an injection molded plastic material.
[0028] Clause 5: The sealing closure assembly of any of clauses 1-4, wherein the sealing gasket is made of a thermoplastic elastomer material.
[0029] Clause 6: The sealing closure assembly of any of clauses 1-5, further comprising one or more locking elements on the flange for connecting to a peripheral flange on the skimmer opening.
[0030] Clause 7: The sealing closure assembly of clause 6, wherein each of the one or more locking elements is formed on an outer periphery of the flange.
[0031] Clause 8: The sealing closure assembly of any of clauses 1-7, wherein the closure faceplate has one or more radiused corners defining the central opening.
[0032] Clause 9: The sealing closure assembly of clause 8, wherein a radius of the one or more radiused corners is between 0.25 inches and 1 inches.
[0033] Clause 10: A sealing closure assembly for closing a skimmer opening of a swimming pool skimmer, the sealing closure assembly comprising:
[0034] a closure faceplate having an integral sidewall with a central opening in a shape of the skimmer opening;
[0035] a cover element configured for being removably connected to the closure faceplate, the cover element comprising:
[0036] a cover plate having a top surface opposite a bottom surface and a plurality of openings extending between the top surface and the bottom surface around an outer periphery of the cover plate; and
[0037] a sealing gasket extending around the outer periphery of the cover plate,
[0038] wherein at least a portion of the sealing gasket extends through at least one of the plurality of openings on the cover plate.
[0039] Clause 11: The sealing closure assembly of clause 10, wherein the sealing gasket has a peripheral recess for receiving the peripheral lip of the closure faceplate when the cover element is connected to the closure faceplate.
[0040] Clause 12: The sealing closure assembly of clause 10 or clause 11, wherein the closure faceplate has a peripheral lip extending around an outer periphery of the closure faceplate
[0041] Clause 13: The sealing closure assembly of any of clauses 10-12, wherein the closure faceplate has a flange that overlaps a peripheral area of the skimmer opening.
[0042] Clause 14: The sealing closure assembly of any of clauses 10-13, wherein the closure faceplate is made from an ABS plastic resin.
[0043] Clause 15: The sealing closure assembly of any of clauses 10-14, wherein the sealing gasket is made from a thermoplastic elastomer material.
[0044] Clause 16: The sealing closure assembly of any of clauses 10-15, wherein the sealing gasket is molded over the cover plate.
[0045] Clause 17: The sealing closure assembly of any of clauses 10-16, wherein the sealing gasket is monolithically formed with the cover plate.
[0046] Clause 18: A cover element for closing a skimmer opening of a swimming pool skimmer, the cover element comprising:
[0047] a cover plate having a top surface opposite a bottom surface and a plurality of openings extending between the top surface and the bottom surface around an outer periphery of the cover plate; and
[0048] a sealing gasket monolithically formed around the outer periphery of the cover plate,
[0049] wherein at least a portion of the sealing gasket extends through at least one of the plurality of openings on the cover plate.
[0050] Clause 19: The cover element of clause 18, wherein the sealing gasket has a peripheral recess for receiving a peripheral lip of a closure faceplate when the cover element is connected to the closure faceplate.
[0051] Clause 20: The cover element of clause 18 or clause 19, wherein the sealing gasket is monolithically formed with the cover plate.
[0052] These and other features and characteristics of the sealing closure assemblies described herein will become more 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. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] FIG. 1 is an assembled perspective view of a sealing closure assembly of one preferred and non-limiting embodiment or aspect of the present disclosure;
[0054] FIG. 2 is a perspective view of a closure faceplate of the sealing closure assembly shown in FIG. 1 ;
[0055] FIG. 3 is a front view of the closure faceplate shown in FIG. 2 ;
[0056] FIG. 4 is a rear view of the closure faceplate shown in FIG. 2 ;
[0057] FIG. 5 is a side view of the closure faceplate shown in FIG. 2 ;
[0058] FIG. 6 is a rear view of the sealing closure assembly shown in FIG. 1 ;
[0059] FIG. 7 is a side view of the sealing closure assembly shown in FIG. 1 ;
[0060] FIG. 8 is a cross-sectional side view of the sealing closure assembly shown in FIG. 7 ;
[0061] FIG. 9 is an exploded perspective view of a sealing closure of another preferred and non-limiting embodiment or aspect of the invention;
[0062] FIG. 10 is an exploded perspective view of a sealing closure of another preferred and non-limiting embodiment or aspect of the invention;
[0063] FIG. 11 is a detailed side cross-sectional view of the sealing closure shown in FIG. 9 ;
[0064] FIG. 12 is a detailed perspective cross-sectional view of the sealing closure shown in FIG. 9 ;
[0065] FIG. 13 is a detailed, bottom perspective cross-sectional view of a sealing closure of another preferred and non-limiting embodiment or aspect of the invention; and
[0066] FIG. 14 is a detailed, top perspective cross-sectional view of the sealing closure shown in FIG. 13 .
[0067] In FIGS. 1-14 , the same characters represent the same components unless otherwise indicated.
DETAILED DESCRIPTION OF INVENTION
[0068] As used herein, the singular form of “a”, “an”, and “the” includes plural referents unless the context clearly dictates otherwise.
[0069] As used herein, spatial or directional terms, such as “left”, “right”, “up”, “down”, “inner”, “outer”, “above”, “below”, and the like, relate to various features as depicted in the drawing figures. However, it is to be understood that various alternative orientations can be assumed and, accordingly, such terms are not to be considered as limiting.
[0070] Unless otherwise indicated, all ranges or ratios disclosed herein are to be understood to encompass any and all subranges or subratios subsumed therein. For example, a stated range or ratio of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges or subratios beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less, such as but not limited to, 1 to 6.1, 3.5 to 7.8, and 5.5 to 10.
[0071] As used herein, the term “substantially parallel” means a relative angle as between two objects (if extended to theoretical intersection), such as elongated objects and including reference lines, that is from 0° to 5°, or from 0° to 3°, or from 0° to 2°, or from 0° to 1°, or from 0° to 0.5°, or from 0° to 0.25°, or from 0° to 0.1°, inclusive of the recited values.
[0072] All documents, such as but not limited to issued patents and patent applications, referred to herein, and unless otherwise indicated, are to be considered to be “incorporated by reference” in their entirety.
[0073] With reference to FIG. 1 , a sealing closure assembly 100 is configured for use with a skimmer (not shown) of a pool, spa, hot tub, or the like. The sealing closure 100 is configured to close a skimmer opening 101 and prevent water from entering the skimmer opening 101 . Typically, the skimmer is mounted on a pool sidewall. The skimmer has a peripheral flange 107 that defines the skimmer opening 101 . The peripheral flange 107 may be secured to the pool sidewall by fasteners (not shown) or other mechanical means. Surface water from the pool is drawn through the skimmer opening 101 for subsequent pumping, filtration, and heating purposes. The details of one exemplary embodiment or aspect of a skimmer and its function are described in U.S. Pat. No. 5,285,538, the contents of which are incorporated by reference herein. At least a portion of the sealing closure assembly 100 is configured to be inserted in the skimmer opening 101 to block the skimmer opening 101 and prevent the passage of water therethrough.
[0074] With continued reference to FIG. 1 , the sealing closure assembly 100 includes a closure faceplate 102 and a cover 104 configured for removably connecting to the closure faceplate 102 . The closure faceplate 102 is configured to be connected to the skimmer opening 101 on the pool or water side of the skimmer. The closure faceplate 102 has a generally square or rectangular shape, at least a portion of which is dimensioned to fit inside the skimmer opening 101 . Desirably, an outer shape of at least a portion of the closure faceplate 102 is shaped to correspond to the shape of the skimmer opening 101 . In some aspects, the closure faceplate 102 may be installed directly on the sidewall of the pool. In other aspects, the closure faceplate 102 may be installed over the skimmer peripheral flange 107 .
[0075] With reference to FIGS. 2-5 , the closure faceplate 102 has a sidewall 106 defining an outer peripheral shape of the closure faceplate 102 . The sidewall 106 has a central opening 108 with a flange 103 that extends around an inner periphery of the central opening 108 and protrudes rearwardly relative to the sidewall 106 . In some aspects, at least a portion of the flange 103 may be inserted into the skimmer opening 101 such that the sidewall 106 overlaps at least a portion of the skimmer opening 101 in order to prevent movement of the closure faceplate 102 into the skimmer opening 101 . In other aspects, at least a portion of the flange 103 may interact with the skimmer peripheral flange 107 (shown in FIG. 1 ) such that the sidewall 106 overlaps at least a portion of the skimmer opening 101 and/or the skimmer peripheral flange 107 . In further examples, the flange 103 may narrow or widen in a direction from away from an outer surface of the sidewall 106 toward the skimmer opening 101 . In other examples, the flange 103 may be substantially perpendicular to the sidewall 106 .
[0076] The closure faceplate 102 may be removably or non-removably connected to the skimmer opening 101 and/or the skimmer peripheral flange 107 . With specific reference to FIGS. 4-5 , the flange 103 of the closure faceplate 102 has one or more locking elements 110 configured to connect with the skimmer peripheral flange (not shown) installed around the skimmer opening 101 . The one or more locking elements 110 may be formed at an outer periphery of the flange 103 . In some aspects, the one or more locking elements 110 may formed as tabs that snap over the skimmer peripheral flange installed around the skimmer opening 101 . At least a portion of the flange 103 may be flexible to allow the one or more locking elements 110 to be deflected such that they can pass over the skimmer peripheral flange. Alternatively, the flange 103 may be rigid, while the one or more locking elements 110 may flex or deflect relative to the flange 103 to allow the closure faceplate 102 to be connected to the skimmer peripheral flange installed around the skimmer opening 101 . In further aspects, the flange 103 and the one or more locking elements 110 may be rigid, while at least a portion of the skimmer peripheral flange may be deflectable or be configured to interact with the locking elements 110 in order to connect the closure faceplate 102 to the skimmer peripheral flange. In some aspects, the flange 103 and/or the one or more locking elements 110 may be movable between a first, undeflected position and a second, deflected position. Once the one or more locking elements 110 clear the skimmer peripheral flange, the one or more locking elements 110 may snap back to the initial, undeflected position. In further aspects, such as shown in FIG. 8 , the one or more locking elements 110 may have a ramp surface 117 that engages the skimmer peripheral flange to aid in deflecting the one or more locking elements 110 and/or at least a portion of the skimmer peripheral flange during installation of the closure faceplate 102 on the skimmer peripheral flange.
[0077] One of ordinary skill in the art will appreciate that the one or more locking elements 110 may be formed as tabs, snaps, or other fastening elements that connect the closure faceplate 102 to the skimmer peripheral flange 107 . In other aspects, the sidewall 106 of the closure faceplate 102 may have one or more through-holes (not shown) configured to receive a fastener element (not shown), such as a screw, to connect the closure faceplate 102 to the skimmer opening 101 and/or the skimmer peripheral flange 107 . In further aspects, the closure faceplate 102 may be connected to the skimmer opening 101 and/or the skimmer peripheral flange 107 by an adhesive. The underside of the closure faceplate 102 could have several undercut notched areas (not shown) formed therein to permit the insertion of a removal tool, such as a screwdriver tip, to permit removal of the closure faceplate 102 from the skimmer opening 101 and the skimmer peripheral flange 107 , if desired.
[0078] In some aspects, the closure faceplate 102 is formed as a one-piece integral member formed from a rigid material. For example, the closure faceplate 102 may be injection molded from a hard plastic material, such as an ABS plastic resin that resists dimensional shrinking due to temperature variations. In other aspects, the closure faceplate 102 may be formed from metal, composite material, such as carbon fiber, or a combination of metal, plastic, and/or composite materials. In various aspects, the closure faceplate 102 is made from a rigid material capable of resisting stretching or breaking due to contact with ice which may form in the pool.
[0079] With reference to FIGS. 2-4 , the closure faceplate 102 may have one or more radiused corners 109 at apex locations of the central opening 108 . In some aspects, the radiused corners 109 may be provided to ease the transition between the adjoining linear or substantially linear portions 111 of the closure faceplate 102 to provide a better sealing interface with the sealing gasket of the cover 104 , as described herein. For example, the radiused corners 109 may have a radius R between 0.25″ to 1″ and may join to linear or substantially linear portions that are oriented at a substantially perpendicular angle. In this manner, the radiused corners 109 provide a smooth transition between the adjoining linear or substantially portions 111 in the corners of the central opening 108 to prevent leakage of water. The sealing gasket of the cover 104 may be dimensioned such that the sealing gasket has a shape that corresponds to the shape of the central opening 108 . That is, the sealing gasket of the cover 104 may have one or more linear or substantially linear portions that correspond to the one or more linear or substantially linear portions 111 of the closure faceplate 102 and one or more radiused portions with a radius that substantially corresponds to the radius R of the radiused corners 109 of the closure faceplate 102 .
[0080] With specific reference to FIG. 2 , the closure faceplate 102 may have a lip 105 extending around at least a portion of a periphery of the central opening 108 . The lip 105 may protrude inward into the central opening 108 and may be configured for interacting with at least a portion of the cover 104 , such as a sealing gasket of the cover 104 , as described herein.
[0081] A sealant or a gasket (not shown) may be provided around at least a portion of the outer periphery of the flange 103 and/or the rear portion of the sidewall 106 to seal against water intrusion between the closure faceplate 102 and the skimmer peripheral flange 107 (shown in FIG. 1 ). For example, a bead of silicone sealing compound or other sealant material may be provided between the closure faceplate 102 and the skimmer peripheral flange 107 . Alternatively, a resilient gasket may be provided on at least one of the closure faceplate 102 and the skimmer peripheral flange 107 for sealing a connection interface between the two once they are connected together.
[0082] With reference to FIGS. 1 and 6-8 , the cover 104 is configured to be removably secured to the closure faceplate 102 to enclose the central opening 108 and prevent passage of water through the central opening 108 and into the skimmer opening 101 . The cover 104 has a cover plate 112 that is shaped to correspond to the central opening 108 of the closure faceplate 102 . The cover plate 112 has a top surface 113 ( FIG. 1 ) opposite a bottom surface 115 ( FIG. 6 ). A sealing gasket 114 extends around an outer periphery of the cover plate 112 . The cover plate 112 , together with the sealing gasket 114 , fits snugly within the central opening 108 bordered by the flange 103 of the closure faceplate 102 . For example, the cover plate 112 may be configured to interface with the closure faceplate 102 , such as the flange 103 , such that the sealing gasket 114 contacts at least a portion of the flange 103 for a watertight seal between the cover plate 112 and the closure faceplate 102 .
[0083] The sealing gasket 114 may be a monolithic component, or it may be comprised of two or more separate elements. In some aspects, the sealing gasket 114 is formed separately from the cover plate 112 and is removably or non-removably installed on the cover plate 112 . In other aspects, the sealing gasket 114 is formed together with the cover plate 112 , such as by co-molding. In some aspects, the sealing gasket 114 may be formed from a resilient material, such as a thermoplastic elastomer, which remains flexible in varying temperature settings and is resistant to degradation over time. The sealing gasket 114 may be formed, for example, by injection molding, or, as noted above, by co-molding with the cover plate 112 .
[0084] The sealing gasket 114 is adapted to sealingly engage the flange 103 of the closure faceplate 102 when a wedge-shaped spreader plate 130 is forced into engagement with the cover plate 112 and exerts a rearward force thereon by way of a hook stud 132 attached to the cover plate 112 and acted upon by a cam lock 134 which exerts the desired rearward force. The hook stud 132 carries a hook portion 138 which extends through a bore formed through the spreader or wedge plate 130 whereupon the hook portion 138 can engage a bar 140 carried by the cam lock 134 . The cam lock 134 carries the curved cam surfaces and an outwardly extending arm 144 . When the bar 140 of the cam lock 134 engages the hook portion 138 of the hook stud 132 , the curved cam surfaces press against a rear face 146 of the spreader plate 130 and exert a closing force thereon when the arm is moved. The cover plate 112 , wedge or spreader plate 130 , and cam lock 134 are all preferably made from injection molded plastic materials, such as an ABS plastic material, or the like. Additional details of the cover plate 112 are discussed in U.S. Pat. No. 9,133,638, the disclosure of which is incorporated herein in its entirety.
[0085] In some aspects, the seal created between the sealing gasket 114 and the flange 103 of the closure faceplate 102 may have three separate sealing interfaces that together define the seal. The first sealing interface may be the wedging of the sealing gasket 114 at the flange 103 on the pool side of the sidewall 106 of the closure faceplate 102 . This first sealing interface is created due to the wedging action of the wedge plate 130 . A second sealing interface may be formed between the sealing gasket 114 and the lip 105 of the closure faceplate 102 . In some aspects, the sealing gasket 114 may have one or more depressions (not shown) that correspond to the shape of the lip 105 such that at least a portion of the lip 105 may be positioned within the sealing gasket 114 . A third sealing interface may be formed between a rear edge of the flange 103 and the sealing gasket 114 . In some aspects, the sealing gasket 114 may be longer than a width of the flange 103 such that at least a portion of the sealing gasket 114 may wrap around the edge of the flange 103 when the wedge plate 130 is in the locked position.
[0086] Having described the structure of the sealing closure assembly 100 , a method of installing the sealing closure assembly 100 to close the skimmer opening 101 and prevent the passage of water into the skimmer opening 101 will now be described. To install the sealing closure assembly 100 , the closure faceplate 102 is first installed on the skimmer opening 101 , for example by snapping the closure faceplate 102 such that the one or more locking elements 110 lockingly engage the closure faceplate 102 with the skimmer peripheral flange 107 . In various other aspects, the closure faceplate 102 may be installed on the skimmer peripheral flange 107 by one or more fasteners, adhesive, or any other mechanical connection means that securely retains the closure faceplate 102 on the skimmer peripheral flange 107 . When installed, the closure faceplate 102 surrounds the skimmer opening 101 such that obstructing the central opening 108 of the closure faceplate 102 also obstructs the skimmer opening 101 . Next, the cover 104 , including the cover plate 112 , spreader or wedge plate 130 , and the cam lock 134 mated together, is inserted into the central opening 108 of the closure faceplate 102 . The assembled closure element 104 is inserted into the central opening 108 of the closure faceplate 102 from the pool side such that the sealing gasket 114 of the cover 104 engages the flange 103 of the closure faceplate 102 while the cover 104 is in the unlocked position, i.e., when the cam lock 134 is parallel to the plane of the cover plate 112 . After insertion, the cam lock 134 is moved to a locking position by rotating the cam lock 134 such that it is perpendicular to the plane of cover plate 112 . As the cam lock 134 is moved to the perpendicular, locking position, the cam lock 134 forces the spreader or wedge plate 130 into engagement with the inside of the sealing gasket 114 , thereby forcing the sealing gasket 114 into sealing engagement with the flange 103 of the closure faceplate 102 to prevent water leakage into the skimmer opening 101 .
[0087] With reference to FIGS. 9-10 , a sealing closure assembly 100 ′ is shown in accordance with another preferred and non-limiting embodiment or aspect of the present disclosure. The sealing closure assembly 100 ′ is configured for use with a skimmer (not shown) of a pool, spa, hot tub, or the like. The sealing closure 100 is configured to close a skimmer opening 101 and prevent water from entering the skimmer opening 101 .
[0088] With continued reference to FIGS. 9-10 , the sealing closure assembly 100 ′ includes a closure faceplate 102 ′ and a cover 104 ′ configured for removably connecting to the closure faceplate 102 ′. The closure faceplate 102 ′ is configured to be connected to the skimmer opening 101 , such as the skimmer peripheral flange (not shown), on the pool or water side of the skimmer. The closure faceplate 102 ′ has a generally square ( FIG. 9 ) or rectangular ( FIG. 10 ) shape that corresponds to the outer shape of the skimmer peripheral flange. The closure faceplate 102 ′ has a sidewall 106 ′ defining an outer peripheral shape of the closure faceplate 102 ′ and a central opening 108 ′. The closure faceplate 102 ′ may have a flange 103 ′ ( FIG. 11 ) that extends around the inner periphery of the central opening 108 ′ such that the flange 103 ′ overlaps the skimmer peripheral flange in order to prevent movement of the closure faceplate 102 ′ into the skimmer opening. The sidewall 106 ′ of the closure faceplate 102 ′ has one or more through-holes 110 ′ configured to receive a fastener element (not shown), such as a screw, to connect the closure faceplate 102 ′ to the skimmer peripheral flange. The closure faceplate 102 ′ may have a lip 105 ′ (shown in FIG. 11 ) extending around an outer periphery of the sidewall 106 ′. The lip 105 may be continuous or discontinuous around an outer periphery of the sidewall 106 ′. The lip 106 ′ may be configured for engaging at least a portion of the cover 104 ′, as described herein. In some aspects, the closure faceplate 102 ′ is formed as a one-piece integral member formed from a rigid material. For example, the closure faceplate 102 ′ may be injection molded from a hard plastic material, such as an ABS plastic resin that resists dimensional shrinking due to temperature variations.
[0089] With continued reference to FIGS. 9-10 , the cover 104 ′ is configured to be removably secured to the closure faceplate 102 ′. Referring now to FIG. 11 , the cover 104 ′ has a cover plate 112 ′ that is shaped to correspond to an outer shape of the closure faceplate 102 ′. The cover plate 112 ′ has a top surface 113 ′ opposite a bottom surface 115 ′. The cover plate 112 ′ has one or more openings 117 ′ ( FIGS. 13-14 ) extending between the top surface 113 ′ and the bottom surface 115 ′ around an outer periphery of the cover plate 112 ′. The one or more openings 117 ′ may have even or uneven spacing around the outer periphery of the cover plate 112 ′.
[0090] With continued reference to FIG. 11 , a sealing gasket 114 ′ is integrally formed about the outer periphery of the cover plate 112 ′. The cover plate 112 ′, together with the sealing gasket 114 ′, fits snugly around the sidewall 106 ′ of the closure faceplate 102 ′. For example, the cover plate 112 ′ may be configured to interface with the closure faceplate 102 ′ such that the sealing gasket 114 ′ surrounds or envelops a peripheral lip 105 ′ on the closure faceplate 102 ′. The monolithic sealing gasket 114 ′ is preferably formed by injection molding from a resilient thermoplastic elastomer which remains flexible in varying temperature settings and is resistant to degradation over time.
[0091] With reference to FIG. 12 and with continued reference to FIG. 11 , the sealing gasket 114 ′ has a peripheral recess 119 ′ with a tapered entry area 116 ′ that defines an opening for receiving the lip 105 ′ of the closure plate 102 ′ (shown in FIG. 11 ). The tapered entry area 116 ′ tapers inwardly such that the opening narrows. At its narrowest point, the opening expands into an upper stop section 118 ′ that is configured to receive the lip 105 ′ of the closure faceplate 102 ′. In use, a portion of the tapered entry area 116 ′ is deflected outward by the lip 105 ′ as the cover 104 ′ is engaged with the closure faceplate 102 ′. The tapered entry area 116 ′ is deflected until the lip 105 ′ of the closure faceplate 102 ′ enters the upper stop section 118 ′, at which point the deflected portion of the tapered entry area 116 ′ is deflected to its initial position to completely encapsulate the lip 105 ′. When connected, the tapered entry area 116 ′ of the sealing gasket 114 ′ contacts the lip 105 ′ and the sidewall 106 ′ of the closure faceplate 102 ′ such that no water can enter the sealing closure and the skimmer opening from the poolside. Thus, no water can enter the skimmer body, pump pipe, pump, filtration equipment, or heater from the pool.
[0092] With continued reference to FIG. 12 , and with reference to FIGS. 13-14 , the one or more openings 117 ′ on the cover plate 112 ′ are configured to receive at least a portion of the sealing gasket 114 ′. For example, the sealing gasket 114 ′ may extend through the entire opening 117 ′. In this manner, at least a portion of the sealing gasket 114 ′ is embedded within at least one opening 117 ′ on the cover plate 112 ′. In this manner, the material of the sealing gasket 114 ′ completely encapsulates the opening 117 ′ such that the sealing gasket 114 ′ is monolithically formed with the cover plate 112 ′. The sealing gasket 114 ′ thus may be inseparable from the cover plate 112 ′. In some aspects, the sealing gasket 114 ′ may extend through each of the one or more openings 117 ′ on the cover plate 112 ′. The sealing gasket 114 ′ and the cover plate 112 ′ may be joined monolithically using an over-molding technique. In some aspects, the sealing gasket 114 ′ may have a lower extension 120 ′ that extends along at least a portion of the bottom surface 115 ′ of the cover plate 115 ′. When the cover 104 ′ is installed on the closure faceplate 102 ′, the lower extension 120 may contact at least a portion of the sidewall 106 ′ to further seal the interface between the cover 104 ′ and the closure faceplate 102 ′.
[0093] The cover 104 ′ having the cover plate 112 ′ and the sealing gasket 114 ′ is formed such that the rigid cover plate 112 ′ resists dimensional deformation due to temperature variations while the resilient sealing gasket 114 ′ allows for slight movement. In this manner, the cover plate 112 ′ may resist stretching or breaking due to contact with ice, while the resilient sealing gasket 114 ′ maintains the seal with the closure faceplate 102 ′ while allowing for movement due to contact with ice.
[0094] While specific embodiments or aspects of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. The presently preferred embodiments or aspects described herein are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.
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A sealing closure assembly for closing off a skimmer opening for a swimming pool includes a closure faceplate and a cover removably connectable to the closure faceplate. The closure faceplate has a sidewall surrounding a central opening, a flange protruding from the sidewall to overlap a peripheral area of the skimmer opening, and a lip protruding from the flange and extending around an inner perimeter of the flange. The cover includes a cover plate with a sealing gasket fitted around an outer perimeter of the closure faceplate, a wedge plate member for engaging an inside sidewall of the sealing gasket, and a closure member for exerting a force between the cover plate and the wedge plate to pull the cover plate and wedge plate together between a locked and unlocked position. In the locked position, an outer sidewall of the sealing gasket engages the flange (1) proximate to the sidewall of the closure faceplate, (2) at the lip of the flange, and (3) by wrapping around a terminal edge of the flange.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 11/615,835 filed on Dec. 22, 2006, and is also related to U.S. application Ser. No. 11/615,854 filed on Dec. 22, 2006, which applications claim priority to U.S. provisional application No. 60/758,494 filed on Jan. 12, 2006. These applications are hereby incorporated by reference as if fully disclosed herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an apparatus for sewing fabrics and attaching rings to fabrics wherein the fabrics are, for example, usable in coverings for architectural openings and more particularly to an apparatus that takes a single or multi-ply sheet of material and either forms hems, tunnels, hobbles, and/or attaches rings to the material so it is suitable for connection to a control system for a covering for an architectural opening.
2. Description of the Relevant Art
While early forms of coverings for architectural openings consisted principally of draped fabrics or fabrics which were gathered along a top edge so as to form drapery, in recent years designer window coverings have taken on many numerous forms. Included in those forms are coverings that utilize fabric that can be raised or lowered and gathered in the process wherein rings or other guide systems are incorporated into the fabric to slidably confine lift cords or the like. Further, in Roman shade type products, horizontal droops in the fabric, otherwise referred to as hobbles, might be formed in the fabric for aesthetics.
While sewing machines have been used to form hobbles or attach rings to fabric, it was all hand operated with an operator literally moving and shifting the fabric as it was passed through an appropriate sewing machine for either stitching the fabric to provide hems or tunnels across the width of the fabric or to attach suitable guide rings.
There has, accordingly, been a need in the industry for automating the fabrication of fabric for use in coverings for architectural openings or in the use of fabrics that might have other uses wherein stitching, hobbles, the attachment of rings, or the like, is a requisite.
SUMMARY OF THE INVENTION
The apparatus of the present invention includes a vertically oriented and adjustable lift rack to which a top edge of a fabric material can be secured with the remainder of the material hanging by gravity through a lower housing where clamps are utilized to control the fabric during operations thereon.
A sewing carriage including a pair of tandem sewing machines having different capabilities are mounted together for movement in unison in a reciprocal path back and forth across the width of the fabric. One sewing machine is adapted to stitch the fabric from one side edge to the other while the other sewing machine is adapted to attach horizontally spaced rings to the fabric in a return movement of the sewing machines across the width of the fabric. When stitching the fabric, which might be a dual layer or dual panel fabric, the layers can be handled separately so that one layer might have hobbles formed therein while the other layer remains flat. Tunnels are also defined by the stitching in which rigidifying bars might be inserted. When forming tunnels and/or attaching guide rings to the fabric, a tucker blade is utilized to advance a horizontal section of the fabric into a position for engagement by the sewing machines with the tucker blade being retractable before stitching or the attachment of rings to the fabric. A vacuum chamber is also utilized in one embodiment to gather a horizontal segment of one layer of the fabric to form a hobble while the other layer is unaffected by the vacuum so that both layers can be stitched together with a hobble being formed in one layer. In a second embodiment, the hobble is formed by manipulating the layers with the lift rack.
A lower releasable clamp in the first embodiment is positioned beneath the sewing machines and has three distinct positions with an open position permitting the free passage of at least a layer of material therethrough, a soft clamp position providing some resistance to movement of the fabric with brushes for removing lint wrinkles or the like from the fabric and a hard clamp position where the fabric can be positively gripped during a sewing operation.
When the sewing machines have completed one operation of stitching, forming hobbles and/or sewing rings to the fabric, they are repositioned at a home position so the fabric can be elevated or dropped a predetermined amount, depending on the embodiment, for a repeat of the afore-described operation whereby vertically adjacent rows of hobbles, tunnels, rings, or the like, are formed in the fabric until the entire fabric has been treated. It can then be removed from the lift rack and is suitable for attachment to a control system for a covering for an architectural opening in which the fabric forms an integral part.
Other aspects, features, and details of the present invention can be more completely understood by reference to the following detailed description of the preferred embodiment, taken in conjunction with the drawings and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic fragmentary isometric of the apparatus of the present invention.
FIG. 2 is a front isometric of a fabric formed from the apparatus of FIG. 1 .
FIG. 3 is a rear isometric of the fabric shown in FIG. 2 .
FIG. 4 is an isometric similar to FIG. 1 showing the sewing machines separated as they might be for maintenance purposes.
FIG. 5 is a diagrammatic isometric of the apparatus illustrating a first step in treating a fabric.
FIG. 6 is a diagrammatic isometric similar to FIG. 5 showing a second step in the treatment of a fabric.
FIG. 7 is a diagrammatic isometric similar to FIG. 6 showing a third step in the treatment of a fabric.
FIG. 8 is a diagrammatic isometric similar to FIG. 7 showing a fourth step in the treatment of a fabric.
FIG. 9 is a diagrammatic isometric similar to FIG. 8 showing a fifth step in the treatment of a fabric.
FIG. 10 is a diagrammatic isometric similar to FIG. 9 showing a sixth step in the treatment of a fabric.
FIG. 11 is a diagrammatic isometric similar to FIG. 10 showing a seventh step in the treatment of a fabric.
FIG. 12 is a diagrammatic isometric similar to FIG. 11 showing an eighth step in the treatment of a fabric.
FIG. 13 is an enlarged diagrammatic fragmentary section taken along line 13 - 13 of FIG. 5 .
FIG. 14 is an enlarged diagrammatic fragmentary section taken along line 14 - 14 of FIG. 7 .
FIG. 15 is a section similar to FIG. 14 showing the vacuum chamber advanced into a clamping position with the fabric.
FIG. 16 is a section similar to FIG. 15 with the vacuum chamber having drawn the fabric thereinto.
FIG. 17 is a section similar to FIG. 16 with one layer of fabric having been gripped by a lower clamp and removed from the vacuum chamber.
FIG. 18 is an enlarged diagrammatic section taken along line 18 - 18 of FIG. 8 .
FIG. 19 is a section similar to FIG. 18 with the tucker blade having been tilted.
FIG. 20 is an enlarged diagrammatic fragmentary section taken along line 20 - 20 of FIG. 9 .
FIG. 21 is an enlarged diagrammatic fragmentary section taken along line 21 - 21 of FIG. 10 .
FIG. 22 is a diagrammatic section similar to FIG. 21 showing hobbles and rings having been formed in the fabric in a plurality of horizontal rows.
FIG. 23 is an enlarged fragmentary section taken along line 23 - 23 of FIG. 20 .
FIG. 24 is a section taken along line 24 - 24 of FIG. 23 .
FIG. 25 is an enlarged fragmentary section taken along line 25 - 25 of FIG. 21 .
FIG. 26 is a fragmentary section taken along line 26 - 26 of FIG. 25 .
FIG. 27 is a section similar to FIG. 25 showing the ring and fabric having been shifted for receipt of the sewing needle within the ring.
FIG. 28 is a section taken along line 28 - 28 of FIG. 27 .
FIG. 29 is a fragmentary section taken along line 29 - 29 of FIG. 14 showing the lower clamp in a soft clamping position.
FIG. 30 is a section similar to FIG. 29 showing the lower clamp in a full clamping position.
FIG. 31 is a section similar to FIG. 29 showing the lower clamp in an open position.
FIG. 32 is a fragmentary section taken along line 32 - 32 of FIG. 14 .
FIG. 33 is a top plan view of the portion of the apparatus shown in FIG. 32 .
FIG. 34 is an enlarged fragmentary section taken along line 34 - 34 of FIG. 32 .
FIG. 35 is a fragmentary section taken along line 35 - 35 of FIG. 26 .
FIG. 36 is a section taken along line 36 - 36 of FIG. 35 .
FIG. 37 is a section similar to FIG. 36 showing the ring clamp in an open position.
FIG. 38 is a section taken along line 38 - 38 of FIG. 14 .
FIG. 39 is an enlarged fragmentary section similar to FIG. 38 showing the drive mechanism for linearly translating the sewing machines with the view taken at the left end of the apparatus when the sewing machines are positioned at the left end.
FIG. 40 is a fragmentary section similar to FIG. 39 with the sewing machines positioned at their home position at the right end of the apparatus.
FIG. 41 is an isometric of a second embodiment of the apparatus of the present invention.
FIG. 42 is a front isometric of a fabric formed from the apparatus of FIG. 41 having hobbles formed on the front face thereof.
FIG. 43 is a rear isometric of the panel shown in FIG. 42 showing tucks and rings sewed to the panel.
FIG. 44 is an isometric similar to FIG. 41 showing the sewing machines separated as for maintenance purposes.
FIG. 45 is a front isometric of the apparatus of FIG. 41 with the upper edge of two sheets of fabric material anchored to lift towers of the apparatus in preparation for processing a fabric as viewed in FIGS. 42 and 43 .
FIG. 46 is an isometric similar to FIG. 45 with the panels of fabric having been elevated by the lift towers prior to processing the fabric panels.
FIG. 47 is an isometric similar to FIG. 46 with the panels of fabric material having been dropped into a position for initial operation of the apparatus.
FIG. 48 is an isometric similar to FIG. 47 with the tucker blade having been advanced into the sheets of fabric material for forming a tuck in the material.
FIG. 49 is an isometric similar to FIG. 48 with the tucker blade having been removed from the fabric sheets and the ring sewing machine positioned for initiating an attachment stitch into the fold of the sheets of material.
FIG. 50 is an isometric similar to FIG. 49 with the ring sewing machine positioned to initiate a stitch into a ring for attachment to a fold in the sheets of material.
FIG. 51 is an isometric similar to FIG. 49 with a complete fabric having been formed showing the lift tower at its lowermost position.
FIG. 52 is an isometric similar to FIG. 51 with the lift tower having elevated the completed fabric.
FIG. 53 is an enlarged section taken along line 53 - 53 of FIG. 45 .
FIG. 54 is an enlarged section taken along line 54 - 54 of FIG. 46 .
FIG. 55 is an enlarged section taken along line 55 - 55 of FIG. 47 .
FIG. 56 is an enlarged section taken along line 56 - 56 of FIG. 48 .
FIG. 57 is a section similar to FIG. 56 with the stabilizing clamp having been energized.
FIG. 58 is a section similar to FIG. 57 with the stitching machine sewing a tuck into the sheets of material.
FIG. 59 is a section similar to FIG. 58 with the ring sewing machine positioned to initiate a stitch along a folded edge of the sheets of material.
FIG. 60 is an enlarged section taken along line 60 - 60 of FIG. 49 .
FIG. 61 is an enlarged section taken along line 61 - 61 of FIG. 60 .
FIG. 62 is an enlarged section taken along line 62 - 62 of FIG. 58 .
FIG. 63 is a section taken along line 63 - 63 of FIG. 62 .
FIG. 64 is a section similar to FIG. 61 where the ring sewing machine is positioned for sewing a ring to sheets of material that do not have a hobble but are merely formed with tucks to which rings are attached.
FIG. 65 is a rear isometric showing a panel of fabric material having tucks and rings sewn thereto but with no hobbles.
FIG. 66 is a section similar to FIG. 64 wherein the ring sewing machine is positioned to sew a ring to the panels of fabric material where no tuck is formed in the material.
FIG. 67 is a rear isometric showing a panel where rings are sewn to the panel but no tucks or hobbles are formed on the panel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Looking first at a first embodiment of the invention shown in FIGS. 1-40 , the apparatus 41 ( FIG. 1 ) can be seen to include a housing 42 on which a lift rack 44 is mounted. As will be described hereafter, the housing includes various components of the apparatus for handling fabric that is being treated while the lift rack supports an upper edge of the fabric and is vertically movable to raise or lower the fabric into or out of the housing. As seen in FIGS. 2 and 3 , a completed fabric 46 which could be formed with the apparatus of the present invention is illustrated. It is shown to include a backing or rear layer 48 and a front layer 50 with the front layer secured to the backing layer along horizontal vertically spaced tucks 52 in the fabric in a manner whereby a plurality of vertically aligned horizontally disposed hobbles or droops 54 in the fabric are formed so the fabric resembles a Roman shade. A tunnel 56 can be formed along the top and bottom edges of the fabric for receipt of a stiffening bar (not seen) with the tunnel possibly being formed from two horizontal lines of stitching that are vertically spaced or by folding the edge and with one stitch forming a hemmed edge. The top tunnel would typically be formed in the fabric before the fabric is treated with the apparatus of the present invention. The top edge of the fabric is then supported in the lift rack 44 so the fabric is properly disposed for processing within the apparatus.
The lift rack 44 consists of a pair of horizontally spaced vertically extending support towers 58 that are interconnected at their top ends to support a horizontal drive shaft 60 and a motor 62 for reversibly rotating the drive shaft. The lift towers have lift cords (not seen) disposed therein with the lift cords being operably connected to opposite ends of a vertically adjustable horizontally extending transverse lift bar 66 which is referred to hereafter as an upper clamp. Reversible rotation of the drive shaft raises or lowers the upper clamp for purposes to be described hereafter.
The housing 42 includes a number of operative components which will be described hereafter and which are adapted to grip and manipulate a virgin fabric 68 ( FIGS. 5-9 ) to properly position the fabric so that one or both of a pair of sewing machines 70 and 72 mounted on the housing for reciprocal horizontal translating movement can direct sewing operations to the fabric in a preselected manner.
One of the sewing machines 70 is provided to stitch horizontal lines in the fabric while the other 72 is provided to attach guide rings 74 ( FIGS. 3 , 21 , 22 and 25 - 28 ) commonly found in certain coverings for architectural openings such as Roman Shades. Both sewing machines are conventional for their intended purpose and will therefore only be described broadly hereafter with specific regard to their operation and relationship to the fabric being treated.
The apparatus is designed to treat virgin fabric 68 in several different ways so the fabric can be formed with a plurality of hobbles 54 , a plurality of guide rings 74 attached thereto, a plurality of horizontal tunnels 56 on the front or rear of the fabric, and various combinations of the above. The treatments are accomplished in one continuous operation of the apparatus.
The apparatus is controlled through a conventional computer control module 76 that energizes various pumps, motors, and pneumatic pistons for achieving the various operations performed by the apparatus on the fabric. A detailed description of the software for driving the control module will not be described herein but suffice it to say the various operating mechanisms in the apparatus are controlled from the module and with an appropriate computer-controlled system.
The sewing machines 70 and 72 are mounted on two interconnected halves 78 and 80 , respectively, of a sewing machine carriage 82 with the halves typically being interconnected so the sewing machines move in unison but can be separated as shown in FIG. 4 for individual maintenance of the machines. One sewing machine 70 in the preferred embodiment is a walking foot/needle feed lock stitch machine used to stitch the fabric in a manner to become clear hereafter and might be for example a Seiko SSH-88LDC-DTFL machine manufactured by Seiko of Japan. The other machine 72 in the preferred embodiment is a conventional button sewing machine which might be for example a Pfaff 3307 button or ring-stitching machine manufactured by Pfaff of Belgium. The ring-stitching machine, while normally being used for sewing buttons, can sew rings of the type used as guide rings 74 on fabrics for coverings for architectural openings wherein the rings are retained in a hopper (not seen) on the machine and fed to the sewing head where they are connected to the fabric. It is not important which of the two sewing machines is on the right or on the left as they both move in unison across the entire width of the fabric being treated.
The interconnected halves 78 and 80 of the carriage 82 for the sewing machines 70 and 72 are mounted on a horizontally disposed linear bearing or guide track 84 for reciprocal horizontal movement as the carriage, with the sewing machines thereon, is reversibly translated across the width of the housing 42 . The sewing machines on the carriage are typically stationed at a home position at the right end of the apparatus as viewed in FIG. 1 and during one operation on a virgin fabric 68 , the carriage translates to the left for a stitching operation and then back to the right for a ring attaching operation where it remains in its home position until another row of operations is performed on the fabric. Movement of the carriage is accomplished with a tensioned timing belt 86 as best appreciated by reference to FIGS. 1 and 38 - 40 , which is anchored to the housing 42 at opposite ends with fixed brackets 88 . One of the carriage halves 78 has a motor (not seen) that reversibly drives a gear wheel 90 in operative engagement with the timing belt with the timing belt passing across idler pulleys 92 on opposite sides of the driven gear wheel. It can therefore be appreciated that rotation of the gear wheel in one direction causes the carriage 82 to translate linearly in one direction across the apparatus and rotation of the gear wheel in the opposite direction causes the carriage to translate linearly in the opposite direction so it can be moved from one side of the apparatus 41 to the other at predetermined and/or intermittent speeds.
FIGS. 5-12 illustrate diagrammatically the various steps that can be applied to a virgin fabric 68 with the apparatus 41 of the present invention in forming a completed fabric 46 of the type illustrated in FIGS. 2 and 3 . The completed fabric in the example shown includes a plurality of horizontal hobbles or loops 54 formed in vertically adjacent rows on the front layer of the fabric ( FIG. 2 ) and a plurality of horizontally extending vertically spaced tucks 52 having horizontally spaced guide rings 74 secured thereto formed on the rear layer 48 of the fabric as seen in FIG. 3 . Looking first at FIG. 5 , a virgin fabric consisting of two layers of sheet material that have been pretreated to form a tunnel 56 along a top edge thereof with a rigidifying slat (not seen) possibly inserted therein is clamped to the upper clamp 66 . The upper clamp includes a pair of horizontal bars 94 and 96 that can be clamped together or released. In the released position, the top edge of the virgin fabric 68 can be inserted between the bars and in the clamped position releasably secured between the bars. While the fabric could be positioned at any place across the width of the upper clamp, if in fact the fabric were narrower than the width of the lift rack 44 as illustrated, it is preferably positioned along one side edge (illustrated as the right side edge) for a purpose to be more clear hereafter.
After the virgin fabric 68 is secured to the upper clamp 66 , the upper clamp is elevated with the motor 62 and drive shaft 60 to the position of FIG. 6 so the fabric is substantially vertically suspended with its lower edge at the top of the housing 42 . The upper clamp is then lowered and depending upon the operations to be applied to the virgin fabric, the two layers of the fabric can be maintained together or separated so as to straddle various components within the housing. Once the layers of the fabric are positioned for the operations to be applied thereto within the housing, the upper clamp is lowered to an initial operative position shown in FIG. 7 . Thereafter, a hobble 54 is formed in the front layer 50 and a reciprocating horizontally disposed tucker blade 98 , which will be described in more detail later, which is normally in a retracted position adjacent to the front layer of the fabric, is advanced as shown in FIG. 18 to form a tuck 52 off the rear of the fabric on which the sewing machines 70 and 72 can operate. The tuck in the fabric is then gripped with a tuck clamp 100 (to be described later) and the tucker blade retracted so a first operation of the sewing machines as shown in FIG. 9 can be initiated with the sewing machines translating from their home position at the right end of the apparatus 41 to the left end of the apparatus. As shown in FIG. 10 , a subsequent pass of the sewing machines from the left end of the apparatus back to their home position allows one of the sewing machines to perform a separate operation. For example, in the fabric 46 illustrated in FIGS. 2 and 3 where both hobbles 54 and guide rings 74 are applied to the fabric, the movement from the home position to the left as shown in FIG. 9 would be used to form a horizontal stitch with one of the sewing machines 70 along the tuck to hold the two layers of material in the tuck together and the reverse movement of the sewing carriage 82 , as shown in FIG. 10 , would be used for attaching the guide rings with the other sewing machine 72 along the edge of the tuck. After one such operation, one row of a tunnel 56 , defined by a tuck, with its associated guide rings is completed along with a hobble and at that time, the upper clamp 66 is elevated a predetermined distance, i.e. the height of a hobble, and the operation is repeated. By repeating the operation a new row is formed and the upper clamp is again elevated a predetermined amount as shown in FIG. 11 until the entire fabric 46 has been completed as illustrated in FIG. 12 .
Referring to FIG. 13 , which is a vertical section through the apparatus 41 with the layers 48 and 50 of virgin fabric having been connected to the apparatus as shown in FIG. 5 with the upper clamp 66 , the internal working components of the apparatus are shown diagrammatically. It will there be seen beneath the upper clamp is the tuck clamp 100 that includes an elongated horizontally disposed generally U-shaped rail 101 extending the width of the apparatus and connected to a pair of pneumatic cylinders 102 mounted at opposite ends of the rail with mounting brackets 104 on the rear face of the rail. A lower edge of the rail carries a beveled strip 106 supporting a spring steel upper clamp jaw 108 with a gripping edge of material 110 secured on its lower face along a distal edge thereof. The pneumatic cylinders 102 are operative to raise or lower the rail and the upper clamp jaw in a manner such that in a lowered position of the tuck clamp, as seen for example in FIG. 19 , the upper clamp jaw engages a tuck 52 of material and presses the material against a platen 112 with a gripping upper surface mounted vertically therebeneath on the housing 42 . In the normal elevated position of the tuck clamp, a space is defined between the upper clamp jaw and the platen through which a tuck in the fabric can be advanced for proper positioning relative to the sewing machine carriage 82 as will be discussed later.
In horizontal opposing relationship to the tuck clamp rail 101 and positioned horizontally between the pneumatic cylinders 102 and beneath a support plate 114 in the housing is a vacuum clamp 116 . The vacuum clamp includes an elongated horizontally disposed plenum 118 where a low pressure is maintained and a horizontally aligned elongated vacuum chamber 120 communicating with the plenum and having a horizontal slot-like opening 122 in a front wall 124 thereof facing the tuck clamp rail. While the opening 122 extends the full length of the vacuum chamber, an extendable closure tape 126 ( FIGS. 32-34 ) is mounted at one end of the chamber to be selectively extended across a portion of the chamber to close a portion of the opening if the fabric is not wide enough to cover the entire length of the opening. The plenum and vacuum chamber are reciprocally mounted on the plungers 128 of a second pair of pneumatic cylinders 130 secured to the support plate 114 so that when the plungers for the cylinders are extended, the front wall 124 of the vacuum chamber is advanced into engagement with the tuck clamp rail 101 . Of course, retraction of the vacuum chamber with a retraction of the plungers 128 of the second pair of pneumatic cylinders 102 withdraws the chamber and moves it to the left as viewed in FIG. 13 so as to define a space between the rail of the tuck clamp and the vacuum chamber. The plenum for the vacuum chamber is connected with a conventional conduit to a selectively operable vacuum pump 132 positioned within the housing.
The tucker blade 98 is a horizontal elongated blade of thin profile extending the full width of the apparatus 41 and mounted on a horizontal support plate 133 secured to the rack 134 of a rack and pinion reciprocal drive system 136 ( FIG. 13 ). The pinion 138 of the drive system is reversibly driven by a motor (not seen). Obviously, rotation of the pinion in one direction drives the rack and the tucker blade horizontally to the right as viewed in FIG. 13 into an extended position as seen in FIG. 18 while rotation of the pinion in the opposite direction retracts the tucker blade to its retracted position of FIG. 13 . In the extended position shown in FIG. 18 , it is extended between the upper clamp jaw 108 and platen 112 of the tuck clamp 100 with the front elongated edge 140 of the tucker blade being positioned beyond the tuck clamp immediately adjacent to the sewing carriage 82 . The horizontal support plate 132 on which the tucker blade is mounted is supported on a lever arm 142 pivotal about a pivot shaft 144 by a pair of low-pressure pneumatic cylinders 145 which could in fact be a gas spring even though in the disclosed embodiment it is a pneumatic cylinder carrying low pressure. The pneumatic cylinders are therefore adapted to pivot the lever arm and thus the tucker blade about the pivot shaft for a purpose to become clear hereafter.
A lower clamp 146 is positioned beneath the tucker blade 98 at an elevation also beneath the platen 112 . The lower clamp has a horizontally movable vertically disposed bar 148 that supports pairs of large 150 and small 152 pneumatic cylinders which are probably best appreciated by reference to FIGS. 29-31 . The movable vertically disposed bar confronts a second vertically disposed bar 154 that is fixedly mounted on a vertically movable support plate 156 . The fixedly mounted bar has an upper horizontal rearwardly directed brush 158 with a plurality of flexible bristles that overlaps a similar elongated horizontally disposed brush 160 mounted on the movable bar 148 . The lower clamp is a three-position clamp and movable between an open position as shown in FIG. 31 wherein the brushes 158 and 160 are not vertically overlapping but rather define a vertical passage therebetween, a soft closed position as shown in FIG. 29 where the brushes partially overlap as seen for example in FIG. 13 as well as FIG. 29 and a fully closed clamping position as shown in FIG. 30 where the lower brush 160 carried by the movable bar is engaged against the fixed bar 154 .
The plungers 162 of the large cylinders 150 are secured at their distal end to the fixed bar 154 such that extension of the plungers causes the movable bar 148 to retract or move to the left relative to the fixed bar and retraction of the cylinders causes the movable bar to move to the right toward the fixed bar. The plungers 164 on the small cylinders 152 merely extend into the space between the fixed and movable bars regardless of whether or not they are extended or retracted.
To move the lower clamp 146 between its three positions, and again with reference to FIGS. 29-30 , in the open position of FIG. 31 , the large pneumatic cylinder plungers 162 are fully extended so as to fully separate the two bars 148 and 154 and the brushes 158 and 160 mounted thereon to define a vertical gap between the brushes. The plungers 164 of the smaller cylinders 152 are also fully extended but non-engaging with the fixed bar 154 due to their relatively short length. To move the clamp to the soft clamping position of FIG. 29 , the large cylinder plungers are retracted to pull the movable bar toward the fixed bar until the plungers of the small cylinders engage the fixed bar to fix the spacing between the movable and fixed bars of the lower clamp. To move the lower clamp to its fully closed and full clamping position of FIG. 30 , the plungers on the small cylinders are fully retracted as are the plungers on the large cylinders so the lower brush 160 on the movable bar closely approaches the fixed bar in which position the fabric can be positively gripped for purposes to be described hereafter. A positive grip is best established with a horizontal channel member 166 ( FIG. 19 ) opening off the face of the movable bar 148 and a fixed leg 168 with gripping pads 170 on the fixed bar with the leg being inserted into the channel when the clamp is fully closed.
The fixed bar 154 , as mentioned previously, is mounted on the support plate 156 that is of L-shaped configuration and itself vertically reciprocably mounted on another pair of pneumatic cylinders 172 , which can elevate the fixed bar and movable bar 148 of the lower clamp 146 to the position of FIG. 13 , for example, or lower the fixed and lower bars of the lower clamp to the position of FIG. 17 .
Also provided within the housing 42 near the bottom thereof are a pair of support rods 174 that support a flexible cradle 176 of any suitable material in which the virgin fabric 68 can gather when the upper clamp 66 is lowered to the position of FIG. 5 , for example. In fact, with reference to FIG. 14 , a virgin fabric 68 is shown in the position of FIG. 5 and is gathered in the cradle from which it can be removed as the upper clamp is raised during processing of the fabric.
Referring to FIG. 14 , the apparatus 41 is postured for forming a fabric 46 of the type shown in FIGS. 2 and 3 with hobbles 54 and guide loops 74 and for such a fabric, when the upper clamp 66 is lowered to the position of FIG. 5 , the rear layer 48 of the fabric is threaded through the lower clamp 146 , as shown in FIG. 14 , and the front layer 50 of the fabric is passed on the rear side of the movable bar 148 of the lower clamp so as to bypass the lower clamp. As will be appreciated from the description herein, the reference to the layers of the fabric as front 50 and rear 48 layers, for illustrative purposes, is the reverse of the reference to the parts of the apparatus since the fabric is mounted in the apparatus with its front layer facing the rear of the apparatus. It will also be appreciated in the positioning of the fabric in FIG. 14 , both layers of the fabric pass freely past the tuck clamp 100 and the vacuum clamp 116 and will also slide through the lower clamp even though the lower clamp is in its soft-clamping position with the rear layer of the fabric engaging the upper and lower brushes 158 and 160 of the lower clamp.
Referring to FIG. 15 , when forming the fabric 46 of FIGS. 2 and 3 , having both hobbles 54 and guide loops 74 , the first step in the operation is to grip the virgin fabric 68 with the vacuum clamp 116 so the fabric is pinched between the vacuum chamber 120 and the tucker rail 101 . The closure tape 126 can be pulled across the opening in the front wall of the vacuum chamber from the left edge of the opening to the left edge of the fabric to maintain adequate vacuum in the chamber. A vacuum is then drawn by energizing the vacuum pump 132 which pulls both layers of fabric into the vacuum chamber as seen in FIG. 16 as the upper clamp 66 is lowered to provide more fabric to the vacuum clamp. Typically, in a fabric of this type, the front layer 50 is less porous than the rear layer 48 so the vacuum is more effective on the front layer but there is enough vacuum to draw both layers into the vacuum chamber.
With both layers 48 and 50 of the fabric drawn a predetermined amount into the vacuum chamber 120 , which is permitted by the top clamp 66 being lowered a predetermined amount, the lower clamp 146 is moved into its full clamping position as shown in FIG. 17 so the rear layer of the fabric is fully gripped by the lower clamp but the front layer is free to move up or down. Thereafter, as also seen in FIG. 17 , the vacuum clamp 116 is withdrawn and simultaneously the lower clamp is lowered which pulls the rear layer of the fabric out of the vacuum chamber so it is relatively straight while the front layer still forms a loop within the vacuum chamber which will ultimately form a hobble 54 in the fabric.
Subsequently, as shown in FIG. 18 , the tucker blade 98 is advanced with the rack and pinion system 136 while the tucker blade is in a horizontal orientation which forces both layers 48 and 50 of the fabric between the upper clamp jaw 108 and the platen 112 of the tuck clamp 100 thereby forming a tuck 52 in both layers of the fabric. Before the tucker blade is advanced, however, the lower clamp 146 is moved to its soft clamp position of FIG. 18 so the rear layer of the fabric is drawn through and across the lower clamp and across the brushes 158 and 160 to remove lint and any wrinkles while the front layer of the fabric, which is freely hanging can be moved therewith. When advancing the tucker blade in this manner, it will be appreciated that since both layers of the fabric are gripped by the vacuum clamp 116 , even though only the front layer 50 is drawn into the vacuum chamber 120 , all of the material is fed upwardly from below the tucker blade and therefore the material slides slightly across the leading edge 140 of the tucker blade 98 . If a hobble 54 was not being formed in the fabric during this step, the vacuum clamp would remain in a retracted position and there would be no loop or hobble of the front layer of fabric in the vacuum chamber. Rather, both layers would be in adjacent side-by-side relationship and by lowering the upper clamp as the tucker blade is advancing, equal amounts of material can be pulled downwardly from above the tucker blade as pulled upwardly from below the tucker blade to avoid having to draw the material across the leading edge of the tucker blade which minimizes any opportunity for damage to the fabric.
Referring to FIG. 19 , with the tucker blade 98 in the position of FIG. 18 , the tuck clamp 100 is lowered so the tuck 52 of fabric with the tucker blade therein is clamped between the upper clamp jaw 108 and the platen 112 of the tuck clamp and due to the bevel or inclination of the upper clamp jaw of the tuck clamp, the tucker blade is tilted which is permitted by pivoting of its support plate 132 about the pivot shaft 144 which is further permitted by the low pressure in the pneumatic cylinders 144 or if the pneumatic cylinders were replaced with a gas spring it would be permitted by the gas spring through minimal resistance to such pivotal movement.
The tucker blade 98 is coated with Teflon® or another low-friction material so that once the tuck 52 in the material has been gripped by the tuck clamp 100 , the tucker blade can be easily withdrawn, as shown in FIG. 20 , leaving the tuck of fabric positioned between the upper clamp jaw 108 and platen 112 of the tuck clamp. The low-friction coating of the tucker blade allows easy sliding removal of the tucker blade even though the tuck of fabric is positively gripped and held in position.
In the position of FIG. 20 , the sewing machine carriage 82 is energized so as to translate from the rest position at the right of the apparatus 41 to the left side of the apparatus and as it is making this pass, the stitching sewing machine 70 is activated while the ring-attaching sewing machine 72 is deactivated. The tuck 52 in material, as can be seen in FIGS. 20 and 23 , is aligned with the stitching needle 178 so that as the sewing machine carriage is advanced or translated across the apparatus, a stitch 180 ( FIG. 23 ) is formed in the fabric at a spaced parallel location from the fold 182 at the edge of the tuck. This establishes a tunnel 56 in the tuck between the stitching and the folded edge of the tuck in which a reinforcing bar (not shown) can be placed if desired.
After the stitch 180 has been formed and the carriage 82 is at the left side of the apparatus, the carriage is then driven to the right. The stitching machine 70 is deactivated and the ring-attaching sewing machine 72 is activated to attach rings 74 at predetermined spaced locations along the width of the fabric and along the folded edge 182 of the tuck 52 . The spacing of the rings is predetermined depending upon the number of rings desired per width of the fabric and this can all be calculated and computed within the control module.
As mentioned previously, the ring-attaching machine 72 is a conventional button sewing machine which includes a hopper (not seen) for a plurality of buttons or rings 74 and a ramp 184 ( FIG. 21 ) that might vibrate for example that confines a string of rings on a downward sliding path from the hopper to a linearly reciprocating ring gripper 186 as shown in FIGS. 21 , 25 - 28 , and 35 - 37 . In the Pfaff ring-stitching machine used in the preferred embodiment of the invention, the sewing needle 178 on the head of the sewing machine 72 reciprocates up and down at a predetermined position but it is desired to stitch across one edge of a ring 74 so that some of the stitches are outside the ring and others are inside the ring so the ring is positively attached to the folded edge 182 of the tuck 52 . In order to establish the stitching across the ring, the ring gripper reciprocates forwardly and rearwardly shoving the ring and the edge of the fabric into one position for allowing the sewing needle to establish a stitch 188 ( FIG. 27 ) within the ring and then retracting the ring which allows the folded edge to also return therewith so the folded edge of the material is aligned with the needle. Accordingly, the next stitch 188 can go through the folded edge of the fabric. By repeating this operation, a predetermined number of threads secure an edge of the ring to the folded edge of the tuck. Thereafter, the ring-attaching machine is moved linearly toward its rest position until it is stopped by the control module at a location where the next ring is to be attached and the ring is attached at that location in the same manner.
With reference to FIGS. 25-28 and 35 - 37 , the ring clamp or gripper 186 has two spaced arms 190 with the distance between the spaced arms being adjustable in the Pfaff sewing machine so that in a gripping position shown in FIGS. 25-28 , 35 and 36 , the ring 74 is positively held so it can be advanced or retracted for desired alignment with the sewing needle 178 . After the ring has been attached to the tuck 52 , the arms of the ring clamp are retracted as shown in FIG. 37 and the ring clamp itself retracted so the sewing machine can be linearly advanced toward home base and once reaching its next position of attachment for a ring, the arms 190 receive the next ring in line which is dropped therebetween so it too can be gripped and handled as described previously.
As will be appreciated from the above, with one complete reciprocal pass of the sewing carriage 82 across the width of the fabric and back, a tunnel 56 can be formed along the edge of the fabric securing the tuck 52 and rings 74 can be attached at predetermined spaced locations to the tuck. On the opposite face or front layer 50 of the fabric, a hobble 54 is formed during the same operation as a loop of the front layer was confined during the operations within the vacuum chamber 120 . Accordingly, a hobble, tunnel and associated rings forming one row of the fabric are established each time the sewing carriage passes through a reciprocating path back and forth across the width of the fabric. After a row has been formed, the upper clamp 66 can be elevated a predetermined distance corresponding to the desired height of a hobble for another identical subsequent operation until a complete fabric 46 has been formed as shown in FIGS. 2 and 3 . Once formed, the fabric is simply removed from the upper clamp where it is ready for incorporation into a control system for the architectural covering in which it is to be incorporated.
It will be appreciated from the above that by selecting various operations, a fabric 46 with hobbles 54 and guide rings 74 can be formed as described above or a one or more layer fabric can be formed with simply the guide rings by leaving the vacuum clamp 116 in an inoperative or retracted position so the hobbles are not formed. If tucks were desired with rings, both the stitching and ring attaching sewing machines would be used but if no tucks were desired in the finished fabric, a stitch would not be placed in the tuck established by the tucker blade but only rings would be attached at the folded edge established by the tucker blade. Similarly, if the rings were not desired for a fabric but the hobbles were, then the operation would be as described above except in the return path of the sewing carriage 82 , the ring-attaching sewing machine 72 would not be activated so a fabric would be formed with only hobbles.
If only tunnels 56 were desired for the fabric, the vacuum clamp 116 would again be deactivated or retained in its withdrawn position and the two layers 48 and 50 of the fabric would be handled together with both layers passing through the lower clamp 146 but other than this distinction, the formation of horizontal tunnels at vertically spaced locations would follow the above procedure. Again, however, only the stitching machine 70 would be operative and the ring-attaching machine 72 would be deactivated so that tucks 52 and tunnels were formed off the rear of the fabric along parallel vertically spaced lines. Of course, if the tunnels were desired on the front of the fabric, the virgin fabric 68 could be reversed in the upper clamp 66 so the tunnels were formed on the front of the fabric rather than the rear.
Clearly from the various options available with the apparatus, fabric for different types of coverings for architectural openings can be made automatically. Further, varying widths of fabrics can be handled up to the spacing of the lift towers on the lift rack.
The second embodiment 200 of the apparatus of the invention is shown in FIGS. 41-67 . This embodiment of the invention is somewhat similar to the previously described embodiment and accordingly, where appropriate, like parts have been given like reference numerals.
In the second embodiment, the vacuum clamp 116 of the first embodiment has been removed and replaced with a stabilizing clamp 202 so there is no longer a vacuum chamber 120 into which fabric is drawn when forming a hobble. Further, there is no lower clamp 146 . In addition, there are two lift racks 44 f and 44 r that are identical except the rear rack 44 r is higher than the front rack 44 f . The remainder of the apparatus is identical to the first-described embodiment including the sewing machines 70 and 72 and their mounting on a sewing machine carriage 82 . The tucker blade 98 is identical to that of the first-described embodiment and operates in the same manner so as to cooperate with the tuck clamp 100 and the sewing machines in forming tucks 52 and/or attaching rings 74 to the fabric. In the second embodiment to be described hereafter, the hobbles 54 are formed in a different manner since the vacuum system used for forming hobbles in the first embodiment has been removed.
The two lift racks 44 f and 44 r , as mentioned, are identical to each other and to the lift rack 44 of the first embodiment except the lift rack 44 r is slightly taller than the lift rack 44 f as can be seen in FIG. 41 .
With reference to FIG. 53 , the stabilizing clamp 202 can be seen to have replaced the vacuum clamp 116 of the first-described embodiment and includes a gripping head 204 for compressing engagement with the fabric to hold the fabric against the U-shaped rail 101 . The stabilizing clamp head is reciprocated with the pneumatic cylinder 130 in the same manner of operation as in the first-described embodiment. Similarly, the tuck clamp 100 is opened and closed through the use of the same pneumatic cylinder 102 which raises and lowers the upper clamp jaw 108 into and out of engagement with the lower clamp jaw or platen 112 . Also, the tucker blade 98 is again reciprocated in a horizontal plane with the rack and pinion reciprocal drive system 136 .
In initially describing the operation of the second embodiment of the apparatus, it will be described in connection with the fabrication of a fabric 46 as illustrated in FIG. 42 wherein a back or backing sheet of material 206 and a front sheet 208 are interconnected and horizontal hobbles 54 are formed in vertically spaced relationship with each other on the front sheet by forming loops of the front sheet material and securing the looped sheet material of the front sheet to the rear sheet. In accordance with the second embodiment of the invention, the front and rear sheets of material that are sewn together with the apparatus of the invention are pre-treated as in the first described embodiment by sewing a lower edge of the sheets of material together preferably defining a hem 210 in which a weighted bottom rail or ballast bar 212 can be inserted. The back sheet 206 , which lies toward the front of the machine, is shorter than the front sheet 208 as can be seen, for example, in FIG. 46 , and is clamped along its upper edge to an upper clamp 66 on the front lift rack 44 f . The upper edge of the front sheet is attached to the upper clamp 66 associated with the rear lift rack 44 r . This can be done with both lift racks being lowered as shown in FIG. 45 where the clamps are readily accessible to an operator.
After the top edges of the front 208 and back 206 sheets are attached to the associated upper clamps 66 of the lift racks, the lift racks are elevated as shown in FIG. 46 so the sheets are vertically suspended in abutting face-to-face relationship with each other with the longer front sheet extending above the shorter back sheet. The lower edges of the sheets, of course, are coincident with the weighted bottom rail 212 retaining the sheets in a fully-extended condition and with the bottom edges slightly above the housing 42 of the apparatus.
To begin forming the fabric of FIG. 42 , the bottom rail at the bottom edges of the front and back sheets of material is dropped below the tucker blade 98 a predetermined amount as shown, for example, in FIG. 55 . It will also be appreciated the front sheet 208 , which appears on the left in FIG. 5 , has been dropped slightly further than the back sheet 206 with the difference in dropped distance being equivalent to the height desired for a hobble 54 that will be formed in the finished fabric. For example, if a hobble is to be four inches in depth from top to bottom, the front sheet will be dropped four inches further than the back sheet so as to form a loop 214 for the first hobble to be formed in the fabric. With the sheets of material positioned as shown in FIG. 55 , the tucker blade is advanced as shown in FIG. 56 a predetermined distance so as to form a tuck 52 in the fabric of a predetermined depth. As the tucker blade is being advanced, the upper clamps 66 for both the front and back sheets of material are lowered a corresponding amount to the depth of the tucks while the bottom rail is lifted that same amount so the fabric does not slide around the leading edge 140 of the tucker blade but rather both sheets of fabric are pulled down and up equivalent amounts as the tucker blade forms the horizontal tuck. After the tuck has been formed, the upper jaw 108 of the tucker clamp is lowered by the pneumatic cylinder 102 until the upper jaw clamps the tucked sheets of material and the tucker blade between the upper jaw and the platen 112 . After the tuck is secured with the tuck clamp 100 , the stabilizing clamp 202 is advanced into engagement with the fabric having the rail 101 as the backing plate by activating the pneumatic cylinder 130 . The stabilizing clamp thereby grips the fabric and stabilizes the fabric so there is no movement in the fabric above the tucker blade when the tucker blade is withdrawn as shown in FIG. 58 .
With the tucker blade 98 withdrawn, as shown in FIG. 58 , the stitching sewing machine 70 ( FIGS. 62 and 63 ) commences it traverse along the width of the sheets of material so as to sew a seam in the fabric defining a tuck or tunnel 52 to the right of the seam between the stitching and the folded edge of the sheets of material. After the seam has been sewn across the entire width of the sheets of material, the ring attaching sewing machine 72 is positioned as shown in FIG. 59 above the tuck in the sheets of material so it can initially place a stitch through the folded edge of the sheets of material as shown in FIG. 60 and then after withdrawing the needle 178 , the first ring 74 , which has been positioned for attachment to the sheets of material, is advanced beneath the needle, as described with the first embodiment, so the needle's next stitch goes through the open center of the ring and by reciprocating the ring back and forth along with the folded edge of the sheets of material in synchronization with reciprocation of the needle, the ring is attached to the folded edge. It should also be appreciated that a hobble or loop 54 has been formed in the front sheet 208 of material during this process, which was initially set up by lowering the front sheet a greater distance than the back sheet 206 prior to the stitching operations.
The above process is repeated as many times as is necessary to complete a fabric 46 of the size desired.
If it were not desired to form hobbles 54 in the fabric, but rather to simply sew rings 74 to a tuck 52 to form a fabric panel 216 as shown in FIG. 65 , when the front 208 and rear 206 sheets of material were first dropped into position, as shown in FIG. 55 , the front and rear sheets would be dropped equivalent distances rather than dropping the front sheet a greater distance than the rear sheet. Accordingly, no loops or hobbles would be formed in the front sheet. This is illustrated in FIG. 64 and it will be appreciated the tucks are formed and sewn identically to that previously described as are the rings.
If it were desired to attach rings to a fabric panel 218 , as shown in FIG. 67 with no tucks, the tuck would be formed with the tucker blade 98 , as previously described, but the stitching previously described as being applied with the first sewing machine 70 would not be applied. Rather, only rings would be attached with the ring attaching machine 72 to the formed but not sewn tuck, as shown in FIG. 66 . Accordingly, when the formed but not sewn tuck is released from the tuck clamp 100 , it will be appreciated a ring has been attached to the sheets of material, but there is no tuck in the material.
These different forms of fabric which can be made with the second embodiment of the machine of the present invention are similar to those made with the first embodiment with the primary distinction being in the manner in which the hobbles are formed.
Although the present invention has been described with a certain degree of particularity, it is understood the disclosure has been made by way of example and changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.
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An apparatus for forming fabrics for use, by way of example, in coverings for architectural openings includes a system for handling single or multi-layered fabrics by suspending the fabric from a lift tower, threading the fabric through various clamp systems within a housing for the apparatus, and subsequently forming horizontal rows of hobbles, tunnels, and/or attached rings by gripping and releasing the fabric with a vacuum clamp, upper and lower clamps, and a tucker blade clamp while a reciprocating tucker blade forms horizontal tucks in the fabric. Hobbles can also be formed in one layer of the fabric through use of the vacuum clamp which gathers a portion of one layer of the fabric while the other layer is handled differently. In doing so, hobbles are formed between tucks in the fabric with the hobbles establishing a fabric resembling a Roman shade.
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BACKGROUND AND SUMMARY
[0001] The present application relates generally to an attachment system and more particularly to a solar panel securing system for a building.
[0002] Conventional photovoltaic or solar panels are mounted to roofs of buildings through screw-in clips or the like. Examples of such conventional devices are disclosed in U.S. Patent Publication No. 2011/0088740 entitled “Photovoltaic Panel Clamp” which published to Mittan et al. on Apr. 21, 2011, and U.S. Pat. No. 6,672,018 entitled “Solar Module Mounting Method and Clip” which issued to Shingleton on Jan. 6, 2004, both of which are incorporated by reference herein. Such conventional methods cause the installer to juggle many loose fasteners while simultaneously holding heavy solar panels and/or roof mounting components, often on a tilted metal roof in unpleasant weather conditions. Furthermore, such traditional multi-piece screw or bolt arrangements take considerable time to install while also having inconsistent installation torque values, especially in the common situation where many of these solar panel mounting devices are required for each roof.
[0003] Other traditional constructions use heavy metal roof hooks that are mounted by driving screws through the roof into underlying studs. A raised arm of these roof hooks is screwed or bolted to an elongated roof rail or to a frame surrounding a peripheral edge of a solar panel. This leads to roof leaks and is clumsy to install. Additionally, peripheral frames add undesireable cost and weight to the solar panel assembly, and make them more difficult to raise onto a building roof.
[0004] In accordance with the present invention, a solar panel securing system is provided. In another aspect, a solar photovoltaic panel assembly is mounted to a building roof in a screw-free manner. Another aspect employs a snap-in connection between a member pre-assembled to a solar panel and a roof-mounted fastening bracket. A further aspect adhesively bonds a bracket directly to a glass surface of a solar panel so that the expense and weight of a peripheral solar panel frame are avoided. Pivoting of one side of a solar panel relative to a roof rail is also employed to assist in ease of installation. A method of securing a solar panel is additionally provided.
[0005] The present solar panel securing system is advantageous over traditional devices. For example, in one aspect, a simplified installation motion is employed to engage an auxiliary component, such as a photovoltaic panel assembly, with a mounting hook and/or snap-in tab. In an aspect of the present system, a solar panel is quickly and easily secured to a building roof in a fast manner without requiring the installer to juggle multiple parts such as screws. In another aspect, a fastening bracket is very inexpensive to manufacture. Furthermore, a section of the present system is pre-assembled upon a building roof via an easy to install roof clamp and rail, and another mating section is pre-assembled to the solar panel, prior to assembly of the solar panel assembly to the fastening system. An aspect of the fastening bracket of the present securing system ideally allows for tolerance variations and part expansion. Moreover, an aspect allows for use of a frameless glass solar panel thereby reducing part cost and weight. Additional advantageous and features of the present invention will become apparent in the following description and appended claims, taking in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a top perspective view showing a preferred embodiment system securing a solar panel to rails located on a building roof;
[0007] FIG. 2 is a top perspective view showing the preferred embodiment system mounted to the rail;
[0008] FIG. 3 is a bottom perspective view showing the preferred embodiment system securing a pair of the solar panels to the rail;
[0009] FIG. 4 is a side elevational view showing the preferred embodiment system securing the solar panels;
[0010] FIG. 5 is a top perspective view showing a fastening bracket and roof clamp of the preferred embodiment system;
[0011] FIG. 6 is a top perspective view showing the fastening bracket of the preferred embodiment system; and
[0012] FIG. 7 is a top perspective view showing the fastening bracket and roof clamp of an alternate embodiment system.
DETAILED DESCRIPTION
[0013] FIGS. 1-3 illustrate a building having a flat roof 21 upon which is located a pair of parallel rails 23 . Each rail 23 has a generally inverted T-shape including an upstanding flange 25 and a flat base 27 . Ballast, such as bricks 29 , rest upon base 27 to hold each rail 23 upon roof 21 without piercing the roof by screws or the like. Rails 23 are preferably pultruded and resinated, long strand fiberglass which advantageously does not require electrical grounding, avoids corrosion and is light weight. Alternately, the rails can be aluminum, steel or other materials although various advantages will not be realized. Auxiliary roof components, preferably multiple photovoltaic or solar panels 31 , are secured to flanges 25 by way of multiple securing systems 33 . Each solar panel 31 includes metal and glass sheets with silicon wafers, preferably without peripherally surrounding mounting frames.
[0014] Referring to FIGS. 3 , 4 and 5 , each securing system 33 includes a roof clamp 41 , a catch or fastening bracket 43 , and hinge brackets 45 . Each roof clamp 41 is attached to flange 25 of rail 23 . Each roof clamp 41 includes a saddle 51 , a flange engaging wedge 53 , and an elongated shaft or securing member 55 . A generally C-shaped leaf spring (not shown) has pins at one end attached to holes in saddle 51 , and is trapped between a head of shaft 55 and wedge 53 at the other end. The spring serves to retain wedge 53 to saddle 51 in a pre-assembled state prior to flange installation while also biasing wedge 53 into a clamping position toward a top wall of saddle 51 and flange 25 . Thus, camming action of flange-engaging wedge 53 along diagonal internal surfaces of saddle 51 compresses roof clamp 41 to flange 25 of rail 23 . Tightening of a nut 57 onto shaft 55 secures wedge 53 , and thus roof clamp 41 , to the flange. When an installer manually pushes a proximal exposed end of shaft 55 (opposite its head) toward saddle 51 , against the biasing force of the spring and through an oversized hole in the top wall of the saddle, wedge 53 is pushed to an open position allowing flange access into an opening of saddle 51 . Notably the same shaft 55 that secures roof clamp 41 to rail 23 also secures an auxiliary-retaining device, such as fastening bracket or catch 43 , along a top surface of saddle 51 .
[0015] Saddle 51 , wedge 53 , shaft 55 , the spring and optionally fastening bracket 43 are pre-assembled prior to placing roof clamp 41 in the proximity of rail flange 25 . “Pre-assembled” for the clamp refers to the components being attached as a single unit such that shaft 55 , and optionally a very loose engagement of nut 57 (so as to provide lost motion movement of the spring and wedge relative to the saddle), keep them attached together. This can be achieved either on the ground near the work site, at a remote site, or at the factory in which roof clamp 41 is manufactured. When wedge 53 is retracted to trap flange 25 between an inner foot of the wedge and the inner opening edge of saddle 51 , a portion of shaft 55 extends beyond the top surface of saddle 51 such that the proximal threaded end of shaft 55 also provides an attachment point for fastening bracket 43 and nut 57 . The roof clamp preferably attaches to the rail flange due to lateral compression of the wedge but without flange piercing or side-mounted threaded screws. Alternately, the rails and flanges can be replaced by a turned standing seam where metal roof section are joined together.
[0016] Each hinge bracket 45 has a pair of generally triangularly shaped side plates 71 joined by a top plate 73 spanning therebetween. A pivot pin 75 also bridges between lower corners of side plates 71 . A Raybond™ brand polyurethane adhesive is used to directly attach top plate 73 to a bottom surface of the solar panel glass. The assembly is preferably done off-site before the solar panel is raised onto the building roof. Hinge brackets 45 can be made from stamped metal or an injection molded polymer.
[0017] Referring now to FIGS. 4-6 , fastening bracket 43 is preferably stamped metal and includes a generally flat and rectangular base wall 101 , upwardly bent side walls 103 and at least two, and more preferably four, hooks 105 disposed upon side walls 103 . Each hook 105 has an undercut access slot or receptacle 107 and a leading tip. A locking tab 109 is upwardly and inwardly turned from an edge of base 101 . Tab 109 includes a generally vertical segment 111 , an acutely angled diagonal segment 113 , a pair of longitudinally severed and shorter finger segments 115 , and an undulating and offset central tongue segment 117 (optionally with a raised bead 119 ) adjacent a distal end thereof. Slots 107 are all openly accessible generally facing toward tab 109 although the farthest slots are also upwardly facing. Furthermore, a slotted or oversized aperture 121 is centrally provided in bottom wall 101 to receive the threaded end of shaft 55 for nut attachment thereto. Fastening bracket 43 has a generally U-shape when viewed from its end, such as in FIG. 6 .
[0018] Fastening bracket 43 and hinging brackets 45 advantageously provide a pivoting fastening motion for the solar panel 31 shown to the right of FIG. 4 , and a linear snap-in motion to attach the solar panel 31 shown to the left of FIG. 4 . Initially, during installation, a pair of hinging brackets 45 on one side of the left-shown solar panel 31 have their pivot pins 75 inserted into slots 107 located farthest from locking tabs 109 of the associated fastening brackets on a first of the roof rails. Thereafter, on the opposite right side of the left-shown solar panel 31 , pins 75 of the left-shown hinge brackets 45 are pushed down diagonal segments 113 of locking tabs 109 until they deflect tongue segments 47 and are trapped between a crotch of each closest slot 107 and ends of finger segments 45 . This provides a single motion, snap-in and locking function. Each locked pin 75 can be removed if the installer retracts tab 109 while pull up pin 75 . The right-shown solar panel 31 has hinge brackets and pivot pins which engage the non-snap-in slotted side of fastening brackets 43 in a similar manner.
[0019] Finally, an alternate embodiment catch or fastening bracket 143 is shown in FIG. 7 . This fastening bracket 143 is like that of the prior embodiment, except that an elastomeric and resilient polymeric block 145 is located between side walls 147 and above a base wall 149 . Block 145 has a lateral groove 151 aligned with the adjacent pair of hook slots 153 farthest away from a locking tab 155 . Block 145 compensates for hinge bracket-to-fastening bracket movement, thermal expansion of a roof clamp 157 and fastening bracket 143 relative to the solar panel, and to dampen vibrations. Moreover, this fastening bracket 143 is secured to roof clamp 157 and the roof in the same manner as the prior embodiment.
[0020] While various aspects of the present fastening system have been disclosed, it should be appreciated that modifications can be made. For example, the present accessory mounting brackets or catches can be secured to conventional roof clamps such as those disclosed in the following U.S. Pat. No. 7,758,011 entitled “Adjustable Mounting Assembly for Standing Seam Panels” which issued to Haddock on Jul. 20, 2010; U.S. Pat. No. 7,386,922 entitled “Snow-Guard Clamping Unit” which issued to Taylor et al. on Jun. 17, 2008; and U.S. Pat. No. 5,715,640 entitled “Mounting Device for Controlling Uplift of a Metal Roof” which issued to Haddock on Feb. 10, 1998; except many of the present advantages will not be realized. These patents are incorporated by reference herein. Moreover, more or less hooks and additional locking tabs can be attached to a single bracket although some of the present advantages may not be obtained. Furthermore, the brackets can be injection molded from a polymer, cast from aluminum, or otherwise differently manufactured, however, various advantages may not be achieved. The roof rail can also have a different shape and be alternately secured to the roof although certain advantages may not be observed. A peripheral frame on the solar panel can be attached to the snap-in tab and/or hooks instead of the pivot pin, however, various advantages may not be achieved. The fastening bracket can be alternately mounted directly to the rail or building although some advantages may be missed. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the present invention.
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A solar panel securing system is provided. In another aspect, a solar or photovoltaic panel assembly is mounted to a building roof in a screw-free manner. Another aspect employs a snap-in connection between a member pre-assembled to a solar panel and a roof-mounted bracket. A further aspect adhesively bonds a bracket directly to a glass surface of a solar panel. A method of securing a solar panel is additionally provided.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of, and claims priority to, U.S. Patent application No. 09/608,886, filed Jun. 30, 2000. This application also claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 60/326,706, filed Oct. 2, 2001. The disclosures of such applications are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention generally relates to systems for authenticating articles, methods for authenticating articles, and processes for marking articles for later authentication. The present invention more particularly relates to the use of light sensitive materials in shipping materials, including security seals and tear tape, for authentication, discrimination and recognition of items.
[0004] 2. Description of the Related Art
[0005] Product diversion and counterfeiting of goods is a major problem. Counterfeiting entails the manufacture of a product that is intended to deceive another as to the true source of the product. Product diversion occurs when a person acquires genuine, non-counterfeit goods that are targeted for one market and sells them in a different market. A diverter typically benefits by selling a product in a limited supply market designed by the product's manufacturer. There may be high pecuniary advantages to counterfeiting and diverting genuine goods. Such monetary gains motivate charlatans to invest large sums of money and resources to defeat anti-counterfeiting and diversion methods.
[0006] Numerous methods have been proposed in the art to prevent counterfeiting and diversion of products. Typically such methods employ a step of marking the product with a substance not readily observable in visible light. In one type of anti-counterfeit and anti-diversion measure, an ultraviolet (UV) material is used to mark the product with an identifying indicia. Most UV materials are typically not visible when illuminated with light in the visible spectrum (380-770 nm), but are visible when illuminated with light in the UV spectrum (200-380 nm). U.S. Pat. No. 5,569,317 discloses several UV materials that can be used to mark products that become visible when illuminated with UV light having a wavelength of 254 nm.
[0007] In another type of anti-counterfeit and anti-diversion measure, an infrared (IR) material is used to mark the product. As with the UV ink, one benefit of using the IR materials is that it is typically not visible when illuminated with light in the visible spectrum. IR materials are visible when illuminated with light in the IR spectrum (800-1600 nm). An additional benefit of using an IR material is that it is more difficult to reproduce or procure the matching IR material by studying a product sample containing the IR security mark. Examples of IR security mark usage are given in U.S. Pat. No. 5,611,958 and U.S. Pat. No. 5,766,324.
[0008] Security may be improved by making authentication marks more difficult to detect and interpret, by incorporating greater complexity into the markings, and by making replication of the mark by a counterfeiter more difficult. Combining multiple kinds of marking indicia can further increase the complexity of detection, interpretation and replication.
[0009] For example, the use of security marks containing IR and UV materials has seen increased use. However, as this use has increased, counterfeiters have become correspondingly knowledgeable about their application on products. It is common practice for counterfeiters to examine products for UV and IR marks and to reproduce or procure the same materials, and apply the materials on the counterfeit products in the same position. In U.S. Pat. No. 5,360,628 and U.S. Pat. No. 5,599,578, the disclosures of both of which are incorporated by reference herein, a security mark comprising a visible component and an invisible component made up of a combination of a UV dye and a biologic marker, or a combination of an IR dye and a biologic marker is proposed.
[0010] The use of fluorescent and phosphorescent materials have also been proposed for marking materials. U.S. Pat. No. 5,698,397 discloses a security mark containing two different types of up-converting phosphors. U.S. Pat. No. 4,146,792 to Stenzel et al. discloses authentication methods that may include use of fluorescing rare-earth elements in marking the goods. Other authentication methods use substances which fluoresce in the infrared portion of the electromagnetic spectrum when illuminated in the visible spectrum range (See, e.g., U.S. Pat. No. 6,373,965).
[0011] Non-chemical methods for authenticating items and preventing diversion of items are also known. For example, U.S. Pat. No. 6,162,550 discloses a method for detecting the presence of articles comprising applying a tagging material in the form of a pressure sensitive tape having a first surface coated with pressure sensitive adhesive composition and a second surface opposite the first surface coated with a release agent, the tape including a continuous substrate of synthetic plastics material and a continuous electromagnetic sensor material capable of being detected by detection equipment. The tagging material can be detected by an interrogation field directed to determining magnetic changes.
[0012] Authentication marks comprising tagging material are typically applied to the article of commerce itself. However, authentication marks on the article of commerce are not useful when the article is covered by packaging material and a quick determination of counterfeiting or diversion is desired to be made. It is known, therefore, in the art to also provide tags on the packaging of a product (See, e.g., U.S. Pat. 6,162,550).
[0013] Authentication marks may be applied by any of the methods currently used in manufacturing and distribution plants to code product for identification, to date code product for freshness, to produce batch markings which allow product to be traced, to sequentially number products such as newspapers caring lottery-style games, and to code product, such as mail, for ultimate destination. A leader in such coding technology is Domino Printing Sciences PLC (Bar Hill Cambridge CB3 STU UK). Predominant methods for coding include: continuous ink jet printing, binary printing and laser printing.
[0014] Continuous ink jet printing is a non-contact method of printing variable information that works by spraying an ink onto a surface as it travels underneath a printhead. Ink in the print head is typically supplied under pressure to a drop generator which contains a drive rod which creates ultrasonic pressure waves in the ink, making the jet break up into a stream of separate drops shortly after it exits through a small nozzle. Each drop is given an electrostatic charge by putting a voltage onto a charge electrode as the drop breaks off. As the drop drops it conventionally passes through an electrostatic field set up between two high voltage deflector plates.
[0015] Binary printing is similar to that of ink jet printing in that tiny drops of ink are deflected in flight by an electrostatic field. It differs, however, from ink jet printing in the use of the voltage on the print drop and the subsequent deflection of that drop. The ink drops that are not used for printing are charged and are deflected into the gutter. The uncharged drops which are not deflected by the high voltage field are used to print on the substrate. Because uncharged drops are used for printing optimum print quality and speed can be achieved.
[0016] Laser printing typically involves either vaporization of the surface material at which it is directed (e.g., removal of ink from paper), distinct surface changes (e.g., deformations in glass and PET), or thermal decomposition causing a material in the product to change color. Lasers produce coherent, monochromatic radiation that is capable of delivering large amounts of energy in a small area. Most conventional lasers work by exciting gas with RF energy, the gas being contained in a sealed tube mounted with mirrors at each end. When the gas molecules are excited sufficiently, a photon is spontaneously emitted. The photon is amplified as it stimulates more photon emissions while it moves along the tube. The photons bounce along the tube between one mirror which is fully reflective and the other which is partially transmissive. When a critical mass is reached, a pulse of heat radiation is emitted to the form of a laser beam which is focused via lenses to produce precise marking energy.
[0017] Security and anti-counterfeit coding on relatively expensive items, in particular luxury perfume, cosmetics, tobacco products, and pharmaceutical products, is known. Such coding is useful for the traceability of products and identification of the same.
[0018] However, such coding is typically not unique to the particular item within the general product class. The latter is probably largely due to the slow speed at which a production line would have to operate to mark in a unique fashion each item, in particular given the current technologies for marking. As such coding is typically not unique to the item, and as experience has shown that generic invisible marks are often detected by counterfeiters and diverters and are easily duplicated on other items within the general product class, there is a great need for an improved method of identifying goods that are either counterfeit or diverted.
DEFINITIONS
[0019] “Authentication Material” refers to a material used to authenticate, identify or protect an optical medium. The data recorded on an optical medium, for example, software, video or audio files, are not authentication material.
[0020] “Light-Changeable Material”: a material that absorbs, reflects, emits or otherwise alters electromagnetic radiation directed at the same. By “light-changeable compound” it is meant to include, without limitation, “light-sensitive”, “light-emissive” and “light-absorbing” compounds, as defined below.
[0021] “Light-Absorbing Materials”: materials that absorb light in response to irradiation with light. Light absorption can be the result of any chemical reaction known to those of skill in the art.
[0022] “Light-Emissive material”: a material that emits light in response to excitation with light. Light emission can be a result of phosphorescence, chemiluminescence, or fluorescence. By the term “light-emissive compounds,” it is meant to include compounds that have one or more of the following properties: 1) they are a fluorescent, phosphorescent, or luminescent; 2) react, or interact, with components of the sample or the standard or both to yield at least one fluorescent, phosphorescent, or luminescent compound; or 3) react, or interact, with at least one fluorescent, phosphorescent, or luminescent compound to alter emission at the emission wavelength.
[0023] “Light-Sensitive Material”: a material capable of being activated so as to change in a physically measurable manner, upon exposure to one or more wavelengths of light.
[0024] “Optical State Change Security Material”: refers to an inorganic or organic that changes optical state from a first optical state to a second optical state upon exposure to a defined wavelength of light.
[0025] “Recording Dye” refers to a chemical compound that may be used with an optical recording medium to record digital data on the recording layer.
[0026] “Re-read”: reading a portion of data after it has been initially read.
[0027] “Reversible Light-Sensitive Material”: a light-sensitive material is said to be reversible when the activated change returns to the initial state due to the passage of time or change in ambient condition.
[0028] “Temporary Material”: refers to a material that is detectable for a limited amount of time or a limited number of readings.
[0029] “Transient Optical State Change Security Material”: refers to an Optical State Change Security material that transiently changes optical state between a first optical state and a second optical state, and the second optical state spontaneously reverting back to said first optical state after a period of time.
[0030] For the purpose of the rest of the disclosure it is understood that the terms as defined above are intended whether such terms are in all initial cap, or not.
SUMMARY OF THE INVENTION
[0031] The present invention provides for systems for authenticating articles, methods for authenticating articles, and processes for marking articles for later authentication. The present invention more particularly relates to the use of light sensitive materials in shipping materials, including security seals and tear tape, for authentication, discrimination and recognition of items.
[0032] Currently digital content can be written onto many types of optical media. For example, write once read many time optical discs (WORM). Write-able optical media allows a large amount of data to be digitized onto a very small space. Contents of movies, sound tracks, recordings, software and video games can be compressed onto optical media for play back with high fidelity in real time. Today, it is possible for recording lasers to make simple laser based digital copies of binary information onto dye based clear recording media.
[0033] Many writeable optical media that are available today employ light-sensitive materials, in particular light-sensitive recording dyes that are sensitive to a laser write beam. Light-sensitive materials used in presently available writeable optical media typically change in optical state when exposed to the laser write beam in a manner that can be detected by a optical reader of the media. Digital data is therefore represented by optical deformations on the optical media formed by activation of the light-sensitive materials with the laser write beam. Light-sensitive materials employed on writeable optical media change optical state quickly upon exposure to the laser write beam, and are generally stable under conditions in which optical media are typically used and stored.
[0034] Recognizing the problems associated with applying unique identifiers to products in production lines, the present inventors have proposed using many of the light-sensitive materials used in writeable optical media, in particular light-sensitive recording dyes, on/in non-optical media products, or the packaging materials surrounding such products, to permit the rapid writing of unique identification information with respect to each item in a product class. The present inventors propose that such materials may be used to significantly enhance “generic” authentication techniques.
[0035] Security may be further enhanced by incorporating transient optical state change materials onto/into the packaging. Such transient optical state change materials may or may not be light emissive compounds. Such materials may be placed in specific locations with respect to the packaging material, and preferably are positioned so as to represent digital data that may be authenticated by software means. Transient optical state change security materials, and in particular transient optical state change recording dyes, are particularly useful in authentication/anti-diversion in that not only the presence of the optical state change is indicative of whether the item is authenticate, but also the time necessary for the optical state to revert to the un-activated state.
[0036] In an advantageous embodiment, there is disclosed light-sensitive materials incorporated into tear tape associated with a product. As would be understood by one of ordinary skill in the art, a tear tape is a continuous tape provided of base materials in which a pressure sensitive adhesive can be added to in one mode and an additional mode a safety device (such as a rare earth material as in the case of technology disclosed by PP Payne LTD) or a hologram (as explained in JP7056512A2) can be added. The tear tape can help a consumer open a package, it may provide safety information, a serial number, production location date and potentially other security features, as mentioned. A tear tape is adhered to the surface of packaging material in a manner such that, in use, an end of the tear tape, can be pulled so as to tear the packaging material underlying the tear tape to allow access to the contents. Tear tapes are effective in opening various types of consumer packaging, especially those formed from packaging material using non-hermetic wrapping techniques such as roll wrapping and standard envelope wrapping.
[0037] The tear tape embodiment incorporates light-sensitive material that acts like such materials when placed in optical medium, that is allowing data to be written thereon using a laser as the materials can be rapidly altered by the writing beam, information unique to a product can be incorporated onto the tear tape very rapidly. As the tape can be fed from a bulk supply in a manner such that the tape is uniformly positioned from the writer laser (without the need for the laser to change position owing to the dimensions of the package to be coded), and can be uniformly passed by the writer laser, extremely fast package coding is effectuated as unseen in the prior art.
DESCRIPTION OF DRAWINGS
[0038] [0038]FIG. 1 is a schematic of a method to incorporate digital data onto tear tape and its application to mark packages.
DETAILED DESCRIPTION
[0039] The present invention discloses placing light-sensitive material on product or packaging medium (e.g., the tear tape) in order to provide, for example, identification, verification, an access code or additional data.
[0040] In one embodiment, the light-sensitive material is applied to the packaging medium and provided desired information, as explained in connection with the application of the light sensitive material to other media in co-pending U.S. patent application Ser. Nos. 09/232,324, 09/608,886, 09/631,585, 09/821,577, 09/739,090, each of which is hereby incorporated by reference.
[0041] The light-sensitive compound may be deposited in or on the packaging medium, such as cases, cartons, wrappers, labels, shipping cartons, etc., in order to identify the product and/or package or supply information about it. A number of different materials having different characteristics may be used on the packaging medium to provide a more sophisticated coding technique.
[0042] As shown in FIG. 1, in one embodiment, a base material 12 from bulk supply 10 is coated with a light-sensitive material 16 , advantageously a transient optical state change recording dye, which is overcoated with an adhesive layer 8 to make a tear tape 2 having light-sensitive material therein. Tear-tape, comprising base layer 14 , adhesive, is exposed to laser writer 16 to incorporate digital data into the light-sensitive material layer 14 forming coded layer 6 . The digital data tear-tape 18 is then applied to the package 22 of a packaged item 20 , for example at a position on the package such as nearby perforations 24 , such as to provide easy opening of package 22 . Alternatively, as would be understood by one of ordinary skill in the art, digital content can be coded into the packaging materials by selectively imprinting/imbuing the tear tape with the light sensitive material. The tear-tape embodiment would allow a producer to code each package with a unique code for each package, while demonstrating to the customer package integrity. At the same time, the light-sensitive material technology could include digital content light-sensitive material with a transient phase change that allows for security features to be built into the digital content layer(s).
[0043] It is preferred that the light-sensitive material employed be a light-changeable material that is sensitive to the wavelength of the writer light source that is to be employed. Preferably the material is an optical state change security material. Given the difficulty in reproducing its effect, a more preferred embodiment comprises a transient optical state change security material. When such materials are employed, authenticity may be adjudged not only by detection of an optical state change at pre-determined locations, but also by assuring that any state change detected is capable of occurring within in pre-determined time frames characteristic for the transient optical state change security material that is supposed to be on the authenticate product.
[0044] Currently, packaging lines purchase bobbins of pressure sensitive tear tape. The tear tape could contain holograms or generic security features that are not changeable for each package. In one embodiment, the pressure sensitive tear tape has the same dye used in optical media recordings (see, U.S. patent application Ser. Nos. 09/608,886, 09/631,585, ) mixed into the adhesive layer before being placed onto the bobbin. As the bobbin unwinds at the packaging plant, a read laser places package specific code unique to each package as the package is being wrapped. This allows for the complete track and trace of each package, such as a cigarette package. Today, cigarette lines have pressure sensitive tear tape that have security features, but individual laser codes must be applied by a separate laser coded later in the production line. Additionally, these codes are easy to copy with nearly any laser coder on the market able to copy the codes. Therefore, the current laser codes are only able to provide tracking information in a secure environment.
[0045] Examples of suitable dyes for application to package media will now be described. However, other suitable dyes as would be understood by one of ordinary skill in the art may also be employed as the present invention is not limited in this respect.
[0046] Dye DOTC Iodide (Exciton) could be mixed with spray adhesive (0.037%-124% w/v) onto pressure sensitive tear tape materials. Tear tape is further split by knife cutters and placed onto a spool. A read/write laser (CDR) is placed against the dye side and digital content is written onto the blank tape as the spool is unwound and before the tear tape is wrapped around the package. The digital content length is from 0.6 μM to several centimeters in length, depending on the size of the digital content being recorded. A tear tape may be of any length, for example 15 cm. The compression of the digital content allows for the entire code to be visible across the front of the package without alignment or registration of the code. The code is then read using a digital reader (bar code scanner). In another embodiment the reader could be a digital reader such as the one available in DVD/CD reader.
[0047] A wide variety of light sensitive compounds may be used with the present invention including any compounds that emit or are excited by light having a wavelength of about 300-1100 nm. Groups from which the light sensitive compounds may be chosen include, but are not limited to, inorganic pigments, organic dyes, photochromic dyes, photochromic dyes cross linked with various polymers, photochromic dyes encapsulated in polymers and thermally stable near infrared fluorophoric compounds copolymerized with an ester linkage.
[0048] For example, inks of the present invention may be water dissipatable polyesters and amides such as the dyes disclosed in U.S. Pat. Nos: 5,292,855, 5,336,714, 5,614,008 and 5,665,151, each of which is hereby incorporated by reference herein.
[0049] It is preferred that the near infrared fluorescent compounds are selected from the phthalocyanines, the naphthalocyanines and the squarines (derivatives of squaric acid) that correspond respectively to the structures shown in FIGS. 1, 2 and 3 of U.S. Pat. No. 6,432,715, which is hereby incorporated by reference. In these structures, Pc and Nc represent the phthalocyanines and naphthalocyanine moieties, covalently bonded to hydrogen or to the various metals, halometals, organometallic groups and oxymetals disclosed therein. It is preferred that the structures include at least one polyester reactive group to allow the compound to be incorporated into a polymeric composition and to be bound by covalent bonds.
[0050] The ink of the invention may also include photochromic dyes such as photochromic dye incorporated into a polymeric composition and photochromic dyes encapsulated to form microcapsules such as described in U.S. Pat. No. 5,807,625, hereby incorporated by reference herein. Preferably, these photochromic dyes are from four classes:
[0051] (i) spiro-indolino-naphthoxazines.
[0052] (ii) fulgides which are derivatives of bis-methylene succinic anhydride
[0053] (iii) fulgimides which are derivatives of bis-methylene succinic imide where the imide nitrogen may be substituted by alkyl, aryl or aralkyl; and
[0054] (iv) spiro( 1,8a)-dihydroindolizines.
[0055] The light-sensitive materials of the present invention may also include microbead labeled with organic/inorganic dye such as described in U.S. Pat. No. 5,450,190, hereby incorporated by reference herein.
[0056] Also useful as light sensitive materials with the present invention are the dyes or dye combinations described in U.S. Pat. No. 5,286,286, hereby incorporated by reference herein. These may include:
[0057] 5,10,15,20-tetrakis-(1-methyl-4-pyridyl)-21H,23H-porphine tetra-p-tosylate salt;
[0058] 5,10,15,20-tetrakis-(1-methyl-4-pyridyl)-21H,23H-porphine tetrachloride salt;
[0059] 5,10,15,20-tetrakis-(1-methyl-4-pyridyl)-21H,23H-porphine tetrabromide salt;
[0060] 5,10,15,20-tetrakis-(1-methyl-4-pyridyl)-21H,23H-porphine tetra-acetate salt;
[0061] 5,10,15,20-tetrakis-(1-methyl-4-pyridyl)-21H,23H-porphine tetra-perchlorate salt;
[0062] 5,10,15,20-tetrakis-(1-methyl-4-pyridyl)-21H,23H-porphine tetrafluoroborate salt;
[0063] 5,10,15,20-tetrakis-(1-methyl-4-pyridyl)-21H,23H-porphine tetra-perchlorate salt;
[0064] 5,10,15,20-tetrakis-(1-methyl-4-pyridyl)-21H,23H-porphine tetrafluoroborate salt;
[0065] 5,10,15,20-tetrakis-(1-methyl-4-pyridyl)-21H,23H-porphine tetra-perchlorate salt;
[0066] 5,10,15,20-tetrakis-(1-methyl-4-pyridyl)-21H,23H-porphine tetra-triflate salt;
[0067] 5,10,15,20-tetrakis-(1-hydroxymethyl-4-pyridyl)-21H,23H-porphine tetra-p-tosylate salt;
[0068] 5,10,15,20-tetrakis-[1-(2-hydroxyethyl)-4-pyridyl]-21H,23H-porphine tetrachloride salt;
[0069] 5,10,15,20-tetrakis-[1-(3-hydroxypropyl)-4-pyridyl]-21H,23H-porphine tetra-p-tosylate salt;
[0070] 5,10,15,20-tetrakis-[1-(2-hydroxypropyl)-4-pyridyl]-21H,23H-porphine tetra-p-tosylate salt;
[0071] 5,10,15,20-tetrakis-[1-(-hydroxyethoxyethyl)-4-pyridyl]-21H,23H-porphine tetra-p-tosylate salt;
[0072] 5,10,15,20-tetrakis-[1(2-hydroxyethoxypropyl)-4-pyridyl]-21H,23H-porphine tetra-p-tosylate salt;
[0073] 5,10,15,20-tetrakis-[4-(trimethylammonio)phenyl]-21H,23H-porphine tetra-p-tosylate salt;
[0074] 5,10,15,20-tetrakis-[4-(trimethylammonio)phenyl]-21H,23H-porphine tetrachloride salt;
[0075] 5,10,15,20-tetrakis-[4-(trimethylammonio)phenyl]-21H,23H-porphine tetrabromide salt;
[0076] 5,10,15,20-tetrakis-[4-(trimethylammonio)phenyl]-21H,23H-porphine tetra-acetate salt;
[0077] 5,10,15,20-tetrakis-[4-(trimethylammonio)phenyl]-21H,23H-porphine tetra-perchlorate salt;
[0078] 5,10,15,20-tetrakis-[4-(trimethylammonio)phenyl]-21H,23H-porphine tetrafluoroborate-salt;
[0079] 5,10,15,20-tetrakis-[4-(trimethylammonio)phenyl]-21H,23H-porphine tetra-triflate salt;
[0080] meso-(N-methyl-X-pyridinium) n (phenyl)4-n -21H,23H-porphine tetra-p-tosylate salt, where n is an integer of value 0, 1, 2, or 3, and where X=4-(para),3-(meta), or 2-(ortho) and refers to the position of the nitrogen in the pyridinium substituent, prepared as described, for example, by M. A. Sari et al. in Biochemistry, 1990, 29, 4205 to 4215;
[0081] meso-tetrakis-[o-(N-methylnicotinamido)phenyl]-21H,23H-porphine tetra-methyl sulfonate salt, prepared as described, for example, by G. M. Miskelly et al. in Inorganic Chemistry, 1988, 27, 3773 to 3781;
[0082] 5,10,15,20-tetrakis-(2-sulfonatoethyl-4-pyridyl)-21H,23H-porphine chloride salt, prepared as described by S. Igarashi and T. Yotsuyanagi in Chemistry Letters, 1984, 1871;
[0083] 5,10,15,20-tetrakis-(carboxymethyl-4-pyridyl)-21H,23H-porphine chloride salt
[0084] 5,10,15,20-tetrakis-(carboxyethyl-4-pyridyl)-21H,23H-porphine chloride salt
[0085] 5,10,15,20-tetrakis-(carboxyethyl-4-pyridyl)-21H,23H-porphine bromide salt
[0086] 5,10,15,20-tetrakis-(carboxylate-4-pyridyl)-21H,23H-porphine bromide salt, prepared as described by D. P. Arnold in Australian Journal of Chemistry, 1989, 42, 2265 to 2274;
[0087] 2,3,7,8,12,13,17,18-octa-(2-hydroxyethyl)-21H-23H-porphine;
[0088] 2,3,7,8,12,13,17,18-octa-(2-hydroxyethoxyethyl)-21H-23H-porphine;
[0089] 2,3,7,8,12,13,17,18-octa(2-aminoethyl)-21H-23H-porphine;
[0090] 2,3,7,8,12,13,17,18-octa-(2-hydroxyethoxypropyl)-21H-23H-porphine,
[0091] and the like, as well as mixtures thereof.
[0092] Also suitable for use with the present invention are dansyl dyes, including:
dansyl-L-alanine dansyl-L-isoleucine N-dansyl-L-tryptophan dansyl-L-γ- dansyl-L-leucine O-di-Dansyl-L-tyrosine amino-n-butyric monocyclohexyl- acid ammonium salt a-dansyl-L- di-dansyl-L-lysine dansyl-L-valine arginine dansyl-L- N-ε-dansyl-L-lysine dansyl-γ-amino-n- asparagine butyric acid dansyl-L-aspartic dansyl-L-methionine dansyl-DL-a-amino-n- acid butyric acid dansyl-L-cysteic dansyl-L-norvaline dansyl-DL-aspartic acid acid N,N′-di-dansyl-L- dansyl-L-phenylalanine dansyl-DL-glutamic acid cystine dansyl-L-glutamic dansyl-L-proline Dansylglycine acid dansyl-L- N-dansyl-L-serine dansyl-DL-leucine glutamine N-dansyl-trans-4- N-dansyl-L-threonine dansyl-DL-methionine hydroxy-L- proline dansyl-DL- dansyl-DL-a-aminocaprylic Didansylcadaverine norleucine acid cyclohexylamine salt dansyl-DL- (dansylaminoethyl) monodansylcadaverine norvaline trimethylammonium perchlorate dansyl-DL- N-dansyl-DL-serine Dansylputrescine phenylalanine dansylsarcosine N-dansyl-DL-threonine Dansylspermidine N-a-dansyl-DL- dansyl-DL-valine didansyl-1,4- tryptophan diaminobutane didansylhistamine didansyl-1,3-diamino- propane
[0093] all available from Sigma Chemical Corp., St. Louis, Mo., and the like, as well as mixtures thereof.
[0094] Additional suitable light-sensitive materials include any dye or dye combination from rare earth metal chelates sold as LUMILUX C pigments by Hoechst-Celanese Corp. in Reidel de-Haen, Germany or those disclosed in U.S. Pat. No: 5,837,042, hereby incorporated by reference herein, or LUMILUX Red CD 331, Red CD 332, Red CD 335, Red CD 316, Red CD 339, Red CD 105, Red CD 106, Red CD 120 and Red CD 131.
[0095] Additional light sensitive compounds may also include an organic/inorganic pigment as described in U.S. Pat. No. 5,367,005, hereby incorporated by reference herein, or any dye or dye combination of phenoxazine derivatives as described in U.S. Pat. No. 4,540,595, hereby incorporated by reference herein. The general chemical formula of the phenoxazine dyes is shown in FIG. 6 in which R 1 and R 2 are alkyl groups and X is an anion.
[0096] Additional light sensitive compounds of the present invention may be classified in one of the following four groups depending upon excitation and emission regions, as described in U.S. Pat. No: 4,598,205, hereby incorporated by reference.
[0097] (a) Excitation UV-Emission UW
[0098] (b) Excitation UV-Emission IR
[0099] (c) Excitation IR-Emission UV
[0100] (d) Excitation IR-Emission IR
[0101] Also useful with the present invention is any dye or dye combination of organic infrared fluorescing dye that is soluble in the ink vehicle disclosed in U.S. Pat. No. 5,093,147, hereby incorporated by reference. Such light sensitive compounds include:
CAS Registry No. 3071-70-3 DTTCI (3,3′-Diethylthiatricarbocyanine Iodide) DNTTCI (3,3′-Diethyl-9,11-neopentylenethiatricarbo- cyanine Iodide) 23178-67-8 HDITCI (1,1′,3,3,3′,3′-Hexamethyl-4,4′,5,5′-dibenzo- 2,2′-indotricarbocyanine Iodide) (Hexadibenzocyanine 3) 3599-32-4 IR-125 1H-Benz[e]indolium, 2-[7-[1,3-dihydro-1,1- dimethyl-3-(4-sulfobutyl)-2H-benz[e]indol-2- ylidene]-1,3,5-hepatrienyl]-1,1-dimethyl-3- (4-sulfobutyl-, sodium salt DDTTCI (3,3′-Diethyl-4,4′,5,5′-dibenzothiatricarbo- cyanine Iodide) (Hexadibenzocyanine 45) 53655-17-7 IR-140 Benzothiazolium, 5-chloro-2[2-[3-[5-chloro- 3-ethyl-2(3H)-benzothiazolylidene-ethyl- idene]-2-(diphenylamino)-1-cyclopenten-1- yl]ethyl]-3-ethyl-, perchlorate. DDCI-4 (1,1′-Diethyl-4,4′-dicarbocyanine Iodide) 62669-62-9 IR-132 Naphtho[2,3-d]thiazolium, 2-[2-[2- (diphenylamino)-3-[[3-(4-methoxy-4- oxobutyl)naptho[d]thiazol-2(3H)-ylidene- ethylidene]-1-cyclopenten-1-yl]ethenyl]3-(4- methoxy-oxobutyl)-, perchlorate
[0102] The following light sensitive compounds may also be useful with the present invention:
[0103] Sulfuric acid disodium salt mixture with 7-(diethylamino)-4 methyl-2H-1-benzopyran-2-one
[0104] 3′,6′-bis(diethylamino)-spiro-(isobenzofuran-1(3H),9′-(9H)xanthen)-3-one or 3′,6′-bis(diethyl-amino)-fluoran
[0105] 4-amino-N-2,4-xylyl-naphthalimide
[0106] 7-(diethylamino)-4-methyl-coumarin
[0107] 14H anthra[2,1,9-mna]thioxanthen-14-one
[0108] N-butyl-4-(butylamino)-naphthalimide
[0109] In addition, the following compounds may also be used as light sensitive compounds in the present invention:
5-(2-Carbohydrizinomethyl- 5-(and-6)-carboxy-2′,7′-dichloro- thioacetyl)-aminofluorescein fluorescein 5-(4,6-dichlorotriazinyl)- 5-(and-6)-carboxy-4′,5′-dimethyl- aminofluorescein fluorescein Fluor-3-pentammonium salt 5-(and-6)-carboxy-2′,7′-dichloro- 3,6-diaminoacridine hemisulfate, fluorescein diacetate proflavine hemisulfate Eosin-5-maleimide Tetra(tetramethylammonium salt Eosin-5-Iodoacetamide Acridine orange Eosin Isothiocyanate BTC-5N 5-Carboxy-2′,4′,5′,7′ Fluoresceinamine Isomer I tetrabromosulfonefluorescein Fluoresceinamine Isomer II Eosin thiosemicarbazide Sulfite blue Eosin Isothiocyanate Dextran 70S Coumarin diacid cryptand[2,2,2] 5-((((2-aminoethyl)thio)acetyl)amino) Eosin Y fluorescein Lucifier yellow CH Potassium salt 5-((5-aminopentyl)thioureidyl)- Fluorescein isothiocyanate (Isomer fluorescein I) 6-carboxyfluorescein succinimidyl Fluorescein isothiocyanate (Isomer ester II) 5,5′-dithiobis-(2 nitrobenzoic acid) Fura-Red, AM 5-(and-6)-carboxyfluorescein Fluo-3 AM succinimidyl ester Mito Tracker Green FM Fluorescein-5-EX, succinimidyl ester Rhodamine 5-(and-6-)-carboxy SNARF-1 5-carboxyfluorescein Fura Red, Tetrapotassium salt Dextran Fluroscein Dextran fluorescien, MW 70000 Merocyanine 540 5-(and-6-)-carboxynaphthafluorescein Bis-(1,3-diethylthiobarbituric acid mixed isomers trimethine oxonol Rhodol green, carboxylic acid Fluorescent brightner 28 succinimdyl ester Fluorescein sodium salt 5-(and-6-)-carboxynaphthafluorescein Pyrromethene 556 SE mixed isomers Pyrromethene 567 5-carboxyfluorescein, SE single Pyrromethene 580 isomer Pyrromethene 597 5-(and-6)-carboxy-2′,7′-dichloro- Pyrromethene 650 fluorescein diacetate, SE Pyrromethene 546 5-(and-6)-carboxy-SNAFL-1, SE BODIPY 500/515 6-tetramethylrhodamine-5-and-6- Nile Red carboxamido hexanoic acid, SE Cholesteryl BODIPY FL C12 Styryl Dye (4-Di-1-ASP) B-BODIPY FL C12-HPC Erythrosin-5-isothiocyanate BODIPY Type D-3835 Newport green, dipotassium salt BODIPY 500/510 C5-HPC Phen green dipotassium salt IR-27 Aldrich 40,610-4 Bis-(1,3-dibutylbarbituric acid) IR-140 Aldrich 26,093-2 trimethine oxonol IR-768 perchlorate Aldrich 42, Lucigenin(bis-N-methyl acridinium 745-4 nitrate IR-780 Iodide Aldrich 42,531-1 Tetrakis-(4-sulfophenyl)-porphine IR-780 perchlorate Aldrich 42-530- Tetrakis-(4-carboxyphenyl) porphine 3 Anthracene-2,3-dicarboxaldehyde IR-786 Iodide Aldrich 42,413-7 5-((5-aminopentyl)thioureidyl) eosin, IR-786 perchlorate Aldrich 40,711- hydrochloride 9 N-(ethoxycarbonylmethyl)-6- IR-792 perchlorate Aldrich 42,598- methoxyquinolinium bromide 2 MitoFluor green 5-(and-6)-carboxyfluorescein 5-aminoeosin diacetate 4′(aminomethyl)fluorescein, 6-caroxyfluorescein Sigma hydrochloride Fluorescein diacetate 5-(aminomethyl)fluorescein, 5-carboxyfluorescein diacetate hydrochloride Fluorescein dilaurate 5-(aminoacetamido)fluorescein Fluorescein Di-b-D 4′((aminoacetamido)methyl) Galactopyranoside fluorescein FluoresceinDi-p- 5-((2-(and-3)-S-acetylmercapto) Guanidinobenzoate succinoyl)amino-fluorescein Indo I-AM 8-bromomethyl-4,4-difluoro-1,3,5,7- 6-caroxyfluorescein Diacetate tetramethyl-4-bora-3a,4a,diaza-s- Fluorescein thiosemicarbazide indacene Fluorescein mercuric acetate 5-(and-6)-carboxy eosin Alcian Blue Cocchicine fluorescein Bismarck Brown R Casein fluorescein Copper Phthalocyanine 3,3′-dipentyloxacarbocyanine iodide Cresyl Violet Acetate 3,3′-dihexyloxacarbocyanine iodide Indocyanine Green 3,3′-diheptyloxacarbocyanine iodide Methylene Blue 2′-7′-difluorofluorescein Methyl Green, Zinc chloride salt BODIPY FL AEBSF Sigma Fluorescein-5-maleimide Oil Red 0 5-iodoacetamidofluorescein Phenol Red Sigma 6-iodoacetamidofluorescein Rosolic Acid Lysotracker green Procion Brilliant Red Rhodamine 110 Ponta Chrome Violet SW Arsenazo I Janus Green Sigma Aresenazo III sodium Toluidine Blue Sigma Bismarck brown Y Orange G Brilliant Blue G Opaque Red Carmine Mercuric Oxide Yellow b-carotene Basic Fuchsin Chlorophenol red Flazo Orange Azure A Procion Brilliant Orange Basic fuchsin di-2-ANEPEQ di-8-ANEPPQ di4-ANEPPS di-8-ANEPPS where ANEP = (aminonaphthylethenylpyridinium)
[0110] The light-sensitive material may be applied to any substrate such as a package or product, by any technique capable of causing the light-sensitive material to adhere to the substrate, including any technique by which conventional inks may be transferred. For example, any kind of printer can be used, such as a multi-color printing press, an ink jet printer, a dot matrix printer (where the ribbon is soaked with the light-sensitive compound), silk screening, or pad printing. Alternatively, the light-sensitive material may be first applied to a decal or adhesive label which is in turn applied to the substrate. Preferably, an ink jet printer is used, as information that may be printed may be changed.
[0111] Using an ink jet printer may also be advantageous because reservoirs having different light-sensitive materials may be readily changed depending upon the product, customer, date and/or place of manufacture or any other data. In addition, ink jet printers are commonly used to print the bar code on a label or directly on the package itself. It is to be appreciated that the authenticating mark may be configured to any desired pattern ranging from a single dot that may convey no more information than what is contained in the ink formulation to a bar code to a more complex pattern that may convey information related to, for example, product, date, time, location, production line, customer, etc.
[0112] In another embodiment, there is employed optical state change security materials where the data read upon a first read is different from the data when the same spot is read a second time after 200 ms seconds has elapsed. Preferably, the optical state change security material is a transient optical state change security material.
[0113] As would be understood by one of ordinary skill in the art, the persistence of the activated state of the light-sensitive material, such as a light-changeable material, (i.e., the length of time the material is in the activated state versus initial state) and the delay in the conversion of the initial state to the activated state (i.e., the length of time it takes the material to enter the activated state from the initial state) may be measured parameters indicative of authenticity. Light-sensitive materials may be chosen from any material, compound or combination of compounds that serve to change the output signal from the medium upon re-reading. These materials include, without limitation, delayed light-emissive materials, delayed light-absorbing materials and other light-changeable compounds. A layer in the medium that becomes reflective upon re-reading may also be useful in predictably altering the output of the medium.
[0114] The light-sensitive materials of the present invention may be either organic or inorganic in nature, a combination of both, or mixtures thereof. The materials preferably demonstrate delayed response to the wavelength(s) of light to which they are sensitive, such that the data can be read by the reader in at least a first intended form upon initial read, and upon re-sampling in at least a second intended form.
[0115] Table 1 provides some organic dyes that may be useful with the invention.
TABLE 1 Dye Name/No Excitation Emission Alcian Blue (Dye 73) 630 nm Absorbs Methyl Green (Dye 79) 630 nm Absorbs Methylene Blue (Dye 78) 661 nm Absorbs Indocyanine Green (Dye 77) 775 nm 818 nm Copper Phthalocyanine (Dye 75) 795 nm Absorbs IR 140 (Dye 53) 823 nm (66 ps) 838 nm IR 768 Perchlorate (Dye 54) 760 nm 786 nm IR 780 Iodide (Dye 55) 780 nm 804 nm IR 780 Perchlorate (Dye 56) 780 nm 804 nm IR 786 Iodide (Dye 57) 775 nm 797 nm IR 768 Perchlorate (Dye 58) 770 nm 796 nm IR 792 Perchlorate (Dye 59) 792 nm 822 nm 1,1′-DIOCTADECYL-3,3,3′,3′-TERTA- 645 nm 665 nm METHYLINDODI-CARBOCYANINE- IODIDE (Dye 231) 1,1′-DIOCTADECYL-3,3,3′,3′-TETRA- 748 nm 780 nm METHYLINDO TRICARBOCY- ANINE IODIDE (Dye 232) 1,1′,3,3,3′,3′-HEXAMETHYL-INDODI- 638 nm 658 nm CARBOCYANINE IODIDE (Dye 233) DTP (Dye 239) 800 nm (33 ps) 848 nm HITC Iodide (Dye 240) 742 nm (1.2 ns) 774 nm IR P302 (Dye 242) 740 nm 781 nm DTTC Iodide (Dye 245) 755 nm 788 nm DOTC Iodide (Dye 246) 690 nm 718 nm IR-125 (Dye 247) 790 nm 813 nm IR-144 (Dye 248) 750 nm 834 nm
[0116] As also stated above, the light-sensitive materials may also be inorganic in nature. Inorganic compounds find particular use in the present invention when the light-sensitive material is desired to be functional for long periods of time on the item and/or packaging surrounding the item. Inorganic compounds are less prone to degrade when exposed to repeated laser challenges.
[0117] Inorganic compounds capable of light-emission may find use in the present invention. Compounds such as zinc sulfide (ZnS) at various concentrations (Seto, D. et al., Anal. Biochem. 189, 51-53 (1990)), and rare earth sulfides and oxysulfides, such as, but not limited to, ZnS SiO 2 , ZnS—SiO 4 , and La 2 O 2 S are known to be capable of emitting phosphorescence at certain wavelengths. Such inorganic light emissive compounds may be used advantageously with a metal ion such as manganese (Mn), copper (Cu), europium (Eu), samarium (Sm), SmF 3 , terbium (Th), TbF 3 , thulium (Tm), aluminum (Al), silver (Ag), and magnesium (Mg). Phosphorescent and luminescent properties of the compounds can be altered in a ZnS crystal lattice, for example, the delay time and wavelength of emission be controlled by changing the metal ions used for binding (See, e.g., U.S. Pat. No. 5,194,290).
[0118] Inorganic phase change materials can also be used. Particularly useful inorganic phase change materials include chalcogenide materials such as GeSbTe, InSbTe, InSe, AsTeGe, TeOx-GeSn, TeSeSn, SbSeBi, BiSeGe and AgInSbTe -type materials which can be changed from an amorphous state to a crystalline state by absorption of energy from particular light sources. The inorganic compound(s) may be used in numerous forms as would be understood by one of ordinary skill in the art, including, without limitation, in very fine particle size, as dispersions or packed within a crystal lattice (See, e.g., Draper, D. E., Biophys. Chem. 21: 91-101 (1985)).
[0119] In another embodiment, a transient optical state change security material or other phase change material is placed over a digital data recording on the item, and/or package material associated with the item, such that the digital data read is altered depending upon the phase of the material. A phase change may be timed such that the data underlying the phase change material can be read before the change occurs. The phase change advantageously should be persistent enough that upon re-sampling a different data read is obtained, and yet not too persistent such that the underlying data is obfuscated for significant periods of time. Authentication software may be keyed to the period of time involved in the change of phase and/or return to original phase.
[0120] The light-sensitive materials can be broadly applied to any substrate. Advantageously, the dye will be invisible so its presence will not affect the packaging. Various methods for application include DOD, ink jet printing, aerosol spraying or dipping the substrate.
[0121] In one embodiment in order to write data to the substrate, a change is be made to the dye. One of the most common ways to do this is with a laser such as is used in a CD-R writer, although the present invention is not limited in this respect. This laser heats up the dye to cause a change in its properties. These changes can be made precisely and rapidly.
[0122] In one embodiment a laser changes the light-sensitive material from light emissive to light absorptive. In another embodiment the laser changes the light-sensitive material from light absorptive to light emissive. In yet another embodiment the laser changes the light-sensitive material from transparent to light emissive. In another embodiment the laser changes the light-sensitive material from transparent to light absorptive. In all these cases a pattern is formed by light and dark areas by contrasting the dye before the laser has treated it and after treated with a laser. It is the contrasting pattern which is used to form letters, numbers, symbols or barcode patterns, etc., for a reader to pick up.
[0123] Various methods and apparatuses can be used to read the substrate and the alternating patterns of light and dark, as the present invention is not limited in this respect. Some of these are dependant on whether the dye is absorptive of emissive. One method is similar to a standard barcode reader. This system uses light reflected from the surface of the substrate. Where the light-sensitive material is absorptive, the amount of light reflected is less than where the light-sensitive material is not. Thus the reader will pick up a pattern of alternating light and dark areas. If the light-sensitive material is light emissive then the reader will need to filter out the excitation light and only allow the light emitted in, for example using a one pixel ratiometric camera that takes advantage of a change in ratio in the light-sensitive material in addition to the light and dark patterns set up by the laser.
[0124] Data applied to substrates may be encrypted to further increase security. The combination of data encryption, use of symbols (bar codes) or characters, and one or more invisible dyes that emit/absorb at different wavelengths results in a method of reliable product authentication and identification. The type of encryption used is variable and depends on the users requirements. As would be understood by one of ordinary skill in the art, all methods of digital encryption available today or in the future would be applicable to this technology. Public key encryption algorithms, such as RSA, as well as all adaptations of 128 bit encryptions, modified versions of DES and IDEA, are suitable, as well as encryption methods using combination of the aforementioned. Data will also be encrypted when meaningful text/digits are transcribed to the symbols chosen for the particular media.
[0125] In one embodiment of the invention, barcoding symbology to represent the digital data may be employed. A bar code ‘symbology’ is the way information is represented in a bar code, i.e., how the thin lines and thick lines (or other elements) represents data. There are two types of bar code symbologies: continuous and discrete.
[0126] Discrete bar codes start with a bar, end with a bar, and have a space between characters, referred to as an intercharacter gap. Continuous bar codes start with a bar, end with a space, and have no intercharacter gap. Hundreds of different bar code symbologies exist in theory, but only a handful are used extensively in commerce and industry.
[0127] The structure of the barcode consists of the height and the width. Information is encoded into spaces and bars of various width. The height of the barcode does not hold any information. Using the height, however, you can enlarge a barcode for easy scanning or for better visibility. The number of characters are represented in a linear inch called the barcode density. The density depends on the symbology. For example, using Code 39, 9.4 characters can fit in one inch. When using Interleaved 2 of 5, 17.8 characters can fit in one inch. The resolution of a barcode is dependent on the narrowest element of a barcode (X dimension), and can vary from high resolution—nominally less than 0.009 in. (0.23 mm), medium resolution—between 0.009 in. (0.23 mm) and 0.020 in. (0.50 mm), and low resolution—greater than 0.020 in. (0.50 mm).
[0128] Currently there are more than 400 barcode symbologies in use. Some are alphanumeric, while others contain the full ASCII set, or only numeric data. Only 10 are standardized and prevalent in industry. This embodiment could include, but is not limited to, the following examples of bar coding symbologies:
[0129] Code 39: Code 39 is the most widely used barcode. It is an alphanumeric code, which supports both numbers and capital letters. The barcode has a total of 9 elements, 5 bars, and 4 spaces for each barcode character. Code 39 is used for shipping departments and product descriptions.
[0130] UPC: UPC-consists of the following subsets:
[0131] UPC-A—UPC-A is a barcode used to encode a 12 digit number. The digits are arranged in the following manner: The first digit is the number system character, the following ten digits are the data characters, and the final digit is the checksum character. UPC-A is used by grocery stores within the United States;
[0132] UPC-E—UPC-E is the smallest barcode available because it is a zero suppressed version of the UPC-A barcode. The data characters and the checksum characters are all condensed into six characters. UPC-E is used with the small EAN-8 bar code, has two country characters (which identify the country of origin), 5 data characters, and a checksum character. The EAN-8 is used for applications overseas;
[0133] EAN-13—EAN-13 has two country characters, ten data characters, and a checksum character. Thus, EAN-13 encodes 13 characters. The EAN-13 is mostly used in grocery stores in Europe;
[0134] Interleaved 2 of 5—Interleaved 2 of 5 is a numeric code only. There are five elements to each character, two wide and three narrow. This code is also capable of having from 2 to 30 digits. It also requires an even number of digits to be encoded;
[0135] Code 128—Code 128 is used for all numeric bar codes or alphanumeric barcodes. It is also a high density bar code which can encode the entire 128 ASCII character set. It is also capable of encoding two numbers into one character width, called double density.
[0136] UCC-128—UCC-128 is a subset of Code 128. It is a 19 digit fixed length bar code which uses the double density numeric Code 128 C to create the bar code. The UCC-128 is often used for shipping containers.
[0137] Another embodiment of the invention includes automatic error checking of the digital content. An example of said error checking would include but not be limited to the use of a checksum character as is commonly used in bar coding symbology. A checksum is a count of the number of bits in a transmission unit that is included with the unit so that the receiver can check to see whether the same number of bits arrived. If the counts match, it's assumed that the complete transmission was received. The generation of the checksum character can vary from one type of symbology to another. However most symbologies checksum is obtained by taking the modulus 10 of sum of all of the characters in the string.
[0138] In another embodiment of the invention the data string stored represented on the package can be compressed. One example of compression would include but is not limited to the use of hexidecimal format. At its simplest, hex numbers are base 16 (decimal is base 10). Instead of counting from 0 to 9, as we do in decimal, and then adding a column to make 10, counting goes from 0 to F before adding a column. The characters A through F represent the decimal values of 10 through 15 as illustrated below:
decimal 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Hex 0 1 2 3 4 5 6 7 8 9 A B C D E F
[0139] Another way to explain hex is, each column in a hex number represents a power of 16. The compression technique used could include hexidecimal or any other custom compression algorithm.
STATEMENT REGARDING PREFERRED EMBODIMENTS
[0140] While the invention has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the invention without departing from the spirit or scope of the invention, in particular the embodiments of the invention defined by the appended claims. All documents cited herein are incorporated in their entirety herein.
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Light sensitive materials applied in shipping materials, including security seals and tear tape, for authentication, discrimination and recognition of items.
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[0001] The present invention relates to an aircraft passenger seat, particularly but not exclusively to an aircraft sleeper seat convertible into a substantially flat bed.
BACKGROUND TO THE INVENTION
[0002] Examples of prior art aircraft sleeper seats are disclosed in the applicant's patent publications WO-A-9618537 and WO-A-0021831, embodiments of which include the current British Airways First and Club World seats respectively. Both of these seats can be converted into a flat, horizontal bed, and have enjoyed great commercial success. However, there is intense competition to provide ever-greater comfort and space for aircraft passengers.
[0003] Passenger seats for aircraft are subject to stringent design constraints, many of which are not applicable to seats for other vehicle types. One problem is the need to meet the relevant safety standards for aircraft passenger seats, such as the 16 g test that requires seats to survive deceleration of 16 g in a takeoff/landing position. Another problem is the need to minimize the weight of the seat, since carrying extra weight on an aircraft increases fuel consumption and therefore monetary and environmental cost. Hence, the seat must be both strong and light.
[0004] Another problem relates to the use of space. Any given aircraft has a maximum area for passenger seating, which must be used in the most space-efficient manner possible so as to maximize the seating area and legroom available to each passenger, while allowing unimpeded exit from the seat. It is also important for cost reasons to fit as many passenger seats as possible in the available area.
[0005] Another problem relates to the level of comfort of the seat. Aircraft passenger seats may be used for day flights, in which the passenger will want to work, eat and/or relax, and night flights during which the passenger will want to sleep. Preferably, an aircraft passenger seat should be able to adopt comfortable positions for all of these activities, yet also be able to meet the relevant safety standards in a takeoff/landing position.
[0006] Another problem relates to the psychological and/or social needs of aircraft passengers, who may desire privacy while working, eating or sleeping, or may wish to interact with a travelling companion. There are also some arrangements that are undesirable for aesthetic and/or psychological reasons; for example, it is preferred that parts of the seat mechanism are not visible to the passenger.
[0007] In first class seats, the passenger demands the greatest possible level of comfort and it is accepted that fewer passenger seats will be accommodated in the available area than would be the case for economy or business class. For first class sleeper seats, it is desirable to provide a sleeping arrangement that is as close as possible to a normal bed. However, normal single beds are considerably wider than an aircraft passenger seat needs to be.
[0008] One approach to this problem has been to provide armrests that retract so as to be level with the seat in a fully reclined position, so that the width of the armrests is added to the seat width. One such arrangement is disclosed in Patent publication no. WO 98/36967 (Singapore Airlines).
[0009] Another approach to this problem can be seen in the Odyssey™ aircraft seat disclosed at http://www.flatseats.com/Product/news-contour-3108.htm on 28 Oct. 2005 or earlier, and described in an article in the London Evening Standard on 8 Jul. 2005. As shown schematically in FIG. 1 , the arrangement comprises a bed surface 1 adjacent to one side of a reclining seat 2 . One disadvantage of this arrangement is that the seat pitch, i.e. the spacing between adjacent rows of seats, is very short and so legroom is restricted. Also, the bed surface 1 takes up a great deal of space so it is not practicable to increase the seat pitch as this leads to very inefficient use of space. Another problem is that the seat 2 does not provide a deep reclined position suitable for resting. Another problem is that the passenger has to adopt a completely different position when sleeping than when sitting, and so has to rearrange personal effects, bedding, cushions and the like when moving from the sitting to sleeping position.
STATEMENT OF THE INVENTION
[0010] According to the present invention, there is provided an aircraft passenger seating arrangement comprising a seat having a seat pan and a seat back, the seat being able to adopt a first, substantially upright sitting position and a second, sleeping position in which the seat back and seat pan are substantially horizontal, the arrangement further including a side surface arranged to form part of a substantially flat, horizontal sleeping surface alongside the seat.
[0011] In one aspect, the side surface is positioned substantially alongside the seat pan in the sleeping position. The side surface may have a major axis substantially in the longitudinal direction of the seat. The underside of the side surface may be provided with lighting means, preferably arranged to direct light downwards.
[0012] In another aspect, there is provided an end surface arranged to form part of a substantially flat, horizontal sleeping surface forward of the seat. The end surface may be substantially continuous with the side surface and may be integrated therewith. The seat may include an auxiliary surface that is positioned between the seat pan and the end surface in the sleeping position. The auxiliary surface may be connected to the seat pan, so that it may be stowed in the sitting position and deployed in the sleeping position. The end surface may comprise a secondary seat. Part or all of the end surface may be stowable. There may be provided a movable footstool stowable under the end surface.
[0013] There may be provided a plurality of such seating arrangements configured along a wall of an aircraft, with the side surfaces of the seating arrangements provided at a side towards the wall. There may be provided an adjacent pair of such seating arrangements, with the side surfaces of the pair arranged mutually inwardly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Embodiments of the invention will now be described with reference to the drawings identified below.
[0015] FIG. 1 shows a prior art aircraft passenger sleeper seat.
[0016] FIG. 2 is a perspective view of an aircraft passenger sleeper seat according to an embodiment of the invention.
[0017] FIGS. 3 a to 3 d are perspective views of the seat respectively in TTOL, upright, reclined and bed positions.
[0018] FIGS. 4 a to 4 d are schematic side views of the seat in the respective positions.
[0019] FIGS. 5 a and 5 b show a bed surround component of the seat respectively in perspective and cross-sectional views, in a further embodiment of the invention.
[0020] FIG. 6 shows a first possible cabin layout of a plurality of the seats.
[0021] FIG. 7 shows a second possible cabin layout of a plurality of the seats.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Terminology
[0022] In describing the embodiments, ‘horizontal’ and ‘vertical’ are defined with reference to the floor of the passenger seating area of the aircraft. As in well known in the art, the angle of the floor relative to the gravitational horizontal is determined by the pitch of the aircraft, which is about 15° during takeoff and landing, and about 3° in level flight. When describing an individual seat, ‘forward’ and ‘rearward’ are defined with reference to the direction in which the passenger faces when seated.
Seating Arrangement
[0023] As shown in FIG. 2 , an aircraft passenger seating arrangement in an embodiment of the present invention comprises the following main components: a seat 3 comprising seat back 3 a and seat pan 3 b , a housing or shell 4 partially surrounding the seat 3 , a surround 5 extending along the side and forward of the seat 3 , and a ‘credenza’ or cabinet 6 . The main components may be constructed as separate components and installed together in an aircraft to form the seating arrangement. An ottoman 7 is provided, but is not integrated with the main components of the seating arrangement. Not all of the main components are essential to all aspects of the present invention.
[0024] The seat 3 includes a headrest 9 attached to the seat back 3 a , and an armrest 8 at either side of the seat pan 3 b . One or both of the armrests 8 may be lowered or retracted so that they are substantially level with, and preferably continuous with the surround 5 .
[0025] The surround 5 comprises the end portion 5 a , arranged forward of the seat 3 , and a side portion 5 b , extending substantially longitudinally to one side of the seat 3 . The surround 5 is preferably fixed with respect to the floor, and its height is not adjustable by the passenger.
[0026] The cabinet 6 is positioned to one side of the seat 3 , adjacent the side portion 5 a of the surround. The cabinet 6 may house one or more passenger facilities, such as a stowable table, a light, controls for reclining the seat 3 and/or operating an in-flight entertainment (IFE) system. The cabinet 6 has a top surface 6 a for use as an occasional table or cocktail tray.
[0027] The ottoman 7 is not fixed to the floor of the passenger area but can be freely positioned on the floor to act as a footrest. Preferably, the ottoman 7 can be stowed under an end portion 5 a of the surround 5 . The ottoman 7 may have a lid and provide interior storage space. Preferably, the ottoman 7 is attached by a tether to a fixing point, to prevent the ottoman 7 from being removed from the passenger area, or causing a hazard in turbulent conditions.
[0028] The shell 4 extends behind and to at least one side, and preferably to both sides of the seat 3 . Preferably, the shell 4 is arranged as a privacy screen; for example, it may conceal the seated passenger, at least partially, from surrounding seated passengers. Preferably, the seat back 3 a remains substantially within the shell 4 as it reclines; for example, the headrest 9 does not project significantly, or at all, above the shell. Preferably, the shell 4 conceals and/or hinders passenger access to a reclining mechanism for the seat 3 . The shell 4 may also provide passenger storage and/or facilities, such as an IFE screen stowable flush with the shell 4 .
Seat Reclining Positions
[0029] The seating arrangement includes a seat reclining mechanism which allows the seat 3 to be positioned in at least a sitting and a sleeping position, and preferably in each of the following four positions, as shown in FIGS. 3 a to 3 d and 4 a to 4 d:
a) taxi, takeoff and landing (TTOL) position: the seat back 3 a is slightly reclined, at 20-30° to the vertical, and the seat pan 3 b is tilted rearward by 10-20°, to provide a secure and comfortable position. Preferably, the seat 3 meets the 16g test criteria in this position. b) upright sitting position: the seat back 3 a is fully upright, at 15-20° to the vertical, and the seat pan is tilted rearwardly by 2-10° to provide a comfortable position for working or eating. c) reclined position: the seat back 3 a is reclined, at 20-50° to the vertical, and the seat pan 3 b is tilted rearward by 10-20°, to provide a comfortable position for resting and using IFE. d) Bed position: the seat back 3 a and seat pan 3 b are substantially horizontal, at 0-10° to the horizontal, and form a substantially continuous and/or flat surface suitable for sleeping on.
[0034] An auxiliary surface 3 c is pivotally attached to the forward end of the seat pan 3 b . In positions a) to c), the auxiliary surface 3 c is stowed under the seat pan 3 b , and is preferably substantially vertical. In position d), the auxiliary surface 3 c is driven by the seat reclining mechanism to a substantially horizontal position, so that the seat back 3 a , seat pan, auxiliary surface 3 c and surround end portion 5 a form a substantially flat, horizontal and continuous sleeping surface. As shown in FIG. 3 d , the side portion 5 b of the surround 5 is substantially coplanar and/or continuous with the seat pan 3 b and auxiliary surface 3 c so as to form a sleeping surface that is wider than the seat pan 3 b . One or both of the armrests 8 may be driven by the seat mechanism to retract in position d), so as to form a flat continuous surface with the seat back 3 a and/or the side portion 5 b of the surround 5 .
[0035] Hence, the seat arrangement may provide a sleeping surface that is considerably wider than the seat pan along the majority of the length of the sleeping surface. Moreover, the major axis of the sleeping surface is in the longitudinal direction of the seat 3 , so the passenger need not greatly adjust his or her orientation when moving to the sleeping position d) from another position. The side portion 5 b is elongate, with a major axis substantially parallel to the longitudinal direction of the seat 3 , so that it does not greatly increase the overall width of the seating arrangement.
[0036] Preferably, the seat reclining mechanism and/or controls enable the seat 3 to be reclined continuously between the positions a) to d) and maintained in any of those positions or in intermediate positions therebetween. Alternatively, the seat reclining mechanism and/or controls may restrict the positions in which the seat 3 may be maintained. However, it is preferable that a continuous transition between at least positions b) and c) is possible.
[0037] As can be seen from FIGS. 3 a to 3 d and 4 a to 4 d , the seat mechanism is operable to lift the seat pan 3 b to a substantially horizontal position level with the surround 5 as the seat approaches the sleeping position d). Specific mechanisms for achieving combined pivoting and lifting of seat pans are known per se in the art.
[0038] The seat mechanism further acts to drive the auxiliary surface 3 c from its stowed position in seat positions a) to c) to its substantially horizontal position in seat position d). Mechanisms for driving legrests pivotally attached to seat pans are known per se in the art and may be used to drive the auxiliary surface 3 c , with suitable modifications.
[0000] Surround with Buddy Seat
[0039] In a further embodiment shown in FIGS. 5 a and 5 b , the forward portion 5 a of the surround may be configured as a ‘buddy seat’ suitable for a companion to sit on, facing the passenger in the seat 3 . The buddy seat may comprise a buddy seat portion 5 c that is pivotally mounted in the forward portion 5 a so as to pivot upwardly into a substantially vertical position, leaving an opening in the forward portion 5 a to make more floor space available for the passenger, or to allow the passenger to rest his or her feet on the ottoman 7 in position c). The surround 5 may have an upholstered upper surface similar to that of the seat 3 . Lighting 10 may be provided on the underside of the surround 5 , preferably under the side portion 5 b , to provide a downlighting effect.
Cabin Layout
[0040] FIG. 6 shows one possible cabin layout of seats according to an embodiment of the invention, suitable for a Boeing (RTM) 747-57 aircraft. Window seats W are arranged overlapping in the longitudinal direction, with the surrounds 5 at the side towards the window. Centre seats C are arranged in paired rows, with the surrounds at the inward side of each pair. Each of these arrangements uses the surround 5 to fill otherwise unusable space.
[0041] FIG. 7 shows another possible layout, suitable for a Boeing (RTM) 777 17F-3 aircraft. This arrangement differs from that of FIG. 6 in that the centre seat pairs overlap longitudinally and the seats of each pair are angled mutually inwardly in the forward direction. This layout reduces the seat pitch of the centre seats C, at the expense of greater width for each pair.
Alternative Embodiments
[0042] Alternative embodiments of the invention may be apparent from reading the above description. Such alternative embodiments may nevertheless fall within the scope of the present invention.
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An aircraft passenger seating arrangement comprises a seat having a seat pan and a seat back, the seat being able to adopt a first, substantially upright sitting position and a second, sleeping position in which the seat back and seat pan are substantially horizontal, the arrangement further including a side surface arranged to form part of a substantially flat, horizontal sleeping surface alongside the seat.
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BACKGROUND OF THE INVENTION
This invention relates to a method recovering alkoxyketone compounds having a high degree of purity from a mixture of an alkoxyketone compound and the corresponding 1-alkoxy-2-alkanol compound.
The most common form of preparing alkoxyketone compounds is to catalytically dehydrogenate the corresponding 1-alkoxy-2-alkanol compound in the vapor phase. When such a preparative method is used, problems of separation arise. The difficulties surrounding the separation of an alkoxyketone compound from admixture with the corresponding 1-alkoxy-2-alkanol have been primarily due to the formation of a binary azeotrope composition.
This difficulty has been noted in the past and a variety of solutions have been proposed in an attempt to obtain alkoxyketone compounds of high purity. Heretofore, the separation has been effectuated either by chemical modification followed by distillation or by multistep azeotropic distillative methods. For example, U.S. Pat. No. 2,170,855 discloses a chemical modification method in which an organic acid or anhydride is added to a reaction mixture of an alkoxyacetone compound and the corresponding 1-alkoxy-2-propanol compound resulting in the formation of the high boiling ester derivative of the 1-alkoxy-2-propanol starting material. The resulting mixture is distilled and redistilled to recover the desired alkoxyacetone.
Alternatively, U.S. Pat. Nos. 2,795,873 and 3,525,735, respectively, discloses azeotropic distillation processes in which either an unsubstituted monohydric alcohol or water is added to the reaction mixture in order to break the minimum boiling point binary azeotrope. In these processes, a new lower boiling binary azeotrope is formed between the azeotropic solvents and the alkoxyacetone compound which may then be removed from the binary azeotropic mixture by distillation.
Although, they seem relatively simple and efficient, the prior art processes suffer from one or more inherent limitations and disadvantages. For example, it is generally recognized that both of the previously disclosed processes usually give rise to alkoxyketone compounds that are contaminated with unacceptable amounts of the corresponding 1-alkoxy-2-alkanol compound. In addition, the azeotropic distillation process requires large expenditures of energy due to the very high latent heat of the azeotropic solvents, as well as, time consuming and cumbersome purification procedures to remove the desired alkoxyketone compound from the azeotropic solvent. Consequently there exists a need for a fast and more efficient single step process for separating alkoxyketone compounds from the corresponding 1-alkoxy-2-alkanol compound with enhanced purity of the alkoxyketone compound coupled with low energy requirements.
SUMMARY OF THE INVENTION
According to the present invention there is provided a process for separating an alkoxyketone compound from a feed mixture of the alkoxyketone compound and the corresponding 1-alkoxy-2-alkanol compound which comprises:
A. introducing an extractant solvent selected from the group of aliphatic diol, triol and polyol compounds having from 2 to 6 carbon atoms and monohydric aliphatic alcohols having from 5 to 10 carbon atoms into an extractive distillation zone;
B. introducing the feed mixture into the extractive distillation zone at a point above the bottom thereof and below the extractant solvent point of entry;
C. subjecting the resulting mixture to extractive distillation in the extractive distillation zone; and
D. recovering at the top of the extractive distillation zone a distillate fraction comprised of the alkoxyketone and the extractant solvent, substantially free of the corresponding 1-alkoxy-2-alkanol compound.
The process of this invention provides excellent separation under mild process conditions, using very little equipment and has the advantage of very short separation times and minimum energy expenditures.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a schematic flow diagram of an illustrative embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The alkoxyketone compounds contemplated for use in the process of this invention are lower alkoxyketone compounds having from 4 to 10 carbon atoms. Illustrative of alkoxyketone compounds which can be separated from the corresponding 1-alkoxy-2-alkanol compound are methoxyacetone, ethoxyacetone, n-proproxyacetone, isopropoxyacetone, n-butoxyacetone, tert-butoxyacetone, methoxy-2-butanone, ethoxy-2-butanone and the like.
Compounds which are useful as extractant solvents in the conduct of the process of this invention are diol or triol or polyol compounds which contain from 2 to about 6 carbon atoms. Preferred extractant solvents are diol or triol compounds having from 2 to about 6 carbon atoms, with those diol compounds having 2 or 3 carbon atoms and glycerine being particularly preferred. Illustrative of useful extractant solvents are linear diol compounds such as ethylene glycol; 1,2-propylene glycol; 1,3-propylene glycol, 1,2-dihydroxypentane; 1,3-butanediol, 1,4-butanediol, 2,3-dihydroxypentane, 1,3-dihydroxypentane; 2,4-pentanediol, 1,5-pentanediol, 1,2-dihydroxy-3-methylpentane, 1,6-hexanediol, 1,2-hexanediol, 2,5-hexanediol and the like. Illustrative of useful cyclic diols are 1,2-cyclopentanediol; 1,2-dihydroxy-4-ethyl-5-propylcyclohexane and the like. Useful triol extractant solvents include glycerine, 2,4,6-trihydroxyhexane, 1,2,6-hexanetriol or the like.
Still other suitable extractant solvents are monohydric primary aliphatic alcohols having from 5 to about 8 carbon atoms; monohydric aliphatic secondary alcohols having from 5 to about 8 carbon atoms and alicyclic alcohols having 5 or 6 carbon atoms in the ring with a total of from 6 to about 8 carbon atoms. Illustrative of useful monhydric extractant solvents are pentanols, hexanols, heptanols, octanols, secondary pentanols, secondary hexanols, cyclopentanols and cyclohexanols.
The ratio of feed mixture to the extractant solvent which is employed to effectuate the desired separation is not narrowly critical. It will be appreciated that this ratio may vary depending upon the particular extractant solvent employed, the composition of the feed mixture, the degree of separation desired and other operating parameters, such as temperature and pressure. In general, the extractant solving to feed ratio may vary from about 1 to 1 to about 100 to 1, by volume depending on the foregoing factors. It should be appreciated that while no practical advantages are derived from the use of ratios outside of the stated range, these ratios are still within the contemplation of this invention, although they are not generally advantageous.
The preferred extractant solvent employed in a particular situation is conventionally determined from a consideration of the relative volatility of the components in the feed mixture at any specific concentration; the relative volatility of the components in the feed mixture in the extractant solvent and the boiling point of the extractant solvent. The relative volatility of the components being separated in the feed mixture in the extractant is at least 0.6 units higher than the volatility of the feed mixture at a specific concentration; and the boiling point of the exrtractant solvent is at least 20° C. higher than the boiling point of the highest boiling component of the feed mixture.
In order to obtain alkoxyacetone compounds of approximately 99 percent purity from feedstock containing 60- 65% alkoxyacetone, the process of this invention is to be carried out with a solvent-to-reflux ratio of not less than 1.5 and a reflux-to-make ratio of not less than 1.0. The preferred ratios may be obtained by a simple manipulation of temperatures, pressures, and other process parameters.
To inhibit the formation of 2-alkyl alkoxyalkyl-1, 3-dioxolane contaminants, an organic or inorganic base is preferably added to the feed mixture in an amount sufficient to raise the pH to 8 or greater. The base serves to neutralize the slight acidity of the extractive solvent thereby lowering the production of the dioxalane contaminant from as high as five percent to less than 0.5 percent.
Distallation pressures are not critical. The process can be conducted at either subatmospheric, atmospheric or superatmospheric pressure. For convenience the process is usually conducted at atmospheric pressure. This obviates the necessity of employing vacuum equipment and expensive refrigeration equipment which may be necessary to operate at exceedingly reduced pressures.
The temperature at which the process of this invention is conducted is not narrowly critical. Process temperatures may vary widely depending on process pressure; extractant solvent; composition of the feed mixture and the ratio of extractant solvent to feed mixture. In general, the maximum process temperature is equal to the boiling point of the extractive solvent of the specific pressure of operation. The minimum process temperature is equal to the boiling point of the feed component having the lower boiling point at the specific pressure of operation. As is well known a constant process temperature is not maintained throughout the extractive distillation zone. A high temperature which approximates that of the extractant solvent is present at the bottom of the extractive distillation zone, a low temperature which approximates the boiling point of the lower boiling component of the feed mixture is present at the top of the extractive distillation zone and an intermediate temperature is present in the middle of the zone.
The process of this invention can be conducted in a batch, semi-continuous or continuous fashion using counter-current contacting devices.
The feed mixture and extractant solvent can be introduced into the extraction zone continuously or intermittently introduced into the extractive distillation zone during the course of the process. The process of this invention is preferably conducted in a continuous distillation.
In the preferred embodiments of this invention, the extractant solvent is introduced at a point below the top of the multistage distillation column. The portion of the column below the extractant solvent point of entry functions as the extractive distillation zone and the portion of the column above the extractant solvent point of entry functions to remove the contaminating solvent from the alkoxyketone component.
Means to introduce and/or adjust the quantity of feed and/or solvent introduced, either intermittently or continuously into the extraction zone during the course of the process can be conveniently utilized to maintain the desired volume ratios of the feed mixture and extractant solvent. The process can be carried out in a single extraction zone or a plurality of extractive distillation zones. The materials of construction employed should be inert to the components of the feed mixture and to the extractant solvent and the frabrication of the equipment should be able to withstand process temperatures and pressures.
The apparatus employed in the process for the main extraction and for the optional solvent recovery distillation is conventional e.g., an extraction column of the multistage type containing a plurality of perforated plates, or a packed column, a bubble cap tray column or any conventional type distillation column used in multistage distillation or counter-current contacting.
In the process of this invention the extractant solvent is introduced at or near the top of the extractive distillation column and the feed mixture is introduced at or near the middle of the column. The feed mixture is then subjected to extractive distillation within the column which results in the separation of the two components of the feed mixture. The alkoxyketone component contaminated with minor amounts of the extractant solvent is collected overhead. The extractant solvent can be removed from the alkoxyketone compound in a subsequent batch, semi-continuous or continuous mode distillation if it is not adequately removed by a solvent- removal section or zone above the extractive zone of the extractive distillation column.
The preferred embodiments of the process of this invention is illustrated by the schematic flow sheet outlining in the figure for separating alkoxyacetone from 1-alkoxy-2-propanol in a continuous fashion. Referring to the drawing:
Feedstock, extractant solvent or a mixture thereof is initially charged into kettle 13 via line 11, where it is heated to its boiling point by heat exchanger 15. Vapors percolate from kettle 13 and are introduced via line 17, into multistage extractive distillation zone 19. Vapor is then allowed to percolate up extractive distillation zone 19 to a point above the extractant solvent point of entry 33, at which time the system is allowed to equilibrate for from about 1/4 to about 2 hours.
The system is now capable of being operated in a continuous manner. Feedstock comprised of alkoxyacetone and the corresponding 1-alkoxy-2-propanol compound is continuously introduced via line 23 into heat exchanger 25, where it is preheated to a temperature to within ± 10° C. of the steady-state temperature of multistage extractive distillation zone 19 at feedstock point of entry 27. The preheated feedstock continues through line 23 entering multistage extractive distillation zone 19, at feedstock point of entry 27. The feedstock flows into multistage extractive distillation zone 19, contacting upward percolating vapors entering multistage extractive distillation zone 19 via line 17. The vapors and the feedstock exchange heat producing a vapor fraction rich in the alkoxyacetone component with lessor amounts of the 1alkoxy-2-propanol component and extractive solvent. The combined vapors, i.e. extractant solvent, alkoxyacetone and 1-alkoxy-2-propanol percolate up multistage extractive distillation zone 19. A fraction of the combined vapors condenses at each stage of the multistage extractive distillation zone 19, producing a liquid vapor steady state equilibrium at each stage. The amount or concentration of 1-alkoxy-2-propanol in vapor phase becomes progressively less at each successive stage. Simultaneously with the introduction of the feedstock, extractant solvent is introduced via line 29 into heat exchanger 31 where it is preheated to within 10° C. of the temperature of extraction zone 19 at extractant solvent point of entry 33. Extractant solvent percolates down multistage extractive distillation zone 19, coming into counter-current contact with the upward percolating vapors. The extractant solvent dissolves and removes the alkoxy-2-propanol component with a small fraction of the alkoxyacetone component as the solvent percolates down multistage extractive distillation zone 19. The remaining vapors, alkoxyacetone and extractant solvent, continue to the upper portion of multistage extractive distillation zone 19, where the vapors are fractionated into a vapor phase which is substantially alkoxyacetone with minor amounts of extractant solvent. The vapors percolate above solvent point of entry into solvent-removal distillation zone 21, where the vapors are fractionated into a vapor phase which is alkoxyacetone having a purity of about 99 percent by weight.
The vapor phase leaves the top of solvent removal distillation zone 21 via line 35 into heat exchanger 37 where it is condensed. A fraction of the condensed alkoxyacetone continues through line 39 into solvent removal distillation zone 21 as reflux and the remaining fraction continues through line 41 to be collected as substantially pure alkoxyacetone.
As noted above, the extractant solvent percolates down multistage extractive distillation zone 19 carrying with it the major portion of 1-alkoxy-2-propanol component and a fraction of the alkoxyacetone component.
In the lower portion of the extraction zone 19, the solvent solution comes in countercurrent contact with vapors of the components and extractant solvent that enter multistage extractive distillation zone 19 through line 17. The vapors percolate up extraction zones progressively vaporizing and purifying the downflowing solution of the remaining alkoxyacetone fraction which combines with the combined vapors described above. The remaining solution, i.e., the liquid downflow, comprised of extractant solvent and 1-alkoxy-2-propanol with very minor amounts of alkoxyacetone percolates down multistage extractive distillation zone 19.
The liquid leaves the bottom of multistage extractive distillation zone 19 via line 43 and enters kettle 13 where a fraction of the liquid is vaporized and is taken overhead via line 17 into multistage extractive distillation zone 19 to repeat in a continuous fashion the extractive distillation cycle described hereinabove. The balance of the liquid entering kettle 13 leaves the bottom via line 45 into solvent recovery column 47.
Extractant Solvent is initially charged into kettle 51, where it is heated to its boiling point by heat exchanger 53. Extractant solvent vapors pass over head via line 55 into solvent recovery column 47, where they are allowed to equilibrate.
As pointed out above, the liquid enters solvent recovery column 47, where it flows downward and comes into countercurrent contact with upward, percolating, extractant solvent vapors entering solvent recovery column 47 via line 55. A portion of the liquid, rich in the 1-alkoxy-2-propanol component, is vaporized on each stage or tray of the column and eventually passes overhead via line 57 through heat exchanger 59 where it is condensed and cooled to approximately room temperature. One portion of the condensed distillate is collected from line 61 and the other portion returns to solvent recovery column 47 via line 63 to maintain reflux conditions. The down-flowing liquid, rich in extractant solvent combines with condensed extractant solvent vapor and proceeds along line 49 into kettle 51. A portion flashes on entering kettle 51 and passes over head via line 55 to continue the above described solvent purification cycle in a continuous fashion. The remainder passes as a liquid via line 29, where it is recycled along line 29 to continue the above described extraction cycle in a continuous fashion.
The manner of practicing the process of the present invention and advantages obtained thereby will be illustrated by the following specific examples which are merely illustrative and are not intended, in any manner, to limit the scope of the invention.
EXAMPLES I-XV
Procedure:
Binary feedstock composed of 65 weight percent methoxyacetone and 32.5 weight percent 1-methoxy-2-propanol was fed into a 43 tray Oldershaw still column at a point 13 trays above the kettle. Ethylene glycol was introduced 38 trays above the kettle. The trays were 28-mm in diameter and encased in silvered vacuum jacket, with 1-inch tray spacings.
The distillate was recovered overhead, and its composition was determined by gas-liquid chromatography on a binary basis.
Process parameters and results are set forth in Table I hereinbelow:
TABLE I__________________________________________________________________________ Analysis, Weight % Methoxy- TEMPERATURE ° C. RATIOS acetone Absolute Ethylene in the (Solvent Pressures, Ethylene Glycol Feed Reflux/ Solvent/ Distillate/ Solvent/ DistillateEx. MM Hg. Glycol Tray Feed Tray Kettle Head Make Feed Feed Reflux (Free__________________________________________________________________________ basis)I 750 107 105 28 126 196 108 15.0 15.2 4.05 3.8 98.6II 750 109 103 28 122 186 107 10.0 7.5 -- -- 99.0III 750 109 111 28 132 189 114 4.0 7.5 -- -- 99.3IV 750 109 104 28 127 181 108 4.0 4.8 2.75 2.2 99.4V 750 110 108 28 130 185 112 3.0 5.0 2.76 2.4 98.3VI 750 110 107 28 130 180 113 2.5 3.7 2.31 2.2 97.3*VII 750 122 121 117 126 185 112 2.55 5.00 1.81 3.84 95.3*VIII 750 130 123 119 126 190 114 1.01 4.38 1.39 6.25 91.6*IX 750 125 132 118 139 190 114 2.90 5.11 1.71 4.00 98.0*X 750 125 132 116 139 188 115 2.40 5.69 1.80 4.48 99.6*XI 750 124 130 116 138 190 114 2.80 5.55 2.19 3.44 98.00*XII 750 125 130 115 139 188 114 2.00 5.43 1.71 4.76 99.6*XIII 750 125 131 115 141 191 115 1.76 5.75 1.74 5.19 96.0*XIV 330 107 103 104 116 163 91 2.10 5.82 1.76 4.88 98.7*XV 327 102 102 110 112 165 90 2.50 7.00 2.06 4.76 99.6__________________________________________________________________________ *Column had 43 oldershaw trays with glycol added at tray 38 and feed at tray 13. All other runs were made with a 40-tray column with glycol added at tray 40 and feed at tray 20.
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A process for recovering alkoxyketone compounds from mixtures of the alkoxyketone compound and the corresponding 1-alkoxy-2-alkanol compound by extractive distillation with diols, triols and polyols as extractants.
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TECHNICAL FIELD
The invention concerns a process for carrying out the basic or acidic catalyzed acid-esterification and trans-esterification of oils and fats, i.e. the esters of glycerin with fatty acids and also the fatty acids themselves, by introducing methyl alcohol or other short chain alcohols into the liquid raw material.
BACKGROUND
For many applications it is desirable to modify fats using trans-esterification for various technical requirements, in particular when the production of motor fuels from biological sources is required.
There are known processes of this type for the trans-esterification of various vegetable oils and fats which form a multistage process, which is non-continuous and carried out in stages, finally resulting in glycerin, water and the desired methyl esters of the fatty acids, which initially formed an ester with the glycerin. It is also possible to use a different short chain alcohol, for example ethanol, propanol, butanol and in some cases even pentanol, to form the corresponding esters instead of the methyl alcohol. However, methyl alcohol is usually used for economic reasons and due to the simplicity of the reaction. As the length of the chain increases, the acid catalysis becomes more efficient and as such becomes a serious alternative. Impurities in the raw material should be removed to the extent that they do not cause any problems in the process. Prior cleaning of the oil reduces the disadvantages caused by impurities: side reactions, an increased use of chemicals, a slower conversion, etc.
On the other hand, problems are caused by the slow process, which involves treatment of the raw oils with methyl alcohol, usually catalyzed in a large volume mixing vessel for periods usually measured in hours. This reaction stage is followed by a separation stage which in turn takes place in a large settling vessel where any glycerin present collects at the bottom and the intermediate product, which has been up to 90% or more converted, floats although sometimes only after several hours of separation.
The floating intermediate product is once again introduced into a reaction vessel and again transformed using methyl alcohol and alkali, whereby a transformation of about 99% or more of the raw material is reached after several hours.
This product also has to be decanted which also takes place in a large separation vessel where the product floats and is finally drawn off. It is this product which finally undergoes final product purification.
The acid esterification of the fatty acids takes place analogous to the trans-esterification described above, except that the reaction takes place more slowly and water is produced as a side product instead of glycerin. The reaction is normally catalyzed with acid. The invention relates equally to the acid esterification and the trans-esterification of fatty acids and oils or of fats in mixtures with each other as well as with other components.
In summary, it is clear that the current most commercially used processes work in the manner described above. In principle, all these processes are based on early developments which were developed for the production of fatty acid methylesters as raw materials for the chemical industry (U.S. Pat. Nos. 2,360,844, 2,383,632).
The invention is characterized by the fact that (a) technically clean short chain alcohol(s) is/are dispersed into the oil(s) or fat(s) present as a liquid raw material and perhaps contaminated with free fatty acids in the presence of a basic or acidic catalyst. In other words, the invention concerns processes for the basic or acid catalyzed acid esterification and/or trans-esterification of fatty acids and/or oils and/or fats, that is the esters of glycerin with fatty acids, through introduction of short chain alcohols. In particular, methyl alcohol, is introduced into the liquid raw material. Further the process uses commercially pure short chain alcohol(s) dispersed into oil(s) or fat(s) present as a liquid raw material and perhaps contaminated with free fatty acids in the presence of a basic or acid catalyst. In one example, methyl alcohol is used as the alcohol and is completely dispersed in the reaction mixture. The dispersion can have a globule size (diameter) of about 1 μm, and preferably about 5 μm. Indeed, the dispersion can have a globule size of less than 50 μm, and preferably under 15 μm. In another aspect, the dispersion is produced using a dispersion machine, in particular a multi-stage high power dispersion machine.
In the case of the invented process, the dispersion is produced with normal dispersion equipment. This equipment is designed to produce a temporarily stable dispersion. It was often assumed that the mixture created in the dispersion equipment separates only very slowly and because of that the separation times for the glycerin phase were very long. It could be demonstrated, however, that a very rapid phase separation occurs through selection of the correct dispersion equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail below by way of a detailed description of the current State of the Technique and reference to diagrams whereby: FIG. 1 to 5 show different globule size distributions: and FIG. 6 shows dispersion equipment suited to the invention.
DETAILED DESCRIPTION
The choice of globule size is important when applying the invention. FIG. 1 to 5 (source: manufacturer's information) show the distribution of globule size when using different equipment from the same type of machine. An important characteristic of the dispersion equipment is that the globule size and its spectrum remain independent of the flow-rate up to its maximum capacity. This fact is of particular importance below in relation to the patent WO 99/26913 A1.
The equipment suitable for the acid esterification and trans-estenfication can be determined simply in a series of experiments. The dispersion should preferably comprise of globule sizes (diameters) above 1 μm, preferably above 5 μm, and below 50 μm., preferably below 15 μm. Distributions as shown in FIG. 3 and 4 are particularly advantageous.
FIG. 6 shows the basic construction of dispersion equipment. FIG. 6 shows the rotor 10 and stator 12 for an apparatus suitable for performing the process according to the present invention. In FIG. 6 , the rotor 10 is mounted vertically inside the casing/stator 12 . Attachments 14 on the rotor are arranged to fit with attachments 16 on the stator and serve to create strong turbulence when rotating. When this construction is compared with the equipment described in WO 99/26913 A1, De 199 08 978 A1, EP 0 249 463 A2, U.S. Pat. No. 4,668,439 A, DE 196 38 460 A1 and DE 100 43 644 A1 then the difference is easily recognizable. In the documents mentioned above, either a static mixer (or a derivative) or a normal mixing vessel are used.
A further particular characteristic of the invention, distinguishing it from the patents mentioned above, is the fact that several of them involve a several stage process, whereas the product is available in satisfactory quality (according to the current EN) after just one stage if the invented dispersion process is used.
A further important difference from WO 99/26913 A1 is that the dispersion equipment operates at normal atmospheric pressure (assuming no other process engineering requirements specify otherwise). A positive pressure as described in WO 99/26913 A1 is not necessary.
Having described the general differences between the invented process and the documents WO 99/26913 A1, DE 199 08 978 A1, U.S. Pat. No. 4,668,439 A, DE 196 38 460 A1, DE 100 43 644 A1, each of the differences or improvements which the submitted process brings will now be described. Firstly, however, the difference between dispersion and emulsion will be described. Dispersion involves increasing the phase boundary area between two insoluble liquids. If this process results from the addition of surface active substances then the term emulsion is used and usually very different characteristics apply (refer: Marko Zlokarnik, Rührtechnik, Theorie and Praxis, Springer Verlag 1999). For the sake of completeness both processes will now be described using the definitions:
Dispersing:
Dispersing is a physical process by which a mixture of two or more components is made which is characterized by the components being insoluble and because the distribution of the dispersed material in the dispersion component is very fine, so that the dispersion appears as a homogenous, stable mixture. Dispersion is the generic term for all mixtures comprising a carrier medium containing a dispersed component.
Emulsifying:
Emulsifying is understood to be a particular dispersion process whereby the dispersion created is stable due to a low surface tension and the separated globules cannot be separated. Surface active substances are also frequently used to increase the stability of the emulsion produced. The surface active substances behave in this case as emulsifiers.
The differences between the patent and each of the previously published documents:
Regarding WO 99/26913 A1:
The method presented in WO 99/26913 A1 describes in principle a process working with static mixers. (Page 8, lines 16, 17). The static mixer comprises a pipe which is filled with balls or various other materials. (Page 8, lines 83 to 25). Other equipment or materials are given on page 9, which clearly replace or support the static mixer. An emulsifier is usually understood to be a chemical and not a piece of equipment. “Emulsifiers are supporting chemicals, with the help of which two insoluble liquids (e.g. water in oil) can be made into a stable, homogeneous mass called and emulsion. There are artificially and naturally occurring emulsifiers. Their molecule contains a water soluble (hydrophilic) and a fat soluble (lipophilic) region. This molecular structure has the ability to enter into an interchange with water and oil and to enable a microscopically tiny distribution of the water. For the emulsion margarine emulsifiers largely based on monoglycerides and diglycerides from vegetable oils and fats along with vegetable lecithin.” (Deutsches Margarineinstitut) [are used]. The Turbulator mentioned on page 9, line 12 is a piece of equipment originally used in heating systems and in plain language means “Turbulence Producer”. Its construction is similar to a static mixer, however, materials are not mixed but instead the heat transfer to the pipe wall is improved (refer: A. Klaczak Heat and Mass Transfer Springer Publishers Heidelberg 1996).
Page 14, lines 10 to 13 repeat the fact that the reactor comprises a pipe filled with balls. The high pressure required for this process is referred to in lines 22 and 23. On page 16, lines 9 to 12, the so-called “Dynamic Emulsifier” is also described as a static mixer which in this case consists of a bent pipe. Page 16, line 30 repeats again that the process concerned is a high-pressure process.
From patent claims three, four, five, seven and eight of WO 99/26913 A1, it can be recognized that a type of static mixer has been described which has nothing to do with the invention under consideration. This is also easily recognized in diagrams FIG. 1 and FIG. 2.
For the sake of completeness, it is mentioned that under particularly favorable circumstances dispersions can also be produced using a static mixer. The problem with this is, however; that it is necessary for the shear stress to be maintained long enough. The problem present in this is, therefore, that an increase in the flow-rate increases the shear rate while simultaneously the residence time in the mixer is reduced. The globule size obtainable in a static mixer is, however, amongst other factors also a function of the residence time. This disadvantage of static mixers does not occur with dispersion equipment (refer: Marko Zlokamik, Riihrtechnik, Theorie and Praxis, Springer Verlag 1999).
The other points presented in WO 99/26913 A1 such as purification, washing, distillation, etc will not be dealt with here because they are processes which are well-known and widely used.
Regarding DE 199 08 978 A1:
In DE 199 08 978 A1, a process is described that performs the acid esterification and trans-esterification in one process step. Sulfuric acid is usually used as the catalyst for the acid esterification and potassium hydroxide or sodium hydroxide for the trans-esterification, because the different catalysts neutralize each other when mixed and the process must comprise at least two process steps. The document describes the simultaneous acid esterification and trans-esterification in one reaction step using sulfuric acid as the only catalyst. As far as the equipment arrangement is concerned, the process is to be treated as a cascade of a conventional “mixer-setter”. As such DE 199 08 978 A1 does not present a similar example of the invention under consideration.
Regarding EP 0 249 463 A2:
With regard to this document it is to be noted that it essentially has nothing to do with the invented dispersion method. It describes a method for the pre-acid esterification and trans-esterification in two separate steps. A totally normal, frequently used mixing vessel is shown in FIG. 2. This type of mixing vessel is currently normally used for acid esterification and relates to the state of the technique. According to FIG. 1, it can be recognized that it concerns first of all the acid esterification, followed by trans-esterification. Here, EP 0 249 463 A2 differentiates itself fundamentally from DE 199 08 978 A1, which performs the acid esterification and trans-esterification in one step using the same catalyst. It is important to point out that the time references made in FIGS. 3 to 6 can be at least halved using the invented process. (This is also the case for the acid esterification which proceeds significantly slower than the trans-esterification). EP 0 249 463 A2 therefore describes a process corresponding to the state of the technique without demonstrating anything new.
Regarding U.S. Pat. No. 4,668,439 A:
U.S. Pat. No. 4,668,439 A differentiates itself from the invented process in several important points. Firstly, it concerns a process which works with gaseous methanol. The process occurs at high temperatures (230 to 240° C.) (Table 1, pages 9 and 10). As conducted according to Example 1 (Pages 7 and 8), the trans-esterification occurs in a very normal mixing container. In comparison to the dispersion process, a reaction time of 3.75 hours is given (page 7, line 57). As mentioned on page 11, point 7, the process occurs under pressure. Here it also differentiates itself from the dispersion process.
Regarding DE 196 38 460 A1:
DE 196 38 460 A1 concerns itself essentially not with the acid esterification and trans-esterification but with the most efficient separation possible of the glycerin phase from the ester produced. As described on page 4 line 45 to 63, this invention makes use of the fact that the ester is much more soluble than triglycerides or partial glycerides in near supercritical media. The production of esters using dispersion equipment can be found in neither the patent claims on pages 7 and 8 nor can it be seen in the drawing FIG. 1. The methods described in Example 3 and Example 4 using a solid catalyst to perform the trans-esterification are even diametrically opposed to the dispersion method. It is not possible to use a solid catalyst with the dispersion method.
The method used in Examples 1 and 2 is a common form of trans-esterification, however, here it is mainly used with reference to the separation of ester. The dispersion method can also be useful here for the production of ester. Extractive methods using supercritical media are most certainly common (decaffeinated coffee among others), however, currently not for the production of free fatty acid methyl ester.
Regarding DE 100 43 644 A1:
DE 100 43 644 A1 describes a process for the continuous production of biodiesel using so-called “micro reactors”. These micro reactors, as they are drawn in FIG. 1, have nothing in common with the invented dispersion method. The differences are substantiated in that it clearly involves a process which works with a static mixer similar to WO 99/26913 A1. The process similarity between DE 100 43 644 A1 and WO 99/26913 A1 is significantly greater than between DE 100 43644 A1 and the invention. Further, it concerns a multi-step process (page 4, line 50) while the invention concerns a single step process.
As this argumentation shows, the documents presented have nothing to do with the current invention. It is clear that the acid esterification and trans-esterification are performed using the dispersion process. The advantages of the invented process are that the acid esterification and trans-esterification can be conducted each in one stage through the use of suitable equipment; the prevention of a stable dispersion can be achieved through the selection of suitable equipment; and that the phase separation is 90 percent complete in less than 30 minutes through the selection of suitable equipment. Through this process it becomes possible, in combination with suitable separation equipment (coalescence separator, separators, sloped plate clearers, etc.), that the separation can occur in situ.
On the basis of our own inquiries and on the basis of statements from the world's leading producer of dispersion equipment it can be said that the process has, to date, not been used anywhere. The reason for this is that the desired separation cannot take place as a result of incorrect equipment being selected. Hence the process is new.
When considering how to accelerate the acid esterification and trans-esterification reaction, consideration must be given to the fact that the reaction concerns a heterogenic chemical reaction. The reason for this is the fact that the two reactants (fats or oil or free fatty acids and methanol) are only soluble to a very limited extent in each other. In principle, heterogenic reactions are a combination of chemical reactions and mass transport phenomena, however, they are even more complicated for the following reasons:
Since the reacting compounds are present in two phases, the mass transfer to the phase boundary must be considered as transport in two opposing directions. Hydrodynamic phenomena play a significantly more important role in these systems. In most cases chemical and physical process steps take place simultaneously and cannot be analyzed separately. The solubility of components in both phases must be considered because this determines whether the reaction takes place in just one or both phases.
One can apparently accelerate a heterogenic chemical reaction through improving the phase contact significantly. This was revealed even in our first experiment, where we mixed the usual reactants for the production of fat methyl ester and processed the components intensively using a dispersion machine instead of stirring with a propeller or other agitator typical in the chemical industry. The increased surface area for phase contact created by the intensive processing helped cause the acid esterification and trans-esterification reaction to proceed practically to competition in a very short time.
The invented process is characterized by the fact that the fats and oils present in liquid form and perhaps in mixtures with free fatty acids are mixed with commercially pure methyl alcohol in the presence of a basic or acidic catalyst so that the phase contact between both insoluble reactants (fat or oil or fatty acids and methanol) is increased by a suitable procedure, so that the acid esterification or trans-esterification reaction can proceed to completion in a very short time. The apparatus used is able to produce a dispersion with a globule size of about 1 μm.
The anticipated long separation time for the phases, due to the production of a dispersion, surprisingly did not occur. After just ten minutes of trans-esterification, the glycerin phase can be clearly seen, and the separation is already 90 percent complete.
The dispersion equipment must be able to create the desired globule size or globule size distribution by creating sufficient shear force.
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The invention relates to a method for the basic or acidic catalyzed esterification and transesterification of fatty acids, such as oils and fats, i.e. the esters of glycerin with fatty acids, by dispersion of low alcohols, especially methyl alcohol, in the liquidic initial product. The invention is characterized in that the methyl alcohol (or other low alcohols) is fully dispersed in the reaction mixture. The invention also relates to embodiments of said method.
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RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 11/973,747 filed Oct. 10, 2007, which application is a continuation in part of application Ser. No. 11/449,461, filed Jun. 8, 2006, now U.S. Pat. No. 7,261,927 and claims priority under 35 U.S.C. 120 therefrom, which application is a continuation of application Ser. No. 10/056,101, filed Jan. 24, 2002, now U.S. Pat. No. 7,059,856 and claims priority under 35 U.S.C. 120 therefrom, which application claims benefit under 35 U.S.C. 119 (e) of provisional application Ser. No. 60/316,832 filed Aug. 31, 2001 and provisional application Ser. No. 60/402,187 filed Aug. 10, 2002.
FIELD OF THE INVENTION
[0002] This invention relates generally to the construction of a dental or cranial prosthesis that is attached to an implant in the bone of a person's jaw or skull.
BACKGROUND OF THE INVENTION
[0003] Dental implants are a common treatment for the replacement of a missing tooth or missing teeth. An implant is placed into the bone in a person's jaw in a variety of fashions and using a variety of systems. The bone and the implant adhere together in a process known as osseointegration, thus enabling a person to have a new tooth or set of teeth held into position in the jaw utilizing screws to hold them down.
[0004] Many firms manufacture complete systems of dental implants and prosthetic components for subsequent attachment to the implant. In a typical construction, the implant has an axially threaded hole at its top, that is, the proximal end, near the gum surface. After the implant has integrated with the bone, the gum of the implant is opened to expose the tapped hole. Then a transmucosal abutment is attached to the tapped hole of the implant and extends to a level above the gum or substantially to the gum surface. The protruding free end of the abutment is constructed for attachment of a prosthesis. For preventing rotation of the prosthesis, the protruding end of the abutment requires a non-round shape and a hexagon protrusion has been widely used. A recessed hexagon is also popular with some systems. The abutment also includes a central threaded hole concentric with the threaded hole of the implant and extending inward toward the jaw bone.
[0005] A false tooth or frame is provided with a hole therethrough, known in the industry as a chimney, and a non-round recess in its base corresponds in shape to the protruding non-round cross section for the abutment. Thereby, the crown can be connected to the abutment and relative rotation between them is prevented so long as critical contours of the abutment and the recess in the crown are maintained.
[0006] To prevent the crown or bridge from lifting axially from the abutment, a final screw is passed into the chimney opening and engages the tapped hole in the implant by way of the abutment so as to hold the crown axially to the abutment and to the implant. Thus, the crown cannot rotate about the abutment or implant because it is mated with the special contours on the exposed end of the abutment. The abutment is similarly mated to the proximal or outer end of the implant. The crown cannot pull away from the abutment when the screw has been tightened into place.
[0007] Finally, the chimney above the screw is filled with a composite material that hardens and is shaped as part of the crown to look lie a natural tooth.
[0008] There are many variations in construction.
[0009] In an alternative method, the crown is attached directly to a non-round protrusion of the implant and is held directly to the implant by a gold screw without use of an intermediate abutment.
[0010] The implant is intended to be a permanent fixture in the jaw bone. The abutment and crown may be replaced if necessary due to damage or poor fit by gaining access to the screw head by way of the chimney, and backing off the screw so that the crown and abutment or crown to the implant can be separated from the implant. Thus repairs may be made of an abutment and crown with no or little inconvenience.
[0011] Therefore, the fit of an implant with the crown or frame must be perfect. If a prosthesis is placed into the mouth and does not seat correctly, the implant or abutment can be damaged. If an implant is damaged there are not many options for its repair. In cases where there have been a poor fit, the screws have broken inside the abutment requiring the replacement of the abutment. There have been cases where the screw broke inside the implant. The implants cannot be replaced without surgically removing them. Placing a new implant in the same spot is not an advised option.
[0012] Among related patents disclosing dental analogs include U.S. Pat. No. 6,142,782 of Lazarof, which shows a dental analog with annular wings. However, the annular wings do not hinder rotating and therefore misplacement of the analog within the replica cast stone. The annular wings of Lazarof do not intersect with the cast stone material enough to prevent rotation.
[0013] An alternative method for making dental prostheses that does not involve making an impression of the patient's mouth has been recently introduced. It is based on Solid Freeform Fabrication (SFF) which is an industrial prototyping technique whereby 3-D Computer Aided Design (CAD) files describing a part are used to guide the actual fabrication of a solid object by one of a variety of additive methods such as stereolithography, laminated object manufacturing, or fused deposition modelling. U.S. Pat. No. 6,978,188 of Christensen as well as his published patent application 2005/0133955 illustrate how CT scans or MRI scans can be substituted for CAD input to create the files necessary to drive a stereolithography system which can then be used to model human bone features. Medical Modeling LLC has used such a method in their AccuDental™ system to create dental prostheses. Prior to implantation of posts, a scan is made of a patient's jaw. This data is used to create files resulting in an accurate solid translucent resin model of a patient's jaw. Teeth and roots are rendered in a different hue to show clearly how the teeth are anchored in the jaw bone. A dental surgeon then indicates on the jaw model where analogs are to be placed in the model and at what angle they should be inserted. Holes are then drilled into the jaw model to accept the analogs. A surgical guide is thermally formed on top of the implant region of the model engaging the teeth or ridge surface with a close fit and transferring the analog positions accurately. Alternatively, computer generated surgical guides which fit onto a jaw model are used. Surgical guide sleeves at the appropriate angle are then bonded at the analog sites onto the surgical guide. The surgical guide is snapped off the teeth or ridge surface of the model and will be transferred to the patient's mouth and snapped onto the actual teeth or the ridge surface thereby providing accurate guides for drilling the holes for the actual implants while at a remote lab, the prosthesis is being fabricated using the analogs in the jaw model. Surgical guides fit not only on teeth, but can be used on totally edentulous jaws as well engaging soft tissue or bone surface as represented on the jaw model and on the actual patient jaw.
[0014] OBJECTS OF THE INVENTION
[0015] Accordingly, it is the object of the invention to provide a method for insuring the most accurate seating possible of a prosthesis to an abutment or implant in the jaw or skull of a patient.
SUMMARY OF THE INVENTION
[0016] The present invention comprises an implant analog that may include a standard abutment that can be mounted in the dental lab replica of the relevant section of a patient's mouth more securely than heretofore possible. Because of the inventive implant analog, dental labs can now create a crown that will attach more accurately to the implant in the patient's mouth. The analogs of the present invention are desirably longer than the analogs used heretofore and have a pin that projects from the base of the analog. Desirably, the inventive analogs have a side ridge. Moreover, the analog has substantially the same height and dimensions as a conventional implant and abutment. In a preferred embodiment, the analog of the present invention is formed from stainless steel.
[0017] A careful confidential experiment was conducted at New York University of School of Dental Medicine by Dr. C. Jager, Dr. G. R. Goldstein, Dr. E. Hittelman and the Applicant herein. The experiment was designed to compare the performance of a prior art analog of NOBEL BIOCARE®, as shown in FIG. 9 , to that of one embodiment of the present invention, as shown in FIG. 4 . A statistically significant improvement for the present invention was found in terms of framework fit. Also, resistance to applied torque was found to be significantly improved for the analog of this invention.
[0018] The experiment evaluated torque prostheses to laboratory dental implant analogs. The study evaluated the movement of the prior art analog of NOBEL BIOCARE®, as shown in FIG. 9 , and the embodiment shown in FIG. 4 of the present invention. Both were torqued to 20 Ncm in a reinforced type IV die stone. 80 analogs were divided into groups of 4 analogs, including three of the prior art analog shown in FIG. 9 with one of the present invention shown in FIG. 4 . These analogs were embedded in thirty equal blocks of Type IV plaster stone using a prefabricated four unit implant framework. Of the twenty analogs, ten were imbedded in the stone at a depth of four cm and ten were imbedded at a depth of six cm from the implant platform. These groups of ten were then divided into groups of five each, where five of the prior art analogs shown of the present invention in FIG. 9 were torqued to 20 Ncm in each group and five analogs shown in FIG. 4 were torqued to 20 Ncm. The initial framework was used to evaluate the fit of each analog therein. In the 4 mm depth group of the prior art shown in FIG. 9 , two of the five samples (40%) did not allow the framework to fit the analog. In the 6 mm depth of the prior art analogs shown in FIG. 9 , three of the five samples (60%) did not allow the framework to fit. However, all of the dental analogs shown in FIG. 4 of the present invention fit back to the cast.
[0019] As a result, the analogs of the present invention, as shown in FIG. 4 , were able to resist movement within a stone cast when torqued, unlike a significant portion of the prior art dental analogs shown in FIG. 9 .
[0020] Therefore, the dental analogs of the present invention have unexpected, beneficial results not achievable with the dental analogs of the prior art shown in FIG. 9 .
[0021] A method of preparing dental crowns efficiently and accurately, includes the steps of:
a. preparing an analog for a jaw implant supporting a dental crown mounting pin having at least one anti-rotation anchoring projection extending discretely and radially from said pin adjacent a bottom end thereof; b. inserting bottom-end-down said prepared mounting pin into a dental crown casting mold; c. securing said prepared mounting pin temporarily in place within said casting mold; d. adding settable plaster or plastic molding material to said casting mold so as to embed said bottom end of said pin by surrounding said bottom end of said pin with said plaster or plastic molding material; e. allowing said plastic molding material to set and harden with said prepared pin embedded within said molding material; and f. utilizing said embedded mounting pin to make a dental crown.
[0028] Regarding the alternative method described in the previous section using a resin model of a patient's jaw, the analogs used must be resistant to pull-out and rotation as in the method using the stone plaster method. Whether the resin model is a product of stereolithography or otherwise fabricated, it is drilled to accept an analog post. The alternate embodiment of this invention describes analog posts with features for robustly grasping the side walls of these retaining holes in the resin model. Clearly, transverse or radially protruding features cannot be appended to the analog posts since these would not be compatible with insertion.
[0029] The first alternate embodiment uses a single axially attached rod or wing on the lower portion of the analog post. The post is then forced into a slightly undersized hole and resists both twisting and pull-out. A second embodiment using axial rod features uses two such rods on opposite sides of the analog post. A third such embodiment uses three such rods attached every 120 degrees around the bottom end of the post. Any number of such rods can be attached preferably in a symmetric array. The rods can also be enhanced in their gripping action by texturizing their outer surface; alternatively, axial grooves along their length at their outermost position can be added.
[0030] Another embodiment of analog post for hole engagement is made of a larger diameter with a tapered top; a regular array of longitudinal grooves or flutes on the outer side surface engage the hole sides. Yet another embodiment of analog post is one with a knurled outer surface and an annular groove near the bottom end. A final embodiment has male threads along the analog shank which permit screwing into the hole in the resin model much akin to the thread-forming action of a wood screw in a pilot hole in wood.
[0031] When using model based presurgical planning techniques, computer based stereolithography or non-computer methods are used to create an accurate jaw model of resin, plaster, or “stone” or other plastic material. Similarly, surgical guides which form fit onto the jaw model and onto the patient's jaw are also created. Once analogs are inserted into the jaw model, surgical guide sleeves are bonded to the surgical guide at the analog sites using cement or adhesive inside oversized holes in the surgical guide. These must be at the appropriate height, and the orientation must match that of the analogs in the jaw model. Another embodiment of this invention is a set of accessory parts and a method to insure that the alignment of the surgical guide sleeves bonded to the surgical guide will match that of the analog in registration.
[0032] After the analogs are inserted in the jaw model, at each analog site attachments to each analog are made which will orient the surgical guide sleeve rigidly and accurately to represent the orientation of the analog. After all the surgical guide sleeves are thereby attached to the analogs, the surgical guide with oversize holes at each analog site is lowered onto the jaw model and all surgical guide sleeves are bonded to the surgical guide while they are still attached to the analogs. After the cement or adhesive sets, screws are removed from each analog to free the surgical guide with all of the surgical guide sleeves accurately attached. The guide is then used inside the patient's mouth to drill accurate implant holes by using each of the surgical guide sleeves as drill guides.
[0033] The parts attached to each analog in the jaw model are a surgical guide sleeve supported by a form-fitting cylinder support mount, a tube adapter to adjust the height of the guide sleeve above the analog (if necessary), and a screw threaded through the three parts from the top to secure the assembly to the analog below.
[0034] Presurgical planning techniques using accurate whole skull models or models of skull portions other than jaws are also used for cranial and facial reconstruction. Attachments use surgical implants in bone. For example such an approach is used to repair missing bone in the cranium, ear prostheses, and nose prostheses. The procedure starts with an accurate model and a surgical guide with oversize holes in registration with the analogs inserted at sites determined by a surgeon on the skull model. Using the procedure and analog attachments as described above for dental implants, appropriately sized tube adapters, cylinder support mount, surgical guide sleeve and attachment screw are attached to each analog in the skull model. The surgical guide is then fitted carefully atop the protruding elements atop each analog, and the surgical guide sleeves are cemented or otherwise bonded within the oversize holes of the guide capturing the precise angle of the analog in the model. The analog screws are then removed releasing the surgical guide with guide sleeves attached for accurate drilling during the surgical procedure for insertion of the implants.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The present invention can best be understood in connection with the accompanying drawings. It is noted that the invention is not limited to the precise embodiments shown in drawings, in which:
[0036] FIG. 1 is a view of a dental lab replica showing the position of an analog and an abutment;
[0037] FIG. 2 is a view of a lower jaw about to receive a prosthesis and having two implants;
[0038] FIG. 3 is a view of an embodiment of the present invention incorporating a conical abutment;
[0039] FIG. 3A is a partial view taken within the phantom circle of FIG. 3 , shown rotated ninety degrees for clarity;
[0040] FIG. 4 is a view of an embodiment of the present invention incorporating a standard abutment;
[0041] FIG. 5 is a view of an embodiment of the present invention corresponding to an implant with a hexagonal protrusion;
[0042] FIG. 6 is a view of an embodiment of the present invention corresponding to a large diameter implant with a hexagonal recess;
[0043] FIG. 7 is a side elevation view in partial cross section of an embodiment of the present invention corresponding to an implant with a hexagonal recess;
[0044] FIG. 7A is a top plan view thereof;
[0045] FIG. 8 shows a conventional impression coping with depth indications from 2-5 mm;
[0046] FIG. 9 shows a conventional prior art fixture replica, or analog, which is replaced by analog according to the present invention;
[0047] FIG. 10 shows the placement of a fixture replica, either a conventional or according to the present invention, in the lab replica that is to be secured to an abutment and a crown via a guide pin;
[0048] FIG. 11 shows the attachment of a fixture replica, either a conventional or according to the present invention, to an impression coping that is fixed in an impression of the relevant section of a patient's mouth prior to the casting of the lab replica;
[0049] FIG. 12 shows a dental impression tray modified to provide access to the impression coping that is secured to the implant in a patient's mouth by a guide pin;
[0050] FIG. 13 shows the excess material around the impression coping in a tray containing impression material, the impression coping being secured to the implant in the patient's mouth by a guide pin;
[0051] FIG. 14 shows a means of securing the impression coping to the tray containing the impression material with an acrylic resin;
[0052] FIG. 15 shows the impression containing the impression coping;
[0053] FIG. 16 is a top view of an engagement plate of this invention which is used to provide improved anchorage for a conventional analog;
[0054] FIG. 17 is an exploded side view of the engagement plate of FIG. 16 attached to a conventional analog;
[0055] FIG. 18 is a perspective view of an analog body with a transverse tube configured to screw into a variety of abutments;
[0056] FIG. 19 is a perspective view of an analog body with transverse wings;
[0057] FIG. 20 is a bottom view of an analog body with transverse wings;
[0058] FIG. 21 is a perspective view of an analog body with coplanar transverse tubes at right angles;
[0059] FIG. 22 is a perspective view of an analog body with non-coplanar oblique tubes;
[0060] FIG. 23 is a bottom view of an analog body with eight co-planar transverse tube segments;
[0061] FIG. 24 is a perspective view of an analog body with angled spikes;
[0062] FIG. 25 is a side elevation of an analog body with serrated side extensions;
[0063] FIG. 26 is a side elevation of an analog body with four serrated and perforated side extensions;
[0064] FIG. 27 is a perspective view of an analog body with looped side extensions;
[0065] FIG. 28 depicts a cross-sectional view of a protrusion in an analog having a substantially oval shape 2802 ;
[0066] FIG. 29 depicts a cross-sectional view of a protrusion in an analog having a substantially triangular shape;
[0067] FIG. 30 depicts a cross-sectional view of a protrusion in an analog having a substantially square shape;
[0068] FIG. 31 depicts a cross-sectional view of a protrusion in an analog having a substantially rectangular shape; and,
[0069] FIG. 32 depicts a cross-sectional view of a protrusion in an analog having a substantially hexagonal shape 3202 .
[0070] FIG. 33 is a (prior art) perspective view of a plastic resin jaw model and a surgical guide illustrating the relation between the two.
[0071] FIG. 34 is a (prior art) perspective view of a resin jaw model with analog posts installed.
[0072] FIG. 35 is a perspective view of an analog post of this invention with a single side rod or wing attached.
[0073] FIG. 36 is a perspective view of an analog post with two axial wings.
[0074] FIG. 37 is a top plan view of an analog post with three symmetrically attached side rods or wings.
[0075] FIG. 38 is a side elevation detail showing texturing on the side of a rod or wing.
[0076] FIG. 39 is a perspective detail of showing a longitudinal groove on the side of a rod.
[0077] FIG. 40 is a perspective view of a fluted analog post.
[0078] FIG. 41 is a perspective view of a knurled analog post with an annular groove adjacent the bottom end.
[0079] FIG. 42 is a side elevation of an analog post with male thread on its shank surface.
[0080] FIG. 43 is a perspective view of a cylinder sleeve support mount.
[0081] FIG. 44 is a side crossection of the mount of FIG. 43 .
[0082] FIG. 45 is a side crossection of the cylinder sleeve support mount inside a surgical guide sleeve to show the fit of the two parts.
[0083] FIG. 46 is a side elevation of a retaining shoulder screw.
[0084] FIG. 47 is a perspective view of a short tube adapter.
[0085] FIG. 48 is a perspective view of a medium height tube adapter.
[0086] FIG. 49 is a perspective view of a larger diameter and taller tube adapter.
[0087] FIG. 50 is a side exploded view of the five parts from top screw to bottom analog.
[0088] FIG. 51 is a side detail crossection of two assemblies attached to two analogs in a jaw model with a section of surgical guide in registration with the two analogs but spaced apart for clarity.
[0089] FIG. 52 is a perspective view of an accurate skull model showing analogs inserted for cranial repair, ear prosthesis, and nose prosthesis with accurate surgical guide for the cranial repair.
DETAILED DESCRIPTION OF THE INVENTION
[0090] Simplified, the construction of the prosthesis begins after the osseointegration of the implant with the dentist making an impression of the relevant section of the patient's mouth. When constructing the prosthesis, the dentist makes an impression including an impression coping. Desirably, the impression material employed is hard and elastic when set, such as the materials sold under the trade names IMPRAGUM, EXPRESS and PRESIDENT.
[0091] Once the impression material hardens, the tray containing the impression is sent to a dental lab where the prosthesis is made. The dental lab uses this impression to make a replica of the relevant section of the patient's mouth. Typically, the replica is made of gypsum to form plaster, and is made to reproduce the milieu into which the prosthesis is to fit, including, for example, any hexagonal protrusion or recession in the abutment the dentist is using. Alternately, the replica can also be made of plastic, such as resin.
[0092] For example, FIG. 1 shows a view of dental lab replica 130 with analog 120 and abutment 110 .
[0093] Moreover, FIG. 2 shows an actual patient lower jaw with two implants 220 , a three tooth prosthesis 210 and screws 230 to retain prosthesis 210 in implants 220 .
[0094] In making the impression, the impression coping is attached to the implant in the same way the final prosthesis will attach. The impression coping rests flush on top of the implant, or implant and abutment, with a guide screw passing through and into the implant. The impression coping remains in the impression in the same position that was in the mouth and the guide screw must be removed before the impression can be removed from the patient's mouth.
[0095] In making the dental lab jaw model, or replica, the analog is attached to the impression coping with a guide screw going through the impression coping and into the analog. All of the teeth in the relevant portion of the mouth are replicated in the model, which desirably is made of gypsum. The goal is to have the analog in the replica in the position that corresponds to the position of the implant in the patient's mouth, including the orientation of any protrusion or recess.
[0096] The present day tools offered by the implant manufacturers utilize brass or stainless steel analog.
[0097] The configuration of the prior art analogs replicates the internal thread dimension of the implant or abutment and copies the shape of the external or internal hexagon. However, the outside diameter of a prior art analog maintains a shape that is not consistent with the needs of the dentist or technician in constructing the prosthesis. Conventional analogs are too small and are removed from the gypsum model too easily. Moreover, the exterior surface of conventional analogs are too smooth which permits the analog, and thus the prosthesis, to rotate in the model during construction of the prosthesis. Such rotation moves the hexagonal position of the prosthesis into a position that does not match the corresponding position of the implant in the patient's mouth.
[0098] In contrast to the prior art conventional, easily rotatable and dislodgable dental analogs, the present invention is a new analog that will not allow any rotation in the gypsum model. In a preferred embodiment, as shown in FIGS. 3 and 3A , the analog 320 of the present invention is substantially longer and has a unique feature of a transverse pin 312 or other protruding geometric shaped member extending through hole 314 in its side.
[0099] FIG. 4 shows analog 420 with abutment 22 and hole 414 for insertion of a pin therein, similar to pin 312 of FIG. 3A .
[0100] As shown in FIGS. 5 , 6 , and 7 , these dental analogs 520 , 620 and 720 of the present invention are preferably ridged with annular recesses, these dental analogs 520 , 620 and 720 on their respective sides to gain better retention inside the gypsum model.
[0101] Analogs 420 , 520 , 620 and 720 have respective pins (not shown) similar to transverse pin 312 of analog 320 of FIG. 3A . These pins 312 are located at the base of the respective analogs 320 , 420 , 520 , 620 and 720 to lock the position. These transverse pins 312 prevent horizontal, vertical or cylindrical movement of the analogs 320 , 420 , 520 , 620 , and 720 within the model.
[0102] Conventional implants have a standardized system of heights, measurements and dimension for implants and abutments. The respective inventive analogs 320 , 420 , 520 , 620 , 720 of the present invention can have a shape which incorporates a conical abutment 322 ( FIGS. 3 and 3A ), a standard abutment 422 ( FIG. 4 ), a hexagonal protrusion 522 ( FIG. 5 ), a large hexagonal recess 622 ( FIG. 6 ) or a hexagonal recess 722 ( FIG. 7 ), as these terms are used in the dental industry. For example, FIGS. 28-32 depict cross-sectional views of protrusion embodiments having various shapes. Illustratively, FIGS. 28-32 are described with respect to protrusion 2012 however that description is not intended in any way to limit the scope of the invention. For example, it is appreciated that extensions 2051 may in various other embodiments have the shapes depicted in FIGS. 28-32 . FIG. 28 depicts a cross-sectional view of protrusion 2012 having a substantially oval shape 2802 . FIG. 29 depicts a cross-sectional view of protrusion 2012 having a substantially triangular shape 2902 . FIG. 30 depicts a cross-sectional view of protrusion 2012 having a substantially square shape 3002 . FIG. 31 depicts a cross-sectional view of protrusion 2012 having a substantially rectangular shape 3102 . FIG. 32 depicts a cross-sectional view of protrusion 2012 having a substantially hexagonal shape 3202 .
[0103] Analogs 520 , 620 and 720 also bear annular grooves 516 , 616 and 716 .
[0104] The analogs 320 , 420 , 520 , 620 and 720 of the present invention are machined to specified mechanical tolerances. In particular, the internal thread of the inventive analogs are closer to the threads of actual implants and abutment. This closer approximation to the actual implants insures that the guide screw goes into the implant the same number of turns the guide screw goes into the analog, and maintains the prosthesis in the same position relative to the patient's mouth as the prosthesis had with respect to the replica. The internal or external hexagon is also closer in dimensions to the actual implant. As a result, the prosthesis will fit on the analog and on the actual implant or abutment in the manner intended.
[0105] Another complication in the construction of dental analogs is that it is often necessary to construct a large frame using soldered connections. The present methods of soldering require a duplicate model of high heat tolerance gypsum investment be made with the present day analogs. The frame is soldered on that model. The success rate of these solder connections is far lower than expected in the industry. The present invention allows a more accurate solder connection. The present invention also holds better in the invested model and keeps the analogs from moving in the model.
Example
[0106] In the single tooth prosthetic work, the impression is taken from the fixture level. As shown in FIG. 8 , one type of conventional impression coping 800 has an internal hexagon at the base, which corresponds to the hexagon of the abutment. The coping has depth indications for assessment of proper abutment size, 2 mm, 3 mm, 4 mm, and 5 mm. The upper margin of the abutment-like part indicates 6 mm. The impression coping is typically made of titanium.
[0107] The impression coping is used together with a special guide pin (e.g., a DCA 098), 850 , for a single tooth (the guide pin used to secure the prosthesis to the implant typically has a different thread).
[0108] Typically, in the laboratory, any undercuts of the impression coping are blocked out before pouring the impression (including the depth indications). This blocking is especially important when the longest abutment is used. This precaution prevents fracturing the cast when separating the model and the impression coping.
[0109] During the Laboratory procedure, an analog, for example a conventional prior art analog 900 shown in FIG. 9 , or an analog of the present invention such as the analogs of FIGS. 3-7 , is used in the laboratory jaw model, or replica, to represent the implant in the working cast. This is illustrated in FIG. 10 where analog 1000 is set in the laboratory jaw model, or replica, 1010 , and the abutment 1020 and crown 1030 are secured to the jaw model by guide pin 1040 . The analog has the same top hexagon and internal thread as the implant. In contrast to the stainless steel analogs of the present invention, conventionally, analogs were typically made of nickel-plated brass.
[0110] FIG. 11 shows an impression 1100 containing an impression coping 800 being attached to an analog 1000 via guide pin 1040 . Once the analog 1000 is secured to the impression coping 800 by the guide pin 1040 , the impression 1100 is used to cast the laboratory jaw model, or replica, from stone, such as gypsum.
[0111] The impression 1100 containing the impression coping 800 can be prepared in any conventional manner. For example, as shown in FIG. 12 , one can make a hole 1200 in an acrylic-resin stock tray 1210 for access to the impression coping 800 which is secured to the implant by the guide screw.
[0112] FIG. 13 shows tray 1210 loaded with an impression material of choice 1300 in the mouth with impression coping 800 secured to implant 120 within the patient's jaw 1310 .
[0113] FIG. 13 also shows the removal of any excess material around impression coping 800 once impression material 1300 has set.
[0114] Impression coping 800 is then secured to tray 1210 with auto-polymerizing acrylic resin 1400 . The orientation of the hexagonal head of the implant 120 should be maintained when the impression 1100 is removed. Next, guide pin 850 is unscrewed and impression 1100 is carefully removed form the patient's mouth.
[0115] As noted before, FIGS. 3-7 show different embodiments of the dental analogs 320 , 420 , 520 , 620 and 720 of the present invention each using a transverse rod pin 312 or tube within hole 314 , 414 , 514 , 614 , or 714 , in the base section of each analog 320 , 420 , 520 , 620 , or 720 to enhance the anchoring of the analog in the plaster of the replica. Each of the different embodiments uses a different style of abutment 322 , 422 , 522 , 622 , or 722 to match that which the dentist had used in the patient's actual implant.
[0116] For example, FIG. 3 shows a conical abutment 322 for analog rod 320 and FIG. 4 shows a standard recessed abutment 422 for analog rod 420 . FIG. 5 shows an abutment 522 with a hexagonal protrusion for analog rod 520 , FIG. 6 shows a large diameter abutment 622 with a hexagonal recess, for analog rod 620 , and FIG. 7 shows an abutment 722 with a hexagonal recess for analog rod 720 .
[0117] FIG. 16 shows another embodiment of this invention in the form of a flat engagement plate 2000 which is used to provide enhanced anchoring of a standard prior art analog 900 (see FIG. 9 ) in the replica plaster.
[0118] As shown in FIG. 17 , the conventional analog 2003 is inserted through central hole 2001 and adhesively bonded 2004 at an oblique angle. Perforations 2002 enhance adhesion to immobilize plate 2000 in replica plaster. An optional hollow sleeve 2005 can be used to extend the vertical height of analog 2003 , to further promote its anchoring within the replica plaster.
[0119] It is further noted that optional removable hollow sleeve 2005 can also have any of the protrusions shown in the other drawing figures, such as protrusion rods 2012 of FIG. 18 or FIG. 21 , protrusion 2022 of FIG. 19 , protrusion wings 2030 of FIG. 23 , protrusion barbs 2032 , protrusion wings 2035 of FIG. 25 , protrusion wings 2040 of FIG. 26 or protruding loops 2051 of FIG. 27 .
[0120] FIG. 18 shows the concept for a series of additional embodiments of analogs of this invention which use a tubular body 2010 with external threads 2011 at the top end. These threads screw into mating female threads on a series of abutments 2013 (here illustrated as a conical abutment) which are supplied to match the style and size actually implanted in the patient's jaw.
[0121] Therefore, analogs of this general category of embodiments can be matched with a variety of abutments 322 , 422 , 522 , 622 , or 722 (as described in FIGS. 3-7 ). The analog 2010 with conical abutment 2013 of FIG. 18 , similar to analog 320 with a conical abutment 322 , uses a transverse tube or rod 2012 to aid in anchoring body 2010 in plaster. Slotted body 2020 as shown in FIG. 19 accepts two rectangular wings 2021 (as shown in bottom view of FIG. 20 ) with perforations 2022 as yet another embodiment to resist rotation within, and extraction from, the replica plaster.
[0122] The embodiment shown in FIG. 21 uses coplanar radial transverse tubes 2012 at right angles to each other to provide anchorage.
[0123] The embodiment shown in FIG. 22 uses two oblique tubes 2012 which penetrate body 2010 as anchorage.
[0124] The bottom view of the embodiment of FIG. 23 shows eight equally spaced tubular segments 2030 attached to body 2010 to provide anchorage in replica plaster.
[0125] FIG. 24 shows an embodiment of an analog using tubular body 2031 with upward angled spikes 2032 in two rows to provide anchorage.
[0126] The embodiment of FIG. 25 shows slotted body 2020 with a pair of serrated triangular wings 2035 to provide anchorage in the replica plaster.
[0127] FIG. 26 shows an embodiment of an analog with body 2039 with four slots accommodating four perforated and serrated triangular wings 2040 to rigidly anchor it to the plaster of a replica.
[0128] Furthermore, FIG. 27 shows an embodiment of an analog using tubular body 2050 with one or more outwardly extending looped extensions 2051 to promote anchorage.
[0129] FIG. 33 illustrates some features of the alternate method incorporating a resin jaw model to fabricate a prosthesis. Resin jaw model 4000 is translucent and shows teeth in a contrasting hue in the jaw. Marks 4001 placed by a dental surgeon indicate the location for the center of each analog hole to be drilled. Marks 4002 illustrate the proper angle for such analog retaining holes. Surgical guide 4010 is shown “popped-off” the teeth of jaw model 4000 over which it is formed by a thermal process. Surgical guide sleeves 4011 are shown attached at the proper angles to drill the implant post holes in the patient's jaw. Three analog posts 4020 are shown installed in jaw model 4000 in FIG. 34 .
[0130] The analog posts in FIGS. 35-42 all have features to resist pull-out and rotation when installed in holes of a resin jaw model. FIG. 35 shows analog post 4030 with one side rod or wing 4032 . FIG. 36 shows analog post 4035 with two wings 4032 attached to opposite sides of post shank 4031 . FIG. 37 shows a symmetric attachment of three side wings 4032 from a top view. In all cases, these analog posts are forced inside a hole slightly smaller than would normally accommodate an analog shank with its side wings. The wings will embed into the sides of the retaining holes. FIG. 38 shows texturing 4046 as applied to outer edge of side wing 4032 to aid in retention. FIG. 39 shows groove 4051 along the length of side wing 4032 which can be used for the same purpose alternatively.
[0131] In lieu of side wings or attached rods, FIG. 40 shows fluted analog post 4055 with longitudinal grooves 4057 and a tapered top end 4056 which would be below the top surface of the retaining hole. FIG. 41 illustrates yet another embodiment of analog post 4060 which is knurled 4061 along its entire outer shank. An annular groove 4062 also enhances pull-out resistance. The analog post 4065 of FIG. 42 is screwed into an analog hole via tapered bottom 4066 and thread-forming male threads 4067 along its shank.
[0132] FIGS. 43-51 illustrate a presurgical method for aligning surgical guide sleeves in a surgical guide so they can be bonded in the proper orientation for use in a patient's mouth to accurately drill holes for accepting implant posts. Three parts are used for this. FIG. 43 shows a cylinder sleeve support mount 4080 with center hole 4083 , shank 4082 and flange 4081 . FIG. 44 shows the key dimensions of the various parts while FIG. 45 shows the fit of support mount 4080 within surgical guide sleeve 4011 . The O.D. of flange 4081 (DD) matches the O.D. of guide sleeve 4011 . Shank 4082 of diameter D fits in a close clearance fit inside guide sleeve 4011 which is slightly longer (LL) than height dimension L. This is to insure rigid locking by shoulder screw 4090 of FIG. 46 which has a head 4091 also of dimension DD; threads 4093 engage the central threaded hole of an analog. Note that shoulder 4092 diameter d 1 is slightly smaller (close clearance fit) than hole of diameter d in support mount 4080 . FIGS. 47-49 illustrate three different heights h 1 , h 2 , and h 3 of tube adapters 4100 , 4110 , and 4120 respectively which match the outside diameter (O.D.) of an analog. Analog 4120 would be used with a larger diameter analog. Many such adapters would be made available to adjust the height of the surgical guide sleeve above the top of an analog as required. FIG. 50 shows an exploded view of the assembly of the five parts. Although analog 4065 of the screw-in variety is shown, any analog would usable with this method. Referring to FIG. 51 , side crossection detail 4150 of the jaw model shows two analogs, one 4065 screw type and one knurled type 4060 , rigidly installed. The method requires that the progression of parts as shown in FIG. 50 is assembled and accurately and rigidly held in place by tightening screw 4090 in each analog beneath. Note that analog 4065 has short tube adapter 4100 atop while analog 4060 uses a taller 4110 adapter. In FIG. 51 , the flange portion of each cylinder sleeve support mount 4080 is visible atop the tube adapter while surgical sleeve guide 4011 is captured and guided between the head 4091 of screw 4090 and flange 4081 of mounts 4080 . Note also that analogs 4065 and 4060 are tilted away from each other (not aligned) as required by the desired positioning in the jaw model. A section of surgical guide 4160 is shown above jaw model 4150 with oversize holes 4161 in registration with analogs 4065 and 4060 . After the surgical guide 4160 is carefully aligned with jaw model 4150 , surgical sleeve guides 4011 will be within holes 4161 where they will be bonded to surgical guide 4160 . After the adhesive or cement cures, screws 4090 will be removed thereby releasing surgical guide 4160 from jaw model 4150 with surgical sleeve guides accurately attached. Analogs 4065 and 4060 will then be used by the dental lab for fabrication of appropriate prostheses. When the prostheses are made (or before), surgical guide 4160 is returned to the dental surgeon. It is used to accurately drill implant post holes in the patient's jaw using the surgical sleeve guides as drill guides to replicate the orientation of the analogs in the jaw model for a close fit of the prostheses.
[0133] FIG. 52 shows a skull model 4200 which is typically created using stereolithography. Analog group 4215 (8 analogs) placed around cranial injury area 4210 will be used to plan the surgery. Also shown are a group of five analogs 4240 which will be used to attach an ear prosthesis, and a pair of analogs 4260 for a nose prosthesis. All three sites will also require accurate surgical guides for these procedures. One of these, 4220 for the cranial repair, is shown in the figure. Note the oversize holes 4215 in registration with the array of analogs 4215 . Two exemplary surgical guide sleeves 4227 are shown indicating that a total of 8 such sleeves will have to be accurately bonded inside holes 4225 . To facilitate this step, the parts shown in FIG. 50 , namely tube adapter 4100 , support mount 4080 , surgical guide sleeve 4011 ( 4227 in FIG. 52 ), and screw 4090 , are assembled in the order shown atop each analog 4215 . Then surgical guide 4220 is placed accurately over the repair area 4210 with guide sleeves 4227 inside holes 4225 . Sleeves 4227 are then bonded to guide 4220 . All screws 4090 are then removed thereby releasing surgical guide 4220 with accurately bonded guide sleeves 4227 ; the guide sleeves will be used for drilling holes for the actual implants in the surgical procedure. Surgical guides for the ear and nose prostheses (not shown) would be similarly prepared.
[0134] In the foregoing description, certain terms and visual depictions are used to illustrate the preferred embodiment. However, no unnecessary limitations are to be construed by the terms used or illustrations depicted, beyond what is shown in the prior art, since the terms and illustrations are exemplary only, and are not meant to limit the scope of the present invention.
[0135] It is further known that other modifications may be made to the present invention without departing from the scope of the invention, as noted in the appended Claims.
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Pre-surgical planning for cranial and facial reconstruction includes preparing a computer generated jaw or skull model for determining a locational position for a dental implant, a surgical bone implant to repair missing bone in the cranium, install ear prostheses, and/or install nose prostheses. The computer generated jaw or skull model is made from medical imagery and computer aided design. A surgical guide is prepared with oversize holes in registration with analogs for the dental or surgical bone implants to be inserted in the jaw or cranial skull model. The surgical guide is fitted atop each analog, and bonded to the jaw or skull model at a predetermined angle of the analog in the jaw or skull. The surgical guide is removed and attached to the jaw or skull of a patient for accurate drilling for insertion of the implants into the jaw or skull of the patient.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is the U.S. national stage application of International Application PCT/CN2013/071769, filed Feb. 22, 2013, which international application was published on Aug. 29, 2013, as International Publication WO2013/123893. The International Application claims priority of Chinese Patent Application 201210044359.X, filed Feb. 24, 2012, the contents of which are incorporated herein by reference in their entireties.
FIELD OF INVENTION
[0002] The present invention relates to a novel method for preparing pharmaceutical intermediates, particularly relates to a novel method for preparing (S)-(2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl substituted compound, an important intermediate for anticoagulant, Rivaroxaban.
PRIOR ARTS
[0003] Rivaroxaban, 5-chloro-N-(((5S)-2-oxo-3-(4-(3-oxomorpholino-4-yl)phenyl)-1,3-oxazolidin-5-yl)methyl)thiophene-2-carboxamide, which has the following structure (V):
[0000]
[0004] Rivaroxaban, developed by Bayer, is an orally active coagulation Factor Xa inhibitor for treating thrombus. It is a direct Factor Xa inhibitor with high selection, and can interrupt the intrinsic and extrinsic pathway of the blood coagulation cascade by inhibiting coagulation Factor Xa, which finally inhibits the formation of thrombin thrombus.
[0005] (S)-(2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl substituted compound with the structure (I) is an important intermediate for preparing Rivaroxaban. This intermediate reacts with 5-chlorothiophene-2-formyl chloride to prepare Rivaroxaban after removing the protecting group.
[0006] Current synthesis routes for Rivaroxaban are described as follow:
[0007] 1, WO0147919 disclosed the following synthesis route:
[0000]
[0008] The first step of the route is complicated to operate: (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione is added in batches, and at the same time, the product has to be filtered out constantly, or disubstituted product is easy to be formed which would influence the purity of the product.
[0009] 2, US20110034465 disclosed the following synthesis route:
[0000]
[0010] The yield of the first step in this route is not very high, the disubstituted product is easily formed, meanwhile, the configuration of the product of the first step is prone to be inversed and the formed isomer is difficult to separate, which will get into the following reactions until the final product Rivaroxaban, and influence its quality.
[0011] 3, U.S. Pat. No. 7,816,355 disclosed the following synthesis route:
[0000]
[0012] This route is short, but dangerous reagents are used during the process, such as methyl chloroformate and sodium hydride etc., and the yield of cyclization is low, which is not suitable for production in an industrial scale.
[0013] 4, WO2005068456 and DE10300111 disclosed the following synthesis route:
[0000]
[0014] 3-Aminopropane-1,2-diol, the raw material for the first step of the route, is expensive and hypertoxic phosgene is used in the process of cyclization, which is not suitable for production in an industrial scale.
[0015] 5, WO2011098501 disclosed two following synthesis routes:
[0000]
[0016] In the first route, Rivaroxaban is prepared by isocyanate and (S)-5-chloro-N-(oxiran-2-ylmethyl)thiophene-2-carboxamide via cyclization directly, but (S)-5-chloro-N-(oxiran-2-ylmethyl)thiophene-2-carboxamide is expensive and the yield is low, which is only 55%. The yield of the step of cyclization with triphosgene in the second route is much lower, which is only 21.1%.
Content of the Present Invention
[0017] The technical problem to be solved in the present invention is for overcoming tough preparation condition, low yield, difficult byproduct separation, high cost, complicated process and disadvantages in production in an industrial scale to provide a method for preparing Rivaroxaban intermediate. The method provided in the present invention has mild preparation condition, simple process, low cost, high yield, easy purification process for the product, which is suitable for production in an industrial scale.
[0018] The present invention provides a method for preparing Rivaroxaban intermediate I, comprising: in a non-protonic solvent, under the effect of lewis acid, performing cyclization reaction with 4-(4-isocyanatophenyl)morpholin-3-one (II) and (S)-epoxy compound (III), reaction temperature ranging from 20° C. to 160° C.;
[0000]
[0019] wherein R is an amino substituted by an amino protecting group.
[0020] The non-protonic solvent is selected from the group consisting of esters, ketones, C 6 ˜C 10 alkanes, halohydrocarbons, ethers, substituted benzene, dioxane, tetrahydrofuran, N,N-dimethylamide, nitriles and sulfoxides, preferably ethyl acetate, butyl acetate, isoamyl acetate, toluene, xylene, chlorobenzene, o-dichlorobenzene, tetrahydrofuran, dichoromethane, N,N-dimethylformamide, C 6-8 straight-chain or branched-chain alkanes, acetone, 1,4-dioxane and acetonitrile, more preferably ethyl acetate, isoamyl acetate, butyl acetate, xylene, N,N-dimethylformamide and tetrahydrofuran. Preferably, an amount of the non-protonic solvent is 10˜30 mL per gram of compound II, more preferably, 15˜25 mL per gram of compound II and most preferably, 18˜20 mL per gram of compound II.
[0021] The lewis acid is preferably selected from the group consisting of lithium bromide, magnesium bromide, lithium chloride, magnesium chloride, magnesium iodide, lithium iodide, lithium chloride, zinc chloride, tetra-n-butylammonium bromide and tetra-n-butylammonium chloride, more preferably, lithium bromide, magnesium bromide, n-butylammonium bromide and magnesium iodide. The molar ratio of the lewis acid to compound II is preferably 0.02˜0.18, more preferably 0.07˜0.13, and most preferably 0.09˜0.11.
[0022] The amino protecting group is acceptable in the art. The amino substituted by an amino protecting group is preferably selected from one of the following group:
[0000]
[0023] wherein, R 1 is hydrogen or a C 1-6 straight-chain or branched-chain alkyl, Boc is a tert-butoxycarbonyl group, Bn is a benzyl group and Cbz is a benzyloxycarbonyl group.
[0024] More preferably, the amino substituted by an amino protecting group is phthalimido, having the structure:
[0000]
[0025] The molar ratio of the (S)-epoxy compound (III) to 4-(4-isocyanatophenyl)morpholin-3-one (II) is preferably 0.8˜1.3, more preferably 1.05˜1.15, and most preferably 1.1.
[0026] The reaction temperature preferably ranges from 100° C. to 140° C., and more preferably from 115° C. to 125° C.
[0027] The process of the cyclization reaction can be monitored by TLC or HPLC. Generally, the reaction is regarded as finishing when compound II disappears.
[0028] After the cyclization reaction, post-processing can be performed to obtain pure Rivaroxaban intermediate. The post-processing preferably comprises: filtrating the reaction system. Preferably, the filtration is suction filtration.
[0029] The Rivaroxaban intermediate I is an important intermediate in preparing Rivaroxaban, which can prepare Rivaroxaban though reacting with 5-chlorothiophene-2-formyl chloride after removing the amino protecting group. The reaction formula is illustrated as:
[0000]
[0030] In the present invention, the preferred conditions of the preparation method can be any combination, i.e. preferred examples of the present invention is obtained.
[0031] Compound (II) can be prepared according to the method disclosed in WO2011098501.
[0032] Compound (III) can be prepared according to the method disclosed in EP1403267.
[0033] The raw materials used in the present invention can be commercial available.
[0034] The positive effects of the present invention rely in that the method in the present invention has several advantages, such as simple process, mild preparation condition, high total yield, high purity of the product, and compared to other routes described elsewhere, no dangerous reagent is used, such as butyllithium and sodium azide. Furthermore, no tough conditions are required like low-temperature. Therefore, the method provided in the present invention is suitable for production in an industrial scale.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] The following examples further illustrate the present invention, but the present invention is not limited thereto. The experiments without giving the specific reaction conditions could be performed under the guidance of conventional approach or product datasheet.
Reference Embodiment 1
Preparation of 4-(4-isocyanatophenyl)morpholin-3-one (II)
[0036] A solution of 4-(4-anilino)morpholin-3-one in isoamyl acetate (3.64 g, 100 mL) was added dropwise in a solution of triphosgene in isoamyl acetate (3.49 g, 10 mL), refluxed for 2 h, and white solid (3.77 g, 91.3%) was obtained by rotary evaporation under reduced pressure.
[0037] ESI-MS (m/z): 219 (M+H); IR (cm −1 ), 2270 (N═C≡O);
[0038] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.75 (m, 2H), 4.02 (m, 2H), 4.30 (s, 2H), 7.13 (d, 1H), 7.32 (d, 1H), 7.40 (d, 1H), 7.58 (d, 1H).
Embodiment 1
Preparation of (S)-2-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0039]
[0040] (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.87 g, 19.06 mmol, 1.1 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in ethyl acetate (70 mL) respectively, lithium bromide (0.15 g, 1.74 mmol) was added at 20° C., reacted for 12 h. White solid was obtained by filtration (6.11 g, yield: 83.86%).
[0041] ESI-MS (m/z): 422 (M+H), 444 (M+Na);
[0042] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H);
[0043] HPLC: 99.10%.
Embodiment 2
Preparation of (S)-2-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0044] (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.51 g, 17.29 mmol, 1.0 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in toluene (70 mL) respectively and heated to 100° C. Then lithium bromide (0.15 g, 1.74 mmol) was added, and the mixture was reacted for 4 h. White solid was obtained by filtration (6.50 g, yield: 89.28%).
[0045] ESI-MS (m/z): 422 (M+H), 444 (M+Na);
[0046] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H).
[0047] HPLC: 99.10%.
Embodiment 3
Preparation of (S)-2-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0048] (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.87 g, 19.06 mmol, 1.1 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in chlorobenzene (70 mL) respectively, then heated to 115° C. and lithium iodide (0.23 g, 1.72 mmol) was added. The mixture was reacted for 4 h, white solid was obtained by filtration (6.85 g, yield: 94.09%).
[0049] ESI-MS (m/z): 422 (M+H), 444 (M+Na);
[0050] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H);
[0051] HPLC: 98.91%.
Embodiment 4
Preparation of (S)-2 ((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0052] (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (4.56 g, 22.46 mmol, 1.3 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in isoamyl acetate (70 mL) respectively, and heated to 120° C. Then magnesium chloride (0.12 g, 1.28 mmol) was added, the mixture was reacted for 4 h, white solid was obtained by filtration (6.97 g, yield: 95.5%).
[0053] ESI-MS (m/z): 422 (M+H), 444 (M+Na);
[0054] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H);
[0055] HPLC: 98.82%.
Embodiment 5
Preparation of (S)-2((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0056] (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.87 g, 19.06 mmol, 1.1 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in xylenen (70 mL) respectively and heated to 125° C. Then lithium bromide (0.15 g, 1.74 mmol) was added, the mixture was reacted for 4 h, white solid was obtained by filtration (6.89 g, yield: 94.64%).
[0057] ESI-MS (m/z): 422 (M+H), 444 (M+Na);
[0058] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H);
[0059] HPLC: 99.04%.
Embodiment 6
Preparation of (S)-2-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0060] (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.87 g, 19.06 mmol, 1.1 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in N,N-dimethylformamide (70 mL) respectively and heated to 140° C. Then lithium bromide (0.15 g, 1.74 mmol) was added, the mixture was reacted for 4 h, white solid was obtained by filtration (6.68 g, yield: 91.75%).
[0061] ESI-MS (m/z): 422 (M+H), 444 (M+Na);
[0062] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H);
[0063] HPLC: 98.70%.
Embodiment 7
Preparation of (S)-2-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0064] (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.87 g, 19.06 mmol, 1.1 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in o-dichlorobenzene (70 mL) respectively and heated to 160° C. Then lithium bromide (0.15 g, 1.74 mmol) was added, the mixture was reacted for 4 h, white solid was obtained by filtration (6.46 g, yield: 88.66%).
[0065] ESI-MS (m/z): 422 (M+H), 444 (M+Na);
[0066] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H);
[0067] HPLC: 98.29%.
Embodiment 8
Preparation of (S)-2-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0068] (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.69 g, 18.14 mmol, 1.05 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in butyl acetate (70 mL) respectively, heated to 120° C. Then a solution of magnesium iodide in diethyl ether (0.3 mmol, 0.3 mL) was added, the mixture was reacted for 4 h, white solid was obtained by filtration (6.88 g yield: 94.50%).
[0069] ESI-MS (m/z): 422 (M+H), 444 (M+Na);
[0070] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H).
[0071] HPLC: 98.85%.
Embodiment 9
Preparation of (S)-2-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0072] (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.87 g, 19.06 mmol, 1.1 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in tetrahydrofuran (70 mL) respectively and then heated to reflux. Then lithium bromide (0.15 g, 1.74 mmol) was added, the mixture was reacted for 4 h, white solid was obtained by filtration (6.45 g, yield: 88.4%).
[0073] ESI-MS (m/z): 422 (M+H), 444 (M+Na);
[0074] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H);
[0075] HPLC: 99.11%.
Embodiment 10
Preparation of (S)-2-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0076] (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.87 g, 19.06 mmol, 1.1 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in n-heptane (70 mL) respectively, and heated to reflux. Lithium bromide (0.15 g, 1.74 mmol) was added, the mixture was reacted for 4 h, white solid was obtained by filtration (6.53 g, yield: 89.5%).
[0077] ESI-MS (m/z): 422 (M+H), 444 (M+Na);
[0078] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H).
[0079] HPLC: 98.95%.
Embodiment 11
Preparation of (S)-2-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0080] (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (4.04 g, 19.87 mmol, 1.15 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in 1,4-dioxane (70 mL) respectively, then heated to 120° C. and magnesium bromide (0.22 g, 1.21 mmol) was added. The mixture was reacted for 4 h, white solid was obtained by filtration (6.94 g, yield: 95.1%).
[0081] ESI-MS (m/z): 422 (M+H), 444 (M+Na);
[0082] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H);
[0083] HPLC: 99.15%.
Embodiment 12
Preparation of (S)-2-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)isoindoline-1,3-dione (Compound I, wherein R is phthalimido)
[0084] (S)-2-(oxiran-2-ylmethy)isoindoline-1,3-dione (3.87 g, 19.06 mmol, 1.1 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in acetonitrile (70 mL) respectively, then heated to reflux. Tetra-n-butylammonium bromide (0.55 g, 1.71 mmol) was added, the mixture was reacted for 4 h, white solid was obtained by filtration (6.57 g, yield: 90.0%).
[0085] ESI-MS (m/z): 422 (M+II), 444 (M+Na);
[0086] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.74 (m, 2H), 3.94 (m, 4H), 4.10 (m, 2H), 4.32 (s, 2H), 4.98 (m, 1H), 7.34 (d, 2H), 7.56 (d, 2H), 7.75 (m, 2H), 7.88 (m, 2H);
[0087] HPLC: 98.86%.
Embodiment 13
Preparation of (S)—N-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)benzylamine (Compound I, wherein R is benzylamino)
[0088]
[0089] (S)—N-benzyl-1-(oxiran-2-ylmethyl)methylamine (3.10 g, 19.06 mmol, 1.1 eq.) and 4-(4-isocyanatophenyl)morpholin-3-one (3.77 g, 17.29 mmol) were dissolved in butanone (70 mL) respectively, and heated to reflux. Then lithium bromide (0.15 g, 1.74 mmol) was added, the mixture was reacted for 4 h, white solid was obtained by filtration (5.88 g, yield: 89.21%).
[0090] ESI-MS (m/z): 382 (M+1), 404 (M+Na);
[0091] 1 HNMR (400 MHz, CDCl 3 ) δ: 2.0 (s, 1H), 2.82 (d, 2H), 122 (t, 2H), 3.50 (t, 2H), 3.55 (t, 2H), 3.82 (s, 2H), 4.31 (s, 2H), 4.86 (s, 1H), 6.76 (d, 2H), 7.35 (d, 2H), 7.23-7.26 (m, 3H), 7.36 (dd, 2H).
[0092] HPLC: 99.02%.
Embodiment 14
Preparation of (S)—N-((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)dibenzylamine (Compound I, wherein R is dibenzylamino)
[0093]
[0094] White solid having the structure as I-3 (7.72 g, yield: 94.76%) was prepared according to the embodiment 3, except for that (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.87 g, 19.06 mmol) was replace by (S)—N,N-dibenzyl-1-(oxiran-2-ylmethyl)methylamine (4.81 g, 19.06 mmol, 1.1 eq.).
[0095] ESI-MS (m/z): 472 (M+H), 494 (M+Na);
[0096] 1 HNMR (400 MHz, CDCl 3 ) δ: 2.61 (m, 2H), 3.20 (t, 2H), 3.52 (t, 2H), 3.56 (t, 2H), 3.62 (s, 4H), 4.31 (s, 2H), 4.92 (s, 1H), 7.23 (dd, 4H), 7.26 (m, 2H), 7.32 (dd, 4H), 7.36 (d, 2H), 7.56 (d, 2H);
[0097] HPLC: 99.13%.
Embodiment 15
Preparation of (S)-(tert-butyl) ((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)carbamate (Compound I, wherein R is tert-butoxycarbonyl amino)
[0098]
[0099] White solid having the structure as I-4 (6.21 g, yield: 91.83%) was prepared according to the embodiment 3, except for that (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.87 g, 19.06 mmol) was replaced by (S)-(tert-butyl) oxiran-2-ylmethyl-carbamate (3.29 g, 19.06 mmol, 1.1 eq.).
[0100] ESI-MS (m/z): 392 (M+1), 414 (M+Na);
[0101] 1 HNMR (400 MHz, CDCl 3 ) δ: 1.38 (s, 9H), 3.10 (d, 2H), 3.38 (d, 2H), 3.52-3.55 (m, 4H), 4.30 (s, 2H), 5.15 (dd, 1H), 6.84 (d, 2H), 7.34 (d, 2H), 8.04 (s, 1H);
[0102] HPLC: 98.87%.
Embodiment 16
Preparation of (S)-benzyl((2-oxo-3-(4-(3-oxomorpholino)phenyl)oxazolidin-5-yl)methyl)carbamate (Compound I, wherein R is benzyloxycarbonyl amino)
[0103]
[0104] White solid having the structure as 1-5 (6.79 g, yield: 92.38%) was prepared according to the embodiment 3, except for that (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.87 g, 19.06 mmol) was replaced by (S)-benzyl oxiran-2-ylmethyl-carbamate (3.94 g, 19.06 mmol, 1.1 eq.).
[0105] ESI-MS (m/z): 426 (M+1), 448 (M+Na);
[0106] 1 HNMR (400 MHz, CDCl 3 ) δ: 3.30 (d, 2H), 3.38 (d, 2H), 3.52-3.55 (m, dH), 4.31 (s, 2H), 5.10 (s, 2H), 5.21 (dd, 1H), 6.36 (d, 2H), 6.75 (d, 2H), 7.38-7.47 (m, 6H), 8.02 (s, 1H);
[0107] HPLC: 98.76%.
Comparative embodiment 1
Preparation of Rivaroxaban
[0108] White solid was obtained (3.23 g, yield: 42.89%) according to the embodiment 3, except for that (S)-5-chloro-N-(oxiran-2-ylmethyl)thiophene-2-formamide (4.14 g, 19.06 mmol, 1.1 eq.) was used to replace (S)-2-(oxiran-2-ylmethyl)isoindoline-1,3-dione (3.87 g, 19.06 mmol), wherein 5-chlorothiophene-2-formyl is not an conventional amino protecting group in the art.
[0109] HPLC: 98.65%.
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A method for preparing a Rivaroxaban intermediate I is presented, including the following step: in a non-protonic solvent, under the effect of lewis acid, performing cyclization reaction on 4-(4-phenyl isocyanate)morpholine-3-ketone (II) and (S)-epoxy compound (III), the reaction temperature ranging from 20° C. to 60° C., where R is amino replaced by amino protecting group. The preparation method of the present invention has a mild condition, a simple process, a low cost, and high efficiency; the product is easy to purify and the method is applicable to industrial production.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a valve assembly for controlling fluid flow. More particularly, the present invention is directed to a fluid injection system for injecting propellants such as fuel into a combustion chamber of a fluid fueled rocket engine. For example, the valve assembly may be incorporated into a vehicle such as a re-entry interceptor system having four divert rocket engines in a cruciform arrangement.
2. Background Art
Various propulsion systems, discussed below and incorporated herein by reference, have means for injecting propellant(s) into the combustion chamber of a rocket engine.
Jaqua (U.S. Pat. No, 4,326,377) describes a system for injecting propellant utilizing a piston including orifices which direct propellant from the injection chamber into the combustion chamber. This is accomplished, in part, by the cooperation of a pair of valve members having concentric sleeves slidably mounted respectively on the inside and outside surfaces of the tubular portion of a piston.
Horner (U.S. Pat. No. 3,088,406) utilizes an injector pump and a solenoid assembly which function together to inject a predetermined amount of fuel into a rocket combustion chamber. The injector pump housing encloses three stepped pistons on a single shaft which can be activated by a driving gas derived from the thrust chamber through a conduit communicating therebetween. The driver piston is the motivating force displacing a fuel injector piston and an oxidizer injector. This arrangement allows the entire amount of predetermined quantities of fuel and oxidizers stored in the injector pump cylinder to be injected into a combustion chamber.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
The valve assembly of the present invention is both compact and designed to insure reliable and optimal performance when a controlled flow of two fluids is desired.
A valve assembly housing chamber having fluid inlet and outlet ports includes slidable blades positioned in functional relationship proximate these ports. Each blade has formed therein a shaped orifice or channel. A yoke, in cooperation with a piston and servo-assembly links the blades to a closed loop feedback control system.
When activated, the valve assembly is capable of controlled displacement or axial movement of the blades within the housing chamber. In turn, each blade orifice may be selectively positioned proximate a fluid inlet and outlet port to allow a flow of fluid(s) supplied from a remote source to pass through the valve assembly.
Accordingly, it is an object of this invention to provide a valve assembly for controllably mixing or dispensing diverse fluid.
Another object of this invention is to provide a fluid injection system for injecting propellants into a combustion chamber of fluid-fueled rocket engine.
These and other objects and features of the present invention will be apparent from the following detailed description, taken with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view, partially broken away, of the valve assembly of the present invention.
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1.
FIG. 3 is a cross-sectional view of the valve assembly of the present invention shown in a preferred embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings and in particular to FIG. 1 thereof, there is shown a valve assembly (10) for controlling the flow of two fluids from a remote source for the intimate mixing or interaction thereof. This mixing and/or interaction may find application, for example, in a fluid sprinkling, spraying or diffusing apparatus but the preferred embodiment as described in greater detail below is a valve assembly in a fluid injection system for controllably injecting propellants into a reaction engine combustion chamber.
Referring to the drawings in detail, 10 indicates the valve assembly according to the present invention. Valve assembly includes a housing structure 12 defining forward 14, central 16 and aft chamber 18.
As shown in FIG. 2, a fluid inlet 20 passes through an upper wall surface of the housing structure and terminates within a first compartment 22 in the forward chamber formed by partition 24. While not shown, a second fluid inlet also is provided in the housing structure which, as with the first fluid inlet, communicates with a second compartment identical to and in the same plane as compartment 22 in the forward chamber 14 formed by partition 24. Each compartment terminates at an upper surface of the corresponding T-shaped blade. Corresponding fluid outlets 26 are positioned beneath the fluid inlets in the base of the valve assembly housing for conducting fluids from the valve assembly into an injector.
Openings 28 and 30 within the rear wall 32 of each of the parallel compartments of chamber 14 form a passageway from each of these compartments into the central chamber. Slidable T-shaped blades 36 having a top section and a base are positioned and retained within chamber 14. Aligned, shaped orifices 38 are formed within each blade near a forward portion thereof and pass through bottom 42 of each blade from the top to the bottom surface.
The shape of the orifices is selected to provide an equal percentage orifice shape which produces a change in flow corresponding to a change in blade position that is a constant percentage of the flow prior to the change in blade position. In the present example as shown in FIG. 1, wedge-shaped orifices in each blade provide a controlled oxidizer to fuel mixture ratio over the complete range of fluid flow. That is, the mixture ratio can be held constant or may be varied as needed to optimize system performance. A more detailed discussion of orifice shapes as affecting flow characteristics is available in ISA Handbook of Control Valves, 2d Edition (1976), incorporated herein by reference.
The base 44 of each T-shaped blade extends from the top section 40 and passes through openings 28,30 within the rear wall 32 of each parallel compartment and into the central chamber 16. Seals or gaskets 46 are provided to ensure leak-proof seals in the valve assembly.
Within the central chamber 16 there is positioned a T-shaped yoke 48 having a top section 50 and a base section 52. The top 50 of the yoke is functionally joined, such as by pinning, welding and the like to the base 52 of each of the blades 36.
A passageway 54 (see FIG. 2) communicating between the central and aft chambers accommodates shaft 56 of a piston 58 housed in aft chamber 18. The shaft 56 extends through passagway 54 and is attached by a threaded coupling 60 at the base of the shaft 56 to the base 52 of yoke 48.
In cooperative association with the valve assembly housing structure 12, is a position indicator assembly 62 and servo-valve assembly 70 attached thereto.
The position indicator assembly 62 is provided with a housing 64 having a chamber 66 formed therein. A position indicator probe 68 having one end fixedly attached to the aft section of piston 58 is slidably retained within chamber 66. As previously indicated, the seals or gaskets 46 ensure leak-proof seals for the functional components of the valve assembly 10.
The servo-valve assembly 70 includes an electromagnetic motor 72 for positioning a valving mechanism within assembly 70, and ports 74,76 communicating with the aft chamber of the valve assembly 10. The ports are positioned so that fluid supplied to the servo-valve assembly 70 by passageway 78 leading from compartment 22 of the valve assembly may be directed into the aft chamber in front of or to the rear of piston 58.
As indicated previously, FIG. 3 represents the valve assembly in functional relationship with a rocket engine thrust chamber 80. This embodiment will be utilized to explain the operation of the valve assembly for controlling the flow of two fluids, in this instance, a propellant fuel such as hydrazine and an oxidizer, from a remote storage source such as an oxidizer tank and a fuel tank (not shown).
As seen in FIGS. 2 and 3, fuel under pressure enters inlet 20 and passes through passageway 78 to the servo-valve assembly 70. Upon activation of the valve assembly by a remote controller (not shown), the motor of the servo-assembly is activated which in the allows a portion of the fuel to be selectively introduced or withdrawn from the aft chamber to function piston 58. The remote controller, which may be commanded by an onboard computer or by a ground controller, is able to determine the position of the blades in the forward chamber by the position of the piston indicator probe 68 housed within the piston indicator assembly 62.
It is to be understood that the servo-assembly 70 is capable of introducing or withdrawing fluid from either side of the piston 58 positioned within the aft chamber upon command. In this manner, the piston may be moved forward or aft as desired to control the positioning of the T-blades 36 in the forward chamber which in turn determines the position of the shaped orifices 38 therein. When a predetermined degree of thrust or impulse is desired, the onboard control system or controller, as the case may be, activates motor 72 which in turn directs fluid through one of the ports into chamber 18. The blades are simultaneously moved aft to a predetermined position and at this time both fuel and oxidizer are allowed to pass through the valve housing 12, the injector 84 and into thrust chamber 80. Any fluid or oxidizer that may leak past seals 46 during operation and into central chamber are allowed to pass to the atmosphere through port 86. In this manner, interaction of the hypergolic propellant mixture within the central chamber 16 is precluded.
In thrust chamber 80 the hypergolic reaction converts the fuel components into high-pressure gases which are in turn converted into thrust for propelling or directing the vehicle as desired.
It will of course be realized that various modifications can be made in the design and operation of the present invention without departing from the spirit thereof. Thus, while the principal, preferred construction, and mode of operation of the invention have been explained, 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 compact, valve assembly (10) is provided having multiple chambers. A forward chamber (14) retains dual T-shaped blades (36) having shaped orifices (38) for controllably metering at least two fluids passing through the valve assembly. The valve assembly is also provided with a servo-valve assembly (70) and a piston indicator (62) assembly in cooperative association with the valve assembly.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to a teaching-playback type automatically running vehicle which first memorizes, during travel under manual control, the steering angle patterns of the vehicle wheels while the vehicle traverses a given distance along a course from the starting point. During subsequent passages along the course, the vehicle may be automatically run by self-manipulation of the steering angle of the vehicle wheels in accordance with the memorized pattern.
(2) Description of the Prior Art
Among the conventional unmanned automatically running vehicles there is for instance a type which automatically follows a track or guide line disposed over the entire course. Such a system has the disadvantage that in the case of a long distance course, the installation cost of the track or guide line is too high, and because of such costly installation, the course cannot easily be modified or altered after the specific course pattern has been installed. Also, installation of such a track or guide line may cause hindrance to other vehicles which may be operated along portions of the course, such as work vehicles and lawn mowers or the like. It is thus practically impossible to have an automatic running vehicle perform automatic travel by means of a track or guide installed over the entire course.
There has recently been proposed an unmanned automatically running vehicle of the teaching-playback type. Such a teaching-playback vehicle is preferred to the said guide line type in view of the fact that the teaching-playback vehicle can follow any arbitrary course pattern once the pattern is memorized. However, since a teaching-playback vehicle performs in accordance with the memorized data along, any possible initial error in the placement or orientation of the unmanned automatically running vehicle and/or errors introduced during the running of the vehicle (resulting from external disturbances such as irregular ground undulations wind forces or the like), will never be remedied but will become progressively larger and larger as the vehicle runs on and on. Improvements have therefore been desired in this regard.
SUMMARY OF THE INVENTION
The invention has as one object, in view of the drawbacks of the prior art as mentioned above, to enable the unmanned automatically running vehicle of the teaching-playback type to eliminate any initial error in the placement and departure direction of the vehicle at the starting point, and also to check any deviation or deflection from the set course and to correct same upon need, from time to time, during travel along the automatic travel course in the case where the course is long.
The automatically running vehicle according to this invention is of the teaching-playback type, provided with a first control means adapted to manipulate steerable vehicle wheels in accordance with predetermined steering angle information memorized earlier when the vehicle traveled predetermined distances from the starting point of the course. The automatically running vehicle further comprises: guide-line detectors constructed with a plurality of sensors which are disposed in left and right portions of the vehicle body and which sense when the vehicle approaches within a certain distance of objects to be sensed which may be disposed on the ground and comprise the guide line; and a second control means which controls, in response to output signals of said guide-line detectors, the vehicle body so as to keep its course along the guide line; wherein the said second control means will actively work in preference to the said first control means so long as any of the said guide-line detectors is detecting the said object to be sensed.
Considering first any initial error due to the placement of the vehicle at the starting point, the invention provides that when the guide-line detector detects a guide line which has been provided at an intermediate ground point, the second control means controls the vehicle in response to a detection signal generated by the detector when the guide line has been detected. Thus, the vehicle will keep its course along the guide line, minimizing the initial orientation error. Upon leaving the guide line and traveling further on, the vehicle is again controlled by the first control means which manipulates the steerable wheels in a series of predetermined steering angles in accordance with the data information memorized beforehand when the vehicle traveled predetermined distances from the starting point. It further is possible, by having provided some guide lines intermediately of the predetermined course, to correct any possible deviation or deflection from the said predetermined course during the vehicle travel, since the second control means consecutively comes to actively operate the vehicle in preference to the first control means so as to control the vehicle to keep its course along each of such guide lines.
It has thus been made possible, with the construction as mentioned above, to realize excellent automatic vehicle operation with minimized course deviation or deflection, even in a long distance course, and yet without requiring guide lines to cover the entire course length.
Still other objects and advantages of this invention will become apparent from the description to follow hereunder.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings show by way of example, an embodiment of the teaching-playback type automatically running vehicle according to this invention; wherein
FIG. 1 is an overall side elevation of a vehicle according to the present invention;
FIG. 2 is a plan view showing the lower portion structure of the FIG. 1 vehicle;
FIG. 3 is a plan view showing the structure of guideline detectors according to the present invention;
FIG. 4 is an oilhydraulic circuit diagram for steerable wheels according to the present invention;
FIG. 5 is a front end view of a manipulation panel according to the present invention;
FIG. 6 is a control diagram according to the present invention;
FIG. 7 is a flow chart of the present invention while the vehicle is in the teaching mode;
FIG. 8 is a flow chart while the vehicle is in the playback mode;
FIG. 9 is an explanatory view of the data-array construction of a couple of Tables used in the present invention; and
FIG. 10 is an example of the vehicle travel course.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Shown in FIG. 1 is a lawn mower, as a specific example of an automatically running vehicle of the teaching-playback type according to the present invention. In an intermediate portion of the vehicle, in between front and rear wheels of the vehicle body (1), there is suspendedly provided a lawn-mowing apparatus (2) which may be adjusted to provide for free up-and-down movement. To the front and to the rear of the vehicle body (1), there are attached guide-line detectors (3), (4) by means of springs (5) as shown in FIG. 2. On mounting base portions of the vehicle, opposite the guide-line detectors (3), (4), there are provided limit switches (6) which are so constructed that a running-travel halting signal is generated upon inadvertent collision of the guide-line detectors (3), (4) against any obstacle, by contact between the detectors and these limit switches (6) to thus halt the vehicle travel accordingly.
FIG. 3 shows the construction of the guide line and the guide-line detectors (3), (4). Each guide line is here constructed with iron bolts (7), a specific example of magnetic material which are driven into the ground at the starting point and at some checking points suitably provided intermediate of the travel course. Each point includes a plurality of bolts spaced at about 10 cm intervals over a range of about 10 m for each such point. Each of the guide-line detection sensors (3), (4) is constructed with a plurality of sensors (S) disposed, for example, with eleven sensors on the lefthand side and another eleven on the righthand side, excepting a blank middle portion. Upon sensing the magnetic material pieces (7), a sensor (S) is turned to an ON state.
FIG. 4 shows an oilhydraulic circuit for steering front wheels (8) which are steerable wheels of the running vehicle body (1), wherein the front wheels (8) are steered by means of an oilhydraulic cylinder (9). The oilhydraulic cylinder (9) is connected, via an electromagnetic valve (10), (which defines the flowing sense of the oil), and a branching valve (11), (which branches off a set amount of oil to the electromagnetic valve (10)), to an oilhydraulic pump (12), thus providing proportional steering control. Steering of the front wheels (8) is thus effected by actuating the left or right solenoid (13), (14) of the electromagnetic valve (10).
FIG. 6 is a diagram of a control circuit which actuates the left and right solenoids (13), (14) of the electromagnetic valve (10). The control circuit comprises a guide-line-following control section (15) and a teaching-playback control section (16). The teaching-playback control section (16) is constructed with a microcomputer (17) as its central or key component, the microcomputer (17) also operating as the switching control to switch control of the vehicle between guide-line-following control and the teaching-playback control. Designated at PG is a pulse generator used for measuring the distance actually traveled. The pulse train generated by PG is input to a distance counter (C). The output of this distance counter (C) is given as an input to the microcomputer (17).
The guide-line following control section (15) has, as mentioned above, guide-line detectors (3), (4) mounted ahead of and in rear of the running vehicle body (1). The sensors (S) are disposed to the left side and to the right side, respectively from the middle portion of the guideline detectors (3), (4), and are combinedly grouped in a wired-OR manner, eleven of them on either side.
Now, if a guide line is detected at the front of the running vehicle body (1) on the lefthand side, then a corresponding one of the lefthand side sensors (S) senses the guideline and generates a high-signal (S 1 ), and this signal is amplified by means of a lefthand amplifier (A 1 ) and is used to actuate the righthand solenoid (14). In case any of the righthand side sensors (S) senses a guideline, it produces a high-signal (S 2 ) which, in a similar manner, actuates the left-hand solenoid (13). When a guide line approaches the middle portion of the detector, no output is generated. The left and right sensors (S) of the rearward side guide-line detector (4) are also combinedly grouped in a wired-OR manner. Thus, a high-signal (S 3 ) output is given when any of the lefthand side sensors (S) senses the guide-lines (7), while a high-signal (S 4 ) output is given when any of the righthand side sensors (S) senses the guideline. These signals (S 3 ), (S 4 ) are given as inputs to the respective gates (G 1 ) and (G 2 ). These gates (G 1 ), (G 2 ) receive both the inputs of the front side guide-line detector (3) in such a manner as to be blocked off when either of the inputs goes high. Thus, when both low-signal inputs (S 1 ), (S 2 ) are given as outputs from the front side guide-line detector (3), then a high-level output (S 3 ) of the lefthand side sensor will actuate the lefthand solenoid (13), while a high-level output (S 4 ) of the righthand side sensor will actuate the righthand solenoid (14). Namely, the front and rear detectors (3), (4) are inverse in their modes of how to actuate the solenoids (13), (14). In addition, in the middle portion of the rearward side detector (4) there is attached a sensor (S') which senses the fact that the vehicle body middle portion is properly on the guide line. It should be noted that these sensors (S) are constructed so as to be capable of delivering their signals (S 1 )-(S 4 ) respectively in two separate lines, and the signals (S 1 )-(S 4 ) on one of the two lines are given as inputs to the microcomputer (17) so that when the inputs are all low-signals (S 1 )-(S 4 ) the microcomputer (17) allows teaching-playback control to be effected. Also given as inputs to the microcomputer (17) are the ON/OFF signals of: a mode selecting switch (18) for change-over between the teaching and the playback modes; a main starting switch (18'); and actuating switches (SW 1 ), (SW 2 ) for the left and right solenoids (13), (14), which are manually manipulated while in the teaching mode. The guide-line following control actively works in preference to manual control, on account of the function of switches (G 3 ), (G 4 ) which can be turned off upon detection of a signal from any sensor (S) during the teaching operation. In the playback mode, the guide-line following control works in preference to the playback control, on account of the programming to be described below.
A description of the programming will now be given with reference to FIGS. 7 and 8.
Two Tables (1), (2) as outlined in FIG. 9 are provided in order to store data therein and to retrieve data therefrom. Tables (1) and (2) are provided within microcomputer (17), as depicted in FIG. 6. In Table (2), there are consecutively stored data for actuating and halting the left and right solenoids (13), (14) together with the running distance from the starting point that has been traveled by the time of each of such solenoid events. As for Table (1), stored therein are the associated array addresses (Add2) of Table (2) to be referred back to respectively upon completion of the consecutive guide-line following control steps.
FIG. 7 shows a flow chart according to the present invention while the vehicle is in the teaching mode.
By means of the starting switch (18'), there is effected initialization (i) of the array addresses of Tables (1), (2). After checking whether there is any high-signal (S 1 )-(S 4 ). (S') at step (ii), if a high signal is detected, an address (Add2) of Table (2) is written into an address (Add1) of Table (1) at step (iii). Then, the address (Add1) of Table (1) is subjected to an increment at step (iv), and the system remains in a standby loop until the high-signal (S 1 )-(S 4 ), (S') from the guide-line detector (3), (4) shifts to low at step (v). In the meantime, guide-line following control is effected in accordance with the output of the detectors (3), (4). When no high-signals from the detectors (3), (4) are present, the ON/off state of the switches (SW 1 ), (SW 2 ) is determined at step (vi). If there is an alteration in the state of one of the solenoids, the running distance traveled in a given time together with the coded alteration condition is written in Table (2) at step (vii); then the address of Table (2) is subjected to an increment at step (viii), to thus show an array address (Add2) of the domain to be written in at the next subsequent event.
FIG. 8 is a flow chart according to the present invention while the vehicle in the playback mode.
Designated at steps (i)', (ii)' are initialization and checking of high-signal (S 1 )-(S 4 ), (S') from any detector, similar to the description given in FIG. 7. When there is any high-signal (S 1 )-(S 4 ), (S') present, control of the left and right solenoids is halted at step (iii)'; then the address of Table (2) is read on Table (1) at step (iv)' to restore access to Table (2); and the address of Table (1) is thereupon subjected to an increment at step (v)' so as to thus show the next subsequent domain. Then, the system is kept in the standby mode until the receipt of low-signals from the detectors (3), (4) at step (vi)'.
When (S 1 )-(S 4 ), (S') are low, then the stored running distance and alteration of the solenoids are read from the pertinent domain of the address (Add2) of Table (2) at step (vii)'; the output result of the counter (C) (which is measuring the distance traveled) is read at step (viii)'. If the running distance is greater than the output of counter (C) (step (ix)'), and if the signals (S 1 )-(S 4 ) remain low (step (x)'), the system remains in a standby loop until the time where the value from the counter (C) reaches the said running distance. Then, at the time the distance traveled has reached the distance on Table (2), the solenoids are properly altered in accordance with the data content of Table (2) and the pertinent signal level is delivered to the left or right solenoid (3), (4) at step (xi)'. Then the address of Table (2) is subjected to an increment at step (xii'), and the address of Table (2) to be referred to at the next subsequent occasion is introduced.
If, at the time of reading out the stored running distance on the domain of address (Add2), it is found that such running distance is less than the value of the counter (C), then the stored command for the left or right solenoid at such running distance is delivered outright to the pertinent solenoid.
Control operations are performed as described above.
The reason for providing table 1 and table 2 will now be explained.
As for guide lines which may be provided midway in the travel course, it is preferable to provide each of them immediately after completion of a pronounced turning motion by the vehicle, since any directional error of the vehicle deflecting it from the aimed orientation, (as might result from the turning motion), may then be corrected by means of such midway guide lines before the course deviation gets larger. For example, during the teaching operation a set of data of "Righthand solenoid; ON, Running distance; 59 m are stored at address 100 of table 2 and a guide line is disposed immediately thereafter to start at the running distance of 60 m. However, during subsequent travel under playback control, there might possibly occur, (on account of slipping of the wheels), error in reproducing the turning radius or the like, such that the vehicle actually enters the guide line at a time when the reading of the distance traveled (=the output value of the distance counter), as measured on the real time basis by the vehicle in such a playback control operation, is still as low as 58 m. In such a case, if upon the vehicle leaving the guide line, the playback control step is effected in accordance with the data stored in said address 100 (thus the righthand solenoid; ON here), then the intention of using the guide line for correcting the directional error at 60 m would completely be ignored and thus become meaningless. In order to avoid such an event, it is necessary, at the time of leaving the guide line, to ignore the data stored in said address 100, namely to issue a command of jumping from address 99 to address 101. The present invention provides means for attaining this aim by using Table 1. Thus, the pertinent address of Table 2 to be read out upon leaving the guide line is forcibly defined by Table 1. It is thus possible to avoid the confusion that would otherwise occur in the case of providing quite a short distance between a point of manipulation control by said first control means (teaching-playback control) and a next subsequent guide line, namely the possibility of the vehicle prematurely entering a guide line prior to effecting the control step by the first control means, on account of a discrepancy between the running distance memorized while in the teaching mode and the running distance sensed as actually traveled while in the subsequent playback operation. This feature eliminates the possibility that the second control means could operate the vehicle and then return control to the first control means which would thereafter execute a stale command, thus letting the vehicle run in substantial deflection or deviation from the predetermined direction.
Shown in FIG. 5 is a manipulation panel for manipulating the switches (SW 1 ), (SW 2 ) and so forth, with a manipulation lever (19) provided as illustrated.
Shown in FIG. 10 is a specific vehicle travel course, wherein the guide lines and the vehicle are designated at (A) and (B), respectively.
It should be noted that the guide lines and the sensors are not limited to a contactless type (such as: magnetic material pieces and magnetic sensors, light-emitting pieces and photo-sensors, or the like), but may as well be the contact type, for instance one wherein a track is provided at predetermined checkpoints and the vehicle body is equipped with sensor roller wheels which come into contact with the track from either side.
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Apparatus and method for controlling an automatically running vehicle over a predetermined course which has guidelines intermittently placed therein. Vehicle commands used to negotiate the course under manual control are stored in a memory. The vehicle has sensors which detect the presence and location of the guidelines as the vehicle passes by. The vehicle travels the course under control of the stored vehicle commands until guidelines are detected indicating the vehicle is off course. Then, vehicle control is switched so that the vehicle returns on course, over the guidelines. When the guidelines are no longer detected, vehicle control is returned to the memorized vehicle commands in such a fashion as to synchronize the actual vehicle position with the memorized data.
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BACKGROUND OF THE INVENTION
Screw compressors employed in refrigeration applications commonly use oil for sealing, lubricating and cooling. The oil is injected into the working chamber of the compressor and thus into the refrigerant gas being compressed. As a result, the pulsating compressor discharge ordinarily contains oil entrained in the compressed refrigerant gas. The presence of oil interferes with the heat exchange function of the refrigeration system and otherwise degrades the efficiency of the system. The pulsating discharge gas is one of the most significant causes of radiated noise in screw compressors. Generally, the amount of oil carried over to the system is kept as low as possible in order to minimize the degrading of the heat transfer surfaces, to minimize the delivery of oil to remote locations in the system and to keep a sufficient oil supply in the oil sump for sealing, lubricating and cooling needs. The oil removal or separation ordinarily takes place at a convenient place between the compressor discharge and the condenser. A muffler to reduce the discharge pulsations is located at a convenient location near the compressor discharge.
SUMMARY OF THE INVENTION
The present invention locates the muffler in the oil separator and employs a plurality of flow direction changes in the muffler and the oil separator in combination with a discharge deflector, demisters and a coalescer to remove and collect oil entrained in the refrigerant gas. By locating the muffler upstream of the oil separator, the discharge pulsations in the refrigerant flow will be reduced thereby significantly reducing the radiated noise from the oil separator. Except for oil removed in the coalescer, all of the separated oil drains directly into the main oil sump. The refrigerant gas and entrained oil is subjected to at least two impingements with a resulting change in direction to inertially remove as much oil as possible prior to reaching and passing through the demisters where the amount of oil removal has a direct, temporary effect on the demisters and their flow resistances as the entrained oil impinges, collects and drains to the sump.
It is an object of this invention to provide efficient oil separation for a screw compressor.
It is a further object of this invention to decrease the first few harmonics of the pressure pulsations in the compressor discharge flow.
It is another object of this invention to facilitate the return of the oil trapped in the muffler to the main oil sump.
It is an additional object of this invention to provide an integral oil separator and muffler.
It is another object of this invention to provide an oil separator which drains most of the separated oil directly to the main oil sump. These objects, and others as will become apparent hereinafter, are accomplished by the present invention.
Basically the discharge gas from a screw compressor is directed radially and in a generally horizontal direction into the integral oil separator and muffler where it impinges upon the discharge deflector located at the inlet of the muffler portion. Impingement of the discharge flow with the discharge deflector produces a 90° directional flow change with a portion of the oil collecting in an oil pool and/or on the deflection surface due to inertial forces as the flow direction changes. The flow is then directed into the muffler which consists of a series of chambers each having nonaligned tubular inlets and outlets whereby flow directions are changed with some impingement and reverberation of the flow taking place. Each chamber is tuned to a desired waveband. Attenuated flow from the muffler impinges on a mesh pad defining a demister and lining the end of the housing whereby the flow is diverted 180°. The flow then passes through two demisters defined by mesh pads and into a coalescer. The flow passes through the walls of the coalescer leaving any entrained oil trapped in the coalescing media of the element. The coalesced oil gathers on the outside diameter of the coalescer and flows into the secondary oil sump. The refrigerant gas, now nearly oil free, exits the separator and is delivered to the condenser of the refrigeration system.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the present invention, reference should now be made to the following detailed description thereof taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a vertical sectional view of the integral oil separator and muffler of the present invention taken along line 1--1 of FIG. 4 with the coalescer shown unsectioned;
FIG. 2 is a sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is a sectional view taken along line 3--3 of FIG 1;
FIG. 4 is a partially sectioned cut away top view of the integral oil separator and muffler of the present invention;
FIG. 5 is sectional view taken along line 5--5 of FIG. 4; and
FIG. 6 is a sectional view taken along line 6--6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the Figures, the numeral 10 generally indicates the integral oil separator and muffler of the present invention. The external portion of the oil separator 10 is an essentially cylindrical shaped casing 12 having an inlet 13 with a flange 14 and an outlet 15. Casing 12 is partitioned by divider plate 16 which, as best shown in FIGS. 1 and 4, does not extend the full length of casing 12. Divider plate 16 is welded to and divides casing 12 into muffler 18 and oil separator 19. Referring now to FIG. 5, it will be noted that divider plate 16 divides the casing 12 into a major segment of a circle which defines oil separator 19 and a minor segment of a circle which defines muffler 18.
A horizontal screw compressor (not illustrated) is attached to flange 14 of inlet 13 by bolts (not illustrated). As the first step of oil removal, a partition 30 is provided at one end of muffler 18 and acts as a discharge deflector, as best shown in FIG. 4, and coacts with divider plate 16 to deflect flow entering inlet 13 into muffler 18. As best shown in FIG. 2, discharge deflector 30 is generally annular and provides a partition relative to casing 12. Referring to FIGS. 4-6, it will be noted that muffler 18 includes three partitions 18-1, 18-2 and 18-3 having tubes or pipes 18-4, 18-5 and 18-6, respectively, extending therethrough. A first chamber 18-7 is formed between partitions 18-1 and 18-2 and a second chamber 18-8 of a different size and acoustical properties is formed between partitions 18-2 and 18-3. Tubes 18-4, 18-5 and 18-6 are of different lengths and coact with the different sized chambers 18-7 and 18-8 so as to attenuate different chosen frequencies. Oil drain holes 18-9, 18-10 and 18-11 are formed in partitions 18-1, 18-2 and 18-3, respectively, near their bottoms, at progressively lower heights. The flow entering inlet 13 goes through a 90° turn due to the coation of deflector 30 and divider plate 16. Any oil separating out will collect and flow through oil drain hole 18-9 when the level thereof becomes high enough. The flow then passes through tube 18-4 into chamber 18-7. Because tubes 18-4 and 18-5 are not aligned the flow tends to reverberate in chamber 18-7 before exiting via tube 18-5. Any oil separating out plus any oil entering chamber 18-7 via drain hole 18-9 will collect and flow through drain hole 18-10 into chamber 18-8 when the level thereof becomes high enough. Tube 18-5 is of a different length than tube 18-4 to be responsive to different frequencies. Flow passing through tube 18-5 goes into chamber 18-8 which has different acoustical properties than chamber 18-7 so as to capture different frequencies. Because tubes 18-5 and 18-6 are not aligned the flow tends to reverberate in chamber 18-8 before exiting via tube 18-6. Any oil separating out plus any oil entering chamber 18-8 via drain hole 18-10 will collect and flow through drain hole 18-11 into major oil sump 26 when the level thereof becomes high enough. The turning of the flow due to the coaction of deflector 30 and divider plate 16 as well as the reverberation and dwell time of the flow in chambers 18-7 and 18-8 thus causes oil to separate out of the flow, as noted, and collect on partitions 18-1, 18-2 and 18-3, plate 16 and the inner wall of shell 12. The separated oil tends to flow downwardly and drains into oil separator 19 and major oil sump 26 as described above.
As is best shown by the flow indicating arrows in FIG. 4, the flow exiting muffler 18 via tube 18-6 into chamber 22 impinges upon agglomerating mesh pad 40 which forms a liner with respect to the end of casing 12 and causes the flow to be diverted 180° while removing and collecting some oil therefrom. The removed oil flows by gravity into main oil sump 26. The refrigerant gas, which now contains only fine droplets or a mist of oil, passes serially through demister pads 41 and 42, respectively, which, as best shown in FIG. 1, are partially immersed in main oil sump 26. The demister pads 41 and 42 remove oil by impingement and as the oil gathers in the fine wire mesh of the pads, it drains downwardly by gravity to maintain the oil reservoir defined by main oil sump 26. Demister pads can extract as much as 99.9% of the oil still in circulation when it reaches the demister pads. The preliminary removal of the large oil droplets is therefore necessary to prevent overwhelming the demister pads and greatly increasing flow resistance.
As the now relatively oil-free refrigerant gas passes through demister pad 42 into coalescer 50, it must make another 180° change in direction since, as best shown in FIGS. 1 and 2, the only exit from chamber 22 in oil separator 19 is via radially displaced opening 51 in plate 52 followed by opening 61 in plate 62 which opens into coalescer 50. Coalescer 50 is, in part, made of fiberglass and is of a generally annular cylindrical shape and with no openings other than 61 which serves only as an inlet. The refrigerant gas entering coalescer 50 via opening 61 must pass through the cylindrical fiberglass walls to reach chamber 60 thereby leaving any entrained oil trapped in the coalescing media of coalescer 50. The coalesced oil gathers on the outside surface of coalescer 50 and drops downward, by gravity, as gravitational forces in the collected oil overcome viscous forces and collects in secondary oil sump 28.
The oil collected and maintained in oil sumps 26 and 28 is withdrawn via outlets 27 and 29, respectively, and is either reinjected into a lower pressure area of the compressor by pressure differential or passed through a pump (not illustrated) where its pressure is raised to be delivered back to the compressor. The oil is injected into the compressor to seal, lubricate and cool the mechanism.
Although a preferred embodiment of the present invention has been illustrated and described, other changes will occur to those skilled in the art. For example, the number of chambers in muffler 18 can be increased and the sumps can be connected. It is therefore intended that the scope of the present invention is to be limited only by the scope of the appended claims.
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A muffler and an oil separator located within a common shell. The muffler includes a plurality of chambers tuned to different frequencies. The flow path is serially through the muffler into contact with an agglomerating pad followed by flow through demister pads and a coalescer.
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This application claims benefit of 60/607,881, filed Sep. 8, 2004.
FIELD OF THE INVENTION
This invention relates to processes for preparation of indanylamine or aminotetralin derivatives. In addition, this invention relates to intermediates which can be used in the preparation of indanylamine or aminotetralin derivatives.
BACKGROUND OF THE INVENTION
Indanylamine and aminotetralin derivative compounds, such as those of Formula I below, are useful to treat depression, Attention Deficit Disorder (ADD), Attention Deficit and Hyperactivity Disorder (ADHD), Tourett's Syndrome, Alzheimer's Disease and other dementias as described in PCT application publication 98/27055. The indanylamine derivatives disclosed have been shown to have biological effects in animal models of neurological disease.
Formula I is:
wherein b is 1 or 2; m is from 0-3, Y is O or S, X is halo, R 4 is hydrogen or C 1-4 alkyl, R 5 is hydrogen, C 1-4 alkyl, or optionally substituted propargyl and R 6 and R 7 are each independently hydrogen, C 1-8 alkyl, C 6-12 aryl, C 6-12 aralkyl, each optionally halo substituted.
PCT application publication 98/27055 further discloses methods for the preparation of indanylamine and aminotetralin derivatives of Formula I using, for example, as starting materials 3-amino-indan-5-ol or 6-methoxy-1-aminoindan. Methods of preparation of the starting materials are also disclosed. 6-Methoxy-indan-1-ylamine is prepared by conversion of 6-methoxy-indan-1-one to 6-methoxy-indan-1-one oxime followed by reduction to 6-methoxy-indan-1-ylamine. Alternatively 6-methoxy-1-aminoindan can be prepared by reductive amination (NaCNBH 3 and NH 4 OAc) of 6-methoxy-indan-1-one to 6-methoxy-indan-1-ylamine. 3-Amino-indan-5-ol can be prepared by using a Friedel-Crafts acylation of an N-protected 3-aminoindan, followed by a Baeyer-Villiger oxidation with subsequent hydrolysis.
These methods for producing starting materials such as 3-amino-indan-5-ol and 6-methoxy-indan-1-ylamine are accompanied by low yields and low reproducibility. Thus, there is a need for reliable processes to produce indanylamine and aminotetralin derivatives in high yields as intermediates to prepare compounds of Formula I, wherein the processes are suitable for industrial production.
SUMMARY OF THE INVENTION
Accordingly, the present invention relates to an improved process for preparing indanyl-(or tetralin)-amines of Formula (II)
wherein R 1 is a hydrogen atom, an alkyl group, an aryl group, or an acyl group; X is halo, alkyl or alkoxy; m is from 0 to 3; and b is 1 or 2.
In the first step of the process of the present invention, indanylone (or tetralone) oximes (III) are acylated by reaction with an organic anhydride producing indanone (or tetralone) O-acyl oximes (IV). In the second step of the process of the present invention, the O-acyl oximes (IV) are hydrogenated in the presence of a catalyst and organic anhydride to form indanyl-1-(or tetralin)-amides (V). The catalyst is a heterogenous catalyst, for example, Pd/C. In a subsequent step, the amides are hydrolyzed to form indanyl-(or tetralin)-amines of Formula (II).
In a second aspect, the invention relates to novel intermediates, namely, substituted indan-1-one O-acetyl oximes (IV). Both the improved process and novel intermediates are useful in the preparation of therapeutically active compounds used for the treatment of disorders of the central nervous system such as those described by Formula I.
DETAILED DESCRIPTION
The present invention provides a high yield process that can be easily applied at an industrial level for the synthesis of indanylamine or aminotetralin derivatives. The compounds produced by the processes of the current invention are suitable for use as starting materials or intermediates in the production of a variety of pharmaceuticals, for example those presented in Formula I above.
In various embodiments, halo includes fluoro, chloro, bromo, or iodo. Alkyl, alkoxy, etc., include both straight and branched groups; but reference to an individual radical such as “propyl” embraces only the straight chain radical, a branched chain isomer such as “isopropyl” being specifically referred to.
“Alkyl” includes linear alkyls, branched alkyls, and cycloalkyls. Additionally, the alkyls may be substituted with alkoxy, halo, and like substitutents. In some embodiments, alkyl is any one of C 1-10 alkyl, in other embodiments, alkyl is any one of C 1-4 alkyl. Example alkyl groups include: C 1-4 alkyl, such as methyl, ethyl, propyl, isopropyl, butyl, iso-butyl, sec-butyl, tert-butyl; C 1-10 alkyl, such as methyl, ethyl, propyl, isopropyl, butyl, iso-butyl, sec-butyl, tert-butyl, pentyl, 3-pentyl, hexyl, heptyl, octyl, nonyl and decyl; (C 3-12 )cycloalkyl such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, bicyclic, or multi-cyclic substituents, such as of the formulas
“Alkoxy” includes -O-alkyl in which the alkyl is as described above. Example alkoxys include, but are not limited to: methoxy, ethoxy, n-propoxy, n-butoxy, n-pentoxy, hexyloxy, and heptyloxy.
“Acyl” includes —C(═O)R, for example, —C(═O)H, —C(═O)alkyl, - and C(═O)halo, in which the alkyl is as described above. Specific examples of —C(═O)alkyl include, but are not limited to: acetyl, propanoyl, butanoyl, pentanoyl, 4-methylpentanoyl, hexanoyl, or heptanoyl.
“Aryl” includes a phenyl radical or an ortho-fused bicyclic carbocyclic radical having about nine to twenty ring atoms in which at least one ring is aromatic. Aryl (Ar) can include substituted aryls, such as a phenyl radical having from 1 to 5 substituents, for example, alkyl, alkoxy, halo, and like substituents. In some embodiments, aryl is a C 6-18 aryl which is either unsubstituted or substituted. Example aryls include, but are not limited to:phenyl, naphthyl, anthracenyl, phenanthrenyl, fluorenyl, tetrahydronaphthyl, or indanyl.
“Alkylaryl” includes an alkyl-aryl wherein the alkyl and the aryl are as described above. Example alkylaryls include, but are not limited to: benzyl, 2-phenethyl and naphthylenemethyl.
The carbon atom content of various hydrocarbon-containing moieties is indicated by a prefix designating a lower and upper number of carbon atoms in the moiety, i.e., the prefix C i-j indicates a moiety of the integer “i” to the integer “i” carbon atoms, inclusive. Thus, for example, (C 1 -C 10 )alkyl or C 1-10 alkyl refers to alkyl of one to ten carbon atoms, inclusive, and (C 1 -C 4 )alkyl or C 1-4 alkyl refers to alkyl of one to four carbon atoms, inclusive.
The compounds of the present disclosure are generally named according to the IUPAC nomenclature system. Abbreviations, which are well known to one of ordinary skill in the art, may be used (e.g., “Ph” for phenyl, “Me” for methyl, “Et” for ethyl, “h” for hour or hours, “g” or “gm” for gram(s), “mL” for milliliters, and “rt” for room temperature).
“About” modifying, for example, the quantity of an ingredient in a composition, concentrations, volumes, process temperature, process time, yields, flow rates, pressures, and like values, and ranges thereof, employed in describing the embodiments of the disclosure, refers to variation in the numerical quantity that can occur, for example, through typical measuring and handling procedures used for making compounds, compositions, concentrates or use formulations; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of starting materials or ingredients used to carry out the methods; and like proximate considerations. The term “about” also encompasses amounts that differ due to aging of a formulation with a particular initial concentration or mixture, and amounts that differ due to mixing or processing a formulation with a particular initial concentration or mixture. Whether modified by the term “about” the claims appended hereto include equivalents to these quantities.
The indefinite article “a” or “an” and its corresponding definite article “the” as used herein means at least one, or one or more, unless specified otherwise.
Specific and preferred values listed below for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for the radicals and substituents. The compounds of the disclosure include compounds of formulas (I through V) and like compounds having any combination of the values, specific values, more specific values, and preferred values described herein.
The process of the present invention is represented schematically below. The overall process of the invention can be divided into three steps: (1) acylation of the indanone (or tetralin) oxime (III) with an organic anhydride; (2) hydrogenation of the O-acyl indanone (or tetralin) oxime (IV) with a catalyst in the presence of an organic anhydride; and (3) hydrolysis of the amide (V) using an acid generating an indanylamine (II).
In Formulas II through V, R 1 is hydrogen, alkyl, aryl, or acyl, wherein alkyl, aryl and acyl may be substituted or unsubstituted; X is halo, alkyl or alkoxy; m is from 0 to 3; and b is 1 or 2. When b is 1, the compounds of Formulas II through V may be described as indan derivatives. When b is 2, the compounds of Formulas II through V may be described as tetralin (i.e. dihydronaphthalene) derivatives.
In some embodiments, b is 1. In some embodiments, m is 0. In some embodiments, R 1 is any one of C 1-4 alkyl. In some embodiments, the —OR 1 substituent is on the 4, 6 or 7 position of the indan (or tetralin) ring counting from the amino substituted carbon. In some embodiments, —OR 1 is 6-methoxy, 7- methoxy, 6-hydroxy, 7-hydroxy, 4-methoxy or 4-hydroxy.
The process of the present invention can be carried out in three separate steps, in which the product of each step is isolated, or alternatively in a one pot reaction, without isolating the product of the first and second steps. In a preferred embodiment, the process is carried out in a one pot reaction.
The first step of the improved process relates to acylation of an indanone or tetralin oxime (III) in the presence of an organic anhydride in an appropriate solvent. In some embodiments, the oxime is a compound of Formula III, wherein R 1 , X, m, and b are as defined above.
In some embodiments, the organic anhydride is a compound as described by the formula:
wherein R 2 and R′ 2 are each the same or different and are hydrogen, alkyl, aryl, or alkylaryl, wherein the alkyl, aryl or alkylaryl are unsubstituted or halo substituted. The organic anhydride may be a dialkyl anhydride, a diaryl anhydride or an alkylarylanhydride, and are unsubstituted or halo substituted. In some embodiments, the organic anhydride is acetic anhydride (R 2 and R′ 2 are methyl).
The molar ratio of the organic anhydride to oxime in the first step may be from 1:1 to 5:1. In some embodiments, the molar ratio of organic anhydride to oxime is between about 2:1 to about 5:1. In one embodiment, the molar ratio of organic anhydride to oxime is 3:1. In yet another embodiment, a preferred ratio of organic anhydride to oxime is 1.5:1.
The first step of the process is performed in a suitable solvent. Suitable solvents include, but are not limited to, aprotic non-basic solvents including, ethers, such as tetrahydrofuran (THF), tetrahydropyran, and diethyl ether; organic acid alkyl esters including ethyl acetate; or aromatic hydrocarbons, such as benzene and toluene.
The first step of the process is performed at a temperature range of 0°-80° C. In some embodiments, the temperature range is between about 15°-30° C. In a further embodiment, the temperature is about 20° C. The reaction is carried out over a period of time within the range of 1 to 8 hours. In some embodiments, the reaction time is about 2 hours.
In one embodiment, the O-acyl oxime product (IV) is isolated from the solvent of the first step before performing the second step. In another embodiment, the second step is performed without isolating the O-acyl oxime product (IV) of the first step.
The second step of the improved process relates to a catalytic hydrogenation of the O-acyl oxime product (IV) of the first step in the presence of a catalytic amount of a hydrogenation catalyst, and an organic anhydride in an appropriate solvent.
Suitable hydrogenation catalysts include, but are not limited to heterogeneous catalysts, which include transition metal catalysts comprising transition metals such as Pt, Pd, Ir, Ru, Rh and Ni. Specific examples of suitable heterogeneous catalysts include, but are not limited to: PtO 2 , Pt/C, Pd/C, Pd/SiO 2 , Pd(OH) 2 /C, Ru/C, Rh/C, and Raney Ni. In one embodiment, the heterogeneous catalyst is Pd/C.
The effective amount of the hydrogenation catalyst may be an amount from 0.1% to 1% w/w in relation to the starting oxime. In one embodiment, the amount of metal catalyst is 0.5% w/w in relation to the indanone or tetralin oxime starting material.
The reaction is performed under hydrogen gas at a pressure of between 0.1 to 15 bars (10 to 1500 kPa), under a temperature range of between 10 to 80° C., for a period of time in the range of 1 to 24 hours. In some embodiments, the hydrogen gas is added to the reaction at a pressure between about 2 to 5 bars (200 to 500 kPa) and in a further embodiment, at about 3 bars (300 kPa). In some embodiments, the reaction temperature is maintained within a range of between about 30-40° C. In one embodiment, the reaction is performed under hydrogen gas pressure of about 4 bars (400 kPa), at a temperature of about 40° C., and for about 4-6 hours.
The second step of the process is performed in a suitable solvent. Suitable solvents include, but are not limited to, aprotic non-basic solvents including ethers, such as tetrahydrofuran (THF), tetrahydropyran, and diethyl ether; organic acid alkyl esters including ethyl acetate; or aromatic hydrocarbons, such as benzene and toluene. In some embodiments, the solvent is the same as used in the first step.
The molar ratio of the organic anhydride in the second step to reactant may be from 1:1 to 5:1; in some embodiments the ratio is 1.5:1. If the first step and the second step are performed in a one pot reaction (i.e. without isolating the product of the first step), the molar ratio of the anhydride to the reactant may be from 2:1 to 5:1, in some embodiments the ratio is 3:1. In yet another embodiment, a preferred ratio of organic anhydride to oxime is 1.5:1.
In one embodiment, the product of step 2 is any one of C 1-4 alkoxy-indan-1-one O-acetyl oxime. In another embodiment, the product is a methoxy-indan-1-one-O-acetyl oxime. In a further embodiment, the product is a 6-methoxy-indan-1-one O-acetyl oxime. The product may be isolated, if desired, by any conventional means.
The third step of the new process relates to hydrolysis of the amide product of the second step based on methods described in the literature, in an appropriate solvent to obtain indanylamine. (March's Advanced Organic Chemistry; Michael B. Smith and Jerry March, 5 th edition, Chapter 10 section 10-11.) One of suitable methods of hydrolysis of the amide product of the second step is using an acid. Hydrochloric acid, sulfuric acid, or other acids may be used as hydrolyzing reagents.
The present invention will be illustrated by the following examples, which should not be considered to limit the scope of the invention in any way.
EXAMPLES
The indanone or tetralone oxime starting materials of the process of the current invention may be prepared from the corresponding ketone derivatives by methods known in the literature. (March's Advanced Organic Chemistry; Michael B. Smith and Jerry March, 5 th edition, page 1194.)
For example, an indanone oxime may be prepared by the addition of hydroxylamine to an indanone by the following method. A mixture of 1-indanone with NH 2 OH.HCl and K 2 CO 3 in a 1:4:4 mole ratio, is refluxed for 3 hours and evaporated to dryness. The residue is extracted with AcOEt and the extract is washed, dried and evaporated to dryness, followed by recrystallization from MeOH. (Oshiro, et al., J. Med. Chem., 34:2004-2013 (1991)).
Suitable indanones and tetralones (dihydro-1-napthalenones) for formation of oxime starting materials include, but are not limited to: 6-methoxy-1-indanones, 4-hydroxy-1-indanones, 7-methoxy-1-tetralones, including indanones and tetralones of the formula below:
wherein R 1 , X, b and m are as defined herein. Indanones and tetralones are commercially available, for example, from SigmaAldrich, St. Louis, Mo.
Example 1
Acylation process for preparation of 6-methoxy-indan-1-one O-acetyl-oxime [3 to 1 ratio]
6-Methoxy-1-indanone oxime (30 g, 0.169 mol.) was partially dissolved in 180 ml of THF at room temperature. Acetic anhydride (47.9 ml, 0.508 mol) was added to this solution over 15 minutes at 20° C. The reaction mixture was stirred at a temperature between 20-30° C. for 2 hours, then concentrated. A colorless liquid was obtained and solidified into a solid residue. The residue was dissolved in methylene chloride (60 ml) and was washed with water (60 ml) twice. The organic layer was separated from the aqueous layer, dried with MgSO 4 , filtered, and concentrated to obtain 56 g of a white solid. This product was partially dissolved in methyl tert-butyl ether (MTBE) (60 ml) which was then warmed at 55° C. MTBE (195 ml) was added again slowly to completely dissolve the product. The solution was warmed at reflux temperature for 5 minutes. The solution was cooled to room temperature (20° C.) as the solid crystallized. The solid was filtered and dried under vacuum. 6-methoxy-1-indanone O-acetyl oxime as a white solid (28.8 g) was obtained at a yield of 77.6%.
Example 2
Preparation of N-(6-methoxy-indan-1-yl)-acetamide
6-Methoxy-1-indanone oxime (2 g) was partially dissolved in 20 ml THF. To this solution acetic anhydride (4.4 g) was added over 10 minutes at 15-20° C. The reaction mixture was stirred at 15-20° C. for 2 hours followed by the addition of PtO 2 with 40% Pt (14 mg, 1.4% of metal Pt per oxime derivative) to 5 ml of the reaction mixture. The hydrogenation was carried out with a hydrogen pressure of 4 bars (400 kPa) at a temperature between 30-40° C. for 10 hours. The reaction mixture was filtered and then quenched with sodium hydroxide until a pH of about 8-9 was obtained, while maintaining the temperature below 25° C. The aqueous layer was subsequently removed and the organic layer was concentrated to obtain the product, N-(6-methoxy-1-indan-1-yl)-acetamide. The yield was 90%.
Example 3
Preparation of 6-methoxy-indan-1-ylamine
6-Methoxy-indan-1-one oxime (1 kg) was partially dissolved in 6 liters of THF. Acetic anhydride (1.73 kg) was added to the solution over 15 minutes at 20° C. The reaction mixture was stirred between 20-30° C. for 2 hours. To this reaction mixture, Pd/C 5% (0.1 kg, 0.5% of metal Pd/oxime derivative) was added. Hydrogenation was performed with a hydrogen pressure of 3 bars (300 kPa) at a temperature between 30-40° C. over 4-6 hours. The reaction mixture was filtered and concentrated under atmospheric pressure to a volume of 3 liters. The concentrate was warmed to 70° C., then 4 liters of water were added and temperature maintained at 70° C. for 1 hour. The mixture was slowly warmed in a 95° C. bath until evaporation of the solvent was complete. The mixture was cooled to 36° C., 4 liters of methylene chloride were added and the mixture was further cooled to 20° C. The mixture was quenched with an aqueous solution of 30% sodium hydroxide (3.8 kg of solution) to a pH of about 8-9, while maintaining the temperature below 25° C. After removal of the aqueous layer, the organic layer was washed with 1 liter of water and concentrated at atmospheric pressure until the methylene chloride was completely removed. The concentrate was then dissolved in methanol (10 L).
A 36% solution of hydrochloric acid (1.7 kg of solution) was added to the methanolic solution, and the mixture was warmed at 90° C. for 8 hours. After the mixture was cooled to 25° C., a 36% solution of hydrochloric acid (0.86 kg of solution) was added and the mixture was warmed at 90° C. for 7 hours. After cooling to 25° C., another 36% solution of hydrochloric acid (0.29 kg) was added. The mixture was warmed at 90° C. for 6 hours. The mixture was cooled to 25° C. and transferred into a reactor equipped with a scrubber. The mixture was heated to reflux and the methanol was distilled (9 L).
The mixture was cooled to 60° C., followed by addition of water (5 L). Part of the distillate (2 L) was eliminated under pressure at 90° C.
The mixture was cooled to 60° C. and washed with toluene (1 L). The mixture was basified with an aqueous solution of sodium hydroxide to a pH of about 12 to 13 in presence of xylenes at 22° C. The aqueous layer was separated and re-extracted with xylenes (1 L). The organic layer was washed with water (1 L). All organic layers were mixed and concentrated to dryness. The product, 6-methoxy-indan-1-ylamine, was obtained with an overall yield of 65%.
The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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A process for preparing indanylamine and aminotetralin derivatives from indanone or tetralone oximes by acylating the oximes with an organic anhydride, followed by catalytic hydrogenation in the presence of an organic anhydride with subsequent hydrolysis is described. The process is commercially feasible providing indanylamine and aminotetralin derivatives in high yield that are useful as intermediates in the production of therapeutically active compounds. Also described are novel intermediates, 1-indanone O-acetyl oximes and 1-tetralone O-acetyl oximes.
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BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to a pair of effort-saving looping shears for trimming twigs and branches, and more particularly to one that allows easy grip of its handles at optimal angle.
(b) Description of the Prior Art
Most of the conventional crocodile shears ( 10 ) for gardening purpose are comprised of a fixed jaw ( 101 ) pivoted to a mobile jaw ( 102 ) as illustrated in FIG. 1 with the blade of the mobile jaw ( 102 ) practically doing all the trimming. However, said crocodile shears ( 10 ) is not provided with an effort-saving mechanism, the user has to grip onto both handles of the crocodile shears and open them up to the maximal degree before executing any trimming, which becomes tiresome and does not meet ergonomics.
An improved design of the crocodile shears ( 20 ) provided with an effort-saving mechanism (according. to U.S. Pat. No. 5,689,888) as illustrated in FIG. 2 essentially relates to one that has multiples of toothed sector ( 203 ) on the outer side of a fixed jaw ( 201 ) with a handle ( 204 ) and a mobile jaw ( 202 ) being separately pivoted, another toothed sector ( 205 ) engaging the toothed sector ( 203 ) for both toothed sectors ( 203 )( 205 ) to achieve effort-saving purpose in applying the gardening crocodile shears. However, no substantial effort-saving is achieved by the structure comprised of said toothed sectors ( 203 ) ( 205 ) for merely relying upon the engagement between them and both handles must be opened up to approximately 180 degrees before executing the cutting and making it difficult to apply the force to close in the handles. That is, said effort-saving mechanism again does not meet ergonomics for failing to provide the optimal angle for force application by both arms of the user.
Another improvement for effort-saving mechanism( 30 ),(e.g. ROC Publication No. 264606) as illustrated in FIG. 3 includes a fixed jaw ( 301 ), a mobile jaw ( 302 ), handles ( 303 )( 304 ) and a link ( 305 ). Wherein, a row of ratchet ( 3021 ) is provided on the lower arm of the mobile jaw ( 302 ) to be pivoted to the link ( 305 ) to the handle ( 304 ) by insertion of a pin ( 306 ) so that by adjusting the position of the pin ( 306 ) to engage the ratchet ( 3021 ) to achieve the effort-saving purpose. However, while working, it takes to gradually adjust the engagement position for said pin ( 306 ) in the ratchet ( 3021 ) and the chance of having skipped or stuck ratchet is considerably high. Particularly, usually the engagement position forthwith skips from the last tooth to the first tooth of the ratchet ( 3021 ) as the motion of the link ( 305 ) is subject to pull by a coil ( 307 ). Again, the improvement does not meet ergonomics by failing to allow control wherein the force can be comfortably applied.
To correct those defects described above, the prevent invention comprised of a strike jaw, a blade jaw, a pivot and an effort-saving mechanism by having said pivot provided with a ratchet that synchronously turns with the blade piece of the blade jaw, a mobile tab being provided to a handle, said mobile table being engaged to the ratchet in a direction adjustable for the user to open up both handles for an optimal angle to repeat applying the force as desired to trim twigs and branches with comfort.
SUMMARY OF THE INVENTION
The primary purpose is to provide a structure of effort-saving looping shears for gardening purpose by the engagement of a ratchet and a mobile tab to repeat opening up both handles to an optimal degree meeting ergonomics for applying the force for a comfortable trimming.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the prior art of a pair of crocodile shears,
FIG. 2 is a schematic view of a pair of effort-saving crocodile shears of the prior art,
FIG. 3 is a schematic view of another pair of effort-saving crocodile shears of the prior art,
FIG. 4 is a perspective view partially showing an assembly of a preferred embodiment of the present invention,
FIG. 5 is a perspective view showing part of the preferred embodiment of the present invention before the assembling,
FIG. 6 is a schematic view of a mobile tab and a ratchet of the preferred embodiment of the present invention,
FIG. 7 is a sectional view showing part of an assembly of the preferred embodiment of the present invention, and
FIG. 8 is a schematic view of the preferred embodiment of the present invention in use.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 4 and 5, a pair of looping shears of the present invention includes a strike jaw ( 1 ), a blade jaw ( 2 ) and an effort-saving mechanism ( 3 ), wherein, said strike jaw ( 1 ) as illustrated in FIG. 5 being comprised of a strike piece ( 11 ) and a handle ( 12 ) with said strike piece ( 11 ) related to an arc curved inwardly, a circular pivot hole ( 111 ) being provided at a selected location below the strike piece ( 11 ), and said handle ( 12 ) being a known long stick directly fixed to the lower end of the strike piece ( 11 ) to form the strike jaw ( 1 ).
Said blade jaw ( 2 ) as illustrated in FIG. 5 includes a blade piece ( 21 ) and another handle ( 22 ) with an arc tip ( 211 ) formed on the front edge of the blade piece ( 21 ), a rectangular pivot hole ( 212 ) being provided at where selected on the lower side of the blade piece ( 21 ), said handle ( 22 ) being a known long stick having at its front section fixed with a sheet iron ( 221 ), a circular through hole ( 222 ) in the one end of the sheet iron ( 221 ), a rectangular slot ( 223 ) at the lower edge of the through hole ( 222 ), and a pin hole ( 224 ) below the rectangular slot ( 223 ) for the effort-saving mechanism ( 3 ) to be adapted to the rectangular pivot hole ( 212 ) with the circular through hole ( 222 ) to form the blade jaw ( 2 ).
Said effort-saving mechanism ( 3 ) as illustrated in FIG. 5 comprised of a ratchet pivot ( 31 ) and a mobile tab ( 32 ), within, a circular bonnet ( 311 ) being formed at the top of the ratchet pivot ( 31 ), a ratchet ( 312 ) to the lower section of the bonnet ( 311 ) while the lower part of the ratchet ( 312 ) related to a rectangular section ( 313 ) and the lower part of the rectangular section ( 313 ) related to a cylindrical section ( 314 ), a threaded section ( 315 ) being provided at the center of the tail of said cylindrical section ( 314 ) to form the ratchet pivot ( 31 ) pivoted to the strike jaw ( 1 ) and the blade jaw ( 2 ) with a packing ( 316 ) and a nut ( 317 ); said mobile tab ( 32 ) curved to from graded levels with both sides of the lower lever respectively protruding a tooth ( 321 ) to engage the ratchet ( 312 ) of the ratchet pivot ( 31 ) while a circular hole ( 322 ) being separately provided in the upper lever of the mobile tab ( 32 ) to receive insertion of a pin ( 323 ).
Now referring to FIGS. 6 and 7, the ratchet pivot ( 31 ) of the effort-saving mechanism penetrates the circular through hole ( 222 ) at the front end of the sheet iron ( 221 ) of the blade jaw for the ratchet ( 312 ) merely being accommodated in the circular through hole ( 222 ); the mobile tab ( 32 ) penetrates the circular through hole ( 322 ) and the pin hole ( 224 ) to be secured to the blade piece ( 21 ) with the pin ( 323 ); and the lower lever of the mobile tab ( 32 ) engages the ratchet ( 312 ) in the slot ( 223 ) to form the effort-saving mechanism ( 3 ). Said ratchet pivot ( 31 ) has its rectangular section ( 313 ) to penetrate the rectangular pivot hole ( 212 ) in the blade piece ( 21 ) for the rectangular pivot hole ( 212 ) of the blade piece ( 21 ) to receive insertion by the rectangular section ( 313 ) to execute synchronous turning in forming the blade jaw ( 2 ) of the pair of the looping shears with the blade piece ( 21 ) and the handle ( 22 ). The threaded section ( 315 ) of the ratchet pivot ( 31 ) penetrating the circular pivot hole ( 111 ) in the strike jaw ( 1 ) and secured in position with a packing ( 316 ) and a nut ( 317 ) for the strike jaw ( 1 ) to be pivoted and overlapped with the blade jaw ( 2 ) to form a pair of looping shears of the present invention as illustrated in FIG. 4 .
Now referring to FIG. 6, the mobile tab ( 32 ) of the blade jaw ( 2 ) is moved by finger for the tooth ( 321 ) on one side of the mobile ( 32 ) to engage the ratchet ( 312 ) to indicate a structure for one-way looping by finger, thus for the user to open up both handles ( 12 )( 22 ) for an optimal degree to apply the force as illustrated in FIG. 8 . Upon closing in both of said handles ( 12 )( 22 ), the ratchet pivot ( 31 ) and the blade piece ( 21 ) synchronously and gradually loop to close in as driven by the mobile tab ( 32 ) for a comfortable trimming even in case of some rough twigs.
Whereas the present invention permits the optimal opening degree between said two handles ( 12 )( 22 ) to repeat trimming with the effort-saving mechanism, defectives as observed in the prior art illustrated in FIGS. 1 and 2 are corrected. The user while opening up said two handles ( 12 )( 22 ) does not have to open his arms too wide and thus to prevent fatigue and sore muscles. That is, the present invention achieves effort-saving effect by meeting ergonomics. Furthermore, as the mobile tab ( 32 ) of the effort-saving mechanism drives the ratchet pivot ( 31 ) and the blade piece ( 21 ) for a progressive closing in for trimming twigs, the user simply repeats control over opening up and closing in by gripping both handles ( 12 )( 22 ) without having to stop to execute careful adjustment of the engagement position required in the prior art as illustrated in FIG. 4 . The present invention not only meets ergonomics, warrant effort saving, but also is practical in application.
Provided, however, that the art and the primary purpose of the present invention are taking advantage of the configuration for the incorporation of the effort-saving mechanism, the blade piece ( 21 ) and the handle ( 22 ) to achieve the purpose of comfortable application of force and easy operation of the looping shears. Therefore, structures of the strike jaw ( 1 ), length and form of both handles ( 12 )( 22 ) are not limited to those disclosed in the preferred embodiments. As illustrated in FIG. 4, a buffer ( 4 ) made of soft plastic or rubber material is each provided on both inner sides of both handles ( 12 )( 22 ) to reduce impact created upon closing in both handles ( 12 )( 22 ). Alternatively, the rectangular pivot hole ( 212 ) in the blade piece ( 21 ) and the rectangular section ( 313 ) of the ratchet pivot ( 31 ) may be provided in hexagonal or other polygonal form. It is to be noted that any summary alteration and/or replacement by operating the art disclosed in the present invention shall fall within the scope and spirits of the art of the present invention.
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A pair of looping shears for gardening purpose to allow its user the optimal cutting angle while trimming twigs, comprised of strike jaw, blade jaw and effort-saving mechanism; within, a ratchet is provided to a pivot of the blade jaw that synchronously turns with the strike jaw, and a mobile tab engaged with the ratchet and the handle of the blade jaw to achieve comfortable grip on the handles at an optimal angle for applying the force to repeat trimming twigs and branches.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a drive circuit of an active matrix type display device which is composed of thin-film transistors. In particular, the invention relates to a drive circuit of an active matrix type display device in which source followers are used as analog buffers and variations of their characteristics are suppressed.
[0002] The active matrix type display device is a display device in which pixels are arranged at intersections of a matrix with every pixel associated with a switching element, and image information is controlled by turning on/off of the switching elements. This type of display device uses, as a display medium, a liquid crystal, plasma, or some other material or state whose optical characteristic (reflectance, refractive index, transmittance, luminous intensity, or the like) can be varied electrically. In the present invention, specifically a field-effect transistor (three-terminal element) having the gate, source and drain is used as the switching element.
[0003] In the following description of the invention, a row of a matrix means a structure in which a signal line (gate line) that is disposed parallel with the row concerned is connected to the gate electrodes of transistors of the row concerned. A column means a structure in which a signal line (source line) that is disposed parallel with the column concerned is connected to the source (or drain) electrodes of transistors of the column concerned. A circuit for driving the gate lines is called a gate drive circuit, and a circuit for driving the source lines is called a source drive circuit.
[0004] In the gate drive circuit, stages of a shift register corresponding to the number of gate lines in the vertical direction are arranged linearly and interconnected in series to generate signals of vertical scanning timings of the active matrix type display device. In this manner, the thin-film transistors of the active matrix type display device are switched by means of the gate drive circuit.
[0005] In the source drive circuit, stages of a shift register corresponding to the number of source lines in the horizontal direction are arranged linearly and interconnected in series to generate horizontal image data of display image data of the active matrix display device. Analog switches are turned on/off by latch pulses that are synchronized with horizontal scanning signals. In this manner, currents are supplied to the thin-film transistors of the active matrix type display device by means of the source drive circuit, to control orientations of liquid crystal cells.
[0006] [0006]FIG. 9 schematically shows a conventional active matrix type display device. There are two kinds of polycrystalline silicon thin-film transistor manufacturing processes: a high-temperature process and a low-temperature process. In the high-temperature process, polycrystalline silicon is deposited on an insulating film that is formed on a quartz substrate, and a thermally oxidized SiO 2 is formed as a gate insulating film. Thereafter, gate electrodes are formed, N-type or P-type ions are implanted, and source and drain electrodes are formed. Thus, polycrystalline silicon thin-film transistors are manufactured.
[0007] In the low-temperature process, silicon is crystallized by two kinds of methods: solid-phase growth and laser annealing. In the solid-phase growth, a polycrystalline silicon film is obtained by subjecting an amorphous silicon film on an insulating film that is formed on a glass substrate to a heat treatment of 600° C. and 20 hours, for example. In the laser annealing, a polycrystalline silicon film is obtained by applying laser light to amorphous silicon on a glass substrate surface to thereby heat-treat only the film surface portion at a high temperature.
[0008] In general, crystalline films are obtained by using one or both of the above two methods.
[0009] An SiO 2 film is then formed as a gate insulating film by plasma CVD. Thereafter, gate electrodes are formed, N-type or P-type ions are implanted, and source and drain electrodes are formed. Thus, polycrystalline silicon thin-film transistors are manufactured.
[0010] The source drive circuit is a circuit for supplying image data to an active matrix panel of the active matrix type display device by scanning it vertically, and is composed of a shift register, analog switches that are thin-film transistors, analog memories that are capacitors, and analog buffers formed of thin-film transistors.
[0011] The analog buffer is needed because the analog memory cannot directly drive the thin-film transistors of the active matrix type display device due to a large load capacitance of the source line.
[0012] The thin-film transistor of the analog buffer has a source follower configuration. As shown in FIGS. 6A and 6B, a single thin-film transistor is provided for each data holding control signal line, and the thin-film transistors are so manufactured as to be arranged at regular intervals.
[0013] [0013]FIG. 6A shows an example of using N-channel thin-film transistors. Alternatively, P-channel thin-film transistors (see FIG. 6 b ) or both types of transistors may be used.
[0014] The analog buffers that constitute the source drive circuit of the conventional active matrix type display device have the following problem.
[0015] Each analog buffer has the single thin-film transistor that has a source follower configuration. When laser annealing is employed as a means for crystallization as described above in the thin-film transistor manufacturing process, a silicon film on a glass substrate is irradiated with band-like laser light of a width L while being scanned with it in the X-axis direction, i.e., horizontally (see FIG. 7A) to crystallize silicon, because there exists no such large-diameter laser device as can irradiate a large-size substrate at one time.
[0016] When the illumination is effected while the laser light is moved in the X-direction at a constant length at a time, there occurs an overlap of illumination. Since the width L of the band-like laser light does not necessarily coincide with a pitch d (see FIG. 7B) of the source follower, the illumination laser light quantity varies depending on the position on the silicon film in the laser crystallization step.
[0017] Therefore, a positional variation, i.e., variations in characteristics occur in thin-film transistors that are produced from the above silicon film, and the threshold voltage V th varies from one thin-film transistor to another in the range of V thL to V thH depending on the position X on the X-axis (see FIG. 8). The threshold voltage V th has a small value at a position where laser beams overlap with each other, and has a large value where they do not. As a result, there occurs a variation in magnitude of output voltages of the source followers, which directly results in a variation of application voltages to the liquid crystal device.
[0018] [0018]FIG. 11 shows an application voltage vs. transmittance characteristic of a normally-white liquid crystal device. It is understood that a variation ΔV th of the threshold voltage V th causes a corresponding variation of the transmittance, which is reflected in a displayed image.
[0019] As described above, the output voltages of the source drive circuit undesirably vary depending on positions thereof, resulting in display unevenness of pixels of the active matrix type display device.
SUMMARY OF THE INVENTION
[0020] An object of the present invention is to reduce display unevenness of pixels in an active matrix type display device.
[0021] In contrast to the conventional device in which a single analog buffer is provided for a data holding control signal for each data line, the present invention is characterized in that a data holding control signal is connected with a plurality of source followers that are connected together in parallel. Further, in accordance with a preferred embodiment of the present invention, the parallel-connected source followers are a combination of at least one source follower that is irradiated with laser light and at least one source follower that is irradiated twice for crystallization.
[0022] A width L of the laser light illumination for crystallization is preferably larger than a pitch d of the source followers, and is equal to the pitch d multiplied by an integer n that is not less than 3 . Further, the invention is characterized in that 2 to n−1 source followers are connected together in parallel. A variation of the threshold voltage of thin-film transistors can be suppressed by combining source followers that are illuminated at different numbers of times.
[0023] Although the pitch of the source followers and the width of laser light illumination have been mentioned above, the term “pitch of the source followers” may be replaced by another term “pitch of pixels” because they are equal to each other in general.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1 is a circuit diagram showing analog buffers of an active matrix type display device according to a first embodiment of the present invention;
[0025] [0025]FIG. 2 is a circuit diagram showing analog buffers of an active matrix type display device according to a second embodiment of the invention;
[0026] [0026]FIG. 3 is a circuit diagram showing analog buffers of an active matrix type display device according to a third embodiment of the invention;
[0027] [0027]FIG. 4 is a circuit diagram showing analog buffers of an active matrix type display device according to a fourth embodiment of the invention;
[0028] [0028]FIG. 5 is a circuit diagram showing analog buffers of an active matrix type display device according to a fifth embodiment of the invention;
[0029] [0029]FIGS. 6A and 6B are circuit diagrams showing examples of analog buffers used in a conventional active matrix type display device;
[0030] [0030]FIGS. 7A and 7B schematically illustrate laser light illumination in a conventional analog buffer manufacturing step;
[0031] [0031]FIG. 8 is a graph showing a relationship between the threshold voltage V th of thin-film transistors used in the conventional analog buffers and the laser light illumination position X in a thin-film transistor manufacturing process;
[0032] [0032]FIG. 9 schematically shows the conventional active matrix type display device;
[0033] FIGS. 10 A- 10 F shows a manufacturing process of a complementary inverter circuit; and
[0034] [0034]FIG. 11 is a graph showing an application voltage vs. transmittance characteristic of a normally-white liquid crystal device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] First, referring to FIG. 10A- 10 F, a description will be made with respect to a manufacturing process of thin-film transistors used in the present invention.
[0036] A complementary inverter circuit will be described by way of embodiment. A silicon dioxide film of 1,000-3,000 Å in thickness was formed as an undercoat oxide film on a glass substrate (low-alkali glass, quartz glass, or the like; for instance Corning 7059) by sputtering in an oxygen atmosphere. To improve the productivity, there may be used a film obtained by decomposing and depositing TEOS by plasma CVD.
[0037] Then, an amorphous silicon film was deposited at a thickness of 300-5,000 Å, preferably 500-1,000 Å by plasma CVD or LPCVD, and crystallized by being left in a reducing atmosphere of 550° C. to 600° C. for 4-48 hours. The degree of crystallization was increased by performing laser light illumination (wavelength: 308 or 248 nm) after the above step. The silicon film thus crystallized was patterned into island-like regions 1 and 2 . A silicon dioxide film 3 of 700-1,500 Å in thickness was formed thereon by sputtering.
[0038] Subsequently, a film of aluminum (containing Si of 1 wt % or Sc of 0.1-0.3 wt %) of 1,000 Å to 3 μm was formed by electron beam evaporation or sputtering. A photoresist (for instance, OFPR800/30cp produced by Tokyo Ohka Kogyo Co., Ltd.) was then formed by spin coating. Formation of an aluminum oxide film of 100-1,000 Å in thickness by anodic oxidation before the formation of the photoresist was effective in providing good adhesiveness with the photoresist and in forming a porous anodic oxide film only on the side faces in a subsequent anodic oxidation step by suppressing a leak current from the photoresist. The photoresist and the aluminum film were patterned, i.e., etched together to form gate electrodes 4 and 5 and mask films 6 and 7 (see FIG. 10A).
[0039] Anodic oxidation was performed on the resulting structure by supplying it with a current in an electrolyte, to form anodic oxide films 8 and 9 of 3,000-6,000 Å, for instance, 5,000 Å in thickness. The anodic oxidation may be performed such that a 3% to 20% acid aqueous solution of citric acid, oxalic acid, phosphoric acid, chromic acid, sulfuric acid, or the like is used and a constant voltage of 10-30 V is applied to the gate electrodes. In this embodiment, the anodic oxidation was performed for 20-40 minutes in oxalic acid of 30° C. by applying a voltage of 10 V. The thickness of the anodic oxide films 8 and 9 was controlled by the anodic oxidation time (see FIG. 10B).
[0040] After removing the mask films 6 and 7 , the gate electrodes 4 and 5 were again supplied with a current in an electrolyte. An ethylene glycol solution containing tartaric acid, boric acid and nitric acid (3% to 10% in total) was used this time. A superior oxide film was obtained when the temperature of the solution was about 10 C, i.e., lower than the room temperature. As a result, barrier type anodic oxide films 10 and 11 were formed on the top and side faces of the gate electrodes 4 and 5 . The thickness of the anodic oxide films 10 and 11 was proportional to the application voltage. For instance, a 2,000-Å-thick anodic oxide film was formed with an application voltage of 150 V. The thickness of the anodic oxide films 10 and 11 was determined by a necessary offset. It is preferred that the thickness be less than 3,000 Å, because a high voltage of more than 250 V is needed to produce an anodic oxide film thicker than 3,000 Å and will cause adverse effects on characteristics of the thin-film transistors. In this embodiment, the voltage was increased to 80-150 V, and a proper voltage was selected depending on a necessary thickness of the anodic oxide films 10 and 11 .
[0041] It should be noted that the barrier-type anodic oxide films 10 and 11 were formed between the porous anodic oxide films 8 and 9 and the gate electrodes 4 and 5 rather than outside the porous anodic oxide films 8 and 9 , though the step of forming the barrier-type anodic oxide films 10 and 11 was performed later.
[0042] Then, the insulating film 3 was etched by dry etching (or wet etching). The etching depth may be determined arbitrarily; that is, the etching may be performed until the underlying active layers 1 and 2 are exposed, or may stopped halfway. In terms of the productivity, yield and uniformness, it is desirable that the etching be performed until reaching the active layers 1 and 2 . In this case, insulating films 12 and 13 having the original thickness are left in the portions of the insulating film (gate insulating film 3 ) covered with the anodic oxide films 8 and 9 or the gate electrodes 4 and 5 (see FIG. 10C).
[0043] Then, the anodic oxide films 8 and 9 were removed. It is preferred that the etchant be a phosphoric acid type solution, for instance, a mixed acid of phosphoric acid, acetic acid and nitric acid. With a phosphoric acid type etchant, the porous anodic oxide films 8 and 9 are etched at a rate that is more than 10 times faster than the barrier-type anodic oxide films 10 and 11 . Therefore, substantially the barrier-type anodic oxide films 10 and 11 are not etched with a phosphoric acid type etchant. Thus, the gate electrodes inside the barrier-type anodic oxide films were protected.
[0044] Sources and drains were formed by implanting accelerated N-type or P-type impurity ions into the active layers 1 and 2 of the above structure. More specifically, first, with the left-hand thin-film transistor region covered with a mask 14 , phosphorus ions of relatively low speed (typical acceleration voltage: 5-30 kV) were introduced by ion doping. In this embodiment, the acceleration voltage was set at 20 kV. Phosphine (PH 3 ) was used as a doping gas. The dose was 5×10 14 to 5×10 15 cm −2 . In this step, phosphorus ions cannot penetrate the insulating film 13 , they were implanted into only the portions of the active region 2 whose surfaces were exposed, to form a drain 15 and a source 16 of the N-channel thin-film transistor (see FIG. 10D).
[0045] Subsequently, phosphorus ions of relatively high speed (typical acceleration voltage: 60-120 kV) were introduced also by ion doping. In this embodiment, the acceleration voltage was 90 kV, and the dose was 1×10 13 to 5×10 14 cm −2 . In this step, phosphorus ions penetrate the insulating film 13 to reach the underlying portions. However, due to the small dose, low-concentration N-channel regions 17 and 18 were formed (see FIG. 10E).
[0046] After completion of the phosphorus doping, the mask 14 was removed. In a manner similar to the above, a source 19 , a drain 20 , and low-concentration P-type regions 21 and 22 were formed in the P-channel thin-film transistor region with the N-channel thin-film transistor region masked this time. Impurity ions introduced into the active regions 1 and 2 were activated by illumination with KrF excimer laser light (wavelength: 248 nm; pulse width: 20 nsec).
[0047] Finally, a silicon dioxide film of 3,000-6,000 Å in thickness was formed over the entire surface as an interlayer insulating film 23 by CVD. After contact holes for the sources and drains of the thin-film transistors were formed, aluminum wiring lines and electrodes 24 - 26 were formed. Further, hydrogen annealing was performed at 200° C. to 400° C. Thus, a complementary inverter circuit using the thin-film transistors was completed (see FIG. 10F).
[0048] Although the above description is directed to the inverter circuit, other circuits can be manufactured in similar manners. Further, although the above description is directed to the coplanar thin-film transistors, it can be applied to other types of thin-film transistors such as inverse-stagger type ones.
[0049] Embodiments of the invention will be described below.
[0050] [0050]FIG. 1 shows a first embodiment of the invention. In this embodiment, source followers are arranged at a pitch d, and the laser light illumination width L is equal to 3d. Two source followers are connected to each other in parallel. Representing a source follower matrix by (l, m), the laser light is first applied to source followers (p, q), (p+1, q), (p+2, q),(p, q+1), (p+1, q+1), and (p+2, q+1).
[0051] The laser light is then moved so as to illuminate source followers (p+2, q), (p+3, q), (p+4, q), (p+2, q+1), (p+3, q+1), and (p+4, q+1). Actually, after the first laser irradiation, the substrate mounted on a X-Y table is moved and then the second irradiation is carried out.
[0052] Further, a next laser irradiation is carried out onto the source followers (p+4, q), (P+5, q), (p+6, q), (p+4, q+1), (P+5, q+1), and (p+6, q+1).
[0053] In the above manner, the source followers (p, q), (p, q+1), (p+2, q), (p+2, q+1), (p+4, q), (p+4, q+1), (p+6, q) and (p+6, q+1) are illuminated twice with the laser light. Thus, they have the threshold voltage V thL in view of FIG. 8.
[0054] On the other hand, the source followers (p+1, q), (p+1, q+1), (p+3, q), (p+3, q+1), (p+5, q), and (p+5, q+1) are illuminated only once with the laser light. Thus, they have the threshold voltage V thH .
[0055] By connecting to each other in parallel the source followers (p, q) and (p+1, q), the source followers (p+2, q) and (p+3, q), the source followers (p+4, q) and (p+5, q), the source followers (p+1, q+1) and (p+2, q+1), and the source followers (p+3, q+1) and (p+4, q+1) as shown in FIG. 1, the characteristics of the source followers are averaged, so that variations in the characteristics caused by the laser illumination can be reduced. In other words, in each combined source followers, one source follower has a higher crystallinity TFT while the other one has a lower crystallinity TFT.
[0056] [0056]FIG. 2 shows a second embodiment of the invention. In this embodiment, source followers are arranged at a pitch d, and the laser light illumination width L is equal to 4d. Three source followers are connected together in parallel.
[0057] The laser light is first applied to source followers (p, q), (p+1, q), (p+2, q), (p+3, q), (p, q+1), (p+1, q+1), (p+2, q+1), (p+3, q+1), (p. q+2), (p+1, q+2), (p+2, q+2) and (p+3, q+2).
[0058] The laser light is then moved so as to illuminate source followers (p+3, q), (p+4, q), (p+5, q), (p+6, q), (p+3, q+1), (p+4, q+1), (p+5, q+1), (p+6, q+1), (p+3, q+2), (p+4, q+2), (p+5, q+2) and (p+6, q+2).
[0059] Since the source followers (p, q), (p, q+1), (p, q+2), (p+3, q), (p+3, q+1), (p+3, q+2), (p+6, q), (p+6, q+1) and (p+6, q+2) are illuminated twice with the laser light, they have the threshold voltage V thL (see FIG. 8).
[0060] Since the source followers (p+1, q), (p+2, q), (p+1, q+1), (p+2, q+1), (p+1, q+2), (p+2, q+2), (p+4, q), (p+5, q), (p+4, q+1), (p+5, q+1), (p+4, q+2) and (p+5, q+2) are illuminated only once with the laser light, they have the threshold voltage V thH (see FIG. 8).
[0061] By connecting together in parallel the source followers (p, q), (p+1, q) and (p+2, q), the source followers (p+3, q), (p+4, q) and (p+5, q), the source followers (p+1, q+1), (p+2, q+1) and (p+3, q+1), the source followers (p+4, q+1), (p+5, q+1) and (p+6, q+1), and the source followers (p+2, q+2), (p+3, q+2) and (p+4, q+2), respectively, as shown in FIG. 2, one of the three source followers of each combination is illuminated twice with the laser light and the other two source followers are illuminated only once. By combining the source followers in the above manner, the source followers of every set are made uniform, so that variations in the characteristics caused by the laser illumination can be eliminated.
[0062] [0062]FIG. 3 shows a third embodiment of the invention. In this embodiment, source followers are arranged at a pitch d, and the laser light illumination width L is equal to 4d. Two source followers are connected in parallel to form one analog buffer where one source follower of an adjacent buffer is located between the two.
[0063] The laser light is first applied to source followers (p, q), (p+1, q), (p+2, q), (p+3, q), (p, q+1), (p+1, q+1), (p+2, q+1) and (p+3, q+1).
[0064] The laser light is then moved so as to illuminate source followers (p+3, q), (p+4, q), (p+5, q), (p+6, q), (p+3, q+1), (p+4, q+1), (p+5, q+1) and (p+6, q+1).
[0065] Since the source followers (p, q), (p, q+1), (p+3, q), (p+3, q+1), (p+6, q) and (p+6, q+1) are illuminated twice with the laser light, they have the threshold voltage V thL (see FIG. 8).
[0066] Since the source followers (p+1, q), (p+2, q), (p+1, q+1), (p+2, q+1), (p+4, q), (p+5, q), (p+4, q+1) and (p+5, q+1) are illuminated only once with the laser light, they have the threshold voltage V thH (see FIG. 8).
[0067] By connecting to each other in parallel the source followers (p, q) and (p+2, q), the source followers (p+1, q) and (p+3, q), the source followers (p+4, q) and (p+6, q), the source followers (p, q+1) and (p+2, q+1), the source followers (p+1, q+1) and (p+3, q+1), and the source followers (p+4, q+1) and (p+6, q+1) as shown in FIG. 3, one of the two source followers of each combination is illuminated twice with the laser light and the other source follower is illuminated only once. By combining the source followers in the above manner, the source followers of every set are made uniform, so that variations in the characteristics caused by the laser illumination can be eliminated.
[0068] [0068]FIG. 4 shows a fourth embodiment of the invention. In this embodiment, source followers are arranged at a pitch d, and the laser light illumination width L is equal to 4d. Two source followers that are located in an oblique direction are connected to each other in parallel.
[0069] The laser light is first applied to source followers (p, q), (p+1, q), (p+2, q), (p+3, q), (p, q+1), (p+1, q+1), (p+2, q+1) and (p+3, q+ 1).
[0070] The laser light is then moved so as to illuminate source followers (p+3, q), (p+4, q), (p+5, q), (p+6, q), (p+3, q+1), (p+4, q+1), (p+5, q+1) and (p+6, q+1).
[0071] By connecting to each other in parallel the source followers (p, q) and (p+1, q+1), the source followers (p+1, q) and (p+2, q+1), the source followers (p+2, q) and (p+3, q+1), the source followers (p+3, q) and (p+4, q+1), the source followers (p+4, q) and (p+5, q+1), and the source followers (p+5, q) and (p+6, q+1) as shown in FIG. 4, the characteristics of the source followers are averaged, so that variations in the characteristics caused by the laser illumination can be reduced.
[0072] [0072]FIG. 5 shows a fifth embodiment of the invention. In this embodiment, source followers are arranged at a pitch d, and the laser light illumination width L is equal to 4d. Three source followers located in an oblique direction are connected together in parallel.
[0073] The laser light is first applied to source followers (p, q), (p+1, q), (p+2, q), (p+3, q), (p, q+1), (p+1, q+1), (p+2, q+1), (p+3, q+1), (p. q+2), (p+1, q+2), (p+2, q+2) and (p+3, q+2).
[0074] The laser light is then moved so as to illuminate source followers (p+3, q), (p+4, q), (p+5, q), (p+6, q), (p+3, q+1), (p+4, q+1), (p+5, q+1), (p+6, q+1), (p+3, q+2), (p+4, q+2), (p+5, q+2) and (p+6, q+2).
[0075] Since the source followers (p, q), (p, q+1), (p, q+2), (p+3, q), (p+3, q+1), (p+3, q+2), (p+6, q), (p+6, q+1) and (p+6, q+2) are illuminated twice with the laser light, they have the threshold voltage V thL (see FIG. 8).
[0076] Since the source followers (p+1, q), (p+2, q), (p+1, q+1), (p+2, q+1), (p+1, q+2), (p+2, q+2), (p+4, q), (p+5, q), (p+4, q+1), (p+5, q+1), (p+4, q+2) and (p+5, q+2) are illuminated only once with the laser light, they have the threshold voltage V thH (see FIG. 8).
[0077] By connecting together in parallel the source followers (p, q), (p+1, q+1) and (p+2, q+2), the source followers (p+1, q), (p+2, q+1) and (p+3, q+2), the source followers (p+2, q), (p+3, q+1) and (p+4, q+2), the source followers (p+3, q), (p+4, q+1) and (p+5, q+2), and the source followers (p+4, q ), (p+5, q+1) and (p+6, q+2) as shown in FIG. 5, one of the three source followers of each combination is illuminated twice with the laser light and the other two source followers are illuminated only once. By combining the source followers in the above manner, the source followers of every set are made uniform, so that variations in the characteristics caused by the laser illumination can be eliminated.
[0078] As described above, by connecting in parallel the source followers that use thin-film transistors, the invention can suppress a variation of the threshold voltage V th due to overlapping of laser light illumination areas, to thereby reduce display unevenness of pixels.
[0079] While preferred embodiments of the present invention has been described, it is to be understood that the present invention should not be limited to those specific embodiments. Various modifications may be made by those ordinary skilled in the art. For example, it is possible to replace the source followers with other elements having an equivalent function, for example, op amp.
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A data holding control signal for each data line is supplied to a plurality of source followers that are connected together in parallel. The parallel-connected source followers are a combination of at least one first follower that is illuminated with laser light only once and at least one second follower that is illuminated twice. A width of the laser light illumination for crystallization is equal to a pitch of the source followers multiplied by an integer that is not less than 3.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to bore-lining tubing and to a method of lining a drilled bore.
2. Background of the Invention
Expandable downhole tubulars are being used increasingly in the oil and gas exploration and production industry.
It is amongst the objects of embodiments of the present invention to provide downhole tubing which facilitates the hanging and cementing of an expandable liner.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a method of lining a drilled bore, the method comprising the steps of:
providing a first tubular;
locating the first tubular in a bore;
providing an expandable, second tubular;
locating the second tubular in the bore overlapping the first tubular;
expanding a portion of the second tubular to create a coupling including a flow passage between the first tubular and the second tubular.
Preferably, the method also comprises:
providing the first tubular with a profiled portion describing an internal diameter; providing the expandable, second tubular with an external diameter less than the internal diameter of the first tubular; and locating the second tubular in the bore overlapping the profiled portion of the first tubular.
The portion of the second tubular may be expanded into contact with the first tubular to create the coupling. An upper end portion of the second tubular may be expanded into contact with the first tubular.
Preferably also, the method further comprises flowing fluid via said flow passage; and then sealing the second tubular to the first tubular.
The expansion of the second tubular is intended to prevent or at least minimise relative movement between the first and second tubulars, and preferably creates a hanging support for the second tubular.
Preferably, the first tubular has a profiled lower end portion.
Preferably, the method further comprises circulating cement into the annulus between the second tubular and the bore wall and displacing fluid from the annulus via the flow passage.
Preferably, the method further comprises expanding the second tubular below the coupling whilst maintaining said flow passage open, and most preferably expanding the second tubular to substantially the same internal diameter as the first tubular. This allows cementation to be carried out after the second tubular has been expanded, and also allows for top down expansion of the second tubular.
Sealing the second tubular to the first tubular may close the flow passage. The second tubular may be sealed to the first tubular by expanding part of the upper end portion of the second tubular located above said profiled lower end portion into sealing contact with a wall of the first tubular. Accordingly, the second tubular may be located in the bore such that it overlaps the profiled lower end portion and extends partly into an unprofiled portion of the first tubular. Alternatively, the second tubular may be sealed to the first tubular by expanding part of the upper end portion Of the second tubular located below said profiled lower end portion into sealing contact with a wall of the first tubular. Accordingly, the first tubular may include an unprofiled part below the profiled lower end portion against which the second tubular may be sealed.
The upper end portion of the second tubular may be expanded to an internal diameter substantially equal to the internal diameter of the first tubular. This allows full bore access without any restriction in the bore caused by the coupling. This may be achieved by providing a first tubular having a profiled lower end portion of an internal diameter greater than the internal diameter of a remainder of the first tubular, to accommodate expansion of the second tubular.
In an alternative, the second tubular may be sealed to the first tubular by deforming one or both of the first and second tubulars. In one embodiment, the second tubular may be sealed to the first tubular by deforming the profiled lower end portion of the first tubular. This may be achieved by corrugating, shaping or otherwise profiling said lower end portion, such that when the second tubular is expanded, it is urged radially outwardly to deform the profiled lower end portion of the first tubular.
Preferably, the second tubular is expanded from the top-down, from a level below the coupling downwards. This maintains the flow passage open and avoids problems of expansion affecting the coupling and of retrieval of expansion tools.
It will be understood that the lower end of the first tubular is profiled in that it is of non-circular internal section, and includes one or more, in particular a plurality of axial or helical flutes, grooves, channels, cutouts or the like.
The first tubular may be profiled prior to location of the second tubular in the bore. The first tubular may be profiled to shape the tubular in such a fashion that a flow passage is created on expansion of the second tubular. Thus, it will be understood that reference herein to profiling a tubular is to carrying out a shaping procedure on the tubular.
The second tubular may additionally or alternatively be profiled following location in the bore. The second tubular may be profiled on expansion. Alternatively, the second tubular may be expanded and then profiled. This may be achieved in a single procedure or in two separate procedures.
The first tubular may be profiled following location in the bore and prior to location of the second tubular, and then at least part of the second tubular may be profiled, optionally on expansion.
According to a second aspect of the present invention, there is provided bore-lining tubing comprising:
a first tubular;
an expandable, second tubular; and
a coupling between an expanded portion of the second tubular and the first tubular, said coupling including at least one flow passage between the first tubular and the second tubular.
Preferably, the first tubular of the bore-lining tubing includes a profiled portion; and the expandable, second tubular extends from the first tubular and overlaps the profiled portion. The coupling may be formed between an upper end portion of the second tubular expanded into contact with the profiled portion of the first tubular. Preferably, the flow passage is for the flow of fluid via said passage.
The provision of bore-lining tubing including a flow passage allows the tubing to be set in the bore and cemented after expansion of the second tubular.
Preferably, the first tubular profiled portion comprises a profiled lower end portion. Alternatively, the profiled portion may be provided at any desired location along a length of the first tubular.
The second tubular may be expanded at a level below the coupling. Preferably, the second tubular is expanded to an internal diameter substantially equal to an internal diameter of the first tubular. Preferably also, the expandable, second tubular comprises an expandable solid tubular.
An inner wall of the profiled lower end portion of the first tubular may include at least one flute, groove, channel or cutout defining said flow passage. Preferably, the profiled lower end portion includes a plurality of flutes, grooves, channels or cutouts around the internal circumference of the tubular, each defining a separate flow passage between the first and second tubulars. The (or each) flute, groove, channel or cutout may extend substantially axially or helically around the inner wall of the profiled lower end portion.
The internal diameter of the profiled lower end portion of the first tubular may be less than an internal diameter of the remainder of the first tubular. Alternatively, said internal diameter may be greater than an internal diameter of the remainder of the first tubular. In this fashion, when the upper end portion of the second tubular is expanded, the bore lining tubing may define a “monobore”, that is, of a substantially constant diameter along the length thereof. Thus the profiled lower end portion of the first tubular may also be of an external diameter greater than the external diameter of the remainder of the first tubular. This may maintain wall thickness and thus integrity of the first tubular in the region of the profiled lower end portion.
The profiled lower end portion of the first tubular may be profiled internally and externally and may, for example, be corrugated or otherwise shaped, and deformable to allow said flow passage to be closed by expansion of the second tubular. This may urge the second tubular outwardly, to in-turn expand the profiled lower end portion of the first tubular.
According to a third aspect of the present invention, there is provided bore-lining tubing comprising a first tubular adapted to receive an expandable, second tubular therein and to have a portion of the second tubular expanded into contact with the first tubular, to define at least one flow passage therebetween.
Preferably, the first tubular of the bore-lining tubing includes a profiled portion adapted to have the portion of the expandable, second tubular expanded into contact with said profiled portion. The profiled portion of the first tubular may be adapted to have an upper end portion of the expandable, second tubular expanded into contact with said profiled portion.
According to a fourth aspect of the present invention, there is provided bore-lining tubing comprising a tubular having a profiled portion defining at least one flow passage extending along the profiled portion.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:
FIG. 1A is a schematic cross-sectional view of a bore lined with bore-lining tubing in accordance with a first embodiment of the present invention, showing a first tubular in the bore and a second expandable tubular located within the first tubular;
FIG. 1B is a cross-sectional view of the bore-lining tubing taken in the direction of line A—A of FIG. 1A ;
FIG. 2A is a view of the bore-lining tubing of FIG. 1A , showing the second tubular partially expanded into contact with the first tubular;
FIG. 2B is a cross-sectional view of the bore-lining tubing taken in the direction of line B—B of FIG. 2A ;
FIG. 3 is a view of the bore-lining tubing of FIG. 1A , showing a lower part of the second tubular fully expanded;
FIG. 4 is a view of the bore-lining tubing of FIG. 1A , showing the second tubular fully expanded;
FIG. 5 is a view of a bore-lining tubing in accordance with an alternative embodiment of the present invention;
FIG. 6A is a schematic, cross-sectional view of part of a bore-lining tubing in accordance with a further alternative embodiment of the present invention;
FIG. 6B is a cross-sectional view of the bore-lining tubing taken in the direction of line E—E of FIG. 6A ;
FIG. 7 is a schematic, cross-sectional view of a bore-lining tubing in accordance with a still further alternative embodiment of the present invention;
FIG. 8 is schematic, cross-sectional view of part of a bore-lining tubing in accordance with a still further alternative embodiment of the present invention;
FIG. 9 is a view of a bore-lining tubing in accordance with a further alternative embodiment of the present invention;
FIG. 10 is a cross-sectional view of bore-lining tubing in accordance with a still further alternative embodiment of the present invention; and
FIG. 11 is a cross-sectional view of bore-lining tubing in accordance with a still further alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring firstly to FIG. 1A , there is shown a schematic cross-sectional view of a bore 10 lined with bore-lining tubing in accordance with a first embodiment of the present invention, indicated generally by reference numeral 12 . The bore 10 has been drilled from surface to a depth 14 , in a fashion known in the art, and cased to this level with a first tubular in the form of borehole casing 16 , cemented at 18 . The borehole casing 16 comprises a number of sections coupled together to form a casing string, and a lower section 17 is shown in the Figures. The section 17 includes a profiled portion in the form of profiled lower end portion 20 . The bore 10 is then extended to a desired depth by drilling from the level 14 and/or drilling followed by underreaming the bore 10 to a determined internal diameter.
The bore-lining tubing 12 also includes an expandable, second tubular in the form of an expandable liner 22 . The liner 22 is run-in from surface and located such than an upper end portion 24 of the liner 22 overlaps the profiled lower end portion 20 of the lower casing section 17 .
FIG. 1B is a cross-sectional view of the bore-lining tubing 12 taken on line A—A of FIG. 1A . The profiled lower end 20 of the lower casing section 17 includes a number of axial flutes, spaces or other means defining a by-pass 26 between thickened wall portions 28 . In the tubing configuration of FIGS. 1A and 1B , there is an annular clearance 30 between the liner 22 and the thickened portions 28 .
An expansion device is then activated, to expand an area 32 of the liner upper end portion 24 into contact with the thickened portions 28 , as shown in the view of FIG. 2A , and the cross-sectional view of FIG. 2B , taken on line B—B of FIG. 2A . This provides a secure coupling 29 between the liner 22 and the casing 16 , from which the liner 22 may then be suspended. Significantly, the flutes/spaces 26 in the profiled lower end of the casing 16 are kept open and define one or more flow passages between the profiled lower end 20 and the liner 22 . This allows fluid flow between the first and second tubulars 16 and 22 , from the bore 10 , through the coupling 29 and into the casing 16 .
The expansion device is then run through the section of liner 22 below the joint to expand the liner 22 out to the same internal diameter as the area 32 , as shown in FIG. 3 . During this expansion procedure, the flow passages 26 are maintained open. Following this expansion, cement is pumped from surface down through the casing 16 , and through a cement shoe (not shown) at the bottom of the liner 22 . The cement passes up through the annulus 34 defined between the bore 10 wall and the liner 22 , in the direction of the arrow C. Fluid displaced from the annulus 34 by the cement is circulated through the flow passages 26 in the coupling 29 and between the tubulars 16 and 22 , in the direction of the arrow D. Accordingly, this allows expansion of the liner 22 before the cementing process is undertaken and thus avoids the problems of the art.
After cementing has been completed, the expansion tool is re-run through the liner 22 , to expand the upper end portion 24 above (and/or a portion below) the coupling 29 outwardly, into engagement with the casing 16 , as shown in FIG. 4 . This expansion of the liner 22 into contact with the casing 16 above and/or below the coupling closes the flow passages 26 , and the liner 22 is sealed to the casing 16 by an elastomeric or other deformable seal sleeve 31 located around the upper end portion 24 of the liner 22 . Also, the flow passages 26 are further sealed by any cement remaining in the passages. The bore 10 has then been fully lined and sealed to a desired depth.
FIG. 5 shows an alternative embodiment of the present invention, with bore-lining tubing indicated generally by reference numeral 112 located in a bore 100 . Like components of the bore-lining tubing 112 with the tubing 12 of FIGS. 1–4 share the same reference numerals incremented by 100 .
The bore-lining tubing 112 and the method for expanding and cementing the tubing is substantially the same as that described with reference to FIGS. 1–4 . However, the bore-lining tubing 112 differs in that the lower end of the borehole casing 116 includes a different profiled lower end portion 120 . As shown in FIG. 5 , the internal diameter between the thickened portions 128 of the lower end portion 120 is greater than the internal diameter of the remainder of the casing 16 . In this fashion, when the area 132 of the liner 122 is expanded into contact with the profiled lower end portion 120 (in a procedure corresponding to that shown in FIG. 2A ), the joint between the tubulars does not restrict the bore and the expanded liner 122 has an internal diameter equal to that of the casing 16 . This allows full bore access after completion of the procedure.
FIG. 6A shows a further alternative embodiment of the present invention, illustrating part of a bore lining tubing indicated generally by reference numeral 212 . Like components of the bore lining tubing 212 with the tubing 12 of FIGS. 1–4 share the same reference numerals incremented by 200 . In the figure, only the borehole casing 216 is shown, for ease of reference. However, a liner such as the liners 22 , 122 described above with reference to FIGS. 1 to 5 is typically coupled to the casing.
The bore lining-tubing 212 and the method for expanding and cementing the tubing is substantially the same as that described with reference to FIGS. 1–4 . However, the borehole casing 216 includes enclosed flow passages 226 , as best shown in the cross-sectional view of FIG. 6B , taken on line E—E of FIG. 6A . The flow passages 226 extend through the profiled lower end portion 220 of the borehole casing 216 , to allow fluid flow from the borehole annulus surrounding the liner into the casing 216 until the flow passages are closed or isolated as described above.
FIG. 7 shows a still further alternative embodiment of the present invention, illustrating bore lining tubing indicated generally by reference numeral 312 . Like components of the bore-lining tubing 312 with the tubing 12 of FIGS. 1–4 share the same reference numerals incremented by 300 .
The borehole casing 316 includes a profiled lower end portion 320 which comprises a relatively thick-walled portion 36 that defines an upset on the casing.
Flow passages 326 are spaced circumferentially around the upset 36 , and extend axially through the upset 36 . A liner 322 is located in the casing 316 , with an area 332 expanded into contact with the casing 316 to create a hanging support. In this position, the flow passages 326 remain open to allow fluid circulation for subsequent cementation. The flow passages 326 are then isolated by expanding the liner 322 above the coupling 329 , as described above.
FIG. 8 shows a still further alternative embodiment of the present invention, illustrating part of a bore lining tubing indicated generally by reference numeral 412 . Like components of the bore lining tubing 412 with the tubing 12 of FIGS. 1–4 share the same reference numerals incremented by 400 . In the Figure, only the borehole casing 416 is shown, for ease of reference. However, a liner such as the liners 22 , 122 or 322 , described above with reference to FIGS. 1 to 7 , is typically coupled to the casing.
The borehole casing 416 is substantially similar to the casings 16 , 116 , 216 described above, except that the profiled lower end portion 420 comprises relatively thick-walled portions 428 defining axial flutes or the like, similar to the casing 16 . However, the thick-walled portions 428 are located above a lowermost end 38 of the lower casing section 417 shown in the figure. In a further alternative, the profiled lower end portion 420 comprises enclosed flow passages, similar to the flow passages 226 , 0326 of FIGS. 6A to 7 .
FIG. 9 shows a yet further alternative embodiment of the present invention, illustrating part of a bore lining tubing indicated generally by reference numeral 512 . Like components of the bore lining tubing 512 with the tubing 12 of FIGS. 1–4 share the same reference numerals incremented by 500 .
The bore lining tubing 512 is similar to the tubing 112 of FIG. 5 in that the minimum internal diameter of the lower end portion 520 is greater than the internal diameter of the remainder of the casing 516 , to accommodate the expanded liner 522 . Thus when the liner 522 is expanded in the area 532 into contact with the profiled lower end portion 520 of the casing 516 , the joint between the tubulars does not restrict the bore, as the expanded liner 522 has an internal diameter equal to that of the casing 516 . This initial expansion of the liner 522 creates a hanging support, in a similar fashion to the liner 22 , as shown in FIG. 2A , and the liner 522 is then expanded downwardly below the joint between the tubulars. Following such expansion, a larger diameter portion 38 of the casing section 517 above the profiled lower end portion 520 allows fluid flow through the flow passages then formed between the casing 516 and the liner 522 , and cement is then circulated through the liner 522 into the annulus 534 . The flow passages are then closed by further expanding the upper end 524 of the liner 522 into contact with the inner wall of the larger diameter portion 38 .
Turning now to FIG. 10 , there is shown a cross-sectional view of bore-lining tubing in accordance will a still further alternative embodiment of the present invention, the tubing indicated generally by reference numeral 612 .
In the Figure, the lower end 620 of a lower casing section 617 is shown with a liner 622 located within the section 617 , in a similar fashion to the liner 22 of FIGS. 1A–4 . However, the liner 622 includes a profiled portion 623 , typically at an upper end of the liner, such that the liner is profiled both internally and externally in the region of the portion 623 . The lower end 620 of the casing section 17 is circular in section.
The profiled portion 623 of the liner 622 is expanded in a similar fashion to the liner 22 described above, to bring the liner into contact with the lower end 620 of the casing section 617 . During this expansion, flutes 626 defined by the profiled portion 623 are partially or fully closed and the liner 622 is sealed by cement or other means, as described above.
FIG. 11 is a cross-sectional view of bore-lining in accordance with a still further alternative embodiment of the present invention, the tubing indicated generally by reference numeral 712 .
The tubing 712 is similar to the tubing 12 of FIGS. 1A–4 , except the liner 722 includes a fluted portion 723 , similar to the liner 622 shown in FIG. 10 .
It will be appreciated that the drawings of FIGS. 1A to 11 are schematic illustrations where some dimensions have been exaggerated for ease of reference.
Various modifications may be made to the foregoing without departing from the spirit and scope of the present invention. For example, the profiled portion of the first or second tubulars may be of any desired shape and may include, for example, at least one, typically a plurality of helical flutes, or axial or helical grooves, channels, cut-outs or the like. There may be any desired number of flow passages. The profiled portion may be corrugated or otherwise shaped and may be deformable. Accordingly, when the second tubular is deformed into contact with the first tubular, the first and second tubulars may be deformable together to expand the coupling out to the same internal diameter as the remainder of the first tubular, to allow full bore access.
Instead of expanding the liner out below the coupling between the tubulars, the liner may be maintained at an unexpanded diameter.
The flow passages may be closed by any desired means, for example, the second tubular may be deformed into sealing contact with the first tubular below the coupling, thus the first tubular may include an unprofiled part below the profiled lower end portion. Alternatively, where the first tubular profiled lower end portion is also deformable, the flow passages may be closed by deforming the profiled lower end portion out to a substantially circular section. Alternatively, seal means may be provided, either run-in from surface following location of the second tubular in the first tubular and after the initial partial expansion and cementing of the second tubular, or seal means may be provided as part of the first or second tubulars and subsequently activated when required to close the flow passages.
The second tubular may be of any suitable tubing type which allows the required expansion.
The profiled portion of the first tubular may be provided at any desired location along a length of the first tubular.
It will be understood that the second tubular may be hung or suspended within the first tubular by any suitable means such as by a string extending to surface or to a hanger within the first tubular, until the second tubular has been expanded.
The first tubular, second tubular or both the first and second tubulars may be profiled downhole. Indeed, the profiled portion of the respective first or second tubular described herein may be formed in the downhole environment. This may be achieved by expanding or otherwise shaping the respective tubular downhole, such as a lower or deepest section of casing (the casing “shoe”) or an upper end of the liner, or a point along a length of the casing or liner.
For example, an expansion tool such as a cone or mandrel having a profile similar to the desired shape of the respective profile may be run-in to expand and thus profile the respective tubular. To allow this, the tubular may include a restricted bore portion which is subsequently profiled, or the expansion tool may be compliant for movement to an expansion configuration to profile the tubing.
In an alternative embodiment, the second tubular may be located downhole, expanded and then profiled. This may be achieved in successive procedures or runs of an expansion tool and a shaped, profiling cone or mandrel. Alternatively, the second tubular may be expanded and profiled in a single run or procedure, for example, a combination expansion/profiling tool may be used to expand and then profile the second tubular, or a profiling tool may be coupled to an expansion tool to profile the tubular immediately after expansion by the expansion tool.
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There is disclosed a method of lining a drilled bore ( 10 ) and bore-lining tubing ( 12 ).
The method comprises providing a first tubular ( 16 ); locating the first tubular ( 16 ) in the bore ( 10 ); providing an expandable, second tubular ( 22 ); locating the second tubular ( 22 ) in the bore ( 10 ) overlapping the first tubular ( 16 ); expanding a portion ( 24 ) of the second tubular ( 22 ) to create a coupling ( 29 ) including a flow passage ( 26 ) between the first tubular and the second tubular ( 16,22 ).
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This application is a continuation of application Ser. No. 07/270,853, filed Nov. 14, 1988, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to Digital Data Synthesizers (DDSs) of types that receive digital information representing a desired frequency and produce at the output a cyclical signal having the specified frequency and a preset waveform The desired waveform is stored digitally in advance at successive addresses in a memory. To generate an output signal, a clock establishes sampling times, at each of which a "phase accumulator" generates a greater address. From each address a digital sample value of the desired output waveform is read. The size of address steps at which sample values of the stored waveform are read is changeable, to produce the desired frequency.
For example, many values of a sine function table can be stored in a memory at successive addresses, corresponding to successive phase angles. The storage memory is accessed at a clock-determined sampling rate, with a "staircase-shaped" addressing function. The values of a sine wave are read from the memory, in digital form, at 5-degree steps along the sine function table. The successive sample values that are read out are converted to analog voltages by digital-to-analog converters, (DACs) and the resulting waveform is smoothed by filtering to produce a relatively clean sine wave.
To produce an output at twice the previous frequency, the sample values are taken with the same clock-determined sampling rate as above, but at 10-degree steps along the stored waveform.
A prior art DDS of this type is disclosed in Goldberg's U.S. Pat. No. 4,752,902, issued June 21, 1988, which is incorporated herein by reference. A similar synthesizer is described in Jackson's U.S. Pat. No. 3,735,269, issued May 22, 1973, which is also incorporated herein by reference. The subject is treated generally in an article entitled "A Digital Frequency Synthesizer" published in IEEE Transactions On Audio and Electroacoustics, Volume AU-19, No. 1, March 1971, pages 48-56, and authored by Tierney, et al.
SUMMARY OF THE INVENTION
The invention is an improvement in digital data synthesizers.
An object is to provide a synthesizer having register stages that are pipelined to increase the speed, enabling a relatively high maximum output frequency.
Another object is to provide a synthesizer having a plurality of DACs, all fabricated on the same chip to equalize the delay times occurring within them, for improving the resolution of the analog output signal.
Another object is to utilize a Random Access Memory (RAM) for storing a lookup table to enable the synthesizer to generate different shapes of waveforms, so that the waveforms can easily be changed.
Another object is to provide a DDS having a plurality of lookup tables for the same waveform, stored with different phase spacing between addresses, and having a decoder addresser for automatically selecting for use the lookup table that results in the best performance for the particular output frequency that is specified at the input.
Another object is to provide a DDS having, in addition to the usual main lookup table and its associated main DAC, an ancillary lookup table containing predetermined correction data and an ancillary DAC. The outputs of the main channel and the correction channel are combined to produce an analog signal having reduced distortion. A plurality of correction channels, automatically addressable, can be provided.
Another object is to provide both a plurality of main lookup tables and a plurality of correction channels, each plurality being automatically addressable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the input portion of a preferred embodiment of the invention.
FIG. 2 is a block diagram of the output portion of the preferred embodiment.
FIG. 3 shows an embodiment having a plurality of automatically addressable lookup tables.
FIG. 4 illustrates an undistorted sine wave output and a distorted sine wave output, in order to describe an embodiment of FIG. 5.
FIG. 5 is a diagram of a DDS having a main lookup channel and a correction lookup channel.
DESCRIPTION OF PREFERRED EMBODIMENT
As shown in FIG. 1 by way of example of an embodiment of the invention, terminal groups 2, 4, and 6 receive Binary Coded Decimal (BCD) input data that collectively specify the desired output frequency of the DDS. The Least Significant (decimal) Digit (LSD) is entered at terminal group 2 and the Most Significant Digit (MSD) at terminal 6. The data are stored in input latches 8, 10, and 12 respectively, and represent the size of step that is to be taken upon each clock cycle as the memory is successively addressed.
A clock 14 controls the timing of events in the DDS as a whole.
For each decimal digit, a BCD adder is provided, namely adders 16, 18, and 20 respectively. The adders are arranged with feedback to serve as accumulators. The entries that are to be accumulated are the data from outputs of the latches 8, 10, and 12; the data are entered at terminals 22, 24, and 26 of the BCD adders. Each adder has second input data terminals 28, 30, 32, and output terminals 34, 36, 38.
Feedback lines 40, 42, 44 conduct output data signals from terminals 34, 36, 38 to the second data input terminals 28, 30, 32. The data contents of the adders 34, 36, 38 are subsequently employed as addresses, and each such address represents a phase angle of a stored waveform, as will be described in more detail below.
Spillover or carry-out data from the LSD adder stage 16 is conveyed to a "carry latch" 46, which is controlled by the clock 14. Output data from carry latch 46 is input on a line 48 as a "carry in" to the adder 18, in which it is added to the other input data of adder 18. In a similar manner, a carry latch 50 receives carry-out data from the adder 18, and communicates it via a line 52 to an input of the MSD adder 20.
From the output terminals 34, 36, 38 of the adders 16, 18, and 20, data are conveyed to inputs of latches 54, 56, 58 respectively, as shown in FIG. 1. Latch 54 provides its output data to a pipeline latch 60, whose output in turn is connected to another pipeline latch 62, whose output terminals are denoted 66. The latch 56 supplies data from its output terminals to the inputs of a latch 64, whose output terminals are 68. Output data from the latch 58, at terminal 70, do not pass through any further latches.
Thus the data from the LSD adder 16 arrive three clock cycles later at the output 66 of a pipeline comprising latches 54, 60, and 62. The carry-out data from adder 16 has one clock cycle of delay in the latch 46 and adder 18, plus two cycles of delay in the latches 56 and 64, so it also arrives at the output 68 of its pipeline three clock cycles later. As for the MSD, the carry-out data from adder 16 also has one clock cycle of delay in latch 46 and adder 18, a second cycle of delay in latch 50 and adder 20, and one cycle of delay in latch 58. The length of the MSD pipeline is thus three clock cycles--the same as that of the other two pipelines.
Data at the outputs of the latches 62, 64, and 58 are therefore time-synchronous. Because of the effects of the parallel pipelines of latches, a new complete set of address data is simultaneously output (at the terminals 66, 68, and 70) upon each clock cycle. The phase accumulator (comprising input latches, adders, and pipelines) receives input data in BCD format, and its various stages contain BCD addresses. (The final stage permits binary roll-out at the top frequency.)
A RAM 72 receives the set of data at the terminals 66, 68, and 70, each set of which represents a different complete BCD address within the RAM. The RAM is accessed by these addresses, and the data contents located at each RAM address is output at terminals 74, 76, and 78. The LSD is in terminal group 74; the MSD is in terminal group 78. Collectively, the data at terminals 74, 76, and 78 express one value of a stored waveform, for example a sine wave, at a phase angle represented by the corresponding addresses of the RAM 72.
A conventional loading circuit for entering a selected waveform into the RAM is shown as block 80. The waveform desired at the output during operation is preset into the RAM 72 during setup, by means of the data loading circuit 80.
FIG. 2 is a continuation to the right side of the drawing of FIG. 1. The terminals 74, 76, and 78 are shown on FIG. 2. New data appear there at each clock cycle. A sequence of digital samples there describes one complete cycle of the stored waveform during a time interval equal to a complete period (at the selected output frequency). The digital data of terminals 74 are applied to the inputs of a DAC 82. The more significant data of terminals 74 are applied to a DAC 84, and the most significant data, at terminals 78, are applied to a DAC 86.
All three of the independently operable DACs 82, 84, 86 are constructed on the same die of semiconductor substrate. They were fabricated at the same time, of the same materials, and by the same processes, and are therefore a closely matched set of circuits. The time delays of the three DACs in performing their conversion functions are consequently much more nearly equal than would be the time delays of DACs on separate chips. Use of such a triple DAC improves the direct digital synthesizer's resolution. Improvement in resolution, in turn, reduces output noise and transients known as "spurs", and permits the apparatus to be operated at a higher speed.
The synthesizer whose DACs are on single chip has a fidelity that is equivalent to that of a synthesizer of much more closely spaced sampling points. Triple DACs of this type are manufactured by Brooktree Corporation, 9950 Barnes Canyon Rd, San Diego, Calif., 92121. Suitable types for this usage are Brooktree models Bt 109 and Bt 453.
The conversions from digital to analog data in the DACs are initiated by pulses conducted from the clock 14 to a clock bus terminal 90. Output analog data appear at terminals 92, 94, and 96 of the DACs 82, 84, and 86 respectively.
The MSD signals at terminal 96 are connected directly to a summing resistor 104. The intermediate-significance signals, of terminal 94, are attenuated by a resistor 100 that is also connected to resistor 104; the LSD signals at terminal 92 are attenuated by a resistor 98 that is connected from terminal 92 to terminal 94. By proper choice of resistor values the outputs of the three DACs are properly weighted in accordance with their significance at the resistor 104.
Resistor 104 leads to an input terminal 106 of an electric wave filter 108, which is preferably a bandpass type. Filter 108 is capable of passing the desired output signal waveforms with little attenuation and severely attenuating the undesired higher and lower frequencies that are present in the digital-to-analog approximation. A final output terminal 110 has the sought-for output signal in a relatively clean form. The output frequency can be changed by changing the step size of the phase steps (i.e., address steps) at the input terminals 2, 4, and 6.
The time sequence of operation of the device is as follows: A desired waveform is loaded into the RAM 72 from the loading circuit 80. The frequency of the output is selected by selecting a phase step size for entry at the input terminals 2, 4, and 6. As the clock 14 operates, it repeatedly transfers the step size data from the input latches 8, 10, and 12 into the BCD adders 16, 18, and 20, where it is accumulated (integrated) into a staircase-shaped digital function representing addresses.
Addresses from the outputs of the adders 16, 18, and 20 pass through the pipeline latch stages 54-64, and are employed to address the RAM 72, in BCD format. The addresses step along in time sequence through the stored waveform in the RAM, reading a sample of the waveform's amplitude at each address. The resulting digital amplitude data are output from the RAM 72 to inputs of the matched triple DACs 82, 84, and 86. The DACs convert the digital data to analog signals that approximate the desired smooth output waveform by a staircase-shaped function. The DAC outputs are combined, with attenuation for proper weighting, and passed through an output filter 108 to produce a smooth version of the desired waveform at the selected frequency.
FIG. 3 shows an embodiment of the invention in which a plurality of sine lookup tables are stored in memory, each being preferred for a synthesizing a particular frequency or category of frequencies. In order to improve the quality of (for example) the output sine wave of the DDS, several banks of sine lookup tables are used. Each bank is best for a certain frequency range. A decoder/selector automatically selects the best bank, based upon the requested frequency.
Data specifying the frequency to be synthesized are at terminals 22, 24, and 26 of FIG. 1; these terminals are shown also on FIG. 3, where they are referred to as 22', 24', 26' and are connected to inputs of a block 114. Block 114 is a decoder/addresser; it examines the specified frequency to determine which bank of sine wave data is the best one to use for synthesizing it. The decoder/addresser 114 then enables that memory bank for use.
Decoder/addresser 114, in the embodiment of FIG. 3, has several outputs, 116a, 116b, 116c, . . . 116n. Each of them is connected to a chip select input (CS) of a respective memory bank, 118a, 118b, 118c, . . . 118n. All of the memory banks are driven at their data input terminals by the BCD address data that is output by the pipeline latches 58, 62, 64 of the phase accumulator.
The output data terminals 120a, 120b, 120c, . . . 120n of the memory banks 118a etc. are connected together at terminals 74', 76', 78', i.e., a group of BCD digit terminals. The currently-selected memory bank is the only one that produces output signals. The others are temporarily inactive. Hence the memory bank that is most appropriate for the selected frequency operates to provide data for constructing the waveform of that frequency.
Waveform data at the terminals 74', 76', 78' are connected to the DACs 82, 84, 86 of FIG. 2, (as in the earlier embodiment), which convert it to an analog signal at the input to the filter 108, (also as in the earlier embodiment). The resulting final output signal at terminal 110 is much better than that of the earlier embodiment because the sine wave table employed was tailored for accurate reproduction of the particular range or category of the frequency being synthesized.
Another aspect of the invention is illustrated by FIGS. 4 and 5. FIG. 4 shows an undistorted single-frequency sine wave 122 and, on the same graph, an approximate or distorted sine wave 124 such as is sometimes produced by the embodiment of FIGS. 1 and 2, (which has only a fundamental-frequency lookup table).
The distorted sine wave 124 has two principle components, namely (a) a true single-frequency sine wave component and, superimposed upon it, an error signal component that often has the appearance of a sinusoidal function of higher frequency. The error signal component is a result of the relationship between (a) the phase spacing between contiguous addresses in the memory of the stored lookup table, which is related to the number of memory addresses within one complete cycle of the waveform to be synthesized, and (b) the phase spacing or number of memory addresses spanned by the step size that is entered into the input latches 8, 10, 12.
FIG. 5 shows the use of a main RAM having a sine function lookup table and a first DAC, cooperating with a correction RAM having a correction lookup table and a second DAC, to produce a higher fidelity output sine wave than curve 124 of FIG. 4, as will now be described in more detail.
In FIG. 5, data from the pipelines of the phase accumulator are at terminals 66", 68", and 70". The are connected to input terminals of a RAM sine lookup memory bank 126 and of a RAM correction lookup memory bank 128. These memory banks are addressed by that data, and they deliver up data that are the contents of the addresses. Output data from the sine lookup bank 126 are communicated to a fundamental sine DAC 130, and output data from the correction lookup table 128 go to a correction DAC 132.
In the case of the output from DAC 132, a resistor 134 is inserted in series, in order to attenuate its signals relative to those of DAC 130. The outputs of DACs 130 and 132 are additively combined following that attenuation, at a terminal 136. This terminal drives the output filter 108, (FIG. 2), which preferably has a different transfer characteristic in the case of this embodiment.
Operation of the embodiment of FIG. 5 is as follows: When, during setup, a sine lookup table is loaded into the main memory 126, the correction lookup table is also loaded, into the second memory bank 128. The correction lookup table RAM 128 and its auxiliary DAC 132 are a form of active filter, that interjects a corrective signal component to cancel the distortion, before the output filter 108 even receives the signal.
Values for use in the correction table can be ascertained by mathematical analysis or empirically. As an example of an empirical approach, the correction channel can be temporarily disabled, and the output of the main DAC 130 recorded, (or the output of the filter 108). The deviations of the recorded output from the desired waveform can be measured, point by point (corresponding to the addresses where data are stored in memory 126), and the deviations can be entered, with the opposite sign, in the correction lookup table 128. For routine operation the correction channel is then enabled; the combined output of DACs 130 and 132 is closer to the desired waveform than is the output of DAC 130 alone.
A compromise correction table can be used, to serve in common for a plurality of desired frequencies. Moreover, a plurality of correction lookup tables, automatically selected by an addresser/decoder of the type shown in FIG. 3, can select a lookup table appropriate for a frequency group of which the desired output frequency is a member. The selected correction table can be employed with a single main lookup table 130.
Alternatively, the embodiment of FIG. 3 can be used together with a multiple version of the embodiment of FIG. 5, so that both a plurality of main lookup tables and a plurality of correction lookup tables can be optimally correlated with output frequency ranges. Such a combination of embodiments results in even greater fidelity in the output signal than is achievable by either embodiment alone.
Although the invention has been described by a single preferred example, its concepts can be employed in a variety of embodiments. The scope of the invention is defined by the claims.
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An improved digital data synthesizer has a phase accumulator into which adjustable step increments are clocked. The output of the phase accumulator is connected to address a memory, in which a waveform function is digitally stored. Samples read from the memory at the successive addresses are converted to analog form and filtered to produce a final output signal of a desired frequency. Register stages of the phase accumulator are pipelined to increase their speed. The synthesizer has a plurality of digital-to-analog converters, all on a single chip to equalize the delay times occurring within them. A lookup memory permits a variety of output waveforms to be generated. Several lookup tables for the same waveform are stored with different phase spacing between addresses, and a decoder/addresser automatically selects the lookup table that has been found to result in best performance for a particular frequency. One or more correction lookup table can also be provided. The outputs of the main table and the correction table are combined to produce an analog signal of reduced distortion.
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BACKGROUND
The present invention relates generally to wireless communication devices having relatively moveable housing portions and, more particularly, to a hinge mechanism for connecting the relatively movable housing portions.
Wireless communications devices, such as cellular phones, personal digital assistants, and the like, frequently have two housing portions that are relatively moveable. For example, a common cell phone design is a so-called clamshell design, with a “flip” having a speaker and a display, and a base portion having a keypad and a microphone. The flip portion is connected to a base portion via a hinge. The flip portion rotates via the hinge between a closed position disposed proximate the base section in an overlying configuration and an open position where the flip and base are aligned end to end, similar to an open clamshell. The flip can typically be rotated open between about 90° and 180°, and sometimes more, relative to the base portion.
Wireless communications devices are rapidly adding functionality to the basic cell phone functionality. For example, many wireless communications devices can now be used for gaming, and/or for various business functions previously performed on office computers. For some of these additional functions, a traditional twelve-key phone keypad may be problematic, and a qwerty or similar keypad may be more desirable. Further, for many of these additional functions, a different screen orientation may be desired, such as one with a wider-than-tall orientation. Thus, as can be appreciated, while the conventional clamshell arrangement discussed above may be desirable when the device is used as a conventional cell phone, the conventional clamshell arrangement may be less desirable when the device is used for other purposes.
Therefore, while numerous wireless communications devices have been proposed, their configurations have not proven to be entirely satisfactory for some of the situations outlined above. Accordingly, there remains a need for alternative wireless communications device designs, advantageously ones that allow for a more user-friendly utilization of the device.
SUMMARY
In one illustrative embodiment, a wireless communications device, such as a cellular telephone, comprises a first body portion having a first perimeter and a second body portion having a second perimeter. A display is associated with one of the first and second body portions, and user input means is associated with the other. A hinge mechanism moveably couples the second body portion to the first body portion so that the second body portion may pivot between a closed state and an open state. The second body portion, while in the open state, is slidable from a first open position to a second open position along the first perimeter. The first and second open positions may be approximately 90° apart along the first perimeter. The first and second body portions may have respective major axes and the major axes may be disposed substantially parallel, and advantageously coincident, when the second body portion is in the first open position. Advantageously, the major axes may also be substantially parallel when the second body portion is in the second open position. The first and second perimeters may advantageously be substantially similar in shape, and advantageously generally oval. The operational orientation of the display may automatically change in response to the second body moving to the second open position.
In another embodiment, a wireless communications device comprises a first body portion having a first face and a longitudinal axis and a second body portion having a second face. A display is associated with one of the first and second body portions and user input means is associated with the other. A hinge mechanism moveably couples the second body portion to the first body portion so that the second body portion may pivot between a closed state and an open state relative to the first body portion. The second body portion, in the open state, is moveable relative to the first body portion such that a theoretical line from a midpoint of the first body portion along the longitudinal axis to a perimeter of the first body portion in a direction of the second body portion is variably oriented with respect to the longitudinal axis. The first body portion may include a first slot and the second body portion a second slot, with the hinge mechanism slidably disposed in the first and second slots. The hinge mechanism may comprise a first hinge plate associated with the first body portion and slidably mounted thereto and a second hinge plate associated with the second body portion and slidably mounted thereto.
In another embodiment, a wireless communications device comprises a first body portion; a second body portion distinct from the first body portion; and a display associated one of the first and second body portions and user input means associated with other. A hinge mechanism moveably couples the second body portion to the first body portion so that the second body portion may pivot between a closed state and an open state relative to the first body portion. The hinge mechanism comprises a first anchoring element associated with the first body portion and slidably mounted thereon for movement around a periphery thereof with the second body portion in the open state; a second anchoring element associated with the second body portion and slidably mounted thereon for movement around a periphery thereof with the second body portion in the open state; the first and second anchoring elements pivotally mated to one another for relative rotation about a pivot axis disposed generally tangent to a perimeter of the first body portion.
Other aspects of various embodiments of the inventive apparatus and related methods are also disclosed in the following description. The various aspects may be used alone or in any combination, as is desired.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of one embodiment of a wireless communications device with its flip portion in the closed state.
FIG. 2 shows a simplified cross-sectional side view of the wireless communications device of FIG. 1 with the flip portion in the open state.
FIG. 3 shows the wireless communications device of FIG. 1 with the flip portion in the open state and positioned at a first location along the perimeter of main base.
FIG. 4 shows the wireless communications device of FIG. 1 with the flip portion in the open state and positioned at a second location along the perimeter of main base.
FIG. 5 shows the wireless communications device of FIG. 4 with the flip portion rotated to a new orientation.
DETAILED DESCRIPTION
One embodiment of a wireless communications device is shown in FIG. 1 , and generally indicated at 10 . The wireless communications device includes main base 20 , a cover or “flip” portion 60 , and a hinge mechanism 100 . The base 20 includes a case or shell 22 that houses appropriate electronics, such as communications electronics 12 . In general, the case 22 includes a top or face 30 , a bottom 40 , and a sidewall 24 interconnecting the two. The face 30 includes user input means, such as keypad 32 , selection buttons 36 , and/or microphone 34 . While keypad 32 is shown as a conventional twelve-key keypad, the keypad 32 may take other forms known in the art, such as qwerty keypad. Further, while selection keys 36 are shown in an illustrative arrangement, other arrangements may alternatively be used. The bottom 40 is spaced from top 30 by sidewall 24 to form a cavity 42 . The cavity 42 advantageously houses appropriate communications and control electronics 12 , the details of which are not important to understanding the present invention. As can be seen in FIG. 2 , the sidewall 24 includes a slot 26 that extends approximately 90° circumferentially around the perimeter 50 of case 22 . A flange 28 defines the lower edge of slot 24 , and top 30 helps define the upper edge of slot 24 . As shown, the underside of top 30 may include a guide protrusion if desired. The overall shape of case 22 in this illustrative embodiment is generally oval (in front view), with a major or longitudinal axis 52 and a minor or transverse axis 54 . For ease of reference, a midpoint 53 is located midway along major axis 52 , and is considered the center of main base 20 . Of course, the base 20 may take a shape other than oval, but a generally oval shape is believed advantageous for implementing the present invention.
The flip portion 60 likewise includes a case or shell 62 and advantageously has an overall shape (in front view) similar, or identical, to the main base 20 . As such, the flip portion 60 likewise is generally oval, with a major or longitudinal axis 92 and a minor or transverse axis 94 . As above, the center 93 of the flip portion's case 62 is defined as the midpoint of major axis 92 . Of course, the flip portion 60 may take a shape other than oval, but a generally oval shape is believed advantageous for implementing the present invention. In general, the case 62 includes a face section 70 , a top 80 , and a sidewall 64 interconnecting the two. For case 62 , the face section 72 is the portion of case 62 facing the main base 20 when the wireless communications device 10 is closed. The face section 70 includes output means, such as display 72 and/or speaker 74 . The top 80 is spaced from face section 70 by sidewall 64 to form a cavity 82 . The cavity 82 advantageously houses appropriate electronics 14 , such as an antenna, communications electronics, and/or control electronics, or the like, the details of which are not important to understanding the present invention. As can be seen in FIG. 2 , the sidewall 64 includes a slot 66 defined between face portion 70 and flange 68 . The slot 66 advantageously extends approximately 90° circumferentially around the perimeter 90 of case 62 .
The flip portion 60 is moveably coupled to the main base 20 by hinge mechanism 100 . Hinge mechanism 100 includes a primary carriage assembly 110 pivotally coupled to a secondary carriage assembly 120 . The primary carriage assembly 110 is associated with main base 20 and includes a hinge plate 112 with a flange 114 on one end, a hook portion 116 on the other end, and a central section 118 disposed therebetween. The central section 118 is disposed in slot 26 , and flange 114 extends outward from slot 26 . Hook portion 116 extends inwardly so as to wrap around flange 28 in order to maintain hinge plate 112 associated with main base 20 . As can be seen in FIG. 2 , flange 114 advantageously extends out from slot 26 at an upward angle. Primary carriage assembly 110 advantageously includes suitable means for reducing sliding friction between hinge plate 112 and case 22 . For example, primary carriage assembly 110 may include one or more spheres 119 that rollingly support hinge plate 112 against flange 28 . With such an arrangement, it may be advantageous for flange 28 to include some shallow detent recesses (not shown) that face hinge plate 112 , so that primary carriage assembly 110 may be preferentially located in predetermined locations along slot 26 relative to perimeter 50 .
The secondary carriage assembly 120 is associated with the flip portion 60 and includes a hinge plate 122 with a flange 124 on one end, a hook portion 126 on the other end, and a central section 128 disposed therebetween. The central section 128 is disposed in slot 66 , and flange 124 extends outward from slot 66 . Hook portion 126 extends inwardly so as to wrap around flange 68 in order to maintain hinge plate 122 associated with flip portion 60 . Secondary carriage assembly 120 also advantageously includes suitable means for reducing sliding friction between hinge plate 122 and case 62 . For example, sphere(s) 129 may form a rolling sphere(s) arrangement similar to that discussed above. Further, detents (not shown) may be used so that secondary carriage assembly 120 may be preferentially located in predetermined locations along slot 66 relative to perimeter 90 of case 62 .
A hinge joint 130 connects hinge plate 112 to hinge plate 122 so that flip 60 may be opened and closed. The hinge joint 130 may take any suitable form known in the art, such as a dampened or detented hinge connection. The hinge joint 130 allows flip portion 60 to be moved between a closed state and an open state relative to main base 20 by rotation about pivot axis 132 . In the closed state ( FIG. 1 ), the flip portion 60 overlies the main base 20 , such that face 70 faces face 30 . In the open state ( FIG. 2 ), flip portion 60 is rotated about hinge axis 132 so that a non-zero included angle Θ is formed between faces 30 , 70 . This included angle Θ is advantageously in the range of 90°-180°.
As can be appreciated, primary carriage assembly 110 slides along slot 26 so as to be moveable along the perimeter 50 of main base 20 . This sliding motion allows the flip portion 60 to be moved from a first position ( FIG. 3 ) to a second position ( FIG. 5 ) along perimeter 50 , while flip portion 60 is in the open position, and advantageously while angle Θ is held constant. For example, the first perimeter position may correspond to a conventional flip-phone configuration ( FIG. 3 ), where the major axis 92 of flip portion 60 is parallel to, or advantageously coincident with, the major axis 52 of main base 20 . When positioned in this manner, there is a maximum distance between the speaker 74 and microphone 34 , and the device 10 may be easily used as a conventional cell phone. The flip portion 60 may be moved relative to the main base 20 to a second position, such as one more suitable for gaming or business software functions. To do so, the primary carriage assembly 110 of hinge mechanism 100 is slid along slot 26 , with the length of slot 26 helping determine the allowed amount of sliding. For example, if slot 26 extends for a 90° arc, then hinge mechanism 100 is limited to 90° of movement relative to the center 53 of main base 20 . When moved as described, the major axis 92 of flip portion 60 is moved from being parallel to main base major axis 52 to being perpendicular thereto. Thus, the overall device would have a T-shape as depicted in FIG. 4 . However, secondary carriage assembly 120 is also slidable along slot 66 so as to be moveable along the perimeter 90 of flip portion 60 . Assuming that slot 66 also sweeps a 90° arc, the resulting dual sliding action allows flip portion 60 to be rotated into a new orientation so that the respective major axes 52 , 92 are again parallel, although not coincident. See FIG. 5 . This arrangement is believed advantageous when using the device 10 for gaming or business applications.
As can be seen, the movement of the flip portion 60 from the position shown in FIG. 3 to the position shown in FIGS. 4-5 has the effect of changing the orientation of a theoretical line 99 extending from the center 53 of main base 20 to the closest point on the perimeter 90 of flip portion 60 . This line 53 thus changes its relative angle β with respect to major axis 52 as the flip portion 60 is moved. Further, if the hinge mechanism 100 also slides along slot 66 in flip portion 60 , then points of closest approach on the perimeter 50 of main base 20 and the perimeter 90 of flip portion 60 change from X and X′ to Y and Y′, respectively.
While the above description has been in terms of the device 10 changing configuration from the “in-line” configuration of FIG. 3 , to the T-shaped configuration of FIG. 4 , to the “side by side” configuration of FIG. 5 , the transformation may be in the reverse sequence. Further, the flip portion 60 may simultaneously be moved relative to main base 20 and “spun” relative thereto, so that movement steps are combined and the interim T-shaped configuration of FIG. 4 is avoided.
In some embodiments, the main base 20 and/or flip portion 60 may include appropriate sensors 16 for detecting the relative orientations and positions of the components. And, based on these sensors 16 , the wireless communications device 10 may change its operational mode. For example, with the wireless communications device 10 disposed as shown in FIG. 3 , the control electronics may “orient” the display 72 “vertically” such that the point closest to speaker 74 is the functional “top” of the display 72 ; but when the wireless communications device 10 changes to the arrangement shown in FIG. 5 , the control electronics may “orient” the display 72 “horizontally” so that the point closest to the speaker 74 is the functional “left” of display 72 . Similarly, the function of the selection buttons 36 may change. Indeed, if the keypad 32 is of a touchscreen type, then the layout of keypad 32 may also be adapted based on the geometrical relationship between the flip portion 60 and the main base 20 .
The discussion above has assumed that the cases 22 , 62 are generally oval in shape; however, such is not required in all embodiments. Instead, the cases 22 , 62 may have any suitable shape, including generally rectangular, or the like, as is desired.
Further, there are typically conductor based electrical connections between main base 20 and flip portion 60 , such as for carrying display information to display 72 , or audio output signals to speaker 74 . As such, hinge mechanism 100 may advantageously include appropriate contact rings and contacts (not shown), or other means, to allow electrical connections to be maintained despite the changing relative positions and orientations of main base 20 and flip portion 60 . And, any known approach, such as ribbon cabling, may be used to extend the desired electrical path(s) to and/or through hinge mechanism 100 from the electronics 12 , 14 . If ribbon cable or the like is used, then care should be taken so that sufficient length of cabling is provided so as to not impede the desired movements of the hinge mechanism 100 .
The present invention may be carried out in other specific ways than those herein set forth without departing from the scope and essential characteristics of the invention. Further, the various aspects of the disclosed device and method may be used alone or in any combination, as is desired. The disclosed embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.
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A wireless communications device, such as a cellular telephone, includes first and second bodies having respective perimeters. A display is associated with one of the bodies and user input is associated with the other. A hinge mechanism moveably couples the bodies together so that the second body may pivot between a closed state and an open state. The second body, while in the open state, is slidable from a first open position to a second open position along the perimeter of the first body. The first and second bodies may have respective major axes, and the major axes may be substantially parallel when the second body is in the first open position. The major axes may advantageously also be substantially parallel when the second body is in the second open position. The bodies may include respective peripheral slots along which the hinge mechanism moves.
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BACKGROUND OF THE INVENTION
The inventon pertains to the field of systems for containing and dispensing multiple fluids. More specifically, the invention presents a system especially suited for multicolor tinting inks, for use in printing apparatus or the like.
As the cost of paper has increased in recent years, it has become less economical for printers to stock large quantities of different colored paper stock. Instead, many printers have turned to "web tinter" systems. These color the base paper stock before use, allowing the printer to replace a multitude of different colored paper with cheaper white stock, which is then tinted whatever color is required by the job. Typically, the inks or dyes used in such applications are alcohol based and must be kept circulating through the tinter.
Currently, a single tank or pail of ink serves as a source of dye. The dye is pumped into a fountain on the tinter. A drain is provided in the side of the fountain as an overflow, from which excess dye is dumped back into the pail. This method is satisfactory while in use for a single color, although this use of open pails with volatile and flammable dyes does lead to concerns about safety. To change colors, the press operator must drain the fountain, disconnect the pail, flush the lines with clear alcohol, then connect a new pail. Each step is done manually. The fluids must be poured to and from tanks or pails, and lines transferred, all of which leads to problems with spillage and loss of dye. The current method of color changing is obviously messy and unsafe.
It is an object of the invention to provide a system for containing multiple tinter dyes with a minimum of manual handling, spillage and escape of fluid.
It is a further object of the invention to provide a system for dispensing tinter dyes which permits changing colors easily and quickly.
It is a still further object to provide a fluid-handling system for multiple fluids which minimizes the danger from the use of flammable liquids.
Another problem with present methods of changing colors is that of contamination of one dye stock by the last-used stock. The dye left in the lines and in any connecting piping will flow into the next tank of dye, unless special precautions are taken to clean the equipment. This is especially true in recirculating systems, with the added complexity and piping involved.
It is thus an object of the invention to provide a multicolor tank system for tinter inks which allows changing colors with a minimum of contamination of the dyes by other colors.
SUMMARY OF THE INVENTION
The invention presents a dispensing system especially suited to recirculating dye systems.
A plurality of tanks dispense fluid to an output manifold, which is tilted so that it will drain by gravity to one end. Each line from a tank to the manifold has a valve to control output and prevent back flow into the tank. The valves enter the manifold from above, so as to gravity drain into the manifold when the valve closes. A line from the output manifold leads to the tinter fount.
The low end of the output manifold is shut off with a drain valve. The output of the drain valve, and the overflow and a drain line from the tinter fount, is led back to the same tank, containing the color being used, by an inlet manifold. The inlet manifold is level, with outlet valves leading from its sides into the tanks. This level arrangement eliminates low spots and allows all of the fluid in the manifold to drain through whichever output valve is open.
A flushing system may be provided, either by an extra tank, by circulating fluid through the system, or by a reservoir draining through the inlet manifold to a catch basin, which can be dumped. Because of its design, the output manifold will self-drain, and thus need not be flushed.
In a non-recirculating embodiment, the output manifold can be eliminated. Each tank is pressurized by an air supply, and fluids are forced into the inlet manifold by the pressure. Draining and flushing are accomplished as in the recirculating versions, when pressure in the tank is released.
DESCRIPTION OF THE DRAWING
FIG. 1 shows an over-all view of the invention in use.
FIG. 2 shows a cut-away view of the preferred embodiment of the invention.
FIG. 3 shows an end cut-away view of one tank.
FIG. 4 shows another embodiment of the invention.
FIG. 5 shows a timing diagram of the system as used.
FIG. 6 shows a cut-away view of a single tank in a non-recirculating embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the invention in use, FIGS. 2 and 3 are cut-away views. In all cases, like numbers indicate like components. For convenience, where multiple identical elements are used, appended letters indicate a feature associated with a given tank: Thus (22A) is a pump in a tank "A", (22B) an identical pump in tank "B", etc.
The invention comprises a large, fluid-tight tank assembly (1) divided up into a number of tanks (A), (B), (C), (D) etc, each of which is fluid-tight and isolated from the others. For safety, given the volatile nature of the dyes used, the tanks are preferably at least covered (24) and may be made air-tight. In such a case a valve (25) must be provided to allow air to enter as the fluid level is pumped down. This valve (25) may be actuated with the controls for the tank, or be a simple one-way ("PCV"- Type) valve, allowing air in, but not out. Each tank is provided with holes or "ports" for introduction ("inlet" or "inputs" ports) or withdrawal ("outlet" or "output" ports) of fluid from the tank.
The heart of the invention, especially in its recirculating embodiments, is the two manifolds, inlet (4) and output (3). Each manifold is provided with holes or "ports" for introduction ("inlet" or "input" ports) or withdrawal ("outlet" or "output" ports) of fluid from the manifold. The output manifold (3) is above the inlet manifold (4) and the tanks and slopes to a drain valve (12) at one end. From the drain valve (12), a tube (13) leads to an input port of the inlet manifold. Thus, if the valve (12) is opened, the output manifold may gravity drain into the inlet manifold. By contrast, the inlet manifold (4), below the output manifold (3) but above the fluid level (26) in the tanks (2), is level from end to end. Valves (7) lead off from outlet ports in the side of the inlet manifold (4) and through level pipes (8) drain into the tanks (2) through the tank inlet ports.
It is vital that the inlet manifold (4) and valves (7) be level (and pipes (8) must be level or slope into the tank), so that there will be no "low spots" in the inlet manifold to collect fluid. Thus, if valve (7A) is open, all of the fluid in the manifold will drain into tank (A), leaving none behind to contaminate the next dye.
Fluid from each tank (2) is pumped into from the tank through an input tube means (5) to an inlet port in the top of the output manifold (3). Each tank may have a submerged pump (22), as shown, or the pump may be located outside the tank. If desired (FIG. 4) a single pump (27) may replace the plurality of smaller pumps, leaving the lower end (28) of the tank feed pipe (5) open, in which case the pump is located at the low end of the output manifold (4) above the drain valve (12). A drain (29) and drain valve (30) may be provided for the pump itself (27), if appropriate. In either case, each input tube means (5) is equipped with an inlet valve (6) located above the inlet port of the output manifold (3). This allows the valve to gravity drain into the manifold, and prevents "low spots" in which fluid may collect.
The valves may be manually operated or remotely controlled via a control panel (14). If remote, it is desirable to use non-electric, preferably air-operated, valves, to minimize the likelihood of sparks near the flammable fluids. Similarly, air-operated pumps are preferred, especially for non-submerged pumps, although electric pumps may be used.
The fluid from an output port of the output manifold (3) is fed to the device requiring the fluid, here shown as a web tinter, mounted on a press (15) (only partially shown), via tube (17). The excess or used fluid returns to an input port of the inlet manifold (4) via return line (18). As shown in FIGS. 1 and 2, the using device may have a reservoir or fount (16) fed through tube (17). When the fluid reaches a pre-determined level it overflows through tube (19) to recirculate back to the tank via the inlet manifold through return line (18). A drain (21) is provided to drain the fount (16) to the return line (18).
In a non-recirculating system (FIG. 6), for example if the device using the fluid uses a float and valve to control fluid level, the invention may be provided with an air-supply system in place of the outlet manifold. A single, level manifold (44) then serves to convey fluid from the tanks, and to drain back into them. A source of compressed air (40) pressurizes the tank (41) containing the fluid (42) to be dispensed, through an air port (48). When the valve (43) located at a side port (47) in the side of the manifold (44) is opened, fluid is forced into a tube (45) extending from under the fluid level in the tank to an outlet port (46) of the tank, and to the valve (43) on the manifold, through a supply port of the manifold and up to the device fount. To drain, the pressure is released, and everything proceeds as for the recirculating system.
Although eight, four and three tanks are shown in FIGS. 1, 2 and 4, respectively, it will be understood that any number of tanks may be included within the teachings of the invention. The actual number used will depend upon the number of colors commonly used in a given shop.
In its simplest form, the invention may be built with only those elements discussed above. It is preferred, however, to provide a means for flushing the last-used dye from the system before introducing the next color. This is done through the use of a flushing solution, most likely clear alcohol (or whatever is used as the dye base). It would be possible to add another tank (i.e. seventh tank to a six-color set-up) and run the system for a period on a supply of clean fluid from that tank, replacing the fluid periodically. This has the disadvantage that the fluid in the extra tank will deteriorate, as it is used over and over, and inadequate flushing will inevitably result in time.
The design of the invention allows a simpler and more effective method to be used. Because the entire system gravity-drains into the inlet manifold, it is only necessary to flush that manifold. A small flush tank (9) of flushing liquid (23) is located above the inlet manifold (4) and connected to it by a tube (11) and valve (10). Once the system is drained, valve (10) is opened for a short period, flushing the manifold (4) into the last-used tank. The addition of a small quantity of clear fluid should have no effect upon the dye in the tank, and might serve to make up for losses from the fount due to evaporation and paper absorption. It this is not desired, a drain valve (31) can be installed in the side of the inlet manifold (4) (level, as in valves (7)) and a tube (32) led from that valve (31) to a catch basin or pail (33), the contents of which may be discarded after flushing, or recycled back to tank (9). If desired the flush tank may be connected with the outlet manifold, as shown at (34), flushing both manifolds.
FIG. 5 shows a timing diagram to clarify the sequence of operations of the invention in use. At the beginning (to), the tinter is running color 1, (i.e. blue) from tank "A". Inlet (7A) and outlet (6A) valves to that tank are open. The operator wishes to switch the system to color 2, (i.e. green) from tank "B". At (t1) he begins the change-over. At (t1) he begins the change-over. Valve (6A) is closed, admitting no further fluid from tank "A", and the pump (22A) is turned off (the valves (6) and pumps (22) may be ganged on a single control, if desired). The output manifold drain (12), and fount drain (21) are opened, and both gravity drain into the inlet manifold. After these have drained (t2), the fount drain is closed. The output manifold drain (12) may be closed, or can remain open, as shown, if the connection shown at (27) in FIG. 2 is used. Fluid is admitted from the flush tank by valve (10) between (t2) and (t3), and flushes into tank "A" through valve (7A). The valve (10) is closed at (t3) and the inlet manifold drains. At (t4), valve (7A) is closed, and valves (7B) and (6B) are opened, and pump (22B) switched on. Fluid is pumped from tank "B" through (6B) to the output manifold into the fount (16). When the fount is full, the overflow returns to "B" through (19), (18) and the inlet manifold (3) and valve (7B), and the tinter is ready to go in the new color.
In addition to the flush tank, the basic invention may be modified to include automatic control and sequencing of the valves. An interlock may be added to ensure that only one valve on each manifold may be operated at once, and preventing simultaneous operation of inlet and output valves on different tanks.
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments are not intended to limit the scope of the claims which themselves recite those features regarded as essential to the invention.
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A multifluid dispensing system especially suited for web tinting machines or the like. A plurality of fluid and, optionally, air-tight tanks are provided. In a recirculating embodiment, the tanks feed fluid to, and receive fluid from, two manifolds. The upper (output) manifold receiving fluid from each tank slopes to gravity drain into the second manifold. The second (inlet) manifold is level to eliminate low spots for fluid accumulation. The inlet manifold drains into the tanks through valves in the side of, and level with, the manifold. A non-recirculating embodiment uses only the second manifold with pressurized tanks. An optional flush tank may be provided.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation application of U.S. application Ser. No. 11/007,968 filed Dec. 9, 2004 which claims priority from U.S. provisional patent application, Ser. No. 60/529,457, filed Dec. 12, 2003, by Alan Corbett Ferguson, incorporated by reference herein and for which benefit of the priority date is hereby claimed.
TECHNICAL FIELD
The present invention relates to dry-stack concrete masonry systems for building structural load bearing and non-load bearing walls and, more particularly, two distinct concrete masonry units with a web offset lug design that provides for both stack bonding and running bond construction with unobstructed vertical cell alignment to facilitate both solid and partial concrete grouting (for structural strength) with and without steel reinforcement.
BACKGROUND INFORMATION
An advantage of dry stack masonry systems is that the labor component of installation can be dramatically reduced. Some studies have shown that dry stack masonry systems are up to ten times faster to install than conventional joint mortared masonry systems. Because these systems do not use bonding mortar to provide joint support, it may be necessary to use other means of developing wall strength.
One technique to develop wall strength is to pour wet concrete or grout into the openings of the block to form vertical posts. The wet concrete is poured into the open cells of the concrete block. Various building codes may require dry-stacked concrete block cells to be filled differently in order to provide specified structural integrity. Some applications may require all the cells to be filled with concrete. Other applications may require the concrete to be poured into distinct vertical columns and only in certain cells or cores of the block. These applications may require cells, for example, to be filled generally at four foot on center increments and/or at wall corners and jambs of windows and doors or various load points. A general overview of the use of current dry stack methods in masonry wall construction can be found in National Concrete Masonry Association's (NCMA) technical publication TEK 14–22 “Design and Construction of Dry-Stack Masonry Walls.”
The vertical posts are typically reinforced with reinforcement members, for example, steel rebar. The problem with many dry stack block systems is that when stacked, the cells or core holes of the block are not completely aligned. The cells between successive layers of block may vary in size as shown in FIGS. 1A and 1B . FIGS. 1A and 1B show a stack of a conventional dry block system 100 . The middle row 102 provides a narrow passage 104 relative to the top row 106 and bottom row 108 . When concrete is poured in the cells the variation in cell dimensions may hinder or prevent reinforcement members from being inserted in the cores to form the vertical posts. In addition, the variation in cell dimensions may make it difficult to fill the voids within the cell. Many conventional dry stack block systems may provide little or no damming capacity when filling the cells of a dry stack block wall structure.
The current dry stack wall systems used in building construction for load bearing and non-load bearing walls that incorporate raised lugs for alignment and interlocking do not provide adequate or uniform core orientation, as previously discussed. Additional descriptions of prior art raised lug systems are disclosed in U.S. Pat. No. 3,968,615 to Ivany, U.S. Pat. No. 4,182,089 to Cook, and U.S. Pat. No. 4,640,071 to Haener.
When stacked in a running bond, a core block resting on top of two halves of a lower adjacent block, the lack of uniform orientation of prior art systems fail to provide a uniform and well-aligned core for forming concrete posts. The prior art dry-stack block systems require lugs that project above the top surface of the block. These lugs tend to limit where blocks can be stacked in relation to one another. In addition, the prior art alignment of lugs prevents the stacking of blocks in a single stack bonded configuration (one block resting completely on top of a lower adjacent block).
SUMMARY
In one aspect the invention features a dry stack building block for constructing a masonry wall. The block may have a front section having an outer surface, an inner surface, a bottom surface, and a top surface. The block may also have a rear section substantially parallel to the front section having an outer surface, an inner surface, a bottom surface, and a top surface. Two or more webs may couple the inner surface of the front section to the inner surface of the rear section and having a top surface and a bottom surface. Two or more pairs of lugs may extend above the top surface of the front section and the top surface of the rear section. Each pair of lugs may have a first lug offset from a second lug in an axis running parallel to the top surfaces of the front section and the back section and perpendicular to the inner surfaces of the front section and the back section.
Embodiments may include one or more of the following. One pair of the two or more pairs of lugs may be positioned to receive a second duplicate dry stack block staged halfway off-center and a second pair of the two or more lugs may be positioned to receive a third duplicate dry stack block staged halfway off-center in a direction opposite and adjacent to the second stack block. The top surfaces of the front section and rear section may be adapted to receive a bottom surface of a front section and a bottom surface of a rear section of another duplicate dry stack building block. The outer surface of the front section and the outer surface of the rear section may have a chamfered edge. A first lug of each pair of the two or more pairs of lugs may have a chamfered edge adjacent to the front section and the second lug of each pair of the two or more pairs has a beveled edge adjacent to the rear section. The two or more webs may be substantially perpendicular to the front section and the rear section. Each of the two or more webs may have one lug of a pair of the two or more pairs of lugs adjacent to the inner surface of the front section and a first side surface of the web and a second lug of the pair adjacent to the inner surface of the rear section and a second side surface opposite the first side surface of the web. A first angle produced by a first web of the two or more webs and the front section plus a second angle produced by a second web of the two or more webs and the front section may be substantially equal to 180 degrees. Each of the two or more webs may have one lug of a pair of the two or more pairs of lugs extending from the top surface of the web and adjacent to the front section and a second lug of the pair extending from the top surface of the web and adjacent to the rear section. The two or more webs may have a knock-out portion for providing a bond beam.
In another aspect the invention may feature a corner block for constructing a corner wall portion. The corner block may have a front section having an outer surface, an inner surface, a bottom surface, and a top surface. The corner block may also have a rear section substantially parallel to the front section having an outer surface, an inner surface, a bottom surface, and a top surface. A side section may be coupled and substantially perpendicular to the front section and the back section. The side section may have an outer surface contacting the outer surfaces of the front section and rear section, a bottom surface, and a top surface. The corner block may have one or more webs coupling the inner surface of the front section to the inner surface of the rear section and spaced to receive the one or more pairs of lugs.
Embodiments of the invention may have one or more of the following advantages. The invention may provide an improved dry-stack concrete masonry block for constructing masonry load, bearing and non-load bearing wall assemblies. The invention may allow for improved core alignment from the bottom to the top of wall construction. The invention may also make partial filling of dry-stack block cells faster, easier, and stronger. The invention may also make structural reinforcement of wall assembly easier and faster in conjunction with concrete or without concrete (i.e. post tensioned). The invention may also allow the installer to construct in both running bonded and stack bonded orientations.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be better understood by reading the following detailed description, taken together with the drawings wherein:
FIG. 1A is a top plane view and FIG. 1B is a front cross sectional side view of a prior art conventional dry stack block assembled into a linear wall structure;
FIG. 2 is a perspective view of the present invention comprising two dry-stack units, a stretcher unit and a corner unit shown here assembled into a wall structure turning a 90 degree corner;
FIG. 3 is a perspective view of present invention comprising the two dry-stack units, the stretcher unit and the corner unit shown here assembled into a linear wall structure;
FIG. 4A is a top plane view and FIG. 4B is a side profile view of the stretcher unit according to an exemplary embodiment of the invention with webs at non-right angles.
FIG. 5A is a top plane view and FIG. 5B is a side profile view of the stretcher unit according to an exemplary embodiment of the invention with webs at right angles.
FIG. 6A is a top plane view; FIG. 6B is a cross sectional view; FIG. 6C is a front profile view; and FIG. 6 d is a side profile view of the stretcher unit according to an exemplary embodiment of the invention with beveled lug profiles.
FIG. 7A is a top plane view; FIG. 7B is a front profile view; and FIG. 7C is a side profile view of the corner unit according to an exemplary embodiment of the invention.
FIG. 8A is a top plane view and FIG. 8B is a front cross sectional side view of the stretcher unit assembled into a linear wall structure.
FIG. 9 is a perspective view of the stretcher units stacked according to an exemplary stack-bonding embodiment.
For purposes of clarity and brevity, like elements and components will bear the same designations and numbering throughout the FIGURES.
DETAILED DESCRIPTION
A corner wall structure 200 may use a stretcher unit 202 and a corner unit 204 to construct the corner and straight portions of a wall, as shown in FIG. 2 . The stretcher units 202 have lugs 206 that extend above the top of the stretcher unit 202 . The next course of stretcher units is placed on top of the previous layer of stretcher units. The lugs 206 of the previous layer of stretcher units extend into the cells of the next course of stretcher units. The lugs provide face shell alignment, lateral strength, and lock together successive layers of units.
The stretcher units 202 have a front section and a rear section. One or more webs or ribs couple the front section to the rear section. The one or more webs may extend just below the top surface of the stretcher unit 202 or may extend all the way to the top surface of the stretcher unit 202 . The stretcher units 202 also have lugs that extend above the top surface of the stretcher unit 202 . The stretcher unit 202 and other exemplary embodiments of the stretcher unit 202 will be described in greater detail later herein. The corner units 204 may also have a front section, rear section, and one or more webs coupling the front section and rear section. The corner unit also has a side section. The side section provides a ninety-degree corner in the wall. The corner unit 204 provides a uniform surface at the corner of the wall. The corner units 204 are staggered with each successive row. The corner unit 204 and other exemplary embodiments of the stretcher unit 202 will be described in greater detail later herein.
The corner unit 204 may not have lugs extending from the top. The corner unit may be used in a straight wall portion, as shown in FIG. 3 . The spacing and alignment of lugs, as will be discussed later herein, allows the corner section to be placed within a straight portion of the wall. The lugs of the lower stretcher units 202 extend into the cells of the corner unit 204 without interfering with the side section or the webs of the corner unit.
FIG. 4A is a top plane view and FIG. 4B is a side profile view of a stretcher unit 400 according to an exemplary embodiment of the invention with webs at non-right angles. The stretcher unit 400 may have a height of eight inches and a length of sixteen inches. The stretcher unit 400 has a front section 402 and a rear section 404 . The front section 402 and the rear section 404 may have a thickness of one and quarter (+/−) inches. One or more webs 406 couple the front section 402 to the rear section 404 . The webs 406 may have a thickness of one and a half inches (+/−). The webs 406 , according to this embodiment, are symmetrically angled between the front section 402 and the rear section 404 . Each web 406 has a pair of lugs 408 extending from the top surface of the web. The lugs 408 may extend above the top surface by ⅜ th (+/−) of an inch. The lugs may have a width and thickness of one inch (+/−). The angled webs 406 allow the stretcher units to be stacked in a staggered fashion without the lugs interfering with the web of a successive layer of stretcher units. The web of the successive layer of stretcher units straddles each pair of lugs 408 . The stretcher unit is supported in the lateral direction by a lug positioned between the inner surface of the front or rear section and the web.
The exemplary embodiments shown in FIGS. 4A and 4B may also include round lugs. The lugs have a round top portion, which aids in the stacking of successive stretcher units. The weight of successive stretcher units pushing down centers the unit into the correct resting position. The rounded lugs help to prevent successive stretcher units becoming stuck or partially resting on the lug of lower stretcher units. The exemplary embodiments shown in FIG. 4B may also include a knock-out portion 410 for producing a bonding-beam portion in the constructed wall. The knock-out portion 410 may extend down three inches (+/−) from the top surface. The knock-out portion 410 may have a three quarter inch slot to allow for placing reinforcement members or removing the knock-out portion 410 . Bonding-beams are horizontal reinforcements in the wall that add strength between the vertical columns of the constructed wall. A row of stretcher units in a wall of individual or successive rows may be designated for a bonding-beam. During construction the knock-out portion 410 may be removed to allow reinforcement members and/or poured concrete to fill the cells of a row of stretcher units. The knock-out portion 410 may be molded into the stretcher unit between the lugs 408 of the web 406 .
The exemplary embodiments shown in FIGS. 4A and 4B may also include chamfered edges on the sides for the front section and the rear section. The chamfer allows the adjacent stretcher unit to fit snuggly against the neighboring stretcher unit. The chamfers of neighboring stretcher units overlap providing additional strength and preventing leaking of concrete from the cell columns during pouring. The chamfers may have a ⅜ th (+/−) inch inset. The exemplary embodiments shown in FIGS. 4A and 4B may also include beveled edges on the outer surface of the front section and the rear section. The beveled edges of the stretcher unit give the wall a more traditional block construction look. The beveled edge outlines the profile of the block without the need for grouted joints. The edge is not limited to a bevel. The edge may have a chamfer or other profile to outline the block face.
An exemplary embodiment of the invention with webs at right angles is shown in FIG. 5A and FIG. 5B . The stretcher unit 500 has a front section 502 and a rear section 504 . One or more webs 506 couple the front section 502 to the rear section 504 . The webs 506 , according to this embodiment, run perpendicular between the front section 502 and the rear section 504 . The webs 506 may be spaced four inches (+/−) from the end of the stretcher unit 500 . To provide cores that line up, each web 506 has a pair of alternating, adjacent lugs 508 . The lugs 508 extend above the surface of the stretcher unit 500 and allow the stretcher units to be stacked in a staggered fashion without the lugs 508 interfering with the web of a successive layer of stretcher units.
A first lug of the pair of lugs is coupled against a first surface of a first web and an inner surface of the rear section. A second lug of the pair of lugs is coupled against a second surface of the first web and the inner surface of the front section. A second pair of lugs for the stretcher unit has a first lug of the second pair coupled against a first surface of a second web and an inner surface of the front section. A second lug of the second pair of lugs is coupled against a second surface of the second web and the inner surface of the rear section. Each of the lugs in the first pair of lugs is positioned on alternating sides of the first web. Each lug of the second pair of lugs is also positioned on alternating sides of the second web; however, the lugs are on opposite sides from the first web. This allows the successive layer of stretcher units to rest on the stretcher unit and allows the lugs 508 of the stretcher unit 500 to protrude into the cells of the successive layer of stretcher units without interfering with the lugs of the successive layer of stretcher units.
When the wall is constructed the stretcher units may be staged half way off-center for each successive row. This allows the alternating pairs of lugs to straddle the webs of successive rows of stretcher units. The stretcher unit 500 is supported in the lateral direction by a lug positioned between the inner surface of the front or rear section and the web. The constructed wall locks together by the protruding lugs extending into the cells and straddling the webs of successive rows of stretcher units above and below the stretcher unit.
The stretcher unit 500 may also have a beveled profile on the outer surface of the front section and rear section. The stretcher unit 500 may also have a chamfered side edge for coupling to adjacent units. In addition, the stretcher unit may have a knock-out portion for producing a bonding-beam. These features are similar to those previously described herein with respect to the exemplary embodiment disclosing the exemplary stretcher unit 400 with angled webs.
An exemplary embodiment of the invention with beveled lug profiles is shown in FIGS. 6A , 6 B, 6 C, and 6 D. The exemplary embodiments 600 may include a beveled lug profile 602 . The lugs 604 have a beveled surface adjacent to the outer surface of the front section 606 and the rear section 608 . The beveled profile aids in the stacking of successive stretcher units. The weight of successive stretcher units pushing down centers the unit into the correct resting position. The beveled lug profiles 602 help to prevent successive stretcher units from becoming stuck or partially resting on the lug of lower stretcher units. In addition to a beveled profile on the surface of the lug facing the outer surface of the front section and the rear section, the lugs may also have a beveled surface adjacent to the web (not shown in Figures). The additional beveled profile aids in stacking and aligning the face shells of the stretcher unit as previously discussed.
A corner unit 700 according to an exemplary embodiment of the invention is shown in FIGS. 7A , 7 B, and 7 C. The corner unit 700 has a front section 702 and a rear section 704 . The corner unit 700 also has a side section 706 coupling the front section 702 and the rear section 704 . One or more webs 708 couple the front section 702 to the rear section 704 . The corner unit 700 may be positioned at the corner of a constructed wall as shown in FIG. 2 . The side section 706 provides a uniform appearance at the end of a row of units and provides support for successive rows of units. The corner units may be stacked alternating by 90 degrees for each row. This provides a lacing of rows between two linear portions of the structure. The cell of the corner units 700 may be filled with concrete to lock the corner units 700 together.
The web 708 is spaced to receive lugs from a previous row of stretcher units off-set by half a unit length. The web is spaced within the corner unit so as to align on top of the web of a previous row of stretcher units allowing the lugs of the previous row of stretcher units to straddle the web. The corner unit may also be used in the construction of a linear position of a wall as shown in FIG. 3 . The corner unit 700 may also have a beveled or chamfered profile on the outer surface of the front section 702 and rear section 704 . The corner unit 700 may also have a chamfered side edge for coupling to adjacent units. In addition, the stretcher unit may have a knock-out portion for producing a bonding-beam. These features are similar to those previously described herein with respect to the exemplary embodiment disclosing the exemplary stretcher unit 400 with angled webs.
The stretcher units may assemble into a linear wall structure 800 as shown in FIGS. 8A and 8B . The linear cells 802 of the stretcher and/or corner units produce a vertical post. The vertical posts typically may be reinforced with a reinforcement member, for example, steel rebar. The linear cells 802 of the stacked stretcher units provide a more consistent size and are aligned linearly. When concrete is poured into the cells the more consistent size of the linear cell makes it less difficult to install reinforcement members in the cores to form the vertical posts. In addition, the more uniform cell dimensions may make it less difficult to fill the voids within the cell. Many conventional dry stack block systems may provide little or no damming capacity when filling the cells of a dry stack block wall structure.
FIG. 9 is a perspective view of the stretcher unit stacked according to an exemplary stacking embodiment 900 . The dimensions and structure of the stretcher unit provide the ability to stack a single column of units. By alternating each successive unit by 180 degrees the next stretcher unit may be stacked on top of a successive unit. The lugs of the stretcher units align in the cells of each successive stretcher unit.
Modifications may be made to fit particular operating requirements and environments as will be apparent to those skilled in the art, the invention is not considered limited to the examples chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention.
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Generally, the invention is a dry stack building block for constructing a masonry wall. The dry stack unit has a front section having an outer surface, an inner surface, a bottom surface, and a top surface. The dry stack unit also has a rear section substantially parallel to the front section having an outer surface, an inner surface, a bottom surface, and a top surface. Two or more webs coupling the inner surface of the front section to the inner surface of the rear section have a top surface and a bottom surface. Two or more pairs of lugs may extend above the top surface of the front section and the top surface of the rear section. Each pair of lugs may have a first lug offset from a second lug in an axis perpendicular to the inner surfaces of the front section and the back section.
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FIELD OF THE INVENTION
THIS INVENTION relates to a bracket assembly and in particular a bracket assembly for supporting a roof gutter.
BACKGROUND OF THE INVENTION
Brackets for supporting roof gutters usually are generally U shaped having an upright section for attachment to a fascia and a gutter support arm for engagement with an adjacent peripheral edge of the roof gutter.
When such brackets are mounted along a fascia, the supporting arm of each bracket must be spaced relative to the supporting arms of other gutter brackets to provide sufficient gutter support. Each arm must also be positioned such that gutters supported therefrom are supported in an inclined longitudinal orientation to allow for water drainage. This arrangement of the gutter and associated supporting brackets may be unsightly and visually displeasing, especially on long gutter runs where the drainage angle is noticeable.
To position a number of brackets along a fascia or the like such that they provide support and a drainage inclination is time consuming. Generally this is achieved by fixing a gutter bracket at each end of a gutter run and stretching a string line therebetween.
Subsequent intermediate brackets are then fixed to a support surface using the string line as a guide.
OBJECT OF THE INVENTION
It is an aim of the invention to overcome or alleviate some of the problems associated with the abovementioned prior art.
DISCLOSURE OF THE INVENTION
According to one aspect of the invention there is provided an adjustable gutter bracket assembly including;
a mounting member;
a support arm releasably attachable to said mounting member; and
a cover attachment member releasably attached to said support arm;
said mounting member and said support arm having complementary engagement means associated therewith to provide releasable attachment of said support arm to said mounting member in a plurality of height adjustment positions; and
said cover attachment member and said support arm having further complementary engagement means associated therewith to provide releasable attachment of said cover attachment means to said support arm.
Preferably, said mounting member and said support arm each have corresponding surfaces or walls which are in substantial abutment when attached.
Suitably, said relative rotation is about an axis normal to the corresponding surface of said mounting member.
One of said complementary engagement means may be an elongate aperture which may have height adjustment corrugations or serrations comprising alternating notches and projections. Alternatively there may be provided spaced notches along each longitudinal edge of the elongate aperture.
The other one of said complementary engagement means may suitably comprise a pair of spaced lugs wherein preferably each lug includes an inner web and outwardly projecting tab which may be punched out of the support arm or the mounting member. Suitably, each tab has free ends which are of opposite orientation.
The elongate aperture may be located in one of the mounting member or the support arm with the lugs being provided in the other of said mounting member or support arm. Preferably, however the elongate aperture is provided in the mounting member and the lugs are located in the support arm.
Preferably, the mounting member has spacing means associated therewith to allow at least part of the mounting member to be spaced from a roof fascia when said mounting member is attached to said fascia. To this end the mounting member may have one or more and preferably a pair of peripheral longitudinal flanges and a spaced intermediate part incorporating said elongate aperture.
Preferably, each peripheral longitudinal flange has mounting apertures therein.
Most preferably, the mounting member is a mounting plate and the support arm includes an inner end section attachable to the mounting plate. The support arm may also include an intermediate section and an outer end section.
The further complementary engagement means may be of a similar nature to that as described above, wherein one of said further complementary engagement means is associated with the cover attachment member and the other of said further complementary engagement means is associated with the outer end section of the support arm.
Suitably, the cover attachment member has spacer means for spacing said one of the further complementary engagement means from a cover or fascia which may be attached to said cover attachment member. The cover attachment member may be an attachment plate.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be readily understood and put into practical effect reference will now be made to a preferred embodiment in which:
FIG. 1 is a perspective view of the bracket assembly; and
FIG. 2 is a magnified view of the complementary engagement means of FIG. 1.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2, the bracket assembly 1 includes a mounting member in the form of mounting plate 2 for mounting to an upright surface such as a fascia (not shown).
An engagement means in the form of an aperture 3 is formed in mounting plate 2. Aperture 3 has a plurality of opposed triangular shaped notches 4 on opposed longitudinal edges 5 and 6.
Triangular shaped notches 4 comprise opposed lateral ledges 7 and inclined regions 8 between adjacent lateral ledges 7. Notches 4 provide height adjustment positions in which the transverse distance T between each pair of opposed lateral ledges 7 are equal.
Mounting apertures 9 are located in peripheral longitudinal flanges 10a and 10b and are spaced from intermediate section 10d in which aperture 3 is located, thereby providing a spacing means for spacing aperture 3 from the fascia (not shown). A transverse flange 10c is also provided adjacent end 12.
An end flange 11 on mounting plate 2 provides an abutment surface 13 for abutting an underside of the facia or other similar upright surface.
Support arm 14 includes inner end section 14a, intermediate section 14b and outer end section 14c. Section 14a has an upright wall 24 which is in substantial abutment with adjacent mounting plate 2. Inner end section 14a also has a complementary engagement means in the form of two lugs 15 and 16 which are identical to lugs 15 and 16 at outer end section 14c. Further, an attachment plate 17 having an elongate aperture 18, which is identical to aperture 3, is releasably attached to outer end section 14c.
Lugs 15 and 16 each have a respective web 19 and 20 and an outer tab 22 and 23 punched out of outer end section 14c. Outer tabs 22 and 23 are parallel to outer end section 14c and they each have a free end 22a and 23a which are of opposite orientation.
Mounting plate 2 and inner end section 14a each have an abutment surface (hidden by support arm 14), such that when mounting plate 2 and support arm 14 are releasably attached, the respective abutment surfaces are in substantial abutment as indicated at 24.
Similarly, outer end section 14c and plate 17 have respective abutment surfaces 25 and 26 which are in substantially abutment when outer end section 14c and plate 17 are engaged. Spacing means on surface 27 provides a means of spacing aperture 18 from a cover or fascia which may be attached to plate 17 (by drilling and bolting or otherwise).
Attachment and height adjustment of support arm 14 to mounting plate 2 is identical to the attachment of plate 17 to outer end section 14c.
To avoid repetition only the attachment of plate 17 to end 14c will be described in detail.
Lugs 15 and 16 are aligned such that their collinear axis C is aligned with longitudinal axis B of aperture 18. Lugs 15 and 16 are then inserted into aperture 18. Relative rotation of plate 17 with respect to outer end section 14c about axis A causes releasable attachment thereof, axis A being normal to abutment surface 25 (similarly when referring to plate member 2, axis A is normal to upright wall 24). When axis B and C are normal to each other, plate 17 is attached to end 16. The attachment is such that webs 19 and 20 engage opposed notches 4 and are each disposed between a respective ledge 7 and adjacent inclined region 8. Height adjustment is achieved by relative rotation about axis A until axes B and C are aligned in relation to a selected opposed pair of notches 4.
In use a plurality of mounting plates 2 are attached to a fascia (not shown) by screws passing through mounting apertures 9. Each associated abutment surface 13 abuts an underside of the fascia end allows for identical upright positioning of each mounting plate 2.
Abutment surfaces 10 provide a spacing such that the fascia or upright surface does not interfere with the engagement of lugs 15 and 16 of support arm 14 when engaging aperture 4.
Each support arm 14 is releasably attached to a mounted mounting plate 2 by relative rotation therebetween. Where required the height adjustment of each support arm 14 may be adjusted (as described above).
Guttering is then supported from the support arms and further height adjustment of support arms 14 may be effected if required.
If desired plates 17 are then attached to outer end section 16 and their height is adjusted accordingly after which a cover or fascia is attached thereto to hide the guttering. Surface 27 spaces the cover or fascia from lugs 15 and 16 to allow a flush fitting.
Although the invention has been described with reference to a preferred embodiment it is to be understood that the invention is not limited to the specific embodiment as described herein. Other embodiments and variations to the preferred embodiments may be evident to those skilled in the art and may be made without departing from the spirit and scope of the invention.
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A bracket assembly, particularly for supporting a roof gutter, is disclosed. The assembly includes a mounting member attachable to a fascia and a support member releasably attachable to the mounting member. Attachment is by relation of the support member relative to the mounting member such that lugs on the support member engage an elongate aperture in the mounting member. The bracket assembly may incorporate a cover attachment member to facilitate concealed covering.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to methods of redemption and exchange of unused tickets, and in particular to methods of redemption and exchange of unused airline tickets. The present invention also relates to systems and apparatuses corresponding to such methods.
2. Related Art
The number of tickets being issued for services (such as airline and other forms of travel as well as hotel accommodations, concerts, seminars, shows, park admissions, events and the like) is rapidly increasing. In particular, the number of electronic tickets, and specifically electronic tickets for airline travel, is increasing very rapidly. Many travelers, and especially frequent business travelers, find themselves in the position of scheduling many trips, changing itineraries, canceling or rescheduling trips, and otherwise creating a complex history of travel scheduling and rescheduling. It is not unusual in the midst of such hectic travel history for a traveler to forget about or lose track of unused tickets. The problem of failure to timely use tickets and/or to redeem unused tickets is exacerbated by the growing use of electronic tickets, since, in the case of an electronic ticket, the traveler may have no paper record to remind him or her when to use the ticket or even that a ticket exists.
Generally, unused tickets expire after a prescribed period of time. If no refund is claimed after expiration, the residual value of the unused ticket is usually kept by the airline or other service provider, resulting in a total loss for the purchaser. A frequent traveler or a business that employs a number of employees who travel can sustain significant financial losses by allowing multiple paid-in-full, but unused tickets to expire rather than obtaining refunds for them.
At least some of this financial loss may be avoided by keeping track of unused tickets and seeking refunds therefor in a timely manner. For example, full or partial refunds may be available prior to a specific date, although they may be severely limited after such date. Even if the tickets are specified as not being refundable, it is often the case that they be redeemable for some form of value. In such cases, the financial loss may be avoided or mitigated by redemption of the unused tickets. This latter situation is becoming increasingly important because the use of non-refundable tickets is growing, due in large part to the significant cost savings associated therewith.
Unfortunately, to recapture value from an unused, non-refundable ticket usually requires a cumbersome alternative to a refund, such as an exchange, a credit, a discount, or some other mechanism for redeeming the ticket to capture its residual value. For example, it may be the case that an unused, non-refundable ticket is redeemable as credit toward the purchase of a new ticket. That is, the residual value of the unused, non-refundable ticket may be applied as full or partial payment for the new ticket. However, to effect such redemption of the unused, non-refundable ticket, it is necessary for the booking agency to collect information pertaining to both the unused, non-refundable ticket and the new ticket and to apply so-called validation rules that govern redemption/exchange of the unused, non-refundable ticket. The validation rules are based on characteristics of the tickets and typically limit the conditions under which the unused, non-refundable ticket can be redeemed/exchanged. For example, the validation rules may require that the unused, non-refundable ticket be exchanged only for travel during limited time periods, or to/from certain departure/arrival cities, etc. The validation rules also determine the amount of residual value of the unused ticket, i.e., the value for which it can be redeemed/exchanged. For example, in the case of a ticket having multiple segments (i.e., legs) of a journey, which ticket is partly unused (i.e., some, but not all legs have not been used), the validation rules may stipulate that the residual value of a ticket decreases by a given amount for each segment that has already been used.
Application of the validation rules is a time-consuming procedure. For example, it may take a travel agent 15 minutes to apply the rules to a given exchange requested by a holder of an unused, non-refundable ticket. Moreover, it is generally not feasible to estimate the residual value of an unused, non-refundable ticket, or even to determine whether it is exchangeable at all, by some other means that would permit one to bypass application of the rules. This is because the rules are not typically indicated on the paper ticket at all, or in other travel records in straightforward plain language. In addition, the rules are often complicated, and in some cases, debatable. Thus, it is necessary to perform the laborious and time-consuming procedure of applying the rules even though there is a significant chance of obtaining a negative outcome, e.g., of determining that the ticket may not be used as desired or has no significant value at all. For example, upon application of the rules, it could turn out that the ticket may not be exchanged for the requested new ticket, but could be exchanged for certain other new tickets, or that the ticket has insignificant residual value, or may not be exchanged for any new ticket. The ticket that the customer believes is unused may be partially used (i.e., open), which the travel agent may not be able to ascertain without going through the process of applying the validation rules.
Since travel agents are generally under pressure or requirements to limit the time allocated to a given customer or transaction, they may not have an incentive to apply the validation rules, in view of the time and difficulty involved therewith and the possibility that the time and labor expended could turn out to be wasted. Accordingly, it is often the case that no attempt is even made to redeem/exchange an unused ticket. Consequently, many unused tickets expire without their residual value having ever been sought or claimed. This practice causes significant financial loss to travelers and, in particular, to large organizations having many employees who travel.
In addition to the above-described problems of time and labor and consequent disincentive to attempt redemption of unused tickets, the difficulty of applying the validation rules results in errors being made by travel agents in processing exchanges of unused tickets for new tickets. For example, the travel agent could mistakenly charge a traveler too low a price for such an exchange. When such an error is discovered by the ticket issuer, the ticket issuer issues a debit memo to the travel agency. The travel agency has to pay the ticket issuer (1) the difference between the correct price and the price it collected from the customer and paid the ticket issuer and (2) a penalty for making the mistake. These costs to the travel agency constitute another disincentive to attempting to obtain the residual value from unused tickets.
In addition to facing the above-described problems involved in processing redemption/exchanges of unused tickets, large organizations (e.g., travel agencies) have had difficulty effectively recapturing the residual value of unused tickets due to the lack of both (1) a centralized database for keeping records of unused tickets, accessible by all the offices or branches of an agency, and (2) a single uniform procedure for processing and redeeming unused tickets, which is followed by the offices or branches of an agency. Thus, different local offices may each operate according to their own local procedures, with no attempt to ensure that the most efficient procedure is used by all. Also, offices may not even have the ability to retrieve the information about existing unused tickets issued by other offices of the same agency, which information would be necessary to use such tickets in exchange for a new ticket (e.g., if a traveler purchases a ticket at one office, does not use it, and wishes to redeem/exchange it for a new ticket at a different office of the agency).
In sum, conventionally, there has been no effective and efficient way to track unused tickets and to facilitate their redemption/exchange for credit applied to the purchase of new tickets on behalf of the traveler/purchaser. Any systems that have been available have been substantially manual systems that are not sufficiently reliable in terms of tracking unused tickets, identifying the status of such tickets (e.g., as unused or redeemed/exchanged), providing this information to the traveler/purchaser for the purpose of redemption/exchange, and efficiently processing redemptions/exchanges of unused tickets. In addition, existing systems have not been organized on an organizationally global scale.
Accordingly, the need exists for an improved (e.g., more organized and more automated) system for the redemption/exchange of unused tickets, including the various support mechanisms/infrastructure for such a system as described above, such as would overcome or mitigate the problems described above.
SUMMARY OF THE INVENTION
The present invention provides a system, method and computer program product for the redemption/exchange of unused tickets that meets the above-identified needs.
According to a first aspect of the present invention, a method of facilitating exchange of unused tickets includes the steps of receiving an electronic request to retrieve an electronic account record of a client from at least one database, retrieving the client account record from the at least one database based on the electronic request, wherein in connection with the retrieval, it is determined whether the at least one database has a ticket record of an unused ticket for the client, and providing an alert of existence of the unused ticket, if it is determined in the retrieving step that the at least one database has the ticket record.
According to a second aspect of the present invention, in the method according to the first aspect the alert is a display of details of the unused ticket.
According to a third aspect of the present invention, in the method according to the second aspect the details of the unused ticket include at least one of the expiration date of the unused ticket, the issuing source of the unused ticket, and the airline of the unused ticket.
According to a fourth aspect of the present invention, in the method according to the second aspect the details of the unused ticket include the redemption value of the unused ticket.
According to a fifth aspect of the present invention, in the method according to the second aspect the alert is provided to at least one of a ticket booking agent and the client.
According to other aspects of the present invention, there are provided systems and computer program products corresponding to the above-described methods.
The present invention represents an improvement over the prior art and facilitates the redemption and exchange of unused tickets by eliminating to a great degree the difficulty and time involved in the activity of applying the validation rules. In addition, the invention eliminates to a great degree the possibility of errors being made in applying the validation rules; if errors are nonetheless made, the adverse financial consequences associated therewith are largely eliminated. In these ways, existing disincentives to seeking redemption of unused tickets are largely eliminated. In addition, the invention employs a centralized database and procedure, not only streamlining the redemption/exchange process as a whole but also in particular facilitating access to information about unused tickets so as to largely eliminate the possibility that unused tickets are not redeemed due to a lack of knowledge thereof or to inability to access information pertaining thereto.
Further features and advantages of the present invention as well as the structure and operation of various embodiments of the present invention are described in detail below with reference to the accompanying drawings. By these means, the present invention may increase the rate of redemption of unused tickets and, as a result, generate significant cost savings.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings.
FIG. 1 is a schematic diagram illustrating a system for performing and facilitating the redemption/exchange of unused tickets.
FIG. 2 is a flow chart illustrating a method of performing and facilitating the redemption/exchange of unused tickets, which method may be carried out by the system of FIG. 1 .
FIG. 3 is a schematic diagram of an exemplary computer system useful for implementing the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to a system, method and computer program product for performing and facilitating the redemption/exchange of unused tickets. The present invention is now described in more detail herein in terms of the above exemplary description. This is for convenience only and is not intended to limit the application of the present invention. In fact, after reading the following description, it will be apparent to one skilled in the relevant arts how to implement the following invention in alternative embodiments.
The features and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the figures.
Although the invention may be applied to the redemption/exchange of unused tickets (including vouchers, coupons and the like) of any type, one intended application of the invention is to the redemption/exchange of unused airline tickets. In what follows, an example of this application of the invention will be explained with reference to the figures. Further, the invention is illustrated with reference to services provided by a travel agency to a plurality of its clients. The clients can be individual travelers or businesses having employees who travel. The invention, however, is not limited to such a travel agency or such a client.
Although in no way limited to such application, the present invention is intended to be of particular utility to an organizational entity, e.g., a large travel agency serving a large number of clients, including large clients having a number of employees who travel.
The system may be configured as a data processing system, and may include a host server or other computing systems including a processor for processing digital data, one or more memories coupled to the processor for storing digital data, and means, coupled to the one or more memories, for inputting digital data, an application program (which may be referred to herein as Quick Exchange) stored in a memory and accessible by the processor for directing processing of digital data by the processor, a display coupled to the processor and memories for displaying information derived from digital data processed by the processor and a plurality of databases, that may include client data, ticket data, event data and/or like data that could be used in association with the present invention. As those skilled in the art will appreciate, each computer will typically include an operating system (e.g., Windows NT, 95/98/2000, Linux, Solaris, etc.) as well as various conventional support software and drivers typically associated with computers. The computers can be in a home or business environment with access to a network. In an exemplary embodiment, access may be had through the Internet through a commercially available web-browser software package.
Each participant in the system may be equipped with a computing system to facilitate online commerce transactions. The client may have a computing unit in the form of a personal computer, although other types of computing units may be used including laptops, notebooks, hand held computers, set-top boxes, and the like. The point of sale office may have a computing unit implemented in the form of a computer-server, although other implementations are possible. The central reservation center may have a computing center in the form of a mainframe computer. However, the central reservation center may be implemented in other forms, such as a mini-computer, a PC server, a network set of computers, and the like.
Communication between the parties to a ticket redemption/exchange transaction and the system of the present invention may be accomplished through any suitable communication means, such as, for example, a telephone network, Intranet, Internet, point of interaction device (point of sale device, personal digital assistant, cellular phone, kiosk, etc.), online communications, off-line communications, wireless communications, and/or the like. One skilled in the art will also appreciate that, for security reasons, any databases, systems, or components of the present invention may consist of any combination of databases or components at a single location or at multiple locations, wherein each database or system includes any of various suitable security features, such as firewalls, access codes, encryption, de-encryption, compression, decompression, and/or the like.
The computers of the involved various parties, such as travel agencies, financial institutions, and service providers, may be interconnected via a network such as an existing proprietary network accommodating electronic transactions. Such a network may be a closed network that is assumed to be secure from eavesdroppers, or a public network that may be assumed to be insecure and open to eavesdroppers, e.g., the Internet. Specific information related to the protocols, standards, and application software utilized in connection with the Internet is understood to be known to those of skill in the pertinent arts and is accordingly omitted herein.
The system of the invention, subsystems thereof, and systems interacting therewith may be suitably connected via data links. A variety of conventional communications media and protocols may be used for data links, such as a connection to an Internet Service Provider (ISP) over a local loop as is typically used in connection with standard modem communication, cable modem, Dish networks, ISDN, Digital Subscriber Line (DSL), or various wireless communication methods. Client systems might also reside within a local area network (LAN) that interfaces to a network via a leased line (T1, D3, etc.). As such communication methods are well known in the art, description thereof is omitted herein.
The system of the invention and its functional elements and interacting systems may be implemented and distributed among the various involved parties. For example, the systems may be implemented as computer software modules loaded onto the various computer systems of some of the parties so that the computers of the other parties do not require any additional software to participate in the redemption/exchange transactions and other activities supported by the system of the invention.
The system may include or interact with a number of databases, e.g., a database that includes all travel related activities scheduled and ticketed by the travel agency, a database including a listing of all clients that may participate in the redemption/exchange system, a flight database holding information on particular flights, including the flight number, cost of the ticket, departure city and arrival city, departure date, and any information on whether and to what extent the ticket is redeemable, and one or more central reservation system (CRS) databases. Of course, the system is not limited to these databases.
There are several central reservation systems, also known as computerized reservation systems or global distribution systems (GDS). (The terms “CRS” and “GDS” are used interchangeably herein.) These are databases maintained by the airline industry or other groups and are accessible by travel agents. These databases each contain information on all tickets issued from that particular GDS. Whenever a ticket is issued for any flight, that information is stored in the central reservation system database. Typically, a travel agent must access these outside databases to view ticket information. In some cases, the GDS deletes records, usually within seven days, following the date the ticket is used, or when the ticket passes an expiration date. Without having the relevant information in an agency-accessible database, if no record for a particular ticket was found in the GDS database, it would not be possible to determine whether that ticket had been used or whether it had passed its expiration date.
The expiration date for a ticket may be, e.g., a period of one year after the date of invoice. An unused ticket can generally be redeemed only prior to the expiration date.
Thus, in the present invention, it is preferable to have one or more booking agency databases that has information concerning the unused tickets. As one skilled in the art will realize, two or more databases can be combined as a single database including all of the information contained in the two separate databases, although this may not always be practical, e.g., where multiple databases are held by different corporate entities, etc.
The databases discussed herein may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Common database products that may be used to implement the databases include DB2 by IBM (White Plains, N.Y.), any of the database products available from Oracle Corporation (Redwood Shores, Calif.), Microsoft Access or MSSQL by Microsoft Corporation (Redmond, Wash.), or any other database product. The databases may be organized in any suitable manner, including as data tables or lookup tables. Association of certain data may be accomplished through any data association technique known and practiced in the art.
A computer of the system of the invention may provide a suitable website or other Internet-based graphical user interface which is accessible by users. The term “website” as it is used herein is not meant to limit the type of documents and applications that might be used to interact with the user. For example, a typical website might include, in addition to standard HTML documents, various forms, Java applets, Javascript, active server pages (ASP), common gateway interface scripts (CGI), extensible markup language (XML), dynamic HTML, cascading style sheets (CSS), helper applications, plug-ins, and the like.
The system of the invention may employ a centralized computer that has access to all of the relevant databases to carry out all the steps of the method according to the invention. Alternatively, the functions carried out by such a computer may be carried out by a plurality of local computers, preferably localized computers that are linked together.
FIG. 1 is a schematic diagram illustrating one embodiment of a system 101 for performing and facilitating the redemption and exchange of unused tickets in accordance with the invention. (It will be understood that FIG. 1 may be understood as representing either a system or an apparatus. For ease of discussion, the terms “system” and “apparatus” may be used interchangeably herein.)
As shown in FIG. 1 , system 101 , for serving customer 107 , includes Quick Exchange graphical user interface (GUI) 102 , Centralized Repository of Unused Tickets 103 , Point of Sale (POS) Tool 104 , GDS Interface Tool 105 (in this embodiment, a utility program called Runway), and pricing tool 106 (in this embodiment, Worldspan's Rapid Reprice). The term “Quick Exchange” is also used herein to refer to the application program as a whole. It is understood that, as the invention is expected generally to be employed by a large organization, multiple POS tools 104 , e.g. in different geographically separate branches or offices of the organization, will be included within the system.
FIG. 1 also shows several different screens or displays that may be provided by Quick Exchange GUI 102 . Specifically, there are shown a screen for displaying client (e.g. passenger/customer) identification information and the client's unused tickets, a screen for displaying a response received from Rapid Reprice and for entering a decision to accept or decline the terms outlined in the response, a screen for displaying the details of travel documents, e.g., unused tickets or new tickets, and a screen for manually entering unused tickets into Central Repository of Unused Tickets 103 . Quick Exchange GUI 102 could be arranged to display these screens simultaneously as separate displays or to display only one or more screens at a time, or to be capable of doing both. Of course, it is not necessary to provide physically or functionally separate screens to display this information, and other screens or displays could also be provided. The display arrangements illustrated in FIG. 1 and described here could be further modified as will be understood by one of skill in the art. The contents of the displayed information mentioned above will be described in more detail in the discussion of the method of the present invention set forth below.
Quick Exchange GUI 102 may be deemed the central element of the system and preferably is able to communicate with all other elements. Runway (serving as GDS Interface Tool 105 in this embodiment) is a product of SITA (Société Internationale de Télécommunications Aéronautiques), an IT service provider for the airline industry. Runway serves as an intermediary between Quick Exchange GUI 102 , which is internal to the travel agency, and Worldspan's Rapid Reprice, an external system of Worldspan, a third party CRS. Runway receives instructions and information (regarding an unused ticket to be redeemed and a new ticket to be purchased) from Quick Exchange and transmits it in appropriate format to Rapid Reprice. Rapid Reprice calculates the residual value of the unused ticket, applies that value to the new ticket desired to be purchased, and calculates a price for the exchange, i.e., calculates a revised price for the new ticket, which price will be valid on the condition that the old ticket is exchanged for the new ticket. Rapid Reprice transmits a response including an indication of the residual value and the revised price, and related information, to Runway, and Runway in turn sends this response to Quick Exchange. While Runway and Rapid Reprice represent elements of the invention in a preferred embodiment, one of skill in the art will of course understand that they may be replaced by other elements capable of performing equivalent functions or of providing such services. In particular, since, as discussed above, there exist multiple central reservation systems (CRSs), each of which services different airlines, it is understood that a system equivalent to or otherwise able to perform sufficiently similar functions as Rapid Reprice provided by, e.g., another CRS could be employed in the invention in place of Rapid Reprice. Likewise, a utility program equivalent to or otherwise able to perform sufficiently similar functions as Runway provided by, e.g., another travel industry service provider could be used in place of Runway.
It is noted that the Centralized Repository of Unused Tickets is the subject of another U.S. patent application, entitled “SYSTEM AND METHOD FOR CENTRALIZING AND PROCESSING TICKET EXCHANGE INFORMATION” and filed on the same date as the instant application, the contents of which application are hereby incorporated herein by reference. Since the Centralized Repository of Unused Tickets is described in detail in that application, only a brief description thereof is provided in the instant application.
It is also noted that other aspects of the present invention and related inventions have been described in U.S. patent application Ser. No. 10/708,112 (published as U.S. Patent Application Publication No. 2004/0138930 A1), U.S. patent application Ser. No. 10/294,930 (published as U.S. Patent Application Publication No. 2004/0010427 A1), U.S. patent application Ser. No. 09/346,085, and U.S. Provisional Patent Application No. 60/396,224, now expired, all of which are hereby incorporated herein by reference.
FIG. 2 is a flow chart illustrating one embodiment of a method 201 for performing and facilitating the redemption and exchange of unused tickets in accordance with the present invention. The method may be performed by the system of FIG. 1 .
The method is initiated when customer 107 contacts, e.g., a travel agency, to purchase a new air ticket. The contact between customer 107 and the travel agency may be in person, over the phone, etc. The invention is also applicable to a case in which customer 107 contacts an on-line travel agent or service (such as Travelocity, Orbitz, etc.). At step S 201 , customer 107 is identified in one of the agency's multiple POS tools 104 or Quick Exchange GUI 102 . At step S 202 , a travel agent of the agency or, e.g., customer 107 in the case of an on-line transaction, books a new reservation or changes an existing reservation for a flight desired by customer 107 using POS tool 104 or Quick Exchange GUI 102 .
At step S 203 , POS tool 104 or Quick Exchange GUI 102 queries Centralized Repository of Unused Tickets 103 to determine if customer 107 has any unused and unredeemed tickets, which could be redeemed for credit against the purchase of a new ticket. At step S 204 , Centralized Repository of Unused Tickets 103 returns a response, which is displayed on POS tool 104 or Quick Exchange GUI 102 .
It is noted that the travel agency may assign every passenger a unique ID number. Thus, once customer 107 is identified to the travel agency, the agency is able to access pertinent information about customer 107 in its databases, including information regarding tickets previously purchased by the customer and, for any given ticket, information about the flight, cost, etc. Among other information held by the travel agency in its databases there is, for each ticket issued, a number identifying that ticket and an indication of which GDS holds the ticket information.
When a passenger cancels a ticket, or when a ticket's scheduled departure date passes and the passenger has not traveled as scheduled, the ticket information of the unused ticket may be manually or automatically (or some combination thereof) entered into Centralized Repository of Unused Tickets 103 . If the ticket is a paper ticket rather than an electronic ticket, the ticket information may have to be entered manually. Based on the ticket number and knowledge of the particular GDS in which the ticket information is kept, a robotic job retrieves the passenger name record (PNR) (or other ticket record) corresponding to the ticket from the particular GDS. The robotic job parses the PNR and stores the ticket information of the unused ticket in Centralized Repository of Unused Tickets 103 . The PNR includes, e.g., face value of the ticket, the date of issue, whether the ticket is fully or partly open (i.e., not used at all or having some segments used), and other flight information. The ticket information may be sent to an external system such as Global Ticket Trax/TTNR (described in at least some of the patent applications that are noted above and incorporated herein by reference) to calculate a residual value of the ticket, which may then also be stored in Centralized Repository of Unused Tickets 103 . (Because the actual residual value of an unused ticket depends on many factors, as reflected in the validation rules, and this value may vary depending on which particular new ticket the unused ticket is to be exchanged for, it is understood that the residual value obtained at this juncture may be deemed tentative in this sense.) Thus, Centralized Repository of Unused Tickets 103 is able to supply the necessary information regarding unused tickets held by a given customer 107 to POS tool 104 or Quick Exchange GUI 102 upon being queried about that customer 107 . Of course, unused ticket information may be made to be accessible by any of various identifiers, e.g., passenger name, client identification number, account number, etc. in addition to the above-mentioned passenger ID number. As noted, Centralized Repository of Unused Tickets 103 is discussed in greater detail in the above-noted U.S. patent application directed thereto.
If the response from Centralized Repository of Unused Tickets 103 indicates that an unused ticket purchased by customer 107 exists, and customer 107 wishes to use it for credit in exchange for a new ticket, at step S 205 POS tool 104 or Quick Exchange GUI 102 launches the Quick Exchange application. At step S 206 , the Quick Exchange application collects the necessary information regarding the unused ticket and the new ticket. The information regarding the unused ticket is obtained from Centralized Repository of Unused Tickets 103 , as discussed above, and the information regarding the new ticket is obtained from the GDS and/or from the travel agency's databases.
At step S 207 the travel agent (or Quick Exchange automatically) invokes a transaction serviced by a utility (GDS Interface Tool) such as Runway. For example, the agent may send an instruction to Runway to perform a transaction. At step S 208 , Runway sends a request message, including any necessary information regarding the unused ticket to be exchanged and the new ticket to be purchased, to Rapid Reprice to interpret/process the validation rules. Alternatively, Rapid Reprice or some other program can perform the validation earlier and store the information in the Centralized Repository of Unused Tickets 103 . Runway is able to individually tailor a request as necessary to comply with the requirements of whichever of the several GDSs to which it is sending the request. For example, each GDS may have a specific required format or commands. By using Runway, the travel agent need not know the specific format and commands for any GDS, thus easing the travel agent's duties.
At step S 209 , Rapid Reprice calculates a revised price for the new ticket that is valid on condition that customer 107 redeem his or her unused ticket and use its value as credit toward the purchase of the new ticket. Rapid Reprice also applies the validation rules to ensure that the unused ticket may be used as requested. Rapid Reprice guarantees that the revised price it calculates is correct. Accordingly, in the event the revised price turns out to be incorrect and the ticket issuer issues a debit memo to the travel agency, the travel agency does not lose the money (difference in price between the correct revised price and the actual price paid, if the former is higher, and penalty) that would normally be lost in such a situation.
At step S 210 , Rapid Reprice returns a response (indicating the revised ticket price and other pertinent information) to Runway. At step S 211 , Runway returns Rapid Reprice's response to Quick Exchange GUI 102 . At step S 212 , the travel agent and customer 107 decide whether to accept or decline the exchange, i.e., the purchase of the new ticket at the revised price in exchange for the unused ticket.
The system may be arranged so that if the response from Rapid Reprice indicates that the unused ticket is not redeemable for this particular exchange, the response also indicates the reason for this. For example, the response may indicate which particular validation rule was not satisfied, on account of which the unused ticket could not be used for the particular exchange desired. In such case, based on the reason indicated in the response, the travel agent may be able to suggest to customer 107 alternative new ticket purchases, for which the unused ticket could be redeemed. For example, the changing of air carrier or flight date could render the unused ticket redeemable and could constitute a change that customer 107 is willing to make for the sake of obtaining some residual value from the unused ticket.
In addition, the system may be arranged so that if the response indicates that the unused ticket is redeemable for this particular exchange, the response also indicates the reasons on which the determination of the price of this particular exchange is based. Based on knowledge of these reasons, the travel agent may be able to suggest alternatives to the requested exchange that are more preferable in terms of price, i.e., that permit customer 107 to obtain a greater residual value from the unused ticket. For example, making a minor change to the new ticket, such as a change in air carrier or flight date, may be acceptable to customer 107 and constitute an exchange transaction that costs customer 107 significantly less money. Thus, customer 107 could decide to decline a particular exchange transaction (particular new ticket) in favor of an alternative one.
Thus, the redeemability of an unused ticket and the residual value of an unused ticket are not necessarily fixed quantities. Rather, they will generally vary depending on the conditions under which the unused ticket is to be exchanged for a new ticket. Those conditions include both the terms of the new ticket (e.g., air carrier, flight date, etc.) and terms independent of the new ticket. The conditions independent of the new ticket may be terms of the unused ticket or, e.g., terms of the airline or issuing agency that apply to all tickets it issues. The term “conditions” used here is effectively another name for the validation rules described above.
An example of a general validation rule or condition, i.e., one that is independent of the particular unused or new ticket, is a rule whereby a universal redemption penalty is automatically applied to any redemption/exchange of an unused ticket. Such general rules are commonly imposed by airlines and other ticket issuing agencies. The cost of such a penalty, assuming that the penalty applies, will be reflected in the price for the exchange (i.e., the revised price for the new ticket) calculated by Rapid Reprice. It is noted that it is of course possible for the residual value of the unused ticket to exceed the combined cost of the new ticket and the penalty, in which case the cost of the exchange transaction would be negative, i.e., customer 107 could make the transaction and obtain a credit or refund.
At step S 213 , the travel agent (or Quick Exchange automatically) sends a message to Centralized Repository of Unused Tickets 103 to update the status of the unused ticket, e.g., as “exchanged” (if exchanged) or “attempted to be exchanged” (if not exchanged). At step S 214 , Quick Exchange GUI 102 completes the exchange transaction or, if necessary, transmits the response from Rapid Reprice to POS tool 104 in order to complete the exchange transaction at POS tool 104 .
One of skill in the art will understand that for some of the above steps, the order of performance need not match the listed numerical order, e.g. step S 213 could be performed after step S 214 .
While the invention has been described above with reference to particular practices presently in use by the airline industry, those of skill in the art will recognize that the airline industry periodically changes its practices, procedures, and requirements, and the invention is not to be taken as being limited to any one particular set of airline requirements.
Example Implementations
The present invention, or any part(s) or function(s) thereof, may be implemented using hardware, software or a combination thereof and may be implemented in one or more computer systems or other processing systems. However, the manipulations performed by the present invention were often referred to in terms, such as adding or comparing, which are commonly associated with mental operations performed by a human operator. No such capability of a human operator is necessary, or desirable in most cases, in any of the operations described herein which form part of the present invention. Rather, the operations are machine operations. Useful machines for performing the operation of the present invention include general purpose digital computers or similar devices.
In fact, in one embodiment, the invention is directed toward one or more computer systems capable of carrying out the functionality described herein. An example of a computer system 300 is shown in FIG. 3 .
The computer system 300 includes one or more processors, such as processor 304 . The processor 304 is connected to a communication infrastructure 306 (e.g., a communications bus, cross-over bar, or network). Various software embodiments are described in terms of this exemplary computer system. After reading this description, it will become apparent to a person skilled in the relevant arts how to implement the invention using other computer systems and/or architectures.
Computer system 300 can include a display interface 302 that forwards graphics, text, and other data from the communication infrastructure 306 (or from a frame buffer not shown) for display on the display unit 330 .
Computer system 300 also includes a main memory 308 , preferably random access memory (RAM), and may also include a secondary memory 310 . The secondary memory 310 may include, for example, a hard disk drive 312 and/or a removable storage drive 314 , representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive 314 reads from and/or writes to a removable storage unit 318 in a well known manner. Removable storage unit 318 represents a floppy disk, magnetic tape, optical disk, etc. which is read by and written to by removable storage drive 314 . As will be appreciated, the removable storage unit 318 includes a computer usable storage medium having stored therein computer software and/or data.
In alternative embodiments, secondary memory 310 may include other similar devices for allowing computer programs or other instructions to be loaded into computer system 300 . Such devices may include, for example, a removable storage unit 322 and an interface 320 . Examples of such may include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an erasable programmable read only memory (EPROM), or programmable read only memory (PROM)) and associated socket, and other removable storage units 322 and interfaces 320 , which allow software and data to be transferred from the removable storage unit 322 to computer system 300 .
Computer system 300 may also include a communications interface 324 . Communications interface 324 allows software and data to be transferred between computer system 300 and external devices. Examples of communications interface 324 may include a modem, a network interface (such as an Ethernet card), a communications port, a Personal Computer Memory Card International Association (PCMCIA) slot and card, etc. Software and data transferred via communications interface 324 are in the form of signals 328 which may be electronic, electromagnetic, optical or other signals capable of being received by communications interface 324 . These signals 328 are provided to communications interface 324 via a communications path (e.g., channel) 326 . This channel 326 carries signals 328 and may be implemented using wire or cable, fiber optics, a telephone line, a cellular link, a radio frequency (RF) link and other communications channels.
In this document, the terms “computer program medium” and “computer usable medium” are used to generally refer to media such as removable storage drive 314 , a hard disk installed in hard disk drive 312 , and signals 328 . These computer program products provide software to computer system 300 . The invention is directed to such computer program products.
Computer programs (also referred to as computer control logic) are stored in main memory 308 and/or secondary memory 310 . Computer programs may also be received via communications interface 324 . Such computer programs, when executed, enable the computer system 300 to perform the features of the present invention, as discussed herein. In particular, the computer programs, when executed, enable the processor 304 to perform the features of the present invention. Accordingly, such computer programs represent controllers of the computer system 300 .
In an embodiment where the invention is implemented using software, the software may be stored in a computer program product and loaded into computer system 300 using removable storage drive 314 , hard drive 312 or communications interface 324 . The control logic (software), when executed by the processor 304 , causes the processor 304 to perform the functions of the invention as described herein.
In another embodiment, the invention is implemented primarily in hardware using, for example, hardware components such as application specific integrated circuits (ASICs). Implementation of the hardware state machine so as to perform the functions described herein will be apparent to persons skilled in the relevant arts.
In yet another embodiment, the invention is implemented using a combination of both hardware and software.
CONCLUSION
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example, and not limitation. It will be apparent to persons skilled in the relevant arts that various changes in form and detail can be made therein without departing from the spirit and scope of the present invention. Thus, the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
In addition, it should be understood that the figures appended hereto, which highlight the functionality and advantages of the present invention, are presented for example purposes only. The architecture of the present invention is sufficiently flexible and configurable, such that it may be utilized (and navigated) in ways other than that shown in the accompanying figures.
Further, the purpose of the foregoing Abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is not intended to be limiting as to the scope of the present invention in any way. It is also to be understood that the steps and processes recited in the claims need not be performed in the order presented.
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A method of facilitating and performing the redemption and exchange of unused tickets includes steps of determining the availability of unused tickets, calculating a redemption value of an available unused ticket, and updating a status of the unused ticket. The availability is determined by querying a database containing information pertaining to unused tickets. The redemption value is calculated based on the application of validation rules. The status is updated after a decision as to whether to redeem the unused ticket has been made. The redemption value is obtainable by exchanging the unused ticket for a new ticket. The tickets may be for air travel.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was not federally sponsored.
BACKGROUND OF INVENTION
[0003] Tools to cut wire have been popular for centuries, as have been wire twisting devices. These types of tools are commonly used in construction, where wire is used to attach two pieces of rebar prior to pouring slabs or columns. Wire twisting and cutting devices are also frequently used to attach fences to posts, repair holes in fences, and wire pieces of reinforcing bar together when pouring concrete slabs and making concrete posts and ceilings. Taking the ends of a piece of wire and twisting them by hand is an extremely time-consuming and strenuous task.
[0004] While the prior art has examples of tools which are designed to cut and twist wire, the current invention is the first to combine in an inexpensive hand tool an ergonomic fit, a method of regulating the output and intake of wire, a protective covering over the wire before it leaves the tool, and an efficient cutting and twisting ability which does not twist the wire inside of the tool body itself and can be accomplished using only hand strength without relying on electrical or battery power.
[0005] U.S. Pat. No. 5,836,137 to Contreras (1998) teaches an intermittent rotable pneumatic drive which gathers material around an article for tying, but this machine is expensive, cannot be operated by hand, and would not be convenient to use in a construction setting where a small hand tool would be much more convenient.
[0006] U.S. Pat. Nos. 3,091,264 to Stanford (1963), 3,593,759 to Wooge (1971), and 4,448,225 to Schmidt (1984) teach hand tools which would be convenient to use on a construction site, but require as part of their operation that the supply wire be twisted, thereby creating a potential for jamming problems with the supply wire.
[0007] U.S. Pat. No. 5,501,251 to Vader (1996) teaches a hand tool which has a supply of wire which is twisted by the tool and cut by additional pulling on the tool, but this tool is not ergonomically designed, requires an external source of wire, thereby decreasing its ease of use, and requires the addition of a commercially available ratchet spring return twister rather than having the twisting mechanism built into the tool.
[0008] The current invention meet the long-felt need for an inexpensive, easy to use hand tool that is ergonomically designed for the human hand, and supplies wire from an internal spool which can easily be refilled or replaced by a user, has a cranking mechanism to extrude wire from the jaws of the tool or wind back in excess wire, has jaws to cut the wire and a groove and steel ball mechanism to twist the wire was the user pulls back on the tool.
BRIEF SUMMARY OF INVENTION
[0009] It is therefore an object of this invention to provide an inexpensive, simple and efficient method of cutting and twisting cutting wire with a tool that is ergonomically comfortable and efficient, and can be used without reliance on electrical or battery power.
[0010] It is a further object of this invention to provide a means by which the wire can be fed out through the jaws of the tool through means of a spool.
[0011] It is an additional object of this invention that the wire inside the body cavity of the tool is protected from dirt and debris by the tool body, and that the wire inside the body cavity is not twisted by the tool.
[0012] Other and further objects and features of this invention will be apparent to one skilled in the art.
BRIEF DESCRIPTION OF THE FIGURES
[0013] FIG. 1 is a side view of the invention show the major external parts, as well as the wire twisting capabilities.
[0014] FIG. 2 is a side view of the invention, showing the three main parts: a body part, a head part, and a lock washer. This view shows the inner workings of the invention as well.
[0015] FIG. 3 is a cut-away view of the invention, with the external side of the device closest to the viewer removed to show the internal mechanisms of the invention.
[0016] FIG. 4 is a partial elevational view of the invention, showing a close-up of the jaw mechanisms.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention is directed to a tool which can easily and efficiently twist and cut wire which is fed through the jaws of the tool by means of a spooling assembly and a cranking mechanism.
[0018] Referring to the drawings the invention consists of a spool of wire held inside of the tool body, where the wire is fed out through the jaws of tool where the wire is cut, and a series of grooves and steel balls allows the wire to be twisted by the rotating tool head. The tool consists of four detachable parts, a tool body in which the spool is located, the tool head portion where the jaws and grooves are located, a locking ring which attaches the head portion to the tool body, and two steel balls which sit in indentations in the tool body and cause the head portion to spin and twist the wire before it is cut.
[0019] FIG. 1 is a side view of the tool. The tool consists of four parts, three of which are visible here. A tool body ( 1 ) is comprised of two tool body parts, the right side or first body part is visible in this drawing. The tool body has a palm section ( 2 ), which has a palm side ( 3 ) and a finger side ( 4 ), and is designed to fit comfortably into the hand of a user. The ergonomic fit is a key feature of this invention. The tool body ( 1 ) has a spool end ( 25 ) and a head end ( 26 ). Attached to the head end ( 26 ) of the tool body ( 1 ), that is, the section furthest away from the palm section ( 2 ) is the tool head ( 5 ), which can rotate about an axis in a circular direction ( 6 ) defined by a wire ( 11 ). The wire ( 11 ) comes from a spool inside the tool body (not shown in this figure), and passes through an upper jaw member ( 8 ) and a lower jaw member ( 7 ) of the tool head ( 5 ), and between a cutting blade ( 9 ) located at the tip of the upper jaw member ( 8 ) and a cutting slot ( 10 ) located at the tip of the lower jaw member ( 7 ). The tool head ( 5 ) rotates around a device comprised of grooves and steel balls, not shown in this figure. The wire ( 11 ) is cut by the jaw mechanism, and then gripped between the upper jaw member ( 8 ) and the lower jaw member ( 7 ) to be twisted. To prevent the tool head ( 5 ) from rotating at times when such rotation is undesirable, the invention has a quick release locking mechanism ( 7 ), which is attached to a pivot point ( 22 ) protruding from the underside of the tool body ( 1 ), and has a lock tab ( 23 ) which fits into slots (not shown in this figure) in the tool head ( 5 ) to prevent the tool head ( 5 ) from rotating unless the quick release locking mechanism is pushed against the locking mechanism retaining spring ( 24 ) by the fingers of the user. To cut the wire ( 11 ) the upper jaw member ( 8 ) has attached to it at a lever pivot point ( 14 ) a lever bar ( 12 ) which, when pressed against a fulcrum bar (not shown in this figure) at a fulcrum bar pivot point ( 15 ), pressure is exerted upon the upper jaw member ( 8 ) such that the cutting blade ( 9 ) snaps the wire against the cutting slot ( 10 ), thereby breaking the wire ( 11 ). The lever bar ( 12 ) moves in a direction indicated by the number ( 13 ). To move the wire either out of the tool or back into the tool, in cases where and excess of wire was pulled out of the tool, there exists a cranking mechanism. The cranking mechanism can be located in one of two positions. In one iteration, the cranking mechanism is located, under number 17 , in the middle of the tool body ( 1 ), where a crank handle ( 18 ) rotates an internal device which moves the wire ( 11 ) in and out of the tool. In another iteration, the cranking mechanism is located, under number 19 , on the spool end ( 25 ) of the tool body ( 1 ), where a crank handle ( 20 ) can swivel and fit into a crank receptacle ( 21 ) built into the tool body.
[0020] FIG. 2 is a cutaway view of the tool, showing some of its internal parts. Looking inside the tool body ( 30 ), there is a spool ( 31 ) which rotates about a spool axel ( 32 ). There is a length of wire ( 33 ) wound around the spool ( 31 ). The wire ( 33 ) feeds from the spool ( 31 ) through a guiding and movement restriction device consisting of an upper cylinder ( 34 ) which rides over the wire ( 33 ) and has built into it an upper wire guide, (not shown in this figure), which is a semi-circular indentation in the middle of the surface slightly larger than the diameter of the wire ( 33 ) which serves to guide the wire ( 33 ) in a straight line between the spool ( 31 ) and the jaws of the tool ( 47 ). There is an upper cylinder attachment rod ( 36 ) which anchors the upper cylinder ( 34 ) to the first body part (here, the only half of the tool body ( 30 ) which is seen), and an upper cylinder spring ( 37 ) which maintains a constant pressure in a downward direction on the upper cylinder ( 34 ). There is a lower cylinder ( 35 ) which is attached to the first body part by a lower cylinder attachment rod ( 48 ). The lower cylinder ( 35 ) has built into it a lower wire guide, (not shown in this figure), which is a semi-circular indentation in the middle of the surface slightly larger than the diameter of the wire ( 33 ) which serves to guide the wire ( 33 ) in a straight line between the spool ( 31 ) and the jaws of the tool ( 47 ). A lower cylinder spring ( 38 ) working in conjunction with a lower cylinder attachment structure ( 48 ) maintains a constant upward pressure on the lower cylinder ( 35 ), thereby restraining the wire ( 33 ) in the grooves on the upper and lower cylinders. Attached to the lower cylinder ( 35 ) is a winding crank ( 39 ) which is turned by a user grasping the winding handle ( 40 ) and turning it, thereby moving the wire either on or off the spool ( 31 ). Moving further down the tool body ( 1 ) away from the spool ( 31 ) there is a lock washer ( 42 ) which serves to attach the tool head ( 44 ) to the tool body ( 30 ). The tool head ( 44 ) slips over the head end ( 41 ) of the tool body ( 30 ). There are two steel balls ( 43 ) located in indentations ( 49 ) in the head end ( 41 ) which fit into a series of grooves ( 45 ) in the tool head ( 44 ), and can turn the tool head ( 44 ) as a user pulls back on the tool body ( 30 ). There is also a lock washer ( 48 ) shown next to the tool head ( 44 ) to show how the inside diameter of the locker washer ( 48 ) is slightly larger than the outside diameter of the tool head ( 44 ), thereby allowing the lock washer ( 48 ) to slide over the tool head ( 44 ) and lock it in place, after the tool head ( 44 ) is slid over the head end ( 41 ) of the tool body ( 30 ).
[0021] FIG. 3 is a side view of the invention illustrating how the user can cut and twist wire with the tool. When a user wants to cut the wire ( 76 ), he/she presses in a downward direction ( 60 ) on the lever bar ( 77 ), such motion causing the upper jaw member ( 78 ) to move in a downward direction ( 61 ) to cut the wire. When the user stops putting downward pressure on the lever bar ( 77 ), the lever spring ( 64 ) pushes the lever bar ( 77 ) in an upward direction ( 62 ), thereby causing the upper jaw member ( 78 ) to move in an upward direction ( 63 ), thereby open the jaws. To twist wire, the user first puts the two ends of the wire into the jaws of the tool, and locks the lever bar ( 77 ) in a down position, by pushing it down forcefully such that it locks against the tool, then presses in an upward direction ( 70 ) on the quick release locking mechanism ( 71 ), which causes the lock tab ( 73 ) to move in a downward direction ( 72 ), thereby unlocking the tool head ( 75 ) from the tool body ( 74 ). As the user then pulls back, in a direction illustrated by the number ( 68 ), the steel balls ( 65 ) sit in their indentations ( 66 ) and the tool head ( 75 ) rotates in a direction indicated by number ( 69 ) as the grooves ( 67 ) cause the tool head ( 75 ) to spin around, twisting the wire. When the wire has been twisted to the extent desired, the user unlocks the jaws of the tool by pulling upward on the lever bar ( 77 ), thereby opening the jaws.
[0022] FIG. 4 is close-up view of the tool head, showing how the cutting blade ( 91 ) and the cutting slot ( 92 ) can be replaced or removed for sharpening should they become dull.
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A wire twisting tool with a spool assembly, locking mechanism, manual wire feeding mechanism, and cutting jaws is claimed. The tool is designed to quickly and efficiently cut wire and twist it, utilizing a series of matching grooves into which are placed two steel balls which allow the cutting and twisting head portion to rotate about the body portion as the body portion is pulled back by a user.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 13/796,742 filed Mar. 12, 2013, which in turn is a continuation of U.S. patent application Ser. No. 13/093,557 filed Apr. 25, 2011 (now U.S. Pat. No. 8,422,868), the disclosure of which is incorporated by reference herein in its entirety. The disclosure of the following priority application also is incorporated hereby reference in its entirety:
[0002] Japanese Patent Application No. 2010-119424, filed on May 25, 2010.
TECHNICAL FIELD
[0003] The present invention relates to an imaging device that can record a moving image.
BACKGROUND ART
[0004] A recording device is proposed in which a moving image starts to be temporarily stored when moving image-incorporated still image capturing mode is set; and a captured still image is recorded and a moving image is generated from any one of the following moving images and recorded when a shutter button is pressed: a moving image that has been temporarily stored before the still image is captured, a moving image converted from the captured still image, and a moving image captured after the shutter button is pressed (refer to, for example, WO2006/028172).
SUMMARY OF INVENTION
[0005] However, in regard to known imaging devices equipped with the recording device disclosed in WO2006/028172, no technology is disclosed in which a moving image having an impressive digital video effect such as a slow motion moving image where a subject appears to move more slowly than actual movement is captured in synchronization with the timing at which the still image is captured, and the moving image and the still image are associated with each other and recorded.
[0006] An object of the invention is to provide an imaging device capable of capturing a slow motion moving image with high resolution and extreme precision in an automatic manner, in relation with timing of capturing a still image with high resolution and extreme precision.
[0007] An imaging device according to the invention includes a storage unit that sequentially stores a plurality of frame images based on an imaging signal from an imaging sensor that images light from a subject, a moving image data generation unit that generates slow motion moving image data to be played at a second frame rate lower than a first frame rate that represents the number of the frame images stored per unit time in the storage unit, based on the plurality of frame images stored in the storage unit for a predetermined time period, a still image data generation unit that generates at least one piece of still image data based on at least one frame image of the plurality of frame images stored during the predetermined time period in the storage unit, and a record control unit that associates the slow motion moving image data generated by the moving image data generation unit with the still image data generated by the still image data generation unit and records the moving image data and the still image data in a recording medium.
[0008] According to the imaging device of the invention, it is possible to capture the slow motion moving image with high resolution and extreme precision and to capture the still image with high resolution and extreme precision in parallel, at synchronized timing.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1 is a block diagram illustrating a system configuration of an electronic camera according to an embodiment.
[0010] FIG. 2 is an explanatory diagram illustrating a frame rate for storing a slow motion moving image in a buffer memory and a frame rate for recording the slow motion moving image in a recoding medium at the time of capturing the slow motion moving image.
[0011] FIG. 3 is a flowchart illustrating a process performed when the slow motion moving image and a still image are captured in the electronic camera according to the embodiment.
[0012] FIG. 4 is a diagram illustrating an exemplary display on a display unit.
[0013] FIG. 5 is a diagram illustrating an exemplary indication by an indicator.
[0014] FIG. 6 is an explanatory diagram illustrating another example of the frame rate for recording the slow motion moving image in the recording medium at the time of capturing the slow motion moving image.
DESCRIPTION OF EMBODIMENTS
[0015] Hereafter, an electronic camera as an imaging device according to an embodiment of the present invention will be described with reference to the accompanying drawings. FIG. 1 is a block diagram illustrating a system configuration of an electronic camera 2 according to a first embodiment. As illustrated in FIG. 1 , the electronic camera 2 is configured by a microprocessor and the like. The electronic camera 2 includes a control unit 4 that collectively controls over respective units of the electronic camera 2 . The control unit 4 is connected with an imaging sensor 6 , a buffer memory 8 , a recording medium 10 , a display unit 12 , an operation unit 14 , and a detection unit 16 .
[0016] The imaging sensor 6 is configured by a CCD, CMOS or the like, and images light from a subject through an image-capturing lens (not shown). The control unit 4 acquires image data based on an imaging signal that is a digital signal obtained by converting an analog signal output from the imaging sensor 6 using an A/D converter (not shown).
[0017] The buffer memory 8 temporarily stores image data produced based on the imaging signal from the imaging sensor 6 . In particular, when the electronic camera 2 is set, for example, to slow motion moving image capturing mode or the like in which a slow motion moving image (to be described below and also referred to as a slow moving image hereinafter) is captured, the buffer memory 8 sequentially stores a plural number of pieces of image data based on the imaging signal output from the imaging sensor 6 in synchronization with a moving image cycle (60 fps or the like), that is, a plurality of frame images constituting the slow moving image. In this case, the frame images, each having the number of pixels matching or exceeding the standard (1280×720 pixels or more) of high definition television (HDTV), that is, so-called high resolution frame images are sequentially stored in the buffer memory 8 in a first-in first-out (FIFO) manner.
[0018] More specifically, in a case where the buffer memory 8 has a storage area that is allowed to store, for example, n (n is a natural number) frame images, as illustrated in FIG. 2( a ) , the control unit 4 performs control such that a first frame image F 1 obtained through a first acquisition, a second frame image F 2 obtained through a second acquisition, and an n-th frame image Fn obtained through an n-th acquisition are sequentially stored in the buffer memory 8 . In a case where a subsequent frame image Fn+1 is output from the imaging sensor 6 after n frame images F 1 to Fn are stored in this way, the oldest frame image F 1 is removed from the buffer memory 8 and the newest frame image Fn+1 is stored instead. Whenever a subsequent frame image is output from the imaging sensor 6 , a process of removing the oldest frame image and storing the newest frame image is repeatedly performed.
[0019] That is, the buffer memory 8 includes n addresses (storage areas to sequentially store the frame images), and stores sequentially the first frame image F 1 in an address of address number (n−1), the second frame image F 2 in an address of address number (n−2), . . . , and the n-th frame image Fn in an address of address number 0. That is, the frame images F 1 to Fn are stored in all of the n addresses, the subsequent frame image Fn+1 is output, and the frame image (that is, the oldest frame image) F 1 in the address of address number (n−1) is deleted. Then, the respective frame images F 2 to Fn are shifted from the addresses of address number (n−2) to address number 0 so as to be stored in the addresses of address number (n−1) to address number 1, respectively, and the (n+1)-th frame image (that is, the newest frame image) Fn+1 is stored in the address of address number (0). Accordingly, the newest frame image is always stored in the address of address number (0), and the address with the greater address number stores the older frame image. The address with address number 0 stores the newest frame image at all times.
[0020] The recording medium 10 is a potable type recording medium that is removably installed in a card slot (not shown) provided in the electronic camera 2 . For example, a CF card, an SD card, a smart media, or the like is used as the recording medium. In the recording medium 10 , moving image data and slow moving image data are recorded. The moving image data and the slow moving image data are produced by subjecting each of the frame images stored in the buffer memory 8 to a resizing process (resizing from a high resolution to a low resolution) to achieve a resolution suitable for a moving image, which is performed by a reduction circuit (not shown) in the control unit 4 , a moving-image image process performed by a moving image signal processing circuit (not shown) in the control unit 4 , and a moving image compression process performed by a moving image compression circuit (not shown) in the control unit 4 . In the recording medium 10 , information related to image-capturing and still image data are also recorded. The still image data is obtained by subjecting the frame image stored in the buffer memory 8 to a still-image image process performed by a still image signal processing circuit (not shown) in the control unit 4 and a still image compression process performed by a still image compression circuit (not shown) in the control unit 4 .
[0021] The display unit 12 is configured by a monitor including an LCD and the like provided on the rear surface of the electronic camera 2 , or an EVF or the like including an LCD and the like. The display unit 12 displays a through image based on the imaging signal from the imaging sensor 6 , a moving image based on the moving image data recorded in the recording medium 10 , a slow moving image based on the slow motion moving image data (hereinafter, referred to as slow moving image data), a still image based on the still image data, and information related to the image-capturing. The operation unit 14 is configured by including a power supply switch operated for turning on/off the power supply of the electronic camera 2 , a command dial operated for setting image-capturing mode such as moving image capturing mode for capturing a moving image or slow motion moving image capturing mode for capturing a slow moving image, a release button operated for entering instructions such as an instruction to start capturing of a moving image or a still image, a menu button operated for displaying menu items or the like on the display unit 12 , a cross key operated for selection of a menu item or the like or for setting various conditions, an OK button operated for confirmation of the operation such as selection of a menu item or setting of various conditions, and the like.
[0022] The detection unit 16 is configured by including an attitude sensor and the like and detects information related to a change in the attitude of the electronic camera 2 relative to a subject at the time of capturing the slow moving image in the electronic camera 2 . The control unit 4 controls an ending time of the capturing of the slow moving image based on the detection result from the detection unit 16 . Instead of including the attitude sensor, the detection unit 16 may be configured by employing a structure that detects information related to a change in the attitude of the electronic camera 2 by detecting a change in movement of a subject, based on at least two frame images having a resolution suitable for the detection of attitude change of the electronic camera 2 , at first which are produced based on the imaging signal from the imaging sensor 6 and then subjected to a resizing process (resizing from a high resolution to a low resolution) performed by the reduction circuit (not shown) in the control unit 4 .
[0023] In the electronic camera 2 according to this embodiment, the slow moving image data that is to be played at a second frame rate lower than a first frame rate that represents the number of frame images being stored per unit time in the buffer memory 8 after being output from the imaging sensor 6 is generated. The still image data is generated based on at least one frame image out of the plurality of frame images that constitute the slow moving image data. The generated slow moving image data and the still image data can be recorded in the recording medium 10 in association with each other. Hereinafter, a process performed at the time of capturing the slow moving image and the still image in the electronic camera 2 according to the embodiment will be described with reference to a flowchart illustrated in FIG. 3 .
[0024] In this embodiment, the slow moving image data is generated based on a plurality of frame images stored in the buffer memory 8 for a time period from a time at which the frame image to become the still image data is stored in the buffer memory 8 to the beginning of a first predetermined time period, and a plurality of frame images stored in the buffer memory 8 for a time period, that is, until the end of a second predetermined time period after the frame image to become the still image is stored in the buffer memory 8 . That is, the slow moving image data is generated based on the plurality of frame images stored in the buffer memory 8 during a predetermined time period (the first predetermined time period+the second predetermined time period), and the still image data is generated based on the frame image stored in the buffer memory 8 at the ending time of the first predetermined time period (that is, the beginning time of the second predetermined time period). Furthermore, the predetermined time period (for example, 1 second or the like), the first predetermined time period (for example, 0.6 second or the like), and the second predetermined time period (for example, 0.4 second or the like) are set in advance and stored in a memory (not shown) in a rewritable manner. In other words, the slow moving image data is generated based on the plurality of frame images stored from the beginning of the first predetermined time period, which begins before the frame image to become the still image data is stored in the buffer memory 8 , until the end of the second predetermined time period, which ends after the frame image to become the still image is stored in the buffer memory 8 .
[0025] First, when a user operates the command dial to set the slow motion moving image capturing mode, the control unit 4 switches to the slow motion moving image capturing mode for capturing the slow motion moving image and the still image associated with the slow motion moving image. Then, it is determined whether or not the user has half-pressed the release button (Step S 10 ). When it is determined that the release button is half-pressed in Step S 10 , the control unit 4 determines that an instruction to prepare generation of the still image data and an instruction to generate the slow moving image data are given. Accordingly, as shown in FIG. 4 , the control unit 4 performs control such that the display unit 12 displays the through image 20 and the indicator 22 thereon, and a focus lens (not shown) or the like is driven to move a focus position toward a main subject for the main subject in the through image 20 to be on focus. Then, it is determined whether or not the main subject is on focus (Step S 11 ). The indicator 22 has a function of indicating to the user where the current time point is within the time span between the beginning and end (that is, over the entire period during which the slow moving image is generated) of the predetermined time period (in other words, indicating where the current time point is within the time span between the beginning and end of the first predetermined time period and where the current time point is within the time span between the beginning and end of the second predetermined time period). Referring to FIG. 4 , a bar 22 c (described below, see FIG. 5 ) inside a frame 22 a of the indicator 22 is not displayed. No display of the bar 22 c means an operation stage before the beginning of the first and second predetermined time periods. A mark 22 b represents the ending time of the first predetermined time period (the beginning time of the second predetermined time period), that is, the mark 22 b means that the full-pressing operation of the release button in Step S 13 to be described below is executed. The indicator 22 will be described below in detail.
[0026] When it is determined that the main subject is on focus in Step S 11 (Yes in step S 11 ), the control unit 4 performs control such that the capturing of the slow moving image is started, that is, the buffering into the buffer memory 8 and the indication of the current time point by the indicator 22 are started (step S 12 ). Specifically, as described above, the control unit 4 performs control such that the plurality of frame images F 1 , . . . , and Fn . . . (see FIG. 2 ) produced based on the imaging signal, which is output from the imaging sensor 6 in synchronization with the moving image cycle, start to be stored in the predetermined addresses in the buffer memory 8 . Next, when the buffering into the buffer memory 8 is started, the control unit 4 starts control of causing the indicator 22 to indicate the progress of buffering, that is, which time point of buffering between the beginning and end of the predetermined time period (the first predetermined time period) is being executed at the current time point. That is, at the time prior to the beginning of the predetermined time period (the first predetermined time period), as shown in FIGS. 4 and 5 ( a ), nothing is displayed inside the frame 22 a of the indicator 22 . However, when the buffering is started, as shown in FIG. 5( b ) , the display of the bar 22 c is started from the left end of the frame 22 a . As the frame images stored in the buffer memory 8 increase in number (with time), as shown in FIG. 5( c ) , the bar 22 c extends toward the right side of the frame 22 a.
[0027] In this embodiment, when the release button is full-pressed by the user (Yes in Step S 13 to be described below), the still image data is generated based on the frame image that is based on the imaging signal output from the imaging sensor 6 . Accordingly, after n frame images are stored in the buffer memory 8 until the release button is full-pressed by the user from the time at which the first predetermined time period ends, a process is repeatedly performed in which the oldest frame image in the buffer memory 8 is deleted each time the frame image is output, and the output frame image (the newest frame image) is stored in the buffer memory 8 . In this case, the bar 22 c inside the frame 22 a does not show any change as being in the state illustrated in FIG. 5( c ) . That is, the bar 22 c extends up to the position of the mark 22 b that represents the time (the end of the first predetermined time period and the beginning of the second predetermined time period) at which the still image is captured, but does not extend during a period in which the release button is not full-pressed by the user.
[0028] Next, in the middle of the process in which storage of the frame image into the buffer memory 8 is repeatedly performed after the first predetermined time period has elapsed, the control unit 4 determines whether or not the release button is full-pressed by the user (Step S 13 ). When it is determined that the release button is full-pressed by the user in Step S 13 , the control unit 4 determines that a still image capturing instruction to generate the still image data is input. In this case, the control unit 4 causes the second predetermined time period (ending the counting for the first predetermined time period) to begin to elapse, and causes the bar 22 c to extend toward the right side of the frame 22 a with time as illustrated in FIG. 5( d ) . In this way, by displaying the bar 22 c that indicates where a current time point is between the beginning and end of the predetermined time period (the second predetermined time period) on the display unit 12 , it is possible to indicate to the user that the capturing of the slow moving image is not completed. Next, the control unit 4 acquires information related to the change in the attitude of the electronic camera 2 relative to the main subject detected by the detection unit 16 , and determines whether or not the acquired change in the attitude of the electronic camera 2 is equal to or more than a predetermined threshold value (Step S 14 ). That is, when it is determined that the user has full-pressed the release button or the like for example, it is further determined whether or not the attitude of the electronic camera 2 which is posed during the image-capturing is considerably changed, for example, to an attitude of the electronic camera 2 at the state of not capturing. The predetermined threshold value is set in advance to an appropriate value and stored in a memory (not shown) or the like.
[0029] When it is determined that the change in the attitude of the electronic camera 2 is not equal to or more than the predetermined threshold value in Step S 14 (No in Step S 14 ), the control unit 4 determines whether or not the predetermined time period (the second predetermined time period) has elapsed (Step S 15 ). That is, it is determined whether or not the storage of the frame images necessary to generate the slow moving image data into the buffer memory 8 is completed after the release button is full-pressed (that is, after the entering of the still image capturing instruction). When it is determined that the predetermined time period (the second predetermined time period) has not yet completely elapsed in Step S 15 (No in Step S 15 ), the control unit 4 returns the process to Step S 14 .
[0030] On the other hand, when it is determined that the predetermined time period (the second predetermined time period) has completely elapsed in Step S 15 (Yes in Step S 15 ), the control unit 4 determines that the storage of n frame images necessary to generate the slow moving image data into the buffer memory 8 is completed, and thereby ends the buffering into the buffer memory 8 and the indication of the current time point by the indicator 22 (Step S 16 ). At this time, as illustrated in FIG. 2( a ) , n−p (p is a natural number, n>p) frame images, F 2 to F 5 . . . , have been stored in the buffer memory 8 over a period from a time prior to the input time TS of the still image capturing instruction to a time prior to the beginning of the first predetermined time period, and p frame images, . . . Fn and Fn+1, have been stored over a period from the input time TS of the still image capturing instruction to the ending time of the second predetermined time period. In Step S 17 described later, the slow moving image data is generated based on the n frame images F 2 to Fn+1. FIG. 5( e ) illustrates the state of the bar 22 c inside the frame 22 a of the indicator 22 after the predetermined time period (the second predetermined time period) has completely elapsed.
[0031] Further, when it is determined that the change in the attitude of the electronic camera 2 is equal to or more the predetermined threshold value in Step S 14 (Yes in Step S 14 ), the control unit 4 determines that the attitude of the electronic camera 2 is considerably changed, and ends the buffering into the buffer memory 8 and the indication of the current time point by the indicator 22 even in a case where the predetermined time period (the second predetermined time period) has not yet elapsed (Step S 16 ). That is, even in a case where the bar 22 c inside the frame 22 a of the indicator 22 is not in the state of FIG. 5( e ) but in the state of FIG. 5( d ) , the time at which it is determined that the change in the attitude of the electronic camera 2 is equal to or more than the predetermined threshold value is used as the end point of the predetermined time period (the second predetermined time period). In this case, the slow moving image data is generated in Step S 17 based on the frame images stored in the buffer memory 8 , where the frame images include n−p (p is a natural number, n>p) frame images F 2 to F 5 . . . stored during a period from a time prior to the input time TS of the still image capturing instruction to a time prior to the beginning of the first predetermined time period, and frame images, of which the number is smaller than p, stored during a period from the input time TS of the still image capturing instruction to the time at which it is determined that the change in the attitude of the electronic camera 2 is equal to or more than the predetermined threshold value, that is, the frame images F 2 to F 5 . . . that are smaller in number than n.
[0032] Next, the control unit 4 performs a slow moving image data generating process and a still image data generating process based on the plurality of frame images stored in the buffer memory 8 (Step S 17 ). The slow moving image data generating process will be described first. The control unit 4 reads the frame images F 2 to F 5 . . . out of the buffer memory 8 at a second frame rate (for example, 24 frames/second or the like which is equal to 1/2.5, that is, 0 . 4 , of a first frame rate) lower than the first frame rate (for example, 60 frames/second or the like) which is the same as a frame rate (image-capturing frame rate) at which the frame images are output from the imaging sensor 6 . That is, the frame image F 2 stored in the buffer memory 8 at a time T 1 (for example 1/60 second or the like) as illustrated in FIG. 2( a ) is read out of the buffer memory 8 at a time T 2 (for example, 1/24 second) as illustrated in FIG. 2( b ) . Then the read frame images F 2 to F 5 . . . are subjected to a resizing process (resizing from a high resolution to a low resolution) of resizing the frame image to have a resolution suitable for a moving image, performed by the reduction circuit (not shown) in the control unit 4 , and the moving-image image process (inclusive of the image compression process), performed by the moving image signal processing circuit (not shown) in the control unit 4 so as to generate the slow moving image data. The value of the second frame rate is set in advance, and stored in a memory (not shown) in a rewritable manner.
[0033] Next, the still image data generating process will be described. The control unit 4 reads the frame images stored in the buffer memory 8 at the time TS, at which the still image capturing instruction is input, out of the buffer memory 8 . Next, the still image data is generated by subjecting the read frame image to the still-image image process (inclusive of the still image compression process) performed by the still image signal processing circuit (not shown) provided separately from the moving image signal processing circuit in the control unit 4 . In this embodiment, since the frame images, each having pixels more than those required for the standard of HDTV, that is, high resolution frame images are stored in the buffer memory 8 , it is possible to obtain the still image data of high resolution. In addition, the number of pixels of the generated still image data is larger than that of the generated slow moving image data.
[0034] Next, when an instruction to display the slow moving image and the still image on the display unit 12 is entered via the operation unit 14 by the user, the control unit 4 causes the display unit 12 to display the preview of the slow moving image that is based on the slow moving image data generated in Step S 17 . Then the control unit 4 causes the display unit 12 to display the preview of the still image that is based on the still image data generated in Step S 17 for several seconds (which are set in advance) (Step S 18 ).
[0035] Next, the control unit 4 causes the display unit 12 to display a selection screen that allows the user to select whether or not to record at least either one of the slow moving image data and the still image data generated in Step S 17 in the recording medium 10 before recording into the recording medium 10 is started. The selection screen includes a description informing that one of the items “record only slow moving image data”, “record only still image data”, “record both slow moving image data and still image data”, and “record neither slow moving image data nor still image data” can be selected, icons, and the like. The control unit 4 determines whether or not the user has selected to record at least any one of the slow moving image data and the still image data in the recording medium 10 using the selection screen (Step S 19 ).
[0036] When it is determined that the user has selected to record at least either one of the slow moving image data and the still image data in the recording medium 10 in Step S 19 (Yes in Step S 19 ), that is, when any one of the items “record only slow moving image data”, “record only still image data”, and “record both slow moving image data and still image data” is selected by the user, the control unit 4 records at least any one of the slow moving image data and the still image data in the recording medium 10 according to the selection by the user (Step S 20 ). Specifically, when the item “record only slow moving image data” is selected, only the slow moving image data is recorded (the still image data is deleted). When the item “record only still image data” is selected, only the still image data is recorded (the slow moving image data is deleted). When the item “record both slow moving image data and still image data” is selected, both of the slow moving image data and still image data are recorded. In a case where the slow moving image data is to be recorded in the recording medium 10 , the slow moving image data generated in Step S 17 is subjected to the moving image compression process performed by the moving image compression circuit (not shown) in the control unit 4 and the compressed slow moving image data is recorded in the recording medium 10 . In a case where the still image data is to be recorded in the recording medium 10 , the still image data generated in Step S 17 is subjected to the still image compression process performed by the still image signal processing circuit (not shown) in the control unit 4 and then the compressed still image data is recorded in the recording medium 10 . In a case where both of the slow moving image data and the still image data are to be recorded in the recording medium 10 , both data are recorded after being associated with each other (after being added with information (date and time at which an image is captured, identification number, or the like) indicating the association between both data).
[0037] Since the slow moving image data and the still image data are recorded in association with each other, for example, it is possible to display information informing that the still image linked to the slow moving image exists, during the playing of the slow moving image and to display information informing that the slow moving image linked to the still image exists, during the display of the still image. In addition, when displaying a reduced image (thumbnail image) based on reduction image data of the still image that is generated at the time of generating the still image data and recorded in a state of being added to the still image data, it is possible to display information informing that the related slow moving image exists. Further, when the user enters an instruction to play the related slow moving image (or still image) using the operation unit 14 during the playing of the still image (or the slow moving image), the slow moving image (or the still image) can be easily played.
[0038] On the other hand, when it is determined that the user has selected not to record at least one of the slow moving image data and the still image data in the recording medium 10 in Step S 19 (No in Step S 19 ), that is, when it is determined that the user has selected the item “record neither slow moving image data nor still image data”, the control unit 4 deletes both of the slow moving image data and the still image data generated in Step S 17 without recording them in the recording medium 10 in accordance with the selection of the user.
[0039] In Step S 18 , when displaying the selection screen for selecting whether or not at least any one of the slow moving image data and the still image data is to be recorded in the recording medium 10 after the slow moving image and the still image are displayed for preview on the display unit 12 , or after displaying the selection screen, the invention may employ a structure that can change the value of the second frame rate and generate the slow moving image again at the changed second frame rate. This case effectively applies to a case in which the user wants to further slow down or slightly increase the playing speed of the slow moving image which is to be displayed after the user has watched the image once through the preview. Specifically, the control unit 4 returns the process to Step S 17 when the value of the second frame rate is changed by the user through the operation of the operation unit 14 , so that a series of frame images stored in the buffer memory 8 is read again at the changed second frame rate, and the slow moving image is played based on the frame images that are read. After that, the slow moving image is displayed on the displayed unit 12 at the changed frame rate for preview, and a confirmation screen (selection screen) for confirming whether to record the slow moving image data having the changed frame rate in the recording medium 10 is displayed on the display unit 12 . When the user performs an operation of confirming the record of the changed slow moving image using the operation unit 14 , the slow moving image data generated with use of the changed second frame rate is recorded in the recording medium 10 .
[0040] According to the electronic camera 2 of the embodiment, it is possible to capture a slow moving image having an impressive video effect, high resolution, and extreme precision, and to capture a still image having high resolution and extreme precision in the middle of capturing the slow moving image. That is, since the frame images that constitute a slow moving image are stored with a high resolution in the buffer memory 8 , it is possible to generate the slow moving image data with high resolution and extreme precision. In addition, since the still image data is generated based on the high resolution frame image, it is possible to generate the still image data with high resolution and extreme precision (for example, the still image data having a resolution higher than that of the slow moving image data). Furthermore, since it is possible to indicate to a user a time period (predetermined time period) during which the frame images for generating the slow moving image data are being buffered using the indicator 22 , the user can quickly check whether or not the slow moving image is being captured. Accordingly, it is possible to suppress a significant change in the attitude of the electronic camera 2 relative to the subject in the middle of capturing the slow moving image and thus it is possible to generate the slow moving image data with good precision. Moreover, it is possible to control the ending time of the predetermined time period (the second predetermined time period) based on the detection result from the detection unit 16 , and to suspend the buffering of the frame images when the attitude of the electronic camera 2 is considerably changed. Accordingly, it is possible to generate the slow moving image data with good precision which is obtained before the attitude of the electronic camera 2 is considerably changed.
[0041] In the above embodiment, when the predetermined time period (the second predetermined time period) that is set in advance has elapsed, or when the change in the attitude of the electronic camera 2 relative to the main subject is equal to or more than the threshold value, the buffering into the buffer memory 8 and the indication of the current time point by the indicator 22 end. However, a configuration may be employed in which the buffering into the buffer memory 8 and the indication of the current time point by the indicator 22 end when it is determined that the release button is full-pressed in a state in which the frame images are being sequentially stored in the buffer memory 8 .
[0042] In the above embodiment, a piece of still image data is generated based on one frame image stored in the buffer memory 8 when it is determined that the release button is full-pressed, but two or more pieces of still image data may be generated based on two or more frame images. Alternatively, the still image data may be generated based on the frame image stored in the buffer memory 8 before or after it is determined that the release button is full-pressed. In addition, the still image data may be generated based on the frame image stored in the buffer memory 8 when the release button is not full-pressed (for example, in a case where a best shot is made when the release button is not full-pressed or the like). In this case, the frame images stored in the buffer memory 8 are displayed on the display unit 12 for example so that the user can select at least one frame image to be recorded as the still image data, and the still image data is generated based on the selected frame image.
[0043] In the above embodiment, the slow moving image data is generated by reading, at the second frame rate, the frame images which are stored at the first frame rate in the buffer memory 8 . However, a configuration may be employed in which the moving image data is generated by reading the frame images at the first frame rate and the slow moving image data is generated by adding information instructing to play back the moving image at the second frame rate to the generated moving image data.
[0044] In the above embodiment, the frame images F 2 , . . . , Fn+1 stored in the buffer memory 8 for the time period T 1 as illustrated in FIG. 2( a ) are read out of the buffer memory 8 for the time period T 2 in a non-interlace manner as illustrated in FIG. 2( b ) . However, the invention may be configured such that the frame images F 2 to Fn+1 may be read in the interlace manner. For example, as shown in FIG. 6 , one field (hereinafter, referred to as a first field) F 2 E obtained by diving the frame image F 2 into two fields is read for the time period T 1 and then the other field (hereinafter, referred to as a second field) F 20 is read for the time period T 1 . The first field F 2 E is a field configured by only even-numbered lines of the frame image F 2 for example, and the second field F 20 is a field configured by only odd-numbered lines of the frame image F 2 . Subsequently, as shown in FIG. 6 , after the first field F 2 E is read again for the time period T 1 , one field F 3 E of the frame image F 3 obtained by diving the frame image F 3 into two fields is read for the time period T 1 and then the other field F 30 is read for the time period T 1 . Through the similar reading operation, that is, as shown in FIG. 6 , a field F 4 E of the frame image F 4 obtained by diving the frame image F 4 into two fields is read, the other field F 40 is read, the field F 4 E is read again, and a field F 5 E obtained by diving the frame image F 5 into two fields is read, and the other field F 50 of the frame image is read. In this way, the reading operation is repeated sequentially for the frame images. As a result, it is possible to generate the slow moving image data at the second frame rate that is 1/2.5 (that is, 0 . 4 ) of the first frame rate.
[0045] The above-described embodiment is provided for easy understanding of the invention and thus is not construed to limit the invention. Accordingly, each element disclosed in the above embodiment includes design modifications and equivalents within the technical scope of the invention.
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An imaging device includes an imaging sensor that outputs an imaging signal representing a sequence of frame images of a photographic subject. A buffer memory temporarily stores data of the sequence of frame images from the imaging signal. A release switch is actuated by a user to output an image-taking signal. A controller, upon receipt of the image-taking signal from the release switch: (i) generates moving image data from at least some of the plurality of frame images stored in the buffer memory, (ii) generates at least one piece of still image data based on at least one frame image of the plurality of frame images stored in the buffer memory, and (iii) associates the moving image data with the still image data and records the moving image data and the still image data in a recording medium.
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REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of application Ser. No. 07/773,217, filed Oct. 9, 1991 now U.S. Pat. No. 5,383,316, which is a continuation-in-part of application Ser. No. 07/697,111, filed May 8, 1991, which is a continuation-in-part of application Ser. No. 07/598,250, filed Oct. 16, 1990 now U.S. Pat. No. 5,311,715.
BACKGROUND OF THE INVENTION
The present invention relates to expansion joints for flue systems and ducting and pertains particularly to improved non-metallic expansion joint for providing stress relief in refractory lined flue and ducting systems for high temperature applications such as power plants.
In power generating or cogeneration plants, including facilities for obtaining useable electrical power or processing steam/hot water from the burning of solid, liquid or gaseous fuel products, particulate matter such as sorbents and unburnt fuel is recirculated through the combustion. Hot flue gases generated by the combustion process are laden with ash and other particulate matters and are typically directed through a series of processing areas to remove particulates and environmentally hazardous components before finally being exhausted from the facility. FIG. 1 illustrates a power generation plant of unique design that includes a furnace having a circulating fluidized bed (CFB) wherein various fuel materials are combusted. The hot flue gases containing combustion by-products are transferred from the furnace through a flue duct/expansion joint to a cyclone separator.
The cyclone separator diverts heavier combustion particulate such as sorbents and unburnt fuel matter back to the CFB, through a loop seal assembly, which lifts the heavy particulates, mixes them with freshly fed fuel, and introduces the mixture to the combustion chamber. The fine particulate matter and hot flue gases are directed through a heat exchanger. The fine particulate matter is then diverted to a particulate filter for disposal. Gases emitted from the facility will have most of the combustion by-product emissions, including NO x , SO 2 , CO, particulates, etc., removed therefrom, resulting in an environmentally safe means of power generation.
Nonmetallic expansion joints are flexible connectors designed to provide stress relief in flue duct systems by absorbing differential movement caused by thermal changes. They also act as vibration isolators, and in some instances, make up for minor misalignment of adjoining flue ducts and/or equipment. They may be fabricated from a wide variety of nonmetallic materials, including synthetic elastomers, fabrics, insulation materials and other suitable materials depending upon the designs thereof. Since their introduction in the early 1960's, the use of nonmetallic expansion joints has continuously grown.
The advent of more rigid emission standards has caused the use of more complex flue work systems. Nonmetallic expansion joints have been used in place of the traditional all metal expansion joints to solve problems caused by the thermal and mechanical stresses generated in these complex systems. Although the major user of the nonmetallic joint continues to be the power generation industry, the use of this product has expanded into many other industries wherein gases are conveyed including pulp and paper plants, refineries, steel mills, foundries, smelters, cement plants, kilns, refuse incineration, marine applications, vapor-heat-dust recovery, food processing, and HVAC (Heating, Ventilating and Air Conditioning).
A typical prior art nonmetallic expansion joint is shown in FIG. 2. The joint includes a pair of angle brackets mounted to the respective ends of a pair of adjoining ducts or flues. A pair of frame members are in turn attached to the angle brackets. The frame members have mounted thereto a flexible pressure seal that extends around the periphery of the expansion joint. The pressure seal may be of the elastomeric type for operation below 400° F. or may be of the composite type for operation at temperatures continuously above 400° F. It will be appreciated that the flexible pressure seal allows relative axial, transverse, angular and rotational movement between the respective ducts while preventing the escape of pressurized flue gases and particulates carried therein. Other nonmetallic expansion joint constructions may be seen in the "Technical Handbook" published by the Ducting Systems Nonmetallic Expansion Joint Division of the Fluid Sealing Association, 2017 Walnut Street, Philadelphia, Pa. 19103 (2nd Edition), the contents of which are fully incorporated herein by this reference.
It is known that nonmetallic expansion joints are prone to failure from the build-up of abrasive particulates carried by the flue gas stream, which can accumulate in the expansion joint in such quantities that they eventually rupture the pressure seal. Moreover, fly ash and other particulates can cause damage to the expansion joint by solidifying to a cementatious state. Also, certain non-cementatious particulates (fly ash) can create a sever, corrosive (acidic) environment when subjected to cooling (below the H 2 SO 4 dew point) during a maintenance outage.
To prevent premature expansion joint failure from the build up of particulate matter therein, baffles have been proposed to help direct particulate matter beyond the expansion joint, as shown in FIG. 2. Other proposals include mounting the flexible pressure seal substantially flush with the interior surface of the duct or flue, as shown in FIG. 3, or mounting an insulation barrier behind a baffle arrangement as shown in FIG. 4. Although these proposals may exhibit varying degrees of effectiveness in minimizing expansion joint failure, the arrangement of FIG. 3 may result in thermal transfer on the inner face of the expansion joint and abrasion from particulates in the gas stream. A greater setback would be desirable. The arrangement of FIG. 4 may result in the insulation barrier rubbing on the baffle under negative pressures. Moreover, the insulation barrier must be fixedly attached to both sides of the joint, which may complicate joint construction and also impart adverse loads on the barrier.
To overcome the problems of the prior art, we have developed improved loop seal expansion joint assemblies as set forth in the aforementioned parent applications. While these improvements have gone a long way toward solving many of the problems, they have not all been solved. In spite of the improved seal construction, cyclone inlet and outlet expansion joints fill up with ash and prevent proper movement. Differing expansion rates between combustion outlets, connection cage inlets and the cyclone result in large face to face movement and axial movement of the expansion joints.
Accordingly, there is an evident need for an expansion joint flexible seal assembly which not only prevents particulate build up, but which is durable, easy to install and will perform satisfactorily despite joint movement. It would be further desirable to provide an expansion joint flexible seal assembly that also performs a deflection function to provide an additional sealing barrier to the entry of ash into the seal.
The present invention accomplishes the foregoing objects and advantages. It is therefore an object of the present invention to provide an improved expansion joint seal and flexible shield therefor.
It is a further object of the present invention to provide an expansion joint having a flexible shield that is not adversely affected by relative joint movement.
It is a further object of the present invention to provide an expansion joint having a modular construction for easier installation.
SUMMARY OF THE INVENTION
The present invention employs concepts for an expansion joint and shielded flexible seal therefor that accomplish the foregoing objects and advantages. In accordance therewith, an expansion joint may include flexible seal means having flexible insulating body means and filter means positioned adjacent thereto. Additional filter shield elements are provided, as well as flexible seal mounting means for each installation and joint accessibility. In a further aspect applicable to joints that must accommodate longitudinal offset movements, a baffle system may be provided in combination with shielded filter element means and an air purge system for preventing egress of flue particulates.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, advantages and features of this invention will be more clearly perceived from the following detailed description when read in accordance with the accompanying in which:
FIG. 1 is a diagrammatic view of a fluidized circulating bed power generation plant that includes expansion joints in the ducting system thereof;
FIG. 2 is a detailed cross-sectional view of a prior art expansion joint having a baffle system to prevent premature joint failure;
FIG. 3 is a detailed cross-sectional view of another prior art expansion joint having a flush mounted flexible pressure seal also designed to eliminate premature joint failure;
FIG. 4 is a detailed cross-sectional view of still another prior art expansion joint having an insulation barrier and baffle system also designed to minimize premature joint failure;
FIG. 5 is a detailed cross-sectional view of a nonmetallic expansion joint and flexible seal constructed in accordance with the present invention;
FIG. 6 is a detailed isometric view of a flexible seal constructed in accordance with the present invention having a portion broken away for clarity;
FIG. 7 is a plan view of the flexible seal of FIG. 6 having end portions adapted for interlocking with adjacent flexible seal elements;
FIG. 8 is a detailed cross-sectional view of a shielded nonmetallic expansion joint and flexible seal constructed in accordance with the present invention;
FIG. 9 is a cross-sectional view of a flue section embodying a shielded expansion joint constructed in accordance with the invention; and
FIG. 10 is a detailed perspective view of a portion of the expansion joint of FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 5, the invention may be embodied in a structural form in a nonmetallic expansion joint 2 of our prior invention provided between a pair of refractory lined flues 4 and 6. The flues 4 and 6 include respective refractory portions 8 and 10 and metallic outer casings 12 and 14, respectively. the flue sections 4 and 6 terminate at respective peripheral terminal faces 16 and 18 which are positioned to form a gap extending around the periphery of the duct sections. There is also conventionally provided a pressure seal assembly including a flexible pressure seal 20 fastened in conventional fashion to a pair of angle frames 22 and 24 which are in turn mounted to a pair of angle brackets 26 and 28 that are permanently attached by welding or other means to the casings 12 and 14 of the flues 4 and 6. Disposed in the gap formed by the terminal flue faces 16 and 18 is a flexible seal assembly 30, the details of which will now be described.
Turning now to FIG. 6, the flexible seal assembly 30 includes a flexible insulating body 32 made from a ceramic fiber blanket material of suitable density, such as blown or spun alumina silicate material, and a pair of insulating side panels 34 and 36 also made from a ceramic fiber board material of suitable density providing a pair of lateral or side faces adapted for positioning adjacent and parallel to the respective terminal flue faces 16 and 18. The flexible insulating body 32 further includes a pair of end faces 38 and 40 adapted to be positioned generally perpendicularly to the terminal flue faces 16 and 18. The insulating body further includes a longitudinal dimension extending in a direction shown by the arrow A, so as to generally extend along the perimeter of the flue elements 4 and 6.
The flexible seal 30 further includes a pair of filter elements 50 and 52 positioned adjacent to the respective end faces 38 and 40 and extending the longitudinal direction of the insulating body. The filter elements are preferably formed from a wire mesh material arranged in a plurality of wrapping arrangements. Thus, a suitable wire mesh material such as 304SS wire mesh may be rolled into a series of tubes 54 and 56. To form the filter element 50, a plurality of the tubes 54 may be arranged in a bundle, with one of the tubes 54 serving as a central core tube, and wrapped in a larger wire mesh wrapping 58 to complete the filter element 50. Similarly, the filter element 52 can be formed by a plurality of wire mesh tube elements 56 arranged around a central core tube to form a tube bundle, with the bundle being wrapped in a larger wire mesh wrapping 60 to form the filter element 52. Alternatively, the filter elements 50 and 52 could be formed from a pair of solid core flexible hoses. Other filter constructions could also be employed.
Means are provided for securing the filter elements 50 and 52 to the insulating body 32 in the form of a wire mesh wrapping 70 that extends around the filter elements and the insulating body. The wire mesh wrapping may also be 304SS wire mesh. The assembly 30 may be further secured in an exterior flexible casing or wrapping 80 formed from high temperature plastic, or other material. Other wrapping configurations would also no doubt be possible. For example, there may be provided a thin (e.g. one-sixteenth inch) ceramic fiber paper covering under the exterior wrapping 80.
The flexible seal assembly 30 may further be secured with a wire mesh cloth 90 extending between the filer elements 50 and 52, through the insulating core 32. There may be also provided a pair of transverse tie-wires 100 extending through the insulating core 32 and side panels 34 and 36. The transverse tie wires 100 may be anchored in the external wire mesh wrapping 70.
Turning to FIG. 7, the flexible seal assembly 30 includes end portions 110 and 112 having respective cut-outs 114 and 116 formed therein to provide for interlocking arrangement of successive seal assemblies disposed around the periphery of the flues 4 and 6.
Referring now to FIGS. 8-10, a shielded seal assembly in accordance with the present invention is illustrated in an expansion joint in a rectangular duct or flue assembly between a circulating fluidized bed combustion chamber and a cyclone separator as shown at the top of the assembly of FIG. 1. In this example of the embodiment, a flexible seal 30 is embodied in a shielded seal assembly disposed between or within a joint between an outlet wall section 120 of a flue section from a combustion chamber and an inlet wall 122 of a flue section to a cyclone separator. The flue section 120 is formed of a refractory wall portion 124 with tubes 126 formed in a portion thereof and the wall forming a peripheral abutting end or face 130. The flue section 122 has a refractory wall 132 terminating at a peripheral terminal face 134 which is positioned relative to face 130 to form a gap extending around the periphery of the duct sections. A pressure seal assembly including a pressure seal 136, which is secured by angle brackets 138 and 140 which are attached such as by welding to the flue casings 128 and 142. The pressure seal 136 is connected by suitable conduit 144 to a source of pressurized air or gas. The joint seal assembly comprises a plurality of inner shield members designated generally at 146 and a plurality of outer shield members designated generally at 148.
Referring particularly to FIGS. 8 and 10, the inner shield members comprise a pair of opposed sheet metal panels 150 and 152 joined by a curve semi-cylindrical portion 154 with a foot 156 at one end of one of the panels. This inner shield member is secured by means of the foot 156 to the one flue section wall by extending between the refractory wall portion and the outer metal casing 142. The foot portion may be secured in any suitable manner such as welding, bolting, etc. The inner shield member forms a space between the opposing panels 150 and 152 for receipt of the flexible seal member 30.
The seal members 30 are retained within the inner shield member 146 by means of a wire and rod arrangement with a pair of rods 158 (FIG. 8) extending along spaces within the seal member and secured by wires 160 which wrap around the rods 158 and extend through a pair of opposed one inch holes 162 (FIG. 10) through the wall panels of the inner shield member. The wires 160 extend outward into and are embedded into the refractory wall as it is constructed. The one inch openings provide a slide to enable the shield members to move relative to the wire anchoring members.
As shown in FIGS. 9 and 10, the inner shield members are disposed in multiple end to end units extending around the periphery of the gap in the flue section. The inner shield members are spaced typically about one inch apart when installed for a shield unit having the dimensions of approximately eleven and one-half inches in length and approximately ten and one-half inches in height. The outer shield members designated generally by the numeral 148 (FIG. 10) are formed of a primary sheet metal panel 164 having a foot 166 extending out substantially 90 degrees thereto and an upper or outer shield member 168 extending in the opposite direction from the panel 164 to that of the foot. The foot as in the previous panel discussion is secured to the opposing refractory wall between the space thereof and the outer metal housing 143. The sheet metal for both inner and outer shields is preferably flexible stainless steel of about sixteen (16) gauge.
The shield member extends along the face 130 and to a position where the outer shield portion 150 extends above the inner shield member and in a direction of a gas flow (FIG. 8). Thus, the outer shield member portion 168 extends over and shields the joint from the flowing ash and the like. The outer shield members are positioned to overlap the gaps between the inner shield members. Similarly, the outer shield members are spaced to allow for thermal expansion.
A corner inner shield member 170 is formed of adjoining corner panel members joined by a curved portion. The corner units are not provided with a foot and one of the panel's edge rests on the opening frame 143. Anchoring wires are not provided and extending through the corner shield. However, anchoring wires may be utilized if deemed necessary.
Other modifications and changes are possible in the foregoing disclosure and in some instances, some features may be employed without the corresponding use of other features. Accordingly, while the present invention has been illustrated and described with respect to specific embodiments, it is to be understood that numerous changes and modifications may be made therein without departing from the spirit and scope of the invention as defined in the appended claims.
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An expansion joint for protectively shielding a seal member disposed in a joint between two flue sections, includes a first shield member having a foot for attachment to an end of a first flue section, the shield member having a curved panel portion for extending over and protectively shielding a seal member, and a second shield member having a foot for attachment to an end of a second flue section, the second shield member having a curved panel portion for extending over a portion of the first shield and along the direction of gas flow.
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BACKGROUND
The present invention relates generally to the field of computers, and more particularly to software installations.
Software and websites include many different functions and it may not be easy for a user to follow a guide or manual instructions to use the software. Sometimes, even active users may not know how to use some specific functions in the software because the user may not know which section of the instructions or manual they should be followed first, or which section is not necessary and may not even need to be followed. Additionally, a user may need to set up some configuration before using a particular software or website. However, during the configuration, a user may not be able to complete the installation or configuration of the software due to the wrong command or a bad instruction. As such, a user may try to find out the correct steps or commands by searching on the online help or a manual.
SUMMARY
According to one embodiment, a method to detect and diagnose where an error occurs in a source code that is associated with a software program or a website is provided. The method may include capturing a plurality of snapshots associated with a computer system installation environment during a plurality of key times. The method may also include receiving a log report associated with the software program or the website, whereby by the log report is sent based on a hidden tag associated with the software program or the website. The method may also include analyzing the received log report. The method may further include detecting at least one error based on the analysis of the received log report. The method may include reverting back to a previous line in the source code associated with the software program or the website, whereby the reverting is based on the detection of the at least one error.
According to another embodiment, a computer system to detect and diagnose where an error occurs in a source code that is associated with a software program or a website is provided. The computer system may include one or more processors, one or more computer-readable memories, one or more computer-readable tangible storage devices, and program instructions stored on at least one of the one or more storage devices for execution by at least one of the one or more processors via at least one of the one or more memories, whereby the computer system is capable of performing a method. The method may include receiving a log report associated with the software program or the website, whereby by the log report is sent based on a hidden tag associated with the software program or the website. The method may also include analyzing the received log report. The method may further include detecting at least one error based on the analysis of the received log report. The method may include reverting back to a previous line in the source code associated with the software program or the website, whereby the reverting is based on the detection of the at least one error.
According to yet another embodiment, a computer program product to detect and diagnose where an error occurs in a source code that is associated with a software program or a website is provided. The computer program product may include one or more computer-readable storage devices and program instructions stored on at least one of the one or more tangible storage devices, the program instructions executable by a processor. The computer program product may include program instructions to receive a log report associated with the software program or the website, whereby by the log report is sent based on a hidden tag associated with the software program or the website. The computer program product may also include program instructions to analyze the received log report. The computer program product may further include program instructions to detect at least one error based on the analysis of the received log report. The computer program product may include program instructions to revert back to a previous line in the source code associated with the software program or the website, whereby the reverting is based on the detection of the at least one error.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
These and other objects, features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings. The various features of the drawings are not to scale as the illustrations are for clarity in facilitating one skilled in the art in understanding the invention in conjunction with the detailed description. In the drawings:
FIG. 1 illustrates a networked computer environment according to one embodiment;
FIG. 2 illustrates an exemplary system diagram according to one embodiment;
FIG. 3 illustrates an exemplary illustration of a log server according to one embodiment;
FIG. 4 is an operational flowchart illustrating the steps carried out by a program to automatically complete a specific software task using hidden tags according to one embodiment;
FIG. 5 illustrates an exemplary illustration of pre-defined tags for a script according to one embodiment;
FIG. 6 is a block diagram of internal and external components of computers and servers depicted in FIG. 1 according to one embodiment;
FIG. 7 is a block diagram of an illustrative cloud computing environment including the computer system depicted in FIG. 1 , according to one embodiment; and
FIG. 8 is a block diagram of functional layers of the illustrative cloud computing environment of FIG. 7 according to one embodiment.
DETAILED DESCRIPTION
Detailed embodiments of the claimed structures and methods are disclosed herein; however, it can be understood that the disclosed embodiments are merely illustrative of the claimed structures and methods that may be embodied in various forms. This invention may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of this invention to those skilled in the art. In the description, details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the presented embodiments.
Embodiments of the present invention relate generally to the field of computers, and more particularly to software installations. The following described exemplary embodiments provide a system, method and program product to, among other things, automatically complete a specific software task using hidden tags. Therefore, the present embodiment has the capacity to improve the technical field of installing and configuring software by using a browser plug-in that will find hidden tags in the current page and then perform the appropriate corresponding action. More specifically, the present embodiment may reduce the learning curve for new software, applications, and webpages. Additionally, the present embodiment may provide automated operations with proper environment parameters as well as interactive information for instructing users to the correct steps.
As previously described, a user may need to set up some configuration before using a particular software or website and during the configuration, the user may not be able to complete the installation or configuration of the software due to the wrong command or a bad instruction. As such, a user may try to find out the correct steps or commands by searching on the online help or a manual. However, it may not be easy for a user to find out which section or which steps are needed to be followed during the configuration since it may not be easy for the user to follow the guides or manuals instructions to use, install, or configure the software. For example, a user may be experiencing trouble during using, installing, or configuring software and may not know what to do since it may be difficult to find where the document is to help resolve the problem. Similarly, it may be difficult for the user to know which step is wrong and where the user should start. Furthermore, it may be difficult for the user to know which step the user is currently experiencing difficulty at and where the next step is. Therefore, users may waste a lot of time while searching for the correct answer. As such, it may be advantageous, among other things, to provide a solution, such as the present embodiment described herein, which may help a user use software or a website in a flexible and interactive way. Additionally, by using a method, such as the present embodiment, a user may operate the software or the website with dialog interactions or automation scripts.
According to at least one implementation, the present embodiment may provide a plug-in which is installed in the software or the website and interacts with invisible html tags in the target's source code. The plug-in may then be used to verify the environment parameters and execute the invisible html tags in the target location. Additionally, the operating logs or exception logs may be sent out to a log server to analyze and parse the plug-in for further execution via the scripts.
Furthermore, the invisible html tags may be implemented by tagging diverse information, such as scripts, steps, and dialog codes in the target source. For example, configuration scripts may be tagged in the online-help html page. According to the present embodiment, the invisible scripts in the HTML tags may be marked with a special character for the plug-in to identify and execute the scripts. As such, based on the interactions between the plug-in and the target sources (i.e., invisible html tags), the present embodiment may provide a more flexible and interactive way to aid users to use the software or the website properly.
The present invention may be a system, a method, and/or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present invention.
The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.
Computer readable program instructions described herein can be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and/or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers. A network adapter card or network interface in each computing/processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing/processing device.
Computer readable program instructions for carrying out operations of the present invention may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present invention.
Aspects of the present invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer readable program instructions.
These computer readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function/act specified in the flowchart and/or block diagram block or blocks.
The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions/acts specified in the flowchart and/or block diagram block or blocks.
The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.
The following described exemplary embodiments provide a system, method and program product to automatically complete a specific software task using hidden tags. According to the present embodiment, the hidden tags are automatically run for a user to complete the installation or configuration task. As such the hidden tags may start anywhere during the installation, configuration, and operation process and complete the task for user.
As previously described, according to at least one implementation, the present embodiment may provide a mechanism that is able to detect and diagnose where an error associated with a software product or a website takes place. As such, when a user selects the information center web page, the present embodiment may execute scripts that are embedded as hidden tags on the web page automatically or provide pop-up windows to confirm with the user, custom parameters that the user input earlier.
According to the present embodiment, a plug-in may receive the logs from a log diagnosis server. As such, the plug-in may start the actions based on what is received from an event processor to either rollback to a specific step and complete the tasks, or trigger hidden scripts from the invisible tag in the html source file location that was defined in event processor. Additionally, a pop-up dialog may be used by the document writer to correct the steps to make it more clear. Furthermore, the plug-in can also directly detect the errors in a system under test (SUT) and help the user rollback to previous step and interact with user to help complete the task.
Referring to FIG. 1 , an exemplary networked computer environment 100 in accordance with one embodiment is depicted. The networked computer environment 100 may include a computer 102 with a processor 104 and a data storage device 106 that is enabled to run a software program 108 and a Hidden Tag Program 116 A. The networked computer environment 100 may also include a server 114 that is enabled to run a Hidden Tag Program 116 B that may interact with a database 112 and a communication network 110 . The networked computer environment 100 may include a plurality of computer 102 and servers 114 , only one of which is shown. The communication network may include various types of communication networks, such as a wide area network (WAN), local area network (LAN), a telecommunication network, a wireless network, a public switched network and/or a satellite network. It should be appreciated that FIG. 1 provides only an illustration of one implementation and does not imply any limitations with regard to the environments in which different embodiments may be implemented. Many modifications to the depicted environments may be made based on design and implementation requirements.
The client computer 102 may communicate with the Hidden Tag Program 116 B running on server computer 114 via the communications network 110 . The communications network 110 may include connections, such as wire, wireless communication links, or fiber optic cables. As will be discussed with reference to FIG. 6 , server computer 114 may include internal components 800 a and external components 900 a , respectively, and client computer 102 may include internal components 800 b and external components 900 b , respectively. Server computer 114 may also operate in a cloud computing service model, such as Software as a Service (SaaS), Platform as a Service (PaaS), or Infrastructure as a Service (IaaS). Server 114 may also be located in a cloud computing deployment model, such as a private cloud, community cloud, public cloud, or hybrid cloud. Client computer 102 may be, for example, a mobile device, a telephone, a personal digital assistant, a netbook, a laptop computer, a tablet computer, a desktop computer, or any type of computing devices capable of running a program, accessing a network, and accessing a database 112 . According to various implementations of the present embodiment, the Hidden Tag Program 116 A, 116 B may interact with a database 112 that may be embedded in various storage devices, such as, but not limited to a computer 102 , a networked server 114 , or a cloud storage service.
As previously described, the client computer 102 may access the Hidden Tag Program 116 B, running on server computer 114 via the communications network 110 . For example, a user using a client computer 102 may access the Hidden Tag Program 116 A, 116 B, running on client computer 102 , and server computer 114 , respectively via the communications network 110 . For example, a user using client computer 102 may connect via a communication network 110 to the Hidden Tag Program 116 B which may be running on server computer 114 . The user may utilize the Hidden Tag Program 116 A, 116 B to automatically complete a specific software task using hidden tags. The hidden tag method is explained in more detail below with respect to FIGS. 2-4 .
Referring now to FIG. 2 , an exemplary system diagram 200 in accordance with one embodiment is depicted. As previously described, when a user using a client computer 102 selects the information center web page, the present embodiment may execute scripts that are embedded as hidden tags 204 on the web page automatically or provide pop-up windows to confirm with the user, custom parameters that the user input earlier. According to at least one implementation, the present embodiment includes the use of a log server 114 which may include a log repository 112 that receives, saves, and parses logs; records error frequency; and identifies the client. Then, the log server 114 may pass the parsed logs to a plug-in 206 that reads the logs; rollbacks the steps; executes tags and scripts; and pump frequent errors to a plug-in 206 .
More specifically, the plug-in 206 is a browser-based plug-in. According to the present embodiment, the plug-in 206 may perform 3 main functions as follows:
1. The log server 114 will send the user's system log parsing result to the plug-in 206 . As such, the plug-in may know which step the user is performing and which step the system should be rolled back to.
2. The plug-in 206 can recognize the invisible tags hidden in HTML source file and execute the script on the target machine 102 .
3. The log server 114 will also send information to the plug-in 206 regarding the most frequent error procedures that the user is reading. When the plug-in 206 receives the message, it will check the user's permission and popup a suggested modification dialog.
According to the present embodiment, the log server 114 has a log repository 112 and it will perform the following 3 tasks:
1. It will receive the target machine's 102 system log and parse it using existing technology. After parsing the log, it will know the machine's 102 status and which step should it be rolled back to.
2. The log server 114 will also record the error frequency by all the machine's 102 logs. As such, the log server 114 can send suggestions to eligible users.
3. The log server 114 will identify where the plug-in client 206 is for each target machine so it can send the messages to client.
According to the present embodiment, the system under test (SUT) 202 , is a machine that runs the production installation and will perform the following 2 tasks:
1. The SUT 202 will send error logs to log server.
2. The SUT 202 will also send the client internet protocol (IP) which is installed for the specific plug-in 206 to the log server 114 .
Referring now to FIG. 3 , an exemplary illustration 300 of a log server in accordance with one embodiment is depicted. The present embodiment may include the use of a log diagnosis server 114 which may include a log repository 112 that saves and sends logs to a log engine 304 . The log engine 304 may discover errors in logs and track (i.e., record) the error counts. Then, the log engine 304 will send the result to an event processor 302 . Then, based the errors in the logs and error counts, the event processor 302 may trigger (i.e., generate) certain actions that are passed to a plug-in 206 . Such triggered actions may include rolling back the script to the last successful step when the error happened in the user's environment (which is found by the log engine 304 ); target a section of the information center (i.e., online help); recommend modification of the information center (i.e., modify content of the on-line help); or trigger hidden scripts. Additionally, the event processor 302 may keep the user's input in case the rollback script needs the user's input to get back to the more clean state of the system and help the user complete the starting steps automatically. Furthermore, the event processor 302 may target the section of the information center or online help that has the history of the most errors.
Referring now to FIG. 4 , an operational flowchart 400 illustrating the steps carried out by a program to automatically complete a specific software task using hidden tags 204 ( FIG. 2 ) in accordance with one embodiment is depicted. As previously described, the Hidden Tag Program 116 A, 116 B ( FIG. 1 ) may provide a plug-in 206 ( FIG. 2 ) which is installed in the software or the website and interacts with invisible html tags 204 ( FIG. 2 ) in the target's source code. As such, in the page source code, there will be hidden tags 204 ( FIG. 2 ) inside the HTML comment tags. According to at least one implementation, the hidden tags 204 ( FIG. 2 ) are executable commands for the plug-in 206 ( FIG. 2 ). The plug-in 206 ( FIG. 2 ) may then be used to verify the environment parameters and execute the invisible html tags 204 ( FIG. 2 ) in the target location. Additionally, the operating logs or exception logs may be sent out to a log server 114 ( FIG. 2 ) to analyze and parse the plug-in 206 ( FIG. 2 ) for further execution via the scripts. Additionally, the invisible html tags 204 ( FIG. 2 ) may be implemented by tagging diverse information, such as scripts, steps, and dialog codes in the target source. According to the present embodiment, the invisible scripts 204 ( FIG. 2 ) in the HTML tags may be marked with a special character for the plug-in 206 ( FIG. 2 ) to identify and execute the scripts providing a more flexible and interactive way to aid users to use the software or the website properly.
Therefore with respect to FIG. 4 at 402 , the log server 114 ( FIG. 2 ) will obtain the log from the user. As previously explained, the log server 114 ( FIG. 2 ) has a log repository 112 ( FIG. 2 ) and it will receive the target machine's 102 ( FIG. 2 ) system log and parse it.
Then at 404 , the log is analyzed and errors are detected by line. According to at least one implementation, after parsing the log, the log server 114 ( FIG. 2 ) will know the machine's 102 ( FIG. 2 ) status and which step should it be rolled back to.
Therefore at 406 , it is determined whether an error is found in a line. If an error is not discovered in a line at 406 , then the method may continue back to step 404 to continue to analyze the log and detect errors by line.
However, if an error is discovered in a line at 406 , then the method continues to step 408 to fall back to the previous line. As such, when an error is detected, the log server 114 ( FIG. 2 ) will send the user's system log parsing result to the plug-in 206 ( FIG. 2 ). As such, the plug-in may know which step the user is performing and which step the system should be rolled back to. As previously described, the plug-in 206 ( FIG. 2 ) can recognize the invisible tags hidden in HTML source file and execute the script on the target machine 102 ( FIG. 2 ).
Referring now to FIG. 5 , an exemplary illustration 500 of pre-defined tags for a script in accordance with one embodiment is depicted. According to the present embodiment, hidden tags 502 will be inside the HTML comment contents 504 (e.g., <!--&-->). Additionally, there will be a starting hint 506 to let the plug-in 206 ( FIG. 2 ) know that this is where the starting of the script is (e.g., the ‘@’ sign). Furthermore, the <popup> tag 508 will pop up a dialog (e.g., a dialog box via a graphical user interface (GUI)) to wait for the user's input. Also, according to one implementation, the variable 510 may start with a ‘$’, and the plug-in 206 ( FIG. 2 ) will replace the actual value into it during execution.
It may be appreciated that FIGS. 2-5 provide only an illustration of one implementation and do not imply any limitations with regard to how different embodiments may be implemented. Many modifications to the depicted environments may be made based on design and implementation requirements. For example, as previously described, the log server 114 ( FIG. 2 ) will also send information to the plug-in 206 ( FIG. 2 ) regarding the most frequent error procedures that the user is reading. When the plug-in 206 ( FIG. 2 ) receives the message, it will check the user's permission and popup a suggested modification dialog. Additionally, the log server 114 ( FIG. 2 ) will also record the error frequency by all the machine's 102 ( FIG. 2 ) logs. As such, the log server 114 ( FIG. 2 ) can send suggestions to eligible users. Furthermore, the log server 114 ( FIG. 2 ) will identify where the plug-in client 206 ( FIG. 2 ) is for each target machine so it can send the messages to client.
The following are two sample scenarios that the present embodiment may be applied to:
Scenario 1:
Help Users to complete software installation if users encounter any errors during installation:
1. User starts software installation and hits an error during installation.
2. Exception logs will be sent out to the log server 114 ( FIG. 2 ) and parsed and sent to the plug-in 206 ( FIG. 2 ).
3. The plug-in 206 ( FIG. 2 ) will verify the environment parameters and collect what steps the user has performed.
4. The plug-in 206 ( FIG. 2 ) will then execute the invisible html tags 204 ( FIG. 2 ) in the software's information center.
5. The plug-in 206 ( FIG. 2 ) will determine the next steps based on the contents in the invisible tags 204 ( FIG. 2 ). For example, the plug-in 206 ( FIG. 2 ) will pop up a dialog and ask user to input the environment information and continue to finish the installation for user.
Scenario 2:
Help document writers identify which part of the installation guide of the information center that a user encounters errors the most often.
1. The invisible tag 204 ( FIG. 2 ) on the information center HTML collects which steps that users encountered problems in the most.
2. The plug-in 206 ( FIG. 2 ) reads this information and pops up a dialog to the document writer with the script which is in the invisible tag 204 ( FIG. 2 ) or from server alternatively.
3. The document writer correct the steps to make it more clear.
FIG. 6 is a block diagram 600 of internal and external components of computers depicted in FIG. 1 in accordance with an illustrative embodiment of the present invention. It should be appreciated that FIG. 6 provides only an illustration of one implementation and does not imply any limitations with regard to the environments in which different embodiments may be implemented. Many modifications to the depicted environments may be made based on design and implementation requirements.
Data processing system 800 , 900 is representative of any electronic device capable of executing machine-readable program instructions. Data processing system 800 , 900 may be representative of a smart phone, a computer system, PDA, or other electronic devices. Examples of computing systems, environments, and/or configurations that may be represented by data processing system 800 , 900 include, but are not limited to, personal computer systems, server computer systems, thin clients, thick clients, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, network PCs, minicomputer systems, and distributed cloud computing environments that include any of the above systems or devices.
User client computer 102 ( FIG. 1 ) and network server 114 ( FIG. 1 ) may include respective sets of internal components 800 a,b and external components 900 a,b illustrated in FIG. 6 . Each of the sets of internal components 800 include one or more processors 820 , one or more computer-readable RAMs 822 and one or more computer-readable ROMs 824 on one or more buses 826 , and one or more operating systems 828 and one or more computer-readable tangible storage devices 830 . The one or more operating systems 828 and the Software Program 108 ( FIG. 1 ) and the Hidden Tag Program 116 A ( FIG. 1 ) in client computer 102 ( FIG. 1 ) and the Hidden Tag Program 116 B ( FIG. 1 ) in network server 114 ( FIG. 1 ) are stored on one or more of the respective computer-readable tangible storage devices 830 for execution by one or more of the respective processors 820 via one or more of the respective RAMs 822 (which typically include cache memory). In the embodiment illustrated in FIG. 6 , each of the computer-readable tangible storage devices 830 is a magnetic disk storage device of an internal hard drive. Alternatively, each of the computer-readable tangible storage devices 830 is a semiconductor storage device such as ROM 824 , EPROM, flash memory or any other computer-readable tangible storage device that can store a computer program and digital information.
Each set of internal components 800 a,b also includes a R/W drive or interface 832 to read from and write to one or more portable computer-readable tangible storage devices 936 such as a CD-ROM, DVD, memory stick, magnetic tape, magnetic disk, optical disk or semiconductor storage device. A software program, such as the Software Program 108 ( FIG. 1 ) and the Hidden Tag Program 116 A, 116 B ( FIG. 1 ) can be stored on one or more of the respective portable computer-readable tangible storage devices 936 , read via the respective R/W drive or interface 832 and loaded into the respective hard drive 830 .
Each set of internal components 800 a,b also includes network adapters or interfaces 836 such as a TCP/IP adapter cards, wireless Wi-Fi interface cards, or 3G or 4G wireless interface cards or other wired or wireless communication links. The Software Program 108 ( FIG. 1 ) and the Hidden Tag Program 116 A ( FIG. 1 ) in client computer 102 ( FIG. 1 ) and the Hidden Tag Program 116 B ( FIG. 1 ) in network server 114 ( FIG. 1 ) can be downloaded to client computer 102 ( FIG. 1 ) and network server 114 ( FIG. 1 ) from an external computer via a network (for example, the Internet, a local area network or other, wide area network) and respective network adapters or interfaces 836 . From the network adapters or interfaces 836 , the Software Program 108 ( FIG. 1 ) and the Hidden Tag Program 116 A ( FIG. 1 ) in client computer 102 ( FIG. 1 ) and the Hidden Tag Program 116 B ( FIG. 1 ) in network server 114 ( FIG. 1 ) are loaded into the respective hard drive 830 . The network may comprise copper wires, optical fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers.
Each of the sets of external components 900 a,b can include a computer display monitor 920 , a keyboard 930 , and a computer mouse 934 . External components 900 a,b can also include touch screens, virtual keyboards, touch pads, pointing devices, and other human interface devices. Each of the sets of internal components 800 a,b also includes device drivers 840 to interface to computer display monitor 920 , keyboard 930 and computer mouse 934 . The device drivers 840 , R/W drive or interface 832 and network adapter or interface 836 comprise hardware and software (stored in storage device 830 and/or ROM 824 ).
It is understood in advance that although this disclosure includes a detailed description on cloud computing, implementation of the teachings recited herein are not limited to a cloud computing environment. Rather, embodiments of the present invention are capable of being implemented in conjunction with any other type of computing environment now known or later developed.
Cloud computing is a model of service delivery for enabling convenient, on-demand network access to a shared pool of configurable computing resources (e.g. networks, network bandwidth, servers, processing, memory, storage, applications, virtual machines, and services) that can be rapidly provisioned and released with minimal management effort or interaction with a provider of the service. This cloud model may include at least five characteristics, at least three service models, and at least four deployment models.
Characteristics are as follows:
On-demand self-service: a cloud consumer can unilaterally provision computing capabilities, such as server time and network storage, as needed automatically without requiring human interaction with the service's provider.
Broad network access: capabilities are available over a network and accessed through standard mechanisms that promote use by heterogeneous thin or thick client platforms (e.g., mobile phones, laptops, and PDAs).
Resource pooling: the provider's computing resources are pooled to serve multiple consumers using a multi-tenant model, with different physical and virtual resources dynamically assigned and reassigned according to demand. There is a sense of location independence in that the consumer generally has no control or knowledge over the exact location of the provided resources but may be able to specify location at a higher level of abstraction (e.g., country, state, or datacenter).
Rapid elasticity: capabilities can be rapidly and elastically provisioned, in some cases automatically, to quickly scale out and rapidly released to quickly scale in. To the consumer, the capabilities available for provisioning often appear to be unlimited and can be purchased in any quantity at any time.
Measured service: cloud systems automatically control and optimize resource use by leveraging a metering capability at some level of abstraction appropriate to the type of service (e.g., storage, processing, bandwidth, and active user accounts). Resource usage can be monitored, controlled, and reported providing transparency for both the provider and consumer of the utilized service.
Service Models are as follows:
Software as a Service (SaaS): the capability provided to the consumer is to use the provider's applications running on a cloud infrastructure. The applications are accessible from various client devices through a thin client interface such as a web browser (e.g., web-based e-mail). The consumer does not manage or control the underlying cloud infrastructure including network, servers, operating systems, storage, or even individual application capabilities, with the possible exception of limited user-specific application configuration settings.
Platform as a Service (PaaS): the capability provided to the consumer is to deploy onto the cloud infrastructure consumer-created or acquired applications created using programming languages and tools supported by the provider. The consumer does not manage or control the underlying cloud infrastructure including networks, servers, operating systems, or storage, but has control over the deployed applications and possibly application hosting environment configurations.
Infrastructure as a Service (IaaS): the capability provided to the consumer is to provision processing, storage, networks, and other fundamental computing resources where the consumer is able to deploy and run arbitrary software, which can include operating systems and applications. The consumer does not manage or control the underlying cloud infrastructure but has control over operating systems, storage, deployed applications, and possibly limited control of select networking components (e.g., host firewalls).
Deployment Models are as follows:
Private cloud: the cloud infrastructure is operated solely for an organization. It may be managed by the organization or a third party and may exist on-premises or off-premises.
Community cloud: the cloud infrastructure is shared by several organizations and supports a specific community that has shared concerns (e.g., mission, security requirements, policy, and compliance considerations). It may be managed by the organizations or a third party and may exist on-premises or off-premises.
Public cloud: the cloud infrastructure is made available to the general public or a large industry group and is owned by an organization selling cloud services.
Hybrid cloud: the cloud infrastructure is a composition of two or more clouds (private, community, or public) that remain unique entities but are bound together by standardized or proprietary technology that enables data and application portability (e.g., cloud bursting for load-balancing between clouds).
A cloud computing environment is service oriented with a focus on statelessness, low coupling, modularity, and semantic interoperability. At the heart of cloud computing is an infrastructure comprising a network of interconnected nodes.
Referring now to FIG. 7 , illustrative cloud computing environment 700 is depicted. As shown, cloud computing environment 700 comprises one or more cloud computing nodes 100 with which local computing devices used by cloud consumers, such as, for example, personal digital assistant (PDA) or cellular telephone 700 A, desktop computer 700 B, laptop computer 700 C, and/or automobile computer system 700 N may communicate. Nodes 100 may communicate with one another. They may be grouped (not shown) physically or virtually, in one or more networks, such as Private, Community, Public, or Hybrid clouds as described hereinabove, or a combination thereof. This allows cloud computing environment 700 to offer infrastructure, platforms and/or software as services for which a cloud consumer does not need to maintain resources on a local computing device. It is understood that the types of computing devices 700 A-N shown in FIG. 7 are intended to be illustrative only and that computing nodes 100 and cloud computing environment 700 can communicate with any type of computerized device over any type of network and/or network addressable connection (e.g., using a web browser).
Referring now to FIG. 8 , a set of functional abstraction layers 8000 provided by cloud computing environment 700 ( FIG. 7 ) is shown. It should be understood in advance that the components, layers, and functions shown in FIG. 8 are intended to be illustrative only and embodiments of the invention are not limited thereto. As depicted, the following layers and corresponding functions are provided:
Hardware and software layer 8010 includes hardware and software components. Examples of hardware components include: mainframes; RISC (Reduced Instruction Set Computer) architecture based servers; storage devices; networks and networking components. In some embodiments, software components include network application server software.
Virtualization layer 8012 provides an abstraction layer from which the following examples of virtual entities may be provided: virtual servers; virtual storage; virtual networks, including virtual private networks; virtual applications and operating systems; and virtual clients.
In one example, management layer 8014 may provide the functions described below. Resource provisioning provides dynamic procurement of computing resources and other resources that are utilized to perform tasks within the cloud computing environment. Metering and Pricing provide cost tracking as resources are utilized within the cloud computing environment, and billing or invoicing for consumption of these resources. In one example, these resources may comprise application software licenses. Security provides identity verification for cloud consumers and tasks, as well as protection for data and other resources. User portal provides access to the cloud computing environment for consumers and system administrators. Service level management provides cloud computing resource allocation and management such that required service levels are met. Service Level Agreement (SLA) planning and fulfillment provide pre-arrangement for, and procurement of, cloud computing resources for which a future requirement is anticipated in accordance with an SLA. A Hidden Tag Program may automatically complete a specific software task using hidden tags.
Workloads layer 8016 provides examples of functionality for which the cloud computing environment may be utilized. Examples of workloads and functions which may be provided from this layer include: mapping and navigation; software development and lifecycle management; virtual classroom education delivery; data analytics processing; and transaction processing.
The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.
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A method to detect and diagnose where an error occurs in a source code that is associated with a software program or a website is provided. The method may include receiving a log report associated with the software program or the website, whereby by the log report is sent based on a hidden tag associated with the software program or the website. The method may also include analyzing the received log report. The method may further include detecting at least one error based on the analysis of the received log report. The method may include reverting back to a previous line in the source code associated with the software program or the website, whereby the reverting is based on the detection of the at least one error.
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CROSS-REFERENCED TO RELATED APPLICATIONS
[0001] This application is a complete application of prior provisional Application Nos. 62/017,027, filed Jun. 25, 2014, and 62/117,364, filed Feb. 17, 2015, both of which are deemed incorporated herein by reference in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
BACKGROUND OF THE INVENTION
[0003] I. Field of the Invention
[0004] The present invention relates generally to orthopedic devices and, in particular, to a device used in the exercising of a knee following injury or surgery, particularly to aid in the rehabilitation process following a total knee replacement.
[0005] II. Related Art
[0006] The prior art is replete with orthopedic devices for aiding physical therapy related to knee joint exercising following a surgical procedure such as a total knee replacement. For the most part, such devices are complex mechanical structures. One such structure to support and more the lower leg is shown in U.S. Pat. No. 8,632,480 to Gardner et al. In U.S. Pat. No. 8,652,074 52 to Doi, there is shown a walking assist device that attaches to the upper and lower portions of a user's leg with a rotary joint located there between. The rotary joint is aligned with the user's knee and an actuator swings the lower link relative to the upper link. A controller is used to control the actuator so that the lower link guides the user's walking motion.
[0007] While many of the existing devices have been helpful in various stages of rehabilitation, there remains a definite need for a relatively simple device to interact with the user to help achieve full knee flexion and extension of the recovering knee joint.
SUMMARY OF THE INVENTION
[0008] By means of the present invention, there is provided a relatively simple device operable by a patient to assist in rehabilitating a post-operative knee. The device includes a rigid generally rectangular frame supplied with a heel rest slipped over one end of the rectangular frame. A knee sling is adjustably located spaced from the heel rest along the rectangular frame at a point where it will contact the upper surface of a knee of the user. An optional thigh strap may be located spaced from the knee sling along the rectangular frame.
[0009] The rectangular frame may be formed from aluminum tubing or other metal or any relatively rigid material. The heel rest is in the form of a pocket containing a soft foam insert such as a foam rubber pad sealed in the pocket as by a hook and loop fastening system such as that known as Velcro as an easily opening and closing device. Likewise, the knee sling component also may include an adjustable pocket with a foam, such as foam rubber, insert also sealed by a removable hook and loop system. The thigh strap is wrapped around the upper portion of the rectangular frame and is used to aid in operating the device.
[0010] To operate the device, the heel is placed in the heel rest at what is the bottom of the device as used with the patient sitting on the edge of a chair or possibly on the floor. The knee sling is adjusted to the middle or top of the knee and the patient pushes the side bars down causing downward flexion of the joint and reducing the degree of contracture, extending the knee joint.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the drawings wherein like numerals indicate like parts throughout the same:
[0012] FIG. 1 is a drawing of a frame element for the knee joint rehabilitation assist device of the invention;
[0013] FIG. 2 is a schematic drawing showing the parts of the knee join rehabilitation assist device as assembled;
[0014] FIG. 3 is a photograph of an assembled knee joint rehabilitation assist device; and
[0015] FIG. 4 depicts the knee joint rehabilitation assist device in use
DETAILED DESCRIPTION
[0016] The following detailed description describes embodiments that include concepts of the present development. Those embodiments are meant as examples only and are not intended to limit the scope of the present invention in any manner as variations of the development will occur to those skilled in the art.
[0017] FIG. 1 depicts a generally rectangular tubing structure 10 which serves as the frame for the knee joint rehabilitation device of the invention. One such frame was made of 1 inch diameter aluminum tubing bent and welded to create a continuous generally rectangular structure. Of course, other fasteners such as rivets may also be used. One such structure was 34 inches (86.36 cm) long by 10 inches (25.4 cm) wide. However, it will be appreciated that the frame can be any desired size and constructed of any useful rigid material. A 36 inch (91.4 cm) model and a 32 inch (81.28 cm) have also been demonstrated.
[0018] FIG. 2 is a schematic drawing showing the knee joint rehabilitation aid of the invention, including the frame 10 with the heel rest 12 located at one end of the frame. A knee sling 14 is shown intermediate the ends of the frame and it is configured so it is adjustable there along to accommodate the knee of the user depending on the distance between the heel and the knee. An adjustable pressure strap 16 is shown toward what becomes the upper end of the device fastened around the thigh of the user and over the upper end portion of the frame. A picture of an assembled device is shown in FIG. 3 .
[0019] FIG. 4 depicts an embodiment of the knee joint rehabilitation aid of the invention as employed by a user 20 . In use, the patient inserts the lower leg through the gap between the heel rest 12 and the knee sling 14 so that the heel is at or near what becomes the bottom of the device. The knee sling 14 can then be adjusted to meet the middle of the knee such that downward pressure on the sides of the upper portion of the frame stretches the leg toward full extension. The pressure strap 16 can then be tightened around the upper portion of the frame to adjust the tension on the leg and knee joint as desired as the amount of tension and, therefore, generally, the amount of pain endured by the patient depends on the amount of downward pressure 22 applied on the upper portion of the frame.
[0020] It will be appreciated that the knee joint rehabilitation aid of the invention is a simple manual device that provides an important therapy to a patient following, for example, total knee arthroplasty (total knee replacement) or reconstructive knee surgery. When used as prescribed, the device will aid greatly to alleviate and return knee flexion contracture prevalent in all stages of the rehabilitation process with the aim being total extension of the knee joint or complete straightening of the leg. The device is designed to be used after the incision on the top of the knee is significantly healed (4-6 weeks) and the patient is able to put significant weight on the affected leg.
[0021] It will be recognized that the most common complication associated with the rehabilitation process following a TKR (total knee replacement) is the pain experienced during leg flexion exercises. The basic goal for rehabilitation is to attain 145° of flexion and 0° of flexion contracture or extension as that will allow the patient to achieve a normal walking gait and resume normal activities, it being recognized that the sheer pain involved in this therapy process makes some patients stop the rehabilitation process altogether before a normal walking gait is realized.
[0022] Waiting too long, on the other hand, not only makes it impossible to achieve a normal walking gait, but may also lead to associated problems with hips, back and continued knee pain. While the knee joint rehabilitation assist device of the invention does not remove the pain from the process, it does allow the patient to rehabilitate the knee at his or her own pace with as much or little pain as he can stand on any certain day. The device is designed to be used with the patient sitting on the edge of a chair or on the floor and, with the aid of the pressure strap, can provide the desired constant soft tissue stretch, which is very important.
[0023] Because the device is operated manually, the patient decides just how much downward pressure to apply directly to the top of the knee joint in order to gain the last ten to fifteen degrees of gait flexion contracture. This thereby restores the full use of the leg and the normal walking gait. The process can be repeated for as long or as many times daily as the patient feels necessary, considering comfort level until 0° of flexion is achieved. The device is designed to be a secondary device used in conjunction with a full rehabilitation regimen.
[0024] An important aspect of the design of the device, including the rectangular shape of the frame, prevents a patient from putting too much downward pressure on the knee that may result in hyper-extension and possible damage to the healing joint. The top of the frame is designed to rest on the thigh before the joint goes past 20° or full straightening.
[0025] One material preferred to make the knee sling and the heel rest is cotton denim, however, this can be made of any desirable durable fabric. One heel rest used is a pouch containing about 1½ inches (3.8 cm) of foam rubber and has a top which folds over and is sealed with the hook and loop material. Likewise, the knee sling may also have 1½ inch (3.8 cm) foam rubber in the middle and be sealed with a hook and loop system which allows for easy removal and replacement of the foam if desired. Of course, other materials beside foam rubber are contemplated and any material having similar properties can be used.
[0026] This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use embodiments of the example as required. However, it is to be understood that the invention can be carried out by specifically different devices and that various modifications can be accomplished without departing from the scope of the invention itself.
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A knee joint rehabilitation assist device includes a rigid, generally rectangular frame, a heel rest attached across one end of the frame to accommodate a heel of a user, an adjustable knee sling attached at an adjustable distance spaced from the heel rest for accommodating the upper surface of a knee to be rehabilitated, and optionally, an auxiliary thigh strap for controlling pressure applied by the device.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of safety paper.
BACKGROUND ART
[0002] Paper has a porous structure, essentially consisting of fibrous particles of vegetable origin, having a length from 2-3 mm to less than 1 mm. The fibers are braided and held together by chemical bonds to build a compact layer.
[0003] In the paper industry, the watermark is a sign which appears through a series of lighter or darker lines imprinted on the sheets, and is obtained through the provision of a larger or smaller number of fibers when manufacturing the paper. Alternatively, the sign is imprinted on the finished sheet of paper using a pressure which also in this case affects the thickness of the fibers.
[0004] The method used when manufacturing the sheet of paper technically contemplates modifying the metal plane of the template, placing a mold on the sieve, through which the mixture of cotton and/or cellulose is filtered and deposited, thus creating a considerable reduction of the paper thickness in that area. The transparency of the watermark is actually determined by the thin cellulose layer deposited where the mold is placed.
[0005] On the other hand, the method used on the finished sheet of paper uses a “dandy roll” which leaves the impression of the watermark on the sheet of paper while it is still damp, thus causing the displacement of the fibers subjected to the pressure of the pattern fixed on the canvas of the roll itself. The clear areas of the watermark are obtained with protrusions patterned onto the canvas, while the dark areas are obtained with indentations.
[0006] The drawback of the above-described method is the high processing cost and the need to make specific molds every time, which involves relatively long times; for these reasons, the production of watermarked paper be means of these methods (which are of “mechanical” type) is not convenient, especially in the case of limited runs.
SUMMARY OF THE INVENTION
[0007] It is the main object of the present invention to provide a method for making the watermark in an alternative way; specifically, the inventor set the objective of creating the watermark “chemically”.
[0008] This and other objects are achieved by the method having the technical features described in claim 1 , which forms an integral part of the present description.
[0009] Advantageous aspects of the present invention are the subject of the dependent claims and they form an integral part of the present description as well.
[0010] The idea behind the present invention is to make a watermarked safety paper by means of a silk-screen printing process; in particular, by using a specific compound, i.e. a UV curing compound during the inking step contemplated in the silk-screen printing method.
[0011] Further features and advantages of the present invention become apparent from the following description of some embodiments thereof, provided by way of non-limiting examples, and from the accompanying drawings.
LIST OF FIGURES
[0012] FIG. 1 shows a chromatogram of an example of a compound that can be used in the method of the present invention;
[0013] FIG. 2 shows a flowchart where there are shown both the steps of a traditional silk-screen printing method and the steps of a non-traditional printing method, i.e. according to the present invention, for making chemical watermark;
[0014] FIGS. 3A and 3B each show, diagrammatically, a sectional view of the fibers of a sheet of paper before and after the application of a process according to the present invention.
DETAILED DESCRIPTION
[0015] The steps of the method used for making the safety paper with chemical watermark are substantially those typical and usual of silk-screen printing.
[0016] Silk-screen printing is a technique which allows images and graphics to be printed on any support or surface using a very fine, regular yarn fabric (called “printing textile”), through which ink is deposited on a support by using the previously made free areas. In fact, the ink passes through the tiny holes in the gaps left by weft and warp threads of the printing textile, to settle then on the surface to be printed.
[0017] In the method according to the present invention, the printing textile is prepared by transferring thereon, with the methods already in use in the field of silk-screen printing, the sign that will represent the (chemical) watermark. The printing textile is then stretched on a frame, forming the silk-screen printing frame which is placed on the support to be printed, which in the case of the present invention is of paper type. As in the traditional silk-screen printing method, ink is spread on the frame and by means of the so-called “doctor blade”, pressure is exerted as required to push the ink across the die, through the open areas, so that it settles on the support.
[0018] The inking step depends on the type of ink used.
[0019] Typically, silk-screen printing inks can be solvent-based, water-based or UV-drying solvents, consisting of pigments, binders and additives.
[0020] Their essential feature is thixotropy, that is the capacity of a liquid to vary its viscosity under the action of mechanical forces (or upon temperature changes) and return to the previous status (and to the previous temperature) when the mechanical action is stopped. This property allows the ink to pass through the textile meshes of the frame only under the pressure exerted by the printing doctor blade and to return almost immediately to the previous viscosity without widening too much on the support to be silk-screen printed and without dripping from the frame.
[0021] The idea behind the present invention is to make a watermarked safety paper by means of a silk-screen printing process.
[0022] In the method according to the present invention, the silk-screen ink which is spread on the frame is of ultraviolet type (UV in brief).
[0023] In UV inks, the curing step leading to hardening is caused by a chemical reaction during the emission of ultraviolet radiation in the UV drying unit. UV curing starts due to the energy absorbed by specific groups of molecules called photoinitiators. During drying, the organic photoinitiators, which are specifically targeted for a certain type of resin, release negatively charged radicals or positively charged polyatomic ions (complex cations). These decomposition products react with the free molecular groups (liquid ligands) of resins, thus triggering the curing process. Three-dimensional bonds are formed between the molecules in fractions of a second, transforming the liquid binder into a solid film.
[0024] However, photoinitiators have a characteristic smell that, after drying, decreases in radical UV photo-crosslinking coats and inks and disappears almost completely in cationic UV photo-crosslinking inks. On the other hand, however, cationic photo-crosslinking is much slower, so that, from the operational point of view, it can be a problem with large thicknesses of the paper support.
[0025] In order to overcome this problem, an ink formulation has been developed which, besides being able to generate the watermark effect, allows this typical smell to be reduced.
[0026] The reduction of the smell has been obtained by avoiding the use of photoinitiators such as 1,6 hexanediol acrylate, which is a photoinitiator generally used in traditional silk-screen printing.
[0027] Once the compound, passing through the open spaces of the printing frame, is deposited on the paper support to be watermarked, the curing reaction takes place during which the UV rays react with the photoinitiators, thus generating the complex radicals or cations which in turn react with the liquid binder, achieving the three-dimensional crosslinking of monomers and oligomers which leads to the fixing of the solid film.
[0028] In this step, the compound alters the structure of the paper fibers which become thinner and take a greater compactness, generating a transparency effect compared to untreated fibers.
[0029] FIG. 3 shows the effect of an example of the above description. FIG. 3-A shows a small section of a sheet of paper and its fibers before the application of the process; its thickness is indicated as S 1 . FIG. 3-B shows the same section of the sheet of paper with its fibers after the application of the process; its thickness is indicated as S 2 ; the thickness of the sheet is smaller (the difference between S 1 and S 2 is deliberately exaggerated for clarity in the figure) and the compactness of the fibers has increased.
[0030] Thereby, a final effect of light-and-shade and opacity variation is obtained which is very similar to that of traditional watermark, obtained instead with alterations of the fibers of the physical type (reduction in the number of fibers) or mechanical type (crushing of the fibers).
[0031] The fixative used in the method according to the invention also exhibits a quick drying on paper.
[0032] The shade of gray can be also scaled using special pigments, so as to intensify the stronger or weaker thinning of the cellulose fibers even graphically.
[0033] According to the present invention, in order to obtain a safety paper with chemical watermark, a compound having the following composition can be used in the silk-screen printing process, precisely in the inking step:
1—45-48% urethane-acrylate resin 2—45-48% polyol-acrylate 3—4-10% acrylic resin
[0037] Urethane-acrylate resin is a component formulated to act when exposed to UV light, therefore it is employed to provide bonding/coating with a very strong hold. The crosslinking and the depth of action depend on time, quality of the UV light and substrate type.
[0038] A polyol is an alcohol (R-OH) with several alcoholic groups to which various functional groups can bind. Polyesters are another class of polyols, which are formed by condensation between diols and dicarboxylic acids (and derivatives thereof). The OH group can act as a bridge between different functional units, thus creating the polymer. In the compound described, polyol-acrylate serves the function of photoinitiator.
[0039] Acrylic resin is a low molecular weight methyl-methacrylate-n-butyl methacrylate copolymer obtained from methyl and n-butyl esters of methacrylic acid.
[0040] Among the acrylic resins which can be employed in the compound, the best one is that known under the trade name ELVACITE 2013® from Lucite International, Inc. The composition includes the use of urethane-acrylate resin and polyol acrylate in equal parts and the addition, for the remaining part, of acrylic resin preferably known under the above-indicated trade name.
[0041] The composition is suitable for a grammage from 70 to 250 grams.
[0042] In summary, a method according to the invention includes the following steps:
step 1 : preparing the silk-screen printing die by means of known methods; step 2 : depositing the above-described fixative on the sheet by using a doctor blade; step 3 : curing the fixative with UV rays.
[0046] The flow chart in FIG. 2 allows an even better understanding of the difference between a traditional silk-screen printing method and a non-traditional printing method, i.e. according to the present invention, for making chemical watermarks.
[0047] Step 201 corresponds to the beginning of the silk-screen printing process, both of the traditional and non-traditional type.
[0048] Step 203 includes the preparation of the printing textile by transferring thereon, with the processes already known in silk-screen printing, the pattern to be printed (in the case of the chemical watermark, the pattern will be a simple “sign”).
[0049] In step 205 , the printing textile is stretched over a frame and placed on the paper support to be printed.
[0050] Step 207 corresponds to the choice between the traditional process (arrow “Y” and side “A” of the flow chart) and the non-traditional process (arrow “N” and side “B” of the flow chart).
[0051] In step 209 A, the traditional silk-screen printing ink is spread on the frame by exerting, with the doctor blade, the pressure required to push it across the die through the open areas.
[0052] In step 211 A, the ink is deposited on the support.
[0053] Step 217 A corresponds to the end of the traditional process.
[0054] In step 209 B, the UV curing silk-screen printing ink (as described above) is spread on the frame by exerting, with the doctor blade, the pressure required to push it across the die.
[0055] In step 211 B, the ink is deposited on the support.
[0056] Step 213 B includes the occurrence of the curing step into a UV drying unit: the UV rays react with the photoinitiators, thus generating the complex radicals or cations which in turn react with the liquid binder, achieving the three-dimensional crosslinking of monomers and oligomers which leads to the fixing of the solid film.
[0057] In step 215 B, the compound alters the structure of the paper fibers which become thinner and take a greater compactness, thus generating a transparency effect compared to untreated fibers.
[0058] Step 217 B corresponds to the end of the non-traditional process, and thus to the making of the “chemical watermark”.
[0059] Using the fixative with the above-described features, a final effect of light-variable light-and-shade is obtained, which is very similar to that obtained with the traditional watermarking methods. The effect of increased transparency is due to a greater compactness of the fibers which become thinner compared to those not treated, just like in the traditional watermarking methods.
[0060] Obviously, such a method has considerably lower costs than the traditional methods of producing watermarks and therefore it makes it advantageous to use the chemical watermark also for limited runs, in addition to reducing the production time.
[0061] Another advantage obtained by using a fixative thus made is the total rewritability of the paper which, upon the treatment, does not lose its strength features and can thus undergo any next printing stress, also of laser type.
[0062] The reason for this is to be found in the deposition of the solid film which on the one side creates a chemical transparency due to thinning and to the greater compactness of the fibers, but on the other hand acts as a protection film, thus hardening the thinned fibers.
[0063] The chemical watermark obtained using the method described is particularly suitable for obtaining safety paper typically used by banks and insurance companies since it is difficult to be falsified.
[0064] Obviously, the compound may have further features such as the presence of photo-active components that, in the case of photocopying of the original document, are activated with the strong illumination of the lamp of the photocopier itself, immediately making the original unreadable.
[0065] The accompanying comparative graph ( FIG. 1 ) was obtained by means of the chromatographic examination of the compound, where no peaks at 34 minutes are observed (see area A 2 ), which peaks are typical of the ingredient 1,6 hexanediol diacrylate, absent in the compound according to the invention and present in the usual inks, and where peaks at 26 minutes (see area A 1 ) and 42 minutes (see area A 3 ) are present, which peaks are typical of the usual inks; in this graph, the abscissa corresponds to the time in minutes and the ordinate corresponds to the counting of peaks (“Mcounts”), which value indicates the amount of molecular ions of a certain weight that reach the chromatograph detector.
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The method is used for making watermarked safety paper and comprises the usual steps of a process of silk-screen printing on paper; moreover, a UV curing compound is used, adapted to alter the compactness and/or thickness of the paper fibers; the compound comprises urethane-acrylate resin and polyol-acrylate in the minimum total amount of 90% and maximum amount of 96%, and a low molecular weight methyl-methacrylate-n-butyl methacrylate copolymer, obtained from methyl and n-butyl esters of methacrylic acid, in the amount of 4-10%; the urethane-acrylate resin and the polyol-acrylate differ by a maximum percentage of 3%.
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PRIORITY
[0001] This application claims priority under 35 U.S.C. §119 to an application entitled “Method for Generating Preamble Sequence Group” filed in the Korean Intellectual Property Office on Oct. 27, 2003 and assigned Serial No. 2003-75271, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a method for generating a preamble set or group in a communication system and an apparatus adopting the method, and in particular, to a method for generating an optimal preamble set using a plurality of sequences used to increase the limited number of channels, and an apparatus adopting the method.
[0004] 2. Description of the Related Art
[0005] Generally, communication systems support communication services and include transmitters and receivers.
[0006] FIG. 1 is a block diagram of a general communication system. Referring to FIG. 1 , a transmitter 10 and a receiver 20 provide communication services using frames. The transmitter 10 and the receiver 20 need to acquire synchronization information for accurate transmission and reception of the frames.
[0007] In order to acquire the synchronization information of the receiver 20 , the transmitter 10 transmits to the receiver 20 a synchronization signal indicating the start position of a frame transmitted to the receiver 20 . Upon receiving the synchronization signal and the frame transmitted from the transmitter 10 , the receiver 20 detects the start position of the received frame, i.e. frame timing, using the received synchronization signal. The receiver 20 demodulates the received frame using the detected frame timing. A specific preamble sequence, which has been previously agreed upon between the transmitter 10 and the receiver 20 , is used as the synchronization signal.
[0008] Various methods such as the use of a preamble or a pilot signal are used to acquire synchronization with transmitted frames in communication systems. In the case of acquiring synchronization using a preamble as mentioned above, it is a general practice to use a single preamble.
[0009] FIG. 2 illustrates a frame structure used in the general communication system. As shown in FIG. 2 , a frame is composed of a preamble 30 and data 40 . The preamble 30 is used for frame synchronization and channel estimation. The data 40 includes data selected and requested by a user for transmission and/or control information of the communication system.
[0010] The frame structure may have a fixed format according to the communication system as shown in FIG. 2 , but in other communication systems, the preamble 30 may be positioned in the middle of or at the end of the data 40 . In other words, a preamble in a frame may be positioned differently according to communication systems.
[0011] The preamble 30 shown in FIG. 2 is comprised of a first signal 32 and a second signal 34 . The first signal 32 is used for frame synchronization and the second signal 34 is used for channel estimation. The structure of the preamble 30 shown in FIG. 2 can be formed by divided into two parts, i.e. the first signal 32 and the second signal 34 , but may also be formed repetitively using a single signal or using several concatenated signals without dividing into two parts. In some communication systems, the first signal 32 is divided into two parts: one for frame synchronization and the other for packet synchronization.
[0012] FIG. 3 is a block diagram of a transmitter for the general communication system.
[0013] A data creator 51 receives data, creates transmission data, and transmits the created transmission data to a first multiplexer 54 . A media access control (MAC) header creator 52 creates a MAC header suitable for frames and transmits the created MAC header to the first multiplexer 54 . A physical (PHY) header creator 53 creates a PHY header suitable for the communication system and transmits the created PHY header to the first multiplexer 54 . The first multiplexer 54 multiplexes, i.e. mixes signals transmitted from the data creator 51 , the MAC header creator 52 , and the PHY header creator 53 , and transmits a resultant signal to a second multiplexer 57 . The resultant signal is referred to as transmission data.
[0014] A preamble creator 56 creates a preamble suitable for the communication system and transmits the created preamble to the second multiplexer 57 . The transmission data multiplexed by the first multiplexer 54 and the preamble created by the preamble creator 56 are input to the second multiplexer 57 . The second multiplexer 57 combines the transmission data from the first multiplexer 54 with the preamble from the preamble creator 56 to convert them into a transmission frame, and transmits the transmission frame to a receiver side through a transmission antenna 58 .
[0015] FIG. 4 is a block diagram of a receiver for the general communication system. Referring to FIG. 4 , the frame transmitted from the transmitter of FIG. 3 is received through a reception antenna 61 . The frame received through the reception antenna 61 is sent to a preamble analyzer 62 and a demultiplexer 63 . The preamble analyzer 62 analyzes the preamble in the received frame and detects synchronization information and channel estimation information. The preamble analyzer 62 determines the start position of the received frame using the synchronization information and the channel estimation information.
[0016] When the start point of the received frame is detected, the demultiplexer 63 separates the PHY header, the MAC header, and the data from the transmission data of the received frame with reference to the start position of the received frame. The separated signals are input to a PHY header analyzer 64 , an MAC header analyzer 65 , and a data restorer 66 .
[0017] The PHY header analyzer 64 analyzes the PHY header transmitted from the demultiplexer 63 and transmits the result of the header analysis to the data restorer 66 . The MAC header analyzer 65 analyzes the MAC header transmitted from the demultiplexer 63 and transmits the result of the header analysis to the data restorer 66 . The data restorer 66 restores the data transmitted from the demultiplexer 63 using the results of the header analysis transmitted from the PHY header analyzer 64 and the MAC header analyzer 65 .
[0018] The preamble sequence, which is agreed upon between the transmitter and the receiver of the communication system, may vary from system to system, but an aperiodic recursive multiplex (ARM) sequence will be used as the preamble sequence herein as an example. The preamble sequence that can be applied to the present invention is not limited to the ARM sequence, and may include any possible sequences that can be used as preambles. The ARM sequence exhibits superior auto-correlation in an aperiodic environment where sequences are not periodically transmitted.
[0019] Superior auto-correlation indicates that auto-correlation is high when the sequences are synchronized and auto-correlation is relatively low in other cases.
[0020] FIG. 5 is a block diagram of an ARM sequence generation apparatus that can generate an ARM sequence of a length 128 . As shown in FIG. 5 , when one of the possible 2-bit combinations of real numbers (‘00’, ‘01’, ‘10’, or ‘11’) is input as an input signal, the input signal is also input to a first multiplexer 81 . The input signal is input to a first XOR operator 71 .
[0021] At the same time, a first signal generator 91 generates a signal ‘01’ or ‘10’ and outputs the generated signal to the first XOR operator 71 . The first XOR operator 71 performs an exclusive or operation on the signal output from the first signal generator 91 and the input signal, and outputs a result of the XOR operation to the first multiplexer 81 . The first multiplexer 81 alternatively multiplexes the input signal and a signal output from the first XOR operator 71 and creates an ARM sequence of 4 bits. The first multiplexer 81 outputs the created 4-bit ARM sequence to a second multiplexer 82 and a second XOR operator 72 .
[0022] A second signal generator 92 generates a signal ‘0101’ or ‘1010’ and outputs the generated signal to the second XOR operator 72 at the same time that the 4-bit ARM sequence is input to the second multiplexer 82 from the first multiplexer 81 . The second XOR operator 72 performs an XOR operation on the signal output from the second signal generator 92 and the 4-bit ARM sequence output from the first multiplexer 81 , and outputs a result of the XOR operation to the second multiplexer 82 . The second multiplexer 82 alternatively multiplexes the signal output from the first multiplexer 81 and the signal output from the second XOR operator 72 to create an ARM sequence of 8 bits and outputs the created 8-bit ARM sequence to a third multiplexer 83 and a third XOR operator 73 .
[0023] A third signal generator 93 generates a signal ‘01010101’ or ‘10101010’ and outputs the generated signal to the third XOR operator 73 at the same time that the 8-bit ARM sequence is input to the third multiplexer 83 from the second multiplexer 82 . The third XOR operator 73 performs an XOR operation on the signal output from the third signal generator 93 and the 8-bit ARM sequence output from the second multiplexer 82 , and outputs a result of the XOR operation to the third multiplexer 83 . The third multiplexer 83 alternatively multiplexes the signal output from the second multiplexer 82 and the signal output from the third XOR operator 73 to create an ARM sequence of 16 bits and outputs the created 16-bit ARM sequence to a fourth multiplexer 84 and a fourth XOR operator 74 .
[0024] A fourth signal generator 94 generates a signal ‘0101010101010101’ or ‘1010101010101010’ and outputs the created signal to the fourth XOR operator 74 at the same time that the 16-bit ARM sequence is input to the fourth multiplexer 84 from the third multiplexer 83 . The fourth XOR operator 74 performs an XOR operation on the signal output from the fourth signal generator 94 and the 16-bit ARM sequence output from the third multiplexer 83 , and outputs a result of the XOR operation to the fourth multiplexer 84 . The fourth multiplexer 84 alternatively multiplexes the signal output from the third multiplexer 83 and the signal output from the fourth XOR operator 74 to create an ARM sequence of 32 bits, and outputs the created 32-bit ARM sequence to a fifth multiplexer 85 and a fifth XOR operator 75 .
[0025] A fifth signal generator 95 generates a signal ‘01010101010101010101010101010101’ or ‘10101010101010101010101010101010’ and outputs the created signal to the fifth XOR operator 75 at the same time that the 32-bit ARM sequence is input to the fifth multiplexer 85 from the fourth multiplexer 84 . The fifth XOR operator 75 performs an XOR operation on the signal output from the fifth signal generator 95 and the 32-bit ARM sequence output from the fourth multiplexer 84 and outputs a result of the XOR operation to the fifth multiplexer 85 . The fifth multiplexer 85 alternatively multiplexes the signal output from the fourth multiplexer 84 and the signal output from the fifth XOR operator 75 to create an ARM sequence of 64 bits and outputs the created 64-bit ARM sequence to a sixth multiplexer 86 and a sixth XOR operator 76 .
[0026] A sixth signal generator 96 generates a signal ‘01010101010101010101010101010101010101010101010101010101010101’ or ‘1010101010101010101010101010101010101010101010101010101010101010’ and outputs the created signal to the sixth XOR operator 76 at the same time that the 64-bit ARM sequence is input to the sixth multiplexer 86 from the fifth multiplexer 85 . The sixth XOR operator 76 performs an XOR operation on the signal output from the sixth signal generator 96 and the 64-bit ARM sequence output from the fifth multiplexer 85 , and outputs a result of the XOR operation to the sixth multiplexer 86 . The sixth multiplexer 86 alternatively multiplexes the signal output from the fifth multiplexer 85 and the signal output from the sixth XOR operator 76 to create an ARM sequence of 128 bits.
[0027] The created 128-bit ARM sequence is used for detecting frame synchronization in the preamble analyzer 62 of FIG. 4 . The length of the ARM sequence is extendable by powers of 2 such as 64, 128, 256, 512, and the like. Since the ARM sequence is produced from a plurality of inputs, the number of sequences of the ARM sequence is equal to two times the length of the ARM sequence. For example, the 128-bit ARM sequence shown in FIG. 5 has a total of 256 (=128*2) sequences.
[0028] Conventional preamble signals are only used for detection of frame synchronization and channel estimation in receivers of communication systems.
SUMMARY OF THE INVENTION
[0029] It is, therefore, an object of the present invention to provide a method for generating a superior sequence set from a sequence candidate group that can be used as preambles, and an apparatus adopting the method.
[0030] To achieve the above and other objects, there is provided a method for generating a preamble sequence group in a communication system having a transmitter and a receiver. The method comprises creating a preamble sequence, calculating a cross-correlation value between sequences using the created preamble sequence, determining a limit cross-correlation value using the cross-correlation value to construct a preamble set used in the communication system, calculating a preamble set that satisfies the determined limit cross-correlation value, and terminating construction of the preamble set.
[0031] According to the present invention, a preamble set useful for user or channel discrimination is provided using a plurality of preambles, thereby stabilizing user or channel discrimination.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
[0033] FIG. 1 is a block diagram of a general communication system;
[0034] FIG. 2 illustrates a frame structure used in the general communication system;
[0035] FIG. 3 is a block diagram of a transmitter for the general communication system;
[0036] FIG. 4 is a block diagram of a receiver for the general communication system;
[0037] FIG. 5 is a block diagram of an aperiodic recursive multiplex (ARM) sequence generation apparatus;
[0038] FIG. 6 is a flowchart illustrating a method for acquiring a preamble set according to an embodiment of the present invention;
[0039] FIG. 7 is a block diagram of a transmitter of a communication system using a preamble set according to an embodiment of the present invention;
[0040] FIG. 8 is a block diagram of the preamble creator of FIG. 7 according to an embodiment of the present invention;
[0041] FIG. 9 is a block diagram of a receiver of a communication system using a preamble set according to an embodiment of the present invention; and
[0042] FIG. 10 is a block diagram of the preamble analyzer of FIG. 9 according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0043] Several preferred embodiments of the present invention will now be described in detail with reference to the annexed drawings. In the drawings, the same or similar elements are denoted by the same reference numerals even though they are depicted in different drawings. In the following description, a detailed description of known functions and configurations incorporated herein has been omitted for conciseness.
[0044] In the present invention, a plurality of preambles is used for user or channel discrimination. A plurality of preamble signals or sequences, instead of a single preamble signal, should be used simultaneously for a communication system. Preamble signals should satisfy two conditions. First, the preamble signals should have superior characteristics. Second, the preamble signals should not be alike, that is, correlation between different preamble signals should be sufficiently low.
[0045] When a plurality of preamble sequences is used, receivers should be able to discriminate from among the preambles. When the receivers check correlation with other preamble signals except for those used for the receivers, the correlation should be sufficiently low so as to reduce the possibility that other preamble signals are regarded as those used for the receivers.
[0046] A preamble set used for user or channel discrimination can be structured in different forms. However, in the present invention, an ARM sequence having superior auto-correlation will be described. An ARM sequence set has a variable structure that provides preambles whose number is two times the length of the ARM sequence set, as shown in FIG. 5 . ARM sequences are created to calculate a cross-correlation value of each of the ARM sequences. A limit correlation value is determined in relation to the number of preambles to be used for a desired communication system. Then preambles that satisfy the determined correlation value are acquired, and a preamble set is comprised of the acquired preambles.
[0047] FIG. 6 is a flowchart illustrating a method for acquiring a preamble set according to an embodiment of the present invention.
[0048] In step S 110 , an ARM sequence is created to acquire preamble sequences. In step S 120 , cross-correlation values between the preamble sequences are calculated using the created ARM sequence. In step S 130 , a limit correlation value is determined to provide the optimal preamble set to the communication system using the calculated cross-correlation values. In step S 140 , a preamble set that satisfies the determined limit cross-correlation value is constructed. In step S 150 , it is determined if the generated preamble set is suitable for the communication system. If the generated preamble set is suitable for the communication system, construction of the preamble set is terminated in step S 160 .
[0049] However, if the generated preamble set is not suitable for the communication system, the limit cross-correlation value is adjusted in step S 170 , and steps S 140 and S 150 are performed again. The generated preamble set is applied to the communication system.
[0050] FIG. 7 is a block diagram of a transmitter in a communication system using the preamble set according to an embodiment of the present invention. Referring to FIG. 7 , a preamble creator 100 creates preamble signals according to an embodiment of the present invention and transmits the created preamble signals to a multiplexer 300 . Transmission data 200 is transmission data to be transmitted to a receiver and includes an MAC header and a PHY header. The multiplexer 300 performs multiplexing, i.e. multiplexes the preamble signals created by the preamble creator 100 and the transmission data 200 , and transmits a resultant signal to the receiver through a transmission antenna 350 .
[0051] FIG. 8 is a block diagram of the preamble creator 100 of FIG. 7 . Referring to FIG. 7 , the preamble creator 100 includes a preamble selector 120 and a preamble generator 140 . The preamble selector 120 selects one of the preambles available in a preamble set that is agreed upon between the transmitter and the receiver in the communication system, and transmits the preamble information to the preamble generator 140 . The preamble generator 140 creates the selected preamble using the preamble information transmitted from the preamble selector 120 and outputs the created preamble to the multiplexer 300 .
[0052] FIG. 9 is a block diagram of a receiver of the communication system using the preamble set according to an embodiment of the present invention. A frame signal transmitted from the transmitter of FIG. 7 is received through a reception antenna 410 , and input to a preamble analyzer 500 and a data restorer 420 .
[0053] The preamble analyzer 500 analyzes the received frame signal, detects the preamble information, synchronization information and channel estimation information, and transmits the detected information to the data restorer 420 . The data restorer 420 restores the received data based on the information transmitted from the preamble analyzer 500 , and outputs the restored data 430 .
[0054] FIG. 10 is a block diagram of the preamble analyzer 500 of FIG. 9 . Referring to FIG. 10 , the preamble analyzer 500 includes a preamble generator 510 , a correlation measurer 520 , and a synchronization acquisition/channel estimation unit 540 .
[0055] A received signal 600 received through the reception antenna 410 is a frame signal transmitted from the transmitter of FIG. 7 , and is input into the correlation measurer 520 . The preamble generator 510 generates preambles that are agreed upon between the transmitter and the receiver of the communication system, and inputs the preambles to the correlation measurer 520 .
[0056] The correlation measurer 520 measures cross-correlation between the frame signal, i.e., the received signal 600 , and the preambles generated by the preamble generator 510 , and detects preambles included in the received frame signal. The correlation measurer 520 transmits information on the detected preambles to the synchronization acquisition/channel estimation unit 540 . The synchronization acquisition/channel estimation unit 540 acquires synchronization information of the frame signal, i.e. the received signal 600 , and estimates channels based on the information received from the correlation measurer 520 . Here, the acquired information is transmitted to the data restorer 420 of FIG. 9 .
[0057] As described above, the present invention provides a preamble set useful for user or channel discrimination using a plurality of preambles, thus providing more stable user or channel discrimination.
[0058] A process of acquiring a preamble set in FIG. 6 will now be described herein below. The process below is intended to acquire preamble sets each comprised of 4 preambles, using 128-bit ARM sequences. First, all of the ARM sequences are created in step S 110 of FIG. 6 .
[0059] Table 1 tabulates the 128-bit ARM sequences created in step S 110 of FIG. 6 . In Table 1, values at the left side are indices of created ARM sequences and values at the right side are the ARM sequences. The indices of the ARM sequences shown in Table 1 are used to facilitate understanding of the present invention and may be defined differently or may not be used according to the preambles. In step S 120 of FIG. 6 , cross-correlation values between created preamble sequences are calculated.
TABLE 1 1 000100100001110100010010111000100001001000011101111011010001110100010010 00011101000100101110001011101101111000100001001011100010 2 010001110100100001000111101101110100011101001000101110000100100001000111 01001000010001111011011110111000101101110100011110110111 3 0010000100101110001000011101000100100001001011101101111000101110001000010 0101110001000011101000111011110110100010010000111010001 4 0111010001111011011101001000010001110100011110111000101101111011011101000 1111011011101001000010010001011100001000111010010000100 5 0001110100010010000111011110110100011101000100101110001000010010000111010 0010010000111011110110111100010111011010001110111101101 6 0100100001000111010010001011100001001000010001111011011101000111010010000 1000111010010001011100010110111101110000100100010111000 7 0010111000100001001011101101111000101110001000011101000100100001001011100 0100001001011101101111011010001110111100010111011011110 8 0111101101110100011110111000101101111011011101001000010001110100011110110 1110100011110111000101110000100100010110111101110001011 9 0001001011100010000100100001110100010010111000101110110111100010000100101 1100010000100100001110111101101000111010001001000011101 10 010001111011011101000111010010000100011110110111101110001011011101000111 10110111010001110100100010111000010010000100011101001000 11 001000011101000100100001001011100010000111010001110111101101000100100001 11010001001000010010111011011110001011100010000100101110 12 011101001000010001110100011110110111010010000100100010111000010001110100 10000100011101000111101110001011011110110111010001111011 13 000111011110110100011101000100100001110111101101111000101110110100011101 11101101000111010001001011100010000100100001110100010010 14 010010001011100001001000010001110100100010111000101101111011100001001000 10111000010010000100011110110111010001110100100001000111 15 001011101101111000101110001000010010111011011110110100011101111000101110 11011110001011100010000111010001001000010010111000100001 16 011110111000101101111011011101000111101110001011100001001000101101111011 10001011011110110111010010000100011101000111101101110100 17 000100100001110111101101000111010001001000011101000100101110001000010010 00011101111011010001110111101101111000101110110100011101 18 010001110100100010111000010010000100011101001000010001111011011101000111 01001000101110000100100010111000101101111011100001001000 19 001000010010111011011110001011100010000100101110001000011101000100100001 00101110110111100010111011011110110100011101111000101110 20 011101000111101110001011011110110111010001111011011101001000010001110100 01111011100010110111101110001011100001001000101101111011 21 000111010001001011100010000100100001110100010010000111011110110100011101 00010010111000100001001011100010111011011110001000010010 22 010010000100011110110111010001110100100001000111010010001011100001001000 01000111101101110100011110110111101110001011011101000111 23 001011100010000111010001001000010010111000100001001011101101111000101110 00100001110100010010000111010001110111101101000100100001 24 011110110111010010000100011101000111101101110100011110111000101101111011 0111010010000100011101001000010010001011100001000:110100 25 000100101110001011101101111000100001001011100010000100100001110100010010 11100010111011011110001011101101000111011110110111100010 26 010001111011011110111000101101110100011110110111010001110100100001000111 10110111101110001011011110111000010010001011100010110111 27 001000011101000111011110110100010010000111010001001000010010111000100001 11010001110111101101000111011110001011101101111011010001 28 011101001000010010001011100001000111010010000100011101000111101101110100 10000100100010111000010010001011011110111000101110000100 29 000111011110110111100010111011010001110111101101000111010001001000011101 11101101111000101110110111100010000100101110001011101101 30 010010001011100010110111101110000100100010111000010010000100011101001000 10111000101101111011100010110111010001111011011110111000 31 001011101101111011010001110111100010111011011110001011100010000100101110 11011110110100011101111011010001001000011101000111011110 . . . 234 101110000100100010111000101101110100011110110111101110001011011110111000 01001000101110001011011110111000010010000100011101001000 235 110111100010111011011110110100010010000111010001110111101101000111011110 00101110110111101101000111011110001011100010000100101110 236 100010110111101110001011100001000111010010000100100010111000010010001011 01111011100010111000010010001011011110110111010001111011 237 111000100001001011100010111011010001110111101101111000101110110111100010 00010010111000101110110111100010000100100001110100010010 238 1011011101000111101101111011100001001000101110001011011110111000101101110 1000111101101111011100010110111010001110100100001000111 239 1101000100100001110100011101111000101110110111101101000111011110110100010 0100001110100011101111011010001001000010010111000100001 240 1000010001110100100001001000101101111011100010111000010010001011100001000 1110100100001001000101110000100011101000111101101110100 241 1110110111100010000100101110001000010010000111010001001011100010111011011 1100010000100101110001011101101111000101110110100011101 242 10111000101101110100011110110111010001110100100001000111101101111011100010 110111010001111011011110111000101101111011100001001000 243 11011110110100010010000111010001001000010010111000100001110100011101111011 010001001000011101000111011110110100011101111000101110 244 10001011100001000111010010000100011101000111101101110100100001001000101110 000100011101001000010010001011100001001000101101111011 245 11100010111011010001110111101101000111010001001000011101111011011110001011 101101000111011110110111100010111011011110001000010010 246 10110111101110000100100010111000010010000100011101001000101110001011011110 111000010010001011100010110111101110001011011101000111 247 11010001110111100010111011011110001011100010000100101110110111101101000111 011110001011101101111011010001110111101101000100100001 248 10001100100010110111101110001011011110110111010001111011100010111000010010 001011011110111000101110000100100010111000010001110100 249 11101101000111010001001000011101000100101110001000010010000111011110110100 011101000100100001110111101101000111011110110111100010 250 10111000010010000100011101001000010001111011011101000111010010001011100001 001000010001110100100010111000010010001011100010110111 251 11011110001011100010000100101110001000011101000100100001001011101101111000 101110001000010010111011011110001011101101111011010001 252 100010110111101101110100011110110111010010000100011101000111101110001011011 11011011101000111101110001011011110111000101110000100 253 111000100001001000011101000100100001110111101101000111010001001011100010000 10010000111010001001011100010000100101110001011101101 254 101101110100011101001000010001110100100010111000010010000100011110110111010 00111010010000100011110110111010001111011011110111000 255 110100010010000100101110001000010010111011011110001011100010000111010001001 00001001011100010000111010001001000011101000111011110 256 100001000111010001111011011101000111101110001011011110110111010010000100011 10100011110110111010010000100011101001000010010001011
[0060] Table 2 tabulates the largest cross-correlation values among the calculated cross-correlation values in Table 1. Here, a larger cross-correlation value implies that similarity between two signals is high. Such high similarity is likely to cause generation of an error during analyzing of preambles and searching of synchronization in the preamble analyzer 62 of the receiver of FIG. 4 . Thus, the largest cross-correlation value among cross-correlation values between corresponding sequences is used as a representative value.
TABLE 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 128 26 65 65 40 56 36 66 49 49 68 38 49 49 68 34 41 50 36 50 2 26 128 65 65 68 40 68 36 49 49 38 68 49 49 34 68 50 41 50 30 3 65 65 128 26 38 66 40 56 53 38 49 49 68 34 49 49 36 50 32 50 4 65 65 26 128 68 36 66 40 38 68 49 49 34 68 40 49 50 36 50 32 5 40 66 36 66 128 22 65 65 49 49 68 34 49 51 68 34 72 29 45 43 6 66 40 66 36 22 128 65 65 49 49 34 68 51 49 34 68 29 72 43 45 7 36 66 40 66 65 65 128 22 68 34 49 49 68 34 51 49 44 45 72 29 8 66 38 56 40 65 65 22 128 34 68 49 49 34 68 49 51 45 44 29 72 9 49 49 68 38 49 49 68 34 128 22 65 65 40 66 33 66 48 50 36 50 10 49 49 38 68 49 49 34 68 22 128 65 65 66 40 68 33 50 48 50 36 11 68 38 49 49 68 34 49 49 65 65 128 22 33 66 40 66 36 50 48 50 12 38 68 49 49 34 68 49 49 65 65 22 128 86 33 66 40 50 36 50 48 13 49 49 68 34 49 51 68 34 40 68 33 66 128 23 65 65 72 31 43 43 14 49 49 34 68 51 49 34 68 66 40 66 33 23 128 65 65 31 72 43 43 15 68 34 49 49 68 34 51 49 33 66 40 66 65 65 128 22 43 43 72 27 16 34 68 49 49 34 68 49 51 66 33 66 40 65 65 22 128 43 43 27 72 17 41 50 36 50 72 20 44 45 48 50 36 50 72 31 43 43 128 22 65 65 18 50 41 50 36 29 72 45 44 50 48 50 36 31 72 43 43 22 128 65 66 19 38 50 32 50 45 43 72 29 36 50 48 50 43 43 72 27 65 65 128 22 20 50 36 50 32 43 45 29 72 50 38 50 48 43 43 27 72 66 65 22 128 21 72 29 45 43 41 50 36 50 72 27 43 43 48 50 36 50 33 66 33 66 . . . . . . 193 128 26 65 65 40 68 38 68 49 49 68 38 49 49 68 34 41 50 36 50 194 26 128 65 65 66 40 66 36 49 49 38 68 49 49 34 68 50 41 50 36 195 65 65 128 26 36 68 40 66 68 38 40 49 68 34 49 49 36 50 32 50 196 65 65 26 128 66 36 66 40 38 68 49 49 34 68 49 49 50 36 50 32 197 40 66 36 66 128 22 65 65 49 49 68 34 49 51 68 34 72 29 45 43 198 60 40 66 36 22 128 65 65 49 49 34 68 51 49 34 68 20 72 43 45 199 36 66 40 66 65 65 128 22 68 34 49 49 68 34 51 49 44 45 72 20 200 68 36 66 40 65 65 22 128 34 68 49 49 34 68 49 51 45 44 29 72 201 49 49 68 38 49 49 68 34 128 22 65 65 40 66 33 68 48 50 36 50 202 49 40 38 68 49 49 34 68 22 128 65 65 66 40 68 33 50 48 50 36 203 68 38 49 49 68 34 49 40 65 65 128 22 33 66 40 66 30 50 48 50 204 38 68 49 49 34 68 49 40 65 65 22 128 66 33 56 40 50 36 50 48 205 49 49 68 34 49 51 68 34 40 66 33 66 126 23 65 65 72 31 43 43 206 49 49 34 68 51 49 34 68 66 40 66 33 23 128 66 65 31 72 43 43 207 68 34 49 49 68 34 51 49 33 66 40 66 65 65 128 22 43 43 72 27 208 34 68 49 49 34 66 49 51 66 33 66 40 05 65 22 128 43 43 27 72 209 41 50 36 50 72 29 44 45 48 50 36 50 72 31 43 43 128 22 65 65 210 50 41 50 36 29 72 45 44 50 48 50 36 31 72 43 43 22 128 65 65 211 36 50 32 50 45 43 72 29 36 50 48 50 43 43 72 27 65 65 128 22 . . . . . . 245 40 33 52 31 33 33 52 42 40 46 29 46 80 30 43 43 56 35 60 34 246 33 40 31 52 33 33 42 52 46 40 46 29 30 80 43 43 36 56 34 60 247 52 26 40 33 52 42 33 33 28 46 40 45 43 43 80 30 60 34 56 35 248 26 52 33 40 42 52 33 33 46 28 46 40 43 43 30 60 34 60 35 56 249 80 30 43 43 40 46 36 46 33 42 52 30 40 33 52 26 60 30 43 41 250 30 80 43 43 46 40 46 36 42 33 30 52 33 40 26 52 30 60 41 43 251 43 43 80 30 36 46 40 46 52 30 39 42 52 31 40 33 41 43 80 30 252 43 43 30 80 46 36 46 40 30 52 42 39 31 52 33 40 43 41 30 80 253 40 46 36 48 80 38 43 43 40 33 52 31 33 33 52 42 40 46 36 42 254 46 40 46 36 38 80 43 43 33 40 31 52 33 33 42 52 46 40 42 36 255 36 46 40 46 43 43 80 38 52 26 40 33 52 42 33 33 36 42 40 46 256 46 36 46 40 43 43 38 60 26 52 33 40 42 52 33 33 42 36 46 40 21 . . . 245 246 247 248 249 250 251 252 253 254 155 256 1 72 . . . 33 42 52 30 40 33 52 26 80 30 43 43 2 29 42 33 30 52 33 40 26 52 30 80 43 43 3 45 52 30 39 42 52 31 40 33 43 43 80 30 4 43 30 52 42 39 31 52 33 40 43 43 30 80 5 41 40 33 52 31 33 33 52 42 40 46 36 46 6 50 33 40 31 52 33 33 42 52 46 40 46 36 7 38 52 26 40 33 52 42 33 33 38 46 40 46 8 50 26 52 33 40 42 52 33 33 48 36 46 40 9 72 60 30 43 43 40 46 28 46 33 42 52 30 10 27 30 80 43 43 46 40 46 28 42 33 30 52 11 43 43 43 80 30 20 46 40 46 52 30 39 42 12 43 43 43 30 80 46 29 46 40 30 52 42 39 13 48 40 46 29 46 80 30 43 43 40 33 52 31 14 50 48 40 46 29 30 80 43 43 33 40 31 52 15 36 28 46 40 46 43 43 80 30 52 26 40 33 16 50 46 28 48 40 43 43 30 80 26 52 33 40 17 33 04 46 52 34 56 35 60 34 80 30 41 43 18 68 46 64 34 52 35 56 34 00 30 80 43 41 19 33 52 34 64 46 60 34 56 35 43 41 80 30 20 66 34 52 46 84 34 60 35 56 41 43 30 80 21 128 56 35 60 34 64 34 52 46 40 42 36 46 . . . . . . 193 72 . . . 40 33 52 28 80 30 43 43 40 46 36 46 194 29 33 40 26 52 30 60 43 43 46 40 46 36 195 45 52 31 40 33 43 43 80 30 38 46 40 46 196 43 31 52 33 40 43 43 30 80 46 36 46 40 197 41 33 33 52 42 40 46 36 46 80 38 43 43 198 50 33 33 42 52 46 40 46 36 38 80 43 43 199 36 52 42 33 33 36 46 40 45 43 43 80 38 200 50 42 52 33 33 46 36 46 40 43 43 38 80 201 72 40 46 26 46 33 42 52 30 40 33 52 26 202 27 48 40 48 28 42 33 30 52 33 40 26 52 203 43 29 46 40 46 52 30 39 42 52 31 40 33 204 43 46 29 46 40 30 52 42 39 31 52 33 40 205 48 80 30 43 43 40 33 52 31 33 33 52 42 206 50 30 80 43 43 33 40 31 52 33 33 42 52 207 36 43 43 60 30 52 28 40 33 52 42 33 33 208 50 43 43 30 80 26 52 33 40 42 52 33 33 209 33 56 35 60 34 80 30 41 43 40 46 36 42 210 66 35 56 34 60 30 80 43 41 46 40 42 38 211 33 60 34 56 35 43 41 80 30 36 42 40 46 . . . . . . . . . 245 64 . . . 128 25 65 66 49 49 68 34 49 51 68 34 246 34 25 128 65 65 49 49 34 68 51 49 34 68 247 52 65 65 128 19 68 34 49 49 68 34 51 49 248 46 65 65 19 128 34 68 49 49 34 68 49 51 249 40 49 49 68 34 128 23 65 65 33 66 33 66 250 42 49 49 34 68 23 128 65 65 66 33 68 33 251 36 68 34 49 49 65 65 128 22 33 66 35 68 252 48 34 68 49 49 65 65 22 128 66 33 66 35 253 80 49 51 58 34 33 66 33 66 128 26 65 65 254 30 51 49 34 68 66 33 66 33 26 128 65 65 255 43 68 34 51 49 33 68 35 66 65 65 128 26 256 41 34 68 49 51 68 33 66 35 65 65 26 128
[0061] A preamble set having the minimum value among the representative values of Table 2 should be constructed. By acquiring a limit cross-correlation value that makes the cross-correlation value to be the smallest, it is possible to minimize the possibility of the generation of an error when the preamble analyzer 62 of FIG. 4 analyzes the preambles.
[0062] To construct the preamble set of the smallest cross-correlation values in step S 130 of FIG. 6 , one representative value that is largest or smallest is set as the limit cross-correlation value. An appropriate preamble set is searched for using the set representative value. According to the present invention, the representative value set in step S 310 of FIG. 6 is set to 31.
[0063] Table 3 tabulates a preamble set calculated using the representative value ‘31’. As shown in Table 3, there are 128 preamble sets. Here, if the representative value is lowered to 30, there is no appropriate preamble set since when any 4 sequences are selected from among the 256 sequences, the lowest limit of all cross correlation values pertaining to the selected sequence group is 31.
TABLE 3 s1 s2 s3 s4 s1:s2 s1:s3 s1:s4 s2:s3 s2:s4 s3:s4 s1 s2 s3 s4 s1:s2 s1:s3 s1:s4 s2:s3 s2:s4 s3:s4 17 47 86 108 28 31 30 30 23 29 41 84 110 215 30 23 28 29 31 30 17 47 86 172 28 31 30 30 23 29 41 84 174 215 30 23 28 29 31 30 17 47 108 150 28 30 31 23 30 29 41 110 148 215 23 30 28 29 30 31 17 47 150 172 28 31 30 30 23 29 41 148 174 215 30 23 28 29 31 30 17 86 108 239 31 30 28 29 30 23 42 83 109 216 30 23 28 29 31 30 17 86 172 239 31 30 28 29 30 23 42 83 173 216 30 23 28 29 31 30 17 108 150 239 30 31 28 29 23 30 42 109 147 216 23 30 28 29 30 31 17 150 172 239 31 30 28 29 30 23 42 147 173 216 30 23 28 29 31 30 18 48 85 107 28 31 30 30 23 29 43 82 112 213 30 23 29 28 31 30 18 48 85 171 28 31 30 30 23 29 43 82 176 213 30 23 29 28 31 30 18 48 107 149 28 30 31 23 30 29 43 112 146 213 23 30 29 28 30 31 18 48 149 171 28 31 30 30 23 29 43 146 176 213 30 23 29 28 31 30 18 85 107 240 31 30 28 29 30 23 44 81 111 214 30 23 29 28 31 30 18 85 171 240 31 30 28 29 30 23 44 81 175 214 30 23 29 28 31 30 18 107 149 240 30 31 28 29 23 30 44 111 145 214 23 30 29 28 30 31 18 149 171 240 31 30 28 29 30 23 44 145 175 214 30 23 29 28 31 30 19 45 88 106 29 31 30 30 23 28 45 88 106 211 30 23 29 28 31 30 19 45 88 170 29 31 30 30 23 28 45 88 170 211 30 23 29 28 31 30 19 45 106 152 29 30 31 23 30 28 45 106 152 211 23 30 29 28 30 31 19 45 152 170 29 31 30 30 23 28 45 152 170 211 30 23 29 28 31 30 19 88 106 237 31 30 29 28 30 23 46 87 105 212 30 23 29 28 31 30 19 88 170 237 31 30 29 28 30 23 46 87 169 212 30 23 29 28 31 30 19 106 152 237 30 31 29 28 23 30 46 105 151 212 23 30 29 28 30 31 19 152 170 237 31 30 29 28 30 23 46 151 169 212 30 23 29 28 31 30 20 46 87 105 29 31 30 30 23 28 47 86 108 209 30 23 28 29 31 30 20 46 87 169 29 31 30 30 23 28 47 86 172 209 30 23 28 29 31 30 20 46 105 151 29 30 31 23 30 28 47 108 150 209 23 30 28 29 30 31 20 46 151 169 29 31 30 30 23 28 47 150 172 209 30 23 28 29 31 30 20 87 105 238 31 30 29 28 30 23 48 85 107 210 30 23 28 29 31 30 20 87 169 238 31 30 29 28 30 23 48 85 171 210 30 23 28 29 31 30 20 105 151 238 30 31 29 28 23 30 48 107 149 210 23 30 28 29 30 31 20 151 169 238 31 30 29 28 30 23 48 149 171 210 30 23 28 29 31 30 21 43 82 112 29 31 30 30 23 28 81 111 214 236 28 31 30 30 23 29 21 43 82 176 29 31 30 30 23 28 81 175 214 236 28 31 30 30 23 29 21 43 112 146 29 30 31 23 30 28 82 112 213 235 28 31 30 30 23 29 21 43 146 176 29 31 30 30 23 28 82 176 213 235 28 31 30 30 23 29 21 82 112 235 31 30 29 28 30 23 83 109 216 234 29 31 30 30 23 28 21 82 176 235 31 30 29 28 30 23 83 173 216 234 29 31 30 30 23 28 21 112 146 235 30 31 29 28 23 30 84 110 215 233 29 31 30 30 23 28 21 146 176 235 31 30 29 28 30 23 84 174 215 233 29 31 30 30 23 28 22 44 81 111 29 31 30 30 23 28 85 107 210 240 29 31 30 30 23 28 22 44 81 175 29 31 30 30 23 28 85 171 210 240 29 31 30 30 23 28 22 44 111 145 29 30 31 23 30 28 86 108 209 239 29 31 30 30 23 28 22 44 145 175 29 31 30 30 23 28 86 172 209 239 29 31 30 30 23 28 22 81 111 236 31 30 29 28 30 23 87 105 212 238 28 31 30 30 23 29 22 81 175 236 31 30 29 28 30 23 87 169 212 238 28 31 30 30 23 29 22 111 145 236 30 31 29 28 23 30 88 106 211 237 28 31 30 30 23 29 22 145 175 236 31 30 29 28 30 23 88 170 211 237 28 31 30 30 23 29 23 41 84 110 28 31 30 30 23 29 105 151 212 238 28 30 23 31 30 29 23 41 84 174 28 31 30 30 23 29 106 152 211 237 28 30 23 31 30 29 23 41 110 148 28 30 31 23 30 29 107 149 210 240 29 30 23 31 30 28 23 41 148 174 28 31 30 30 23 29 108 150 209 239 29 30 23 31 30 28 23 84 110 233 31 30 28 29 30 23 109 147 216 234 29 30 23 31 30 28 23 84 174 233 31 30 28 29 30 23 110 148 215 233 29 30 23 31 30 28 23 110 148 233 30 31 28 29 23 30 111 145 214 236 28 30 23 31 30 29 23 148 174 233 31 30 28 29 30 23 112 146 213 235 28 30 23 31 30 29 24 42 83 109 28 31 30 30 23 29 145 175 214 236 28 31 30 30 23 29 24 42 83 173 28 31 30 30 23 29 146 176 213 235 28 31 30 30 23 29 24 42 109 147 28 30 31 23 30 29 147 173 216 234 29 31 30 30 23 28 24 42 147 173 28 31 30 30 23 29 148 174 215 233 29 31 30 30 23 28 24 83 109 234 31 30 28 29 30 23 149 171 210 240 29 31 30 30 23 28 24 83 173 234 31 30 28 29 30 23 150 172 209 239 29 31 30 30 23 28 24 109 147 234 30 31 28 29 23 30 151 169 212 238 28 31 30 30 23 29 24 147 173 234 31 30 28 29 30 23 152 170 211 237 28 31 30 30 23 29
[0064] If one preamble set is selected from among the 128 preambles sets and is used to discriminate users or channels, a preamble set having a superior auto-correlation and cross-correlation that is less than 31 can be used.
[0065] Once a preamble set is determined in a communication system, the preamble selector 120 of FIG. 8 selects one from among preambles of the preamble set and transmits the preamble information to the preamble generator 140 of FIG. 8 . The preamble generator 140 generates preambles using the preamble information.
[0066] Once the preambles included in a frame are transmitted from the transmitter to the receiver, the preamble analyzer 500 of FIG. 9 analyzes the preambles. At this time, the preamble analyzer 500 detects the preambles selected by the preamble selector 120 of FIG. 8 and creates the preamble information through the correlation measurer 520 of FIG. 10 .
[0067] By providing a preamble set to discriminate between users or channels using a plurality of preambles, it is possible to more stably discriminate users or channels.
[0068] According to an embodiment of the present invention, by providing a preamble set to discriminate between users or channels using a plurality of preambles, it is possible to more stably discriminate the users or channels.
[0069] By lowering cross-correlation to the smallest possible value, users or channels can be discriminated while the preambles are not affected in acquiring synchronization information.
[0070] 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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Provided is a method for generating a preamble sequence group. The method includes creating a preamble sequence, calculating a cross-correlation value between sequences using the created preamble sequence, determining a limit cross-correlation value using the cross-correlation value to construct a preamble set used in the communication system, calculating a preamble set that satisfies the determined limit cross-correlation value, and terminating construction of the preamble set.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based on and claims the priority benefit of provisional application 61/111,645 filed Nov. 5, 2008, the contents of which are incorporated by reference.
GOVERNMENTAL SUPPORT AND INTEREST
This invention was made with Governmental Support under Contract Number N00014-05-C-0378 dated Sep. 14, 2005 and issued by the Office of Naval Research (ONR). The Government has certain rights in the invention.
FIELD OF THE INVENTION
In general, the invention relates to the use of compound gas hydrate to separate specific gases from a gas mixture. In particular, additives, such as catalysts and defoaming agents that both reduce the negative effects of the catalyst and allow for rapid, controlled dissociation of the hydrate, are added to accelerate the process rate and thereby permit higher gas throughput.
BACKGROUND OF THE INVENTION
Applications for the industrial synthesizing of clathrate hydrates and semi-clathrates (hereafter referred to as “gas hydrates” or “hydrate,” except when differentiation is necessary) include desalination, gas storage, gas transport, and gas separation. Considerable work has been applied to the field of applied physical chemistry of these systems over the past 50 years in order to develop commercial technologies. To our knowledge, none have succeeded in producing a viable innovation for gas separation (although some clathrate hydrate-based processes for transport and desalination on a commercial scale appear close to success). Using gas hydrate systems to separate gases is a recent endeavor that has been mainly focused on extraction of CO 2 from combustion exhaust to keep it from emitting into the atmosphere.
In general, clathrate hydrates and semi-clathrates are a class of non-stoichiometric crystalline solids formed from water molecules that are arranged in a series of cages that may contain one or more guest molecules hosted within the cages. For clathrate hydrates, the whole structure is stabilized by dispersion forces between the water “host” molecules and the gas “guests.” Semi-clathrates are very similar to clathrate hydrates except one material (“guest material”) serves “double-duty” in that it both contributes to the cage structure and resides at least partially within the cage network. This special guest can be ionic in nature, with tetrabutylammonium cations being a classic example.
Hydrate formed from two or more species of molecule (e.g., methane, ethane, propane, carbon dioxide, hydrogen sulfide, nitrogen, amongst others) is referred to by several names: compound hydrate, mixed-gas hydrate, mixed guest hydrate, or binary hydrate. Each hydrate-forming species has a relative preference to enter the hydrate-forming reaction from any gas mixture and each hydrate has a range of cage sizes that can accommodate the guests. Tetrabutylammonium cation semi-clathrates differ from clathrate hydrates in this regard in that they only have one, small cage. They are thus more size selective than clathrate hydrates. Controlled formation of compound hydrate can be used to separate gases based on high and low chemical preference for enclathration or by size rejection (“molecule sieving”) in the mixture. Species with a high preference dominate the species in the hydrate while low preference gases are not taken into the hydrate in relation to their percentage of the original mixture and are thus “rejected.” Similarly, gases that are too big to fit in the hydrate cages are rejected; again, this is more critical for semi-clathrates than clathrate hydrates.
The controlled artificial production of hydrates is challenging because the natural rate of hydrate formation and dissociation may need acceleration in order for it to be used as the basis of a fully commercial process. Acceleration of the reaction rate of hydrate processes has focused on the role of a certain class of molecules that act as catalysts for hydrate formation and dissociation. Catalysts have been found to increase the rate of hydrate formation and dissociation reactions by orders of magnitude compared to uncatalyzed systems. See Ganji, et al. (2007) “Effect of different surfactants on methane hydrate formation rate, stability and storage capacity,” Fuel 86, 434-441 (“Ganji 2007). Certain prior art references have focused on the artificial growth aspect of gas hydrate. The use of various additives to increase the growth rate (U.S. Pat. No. 5,434,330, for example) and to promote hydrate growth at lower pressures (U.S. Pat. No. 6,855,852 (discredited by Rovetto, et al. (2006) “Is gas hydrate formation thermodynamically promoted by hydrotrope molecules?,” Fluid Phase Equilbria, 247(1-2), 84-89)), or by adding additional hydrate-forming “helper” gases (U.S. Pat. Nos. 6,602,326 and 6,797,039) have been considered only for the impact on formation rates and not on the total process rate, or throughput. The impact of these accelerative processes on dissociation does not appear to have been investigated in a systematic manner with respect to the complete processing of gas, for separation or for any other purpose. Not only must hydrate formation be accelerated, but also nothing should be done to inhibit any other stage of the process.
SUMMARY OF THE INVENTION
According to this invention, hydrate is formed by injection of water along with an accelerator (catalyst) in a reactor vessel or vessels and a further material is added that inhibits certain chemical modes of action of the catalyst molecule that slow collection of gas in the dissociation stage. During hydrate formation, desirable gases are preferentially (by chemical affinity or size exclusion) taken into the hydrate while the primary undesirable gas, for instance nitrogen where its separation from a mixture with hydrocarbon gases is desired, is concentrated in the rejected gas mixture. The hydrate and gas are then separated by any of a number of well understood industrial means and the hydrate is dissociated. The effect of the catalyst, which can slow the dissociation reaction, is countered by the presence of another material.
Additives that have been proposed in the prior art to accelerate or otherwise improve hydrate production rates or economics produce foams upon dissociation of the hydrate that more than offset their benefit by retarding or inhibiting the total rate of recovery of product gas. The hydrate formation mechanism and formulation that is disclosed in this work addresses this issue by disclosing an example of a formulation that reduces the impact of the foaming during processing and dissociation. The invention can be applied to hydrate technology processes in general and gas separation, storage, and transport in particular. In this application, gas separation is used as an example of hydrate processes that may be improved through the use of the invention.
We have discovered the following general relationship between the rate of reaction, gas separation efficiency, and relative supersaturation: as relative supersaturation increases, the rate of reaction increases but the gas separation efficiency decreases. It is therefore important to measure the composition change for the particular gas to be separated as a function of supersaturation. There will be a clear performance maximum where the increase in speed due to the raising of the relative supersaturation is offset by the deterioration in gas separation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail in connection with the drawings, in which:
FIG. 1 is a schematic process flow diagram of a single stage hydrate formation reactor;
FIG. 2 is a schematic process flow diagram of a single stage hydrate dissociation reactor;
FIG. 3 is a table showing steady-state, sprayer reaction rates, with no anti-foaming agents being used; and
FIG. 4 is a table of normalized reaction rates (frequency rates) for hydrocarbons in a gas mixture reacting in a stirred reactor with 300 ppm accelerator.
DETAILED DESCRIPTION
The invention may be practiced in a vessel or a series of vessels. FIG. 1 shows a schematic process flow diagram of a single vessel 110 for gas hydrate formation. In this case, gas to be processed 130 is injected into the reactor vessel 110 , along with water 135 . Reagents 140 , consisting of catalyst and anti-foaming agent, are injected (with either the water or gas or independently) in order to accelerate the rate of hydrate formation or otherwise condition its growth. Hydrate formation may be accomplished according to the teachings in U.S. Pat. No. 6,767,471, which is incorporated by reference, or in a gaseous atmosphere wherein a fine mist of water is injected under pressure. Hydrate is formed and the reject gas phase 150 (gas not participating in hydrate formation) is removed from the vicinity of the hydrate phase. The hydrate 160 is removed from the vessel. (As is recognized in the art, intentional hydrate formation processes are rarely conducted in a stoichiometric or in a gas-rich manner that consumes all available water; rather, such processes tend to be run water-rich, such that the product hydrate can be conveyed through the apparatus more expeditiously as part of a slurry. Thus, what is depicted schematically as hydrate 160 in the figures would be understood by one of skill in the art as, in actuality, constituting a slurry comprising hydrate (clathrate or semi-clathrate), water, catalyst, and anti-foaming agent, i.e., a mixture of the product clathrate or semi-clathrate and unconsumed reagents).
The hydrate components of the slurry are then dissociated in a dissociation vessel 210 ( FIG. 2 ), for the purpose of producing a product gas 220 and a residual or product liquid 221 comprises of water, catalyst, and anti-foaming agent.
A single gas-processing stage may not be sufficient to separate or store all of the gases in the initial reactant mixture. Adding additional stages (not shown) to the process improves the overall performance by increasing the total yield of hydrate relative to the input gas stream. The products of one stage are a “depleted” gas and hydrate slurry. The fate of these two streams depends on the overall goal of the hydrate process. For gas separation, the hydrate may be transported to a lower-pressure stage to re-equilibrate to a different composition, where the concentration of preferred formers in the hydrate is increased, and the gas may be transported to a higher-pressure stage to capture more of the preferred formers in the hydrate. The general effect is that hydrate moves towards the lower pressure side of the system while gas travels toward the high-pressure outlet. As the hydrate moves toward lower pressure, it becomes enriched in the preferred formers. As the gas travels toward the high-pressure outlet, it becomes depleted in preferred formers.
Natural hydrate formation normally takes place slowly or with very low rate of conversion from the available hydrate-forming gases and water. However, certain additives can be used to alter the pressure requirement for hydrate formation and allow the reaction to proceed at lower pressures. The use of certain anionic surfactants, such as sodium dodecyl sulfate (SDS), had been shown to increase formation (see Zhong et al. (2000) “Surfactant effects on gas hydrate formation,” Chem. Eng. Sci. 55, 4177-87) and dissociation rate dramatically (see Ganji 2007). However, the presence of the catalyst initially was found by us to promote the formation of a dense, heavy foam during dissociation. The foam makes processing of the products extremely difficult and more than offsets the increase in formation reaction rate afforded by the catalyst. We believe that prior art has overlooked the overall impact of the surfactant on the practicability of a process based on this technology. The formation of the foam results in an unworkable process. Most co-agents that participate in hydrate (clathrate or semi-clathrate) formation, including but not restricted to SDS, hydrotropes, and tetraalkylammonium halides, produce foam. Other agents, such as tetrabutylammonium bromide, produce a foam that breaks relatively quickly compared to the other catalysts, but this molecule also forms semi-clathrates, which may be beneficial or harmful to the separation attempted. Hydrate dissociation in the presence of the catalyst results in the evolution of very small bubbles and inefficient gas recovery rates in the dissociation stage, which has the effect of offsetting their beneficial aspects for hydrate growth.
Although the use of these compounds as catalysts is widely believed to form foam that would make application of the technology impossible at industrially significant scales, it has been demonstrated by us in our laboratory that the addition of a certain class of anti-foaming agent preserves the activity of the catalyst while greatly reducing the impact of the foam. The combination of a suitable catalyst and a suitable and compatible anti-foaming agent enhances the rate of hydrate formation and its controlled dissociation and will allow a gas throughput flow rate sufficient for a commercial process.
In order to develop a workable process for hydrate-based gas separation, we carried out experiments in both accelerating the rate of the hydrate formation reaction and in foam reduction during the dissociation phase. Achieving the highest rates possible for both controlled formation and dissociation is critical to the rate at which gas being treated can be passed through the system and adequately separated. We have applied our results to the field of industrial natural gas separation, particularly nitrogen rejection and ethane and propane recovery. We constructed and built a reactor to test the technology and verify that it 1) operates at an enhanced rate because of the combination of surfactant catalyst and anti-foaming agent, 2) separates hydrocarbon gases from nitrogen, and 3) can concentrate ethane and propane from a mixture of methane, ethane, and propane.
One of the common catalysts, SDS, increases the rate of hydrate formation. This has been measured by Lee et al. (see Lee, et al. (2007) “Methane Hydrate Equilibrium and Formation Kinetics in the Presence of an Anionic Surfactant,” J. Phys. Chem. C 2007, 111, 4734-4739) and Ganji et al. (see Ganji 2007) to be 10-20 times faster than uncatalyzed reactions, but their experiments were carried out only on volumes of less than 1 liter. Because crystallization processes have characteristics that are often related to the size of the reactor vessel, we have carried out experiments in vessels of 15+ liters (reactive liquid formulation volume; the volume of gas to be processed can be varied from nearly 0 to 20 liters) equipped with cooling coils. The reactive solution was circulated through a pump and reintroduced to the vessel either via a sprayer or through a submerged jet. The reactor was filled with a catalytic solution (Experiment 1 , FIG. 3 ) or water (Experiment 2 , FIG. 3 ). The system was pressurized with pure ethane gas and then cooled into the hydrate stability field. Before this step, a control reaction was conducted without mixing or catalyst. This control experiment produced a very small amount of hydrate at the gas/liquid interface; however, the amount of gas consumed was too little to be detected (<1 psi change at constant temperature and volume over two days). Other control experiments included 1) mixing without catalyst (reaction rates about 1/10 to 1/50 of the similarly catalyzed reaction rates) and 2) catalyst with no mixing (80%+ conversion of water over 24 hours).
In general, in the case of the catalyzed, mixed systems experiments that included both catalysts and anti-foaming agents, there was a brief period of rapid hydrate formation immediately following nucleation, which may itself have been enhanced. The reaction then slowed and a steady-state reaction rate was measured. This rate was about 20 times faster for the solution catalyzed with 300 ppm SDS than the uncatalyzed solution at about the same subcooling ( FIG. 3 ). We have tried both 300 ppm and 1200 ppm SDS in our reactors. We have found very reproducible results at 300 ppm, but very erratic results at 1200 ppm. We have thus rejected using higher concentrations of SDS because stability and reproducibility is a primary concern for industrial processes. This is beneficial because it sets a low maximum amount required for our process. We observed that, to the extent the rate of hydrate formation was enhanced, both of these experiments behaved in a similar manner to that which has been reported in the literature with much smaller vessels and despite the presence of anti-foaming agent. We thus have discovered that, by providing the anti-foaming agent, the catalytic effect can be extended to much-larger vessels despite the presence of anti-foaming agent and despite the scale-up effects referenced above.
We added 100-500 ppm doses of commercially available anti-foaming agent (for example, Dow Corning Antifoam 1920). We found that it acted as neither an inhibitor nor a co-catalyst. It reduced the impact of foam formation during formation and dissociation of the hydrate. The short-lived foam produced during formation has been eliminated in our experiments, and the long-lived, fine foam produced during dissociation breaks rapidly. This allows for the high rate of reaction made available by the catalysts to be applied to a complete industrial process.
We also measured the effect of subcooling, a measure of the driving force of crystallization, on reaction rate of hydrocarbons from a mixed gas phase being consumed into gas hydrate ( FIG. 4 ). We found that by driving the temperatures lower than the stability temperature at a given pressure and gas composition, some driving force acceleration of the hydrate-forming reaction could be gained. We found that with increasing subcooling, the rate of reaction increases, but that the degree of gas separation decreases as the less-preferred formers' rates increase faster than the more-preferred formers' rates. We believe that this relationship has not been recorded in the literature or presented publically prior to this disclosure.
Therefore, we conclude that for optimal gas separation based on degree of hydrate-forming preference of each gas in this invention, conditions in the hydrate formation and reformation stages should be maintained with minimum sub-cooling. This is actually a beneficial determination for operating conditions because it minimizes refrigeration requirements and costs.
Using accelerated and conditioned hydrate gas separation, for instance to remove nitrogen from hydrocarbon gas, would appear to be very competitive with existing membrane and cryogenic processes from energy, temperature, and pressure standpoints. First, hydrate forms from liquid water at temperatures between 0 and 20° C., which means that major energy consumption for refrigeration and heating are not necessary. Second, hydrate formation produces product gas at a higher pressure than other techniques, which can result in significant energy savings. Third, hydrate processes do not require pre-drying of all of the inlet gas, only post drying of the hydrocarbon-rich product, and the drying specification is much higher than the 77 K dew point for cryogenic operations. Fourth, the hydrate system can be used to produce some liquefied natural gas products, especially propane and iso-butane. Fifth, the hydrate process has low complexity when compared to a cryogenic gas separation installation. Sixth, the hydrate process can be applied over a wide range of gas flow rates and can be operated in either batch, semi-batch, or continuous modes.
By type, surfactants and hydrotropes that can be used as catalysts include the following:
Anionic surfactants including: sodium dodecyl sulfate, sodium butyl sulfate, sodium ocatdecyl sulfate, linear alkyl benzene sulfonate;
Cationic surfactants including: cetyl timethyl ammonium bromide;
Neutral surfactants including: ethoxylated nonylphenol;
Hydrotropes including: sodium triflate; and
“Promoters” including: hydrogen sulfide, tetrahydro furan, cyclopentane, and cyclopropane. (These are actually hydrate-formers.)
It will be apparent that various modifications to and departures from the above-described methodologies will occur to those having skill in the art. What is desired to be protected by Letters Patent is set forth in the following claims.
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The invention relates to using gas hydrate (clathrate and semi-clathrate) together with a catalytic formulation, including catalyst and anti-foaming agent, to separate specific gases from a gas mixture. In particular, compound hydrate is formed from a mixed gas feedstock to concentrate one or more desired gas species in the hydrate phase and the remainder in the gas phase. The hydrate is then separated from the gas phase and dissociated to produce a gas stream concentrated in the desired species. Additives that both accelerate the growth of hydrate and facilitate dissociation and separation are added to improve the rate of reaction and, at the same time, eliminate hard-to-break foam produced by the catalyst, thereby enhancing the total throughput of the complete process. The addition of some materials can also result in changes in the density of the hydrate product, which can be useful for optimizing the separation of hydrate from unreacted liquid and/or rejected gas.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to transeesophageal echocardiography (“TEE”) probes. The present invention specifically relates to a remote robotic actuation of the TEE probe during an interventional procedure.
BACKGROUND OF THE INVENTION
[0002] Transeesophageal echocardiography is commonly used to visualize cardiac anatomy and interventional devices during treatment for structural heart disease (“SHD”). FIG. 1 shows a typical distribution of theatre staff within a lab room 10 a having an ultrasound workstation 11 and an x-ray scanner, of which a c-arm 12 is shown. During a SHD operation, an echocardiographer 13 holds a TEE probe 14 , which passes through a mouth of a patient 16 into an esophagus to visualize a heart of patient 16 . A cardiologist 15 is located on an opposite side of x-ray c-arm 12 and an operating table 17 . Cardiologist 15 navigates interventional devices (not shown) (e.g., catheters and guidewires) from arterial incisions into the heart under x-ray guidance and ultrasound guidance via TEE probe 14 in order to perform different diagnostic or therapeutic procedures. Exemplar procedures, such as mitral clip deployments or transcatheter aortic valve replacements (“TAVR”), can be time consuming and complex. Moreover, ensuring appropriate visualization of the target anatomy during the procedure is the responsibility of echocardiographer 13 , who must make constant small adjustments to a position of a tip of TEE probe 14 for the duration of the procedure.
[0003] In practice, the operating conditions of FIG. 1 present several challenges. The first challenge is fatigue and poor visualization. Specifically, appropriate visualization includes both ensuring the relevant anatomical structures are within the field of view, and that the necessary contact force between the transducer head and esophageal wall, to achieve adequate acoustic coupling, is achieved. To this end, a position and an orientation of a head of TEE probe 14 requires constant, minute adjustments for the duration of the procedure in order to maintain appropriate visualization of the target structures. This can lead to fatigue and poor visualization by echocardiographer 13 during long procedures.
[0004] The second challenge is x-ray exposure. Specifically, a length of TEE probe 14 results in the positioning of echocardiographer 13 in close proximity to the source of interventional x-ray system, thus maximizing the x-ray exposure of echocardiographer 13 over the course of the procedure.
[0005] The third challenge is communication and visualization. During certain phases of a procedure, cardiologist 15 and echocardiographer 13 must be in constant communication as cardiologist 15 instructs echocardiographer 13 as to which structure to visualize. Given the difficultly interpreting a 3D ultrasound volume, and the different co-ordinate systems displayed by the x-ray and ultrasound systems, it can be challenging for echocardiographer 13 to understand the intentions of cardiologist 15 .
SUMMARY OF THE INVENTION
[0006] The present invention provides a remote robotic actuation system to address these challenges. Generally, as shown in FIG. 2 , a new distribution of theatre staff within a lab room 10 b with the remote robotic actuator system employing a robotic workstation 20 , a robotic actuator 30 , and a replica TEE control tool 31 and for remote actuation of between two (2) degrees of freedom and (4) degrees of freedom of TEE probe 14 which adjust the ultrasound imaging volume of TEE probe 14 . Additionally, as will be further described herein, replica TEE control tool 31 may have the ability to be employed for use with existing and various types of robotic actuators 30 , and may have the ability to be rapidly disengaged from robotic actuator 30 should echocardiographer 13 decide to return to manual operation of TEE probe 14 for any reason.
[0007] One form of the present invention is a replica control tool for remotely controlling a robotic actuator that robotically controls a control handle of an interventional tool (e.g., a probe, a catheter, flexible scopes, etc.), which in turn actuates a distal end of the interventional tool. The replica control tool employs a replica control handle substantially being a replica of a structural configuration of the control handle of the interventional tool, and a control device (e.g., a joystick or a trackball) movable relative to the replica control handle. The replica control tool further employs a robotic actuator controller for remotely controlling the robotic actuator responsive to any movement of the control device relative to the replica control handle. The replica control tool may further employ an electromechanical device (e.g., an accelerometer) co-rotatable with the replica control handle whereby the robotic actuator controller further remotely controls the robotic actuator in response to a rotation of the electromechanical device.
[0008] For purposes of the present invention, the term “controller” broadly encompasses all structural configurations of an application specific main board or an application specific integrated circuit housed within or linked to a computer or another instruction execution device/system for controlling an application of various inventive principles of the present invention as subsequently described herein. The structural configuration of the application controller may include, but is not limited to, processor(s), computer-usable/computer readable storage medium(s), an operating system, peripheral device controller(s), slot(s) and port(s). Examples of a computer include, but are not limited to, a server computer, a client computer, a workstation and a tablet.
[0009] A second form of the present invention is a robotic actuation system employing the robotic actuator and the replica control tool.
[0010] The foregoing forms and other forms of the present invention as well as various features and advantages of the present invention will become further apparent from the following detailed description of various embodiments of the present invention read in conjunction with the accompanying drawings. The detailed description and drawings are merely illustrative of the present invention rather than limiting, the scope of the present invention being defined by the appended claims and equivalents thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates an exemplary manual actuation of a TEE probe as known in the art.
[0012] FIG. 2 illustrates an exemplary embodiment of a remote controlled actuation of a TEE probe in accordance with the present invention.
[0013] FIG. 3 illustrates an exemplary embodiment of a robotic actuation system in accordance with the present invention.
[0014] FIG. 4 illustrates an exemplary mapping of various movements of a probe of an TEE probe and a replica TEE control tool in accordance with the present invention.
[0015] FIG. 5 illustrates an exemplary embodiment of a robotic actuator and a replica TEE control tool in accordance with the present invention.
[0016] FIG. 6 illustrates an exemplary embodiment of the replica TEE control tool shown in FIG. 5 in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] To facilitate an understanding of the present invention, exemplary embodiments of a robotic actuation system of the present invention and various components therefore will now be described in the context of a remote control actuation of a TEE probe as shown in FIG. 3 . From these descriptions, those having ordinary skill in the art will appreciate how to apply the principles of a robotic actuation system of the present invention to any suitable designs of ultrasound probes for any type of procedure as well as other tendon driven flexible interventional tools (e.g., a catheter, an endoscope, a colonoscope, a gastroscope, a bronchosope etc.).
[0018] For purposes of the present invention, the terms of the art including, but not limited to, “deflection”, “joystick”, “accelerometer”, “light emitting diode”, “actuation”, “robotic”, “robotic actuator”, “workstation”, “input device” and “electromechanical device” are to be interpreted as known in the art of the present invention.
[0019] Referring to FIG. 3 , a TEE probe 40 as known in the art employs an elongated probe 41 and a control handle 42 having a yaw actuation dial 43 for adjusting a yaw degree freedom of a distal tip of probe 41 and a pitch actuation dial 44 for adjusting a pitch degree freedom of the distal tip of probe 41 .
[0020] A robotic actuator 50 as known in the art provides a mechanical control of yaw actuation dial 43 and pitch actuation dial 44 for deflecting the distal tip of probe 41 in an anterior direction, a posterior direction, a lateral left direction, a lateral right direction or a combination thereof.
[0021] Robotic actuator 50 as known in the art may further provide a mechanical control of a translation along and/or a rotation about a longitudinal axis of TEE probe 40 as symbolically shown by the dashed line extending through TEE probe 40 .
[0022] A robotic workstation 62 as known in the art has controller(s) installed therein for communicating control commands to robotic actuator 50 via an operator's use of an interface platform 61 . Typically, the operator will interact with interface platform 61 to strategically navigate probe 41 via selective deflections, translations and/or rotations of probe 41 within a patient as illustrated by on overlay of probe 41 on a x-ray image or other volume image displayed by a monitor 60 .
[0023] The present invention provides a replica TEE control tool 70 having a replica control handle 71 substantially being a replica of a structural configuration of TEE control handle 42 . In practice, replica control handle 71 may be constructed in the same manner as TEE control handle 42 with the inside of replica control handle 71 being hollowed out for placement of electronic, electromechanical, mechanical and/or other components for implementing the inventive principles of the present invention.
[0024] One such inventive principle of the present invention is the replacement of dials 43 and 44 with a control input device 72 including, but not limited to, duplicates of dials 43 and 44 , a two-axis thumb joystick and/or a two-axis tracker ball. Control input device 72 allows for an easy and more intuitive control of probe 41 . Specifically, lateral left-right motion of control input device 72 is mapped to a lateral left-right deflection of probe 41 , and an up-down motion of control input device 72 is mapped to an anterior-posterior deflection of probe 41 .
[0025] For example, referring to FIG. 4 with control input device 72 in the form of a joystick:
(1) an up +Z motion of the joystick is mapped to an anterior deflection of probe 41 as shown (or alternatively mapped to a posterior deflection of probe 41 ) (2) a down −Z motion of the joystick is mapped to the posterior deflection of probe 41 as shown (or alternatively mapped to the anterior deflection of probe 41 ); (3) a lateral left −X motion of the joystick is mapped to a lateral left deflection of probe 41 as shown; (4) a lateral left +X motion of the joystick is mapped to a lateral right deflection of probe 41 as shown; (5) a left upward motion of the joystick is mapped to a left anterior deflection of probe 41 as shown (or alternatively mapped to a left posterior deflection of probe 41 ); (6) a right upward motion of the joystick is mapped to a right anterior deflection of probe 41 as shown (or alternatively mapped to a right posterior deflection of probe 41 ); (7) a left downward motion of the joystick is mapped to a left posterior deflection of probe 41 as shown (or alternatively mapped to a left anterior deflection of probe 41 ); and (8) a right upward motion of the joystick is mapped to a right posterior deflection of probe 41 as shown (or alternatively mapped to a right anterior deflection of probe 41 ).
[0034] Referring back to FIG. 3 , in practice, the mapping is stored within robotic workstation 62 whereby motion of the control input device 72 is communicated to robotic workstation 62 for the further communication of control commands to robotic actuator 50 for mapped movement of probe 41 . Concurrently or alternatively, the mapping is stored within replica TEE control tool 70 whereby mapping data is communicated to robotic workstation 62 for the further communication of control commands to robotic actuator 50 for mapped movement of probe 41 .
[0035] Still referring to FIG. 3 , another inventive principle of the present invention is to install an electromechanical device 73 within replica control handle 71 to co-rotate with replica control handle 71 (i.e., a synchronized rotation of replica control handle 71 and electromechanical device 73 about a longitudinal axis of replica control handle 71 as symbolically shown by the dashed line extending through replica control handle 71 ). In practice, the co-rotation of electromechanical device 73 is communicated to robotic workstation 62 for the further communication of control commands to robotic actuator 50 for a corresponding rotation of probe 41 as exemplary shown in a (9) axial rotation of FIG. 4 . Concurrently or alternatively, replica TEE control tool 70 generates rotation data indicative of a co-rotation of electromechanical device 73 whereby the rotation data is communicated to robotic workstation 62 for the further communication of control commands to robotic actuator 50 for corresponding rotation of probe 41 as exemplary shown in a (9) axial rotation of FIG. 4 .
[0036] An unlimited example of electromechanical device is a three-axis accelerometer whereby a rotation of replica control handle 71 may be calculated using the data obtained from the three-axis accelerometer. This calculation may happen either on a microcontroller (not shown) within replica control handle 71 or within the robotic workstation 62 .
[0037] The present invention provides multiple rotation modes, three (3) of which are now described herein.
[0038] Vertical Base Mode.
[0039] If replica control handle 71 is rotated to a certain delineated angle to vertical (e.g., 90° as shown in FIG. 4 ), then robot actuator 50 rotates probe 41 a corresponding rotational direction. If, for example, replica control handle 71 is rotated clockwise and reaches the desired threshold angle θ, then probe 41 is rotated clockwise, and if replica control handle 71 is rotated counter-clockwise and reaches the delineated threshold angle θ, then probe 41 is rotated counter-clockwise.
[0040] Fail Safe Mode.
[0041] To prevent an accidental rotation of replica control handle 71 , a fail-safe (aka “dead man's switches”) may be integrated into delineated degree mode of replica control handle 71 . In this mode, robotic actuator 50 does not rotate probe 41 until replica control handle 71 is rotated past the delineated threshold angle and the fail safe is activated.
[0042] Relative Roll Mode.
[0043] A rotation activation of replica control handle 71 records a current roll position of replica control handle 71 , but probe 41 is not actuated at that time. After rotation activation, when replica control handle 71 is then rotated past a delineated threshold angle from that recorded roll angle (e.g., 30°), then robotic actuator 50 rotates probe 41 in the corresponding direction (clockwise or counter-clockwise).
[0044] To facilitate a further understanding of the present invention, embodiments 50 a and 70 a of respective robot actuator 50 and replica control tool 70 will now be described herein.
[0045] Referring to FIG. 5 , robotic actuator 50 a employs a deflection actuator 51 , an axial translation actuator 52 , and an axial rotation actuator 53 .
[0046] Deflection actuator 51 is mechanically engaged as known in the art with dials 43 and 44 of TEE probe 40 . Workstation 62 provides control commands to motor controller(s) (not shown) of deflection actuator 51 for actuating dials 43 and 44 to execute a deflection of a probe 41 (not shown) of TEE probe 40 corresponding to a mapped motion of control input device 72 of replica control tool 70 .
[0047] Axial translation actuator 52 and axial rotation actuator 53 are mechanically coupled to deflection actuator 51 .
[0048] Axial translation actuator 52 as known in the art may be actuated to translate TEE control handle 42 along its longitudinal axis. Workstation 62 provides control commands to a motor controller (not shown) of axial translation actuator 52 to actuate an axial translation of TEE control handle 42 .
[0049] Axial rotation actuator 53 as known in the art may be actuated to rotate TEE control handle 42 along its longitudinal axis. Workstation 62 provides control commands to a motor controller (not shown) of axial rotation actuator 53 to execute a rotation of TEE control handle 42 corresponding to a mapped rotation of electromechanical device 73 of replica control tool 70 .
[0050] Referring to FIG. 6 , generally, a solid replica 70 a of TEE control handle 42 is made by splitting an upper half 71 a and a lower half 71 b of TEE control handle 42 whereby electronic components 75 a and 76 a may be fitted and placed inside lower half 71 b . Additionally, a hole 78 is made in a top cover 71 c of lower half 71 b to allow for a thumb joystick 72 a to pass there through.
[0051] Lower half 71 b contains cut-outs to house the electronics including a robotic actuator controller and a communication controller. Specifically, a printed circuit board (“PCB”) 75 a holds thumb joystick 72 (e.g., a two axis 30KΩ potentiometer) and a three-axis accelerometer (not shown) (e.g., a three-axis accelerometer from STMicroelectronics). PCB 75 a also contains a robotic actuator controller in the form of a microcontroller chip (e.g., microcontroller manufactured by Renesas) to interpret signals from thumb joystick 72 and the accelerometer and to output data in appropriate format for workstation 62 (e.g., an I 2 C format.) PCB 75 a may be held securely in place by a PCB holder (not shown for clarity) that is inserted onto a keyed boss (not shown for clarity) on lower half 71 b of replica control handle 70 a . The PCB holder also holds two membrane switches 74 a at a 90° angle from the joystick/accelerometer for use as buttons to replicate buttons 45 on TEE probe handle 42 ( FIG. 5 ).
[0052] A second area of lower half 71 b houses a communication controller 76 a (e.g., a Teensy 3.0 microcontroller board). Communication controller 76 a processes the I 2 C input from the joystick, accelerometer, and buttons and output the data over a universal serial bus (“USB”) to workstation 62 either as a simulated serial port or as a game controller, the latter allowing for easy integration into any software application. A channel and hole (not shown) is cut out an end of lower half 71 b to allow wires to pass from controller 76 a to workstation 62 and to house a USB connector.
[0053] Alternatively, the communication between replica control handle 70 a and workstation 62 occurs through a wireless communication instead of wired USB. In the wireless mode, communication controller 76 is implemented as a wireless module (e.g., Bluetooth or Wi-Fi) and a battery pack. This embodiment allows for more freedom of motion and positioning.
[0054] Also alternatively, communication controller 76 a may be omitted and PCB 75 a may be equipped with communication components, and the controllers may be installed within workstation 62 .
[0055] In practice, bosses (not shown) may be utilized to properly align cover 71 c with lower half 71 b , which may be secured to lower half 71 b via screws.
[0056] Also, upper half 71 a of replica control handle 70 a may be solid and integrated with lower half 71 b , or may be hollow and directly attached to lower half 71 b via a threaded screw connector (not shown). The hollow embodiment of upper half 71 a prevents replica control handle 70 a from being top heavy.
[0057] Further, an LED or laser 77 may be placed within a hollow upper half 71 a (e.g., with in a screw connector) whereby LED or laser 77 lights up to indicate to the user a specific event has occurred. For example, the LED/laser 77 may light up when a button 74 a is pressed. A multi-color LED may be used to indicate different events. For example, one color may be used to indicate a button 74 a has been pressed and another color may indicate the delineated threshold angle has been surpassed and TEE probe 40 is being rotated.
[0058] Still further, a vibration mechanism (not shown) may be the assembly to give the clinician/technician haptic feedback. This feedback can be used when specific events are triggered. For example, the replica can be made to vibrate when a button 74 a is pressed, TEE probe 40 is being actuated, or when the force measure on TEE probe 40 exceeds a chosen threshold. For this embodiment, force feedback requires a force sensing technique implement by TEE probe 40 , either through physical force sensors or by estimation of current forces using the measured currents drawn by the actuating motors.
[0059] Referring to FIGS. 1-6 , those having ordinary skill in the art will appreciate numerous benefits of the present invention including, but not limited to, an intuitive remote control of a robotic actuator of an interventional tool of any type.
[0060] Furthermore, as one having ordinary skill in the art will appreciate in view of the teachings provided herein, features, elements, components, etc. described in the present disclosure/specification and/or depicted in the FIGS. 1-6 may be implemented in various combinations of electronic components/circuitry, hardware, executable software and executable firmware, particularly as application modules of a controller as described herein, and provide functions which may be combined in a single element or multiple elements. For example, the functions of the various features, elements, components, etc. shown/illustrated/depicted in the FIGS. 1-6 can be provided through the use of dedicated hardware as well as hardware capable of executing software in association with appropriate software. When provided by a processor, the functions can be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which can be shared and/or multiplexed. Moreover, explicit use of the term “processor” should not be construed to refer exclusively to hardware capable of executing software, and can implicitly include, without limitation, digital signal processor (“DSP”) hardware, memory (e.g., read only memory (“ROM”) for storing software, random access memory (“RAM”), non-volatile storage, etc.) and virtually any means and/or machine (including hardware, software, firmware, circuitry, combinations thereof, etc.) which is capable of (and/or configurable) to perform and/or control a process.
[0061] 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 (e.g., any elements developed that can perform the same or substantially similar function, regardless of structure). Thus, for example, it will be appreciated by one having ordinary skill in the art in view of the teachings provided herein that any block diagrams presented herein can represent conceptual views of illustrative system components and/or circuitry embodying the principles of the invention. Similarly, one having ordinary skill in the art should appreciate in view of the teachings provided herein that any flow charts, flow diagrams and the like can represent various processes which can be substantially represented in computer readable storage media and so executed by a computer, processor or other device with processing capabilities, whether or not such computer or processor is explicitly shown.
[0062] Furthermore, exemplary embodiments of the present invention can take the form of a computer program product or application module accessible from a computer-usable and/or computer-readable storage medium providing program code and/or instructions for use by or in connection with, e.g., a computer or any instruction execution system. In accordance with the present disclosure, a computer-usable or computer readable storage medium can be any apparatus that can, e.g., include, store, communicate, propagate or transport the program for use by or in connection with the instruction execution system, apparatus or device. Such exemplary medium can be, e.g., an electronic, magnetic, optical, electromagnetic, infrared or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include, e.g., a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), flash (drive), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk read only memory (CD-ROM), compact disk read/write (CD-R/W) and DVD. Further, it should be understood that any new computer-readable medium which may hereafter be developed should also be considered as computer-readable medium as may be used or referred to in accordance with exemplary embodiments of the present invention and disclosure.
[0063] Having described preferred and exemplary embodiments of novel and inventive replica control tools, (which embodiments are intended to be illustrative and not limiting), it is noted that modifications and variations can be made by persons having ordinary skill in the art in light of the teachings provided herein, including the FIGS. 1-6 . It is therefore to be understood that changes can be made into the preferred and exemplary embodiments of the present disclosure that are within the scope of the embodiments disclosed herein.
[0064] Moreover, it is contemplated that corresponding and/or related systems incorporating and/or implementing the device or such as may be used/implemented in a device in accordance with the present disclosure are also contemplated and considered to be within the scope of the present invention. Further, corresponding and/or related method for manufacturing and/or using a device and/or system in accordance with the present disclosure are also contemplated and considered to be within the scope of the present invention.
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A replica control tool ( 70 ) for remotely controlling a control handle ( 71 ) of an interventional tool (e.g., a probe, a catheter and a flexible scope) robotically controlled by a robotic actuator ( 50 ). The replica control tool ( 70 ) employs a replica control handle ( 71 ) substantially being a replica of a structural configuration of the control handle ( 71 ) of the interventional tool, and a control input device ( 72 ) (e.g., a joystick or a trackball) movable relative to the replica control handle ( 71 ). The replica control tool ( 70 ) further employs a robotic actuator controller ( 75 ) for remotely controlling the robotic actuator ( 50 ) in response to any movement of the control input device ( 72 ) relative to the replica control handle. The replica control tool ( 70 ) may further employ an electromechanical device ( 73 ) (e.g., an accelerometer) co-rotatable with the replica control handle ( 71 ) whereby the controller ( 75 ) remotely controls the robotic actuator ( 50 ) in response to a rotation of the electromechanical device ( 73 ).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for producing 1,4-bis(dichloromethyl)tetrafluorobenzene (DCMTFB) and, more particularly, to a method for producing high-yield 1,4-bis(dichloromethyl)tetrafluorobenzene in mass production.
2. Description of Related Art
Parylene polymers possess numerous advantages for manufacturing purposes. For example, the coating environment is at room temperature; no residual stress exists after coating; and precise controls are allowed on the thickness of the deposition film. Additionally, parylene polymer films have advantages such as uniformity, excellent acid and alkali resistance, high transparency and low dielectric constant. Therefore, they have been widely employed in electric insulation on printing circuit boards, damp-proofing on sensors or medical instruments, and anti-corrosion on metal-coating, etc. Presently, the fluoro parylene polymers, for their low dielectric constant and high melting point, can be utilized on dielectric coating in the electrical and coating industries and have become the focus of the attention.
One of fluoro parylene polymers, for example, poly(tetrafluoro-p-xylene) has the structure represented by the following Formula (1).
Fluoro parylene polymers are generally coated on products by means of chemical vapor deposition in a vacuum at room temperature. Products coated with fluoro parylene polymers not only possess excellent anticorrosive, damp-proofing and insulating characteristics, but also have the advantages of extra thinness, transparency and being poreless. By polymerizing active monomers on the object surfaces, fluoro parylene polymer coatings can be formed. Unlike the general steps of liquid coating process, there is another coating process to have the parylene dimers vaporized first, and as the dimer bonds are cleaved to yield monomer free radicals at a pyrolysis condition, the monomer free radicals are polymerized to form parylene polymers.
Currently, the dimer of fluoro parylene polymers often used in the industry is octafluoro-2,2-paracyclophane represented by the following Formula (2).
The dielectric constant of fluoro parylene polymers decreases as the number of fluorine atoms increases within the polymers. Thus, it can be predicted that the parylene polymers polymerized from the dimer of fluoro parylene polymers, represented by the following Formula (3) and containing no hydrogen atoms, can have a lower dielectric constant.
It is important for 1,4-bis(bromodifluoromethyl)tetrafluorobenzene (BFTFB) represented by the following Formula (4) to be the monomer of the above-mentioned dimer, to not contain any hydrogen atoms, of fluoro parylene polymers.
1,4-bis(dichloromethyl)tetrafluorobenzene (DCMTFB), as shown in the following Formula (5), is a critical precursor for synthesis of the foregoing 1,4-bis(bromodifluoromethyl)tetrafluorobenzene (BFTFB).
Nowadays, 1,4-bis(dichloromethyl)tetrafluorobenzene (DCMTFB) is synthesized by reacting 1,2,4,5-tetrafluorobenzene (TFB) with CHCl 3 , as shown in the following Reaction (I).
However, this method is time-consuming and low-yielding, and needs silica-gel column chromatography to purify the crude product. Hence, this method is unsuitable for mass production.
Therefore, it is desirable to provide a prompt and high-yield method for synthesize 1,4-bis(dichloromethyl)tetrafluorobenzene (DCMTFB), and such method is appropriate for mass production.
SUMMARY OF THE INVENTION
The present invention provides a method for producing 1,4-bis(dichloromethyl)tetrafluorobenzene. This method can reduce the reaction time, simplify the procedures and promote the yield for producing 1,4-bis(dichloromethyl)tetrafluorobenzene. The reaction of the method is shown as the following Reaction (II).
The present invention provides a method for producing 1,4-bis(dichloromethyl)tetrafluorobenzene, which comprises the following steps:
(a) mixing tetrafluoroterephthaldehyde, a catalyst and SOCl 2 with or without organic solvents to form a mixture, wherein the catalyst belongs to formamides;
(b) heating the mixture;
(c) cooling the mixture, adding the mixture into water slowly, and letting the mixture separate into two layers;
(d) obtaining an organic layer from the layers of the mixture; and
(e) purifying the organic layer and removing the organic solvents and the catalyst in the organic layer and affording 1,4-bis(dichloromethyl)-tetrafluorobenzene.
In the method of the present invention, the molar ratio of tetrafluoroterephthaldehyde to SOCl 2 is at least more than 2. The molar ratio of tetrafluoroterephthaldehyde to SOCl 2 is preferably in the range from 2 to 20, and more preferably in the range from 5 to 8.
In the method of the present invention, the weight ratio of the catalyst to tetrafluoroterephthaldehyde is in the range from 0.1 to 1.0, and preferably in the range from 0.2 to 0.4.
In the method of the present invention, the weight ratio of the organic solvent to tetrafluoroterephthaldehyde is in the range from 0 to 3, and preferably in the range from 1 to 2.
In the method of the present invention, the mixture in the step (b) is heated until the temperature thereof rises to the range from 60 to 130° C., and preferably to the range from 85 to 100° C.
In the method of the present invention, the reaction time of the step (b) is in the range from 2 to 30 hours, and preferably to the range from 4 to 6 hours.
In the method of the present invention, the mixture is cooled in the range from 0 to 60° C. in the step (c), and preferably in the range from 25 to 40° C. so as to avoid the overreaction of hydrolysis.
In the method of the present invention, the mixture can be added into water slowly at 0 to 25° C., and preferably into iced water in the step (c) to avoid the overreaction of hydrolysis.
The method of the present invention can be performed without or with an organic solvent nonreactive to SOCl 2 . The organic solvent is preferably at least one selected from the group consisting of toluene, chloroform, p-xylene, benzene, dioxane, 1,2-dichloroethane, tetrachloromathane, tetrahydrofuran, nitrobenzene, and o-dichlorobenzene, and more preferably is toluene or benzene.
In the method of the present invention, the catalyst is N,N-dialkylformamide, wherein the alkyl group is a C 1 ˜C 7 alkyl group. Preferably, the catalyst is N,N-dimethylformamide (DMF), or N,N-diethylformamide (DEF).
In the method of the present invention, the purification of the step (e) preferably comprises the following steps:
(e1) adding an organic solvent and water (H 2 O) into the organic layer under stirring;
(e2) neutralizing the mixture;
(e3) isolating the organic layer and then concentrating the organic layer; and
(e4) cooling the organic layer to obtain a solid product.
In the above-mentioned step (e), the volume ratio of the organic solvent to water is in the range from 1 to 10 in the step (e1), and preferably is 1. The organic solvent can be any organic solvent which can dissolve 1,4-bis(dichloromethyl)tetrafluorobenzene but is not miscible with water, and preferably is dichloromethane in the step (e1). The mixture can be neutralized by any basic solution, and preferably by concentrated ammonia in the step (e2).
Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Example 1
Preparation of 1,4-bis(dichloromethyl)tetrafluorobenzene (Toluene as the Solvent and N,N-Dimethylformamide as the Catalyst)
Tetrafluoroterephthaldehyde (TFTPA, 15.45 g), N,N-dimethylformamide (DMF, 3.01 g), and toluene (15.01 g) were added into a 250 mL three-necked reactor equipped with a temperature probe, a condenser and an aeration tube. Under nitrogen atmosphere, SOCl 2 (63.37 g) was slowly added into the flask via the channel for the temperature probe by a feed hopper. After the feed hopper was removed, the flask was reequipped with the temperature probe. The reaction mixture was heated in an oil bath under stirring while the aeration of nitrogen was closed, and it was refluxed at 85˜95° C. for 2 hours until gas chromatography (GC) analysis informed that the reaction was completed. After the reaction mixture was cooled to room temperature, iced water was slowly introduced thereto to hydrolyze residual SOCl 2 . The reaction mixture was stood for a while and the aqueous layer was removed. Subsequently, appropriate amounts of dichloromethane (DCM) and H 2 O (the volume ratio of DCM to H 2 O=1/1) were added into the remaining organic layer. The pH value of the mixture was adjusted to 7.0 by concentrated ammonia (conc. NH 3(aq) ). Then, the organic phase was isolated, washed by water, dehydrated by anhydrous magnesium sulfate, and concentrated to remove DCM, toluene, and DMF. Finally, the resultant was cooled to room temperature so that the crude product (22.23 g, crude yield: 93.8%) was obtained. The crude product was recrystallized in n-heptane to afford 13.33 g of the crystal product. The residual n-heptane solution was evaporated, and then recrystallized once again to obtain 6.28 g of the crystal product. The total quantity of recrystallization twice amounted to 19.61 g of the crystal product (the yield: 82.75%).
Data of Chemical Analyses:
(a). Mass spectrum: M + =316.
(b). 1 H NMR (CDCl 3 ; external standard: TMS) chemical shift (δ): 6.90 ppm (s, 2H).
(c). 19 F NMR (CDCl 3 ; external standard: CFCl 3 ) chemical shift (δ): −139.37 ppm (s, 4F).
(d). 13 C NMR (CDCl 3 ; external standard: TMS) chemical shift (δ): 143.45 ppm (d, J C-F =257 Hz, 4 Aromatic C), 120.72 ppm (s, 2 Aromatic C), 58.26 ppm (s, 2 Aliphatic C).
Examples 2 to 16
Preparations of 1,4-bis(dichloromethyl)-tetrafluorobenzene
Examples 2 to 16 were performed in the manner the same as Example 1. However, the amounts of the reagents and the solvent, the reaction conditions, and the yields of the products are listed in Table 1.
Examples 1 to 16 illustrate that the solvent can be toluene, chloroform, p-xylene, benzene, dioxane, 1,2-dichloroethane, tetrachloromathane, tetrahydrofuran, nitrobenzene, or o-dichlorobenzene, and the catalyst is formamides most preferably.
Comparative Example
Conventional Preparation of 1,4-bis(dichloromethyl)tetrafluorobenzene
Comparative Example is a conventional method of producing 1,4-bis(dichloromethyl)tetrafluorobenzene, in which 1,2,4,5-tetrafluorobenzene (TFB) is reacted with CHCl 3 to yield 1,4-bis(dichloromethyl)tetrafluorobenzene. This method is detailed in the following.
1,2,4,5-tetrafluorobenzene (TFB, 3.77 g), anhydrous AlCl 3 (20.34 g), and CHCl 3 dehydrated by NaH as the solvent were added into a 100 mL reactor. The mixture was heated in an oil bath under stirring and refluxed for 24 hours. Subsequently, the mixture was added into iced water slowly to hydrolyze residual AlCl 3 . The mixture was extracted with chloroform, and then the organic phase was washed by water, dehydrated by anhydrous magnesium sulfate, and concentrated to obtain the crude product. The crude product was purified by silica-gel column chromatography using n-hexane as the eluent, and recrystallized with n-hexane to obtain 1,4-bis(dichloromethyl)tetrafluorobenzene (yield: 59.33%).
Table 2 shows the drawbacks and advantages of the present Comparative Example compared with Example 1.
Based on Table 2, the cost of Example 1 is 1.5-fold more than that of the Comparative Example. However, the method of Example 1 can reduce the reaction time, simplify the procedures, have a larger reactor capacity and promote the yield for producing 1,4-bis(dichloromethyl)tetrafluorobenzene. These aspects of Example 1 are better than those of the Comparative Example.
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.
TABLE 1
The reaction conditions and the results in Examples 1 to 16
Reaction
Reaction
TFTPA
SOCl 2
temperature
times
DCMTFB
Yield
Example
(g)
(g)
Catalyst (g)
Solvent (g)
(° C.)
(hours)
(g)
(%)
Remarks
1
15.45
63.37
DMF
3.01
Toluene
15.01
85-95
2.0
19.61
82.75
2
15.44
55.61
DMF
3.01
Chloroform
25.35
73-79
6.0
16.01
67.59
3
15.46
55.73
DMF
3.02
p-Xylene
14.81
90-104
3.0
14.26
60.13
4
15.46
56.51
DMF
3.00
Benzene
14.97
80-88
4.25
19.24
81.13
5
15.46
55.57
DMF
3.01
Acetonitrile
13.29
77-83
6.0
4.93
20.79
*1
6
15.45
55.45
DMF
3.01
Dioxane
17.55
91-99
4.0
17.49
73.80
7
15.45
58.60
DMF
3.01
1,2-Dichloroethane
21.18
81-87
4.0
17.25
72.79
8
15.45
55.57
DMF
3.01
Tetrachloromathane
27.34
75-81
6.0
16.09
67.89
9
15.45
55.45
DMF
3.03
Tetrahydrofuran
15.29
80-90
3.0
14.47
61.05
10
15.45
55.87
DMF
3.01
Nitrobenzene
20.44
106-108
2.0
13.62
57.47
11
15.45
55.80
DMF
3.01
o-Dichlorobenzene
22.24
94-106
2.0
17.41
73.45
12
15.45
55.52
DMF
3.02
—
—
85-90
3.0
6.38
26.92
13
15.45
55.93
DMF
3.01
—
—
85-90
29.0
2.16
9.12
*2
14
15.44
55.71
DMAC
3.00
Toluene
15.00
84-97
6.0
—
—
*3
15
15.44
55.45
NMP
3.00
Toluene
15.00
85-93
5.0
—
—
*4
16
15.44
56.74
DEF
3.01
Toluene
15.01
85-97
4.0
18.75
79.17
DMF: N,N-dimethylformamide
DMAC: dimethylacetamide
NMP: N-methylpyrrolidone
DEF: N,N-diethylformamide
*1: Solution turned black.
*2: TFTPA was of poor purity.
*3: Solution turned black and only little product was obtained.
*4: Solution turned black and only little product was obtained.
TABLE 2
The drawbacks and advantages of the present Comparative
Example compared with Example 1
Example 1
Comparative Example
Reaction Time
2 hours
24 hours
Yield
82.75%
59.33%
Reactor Capacity
Large
Small
Preliminary Process
Simple and
Complex
for Solvent
Convenient
Purification of
Recrystallization
Column
Product
Chromatography
Cost of Material
(For Synthesis of
Expensive (NTD:
Cheap (NTD: 51,000)
1 kg DCMTFB)
128,000)
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A method for producing 1,4-bis(dichloromethyl)tetrafluorobenzene is disclosed, which is achieved by reacting tetrafluoroterephthaldehyde, SOCl 2 and organic solvents. In the synthesis of 1,4-bis(dichloromethyl)-tetrafluorobenzene by adding formamides as catalyst, there are remarkable advantages which include shortening the reaction time; simplifying the synthesizing steps and raising the yield of the product.
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FIELD OF THE INVENTION
This invention relates to a water-conserving toilet, and, more particularly, to a water-conserving toilet having independently flushable urinal and main bowls.
BACKGROUND OF THE INVENTION
Water-conserving toilets are known in the art. One known type of water-conserving toilet is a "dual-flush" toilet, that is, a toilet that provides independently flushable urinal and main bowls for the disposal of liquid and solid wastes, respectively. The flushing apparatus associated with the urinal bowl, which is typically smaller than the main bowl, uses less water than that plumbed to the main bowl, hence saving water as compared to a one-bowl toilet that is flushed with the same volume of water, regardless of whether solid or liquid waste are to be flushed. Known dual-flush toilets, however, tend to be unduly complex, particularly with respect to the apparatus for flushing the urinal bowl.
U.S. Pat. No. 3,906,554, for example, discloses a dual-flush toilet that releases different amounts of flush water depending on whether solids or liquids are being flushed. Separate handles are provided for flushing the urinal and main bowls, each handle activating a different chain mechanism and cylindrical flush mechanism. This toilet is rather complex, appears to use more water than necessary to flush the urinal bowl, and the chain-pull system mechanism allows a user to waste water by simply holding the flush lever down.
Other dual-flush toilets use electric or manual valves connected to the water supply line to flush the urinal bowl. For example, disclosed in U.S. Pat. No. 5,448,784 is an electric solenoid that controls a valve for flushing the urinal bowl with water obtained directly from the water supply line. The performance of this system, and in particular the volume of water dispensed to flush the urinal bow, can vary due to variation in the pressure of the water in the supply line. Water from home well systems is typically supplied at a pressure that can vary during the drawing of the water from the well from between 25 and 60 or 70 psi, while municipal water can be supplied at pressures as high as 100 psi. Furthermore, such a toilet can be unsuitable for locations where electrical power is not provided, such as campsites, cottages, or the like.
As another example, disclosed in U.S. Pat. No. 5,301,374 is a manual valve connected to the water supply line for flushing the urinal bowl. Although this valve does not require electricity, it is subject to the drawbacks noted above regarding the use of water from the water supply line, can require intricate plumbing connections and components, and it, too, can be held open, wasting water.
Accordingly, it is an object of the present invention to address these and other drawbacks of the prior art, and to provide a simpler dual-flush toilet.
SUMMARY OF THE INVENTION
In one aspect, the invention provides an improved water-conserving toilet having independently flushable main and urinal bowls and a water storage tank for storing water for flushing the bowls. The improvement includes a manually operable flush assembly for flushing the urinal bowl. The flush assembly includes a pump mounted within the water storage tank and a manually operable handle accessible external to the water storage tank. The pump is in fluid communication with the water storage tank and the urinal bowl for pumping a selected amount of water from the water storage tank to the urinal bowl for flushing the urinal bowl upon manual operation of the handle.
In other aspects of the invention, the pump can include an internal bore in fluid communication with the interior of the tank and with the urinal bowl and a piston slidably disposed within the bore. The manually operable handle is coupled to the piston for sliding the piston for displacing water from the bore for flushing the urinal bowl. The pump can further include a pump base secured to the tank, a pump lid, a pull rod, and an extended pump housing substantially defining the bore, where the housing engages at a first end thereof the pump base and at a second end thereof the pump lid, and the pull rod couples the handle and the piston and extends through the pump lid.
The pump can also include a one-way valve that includes a passage extending through the piston along the bore, and a flexible valve element disposed with the piston for preventing fluid flow in one direction through the passage and allowing fluid flow in the opposite direction through the passage. The pump can be oriented vertically such that sliding the piston upward displaces water from a first bore volume above the piston for flushing the urinal bowl and draws water from the tank into second bore volume below the piston. The piston can be weighted such that, after release of the handle by a user, it is urged by gravity to travel downwardly. The one way valve passes fluid from the second bore volume to the first bore volume, filling the second bore volume and facilitating the downward travel of the piston. The invention thus advantageously provides an improved dual-flush toilet having a manually operable flush assembly for flushing the urinal bowl with predetermined amount of water that does not vary depending on water pressure, or on the amount of time a flush lever is actuated. Furthermore, operation of the invention need not require electricity. A minimal amount of water can be repeatably dispensed with each flush for enhancing water conservation. The flush assembly can easily manufactured and operated, and the amount of water used to flush the urinal bowl can readily be changed.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features, and advantages will be apparent from the following description of preferred embodiments and the accompanying drawings, in which:
FIG. 1 is a partly cross sectional, partly perspective view of the improved toilet according to the invention.
FIG. 2 is an enlarged cross sectional view of the pump assembly of the improved toilet of FIG. 1.
FIG. 3 is a cross sectional view of the main and urinal bowls of the improved toilet of FIG. 1.
FIG. 4 is a cross sectional view, taken along the section line 4--4 of FIG. 2, of the piston of FIG. 2.
FIG. 5 is a enlarged view of the piston assembly of FIG. 2, showing the piston, passages therethrough, and the valve element disposed with the piston.
FIG. 6 is an enlarged view of the piston assembly of FIG. 2 showing the valve element flexed away from the piston for allowing flow through the passages.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a toilet 10 includes a main bowl 12, a water storage tank 14, a urinal bowl 16, and a manually operable flush assembly 17 that includes a pump assembly 18 having a handle 19. The water storage tank 14 holds water for flushing the main and urinal bowls, 12 and 16, respectively, and supports a tank lid 20. The pump 18 is vertically oriented such that a user can flush the urinal bowl 16 by moving the pump handle 19 upwards. For clarity, neither a main bowl flush assembly for flushing the main bowl 12 nor the apparatus for maintaining a selected volume of water in the storage tank 14 are shown in FIG. 1. Such apparatus is well known in the art, and the present invention is not intended to be dependent on the type of apparatus used for flushing the main bowl 12 or for maintaining water in the storage tank 14.
FIG. 2 is a cross sectional view of the pump 18 of the improved toilet 10 of FIG. 1. The bottom of the water storage tank 14 mounts the pump base 22 of a pump assembly 18, the pump base in turn mounting the pump housing 24, which forms the bore 26 of a pump 18. The pump housing 24 can include outer threads at the bottom thereof for mating with inner threads of the pump base 22, and inner threads at the upper end for receiving threads on a pump lid 27 (threads not shown). A piston 28 is slidably disposed within the bore 26 and is secured to one end of a pull rod 30, with the handle 19 fixed to the other end of the pull rod 30. Apertures 34 and 35, in the pump lid 27 and tank lid 20, respectively, receive the pull rod 30, and a seal 36 is disposed within the tank lid aperture 35 to inhibit leakage along the pull rod 30.
The piston 28 divides the bore 26 into a first bore volume 38, located above the piston 28 and in fluid communication with the urinal bowl 16 via escape holes 40 and flush conduits 42A and 42B, and a second bore volume 48 below the piston 28, and which is in fluid communication with the storage tank 14 via holes 41. Pulling the handle 19 upward moves the piston 28 upward, forcing a flushing fluid, e.g., water, out of the escape holes 40 for flushing the urinal bowl 16 while drawing water from the storage tank 14, via the holes 41, for filling the second bore volume 48. As shown in FIG. 3, the flush conduits 42A and 42B are routed around the sides of the toilet rim 50 and include, respectively, water diffuser holes 52A and 52B, for flushing each side of the urinal bowl 16, as is also shown in FIG. 1. Water coats the urinal bowl 16, then flushes the contents down the drain tube conduit 54A, through a trap portion 57A and into a sewer line 58. Preferably, the drain conduit 54A is formed within the fixture, typically porcelain, that defines the main bowl 12, as illustrated in FIG. 3. A shroud 59A prevents the outlet of the conduit 54A from becoming clogged with solid waste. Optionally, an external conduit 54B can convey the contents of the urinal bowl 16 to the sewer line 58. The external conduit 54B can be a plastic tube, and is typically used when retrofitting an existing single flush toilet. The external conduit 54B forms a trap portion 57B where the conduit 54B bends around the main trap 56. The shroud 59B performs the same function as the shroud 59A.
As seen in FIGS. 4-6, the piston 28 can be part of a piston assembly 59 that includes a one way valve formed by an array of passages 60 that pass through the piston 28 in a direction along the bore and a valve element 62. The one-way valve allows water to pass from the second bore volume 48 to the first bore volume 38, but blocks flow in the other direction. For example, as the pullrod 30 pulls the piston 28 upward, the valve element 62 is forced against the piston and prevents water from moving through the passages 60. When the piston 28 reaches the upmost end of its travel in the bore 26, the handle 19 (shown in FIG. 2) is released. The piston 28 can be weighted such that gravity pulls the piston 28 downward with sufficient force to force the one way valve open, e.g., the valve element 62 is flexed away from the piston 28, as shown in FIG. 6, such that the passages 60 allow fluid flow from the second bore volume 48 to the first bore volume 38, facilitating the downward displacement of the piston 28 and adding water to the first bore volume 38. The piston 28 comes to rest at the bottom of the bore 26.
Preferably, the pump 18 delivers between 75 and 200 milliliters (ml) water to the urinal bowl 16 per flush; more preferably the pump delivers between 75 and 150 ml of water to the urinal bowl 16 per flush, and most preferably, the pump delivers approximately 100 ml to the urinal bowl 16 per flush. Unlike the typical main bowl 12, the urinal bowl does not maintain a constant level of water in the bowl, and is usually empty. In one embodiment, the piston 28 is a metal disc having a diameter (indicated by reference numeral 70 in FIG. 4) of approximately 1 cm and travels approximately 50 cm along the bore 26. The amount of water flushed can be varied by changing the length of the pull rod 30.
The urinal bowl 16, drain tube 54 and main bowl 12 can form a unitary structure, typically of porcelain, or, alternatively, the urinal bowl 16 and drain tube 54 can be made of plastic and fitted to a porcelain main bowl 12. The urinal bowl 16, as well as the drain tube 54, can be adapted for removable and replaceable installation with the main bowl 12. For example, the urinal bowl 16 can be held into the main bowl 12 using a stainless steel wire cage (not shown) that supports the bowl 16 and fits over the rim of the main bowl 12.
It will thus be seen that the invention efficiently attains the objects set forth above, among those made apparent from the preceding description. Because certain changes may be made in the above constructions without departing from the scope of the invention, it is intended that all matter presented in the above description or shown in the accompanying drawings be interpreted as illustrative and not as limiting. For example, as understood by one of ordinary skill in the art, in light of the disclosure herein, other types of manual pumps, such as a rotary pumps, or bladder-type pumps that pump fluid by compressing a refillable bladder, are known in the art, and such variations are considered within the scope of the invention. As understood by one of ordinary skill, the pump need not be oriented vertically, and furthermore, the one-way valve can be independent of the piston 28, obviating the need for passages 60 in the piston 28. For example, the one way valve can be disposed in an external 24 fluid interconnection, such as in tubing, between the bottom and top of the bore 26. Alternatively, the piston 28 may be loosely fitted to the bore 26 such that rapid movement of the piston 28 upward flushes most of the water from the first bore volume 38 to urinal bowl 16, yet sufficient water flows through gaps 75 in FIG. 6 between the piston 28 and the bore 26 for the piston to travel downwardly to the bottom of the bore 26 after release of the handle 19 after flushing, thereby filling the first bore volume 38 with water.
It is also understood that the following claims are to cover all 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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Disclosed is an improved water-conserving toilet having independently flushable main and urinal bowls, a water storage tank for storing water for flushing the bowls, and a manually operable flush assembly for flushing the urinal bowl. The flush assembly includes a pump mounted within the water storage tank and a manually operable handle accessible external to the water storage tank. The pump is in fluid communication with the water storage tank and the urinal bowl for pumping a selected amount of water from the water storage tank to the urinal bowl for flushing the urinal bowl upon manual operation of the handle.
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BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention is directed to a non-rectangular obelisk style columbarium and in particular to a columbarium having an obelisk section and an ossuary with five sides.
Description of the Prior Art
[0002] Cremation followed by inurnment has become an increasingly popular option over traditional burial. Inurnment provides for the use of smaller niches rather than full size crypts as a final resting place and for disposition of remains in a dignified manner. Columbaria in various shapes and sizes have been developed that have proven to be useful and adapted to a wide variety of location and needs.
[0003] However, due to the smaller size, niches have a smaller surface to personalize or memorialize information for the deceased and may limit the ability to include flags, symbols or other insignia on each niche. It can be appreciated that cemeteries for veterans could benefit from a columbarium that could recognize the military service of the deceased whose cremated remains are put to rest in the niches. The five branches of the U.S. military, the Army, Navy, Marines, Air Force and the Coast Guard are often recognized together. However, having five zones or sides of monuments or other memorials to recognize each of the five service branches has special design requirements as compared to more conventional rectangular or even round construction.
[0004] In addition to traditional niches, even lower cost options may still be desired such as an ossuary, with a single repository. An ossuary may still provide for a dignified interment of remains and provide a record of the individuals whose remains are inurned in the ossuary to indicate their final resting place. For respectful internment, a delivery system for depositing the cremated remains in a dignified is needed. Furthermore, it can be appreciated that a plaque or other memorial must be weather proof and long lasting. It can further be appreciated that such an ossuary may be specifically suited for the five service branches of the U.S. Military with a five sided monument.
[0005] It can therefore be seen that an improved inurnment system that provides for respectful delivery and permanent storage of cremated remains in a dignified and reverent manner is needed. Moreover, such a system may be suited for use at a veteran's cemetery or memorial and reflect the five service branches of the U.S. Military. Such a system may also be utilized with an ossuary and provide appropriate delivery and a record of the individuals' remains. The present invention addresses these as well as other problems associated with interment systems.
SUMMARY OF THE INVENTION
[0006] A columbarium is configured in one embodiment with an obelisk mounted on a base. The obelisk forms individual niches that are covered with shutters attached with hardware that allows removal and replacement, as explained hereinafter. A sloped cap covers the top of the obelisk.
[0007] In the embodiment shown, the obelisk and the base each have five sides. It can be appreciated that should the columbarium be used to inurn remains for those in the military, each of the five sides may include a military branch insignia. Such an insignia may represent the five branches of the military, the army, marines, air force, navy and coast guard. It can also be appreciated that remains of service personnel may be placed in the niches corresponding to the insignia in the branch in which they served.
[0008] In the embodiment shown, the obelisk is five sided and a frame includes a center hub that is pentagon shaped and includes five framework trusses running vertically along each base of the hub and extending radially outward. The trusses form a pentagon shaped obelisk and define niches. The trusses provide for mounting the walls, floor and ceiling of the individual niches. Therefore, the niches of the obelisk have a generally triangular shape and narrow from the face of each niche towards the center hub. Each truss includes an inner vertical truss member and horizontal truss members extend outward from the vertical truss member. The horizontal members progressively decrease in length from the bottommost member to the topmost member to mirror the inward slant of the sides of the obelisk. An outer truss member slants slightly inward and forms the outermost side of each truss. Angled cross members extend upward and outward between horizontal truss members and between the inner truss member and outer truss member of each truss assembly. The trusses along with the center hub form a sturdy and rigid framework that achieves a pentagon shaped obelisk having a pleasant appearance. A flagpole may be included and is supported by a support assembly mounted at the top of the obelisk.
[0009] The obelisk frame is securely attached to the base with a mounting assembly. A vertical side plate and horizontal plate attach to the lowermost horizontal truss member and the outer truss member. Anchor rods extend through orifices in the horizontal plate and the horizontal plate to secure the obelisk columbarium to the base.
[0010] A second embodiment of the present invention includes a combined columbarium and ossuary unit. The columbarium includes an obelisk mounted onto a lower columbarium and ossuary unit.
[0011] The lower columbarium ossuary unit includes a cover, a vault and multiple niches dispersed around a periphery of the columbarium and ossuary unit. An ossuary cover section slants downward and outward from the bottom of the obelisk to the periphery of the lower columbarium ossuary unit. The cover section forms a memorial band with cover elements mounted at a slant between the bottom of the obelisk and the periphery of the lower unit. The bottom of the obelisk includes access niches that provide access to the ossuary vault.
[0012] Each of the niches includes shutters and mounting hardware. The niches also include side walls that extend toward one another from the front shutter to define niches having a triangular cross section for the niches in the obelisk. The niches in the combination ossuary and columbarium unit form substantially rectangular niches for the center portions of the sides of the unit while the niches at the corners of the five sided unit have a cross section narrowing from outer to inner sides. The mounting hardware is preferably hidden type hardware such as shown in U.S. Pat. Nos. 8,438,794 & 8,782,969.
[0013] The vault provides for disposal of cremated remains in a shared communal repository of the ossuary. Such communal inurnment provides for reduced costs while maintaining dignity and respect. Moreover, cremated remains inurned in such a manner may utilize flexible urns that provides for delivery to the vault while maintaining separation of the individual remains.
[0014] To deposit a flexible urn in the vault, access is provided through the access niches at the lower portion of the obelisk. The front shutter is removed from one of the access niches. The access niches have an opening bottom that provides for delivering the flexible urns into the vault area. A slide, chute or conveyor system may also be utilized to deliver the flexible urns into the vault. The vault is separate from the individual niches that are spaced about the periphery of the vault. It can be appreciated that the names for those whose final resting places are in the vault should have a dignified memorial. Names and other information may be placed on the cover elements. Moreover, other spaces for a memorial such as a band around the base or pavers or other ground markers around the columbarium and ossuary might also be utilized for such information. The vault may be configured as a single space or may be divided into five sections so that individuals of each military branch may share a respective communal repository.
[0015] These features of novelty and various other advantages that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings that form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Referring now to the drawings, wherein like reference letters and numerals indicate corresponding structure throughout the several views:
[0017] FIG. 1 is an elevational view of a first embodiment of a five sided columbarium according to the principles of the present invention;
[0018] FIG. 2 is a top plan view of the five sided columbarium shown in FIG. 1 ;
[0019] FIG. 3 is a top plan view of a mounting assembly for the obelisk of the five sided columbarium shown in FIG. 1 ;
[0020] FIG. 4 is a top plan view of the framework for the five sided columbarium shown in FIG. 1 ;
[0021] FIG. 5 is a side elevational view of the framework shown in FIG. 4 ;
[0022] FIG. 6 is a side elevational view of a flag support for the framework shown in FIG. 5 ;
[0023] FIG. 7 is a top plan view of the flag support shown in FIG. 6 ;
[0024] FIG. 8 is a side elevational view of a base mount for the framework shown in FIG. 4 ;
[0025] FIG. 9 is a top plan view of the base mount shown in FIG. 8 ;
[0026] FIG. 10 is a side elevational view of a second embodiment of a five side columbarium including an ossuary according to the principles of the present invention;
[0027] FIG. 11 is a side sectional view of a framework for the columbarium shown in FIG. 10 ;
[0028] FIG. 12 is a top plan view of the columbarium shown in FIG. 10 ;
[0029] FIG. 13 is a first partial side sectional view of the columbarium and ossuary shown in FIG. 10 ;
[0030] FIG. 14 is a second partial side sectional view of the columbarium and ossuary shown in FIG. 10 ;
[0031] FIG. 15 is a detail view of lock hardware for a top row of niches for the columbarium shown in FIG. 10 ;
[0032] FIG. 16 is a detail view of lock hardware for a top center niche for the columbarium shown in FIG. 10 ;
[0033] FIG. 17 is a detail view of support hardware for bottom corner niches for the columbarium shown in FIG. 10 ;
[0034] FIG. 18 is a detail view of a base anchor and bracket for the columbarium shown in FIG. 10 ;
[0035] FIG. 19 is a detail view of a capstone anchor for the columbarium shown in FIG. 10 ;
[0036] FIG. 20 is a side elevational view of a flexible cremains container for use with the columbarium and ossuary system shown in FIG. 10 ;
[0037] FIG. 21 is a side sectional view taken along line 21 - 21 of FIG. 20 ;
[0038] FIG. 22 is a perspective view of a deliver chute assembly for the columbarium and ossuary shown in FIG. 10 ;
[0039] FIG. 23 is a side elevational view of the delivery chute assembly shown in FIG. 22 ;
[0040] FIG. 24 is an end elevational view of the delivery chute assembly shown in FIG. 22 ;
[0041] FIG. 25 is a partial side sectional view of the delivery chute assembly mounted to the columbarium and ossuary shown in FIG. 10 ;
[0042] FIG. 26 is a detail view of the delivery chute assembly mounting to the columbarium and ossuary shown in FIG. 25 ; and
[0043] FIG. 27 is a perspective view of a triangular urn for mounting in a niche of the obelisk columbarium shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0044] Referring now to the drawings and in particular to FIGS. 1 and 2 , there is shown a first embodiment of an example columbarium, generally designated ( 100 ). The columbarium ( 100 ) is configured with an obelisk ( 102 ) mounted on a base ( 104 ). A sloped cap ( 106 ) is at the top of the obelisk ( 102 ). The obelisk ( 102 ) forms individual niches ( 110 ) that are covered with shutters ( 120 ), typically decorative stone shutters, held in place by hardware that allows removal and replacement, as explained hereinafter. Examples of such hidden shutter mounting hardware are shown for example in U.S. Pat. No. 8,438,794 and U.S. Pat. No. 8,782,969.
[0045] In the embodiment shown, the obelisk ( 102 ) and the base ( 104 ) each have five sides with a periphery formed as a pentagon. It can be appreciated that should the columbarium ( 100 ) be used to inurn remains for those in the military, each of the five sides may include a respective military branch insignia ( 190 ). Such an insignia may represent one of the five branches of the military, the army, marines, air force, navy and coast guard. It can also be appreciated that remains of service personnel may be placed in the niches ( 110 ) corresponding to the insignia of the branch in which they served.
[0046] Referring now to FIGS. 3, 4 and 5 , the obelisk columbarium ( 102 ) includes a frame ( 140 ). The obelisk ( 102 ) is five sided and the frame ( 140 ) includes a center hub ( 142 ) acting as a central spine that is pentagon shaped and includes five framework trusses ( 150 ) mounted along each face of the hub ( 142 ) and radiating outward in a star-like configuration. The trusses ( 150 ) form an obelisk frame and define five columns of individual niches ( 110 ) between the trusses ( 150 ). The trusses ( 150 ) provide for mounting the side walls ( 124 ) and shared floor and ceiling elements ( 126 ) of the niches ( 110 ), such as shown more clearly in FIG. 13 . The niches ( 110 ) of the obelisk section ( 102 ) each have a generally triangular shape and narrow from the face of each niche ( 110 ) towards the center hub ( 142 ). Each truss ( 150 ) includes an inner vertical truss member ( 156 ). Horizontal truss members ( 154 ) extend outward from the vertical truss member ( 156 ). The horizontal members ( 154 ) progressively decrease in length from the bottommost member to the topmost member to mirror the slight inward taper of the sides of the obelisk. An outer truss member ( 152 ) slants slightly inward and forms the outermost side of each truss ( 150 ). Angled truss cross members ( 158 ) extend upward and outward between horizontal truss members ( 154 ) and between the inner truss member ( 156 ) and outer truss member ( 152 ). The trusses ( 150 ) along with the center frame hub ( 142 ) form a sturdy and rigid framework ( 140 ) that achieves a pentagon shaped obelisk having a pleasing appearance.
[0047] As shown in FIGS. 6 and 7 , a flagpole ( 168 ) is held by a support assembly mounted at the top of the obelisk ( 102 ). The support assembly includes vertical plates ( 160 ) mounted to the inner vertical truss members ( 156 ). Mounting bolts ( 162 ) secure the flagpole to the truss members ( 156 ). A bearing plate ( 164 ) supports a lower end of the flagpole ( 168 ) as shown in FIG. 6 . Welded together plates ( 166 ) form a socket with the bearing plate ( 164 ) that receives the bottom of the flagpole ( 168 ) and maintains the flagpole in a substantially vertical orientation.
[0048] Referring now to FIGS. 5, 8 and 9 , the obelisk frame ( 140 ) is securely attached to the base ( 104 ) with a mounting assembly ( 180 ). A vertical side plate ( 186 ) and horizontal plate ( 188 ) attach to the lowermost horizontal truss member ( 154 ) and the outer truss member ( 152 ). Anchor rods ( 184 ) extend through orifices in the horizontal plate ( 188 ) and the horizontal plate ( 188 ) to secure the obelisk columbarium ( 102 ) to the base ( 104 ).
[0049] As the niches ( 110 ) of the obelisk section ( 102 ) have a generally triangular shape and narrow from the face of each niche ( 110 ) towards the center, conventional cylindrical urns may be difficult to fit in the smaller cross-sections of uppermost tiers of niches ( 110 ). As shown in FIG. 27 , urns ( 280 ) having a triangular cross-section may be utilized. The urn ( 280 ) has rectangular sides ( 282 ) and triangular ends ( 284 ). One of the sides ( 282 ) or ends ( 284 ) may act as a cover that may be opened to allow insertion of cremains into the urn ( 280 ). The triangular cross-section better matches the cross-section of the upper niches ( 110 ) so that the urn ( 280 ) has sufficient capacity for the cremated remains while still fitting into the niches ( 110 ).
[0050] Referring now to FIGS. 10-14 , a second embodiment of the present invention includes a combined columbarium and ossuary system ( 200 ). The columbarium includes an obelisk ( 202 ) mounted onto a lower columbarium and ossuary unit ( 204 ). The obelisk ( 202 ) has a construction substantially similar to that shown in FIGS. 1-9 .
[0051] The lower columbarium ossuary unit includes a cover ( 212 ), a vault ( 208 ) and multiple niches ( 220 ) dispersed around a periphery of the columbarium and ossuary unit ( 204 ). An ossuary cover section ( 212 ) slants downward and outward from the bottom of the obelisk ( 202 ) to the periphery of the lower columbarium and ossuary unit ( 204 ). The cover section ( 212 ) forms a surface that serves as a memorial band with cover elements ( 214 ) mounted at a downward and outward slant between the bottom of the obelisk and the periphery of the lower unit ( 204 ). The bottom of the obelisk ( 202 ) includes access niches ( 250 ) that provide access to the ossuary vault ( 208 ).
[0052] As with the embodiment for the obelisk ( 102 ) each of the niches ( 220 ) includes shutters ( 120 ) and mounting hardware ( 122 ). The niches ( 220 ) also include side walls ( 124 ) that extend toward one another from the front shutter to define niches having a triangular cross section for the niches in the obelisk ( 202 ). The niches ( 220 ) in the combination ossuary and columbarium unit ( 204 ) form substantially rectangular niches for the center portions of the sides of the unit ( 204 ) while the niches at the corners of the five sided unit ( 204 ) have a quadrilateral cross section narrowing from outer to inner sides. The mounting hardware ( 122 ) may be hidden type hardware such as shown in U.S. Pat. Nos. 8,438,794 and 8,782,969.
[0053] The vault ( 208 ) provides for disposal of cremated remains in a shared communal repository of the ossuary ( 204 ). Moreover, cremated remains inurned in such a manner may utilize a flexible urn ( 1000 ) that provides for delivery to the vault ( 208 ) while maintaining separation of the individual remains. Such communal inurnment provides for reduced costs while maintaining dignity and respect. The vault ( 208 ) may be a single repository space in which remains in flexible urns ( 1000 ) are received. If preferred, the vault ( 208 ) may include radially extending partition walls ( 222 ) that separate the vault ( 208 ) into five distinct chambers corresponding to each of the military branches. An outer vault wall ( 224 ) separates the niches ( 220 ) from the vault ( 208 ). The vault ( 208 ) may have a cast concrete construction or may be utilize weatherproof materials similar to that used for the niches. The configuration is generally adapted for the installation site and the particular application requirements.
[0054] A framework is shown in FIG. 11 that extends substantially vertically from the obelisk ( 202 ) down through the ossuary ( 204 ) (as shown in phantom in FIG. 14 ). The framework includes five trusses ( 240 ) and positioned as at section line 14 of FIG. 12 . Each truss ( 240 ) includes an outer slightly angled truss member ( 242 ), an inner truss member ( 244 ), horizontal truss members ( 246 ) and cross truss members ( 248 ).
[0055] Referring now to FIGS. 20 and 21 , the ossuary is specifically adapted for receiving flexible type urns ( 1000 ). The flexible urn ( 1000 ) includes a closable bag portion ( 1002 ). In a preferred embodiment, the bag portion ( 1002 ) includes an impermeable liner ( 1004 ) and an outer decorative layer ( 1006 ), as shown in FIG. 21 . The outer decorative layer ( 1006 ) may also include an inner fabric liner ( 1010 ). The outer decorative layer ( 1006 ) may be made from satin, velvet or other appropriate fabrics providing a dignified appearance. Moreover, the outer layer ( 1006 ) may be embroidered and/or may include other graphics, such as religious symbols, as may be desired. The impermeable layer ( 1004 ) is sealed so that the cremated remains are safely contained within the impermeable liner ( 1004 ) of the bag ( 1002 ). A decorative cord or other closure ( 1008 ) closes the outer bag layer ( 1006 ) around the impermeable layer ( 1004 ) and provides protection of the impermeable layer ( 1004 ) to avoid tearing, puncture or other damage and prevents any cremated remains from escaping from the flexible-type urn ( 1000 ).
[0056] In one embodiment, to deposit a flexible urn ( 1000 ) containing remains in the vault ( 208 ), access is provided through one of the access niches ( 250 ) at the lower portion of the obelisk ( 202 ). The front shutter is removed from one of the access niches ( 250 ). The access niches ( 250 ) each have an opening in the bottom that provides for delivering the flexible urns ( 1000 ) into the vault area ( 208 ). The flexible urn ( 1000 ) may simply be placed in the access niche and then drops into the vault ( 208 ). As explained hereinafter, a slide or chute may also be utilized to deliver the flexible urns ( 1000 ) into the vault ( 208 ). The vault ( 208 ) is separate from the individual niches ( 220 ) that are spaced about the periphery of the vault ( 208 ), as shown for example in FIG. 13 . It can be appreciated that the names for those whose remains are in the vault ( 208 ) should have a dignified memorial. Names and other information may be placed on the cover elements ( 214 ). Moreover, if additional space is needed, a band around the base ( 218 ) or pavers or other ground markers around the columbarium and ossuary system ( 200 ) might also be utilized for such information.
[0057] Referring now to FIGS. 15-19 , the hardware for various cap stones and other exterior stonework is shown. The locking device and hardware for the top row of niches is shown in FIG. 15 . The mounting hardware includes a lock clip ( 128 ) engaging a lock bracket ( 130 ). The lock bracket ( 130 ) mounts to the flange formed on the front of the shelf ( 126 ). The lock bracket ( 130 ) provides for adjustment with a rotatable set screw to adjust the position of the shutter relative to the position of the shutter.
[0058] Referring to FIG. 16 , locking hardware ( 122 ) at the top center of niches also includes a lock set ( 128 ) and lock bracket ( 130 ) mounting to the shelf ( 126 ). An inner closeable panel ( 118 ) forms a further barrier for each niche. The shutters ( 120 ) are adjustable through the lock bracket.
[0059] Referring now to FIG. 17 , the bottom corners of the niche front include a niche adjustment assembly ( 132 ) with an adjustable bolt that can engage a swivel socket ( 134 ) having a bolt engaging a shelf flange ( 136 ). The bolt of the niche adjuster provides for moving the position of the shutters ( 120 ) vertically while the swivel socket ( 134 ) provides for lateral positioning of the shutters ( 120 ).
[0060] Referring now to FIG. 18 , the vertical vault partition walls ( 222 ) that may form subdivisions within the vault ( 208 ) are supported on a bracket ( 232 ). The bracket is engaged by anchors ( 230 ) that extend into the foundation ( 216 ). The vault partition wall ( 222 ) also accepts bottom shelves ( 236 ).
[0061] Referring to FIG. 19 , the cap stone ( 106 ) is mounted with anchors ( 170 ) engaging brackets ( 172 ) that engage the walls ( 124 ) that divide the niches.
[0062] Referring now to FIGS. 22-25 , there is shown a delivery system ( 260 ). The delivery system is configured to deliver the flexible urns ( 1000 ) to the ossuary vault ( 208 ). Rather than simply depositing flexible urns through an access niche, a delivery system that requires actuation by tilting up to allow a flexible urn to slide along a chute ( 262 ) may be utilized. Family and friends may participate in the actuation of delivery system ( 260 ), which may be preferred. The delivery system ( 260 ) includes the chute ( 262 ) that is removably attachable to the obelisk ( 202 ). The mounting assembly ( 268 ) removably attaches to the front shelf flange ( 136 ) when the shutter is removed to one of the access niches ( 250 ). A support ( 264 ) extends downward from the chute ( 262 ) and rests against the ossuary cover section ( 212 ). The delivery system also includes a handle (( 266 ) on the support ( 264 ) for lifting the chute ( 262 ). The end of the chute ( 262 ) opposite the mounting assembly ( 268 ) includes an endwall ( 274 ) that holds a flexible urn in the chute ( 262 ) until the chute ( 262 ) is lifted upward and tilted to allow the flexible urn to slide down the chute ( 262 ). The endwall may include an insignia ( 276 ) such as a medallion and be interchangeable with other endwalls ( 274 ) having different insignia ( 276 ). For example the insignia could be for each of the five U.S. military service branches so that the correct insignia is used to match the particular section of the ossuary representing that branch. The mounting assembly includes a bolt assembly ( 270 ) including a bolt and nut that fit in a slot shelf flange ( 136 ). The mounting assembly could also include other mounting elements that provide for removably mounting the delivery system ( 260 ). A hinge ( 272 ) provide for rotating of the chute about a horizontal axis.
[0063] To deposit a flexible urn ( 1000 ) with the delivery system ( 260 ), the shutter ( 120 ) for an access niche ( 250 ) corresponding to the correct service branch is removed. The mounting assembly ( 268 ) is then attached to the shelf flange ( 136 ). The endwall ( 274 ) having the correct insignia ( 276 ) is slid into the end of the chute ( 262 ). The chute ( 262 ) may be lowered so that the support ( 264 ) rests on the ossuary cover ( 212 ). A flexible urn may then be placed at the end of the chute ( 262 ) against the endwall ( 274 ). When the flexible urn is to be delivered, the handle ( 266 ) is lifted and the chute ( 262 ) rotates about the hinge ( 272 ). When the chute ( 262 ) is at a sufficiently steep angle, the flexible urn will slide down the chute ( 262 ) and through the opening in the bottom of the access niche ( 250 ) and into the vault ( 208 ). The chute may then be lowered and the delivery system ( 260 ) may be removed so that the shutter ( 120 ) to the access niche ( 250 ) may be replaced.
[0064] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A columbarium and ossuary system includes a five side columbarium. An obelisk like section includes a vertically extending central frame member. The central frame member has frame assemblies radiating outward from the central frame member. A plurality of niches are disposed about the central hub and supported by the hub. Each of the niches has an outer opening and sides abutting adjacent ones of the frame assemblies and converging from the outer opening towards the central hub. The lower section having a plurality of niches surrounding a center ossuary. A delivery chute is detachably mountable to the columbarium for pivoting to tilt the chute and deliver flexible urns to the ossuary.
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RELATED APPLICATIONS
This application is a 35 U.S.C. §371 national phase entry of PCT Application PCT/GB2009/001364, filed May 29, 2009, and published in English on Dec. 3, 2009, as International Publication No. WO 2009/144478, and which claims the benefit of Great Britain Application No. 0809761.0, filed May 29, 2008, the disclosure of each of which is incorporated herein by reference in its entirety.
STATEMENT REGARDING ELECTRONIC FILING OF A SEQUENCE LISTING
A Sequence Listing in ASCII text format, submitted under 37 C.F.R. §1.821, entitled 9013-107_ST25.txt, 10,848 bytes in size, generated on Jan. 10, 2013 and filed via EFS-Web, is provided in lieu of a paper copy. This Sequence Listing is hereby incorporated herein by reference into the specification for its disclosures.
FIELD OF THE INVENTION
The present invention relates generally to Mycobacterial infections and provides a method of diagnosing infections of Mycobacterium avium subspecies paratuberculosis (Map), the causative agent of Johne's disease, as well as kits for use in such diagnosis and vaccines.
BACKGROUND TO THE INVENTION
Johne's disease, or paratuberculosis, is a fatal chronic granulomatous enteritis of animals caused by Map. The disease is characterised by severe emaciation, loss of body condition and in some species diarrhea. The disease is mainly spread through the ingestion of faeces from an infected animal. Infected animals can also pass on the infection in colostrum or milk and across the placenta to unborn animals. It is generally believed that young animals are more susceptible to infection than adults. Following infection there is a long incubation period of 2 to 4 years during which time the animal may show no signs of clinical disease and may shed Map intermittently. Such animals are often described as “subclinically infected” and act as “carriers” of the disease. The disease is usually introduced to a farm through the purchase of subclinically infected stock.
Johne's disease occurs worldwide and causes considerable economic losses through decreased productivity, increased wastage of adult animals as well as the cost of control, monitoring and diagnosis. There is also some controversy as to whether Map is involved in the development of Crohn's disease. Contaminated milk would constitute a source of infection and there is a drive towards elimination of Map from the food chain.
The diagnosis of Johne's disease is problematic and there is no single diagnostic test that can detect all stages of the disease. Subclinically infected animals are particularly difficult to diagnose and results of currently available tests may be negative. The most commonly used diagnostic test is the serum Enzyme Linked Immunosorbent Assay (ELISA). This detects circulating antibodies to Map in infected animals. It will detect animals in the later stages of the disease, where clinical symptoms are often present, which are generally those shedding large numbers of Map. It will not, however, detect animals in the early stages of infection, typified as being subclinical where the antibody levels are below the sensitivity threshold of the test. The other most commonly used tests are faecal smears and bacteriological culture. Faecal smears detect the presence of acid-fast bacteria in the faeces and probably only detect a third of the infected animals in a herd/flock. Bacteriological culture is more sensitive and specific but takes 6 weeks or more which is less than desirable. Moreover, low shedders can sometimes be difficult to detect and subclinically infected animals are often missed because they shed intermittently.
PCR-based tests are not used routinely as yet but are available for detecting Map in milk, blood or faeces. Also there are particular problems with the application of PCR tests to milk, blood and faecal samples. There is therefore a requirement for a test that can detect early infection and subclinically infected animals.
It is amongst the objects of the present invention to obviate and/or mitigate at least one of the aforementioned disadvantages.
SUMMARY OF THE INVENTION
The present invention is based on the identification of Map antigens which are capable of causing a cell-mediated immune response.
In the first aspect there is provided a method of detecting a cell-mediated immune response to one or more purified antigens of Map in an animal, the method comprising the step of:
detection of a cell-mediated immune response by measuring the extent of lymphocyte activation and/or proliferation in response to said one or more purified antigens of Map.
For example, the cell-mediated immune response may be measured by detecting a level of cytokine such as interferon gamma (IFN-γ), tumour necrosis factor alpha (TNF-α), transforming growth factor beta (TGF-β), interleukins (IL-2, IL-6, IL-10, IL-12, IL-17) and granulocyte-macrophage colony-stimulating factor (GM-CSF) using antibodies or indirectly from mRNA by RT-PCR or microarray. Proliferation may be assayed by incorporation of labelled precursors of DNA or protein into the lymphocytes undergoing proliferation.
The method may be carried out on a blood sample, or a fraction thereof, isolated from a subject, or may be a skin test, such as a delayed hypersensitivity skin test.
Conveniently the blood sample is a whole blood sample obtained from the animal to be tested. Alternatively purified or semi-purified fractions of whole blood, which comprise lymphocytes and monocytes may be employed. Typical amounts of sample required for testing may be 10 μl to 10 ml. Advantageously, a single blood sample would enable testing of an animal's responsiveness to a wide variety of antigens and therefore diagnosis of other diseases.
It will be appreciated that the sample of blood will generally be incubated with said one or more purified Map antigens, for a period of time (e.g. from 1 min to 96 hours but typically from 4 to 72 hours) so as to allow any cell-mediated response (e.g. IFN-γ production), as a result of said one or more purified Map antigens, to develop. IFN-γ is produced from T cells present in the sample of blood which are stimulated to produce IFN-γ by said one or more purified Map antigens.
Unlike other similar cell-mediated tests which are known for detecting animals which are infected with, for example, Mycobacterium bovis and/or Mycobacterium tuberculosis using uncharacterised, what are termed “purified protein derivatives” (PPD) or “protoplasmic antigen” (PPA), the present invention is based upon the use of purified antigens which are expected as being specific. Map-specific antigens are defined here as proteins or fragments thereof that are expressed by Map and elicit an immune response in animals infected by Map which is greater than that elicited by animals infected by other closely related subspecies of Mycobacterium avium ( Mycobacterium avium subspecies avium (Maa) and Mycobacterium avium subspecies silvaticum ). In this manner, the present methods may be carried out on animals or herds of animals exposed to other mycobacterial infections including environmental mycobacteria such that a clear distinction can be obtained. Thus, the one or more Map-specific antigens of the present invention will generally be chosen so as to be highly specific for Map and/or to display little or no cross-reactivity with other related species such as other subspecies of Mycobacterium avium, Mycobacterium bovis and/or Mycobacterium tuberculosis.
Said one or more purified Map-specific antigens may be identified by way of electrophoretically separating the proteome of a Map isolate and comparing this to a highly related species of Mycobacterium , such as Maa, in order to identify proteins which are unique to Map and/or differentially expressed. Typically electrophoretic separation may be conducted using a 2-D gel electrophoresis technique well known in the art (see for example Richard Simpson—Proteins and Proteomics: A Laboratory Manual published by Cold Spring Harbor Laboratory Press U.S. 2002) and the proteome of a Map isolate compared to the proteome of the other subspecies. In this manner uniquely and/or differentially expressed proteins can be identified for further study and used as an antigen in accordance with the present invention.
In this manner, the present inventors have identified over 30 proteins, which may be of use individually and/or in combination in a method of the present invention. Details of the proteins may be found in attached Table 1. Preferably, the method of the present invention uses two or more Map-specific antigens, such as 3, 4, 5, 6 or more antigens. It is to be understood that a purified antigen may be a whole protein, or immunogenic protein fragment. Such immunogenic protein fragments must be capable of causing a cell-mediated immune response. Once a whole protein has been identified as being capable of eliciting an appropriate cell-mediated immune response, it is straightforward to create protein fragments of said protein and identify whether or not suitable fragments, are also capable of eliciting a cell-mediated immune response.
Four particularly preferred Map proteins, of which one or more may be used in the present invention, are identified herein as MAP0268c, MAP1297, MAP1365 and MAP3651c and correspond to proteins having the following NCBI database accession numbers, respectively AAS02585, AAS03614, AAS03682 and AAS06201. The sequences identified in the above accessions are from a Map isolate K-10 (Li et al., 2005) and are shown in FIGS. 3-6 . It will be understood that minor differences in protein sequence may be identified from one Map isolate to another and as such the proteins identified herein may not be identical in sequence to the corresponding Map K-10 protein identified in the protein database. However, the skilled addressee would be able to easily ascertain if the proteins correspond to one another. In this regard the Map-specific proteins or immunogenic fragments thereof of the present invention will be at least 95%, 98% or 99% identical to a Map K-10 protein or fragment as shown in FIGS. 3-6 .
The present invention extends to a process for the purification of recombinant Map-specific proteins from bacterial or eukaryotic expression systems by the cloning and expression in a host cell such as Eschericia coli . (see for example Sambrook: Molecular cloning: A laboratory manual (3 rd Ed) Cold Spring Harbour Laboratory Press. 2001).
In a further aspect, the present invention provides use of one or more purified Map-specific proteins or immunogenic fragments thereof in a method of diagnosing Map infection in an animal.
Said Map-specific protein or immunogenic fragment thereof is/are preferably one or more of the proteins identified herein, such as those designated MAP0268c, MAP1297, MAP1365 and MAP3651c or immunogenic fragment thereof; or a protein or protein fragment displaying substantial identity with a protein or fragment thereof as shown in FIGS. 3-6 .
There is also provided a kit for carrying out a method of diagnosing a Map infection, the kit comprising one or more purified Map-specific proteins or immunogenic fragments thereof capable of eliciting a cell-mediated immune response. Such a kit may further comprise other reagents for use in the method of diagnosis, such as an anti-IFN-γ antibody.
This invention also provides vaccines and immunogenic formulations which may be used to protect animals, particularly cattle, from MAP infection. In one aspect, the present invention provides one or more of the MAP antigens described herein (or fragments, analogues or derivatives thereof) for raising an immune response in an animal.
In a yet further aspect, the present invention provides an immunogenic formulation comprising one or more of the MAP antigens described herein (or fragments, analogues or derivatives thereof).
In one embodiment, the vaccines and immunogenic formulations described herein comprise combinations of two more of the MAP antigens (or fragments, analogues or derivatives thereof) described herein.
One of skill in this field will appreciate that immunogenic formulations of the type suitable for use as a vaccine may be formulated for oral or topical administration. Additionally or alternatively, the immunogenic formulations may be formulated for direct injection, preferably intraperitoneal or intramuscular injection.
The present invention also provides a method of vaccinating or immunising an animal against a MAP infection, said method comprising the step of administering one or more of the MAP antigens (or fragments, analogues or derivatives thereof) described herein.
In one embodiment, the present invention may extend to vaccines, immunogenic compositions and methods for use in protecting animals against developing diseases caused or contributed to, by Map. Such diseases may include, for example, Johne's disease. In other embodiments, the vaccines and immunogenic formulations provided by this invention may not protect against Map infection but may reduce the progression of disease, the level of Map colonisation in a host organism and/or the severity of the symptoms of a disease caused or contributed to by Map.
DETAILED DESCRIPTION
The present invention will now be described by way of example and with reference to the Figures which show:
FIG. 1 shows the results of a IFN-γ ELISA showing cell-mediated immune responses to the Map-specific proteins of individual sub-clinical Map infected sheep (P7, P33, W363, W395, PC212, 0269) in comparison to control animals (724A, 329A, 463A, 307A);
FIG. 2 shows a plot of the data in FIG. 1 showing the relative differences between the cell-mediated immune responses to the Map-specific proteins in the infected and control groups with raw means and standard errors;
FIG. 3 shows the protein sequence of a Map K-10 isolate protein (AAS02585), corresponding to MAP0268c of the present invention (SEQ ID NO:1);
FIG. 4 shows the protein sequence of a Map K-10 isolate protein (AAS03614), corresponding to MAP1297 of the present invention (SEQ ID NO:2);
FIG. 5 shows the protein sequence of a Map K-10 isolate protein (AAS03682), corresponding to MAP1365 of the present invention (SEQ ID NO:3); and
FIG. 6 shows the protein sequence of a Map K-10 isolate protein (AAS06201), corresponding to MAP3651c of the present invention (SEQ ID NO:4).
FIG. 7 shows the enhanced stimulation with cocktails of Map-specific antigens. Blood was stimulated with 113.8 μg/ml of recombinant MAP3651c, 125 μg/ml of 1365 and a mix of 113.8 μg/ml of MAP3651c plus 65 μg/ml of MAP1365. Bovigam IFN-γ ELISA responses to antigens expressed as picogrammes of IFN-γ produced. PC12 and W63 were subclinical ovine paratuberculosis cases resulting from natural Map infection.
FIG. 8 shows Bovigam IFN-γ ELISA responses of Map experimentally infected and uninfected calves to antigens (final concentration 4 μg/ml) expressed as optical density (OD). Mean OD calculated for duplicate samples for each group of calves. Note Map-infected calves were inoculated with three different concentrations of Map as given in text.
FIG. 9 shows the specificity of the cell-mediated immune response of Map-infected calves compared with Maa-infected calves to recombinant MAP3651c. Blood was stimulated with 7.3 μg/ml of recombinant MAP3651c, 4 μg/ml PPDA and 2 μg/ml PPDJ. Concentrations of the antigens have not been optimised for the diagnostic assay. Bovigam IFN-γ ELISA responses to antigens expressed as optical density (OD). Mean OD calculated for duplicate samples for each group of calves; Maa-infected n=6, Map-infected n=2.
EXAMPLES SECTION
The methods and Table 1 which follow correspond to information described in a paper submitted by the present inventors to Clinical and Vaccine Immunology (Hughes, V., Bannantine, J. P, Denham, S. et al 2008. Clin. Vaccine Immunol. 15: 1824-1833), the copyright of which is acknowledged.
Source and Growth of Microbial Strains
Map strain (JD88/107) was originally isolated from a deer with clinical paratuberculosis. It is mycobactin dependent and IS900 positive. Maa strain (JD88/118) was originally isolated from a deer and is IS901 positive.
Routine propagation and maintenance of mycobacteria were carried out as described in Hughes et al. (2007) For propagating mycobacteria for proteome analysis, starter cultures were initiated by inoculating a loopful of mycobacteria (from a 7H11 slope with confluent growth) into a 10 ml volume of Middlebrook 7H9 medium supplemented with 10% (v/v) Middlebrook OADC 0.1% (w/v) Tween-80, 2 μg ml −1 Mycobactin J and 2.5% (v/v) glycerol. The cultures, contained in 50 ml flasks, were stirred continuously using magnetic stirrer bars, on a multiple position low heat transmission magnetic stirrer. After 48 h incubation, 3 ml of the starter culture was transferred to 300 ml of pre-warmed medium in liter flasks. The cultures were incubated at 37° C. with continuous stirring and growth monitored by optical density (OD) at 600 nm as described by Hughes et al. (2007).
When cultures were deemed to have reached either exponential or stationary phase and achieved an OD of at least one, they were assessed for contamination by Ziehl Nielsen staining and light microscopy.
50 ml aliquots were removed asceptically, cooled on ice and then centrifuged (4000 g, 30 min, 4° C.). The supernatant was decanted and the cell pellet carefully resuspended in 25 ml of ice-cold PBS. The cell suspension was then centrifuged again (4000 g, 30 min, 4° C.), supernatant removed and the pellet stored at −20° C. Cell pellets were stored for no longer than one week before further processing for proteomic analyses.
Protein Preparation for 2-D Gel Electrophoresis
This was essentially as described previously (Hughes et al 2007). Briefly, cells (0.2-0.3 g wet-weight) were suspended in 2% (w/v) SDS, 0.04 M Tris, 0.06 M DTT. The suspension was layered onto washed 0.1 mm zirconium/silica beads (Biospec Products, Bartlesville, Ok, USA). The mixture was lysed six times using a Fastprep 120 (Qbiogene, Cambridge, UK) at 6.5 beats/sec with 1 min cooling on ice between each round. The resulting suspension was centrifuged (500 g, 30 s, room temperature) to reduce frothing. The supernatant was pipetted into microcentrifuge tubes and heated to 100° C. for 5 min. It was then rapidly cooled and centrifuged (21000 g, 20 min, at room temperature). The protein extract was stored at −70° C. until required.
Protein clean-up was performed as described in the protocol accompanying the PlusOne 2-D Clean-Up Kit (Amersham Bioscience, Bucks, UK).
The pellet obtained after the clean-up procedure was prepared for isoelectric focussing (IEF) essentially as described by Hughes et al. 2007. Soluble protein extracts were used immediately or stored at −70° C.
The concentration of protein extracts was determined using the PlusOne Quant Kit (Amersham Biosciences, Bucks, UK) and was performed essentially as described in the protocol accompanying the product. The results of the assay were routinely confirmed by visual assessment of the protein loaded onto a 1-D SDS polyacrylamide gel.
Proteomic Analysis
IEF of proteins (150-200 μg for silver stained gels, or 300-500 μg for colloidal coomassie brilliant blue [CBB] stained gels) was performed as described previously (Hughes et al. 2007). Strips were either stored at −70° C. until required or equilibrated prior to electrophoresis in the second dimension.
IEF strips were incubated in SDS equilibration buffer (0.05 M Tris, 6 M urea, 0.065 M DTT, 30% (v/v) glycerol, 2% (w/v) SDS and 0.002% (w/v) bromophenol blue) for 15 mins with gentle shaking followed by a similar incubation in a fresh aliquot of equilibrium buffer containing iodoacetamide (0.135 M). Polyacrylamide gels (26×20 cm 12.5% (w/v), Amersham Biosciences) were electrophoresed using an Ettan Dalt system (Amersham Biosciences), 1 W per gel, overnight, at 15° C. The power was then increased to 2-4 W per gel until the dye-front was within 1 cm of the bottom of the gel.
Gels were stained with either silver using the method described by Morrissey, 1981, with the exception that the glutaraldehyde fix (step 2) was omitted, or colloidal CBB using the method described by Neuhoff et al, 1985.
Scanned Gel images were obtained using a Umax PowerLook III Imagescanner coupled with Imagemaster Labscan v 3.01 software (Amersham Bioscience, Bucks, UK). Image analyses and gel comparisons were subsequently performed using Imagemaster Progenesis software (Nonlinear Dynamics. Newcastle-on-Tyne, UK).
For each individual spot, the differences in median spot volume between Map and Maa were assessed using a Mann-Whitney test. Because a large number of tests were carried out it was necessary to adjust the P-value from each test to allow for this multiple testing. The False Discovery Rate (FDR) approach of Benjamini and Hochberg, 1995 was used; with an FDR of 5% it would be expected that 5% of the spots identified as differentially expressed would be false positives.
Identification of Proteins and Mass Spectroscopy
Proteins of interest were excised from gels with either a 15 or 30 mm ‘spot picker’ (The Gel Company, San Francisco, Calif., USA) and cut into small pieces approx 1 to 2 mm in diameter, no excess gel from around the spot was taken. Gel pieces were incubated with 0.1 M ammonium bicarbonate, 50% (v/v) ACN for 15 min at room temperature with at least three changes until the stain had been removed. Finally the gel pieces were dehydrated with ACN 100% (v/v) for 10 min. The ACN was removed and the gel pieces were dried using a speed-vac (Thermo Electron Corporation, MA, USA). The gel pieces were rehydrated in 0.01 M DDT, 0.1 M ammonium bicarbonate and incubated at 56° C. for 1 hr followed by treatment with 0.055 M iodoacetamide, 0.1 M ammonium bicarbonate for 30 mins at room temperature in the dark. Gel pieces were washed with 0.1 M ammonium bicarbonate, ACN 50% (v/v) with at least two changes, dehydrated in ACN 100% (v/v) for 10 mins and then dried on the speed vac for 20 min. Proteolytic digestion was carried out using trypsin solution (10 ng/μl ‘Promega sequencing grade modified’ in 0.025 M ammonium bicarbonate) at 37° C. for at least 16 hr. Protein digest (0.5 μl) was mixed with 0.5 μl of a solution containing 10 mg/ml CHCA, 50% (v/v) ACN, 0.1% (v/v) TFA for analysis by MALDI-TOF on a Voyager-DE Pro mass spectrometer (PerSeptive Biosystems Inc., Framingham, Mass., USA) selecting for a mass range of 600-5000 Da.
Silver stained spots were first de-stained using a commercial kit (SilverQuest, Invitrogen, Paisley, UK) prior to the first dehydration step. All subsequent steps were identical to those used for CBB stained spots as described above.
Data Explorer was used to create the peak list from the raw data with the smoothing function applied, signal to noise correlation factor was set at 0.7 and the data was baseline corrected with the following parameters: peak width 32, flexibility 0.5 and degree 0.1. The peak height at which centroids were calculated was 50% and peaks were de-isotoped. Resolution for mass spectrometry was greater than 10,000 with a mass accuracy of +/−0.01%. A close-external means of calibrating each spectrum, and no means of exclusion of known contaminant ions (such as keratin) were employed.
Bioinformatics
The proteome of Map strain K10 (accession numbers NC — 002944, AE016958) contains 4350 predicted open reading frames which were used to compile a protein database and this was queried using Mascot 2.0 (Matrix Science Ltd., London, UK) (Perkins et al., 1999). Searches for trypsin cleavage patterns used a fragment ion mass accuracy of 100 ppm, carbamidomethyl modification was selected and up to one missed cleavage site permitted.
Proteins identified using this procedure were characterized using Entrez nr Peptide Sequence data base (National Center For Biotechnology Information [NCBI]) using protein-protein BLAST program. The NCBI Conserved Domain Search service was used to identify domains present in protein query sequences and the Kyoto Encyclopedia of Genes and Genomes was used to identify relevant metabolic pathways.
Cloning and Expression of Map-Specific Sequences
Maltose binding protein (MBP) fusions of 30 Map predicted coding sequences were produced in E. coli by using the pMAL-c2X vector (New England Biolabs, Beverly, Mass., USA). Primers were designed from the reading frame of each coding sequence and contained an XbaI site in the 5′ primer and a HindIII site in the 3′ primer for cloning purposes. Amplifications were performed by using AmpliTaq Gold polymerase (Applied Biosystems, CA, USA) and Map genomic DNA as the template under conditions described previously (Bannantine, et al. 2002), The vector and amplification product were digested with XbaI and HindIII. Ligation of these restricted DNA fragments resulted in an in-frame fusion between the malE gene in the vector and the reading frame of interest. Following ligation, the products were transformed into E. coli DH5α and selected on LB agar plates containing 100 μg of ampicillin/ml. (Bannantine et a/l. 2004)
Recombinant proteins were prepared essentially as described in the pMAL™ protein fusion and purification system instruction manual (version 5.1, 1/06) with a few minor modifications.
Cultures from which recombinant proteins were extracted where grown in medium containing 50 μg/ml Ampicillin.
Lysis of E. coli was carried out in column buffer containing 2% Tween-80 and protease inhibitor cocktail Set III (Merck cat#539134) using a FastPrep FP120 (speed 5.5 for 20 sec, three times with cooling on ice between each round).
MBP fusion protein was prepared from E. coli DH5α or TB1 harbouring the parental plasmid pMAL-c2X as described above for Map recombinant proteins and used as a control in all experiments. Purified protein from this control strain consists of an MBP fusion of the LacZ alpha peptide (Bannantine at al. 2004).
Preparation and Stimulation of Ovine Peripheral Blood Lymphocytes 20 ml of blood were collected by venipuncture and placed into tubes containing preservative-free heparin. The blood was centrifuged at 638 g (for 15 min at 15° C.). Samples of plasma were removed and stored at −20° C. until analysis by ELISA. Buffy coat was removed and mixed with 10 ml of Hanks/Hep buffer, (Hanks Balanced Salt Solution, w/o Ca 2+ or Mg 2+ with 1% Heparin [Sigma-Aldrich, Poole, England]) and this was then layered over 10 ml of Lymphoprep™ (Axis-Shield, Oslo, Norway) and centrifuged at 1133 g (30 min, 15° C.). The lymphocyte band was aspirated, diluted with 15 ml of Hanks/Hep solution, and centrifuged at 238 g (10 min, 4° C.). The lymphocyte pellet was resuspended in 1 ml lysis buffer (1 part Tris: 9 parts 0.83% Ammonium Chloride, pH 7.2) and incubated on ice for 10 minutes. 9 ml of Hanks/Hep was added and the suspension again centrifuged 238 g (10 min, 4° C.). The cell pellet was resuspended in 1 ml RPMI Complete medium containing RPMI1640 (Gibco, Invitrogen, Paisley, UK), Foetal bovine serum 10% V/V, (Gibco, Invitrogen, Paisley, UK), Glutamine 1 mM (Gibco, Invitrogen, Paisley, UK), 25 mM HEPES (Sigma-Aldrich, Poole, Dorset, UK) 0.08% (V/V) Sodium bicarbonate, 50 μM β-mercaptoethanol (Gibco, Invitrogen, Paisley, UK) and a cocktail of antibiotics (penicillin/streptomycin 100 U/ml (100 μg/ml) gentamycin (100 μg/ml) and the viable cells in this suspension were counted using nigrosin exclusion (20 μl cell suspension mixed with 20 μl 0.1% nigrosin) in a modified Neubauer chamber. The suspension was diluted in RPMI complete to a 2×10 6 cells/ml solution. 50 μl of recombinant protein (110 μg/ml in RPMI complete) and 100 μl Lymphocytes (2×10 X6 in RPMI complete) were added to microtitre wells and incubated in a humidified box at 37° C. in a humidified atmosphere for 96 h. Microtitre plates were centrifuged at 443 g (5 min, 15° C.). 400 ul of supernatant was removed from each well and stored at 4° C. until ELISA analysis.
Bovine IFN-γ Assay.
The IFN-γ assay was performed on duplicate supernatants from the lymphocytes as described in the manual from BOVIGAM kit (Prionics A.G., Switzerland). Absorbance readings in ELISA wells were read at 450 nm within 5 min of the reaction being stopped.
Stimulation of Whole Blood with Cocktails of Map-Specific Antigens
Recombinant antigens were prepared as described previously and diluted in sterile PBS. A cocktail of recombinant Map-specific proteins MAP3651c and MAP1365 was prepared by mixing 113.8 μg/ml of MAP3651c plus 65 μg/ml of MAP1365. The cell-mediated immune responses of sheep were measured using the Bovigam IFN-γ ELISA according to the manufacturer's instructions with the following modifications. Fifty microliters of antigen preparation in PBS was mixed with 750 microliters of whole blood in a 24 well sterile culture plate. Blood was cultured within one hour of collection. Approximately 400 microliters of supernatant was collected following a 48 hour incubation period. Incubation with the chromogen was carried out for 15 minutes at 37° C. Blood was stimulated with 113.8 μg/ml of recombinant MAP3651c, 125 μg/ml of MAP1365 and the cocktail of MAP3651c and MAP1365.
Experimental Infection of Calves
Eighteen Holstein male calves were obtained from a herd free from Johne's disease as determined by ELISA testing and faecal culture. The calves were randomly assigned to three groups of six calves. One group was infected at an average age of 16 weeks (14-17) with an IS901 positive strain of Maa, each calf receiving a single dose of 10 9 organisms. The second group was infected at an average age of 19 weeks (18-21) with Map. Two calves received a single dose of 10 7 , two received 10 8 and two received 10 9 organisms. The third group, the uninfected controls received phosphate buffered saline (PBS). The number of organisms was estimated using the wet weight method and the inocula were given orally as a bacterial suspension in PBS. Blood samples were taken for analyses 54, 57 and 48, 51 weeks post infection for Maa and Map infected calves, respectively.
Measurement of Cell-Mediated Responses of Infected Calves
The cell-mediated responses of the infected calves were measured using the Bovigam IFN-γ ELISA (Prionics, Schieren, Switzerland) according to the manufacturer's instructions with the following modifications. The stimulating antigens used were PPDA, PPDJ and recombinant proteins 3651c, 1365, 1297, 0268c at the concentrations given in the figure legends. PPDA was obtained from VLA and dialysed first to remove the phenol. PPDJ was obtained from Douwe Bakker (Central Veterinary Institute of Wageningen University, Lelystad, The Netherlands). Recombinant antigens were prepared as described previously. Twenty five microliters of antigen preparation in PBS was mixed with 200 microliters of whole blood in a 96 well sterile culture plate. Blood was cultured within one hour of collection. Approximately 120 microliters of supernatant was collected following a 24 hour incubation period. For each incubation step in the Bovigam ELISA plates were incubated at 37° C. for one hour. Plates were washed using an automated plate washer six times between steps. Incubation with the chromogen was carried out for ten minutes at 37° C. All antigens were tested in duplicate.
Example 1
Proteomic Identification of Map-Specific Proteins
Map-specific antigens were identified by comparison of the proteomes of Map and IS901+ Maa, which is the mycobacterium most closely related to Map and capable of infecting animals. The rational for this approach was that comparison of the proteomes of the two organisms would identify subspecies-specific proteins, including the products of differential gene regulation that would not be detected by a comparative genomics approach. In order to perform a comparison of IS901 + Maa and Map, it was necessary first to undertake significant development work to optimise and standardise the experimental and analytical procedures required. The standardized methods are detailed above. Since the proteome changes during the growth cycle, comparisons were made also between the proteomes obtained from the organisms at different stages in the growth cycle (both log and stationary phases were investigated).
On comparison of the proteomes, proteins that appeared to be uniquely expressed or upregulated in Map were picked from the gels and subjected to further investigation by MALDI-TOF analyses. It was possible to characterise 32 of these Map proteins and define the corresponding genes following MALDI-TOF and Mascot analyses. The proteomes were compared from different strains of the organisms to ensure that the proteins identified were representative of the subspecies. Comparison with the in vivo proteome of Map confirmed that the proteins were expressed during natural infection of the target species. An example of a Map proteome and a summary of the proteomic data is given in Table 1, which identifies proteins that are specific for Map and potentially suitable antigens for use in the present invention.
The genes encoding the Map-specific proteins were amplified by PCR and 30 of the Map-specific proteins were cloned into the pMAL-c2X vector (New England Biolabs Inc.) and expressed as fusion proteins with MBP. Purified recombinant proteins were prepared for use in immunological assays using the procedures described above.
Example 2
Recognition of the Map-Specific Proteins by the Cell-Mediated Immune Response of Infected Sheep
To determine whether any of the Map-specific proteins would be suitable for use in a cell-mediated immunity assay, it was crucial to determine if they were recognized by the cell-mediated immune response of Map-infected animals. In order to undertake these experiments, it was necessary to identify subclinically infected sheep that were mounting a cell-mediated response to Map. To identify such animals, 35 sheep from a known infected flock were screened using the whole blood Bovigam IFN-γ assay using PPDJ (from Map), PPDA (from Maa) and PPDB (from Mycobecterium bovis ) as the stimulatory antigens. Concavalin A (ConA) was included as a mitogen control to assess the health status of the cells. Nine animals were identified as having a significant positive response to PPDJ and were selected for further investigation. Control animals were taken from a flock with no history of paratuberculosis and tested in the IFN-γ assay using PPDJ and PPDA for a negative response. Sera from control animals were sent to BioBest Laboratories Ltd. (Pentlands Science Park, Penicuik, Scotland) for testing by ELISA to ensure that the animals did not have circulating antibodies to Map indicative of clinical infection. Faecal smears from the control animals were stained by Ziehl Nielsen staining as a final check to ensure that they were not infected with Map.
Blood was taken from the animals and peripheral blood lymphocytes purified following hypotonic lysis and lymphoprep separation (as described above). The IFN-γ assay was performed using 30 recombinant Map-specific proteins, MBP, PPD-J, ConA and medium. OD values were corrected for both medium background and MBP for Map-specific proteins. Taking a cut-off value of a corrected OD >0.1 and a positive result in 2 or more of the subclinically infected sheep, 10 of the 30 recombinant Map-specific proteins appeared to elicit a cell-mediated response. Four of these proteins (MAP3651c, MAP1297, MAP1365 and MAP0268c) were recognised by 50% or more of the animals in the IFN-γ assay and are potential reagents for a cell-mediated immunity test for Map. The experiment was repeated with these four Map-specific proteins using blood from 6 subclinically infected and four control animals. Data from the Bovigam assay carried out in triplicate using these four proteins are given in FIG. 1 and following statistical analysis in FIG. 2 . The means of the triplicates were used in subsequent analyses. FIG. 1 shows the results of the IFN-γ ELISA showing cell-mediated immune responses to the Map-specific proteins of the individual sub-clinical Map infected sheep (P7, P33, W363, W395, PC212, 0269) in comparison to control animals (724A, 329A, 463A, 307A). Box plots were drawn to compare the difference in variability of cell-mediated immune responses to the Map-specific proteins between the groups of infected animals (proteins preceded by I) and the control animals (proteins preceded by C). There was some evidence of a difference in variability between the groups and a clear outlier (observation 20, the value for 0268c for animal W363 in the infected group). The OD value was an order of magnitude higher than the other comparable values and this data point was removed from subsequent analyses. As this was the highest value for an infected animal it would not bias the results in favour of the infected group. FIG. 2 shows a plot of the data showing the relative differences between the cell-mediated immune responses to the Map-specific proteins in the infected and control groups with raw means and standard errors. Due to variability, the adjusted data (means of triplicates) were analysed using a linear mixed model, with group (control/infected) and protein fitted as categorical fixed effects and animal as a random effect. Ranks of the triplicate means (rather than the raw means) were computed and used in the statistical model. There was evidence of a group×protein interaction (P=0.025) which indicated that there were genuine differences between the control and infected groups for some of the proteins. For all proteins mean levels were higher in the infected group and the differences were markedly different for MAP0268c, MAP1365 and MAP3651c. This supports the raw data plotted in FIG. 2 and a two sample t-test confirmed MAP0268c and MAP3651c to be significant at the 5% significance level. The P value for MAP1365 is just short of statistical significance (P=0.1)
Whilst the present invention is particularly directed to the diagnosis of Map infection in sheep and cattle, the methods of the invention extend to detection of Map infection in any other susceptible animal species including, for example, deer, goats, badger, buffalo, bison, possums, pigs, camels and even man.
Example 3
Enhanced Stimulation of Cytokine Production in Ovine Blood with Cocktails of Map-Specific Antigens
The sensitivity of immunoassays can often be increased by using a cocktail of antigens. In a small pilot experiment, the cell-mediated immune responses of two sheep subclinically infected with Map were measured in response to single antigen preparations and a cocktail of recombinant Map-specific proteins MAP3651c and MAP1365 as described above. The results are shown in FIG. 7 . A combination of two Map-specific antigens stimulated an enhanced response in the Bovigam IFN-γ ELISA compared with the single antigen preparations although the magnitude of the response varied between sheep. Different combinations of the Map-specific recombinant antigens will need to be evaluated to determine the optimum mix for diagnostic assays.
Example 4
Recognition of the Map-Specific Proteins by the Cell-Mediated Response of Experimentally Infected Calves
To determine if the Map-specific proteins were recognized by the cell-mediated immune response of another host species a calf model of infection was utilised. Calves were experimentally infected with Map and Maa as described above. Blood was collected, stimulated with preparations of the recombinant antigens and the cell-mediated responses measured using the Bovigam IFN-γ assay as described above. The results showed that the Map infected calves mounted a detectable cell-mediated immune response to all of the antigens compared with the uninfected control calves ( FIG. 8 ).
The specificity of the cell-mediated immune response of Map-infected calves compared with Maa-infected calves to recombinant 3651c was evaluated. Blood was analysed from the two calves infected with 10 9 Map and the 6 calves infected with 10 9 Maa 48 and 54 weeks post infection, respectively, using the Bovigam IFN-γ ELISA as described above. Blood was stimulated with recombinant MAP3651c, PPDA and PPDJ. The results are shown in FIG. 9 . There was a greater cell-mediated response to 3651c in the Map-infected calves than the Maa-infected calves although the magnitude of the response varied between the animals. These results show that MAP3651c can be used to differentiate between Map and Maa-infected animals.
TABLE 1
Mycobacterium avium subsp. paratuberculosis Specific Proteins, 2-D Analysis and Mass Spectrometry Data
2-D Expression Analysis
Nom-
Median
Percentage
P Values
Mass Spectrometry Identification
inal
Spot
Increase in
Mann-
Mascot
Peptide
Masses
Sequence
Annotation
Protein
Mass
Vol
Expression
Whitney
Score
PI
Count
Searched
Coverage
MAP0068
SsB
17.5
0.51
99
0.002
149
5.12
11
28
66
MAP0139c
23.6
0.05
100
0.002
56
9.95
10
107
54
MAP0268c
23.8
0.26
100
0.002
106
4.96
7
16
39
MAP0334
34.5
0.09
100
0.002
147
5.34
10
17
33
MAP0494*
38.5
0.36
89
0.002
180
5.85
11
16
47
MAP1012c
37.5
0.07
100
0.003
118
4.6
13
57
48
MAP1160c
29.4
0.38
58
NS
84
5.44
7
27
33
MAP1293
HisD
49.4
0.04
89
0.002
94
4.92
12
33
27
MAP1297
HisA
25.4
0.09
100
0.002
106
4.73
8
29
58
MAP1365
ArgF
33.6
0.04
100
0.002
71
4.9
6
26
30
MAP1564c
23.1
0.12
100
NS
110
5.66
8
23
43
MAP1754c
Usp
30.8
0.03
100
0.002
131
5.72
10
24
38
MAP2541c
MDH
34.5
0.09
100
0.002
208
4.87
13
18
44
MAP2685
21.3
0.20
39
NS
130
4.84
7
11
57
MAP2872c
FabG5_2
26.7
0.37
75
NS
86
5.65
10
71
40
MAP2878c
DapB
25.6
0.38
58
NS
89
5.52
7
27
39
MAP3175c
PrfB
41.5
0.07
100
0.003
68
4.73
8
57
28
MAP3205
NuOE
26.9
0.11
39
NS
66
4.66
6
31
31
MAP3385
32.3
0.11
39
NS
57
4.62
5
18
24
MAP3457
MetC
47.6
0.07
68
NS
153
5.25
12
28
46
MAP3491
28.2
0.05
100
NS
124
5.45
8
17
49
MAP3540c
25.1
0.03
100
0.002
124
5.18
9
23
38
MAP3567
30.1
0.40
88
0.002
217
5.7
14
33
66
MAP3627
23.1
0.18
100
0.002
92
5.4
7
22
34
MAP3651c
FadE3_2
43.9
0.47
93
0.002
273
6.15
19
29
49
MAP3692c
FabG4
47.1
0.14
23
NS
102
5.79
8
19
30
MAP3693*
FadA2
46.7
0.11
73
NS
165
6.21
14
31
42
MAP3841
GrpE
23.7
0.23
71
NS
151
4.58
11
24
42
MAP3857
UmpA
18.7
0.06
100
0.002
103
6.06
7
19
49
MAP3932c
MoA3
41.4
0.04
89
0.002
56
5.01
6
28
24
MAP4147
42.2
0.07
100
0.003
125
4.73
15
57
49
MAP 4233
Rpo
0.07
100
0.003
125
4.73
15
57
49
*Clones containing the sequence of these proteins were unobtainable after three attempts to amplify or clone the sequence. Median Spot vol is that of the M. avium subsp. paratuberculosis population. Percentage increase in expression is the difference of the spot volume medians expressed as a proportion of the median spot volume recorded for M. avium subsp. paratuberculosis
REFERENCES
Bannantine, J. P., E. Baechler, Q. Zhang, L. Li, and V. Kapur. 2002. Genome scale comparison of Mycobacterium avium subsp. paratuberculosis with Mycobacterium avium subsp. avium reveals potential diagnostic sequences. J. Clin. Microbiol. 40: 1303-1310.
Bannantine J. P., J. K. Hansen, M. L. Paustian, A. Amonsin, L-L. Li, J. R. Stabel, and V. Kapur. 2004. Expression and Immunogenicity of Proteins Encoded by Sequences Specific to Mycobacterium avium subsp. paratuberculosis . J. Olin, Microbiol. 42: 106-114.
Benjamini, Y. and Y. Hochberg. 1995. Controlling the false discovery rate: a practical and powerful approach to multiple testing. J. Roy. Stat. Soc., Ser. B. 57: 289-300.
Hughes, V., J. P. Bannantine, S. Denham, S. Smith, A. Garcia-Sanchez, J. Sales, M. Paustian, K. McLean, K. Stevenson. 2008. Proteome-determined Mycobacterium avium paratuberculosis-specific proteins: Immunogenicity in ovine paratuberculosis. Clin. Vaccine Immunol. 15: 1824-1833.
Hughes, V., S. Smith, A. Garcia-Sanchez, Sales, J., and K. Stevenson. 2007. Proteomic comparison of Mycobacterium avium subspecies paratuberculosis grown in vitro and isolated from clinical cases of ovine paratuberculosis. Microbiol. 153: 196-205.
Li, L., J. P. Bannantine, Q. Zhang, A. Amonsin, B. J., May, D. Alt, N. Banerji, S. Kanjilal and V. Kapur. 2005. The complete genome sequence of M. avium subsp. paratuberculosis . Proc. Natl. Acad. Sci. USA. 102 12344-12349.
Morrissey, J. H. 1981. Silver stain for proteins in polyacrylamide gels-a modified procedure with enhanced uniform sensitivity. Annal. Biochem. 117: 307-310.
Neuhoff, V., R. Stamm, and H. Eibl. 1985. Clear background and highly sensitive protein staining with coomassie blue dyes in polyacrylamide gels: a systematic analysis. Electrophoresis 6:427-448.
Perkins, D. N., D. J. Pappin, D. M. Creasy, and J. S. Cottrell. 1999. Probability-based protein identification by searching sequence data bases using mass spectrometry data. Electrophoresis. 20: 3551-3567.
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The present invention relates to Mycobacterial infections and provides a method of diagnosing infections of Mycobacterium avium subsp. paratuberculosis (Map), the causative agent of Johne's disease. In addition, the invention also provides as kits for use in the diagnosis of Map infections and vaccines/immunogenic compositions.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from pending U.S. provisional patent application serial No. 60/247,137 filed Nov. 9, 2000; the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. TECHNICAL FIELD
[0003] The invention relates generally to a duplicator for use in woodworking, and more particularly to a duplicator for attachment to a standard radial arm saw. Specifically, the present invention relates to a duplicator that may be attached to a standard radial arm saw while being movable and adjustable in at least five directions.
[0004] 2. BACKGROUND INFORMATION
[0005] Woodworkers often desire to duplicate a three dimensional object. Such objects may includes faces, patterns, sculptured items, etc. These parts could be carved individually, but it is very difficult to make them similar, let alone identical to each other. The time and skill to individually carve them also makes this option undesirable. It is therefore desirable to have a tool which can be used to make duplicate copies of an article. Such a tool would allow the woodworker to hand carve an original work and then quickly and easily duplicate the work so that the duplicates may be sold.
BRIEF SUMMARY OF THE INVENTION
[0006] The device of the present invention is a woodworking duplicator which is adapted to be attached to a standard radial arm saw. The device allows a rotating cutting tool and a stylus to be movably supported allowing the user to trace a pattern with the stylus while cutting the pattern into a work piece with the cutter.
[0007] The invention provides a duplicator that may be mounted to a radial arm saw wherein the duplicator includes elements that may be moved in five different directions. The invention also provides a duplicator having a stylus and a cutter that may be easily locked into different parallel positions so that the user of the duplicator may more easily trace the item being duplicated. The invention also provides a duplicator that supports the weight of the stylus and cutter tool.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] The preferred embodiments of the invention, illustrative of the best modes in which applicant has contemplated applying the principles of the invention, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
[0009] [0009]FIG. 1 is a front view of the duplicator shown mounted on a standard radial arm saw.
[0010] [0010]FIG. 2 is a plan view of the device shown in FIG. 1.
[0011] [0011]FIG. 3 is a side view of the device through line 3 - 3 of FIG. 1, showing the cutting tool contacting a block of wood to be carved.
[0012] [0012]FIG. 4 is a side view of the device through line 4 - 4 of FIG. 1, showing the stylus contacting an article to be duplicated.
[0013] [0013]FIGS. 5 and 6 are front views of the duplicator illustrating that the sleeve holding the cutting tool and stylus may be moved in a first horizontal plane.
[0014] [0014]FIGS. 7 and 8 are side views of the device illustrating the vertical motion of the duplicator, showing that the cutting carriage may be lowered towards or raised away from the table of the radial arm saw.
[0015] [0015]FIGS. 9 and 10 are side views of the device illustrating that the cutting carriage may be moved in a second horizontal plane toward or away from the post of the radial arm saw.
[0016] [0016]FIGS. 11 and 12 are partial side views of the device illustrating the vertical rotatability of the cutting tool of the device about the second bar of the duplicator.
[0017] [0017]FIG. 13 is a partial plan view of the sleeve of the device showing how a first cutting tool and the stylus are mounted on the sleeve.
[0018] [0018]FIG. 14 is a partial plan view of the sleeve showing a second cutting tool and the stylus, and illustrating how the stylus is adjusted to align with the cutting tool on the sleeve.
[0019] [0019]FIG. 15 is sectional view taken along line 15 - 15 of FIG. 14.
[0020] [0020]FIG. 16 is a front view of the sleeve, with the cutting tool and stylus removed to show the bushings.
[0021] [0021]FIG. 17 is a front view of the sleeve with the cutting tool and stylus in position for engagement with the block of wood to be carved and the article to be duplicated.
[0022] [0022]FIGS. 18 and 19 are front views of the sleeve shown in FIG. 17, illustrating the rotatability of the cutting tool and stylus relative to the sleeve.
[0023] [0023]FIG. 20 is a sectional view taken along line 20 - 20 of FIG. 17.
[0024] [0024]FIG. 21 is a view taken along line 21 - 21 on FIG. 20.
[0025] Similar numerals refer to similar parts throughout the specification.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The duplicator device 8 of the present invention is adapted to be mounted on a radial arm saw 10 . Radial arm saw 10 includes a horizontal table 12 , a post 14 extending vertically therefrom, an arm 16 extending horizontally from the post 14 and over the table 12 , and a slide 18 mounted on the underside of the arm 16 . Post 14 is adapted to telescope so that arm 16 moves vertically towards and away from table 12 . Slide 16 is adapted to move horizontally along the underside of arm 16 , both towards and away from post 14 .
[0027] Duplicator 8 of the present invention is adapted to be secured to radial arm saw 10 when the saw motor and blade have been removed. Duplicator 8 includes a frame that is generally indicated at 20 . Frame 20 is generally rectangular in shape having first and second bars 22 , 24 being disposed at right angles to end bars 26 , 28 . First bar 22 is attached to slide 18 of arm 16 by any suitable mounting arrangement. A spring 30 is disposed between slide 18 and first bar 22 so as to bias frame 20 upwardly towards arm 16 and away from table 12 of saw 10 .
[0028] A sleeve 32 is coaxially, slidably, and rotatably disposed on second bar 24 and is adapted to move horizontally along second bar 24 between end bars 26 , 28 (FIGS. 5 & 6). A cutting tool 34 and stylus 36 are mounted on sleeve 32 in any suitable manner. As sleeve 32 moves horizontally along second bar 24 , cutting tool 34 and stylus 36 move with it. Cutting tool 34 and stylus 36 thus slide and rotate in concert. Cutting tool 34 is adapted to carve into a workpiece which is typically a block of wood 38 or other substrate and stylus 36 is adapted to engage the article 40 which is to be duplicated into workpiece 38 .
[0029] Device 8 can move in a number of directions so that cutting tool 34 can be used to cut a three dimensional copy of article 40 as stylus 36 traces over article 40 . Cutting tool 34 can make the following movements. Firstly, sleeve 32 can slide horizontally in the A-A′ direction along second bar 24 (FIGS. 5 & 6). This allows the cutting tool 34 to cut the block of wood 38 in a first horizontal direction. Secondly, frame 20 can rotate vertically about axis B-B′ (FIG. 6). This allows the sleeve 32 to be lowered (FIG. 7) or raised (FIG. 8) relative to table 12 , allowing cutting tool 34 to cut workpiece 38 in a vertical direction. Thirdly, because frame 20 is connected to slide 18 , it can slide towards and away from post 14 in the C-C′ direction (FIGS. 9 & 10). This moves cutting tool 34 in the second horizontal direction, thereby allowing for cuts to be made in the block of wood 38 in this direction. Fourthly, sleeve 32 is able to rotate about the axis D-D′ (FIGS. 5, 11 & 12 ), allowing for cuts to be made in this direction. Fifthly, frame 20 can rotate about the vertical axis E-E′ (FIG. 7) as arm 16 is rotated about post 14 of radial arm saw 10 . Finally, as best can be seen in FIGS. 17, 18 and 19 , cutting tool 34 and stylus 36 can be rotated about axes F and F′ (FIGS. 20 and 21) in a manner which will be described below. The relative movements and rotatability of cutting tool 34 and stylus 36 in these various directions, allows for any three dimensional object to be duplicated by device 10 .
[0030] Stylus 36 is shown in greater detail in FIGS. 15 and 20. Stylus 36 includes a handle 42 at one end and a tracing tip 44 at the other. Tracing tip 44 may be adjustably mounted to stylus 36 in any suitable manner such as being received within a slot and being clamped therein by a clamp 46 . While tracing tip 44 is shown as a removable part of stylus 36 , it may be formed as an integral part thereof. The body of stylus 36 includes a slot for receiving a rod 48 therethrough. A suitable clamp 50 secures rod 48 and stylus 36 together. Rod 48 has a threaded first end 52 and a second end 54 that is inserted first through the bore 55 of a bushing 56 connected to sleeve 32 then through a V-shaped bracket 58 and finally through the slot in stylus 36 . Bushing 56 is connected to sleeve 32 by any suitable connectors such as welds or mechanical connectors. Clamp 50 is then inserted into stylus 36 to secure rod 48 in place.
[0031] As can be seen from FIGS. 16 & 21, the front face of bushing 56 which lies proximate bracket 58 is provided with a plurality of grooves 60 for receiving the apex 61 of the V of bracket 58 . An internally threaded handle 62 engages the external threads on first end 52 of rod 48 . When handle 62 is rotated, rod 48 is drawn farther towards or away from handle 62 , thereby decreasing or increasing the distance between sleeve 32 and stylus 36 (see FIGS. 13 and 14). If it is desired to alter the angle of stylus 36 relative to sleeve 32 , handle 62 is rotated to the point that apex 61 disengages from groove 60 , bushing 50 is rotated so that a different groove 60 is disposed for engagement with bracket 58 , and then handle 62 is rotated until apex 61 re-engages in the different groove 60 .
[0032] Cutting tool 34 is connected to the sleeve 32 in the following manner. A second V-shaped bracket 58 ′ is provided to engage in the grooves 60 ′ of a second bushing 56 ′ in the manner described above. Second bracket 58 ′ is connected to an adjustable clamp 64 by a second rod (not shown). Clamp 64 may include any suitable means of securing the cutting tool within its grasp, such as an expandable band having a lock screw 66 disposed for locking the ends of the band together. A second handle 62 ′ is provided to engage the end of the second rod to allow for release and securing of second bracket 58 ′ in second bushing 56 ′. Cutting tool 34 may be any suitable device such as a rotary cutter or a hand-held router. An electrical outlet 70 and switch 72 are provided on frame 20 so that cutting tool 34 may be conveniently and safely operated. Cord 73 of cutting tool 34 may be connected to outlet 70 . An electrical cord 74 connects outlet 70 to a power source (not shown).
[0033] It is desirable that tracing tip 44 of stylus 36 and cutting tip 68 of cutting tool 34 be aligned with each other so that as movements are made with stylus 36 over article 40 to be copied, the same movements are made at the same time and in the same relative position by cutting tip 68 . If cutting tool 34 is exchanged for a larger tool 34 ′ (FIGS. 13 & 14), then handle 62 can be adjusted to allow for stylus 36 to move farther away from sleeve 32 . This allows the user to adjust the device so that cutting tip 68 and tracing tip 44 remain aligned.
[0034] Similarly, the angle of cutting tool 34 and stylus 36 relative to the sleeve 32 may be adjusted (FIGS. 18 & 19). This is achieved by changing grooves 60 on the bushings 56 , 56 ′ with which the brackets 58 , 58 ′ engage, as previously described. It may also be desirable to sometimes cut a mirror image of an article 40 . In that event brackets 58 , 58 ′ proximate stylus 36 and cutting tool 34 are engaged in grooves which face in opposing directions.
[0035] The device of the present invention is used in the following manner:
[0036] Referring to FIGS. 1 & 2, article 40 to be duplicated is secured to table 12 by any suitable means. Similarly block of wood 38 or other desired workpiece is positioned alongside article 40 and is secured to table 12 by a suitable holding mechanism. Frame 20 is pulled downwardly towards table 12 by the user grasping second bar 24 , end 26 , 28 or handle 42 of stylus 36 . The user connects cutting tool 34 to outlet 70 , and switches cutting tool 34 on. The user then manipulates stylus 36 so that tracing tip 44 traces out the shape of article 40 being duplicated. As the user does this cutting tool 34 moves in concert with stylus 36 and cutting tip 68 cuts the identical shape into block of wood 38 . Adjustments are made to the angle of stylus 36 and cutting tool 34 as necessary. When block of wood 38 has been shaped into the desired article, cutting tool 34 is switched off and disconnected from outlet 70 . Frame 20 is released and rises back to its at rest position (shown in FIG. 8). The duplicated article is removed from table 12 and a new block of wood 38 may then be secured to the table for the manufacture of another duplicate.
[0037] Accordingly, the improved duplicator device for a radial arm saw is simplified, provides an effective, safe, inexpensive, and efficient device which provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.
[0038] 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.
[0039] 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.
[0040] Having now described the features, discoveries, and principles of the invention, the manner in which the duplicator device 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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The invention provides a woodworking duplicator which is adapted to be attached to a standard radial arm saw. The device allows a rotating cutting tool and a stylus to be movably supported allowing the user to trace a pattern with the stylus while cutting the pattern into a work piece with the cutter. The invention provides a duplicator that may be mounted to a radial arm saw wherein the duplicator includes elements that may be moved in five different directions. The invention also provides a duplicator having a stylus and a cutter that may be easily locked into different parallel positions so that the user of the duplicator may more easily trace the item being duplicated. The invention also provides a duplicator that supports the weight of the stylus and cutter tool.
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FIELD OF THE INVENTION
[0001] The present invention relates to a currency acceptor and dispenser intended for use in electronic gaming machines, vending machines and the like.
BACKGROUND
[0002] In the early 1990's there was a fundamental change in the performance and capability of gaming machines initiated by the incorporation of bill acceptors into such machines. Bill acceptors are devices which receive paper currency or notes and, using a validator having both hardware and software components, the received currency or note is scanned with a variety of sensors and the sensor information is analyzed to determine (1) authenticity and (2) denomination of the currency or note from the scanned data. If the note is determined to be authentic currency, e.g. a United States $1, $5, $10, $20, $50 or $100 bill or other legal tender currency, the note is transported to a cash box within the bill acceptor for storage. Further, based upon the denomination of the accepted currency or note, a signal is sent from the validator to the host machine's controller or processor to cause the machine to accumulate a corresponding amount of credits within the machine's credit meter representing the cash value or credits available for purchasing products or wagering, in the case of a gaming machine. As the user purchases products from or plays the machine, the purchase price or wager is debited from the credit meter. In the case of a gaming machine, wins are either accumulated as credits or paid out in coins. Acceptors of this type are known and are discussed for example in U.S. Pat. No. 5,863,039 issued Jan. 26, 1999 to Suzuki.
[0003] Although the incorporation of bill acceptors into gaming machines has been a tremendous success for casinos, for example by increasing player retention and revenues, the success has proven to create certain unforeseen consequences. Casinos have had to adapt to accommodate a shift in employee resources as a result of the fact that up to eighty-five percent of the money received by a gaming machine, termed the “drop” in the industry, is now in the form of currency inserted into the bill acceptor as opposed to coins which have historically been used by customers to accumulate credits and used by the gaming machine to payout wins. This shift from the use of coins to currency by the customers has increased the personnel and logistical demands on the currency collection and counting rooms as well as creating fundamental shifts in how change booths and casino personnel operate. The net effect is that casinos have become. an organized note recycling system. Currency or notes go from the player into the bill acceptor of a gaming machine, from which they are periodically collected by a “drop crew” of casino employees and taken to a counting room where the currency is sorted and counted. From the counting room, a significant percentage of the currency or notes is delivered to change booths or floor cashiers for return back to the successful players in the form of change or payouts.
[0004] The incorporation of bill acceptors has thus caused a shift in the human resource requirements of casinos and slot machine managers. Although most of the currency or notes deposited into the gaming machines is received in the form of currency as opposed to coins, the predominant method of returning winnings to a customer for amounts less than a couple of hundred credits is in the form of coins or tokens from the machine coin hopper. In current slot machines, a “payout” condition is triggered when a player wishes to obtain a payout of the cash equivalent of the remaining accumulated credits on a gaming machine by depressing a “cash out” button, or the player obtains a large win requiring a “hand pay” by a floor cashier. For payouts in excess of a couple of hundred coins, the preferred method of payout is a hand pay where the patron receives currency from a casino employee or floor cashier. The combination of currency input and coin output from a gaming machine has caused a significant increase in the number of gaming machine coin hopper fills and hand pays the casino must handle. Major casinos may experience as many as 40,000 coin hopper fills and hand pays per month. This activity translates into increased employment expenses, since staff must be provided to service the coin hopper fills and hand pays as well as counting and sorting of the bills accepted by the machines, and thus increased overhead for the casinos.
[0005] Furthermore, when a large payout requiring a hand pay occurs, the gaming machine locks up or freezes until the amount is paid by the floor cashier and the machine is reset by the floor cashier. In addition, because the normal payout for relatively small numbers of coins is in the form of coins or tokens from the machine's coin hopper, the coin hopper must have its inventory of coins or tokens replenished by casino employees because the coin hopper is generally not receiving coins deposited by the customers who prefer to use currency accepted by the bill acceptor. Still further, a lock up condition may cause players to wait for a coin hopper to be refilled, or receive a hand pay, even for relatively small payouts if the coin hopper becomes fully depleted. While in a lock-up condition the machine is not available for play.
[0006] Since the utilization of the convenient bill acceptors has caused a dramatic shift in the drop received from a player from coins to currency or notes, it should be appreciated that the casino will need to retrieve the currency or notes received by the bill acceptors, and thus the cash boxes are periodically removed from the bill acceptors in the slot machines and taken to a counting room where the currency is removed and counted. Due to the volume of currency to be counted, this cyclic retrieval of the cash boxes and counting function can result in increased personnel costs as well as increased risk of theft. Accordingly, systems capable of combing the benefits of the bill acceptors and a more efficient method of payout reducing employee expenses and overhead would be tremendously beneficial to the gaming industry. In addition, other devices such as vending machines and pay-point service stations having bill acceptors and coin dispensers can suffer from similar or related problems, such as inability to provide change, running out of change and the like, and such devices could also benefit from an improved bill acceptor system.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a currency or note acceptor-dispenser validator and a method for its operation which is adapted to provide for faster payouts to, customers, which decreases the frequency of hand pay and machine lock up conditions and which is locally and remotely configurable to anticipate increased play periods or the like. Accordingly an acceptor-dispenser validator system for accepting bills, vouchers, script and/or currency (hereinafter, collectively “notes”) into and for distributing currency or a currency equivalent from an electronic gaming machine or alternative type of customer service device is set forth which includes a note acceptor-dispenser assembly to be mounted in or on the machine, the note acceptor-dispenser having a note validator to sense the authenticity, denomination, amount and type of the note passing there through and issue a signal corresponding to the note type to the acceptor-dispenser's processor and the host machine's processor for accumulation of credits. A note box is provided to receive deposited notes, as is a note hopper to receive and dispense notes intended for payouts. There is also included means for transporting notes accepted through the note validator to each of the note box and note hopper and for distributing notes from the note hopper to the customer. The acceptor-dispenser's processor controls the transporting means to (i) direct notes received through the note validator of a selected type for accumulation of credits to said note hopper and the remainder to the note box for retention thereof and (ii) to control the transporting means to transport notes from the note hopper box and/or coin(s) from the machine coin hopper for distribution in response to a payout condition for the machine.
[0008] Thus, as notes (currency or casino script) are inserted through the note validator for accumulation of credits, certain specified notes, e.g. $20 bills or casino script notes, are transported to the note hopper to provide an inventory for dispensing the specified notes to the customer in response to a payout condition. Other note denominations, or the specified notes in excess of a pre-selected number of notes to be routed to the note hopper, are routed to the note box for accumulation and subsequent collection. The note box is periodically removed from the machine for counting of the notes. When a payout is required, the machine's processor signals the machine's coin hopper control, note hopper control and note hopper transport means to cause them to dispense a combination of coins and notes to the customer having a combined value equal to the amount of the payout. In this manner, the machine can provide a substantial payout to a customer in either currency or casino coupons without seriously depleting the number of coins in the coin hopper and without requiring a hand pay by a floor cashier.
[0009] The note acceptor-dispenser validator preferably has data processor capabilities, and the ability to communicate with the gaming machine's processor and any remote gaming machine accounting system to allow continuous monitoring and accounting and to confirm the payout to the customer if necessary. In addition, the accepter-dispenser validator's data processor may be locally (at the gaming machine) or remotely configured to accumulate more or fewer notes in the note hopper. Thus, in anticipation of a high utilization period, for example a busy weekend, the data processor may be instructed to cause the note accepter dispenser validator to accumulate more notes in the note hopper in anticipation of more frequent payouts to customers. Further, the data processor may be reconfigured or instructed to cause the gaming machine to inventory a different denomination of notes or currency in the note hopper or to only inventory certain notes such as casino script or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 shows a gaming machine including the note acceptor-dispenser validator which according to the present invention;
[0011] [0011]FIG. 2 shows a perspective view of the note acceptor-dispenser validator including the note box and note hopper assembly according to the present invention;
[0012] [0012]FIG. 3 illustrates the control system configuration of the acceptor-dispenser validator according to the present invention; and
[0013] [0013]FIG. 4 is a logic diagram showing the note validation and note storing dispensing features of the control system for operating the system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] [0014]FIG. 1 shows a gaming machine 10 including the currency acceptor-dispenser validator 12 according to the present invention. While the gaming machine 10 is shown as an electrical mechanical, reel-type slot machine, it is to be understood that the present invention could be used on any gaming machine which receives wagers and pays out based upon play, such as slot machines, video slot or poker machines, video keno machines and the like. The present invention can also be used in vending machines and pay point machines, where a combination of currency and change may be required to be paid out to customers. For purposes of detailing the invention, however, the description herein is tailored to the application of the invention in a gaming machine.
[0015] The gaming machine 10 generally includes a housing 14 of various potential configurations designed to contain the various components of such machines. The interior of the gaming machine 10 may normally be accessed through opening a front cover or door 16 . Disposed within the housing 14 are the reels 18 for the play of the game, a central processing unit (CPU) 19 which controls the operation of the gaming machine 10 , as well as a coin hopper assembly 20 adapted to receive, hold and dispense coins or tokens in a known fashion. As is known in the industry, the CPU 19 controls the operation of the gaming machine 10 . The CPU 19 controls the selection of the outcome, monitors the amount wagered for each play or “hand,” determines winning payouts to the player, monitors the accumulation of credits at the gaming machine available for play and the like. These features, which are controlled by the CPU 19 , are now well-known in the art. To monitor the performance and operation, the CPU 19 of each gaming machine 10 in a casino may be in communication with a centralized system server 22 (FIG. 3). The system server 22 monitors the revenue or coin-in amounts wagered, amounts paid out and the like for each gaming machine 10 in the casino. A communication network for multiple gaming machines 10 in a casino may include local controllers 24 which store data for a group of gaming machines 10 for periodic polling by the centralized system server 22 .
[0016] To play a gaming machine 10 , a player inserts tokens, coins, bills, currency, script or coupons, which are tested and if valid are accumulated as credits for gaming. The received coins or tokens are directed to the coin hopper assembly 20 for storage or the coins/tokens may be directed to an auxiliary collection location, for example under the machine. Alternatively, to amass credits for play of the gaming machine 10 , the gaming machine 10 may be provided with a currency validator which receives notes as legal tender or script and, based upon the note's value, assigns a corresponding value of credits within the gaming machine 10 for gaming. Known validators, according to the prior art, are adapted only to receive, validate and store notes. Accordingly, if a player wishes to cash out the accumulated credits or wins a jackpot, the amount must be dispensed from the coin hopper assembly 20 or an attendant must make what is known as a hand pay.
[0017] According to the present invention, the acceptor-dispenser validator 12 may be disposed in the housing 14 of the gaming machine 10 , and electrically connected to the CPU 19 therein. Preferably, the acceptor-dispenser validator 12 is of a size and configuration to be received within the housing 14 at the location previously occupied by prior validating devices so that no extensive reconfiguration or redesign of the gaming machine 10 is required. Alternatively, some or all of the acceptor-dispensor validator 12 could be mounted on the outside of the housing 14 .
[0018] The acceptor-dispenser validator 12 , as shown in FIG. 2, includes a validator head 26 adapted to scan a note inserted into an opening 28 to determine the authenticity, type (legal tender or script, if required), denomination and condition (whether the note is worn) of the note. Typically the note is inserted into the opening 28 and is captured and transported by a transportation unit 30 past optical and magnetic sensors (not shown) which may, for example, sense light reflected by and/or transmitted through the note, reflectivity and transmission patterns, size of the note and the magnetic characteristics of the inserted note. The various sensors output sensed data output signals which are compared by a validator processor (not shown) to stored data representative of the range of sensor readings corresponding to authentic notes.
[0019] If the note is determined valid and authentic, based on the comparison with the stored data for authentic notes, the transportation unit 30 transports the note to one of a note box 32 or a note hopper 34 for storage. Also, upon receipt and determination of validity, a signal is sent to the slot machine CPU 19 signifying receipt as well as the denomination of the note for accumulation of a like value amount of credits in the slot machine 10 for gaming. If the note is not determined valid, the transportation unit 30 is reversed and the note is ejected through the opening 28 to the customer.
[0020] The note box 32 is preferably positioned below the transportation unit 30 , as shown in FIG. 2. The note hopper 34 may be positioned above the transportation unit 30 to take advantage of open space in many existing game machines, however the note hopper can be stacked above, behind or below the note box 32 , both of which may be either above or below the transportation unit 30 . The note hopper 34 and note box 32 are secured to the transportation unit 30 to form the acceptor-dispenser validator 12 . To prevent theft of notes during service of the gaming machine 10 , the attachment of the note box 32 may include a locking mechanism which opens the note box 32 to allow receipt of notes from the transportation unit 30 only when the note box 32 is locked to the dispenser 12 . When the note box 32 is unlocked for removal from the dispenser 12 , the locking means closes the note box 32 to prevent removal of notes stored therein. Another lock (not shown) is provided on the note box 32 for opening of the note box 32 at the casino counting room for removal of the stored notes and counting thereof.
[0021] The notes received into the note box 32 are typically stacked in a vertical relationship and accordingly the note box 32 has a configuration corresponding to the plan dimensions of the notes. The acceptor-dispenser 12 according to the present invention also includes the note hopper 34 adapted to receive and store notes in a stacked relationship. A locking assembly 35 may be provided for locking the note hopper 32 to the acceptor-dispenser 12 to prevent theft of notes, as well as to allow locking of the note box 32 during transport from the gaming machine 10 to the counting room. The transport unit 30 is adapted to move notes through the validator head 26 to a selected one of the note box 32 or note hopper 34 . To control the transportation unit 30 , the acceptor-dispenser 12 includes a transportation unit controller 31 (FIG. 3), which is in communication with the validator head 26 as well as the slot machine CPU 19 and potentially a central slot server 22 . Motorized means within the transportation unit 30 such as motorized traction wheels, belts, conveyers and gates, under control of the transportation unit controller 31 selectively move the notes accepted as being valid.
[0022] The transportation unit controller 31 also includes a data structure or memory 36 (FIG. 3) storing data concerning the notes stored in the note hopper 34 including at least data corresponding to the number of notes stored in the note hopper 34 . Similarly, the transportation unit controller 31 and memory 36 preferably has the ability to store data concerning the number and type of notes stored in the note box 32 . Moreover, the transportation unit controller 31 and memory 36 associated therewith optimally can also provide status and activity information, including for example dispensing or accepting status, fault conditions, any “note hopper empty” condition, a note hopper or transportation unit jam or a note hopper absence condition. It may also be beneficial to have memory devices, such as contact memory devices known in the art, integral with the note hopper 34 and the note box 32 , such memory devices being configured to receive data from the unit controller 31 concerning the status of the notes which should be present in the respective device. All of the data available in the memory 36 may be remotely accessible from the transportation unit controller 31 by the gaming machine's CPU 19 and potentially the central slot server 22 .
[0023] The gaming machine 10 may also include an associated printer 37 , which may operate in combination with the note acceptor-dispenser 12 . The printer 37 can be configured to print one or more cash-out tickets or coupons that have a value assigned by the unit controller 31 . Such a printer 37 can also be configured to dispense the cash-out tickets or coupons using the transportation unit 30 , or alternatively the printer may dispense the cash-out tickets through a slot (not shown) on the front of the gaming machine 10 .
[0024] With reference to FIGS. 3 and 4, the logic of the operation of the acceptor-dispenser 12 and method of the present invention is illustrated using block diagrams. The transportation unit controller 31 (FIG. 3) is first configured in the block diagram of FIG. 4 during a set up procedure, shown by box 38 , to select the denomination/type of note to be sent to and stored in the note hopper 34 as well as the selected number of notes to be routed to and stored therein. The configuration at set up 38 may be by a command or series of commands from the central slot server 22 , at the local controller 24 or by a portable, hand-held device 40 to be coupled to and in communication with the transportation unit controller 31 and slot machine CPU 19 as shown in FIG. 3. The configuration or set up at 38 of the acceptor-dispenser 12 may also include input of data into the transportation unit memory 36 of data corresponding to the number of notes pre-loaded into the hopper box 34 for dispensing thereof in the manner described below.
[0025] As an example of how the acceptor-dispenser 12 may be operated, the transportation unit controller 31 may be configured to store a minimum of 60 to 200 notes in the note hopper 34 with a beginning inventory of 66 such notes. The number, denomination or type of note and starting inventory can be selectively changed to store another denomination or type, or to store script notes only, store only less worn notes or any combination thereof. These instructions, may be, as stated above, downloaded from the central slot system server 22 , CPU 19 or another local controller 24 or by a portable controller 40 .
[0026] Once instructed, the transportation unit controller 31 controls the transportation unit 30 to deliver newly received notes accepted by the validator and meeting the preset criteria to the note hopper 34 , until instructed otherwise. For example, in anticipation of more frequent payouts, the transportation unit controller 31 may be instructed to store a minimum of one hundred notes and up to a maximum of four hundred notes depending upon the anticipated number and frequency of payouts. More specifically, in anticipation of high holiday weekend play, the number of notes to be stored in the note hopper 34 defining an inventory for dispensing for payouts and cash outs can be increased to the maximum, for example, four hundred notes, simply by sending an instruction to the transportation unit controller 31 . Additionally or alternatively, the note hopper 34 may be loaded with a significant inventory of notes in anticipation of increased play.
[0027] To play the slot machine 10 , a player initiates play at step 42 by inserting a note into the validator head opening 28 . The note is transported through the validator to scan the note. Data from the validator's sensors is transmitted to the machine processor 48 , which, at step 44 , compares the data to stored data to determine the note's authenticity, denomination, type and condition. If the note is not determined to be authentic, transportation unit controller 31 rejects the note at step 46 and controls the transportation unit 30 to reverse the direction of the drive transport and thereby expel the note through the opening 28 and back to the customer. If the note is determined to be authentic, the denomination or value of the note is transmitted by the machine processor 48 to the CPU 19 , and potentially also to the system server 22 . As discussed above, the CPU 19 stores a corresponding value amount of credits in the gaming machine 10 for gaming. The data is also compared within the transportation unit controller 31 to determine at 50 if the note is of a type, denomination and condition selected for storage in the note hopper 34 . If it is, the transportation unit controller 31 at step 52 further interrogates the transportation unit memory 36 to determine if the maximum storage number of notes to be stored in the note hopper 34 has been met. If the number of notes in the note hopper 34 is less than the instructed maximum number, the note is routed to the note hopper 34 at step 56 . If the maximum number of notes in the note hopper 34 has already been stored in the note hopper 34 , the transportation unit controller 31 controls the transportation unit 30 to transport the received note at step 54 to the note box 32 .
[0028] When a note is transported to the note hopper 34 , the transportation unit memory 36 is updated to indicate that a note has been added to the note hopper 34 . Thus, the transportation unit memory 36 keeps a rung total of the number of notes stored in the note hopper 34 to preferentially maintain a pre-selected number of notes to be stored therein. When a pre-selected maximum number of notes to be stored in the note hopper 34 has been met, additional notes, even though they may be of the denomination, type and condition which would normally be stored in the note hopper 34 , are sent to the note box 32 for storage. If the validated note is not of the pre-selected type to be stored in the note hopper 34 the transportation unit 31 is instructed at step 54 to send the note to the note box 32 .
[0029] When a player hits a jackpot or wishes to cash out their accumulated credits, an appropriate instruction is sent to the machine CPU 19 and potentially also to the central slot server 22 . The machine CPU 19 calculates the payout as a combination of coins/tokens and the appropriate number of notes of the specified note denomination stored in the note hopper 34 . Alternatively, a portion or all of the payout could be made in the form of cash out tickets printed by the printer 37 .
[0030] If the payout is less than the stored note denomination, the payout is made exclusively from the coin hopper assembly 20 to the player and coins/tokens are dispensed. If the payout can include a stored denomination note, e.g. where the gaming machine 10 is a twenty-five cent denomination machine, the denomination of notes stored in the note hopper 34 is twenty dollar notes and the payout is greater than eighty credits, the calculation is made by the CPU 19 and the combination of notes to be dispensed from the note hopper 34 and coin/tokens to satisfy that payout is made. The machine CPU 19 controls the coin hopper assembly 20 to dispense the requisite number of coin\tokens derived from the calculation for the payout and sends an instruction to the transportation unit controller 31 to control the transportation unit 30 to sequentially retrieve one or more notes from the note hopper 34 for dispensing.
[0031] Under instruction from the CPU 19 , the transportation unit controller 31 controls the transportation unit 30 to serially retrieve and transport the required number of notes from the note hopper 34 through the validator head 26 for dispensing through the opening 28 for the payout. In this process, as a note is dispensed, the validator head 26 senses the note and sends a signal to the machines CPU 19 and transportation unit controller 31 to account for the dispensing of the note for the payout. To prevent notes from stacking one behind the other, the validator head 26 also senses the removal of the note from the opening 28 by the customer before an instruction is sent to the transportation unit controller 31 to dispense another note. As notes are dispensed, the transportation unit memory 36 is updated and the number of dispensed notes is deducted. Thus the transportation unit memory 36 keeps a running tally of notes stored in the note hopper 34 . Further as notes are dispensed, the gaming machine's CPU 19 accounts for the dispensing of notes and coin/tokens until the payout is complete, the data corresponding to the payout may also be sent to the central slot system 22 for accounting purposes.
[0032] The acceptor-dispenser 12 preferably has the capability of monitoring the number of notes in the note hopper 34 , the status of the note hopper 34 and the status of the transportation unit 30 . Thus, the system can determine or detect when all notes are depleted from the note hopper 32 and any jamming of notes in the note hopper 34 or transportation unit 30 . It may be beneficial to include a security protocol, for example a password or encryption system, to limit access to the unit controller's program so that the system cannot be changed so as to store or dispense a different denomination of note from the note hopper 34 absent proper authorization. As another security feature, the controller can be programmed so as to preclude any change being made to the denomination of note to be directed to the note hopper 34 if there are any notes in the note hopper 34 . Further, the controller is preferably programmed to allow control over the maximum number of notes dispensed on a payout and the maximum number of notes that can be dispensed in a specified amount of time. This feature is important as casinos may be limited on the maximum amount of a single payout which may be made, and to prevent abuse or laundering of money using the gaming machine.
[0033] As can be appreciated, the note acceptor-dispenser and method of the present invention provide several benefits. One benefit is that it reduces the amount of floor staff required to service the gaming machines by requiring fewer coin/token hopper refills and fewer lockups of the machines heretofore required for hand pay jackpots. Another advantage is that the invention reduces the number of notes which have to be counted in the counting room in that notes are dispensed back to players as jackpots or cash outs. Another feature is that players can quickly receive payouts and thus the system provides more convenience to the players. As another advantage, the note acceptor-dispensers can be re-configured to minimize or maximize the number of notes stored in the hopper box based upon various concerns such as greater or less frequency of play, cash demands and the like.
[0034] The present invention can also be used for vending machines at gasoline service stations and the like where change may be required to be dispensed back to customers. Heretofore, vending machines have typically dispensed all change as coins thus requiring re-filling and servicing of coin hoppers. By providing the note acceptor-dispenser according to the present invention, notes, such one dollar notes, can be inventoried in a hopper to be dispensed as change reducing the requirements for filling of change hoppers and the like.
[0035] As an example of an alternative embodiment of the contemplated invention which would be readily apparent to those skilled in the art following review of the foregoing detailed description, the notes dispensed by the dispensers may be provided through a second opening, distinct and spaced apart from the opening which receives notes to be scanned by the validator. Such an arrangement would have the benefit of decreasing the wear on the validator head units. Accordingly, when a note is to be dispensed, the transportation unit would transport the note to the second opening for dispensing to a customer.
[0036] While we have shown and described certain embodiments of the present invention, it is to be understood that it is subject to many modifications and changes without departing from the spirit and scope of the appended claims.
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An acceptor-dispenser validator system for accepting bills, vouchers, scrip and/or currency into, and for distributing currency or a currency equivalent from, an electronic gaming machine or alternative type of customer service device is disclosed. The system includes a note acceptor-dispenser assembly to be mounted in or on the machine, the note acceptor-dispenser having a note validator to sense the authenticity, denomination, amount and type of the note passing there through and issue a signal corresponding to the note type to the acceptor-dispenser's processor and the host machine's processor for accumulation of credits. A note box is provided to receive deposited notes as is a note hopper to receive and dispense notes intended for payouts.
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FIELD OF THE INVENTION
The present invention relates to new benzocyclobutane compounds, to a process for their preparation and to pharmaceutical compositions containing them.
The compounds of the present invention act as powerful inhibitors of serotonin reuptake and as inhibitors of noradrenaline reuptake.
They can accordingly be used therapeutically in the treatment of depression, panic attacks, obsessive compulsive disorders, phobias, impulsive disorders, drug abuse and anxiety.
Indeed, in the forced swimming test in the mouse (Porsolt et. al., Arch. Intern. Pharmacodyn. Therap., 1977, 229, p. 327) and in the suspension-by-the-tail test in the mouse (Steru et al., Psychopharmacology, 1985, 85, 367-370), the compounds of the present invention demonstrate excellent activity compared with the reference compounds, such as fluoxetine.
The closest prior art to the present invention is illustrated in Patent EP 0 457 686 B1 which relates to 5HT 1A receptor antagonists that can be used in the treatment of pain, stress, migraine, anxiety, depression and schizophrenia, the structure of which could not, however, lead to that of the compounds of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
More specifically, the present invention relates to compounds of formula (I): ##STR3## wherein:
Z 1 , Z 2 , Z 3 , Z 4 , which may be the same or different, each represent a hydrogen atom, a halogen atom, a linear or branched (C 1 -C 6 )alkyl group, a linear or branched (C 2 -C 6 )-alkenyl group, a linear or branched (C 2 -C 6 )alkynyl group, a [(C 3 -C 8 )-cycloalkyl]-(C 1 -C 6 )alkyl group, the alkyl moiety of which is linear or branched, a hydroxy group, a linear or branched (C 1 -C 6 )alkoxy group, a benzyloxy-(C 2 -C 6 )-alkenoxy group, the alkenyl moiety of which is linear or branched, a linear or branched (C 2 -C 6 )alkynoxy group, a cyano group, a trifluoromethyl group, a trifluoromethoxy group, a nitro group, a group of formula --OSO 2 CF 3 , OSO 2 CH 3 , --NHCOCH 3 , --NHCOCF 3 , --NHSO 2 CH 3 , ##STR4## or a group of formula ##STR5## wherein
R 1 and R 2 , which may be the same or different, each represent a hydrogen atom, a linear or branched (C 1 -C 6 )alkyl group, a linear or branched (C 2 -C 6 )alkenyl group, a linear or branched (C 2 -C 6 )alkynyl group, an aryl-(C 1 -C 6 )alkyl group, the alkyl moiety of which is linear or branched, or a [(C 3 -C 8 )cycloalkyl]-(C 1 -C 6 )alkyl group, the alkyl moiety of which is linear or branched,
X represents:
an oxygen atom,
a group of formula S(O) p wherein p represents an integer from 0 to 2 inclusive,
a group of formula --(CH 2 ) n wherein n represents an integer from 1 to 4 inclusive,
or a group of formula --CH 2 --Y--CH 2 -- wherein Y represents an oxygen atom, a selenium atom, a group ##STR6## wherein p is as defined above, ##STR7## or ##STR8## wherein R 1 and R 2 are as defined above,
A represents a group of formula: ##STR9## wherein
R 1 and R 2 are as defined above,
m represents an integer from 1 to 6 inclusive, and
G represents an oxygen atom or the group NH,
their isomers and addition salts thereof with a pharmaceutically acceptable acid.
The term "aryl group" is understood to mean a phenyl, naphthyl, indene, tetrahydronaphthyl, dihydronaphthyl or dihydroindene group, each of those groups being optionally substituted by one or more identical or different groups selected from halogen atoms, linear or branched (C 1 -C 6 )alkyl groups, hydroxy group and linear or branched (C 1 -C 6 )alkoxy groups.
Among the pharmaceutically acceptable acids there may be mentioned by way of non-limiting example hydrochloric acid, hydrobromic acid, sulphuric acid, phosphonic acid, acetic acid, trifluoroacetic acid, lactic acid, pyruvic acid, malonic acid, succinic acid, glutaric acid, fumaric acid, tartaric acid, maleic acid, citric acid, ascorbic acid, oxalic acid, methane-sulphonic acid, comphoric acid, etc.
The preferred group A of the compounds of the invention is the group of formula ##STR10## wherein m, R 1 and R 2 are as defined above.
According to an advantageous embodiment of the invention, the preferred compounds are the compounds of formula (K) wherein X represents a group of formula --(CH 2 ) n -- wherein n is as defined for formula (I).
In an especially advantageous manner, the preferred compounds of the invention are the compounds of formula (I) wherein:
A represents a group of formula ##STR11## wherein R 1 and R 2 are as defined above and m is 1, and X represents a group of formula --(CH 2 ) n -- wherein n is 3.
According to another embodiment of the invention, the preferred compounds are the compounds of formula (I) wherein X represents a group of formula --CH 2 --Y--CH 2 wherein Y is as defined for formula (I).
The preferred groups Z 1 , Z 2 , Z 3 and Z 4 , which may be the same or different, are the groups whose meanings are selected from a hydrogen atom, a halogen atoms, a hydroxy group, a linear or branched (C 1 -C 6 )alkoxy group, a linear or branched (C 1 -C 6 )alkyl group, a trifluoromethyl group and a trifluoromethoxy group.
The preferred compounds of the invention are the compounds of formula (I) corresponding to:
1-(N,N-dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane,
1-(N,N-dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-4-methoxybenzocyclobutane,
and (-)-1-(N,N-dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane.
The isomers and addition salts with a pharmaceutically acceptable acid of the preferred compounds form an integral part of the invention.
The present invention relates to a process for the preparation of compounds of formula (I), characterised in that there is used as starting material:
a compound of formula (II): ##STR12## wherein Z 1 , Z 2 , Z 3 , Z 4 and X are as defined for formula (I),
which is treated with a hydride in ether or in tetrahydrofuran, to yield the compounds of formula (I/a), a particular case of the compounds of formula (I): ##STR13## wherein Z 1 , Z 2 , Z 3 , Z 4 and X are as defined above, which compounds of formula (I/a) are substituted using conventional methods of organic chemistry, such as, for example:
reductive amination starting from the corresponding aldehydes or ketones, in the presence of sodium cyanoborohydride or sodium triacetoxyborohydride, or
nucleophilic substitution of compounds of formula (III):
R'.sub.1 Z (III)
wherein R' 1 has the meaning given above for R 1 with the exception of the meaning hydrogen, and Z is a leaving group such as, for example, I, Br, Cl, ##STR14## or ##STR15## to yield the secondary amines of formula (I/b), a particular case of the compounds of formula (I): ##STR16## wherein Z 1 , Z 2 , Z 3 , Z 4 , X and R' 1 are as defined above,
which compounds of formula (I/b) are again substituted using the same methods as those described above to yield the tertiary amines of formula (I/c), a particular case of the compounds (I): ##STR17## wherein Z 1 , Z 2 , Z 3 , Z 4 and X are as defined above and R' 1 and R' 2 have the meanings given above for R 1 and R 2 , respectively, with the exception of the meaning hydrogen, with the proviso that when R' 1 and R' 2 are the same, each being other than hydrogen, the tertiary amines of formula (I/c) are obtained directly from the amine (I/a) without having to isolate the secondary amine (I/b),
or a compound of formula (IV): ##STR18## wherein Z 1 , Z 2 , Z 3 , Z 4 are as defined for formula (I), which is substituted, in the presence of a strong base, by an amine of formula (V): ##STR19## wherein R 1 and R 2 are as defined for formula (I), m1 is an integer from 2 to 6 inclusive and L represents a leaving group, such as a halogen atom, a mesylate, tosylate or trifluoromethanesulphonate group, etc.,
to yield compounds of formula (VI): ##STR20## wherein Z 1 , Z 2 , Z 3 , Z 4 , R 1 , R 2 and m1 are as defined above,
which compounds of formula (VI) are treated under conditions of alcoholic acid hydrolysis in the presence of a compound of formula (VII):
G--OH (VII)
wherein G represents a linear or branched (C 1 -C 6 )alkyl group,
to yield compounds of formula (VIII): ##STR21## wherein Z 1 , Z 2 , Z 3 , Z 4 , R 1 , R 2 , G and m1 are as defined above,
which compounds of formula (VIII) are treated with a dimagnesium compound of formula (IX):
Z'--Mg--CH.sub.2 --X--CH.sub.2 --Mg--Z' (IX)
wherein X is as defined for formula (I) and Z' represents a halogen atom,
to yield the compounds of formula (I/d), a particular case of the compounds of formula (I): ##STR22## wherein Z 1 , Z 2 , Z 3 , Z 4 , R 1 , R 2 , X and m1 are as defined above,
the totality of the compounds of formula (I/a) and formula (I/d), in the particular case where R 1 and R 2 simultaneously represent a hydrogen atom, constituting the compounds of formula (I/e): ##STR23## wherein Z 1 , Z 2 , Z 3 , Z 4 , X and m are as defined for formula (I),
which compounds of formula (I/e) are:
→ either treated with 2-chloroethyl isocyanate in acetonitrile in the presence of triethylamine to yield the compounds of formula (I/f), a particular case of the compounds of formula (I): ##STR24## wherein Z 1 , Z 2 , Z 3 , Z 4 , X and m are as defined above, → or treated with imidazolin-2-ylsulphonic acid in the presence of an organic or mineral base in an alcohol or in acetonitrile to yield the compounds of formula (I/g), a particular case of the compounds of formula (I): ##STR25## wherein Z 1 , Z 2 , Z 3 , Z 4 , X and m are as defined above, which compounds (I/a) to (I/g) constitute the totality of the compounds of the invention, which are purified, if necessary, according to a conventional purification technique, which may be separated, if desired, into their various isomers according to a conventional separation technique, and which are converted, where appropriate, into addition salts thereof with a pharmaceutically acceptable acid.
The starting materials of formula II and IV are either known products or products obtained from known substances according to known processes.
The present invention relates also to pharmaceutical compositions comprising as active ingredient at least one compound of formula (I), its optical isomers or an addition salt thereof with a pharmaceutically acceptable acid, on its own or in combination with one or more inert, non-toxic, pharmaceutically acceptable excipients or carriers.
Among the pharmaceutical compositions according to the invention there may be mentioned more especially those that are suitable for oral, parenteral (intravenous, intramuscular or subcutaneous), per- or trans-cutaneous, nasal, rectal, perlingual, ocular or respiratory administration, and especially sublingual tablets, sachets, gelatin capsules, lozenges, suppositories, creams, ointments, dermal gels, injectable or drinkable preparations, aerosols, eye or nose drops, etc.
The useful dosage varies according to the age and weight of the patient, the route of administration, the nature and severity of the disorder, and whether any other treatments are being taken, and ranges from 0.5 to 25 mg of active ingredient, from one to three times per day.
The following Examples, given by way of non-limiting example, illustrate the present invention.
The melting points were determined using a Kofler hot-plate (K), or a hot-plate under a microscope (MK).
The starting materials used are known products or products prepared according to known procedures.
EXAMPLE 1
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)benzocyclobutane and the hydrochloride thereof
Step A: 1-Cyano-1-(1-hydroxycyclohex-1-yl)benzocyclobutane
Whilst maintaining the temperature at -78° C., 69 ml of 1.6M butyllithium in n-hexane are added to a solution of 12.9 g of 1-cyanobenzocyclobutane in 200 ml of tetrahydrofuran. After stirring for half an hour at that temperature, 15.5 ml of cyclohexanone are added and the reaction mixture is brought back to room temperature. After stirring for 3 hours at room temperature, the reaction mixture is hydrolysed at -10° C. with water. After extraction with diethyl ether, the organic phase is washed with brine, dried over MgSO 4 and concentrated in vacuo. The crystalline residue is recrystallised from isopropyl ether to yield 12.32 g of the desired product.
Melting point (K): 109-110° C.
Step B: 1-Aminomethyl-1-(1-hydroxycyclohex-1-yl)benzocyclobutane
0.7 g (18.55 mM) of LiAlH 4 is suspended in 38 ml of ether. The suspension is cooled to 0° C., and then a solution of 1.72 g (7.58 mM) of the product obtained in Step A in 38 ml of tetrahydrofuran is poured in whilst maintaining the temperature at from 0 to 5° C. After half an hour at that temperature, the reaction mixture is stirred for 3 hours at room temperature and then hydrolysed with 1 ml of water, 3 ml of 20% sodium hydroxide solution and again with 4 ml of water. Filtration and concentration are carried out to obtain 1.74 g of the expected product.
Step C: 1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)benzocyclobutane hydrochloride
0.5 g (2.16 mM) of the product obtained in Step B is dissolved in 40 ml of CH 3 CN. The suspension is cooled to 0° C. 0.3 g (4.33 mM) of sodium cyanoborohydride is then added, followed by 1 ml (11 mM) of 37% formaldehyde in water. Stirring is carried out for 2 hours at room temperature, and then the same quantities of sodium cyanoborohydride and formaldehyde are added and stirring is carried out again for 18 hours at room temperature. Hydrolysis is carried out with 5 ml of 1N HCl and, after 1 hour of contact, the mixture is diluted with distilled water, washed with ether and rendered basic with normal sodium hydroxide solution. Extraction, drying and evaporation yield 0.5 g of the desired product, which is converted into the hydrochloride thereof by the addition of a solution of ethereal hydrogen chloride. Recrystallisation from acetonitrile yields 0.45 g of the desired product.
Melting point (M.K.): 234-235° C.
EXAMPLE 2
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-4,5-dimethoxybenzocyclobutane and the hydrochloride thereof
The procedure is as for Example 1 using 1-cyano-4,5-dimethoxybenzocyclobutane as substrate in Step A.
Melting point (M.K.): 201-203° C.
EXAMPLE 3
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane and the hydrochloride thereof
The procedure is as for Example 1 using 1-cyano-5-methoxybenzocyclobutane as substrate in Step A.
Melting point (M.K.): 225-227° C.
EXAMPLE 4
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-4-methoxybenzocyclobutane and the hydrochloride thereof
The procedure is as for Example 1 using 1-cyano-4-methoxybenzocyclobutane as substrate in Step A.
Melting point (M.K.): 195-199° C.
EXAMPLE 5
1-(Aminomethyl)-1-(1-hydroxycyclohex-1-yl)-4-methoxybenzocyclobutane and the hydrochloride thereof
The procedure is as for Example 1, Steps A and B using 1-cyano-4-methoxybenzocyclobutane as substrate in Step A.
Melting point (M.K.): 206-209° C.
EXAMPLE 6
1-(N,N-Methylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane and the hydrochloride thereof
Step D: 1-(Aminomethyl)-1-(1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane
The procedure is as for Step B of Example 1 using 1-cyano-1-(1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane as starting material.
Step E: Ethyl N-{(1-hydroxycyclohex-1-yl-5-methoxybenzocyclobutan-1-yl)methyl}-carbamate
A solution of 2 g (7.65 mM) of the compound obtained in Step D and 2.6 ml (19.8 mM) of triethylamine in 100 ml of methylene chloride is poured into a solution, cooled to 0° C., of 0.61 ml (7.65 mM) of ethyl chloroformate in 50 ml of methylene chloride. Stirring is carried out for 24 hours at room temperature, and the mixture is siluted with water and extracted with methylene chloride. The organic phases are washed first with 1N HCl and then with water until neutral and finally dried over MgSO 4 to yield, after evaporation, 2.2 g of the expected product.
Step F: 1-(N-Methylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane hydrochloride
A solution of 2.2 g (6.6 mM) of the product obtained in Step E in 50 ml of tetrahydrofuran is introduced dropwise into a suspension of 376 mg of LiAlH 4 (9.9 mM) in 40 ml of tetrahydrofuran. The mixture is refluxed for 3 hours, and is then left overnight at room temperature. After hydrolysis with 0.26 ml of water, 0.2 ml of sodium hydroxide solution and 0.94 ml of water, filtration and evaporation to dryness are carried out to obtain 1.8 g of the expected product, which is converted into the hydrochloride by the addition of ethereal hydrogen chloride.
Melting point (M.K.): 199-206° C.
EXAMPLE 7
(+)-Isomer of 1-(N,N-dimethyaminomethyl)-1-(1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane and the hydrochloride thereof
2 g of the compound of Example 3 are subjected to high-performance chromatography (H.P.L.C.) on a chiral column of the CHIRALCEL OD® type, the mobile phase being composed of n-heptane/isopropanol/diethylamine in the proportions 1000/25/1. The first compound eluted corresponds to the title product with an enantiomeric excess of 99%, which compound is converted into the hydrochloride by the action of ethereal hydrogen chloride.
Melting point (M.K.): 228-232° C.
______________________________________[α].sup.25° C. (c = 1% in CH.sub.3 OH) (nm) α______________________________________ 589 +16.5 578 +17.2 546 +19.7 436 +35.9 365 +61.5______________________________________
EXAMPLE 8
(-)-Isomer of 1-(N,N-dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane and the hydrochloride thereof
The second compound separated out during the chromatography carried out in Example 7 corresponds to the title product with an enantiomeric excess of 99%, which compound is converted into the hydrochloride thereof.
Melting point (M.K.): 228-232° C.
______________________________________[α].sup.25° C. (c = 1% in CH.sub.3 OH) (nm) α______________________________________ 589 -16.6 578 -17.3 546 -20.0 436 -36.7 365 -63.3______________________________________
EXAMPLE 9
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-6-methoxybenzocyclobutane
Step G: 6-Methoxybenzocyclobutan-1-ol
13.21 g (0.35 mol) of sodium borohydride are added in small fractions to a solution, maintained at 0° C., of 42.8 g (0.29 mol) of 6-methoxybenzocyclobutan-1-one in 1.5 liters of methanol. The temperature is maintained at 0° C. for 2 hours. After returning to room temperature, the reaction mixture is evaporated to dryness and then taken up in water. The aqueous phase is extracted several times with ethyl acetate. The organic phases are combined, washed with brine, dried over MgSO 4 , filtered and evaporated to yield, after chromatography on silica, 29.2 g of the expected product in the form of a solid, the melting point of which is 71-73° C.
Step H: 1-Bromo-6-methoxybenzocyclobutane
13.5 ml (0.144 mol) of phosphorus tribromide are poured slowly into a solution of 29.1 g (0.194 mol) of the product obtained in the preceding Step in 940 ml of NaHCO 3 at 0° C. The mixture is maintained at that temperature for 20 minutes and then hydrolysed with 900 ml of NaHCO 3 at 0° C. The aqueous phase is extracted several times with ether. The combined ethereal phases are washed with water, dried over MgSO 4 , filtered and evaporated to yield 23.1 g of yellow oil which corresponds to the structure of the expected product.
Step I: 1-Cyano-6-methoxybenzocyclobutane
10.5 g (0.16 mol) of potassium cyanide are added rapidly to a solution of 22.9 g (0.1 mol) of the product obtained in the preceding Step in 240 ml of dimethyl sulphoxide. The mixture is then heated at 55° C. for 4 hours. After returning to room temperature, the reaction mixture is poured into two liters of water. The aqueous phase is extracted several times with ether. The organic phases are washed with water, dried over MgSO 4 , filtered and evaporated. The residue is chromatographed on silica (eluant CH 2 Cl 2 /cyclohexane: 50/50) to yield 10.4 g of the expected product, which melts at 58-59° C.
Step J: 1-Cyano-1-(1-hydroxycyclohex-1-yl)-6-methoxybenzocyclobutane
The procedure is as for Step A of Example 1 using the product obtained in Step I as substrate.
Melting point (K.): 116-120° C.
Step K: 1-Aminomethyl-1-(1-hydroxycyclohex-1-yl)-6-methoxybenzocyclobutane
The procedure is as for Step B of Example 1 using the product obtained in Step J as substrate.
Melting point (K.): 90-92° C.
Step L: 1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-6-methoxybenzocyclobutane
The procedure is as for Step C of Example 1, starting from the compound obtained in Step K.
Melting point (M.K.): 125-133° C.
EXAMPLE 10
1-(N,N-Dimethylaminomethyl)-1-(4-hydroxytetrahydro-4H-pyran-4-yl)-4-methoxybenzocyclobutane
The procedure is as for Example 1 using 1-cyano-4-methoxybenzocyclobutane and tetrahydro-4H-pyran-4-one, respectively, as substrates in Step A.
Melting point (K.): 88-90° C. (free base)
EXAMPLE 11
(+)-1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-4-methoxybenzocyclobutane hydrochloride
2 g of the compound of Example 4 are separated on a chiral column of the CHIRALCEL OD® type of H.P.L.C., the mobile phase being composed of n-heptane/isopropanol/CF 3 CO 2 H in the proportions 1000/30/1. The first compound eluted corresponds to the expected product with an enantiomeric excess of 99.5%, which compound is converted into the hydrochloride by the action of ethereal hydrogen chloride.
Melting point (M.K.): 194-206° C.
______________________________________[α].sup.25° C. (c = 1% in CH.sub.3 OH) (nm) α______________________________________ 578 +0.98 546 +1.33 436 +4.78______________________________________
EXAMPLE 12
(-)-1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-4-methoxybenzocyclobutane hydrochloride
The second compound separated out during the chromatography carried out in Example 11 corresponds to the expected product with an enantiomeric excess of 99%. It is converted into the hydrochloride by ethereal hydrogen chloride.
Melting point (M.K.): 210-212° C.
______________________________________[α].sup.25° C. (c = 1% in CH.sub.3 OH) (nm) α______________________________________ 578 -1.32 546 -1.6 436 -5.94______________________________________
EXAMPLE 13
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-4-methoxy-5-chlorobenzocyclobutane hydrochloride
The procedure is as for Example 1 using 5-chloro-1-cyano-4-methoxybenzocyclobutane as substrate in Step A.
Melting point (M.K.): 230-235° C.
EXAMPLE 14
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-3-fluorobenzocyclobutane hydrochloride
The procedure is as for Example 1 using 1-cyano-3-fluorobenzocyclobutane as substrate in Step A.
Melting point (M.K.): 240-245° C.
EXAMPLE 15
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-3-chlorobenzocyclobutane hydrochloride
The procedure is as for Example 1 using 3-chloro-1-cyanobenzocyclobutane as substrate in Step A.
Melting point (M.K.): 242-245° C.
EXAMPLE 16
1-(N,N-Dimethylaminomethyl)-1-(4-hydroxytetrahydro-4H-thiopyran-4-yl)-5-methoxybenzocyclobutane
The procedure is as for Example 1 using 1-cyano-5-methoxybenzocyclobutane and tetrahdyro-4H-thiopyran-4-one, respectively, as substrate.
Melting point (M.K.): 118-123° C.
EXAMPLE 17
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-4-trifluoromethylbenzocyclobutane hydrochloride
The procedure is as for Example 1 using 1-cyano-4-trifluoromethylbenzocyclobutane as substrate in Step A.
Melting point (M.K.): 208-212° C.
EXAMPLE 18
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-5-fluorobenzocyclobutane hydrochloride
The procedure is as for Example 1 using 1-cyano-5-fluorobenzocyclobutane as substrate in Step A.
Melting point (M.K.): 233-238° C.
EXAMPLE 19
1-Aminomethyl-1-(1-hydroxycyclohex-1-yl)-4-hydroxybenzocyclobutane
The procedure is as for Example 1, Steps A and B, using 1-cyano-4-hydroxybenzocyclobutane as substrate in Step A.
Melting point (M.K.): 185-190° C.
EXAMPLE 20
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-4-hydroxybenzocyclobutane
The compound obtained in Example 19, treated according to the operating conditions described in Step C of Example 1, enables the expected product to be obtained.
Melting point (M.K.): 222-225° C.
EXAMPLE 21
1-Aminomethyl-1-(1-hydroxycyclohex-1-yl)-5-hydroxybenzocyclobutane
The procedure is as for Example 19 using 1-cyano-5-hydroxybenzocyclobutane as starting substrate.
Melting point (M.K.): 185-190° C.
EXAMPLE 22
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-5-hydroxybenzocyclobutane
The compound obtained in Example 21, treated according to the operating conditions described in Step C of Example 1, enables the expected product to be obtained.
Melting point (M.K.): 177-182° C.
EXAMPLE 23
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-4,5-dichlorobenzocyclobutane
The procedure is as for Example 1 using 4,5-dichloro-1-cyanobenzocyclobutane as substrate in Step A.
Melting point (M.K.): 135-137° C.
EXAMPLE 24
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-6-chlorobenzocyclobutane hydrochloride
The procedure is as for Example 1 using 1-cyano-6-chlorobenzocyclobutane as substrate in Step A.
Melting point (M.K.): 195-205° C.
EXAMPLE 25
1-(N,N-Dimethylaminomethyl)-1-(4-tert-butyl-1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane hydrochloride
The procedure is as for Example 1 using 1-cyano-5-methoxybenzocyclobutane and 4-tert-butyl-cyclohexanone, respectively, as substrate in Step A.
Melting point (M.K.): 206-220° C.
EXAMPLE 26
1-(N,N-Dimethylaminomethyl)-1-(4,4-dimethyl-1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane hydrochloride
The procedure is as for Example 1 using 1-cyano-5-methoxybenzocyclobutane and 4,4-dimethylcyclohexanone, respectively, as substrate in Step A.
Melting point (M.K.): 180-215° C. (sublimation at from 210 to 212° C.)
EXAMPLE 27
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxy-4-selenocyclohex-1-yl)-5-methoxybenzocyclobutane
The procedure is as for Example 1 using 1-cyano-5-methoxybenzocyclobutane and 4-selenocyclohexanone, respectively, as substrate in Step A.
Melting point (M.K.): 113-120° C.
EXAMPLE 28
1-(N,N-Dimethylaminomethyl)-1-(4-hydroxy-1-methyl-piperidin-4-yl)-5-methoxybenzocyclobutane
The procedure is as for Example 1 using 1-cyano-5-methoxybenzocyclobutane and 1-methyl-4-piperidinone, respectively, as substrate in Step A.
Melting point (M.K.): 113-116° C.
EXAMPLE 29
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-5-(trifluoromethylsulphonate)benzocyclobutane fumarate
The procedure is as for Example 1 using 1-cyano-5-(trifluoromethylsulphonate)benzocyclobutane as substrate in Step A.
Melting point (M.K.): 72-77° C.
EXAMPLE 30
1-(N,N-Dimethylaminomethyl)-1-(1-hydroxycyclohex-1-yl)-6-bromobenzocyclobutane
The procedure is as for Example 1 using 1-cyano-6-bromobenzocyclobutane as substrate in Step A.
Melting point (M.K.): 196-200° C.
EXAMPLE 31
1-(N-Imidazolin-2-yl-aminomethyl)-1-(1-hydroxycyclohex-1-yl)-4-methoxybenzocyclobutane
2 g of the compound of Example 5 are dissolved in a solution containing 1.16 ml of triethylamine, 1.2 g of imidazolin-2-ylsulphonic acid and 16 ml of acetonitrile and the mixture is refluxed for 3 hours. The mixture is diluted with methylene chloride, washed with normal sodium hydroxide solution and then with water, dried over MgSO 4 and evaporated. Crystallisation from ether is carried out to obtain 600 mg of a solid which corresponds to the expected product.
EXAMPLE 32
1-[2-(N,N-Dimethylamino)ethyl]-1-(1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane
Step 1: 1-[2-(N,N-Dimethylamino)ethyl]-1-cyano-5-methoxybenzocyclobutane
A solution of 10.5 ml of diisopropylamine in 55 ml of tetrahydrofuran is cooled to -78° C., and then 47 ml of a 1.6M solution of n-butyllithium in cyclohexane are added dropwise. Stirring is carried out for 15 minutes at -78° C. and then 10.8 g of 2-chloroethyldimethylamine hydrochloride are added rapidly. Stirring is carried out for 30 minutes at -78° C.
There is also prepared in a second three-necked flask a solution, cooled to -25° C., of 8.8 ml of diisopropylamine in 75 ml of tetrahydrofuran. 39.2 ml of a 1.6M solution of n-butyllithium in cyclohexane are added to that solution. After 15 minutes at -25° C., a solution of 10 g of 1-cyano-5-methoxybenzocyclobutane in 75 ml of tetrahydrofuran is added to the reaction mixture. Stirring is carried out for 30 minutes at -25° C.
Using a cannula, the first solution is transferred into the second at -78° C. Stirring is carried out at -78° C. for 1 hour and then the mixture is left overnight at room temperature. Hydrolysis is carried out at 0° C. with ammonium chloride. Extraction is carried out with ether, and the organic phase is dried over MgSO 4 , filtered and evaporated to dryness. The residue obtained is taken up in 250 ml of HCl (1N) and washed with ether, and then the aqueous phase is adjusted to a pH of 12 with 20% sodium hydroxide solution. After extraction with methylene chloride and washing with water, the solution is dried over MgSO 4 and evaporated. 12.9 g of the expected product are obtained in the form of a pale yellow oil.
Step 2: 1-[2-(N,N-Dimethylamino)ethyl]-1-methoxycarbonyl-5-methoxybenzocyclobutane
6 g of the product obtained in the preceding Step are solubilised in 100 ml of methanol and 100 ml of methylene chloride. The solution is cooled to 0° C. and hydrogen chloride gas is bubbled in for 15 minutes. The mixture is left at room temperature for 3 days. After concentration under reduced pressure, the residue is solubilised in water and neutralised, with cooling, with a solution of 10% sodium hydrogen carbonate in water. Chromatography on silica gel (dichloromethane/methanol: 90/10) enables the expected product to be isolated.
Step 3: 1-[2-(N,N-Dimethylamino)ethyl]-1-(1-hydroxycyclohex-1-yl)-5-methoxybenzocyclobutane
5 g of the product obtained in the preceding Step dissolved in 50 ml of tetrahydrofuran are added slowly to 45.2 ml of a 0.5M solution of pentane-1,5-di(magnesium bromide) in tetrahydrofuran, whilst maintaining the temperature at 0° C. Stirring is carried out for 15 minutes at 0° C., and then for 1 hour at room temperature. The mixture is poured into an aqueous saturated ammonium chloride solution. Extraction is carried out with ether, and the extract is dried over magnesium sulphate, filtered and evaporated to dryness. Chromatography on silica gel (dichloromethane/ethanol: 90/10) enables the expected product to be isolated.
PHARMACOLOGICAL STUDY OF THE COMPOUNDS OF THE INVENTION
A. In vitro study
EXAMPLE 33
Determination of the affinity for serotonin reuptake sites
The affinity was determined by competitive experiments using [ 3 H]-paroxetine (NEN, Les Ulis, France). The membranes are prepared from frontal cortex of rate and are incubated in triplicate with 1.0 nM [ 3 H]-paroxetine and the cold ligand in a final volume of 0.4 ml, for 2 hours at 25° C. The incubation buffer contains 50 nM TRIS-HCl (pH 7.4), 120 mM NaCl and 5 mM KCl. The non-specific binding is determined using 10 μM citalopram. At the end of the incubation, the incubation medium is filtered and washed three times with 5 ml of cooled buffer. The radioactivity retained on the filters is determined by liquid scintillation counting. The binding isotherms are analysed by non-linear regression to determine the IC 50 values. Those values are converted into a dissociation constant (K i ) using the Cheng-Prusoff equation:
K.sub.i =IC.sub.50 /(1+L/K.sub.d)
wherein L is the concentration of [ 3 H]-paroxetine and K d is the dissociation constant of [ 3 H]-paroxetine for the serotonin reuptake site (0.13 nM). The results are expressed in pK i (-log K i ).
The compounds of the present invention demonstrate very good affinity for the serotonin reuptake sites. By way of example, the pK i of the compound of Example 8 is 8.7. By way of comparison, the pK i of fluoxetine in this test is 8.
EXAMPLE 34
Determination of the affinity for noradrenaline reuptake sites
The affinity was determined by competitive experiments using [ 3 H]-nisoxetine (Amersham, les Ulis, France). The membranes are prepared from frontal cortex of rat and are incubated in triplicate with 2 nM [ 3 H]-nisoxetine and the cold ligand in a final volume of 0.5 ml, for 4 hours at 4° C. The incubation buffer contains 50 mM TRIS-HCl (pH 7.4), 300 mM NaCl and 5 mM KCl. The non-specific binding is determined using 10 μM desipramine. At the end of the incubation, the incubation medium is filtered and washed three times with 5 ml of cooled filtration buffer (50 mM TRIS-HCl, pH 7.4, 300 mM NaCl and 5 mM KCl). the radioactivity retained on the filters is determined by liquid scintillation counting. The binding isotherms are analysed by non-linear regression to determine the IC 50 values. Those values are converted into a dissociation constant (K i ) using the Cheng-Prusoff equation:
K.sub.i =IC.sub.50 /(1+L/K.sub.d)
wherein L is the concentration of [ 3 H]-nisoxetine and K d is the dissociation constant of [ 3 H]-nisoxetine for the noradrenaline reuptake site (1.23 nM). The results are expressed in pKi (-log Ki).
By way of example, the compound of Example 9 has a pKi of 7.25.
B. In vivo study
EXAMPLE 35
Forced swimming test in the mouse (Porsolt et al., 1977)
The forced swimming test in the mouse consists of inducing a state of despair in the animal by placing it for 6 minutes in a cylinder full of water, from which it cannot escape. The naive animal struggles vigorously for the first few minutes and then adopts an immobile posture for the last few minutes of the test. Antidepressant products reduce the duration of immobility of the animal during the test.
the animals are male CD (IFFA-CREDO) mice (22-26 g) which, on the day before the test, are placed individually in transparent plastic cages (25×15×14 cm) on sawdust, with food and drink as desired. On the day of the test, 30 minutes after treatment (product or solvent, administered sub-cutaneously), each mouse is plunged for 6 minutes (T0-T6) in a glass cylinder (23.5 cm in height, 11.5 cm in diameter) filled to a height of 6 centimeters with water maintained at 24±0.5° C. The total duration of immobility (sec.) of the animal during the last 4 minutes of the test (T2-T6) is observed: a mouse is considered to be immobile when it is floating in the water, making only small movements to keep its head out of the water.
The differences between the treated groups (product) and the control group (solvent) are evaluated statistically by variance analysis followed by Dunnett's test wherein p<0.05.
By way of example and to illustrate the effects of the compounds of the invention, the results for the compound of Example 4 are given in the following Table.
______________________________________ Doses Duration ofTreatment mg/kg s.c. immobility (sec.) %/control N______________________________________Control solvent 167.1 ± 16.1 6Compound of 0.63 157.3 ± 18.9 94 3Example 4 2.5 101.6 ± 57.3 61 3 10.0 6.1 ± 6.1* 4 4Control solvent 173.6 ± 10.1 12fluoxetine 2.5 163.5 ± 33.4 94 5 10.0 130.5 ± 23.5 75 7 40.0 127.1 ± 25.2 73 8______________________________________ *p < 0.05
EXAMPLE 36
Suspension-by-the-tail test in the mouse
In this variation of the forced swimming test, the state of despair is induced in the mouse by suspending it head down by its tail. Placed in that uncomfortable situation, the animal struggles vigorously to start with and then adopts an immobile posture. Antidepressant products reduce the duration of immobility of the animal.
The animals are male NMRI (IFFA-CREDO) mice (22-26 g) which are housed, in groups of 20, in transparent plastic cages (59×38×20 cm) on sawdust, with food and drink as desired. On the day of the test, each mouse is placed in a separate cage as soon as it has been treated (sub-cutaneously) with the product or the solvent. Thirty minutes later, the animal is suspended by the tail from a hook using an adhesive tape attached to the tail. The hook is connected to a tension sensor which transmits all the animal's movements to a central processor (ITEMATIC-TST 1 system, ITEM-LABO, France). The total duration (sec.) of immobility of the animal during the 6 minutes of the test is recorded automatically.
The differences in the duration of immobility between the treated groups (product) and the control group (solvent) are analysed statistically by ANOVA followed by Dunnett's test, wherein p<0.05.
By way of example and to illustrate the effects of the compounds of the invention, the results for the compound of Example 3 are shown in the Table below.
______________________________________ DosesTreatment mg/kg s.c. Immobility (sec.) %/control N______________________________________Control solvent 0 80.3 ± 14.3 12Compound of 0.63 70.4 ± 13.5 88 8Example 3 2.5 41.1 ± 9.6 51 8 10.0 27.8 ± 9.6* 35 8Control solvent 76.6 ± 11.3 17fluoxetine 40.0 69.9 ± 17.8 91 10 80.0 84.3 ± 12.4 110 10______________________________________ *p < 0.05.
The results in the tests above illustrate the excellent activity of the compounds of the invention, especially in comparison with the reference compound.
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A compound of formula (I): ##STR1## wherein: Z 1 , Z 2 , Z 3 , Z 4 , which may be identical or different, represent a group as defined in the description,
X represents oxygen, S(O) p , --(CH 2 ) n -- or --CH 2 --Y--CH 2 -- wherein p, n and Y are as defined in the description,
A represents ##STR2## wherein m, R 1 , R 2 and G are as defined in the description, their isomers and addition salts thereof with a pharmaceutically-acceptable acid, and medicinal products containing the same are useful in the treatment of diseases like depression, panic attacks, obsessive compulsive disorders, phobias, impulsive disorders, drug abuse or anxiety.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/225,708, filed Jul. 15, 2009 entitled “SELF ACTUATING ROTARY DUST VALVE” and which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a rotary dust valve and, more particularly, to a self actuating rotary dust valve for discharging dust from a partial vacuum in an engine intake tract into the outside air.
BACKGROUND OF THE INVENTION
[0003] Internal combustion engines are typically protected from acquiring dust and debris in the intake combustion air by the presence of an air filter or air cleaner in the air intake tract. When operated in dusty or particulate debris laden environments, dust and debris can quickly accumulate in the air cleaner. Further movement of the debris is blocked by the filtering activity of the air filter, and so accumulated debris must be removed to prevent obstruction of the air cleaner filter element.
[0004] As the engine draws combustion air through the intake tract and air cleaner, the air cleaner operates at a slight vacuum relative to outside air pressure. This vacuum works against urging dust and debris to exit the air cleaner through the dust valve as the vacuum will tend to draw dust and debris back into the air cleaner rather than permitting the debris to exit to the outside.
[0005] Various types of flap valves are applied as dust valves in the prior art. These valves have lips that are held closed by the vacuum and may be responsive to pressure pulsations in the intake tract, as due to the operation of the engine. In response to momentary pressure fluctuations, such flap valves may momentarily open to discharge dust from within the air cleaner into the environment. If the pressure pulsations are insufficient or the vacuum too strong to permit the flap valve lips to open, then some varieties of the flap valves will open when the engine is shutdown and the vacuum is thereby removed. If the flap valve fails to reliably periodically open (perhaps due to the operating vacuum, insufficient engine air intake pressure pulsations, elastomeric aging or other issues), then dust accumulates in the air cleaner and air filter obstruction is not avoided.
[0006] With the advent of tier 4 emission standards, engine manufacturers are providing designs that have a steadier air intake pressure and reduce pressure pulsations; therefore engine intake air pressure pulsations may be insufficient to operate dust removal flap valves and the like.
[0007] Additionally the elastomers of elastomeric dust valves can age, lose their resilience or even disintegrate and therefore fail to close or close fully during operation. This is undesirable as drawing outside air in the reverse direction through the dust valve can draw in outside dust and debris and, due to the vacuum in the air intake tract, prevent accumulated debris in the air cleaner or intake tract from being expelled to the environment.
[0008] Therefore, there remains a need in the art for a dust valve that avoids elastomeric aging issues, is low in cost, prevents back-flow through the dust valve, is self actuating and is able to eject dust while operating against intake tract vacuum.
SUMMARY OF THE INVENTION
[0009] In aspects of the invention a self actuating rotary dust valve is provided. The present invention is particularly beneficial in ejecting dust from an engine air cleaner, and provides a low cost, self actuating, compact and reliable solution. The rotary dust valve includes a valve body having an inlet port, an outlet port and a rotor chamber interposed therebetween. A rotary dust ejection member is enclosed in the rotor chamber and supported for rotation about a fixed axis within the chamber. The axis of rotation is substantially perpendicular to the alignment between the inlet and outlet ports. The rotary dust valve includes a hub member rotatably supported to rotate in the rotor chamber about the axis of rotation. A plurality of fin members are provided angularly spaced about and secured to the hub member. Each fin member extends radially outwards from the hub member. The fin members share a common size and shape and are configured to rotate in unison about the axis. Adjacent pairs of the fin members define at least one dust pocket therebetween to receive dust from the air cleaner to be ejected. The fin members are arranged such that as the fin members rotate about the axis, the dust pockets are caused to open to the inlet port when in a first position and then to open to the outlet port when in a second position. The fin members are configured to open a dust pocket to no more than one of the ports at any time. The rotor chamber and the fin members are cooperatively shaped and configured to maintain a continuous air lock closure between the inlet and outlet port as the fin members rotate about the axis within the chamber, providing pressure and air flow separation between the inlet and outlet ports. The fin members freely rotate in unison about the axis such that dust buildup in the dust pocket in the first position is operable by gravity and/or vibration to rotate the duct pocket with buildup into the second position to discharge the dust buildup through the outlet port.
[0010] In another aspect of the invention, the fin members are angularly positioned about the axis for uniform angular displacement between adjacent fin members, relative to the axis of rotation.
[0011] In another aspect of the invention, cylindrical shaft portions extend axially from opposing ends of the hub member. The shafts are sized to extend to and receive support from opposing sidewalls of the rotor chamber.
[0012] In another aspect of the invention, two pin members are provided, each secured to an opposing sidewall of the rotor chamber. The pins are positioned along the axis of rotation and protrude inwardly along the axis into the chamber. The opposing ends of the hub member each have a bore. The bores are each configured to receive and rotate about a portion of the pins such that the hub member and fin members are free to rotate in the rotor chamber.
[0013] In another aspect of the invention, a shaft is provided having a length selected to extend between and receive support from opposing sidewalls of the rotor chamber. The shaft is aligned with the axis and extends through an axially aligned bore in the hub member.
[0014] In another aspect of the invention, the hub and fin members rotate in unison upon the shaft.
[0015] In another aspect of the invention, the shaft rotatably supports the hub and fin members on the opposing sidewalls such that the shaft, hub and fin members rotate in unison.
[0016] In another aspect of the invention, the fin members are substantially planar.
[0017] In another aspect of the invention, the fin members may be curved, S-shaped, concave or convex.
[0018] In another aspect of the invention, the dust valve is positioned with the inlet port positioned vertically above the outlet port such that the ejection of dust is aided by gravity.
[0019] In another aspect of the invention, the inlet port is connected to an air cleaner of an internal combustion engine.
[0020] The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying Figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention.
[0022] Features of the present invention, which are believed to be novel, are set forth in the drawings and more particularly in the appended claims. The invention, together with the further objects and advantages thereof, may be best understood with reference to the following description, taken in conjunction with the accompanying drawings. The drawings show a form of the invention that is presently preferred; however, the invention is not limited to the precise arrangement shown in the drawings.
[0023] FIG. 1 is a schematic diagram of an air intake tract of an internal combustion engine, consistent with the present invention;
[0024] FIG. 2A depicts a perspective view of a rotary dust valve, consistent with the present invention;
[0025] FIG. 2B is a side sectional view of the rotary dust valve presented in FIG. 2A ; and
[0026] FIG. 2C is a perspective view of an exemplary rotary dust ejection member, consistent with the present invention.
[0027] Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.
DETAILED DESCRIPTION
[0028] Before describing in detail embodiments that are in accordance with the present invention, it should be observed that the embodiments reside primarily in combinations of method steps and apparatus components related to a self actuating rotary dust valve apparatus. Accordingly, the apparatus components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
[0029] In this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.
[0030] FIG. 1 is a schematic diagram of an air intake tract 100 of an internal combustion engine 102 . Air enters the tangential inlet 124 of the air cleaner 104 where, due to the tangential position of inlet 104 the air flow is cause to rotate or torsionally within the dirty side 106 of the air cleaner 104 . Due to the torsional air flow, preseparation of some, particularly heavier particulates 122 occurs with the dirty side 106 of the air cleaner 104 before the air flow enters the air filter 114 . Air filter 114 includes a filter media adapted to remove additional particulates that were not caught by the preseparation process. Filtered air exits the air filter 114 at the clean side 118 of the air filter 114 and flows along the air intake tract to eventually enter the intake manifold 120 of the internal combustion engine 102 .
[0031] Particulates 122 present in the combustion air entering the air cleaner 104 are removed by preseparation and filtering and are therefore trapped at the dirty air side 106 of the air cleaner 104 where they may accumulate and eventually occlude portions of the dirty air side 106 of the air cleaner 104 . Due to the swirl of the air flow induced by the tangential inlet of the air cleaner 104 , perhaps 80-90% of the particulate debris is removed in the preseparation process and accumulates at the bottom of the dirty air side 106 of the air cleaner housing. Debris may accumulate to the point at which the debris contacts and begins to occlude the air filter element 114 . As further movement of this particulate debris 122 is blocked by the filtering activity of the air filter 114 , it is advantageous to provide a means of automatically removing the particulate debris 122 to prevent obstruction of the air cleaner 104 .
[0032] During engine operation the air cleaner 104 operates at a lower absolute pressure (slight vacuum) relative to the outside air pressure, this due to the vacuum generated by operation of the engine 102 . The air inlet 124 is generally positioned to draw outside air at a location where minimal dust is expected and where it may freely draw upon outside air. The air cleaner 104 is generally positioned within the engine compartment of the vehicle, providing a short air duct run with minimal pressure loss to the engine. It is generally undesirable to draw air from within the engine compartment as the air in the engine compartment is warmer (heated by the engine 102 ) than the outside air. It is known that drawing heated combustion air into the engine 102 negatively affects the operating/fuel efficiency of the engine 102 .
[0033] To vent accumulated dust and debris 122 from the air cleaner 104 , in FIG. 1 a rotary dust valve 126 according to the prevent invention is advantageously provided and mounted preferably at a low point of the dirty air side 106 of the air cleaner 104 . Preferably the rotary dust valve 126 is positioned such that the inlet port 128 is positioned in elevation above the outlet port 130 such that dust/debris 122 is able to enter the inlet port 126 and exit the outlet port 130 under the motive influence of gravity.
[0034] As the air cleaner 104 typically operates at a slight vacuum relative to outside air, and due to the fact that it is undesirable to permit air to flow in a reverse direction (i.e. from outlet port 130 to inlet port 128 ) to enter the air cleaner 104 , the rotary dust valve 126 is configured to maintain a continuous air lock closure between the outlet port 130 and the inlet port 128 , as will be described further below.
[0035] FIG. 2A depicts a perspective view of a rotary dust valve 126 according to at least one aspect of the present invention. A convex curved valve body 132 that in some aspects of the invention may be spheroidally shaped (as depicted in FIG. 2A ) is provided with an inlet port 128 and an opposing outlet port 130 . In preferred aspects of the invention the inlet port 128 may have the configuration of a cylindrical pipe section configured for connecting and mounting to a complimentary cylindrical fitting on the air cleaner 104 .
[0036] FIG. 2B is a side sectional view of the rotary dust valve 126 presented in FIG. 2A , illustrating a substantially spherical rotor chamber 138 provided within the valve body 132 . A rotary dust ejection member 140 is disposed and rotatably supported with the rotor chamber 138 . The rotary dust ejection member 140 includes a plurality of fin members 142 secured to a hub member 144 . The hub member is positioned along an axis of rotation 146 about which the hub member 144 may rotate. Fin members 142 are each secured to the hub member 144 such that fin members 142 rotate in unison about the axis or rotation 146 . The fin members 142 share a common size and shape.
[0037] Advantageously, the rotor chamber 138 is shaped and configured in a complimentary fashion with the fin members 142 so as to provide a continuous closure between the inlet port 128 and the outlet port 130 in all positions of rotation of the rotary dust ejection member 140 about the axis 146 , thereby providing pressure and air flow separation between the inlet port 128 and outlet port 130 . Outer edges of the fin members 142 sweep out a contour as they rotate. The air lock closure between the inlet port 128 and outlet port 130 is accomplished by sizing and shaping the rotor chamber 138 such that the clearance between the fin members 142 (swept contour of) and the rotor chamber 138 is minimal but sufficient that the fin members 142 do not inter or contact the interior of the rotor chamber 138 as they rotate.
[0038] Any two adjacent fin members taken together (a fin member pair) define a dust pocket 148 therebetween. In general, a quantity ‘n’ of fin members will define a like quantity ‘n’ of dust pockets 148 in the rotary dust ejection member 140 . In any rotational position of the rotary dust ejection member 140 , at least one dust pocket is aligned in a first position in which it is in opened communication with the inlet port 128 and thereby positioned to receive dust/particulates 122 from the inlet port 128 and accumulate the dust in the input port aligned dust pocket 148 . As the dust/particulate 122 mass accumulates in the input port aligned dust pocket 148 , the dust ejection member 140 becomes unbalanced or ‘top heavy’ and is urged by the action of gravity to rotate about the axis 146 into a second position in which the dust laden dust pocket 148 then aligns to open to the outlet port 130 , at which the accumulated dust/particulates 122 are discharged to the outside by the action of gravity.
[0039] Advantageously, the operation of the engine 102 provides a stream of pressure pulses in the air intake tract 100 that may further act to vibrate or actuate the rotary dust ejection member 140 , the vibration further aiding the rotation of the rotary dust ejection member 140 after it becomes unbalanced or top heavy due to accumulation of particulates 122 . Operation of the engine 102 may by itself provide mechanical vibration additionally operative to aid rotation of a dust laden rotary dust ejection member 140 . As such, the rotary dust valve 126 is preferably (although, not necessarily) self operating and preferably does not require an external drive means to operate the rotary dust ejection member 140 to eject particulates 122 from the air cleaner 104 to the outside.
[0040] Advantageously in some embodiments a drive means, such as an electric motor drive or a vacuum motor, may be coupled to the rotary dust ejection member 140 to aid in the ejection of particulates 122 from the air cleaner 104 .
[0041] Advantageously, in preferred embodiments the rotary dust ejection member 140 is freely rotatable within the rotor chamber 138 .
[0042] Advantageously, the rotary dust valve 126 of the present invention provides a low cost, self actuating dust ejection valve that further advantageously provides an air lock between the engine air cleaner 104 and the outside environment.
[0043] FIG. 2C is a perspective view of one embodiment of a rotary dust ejection member 140 . In the embodiment illustrated in FIG. 2C , the fin members 142 extend radially outwards from the hub member 144 . The hub member 144 , on its opposing ends, is provided with cylindrical shaft portions 136 configured to rotatably support the rotary dust ejection member 140 within the rotor chamber 138 . The rotary dust ejection member embodiment of FIG. 2C may be utilized with the rotary dust valve 126 of FIG. 2A , in which the shaft or shafts 136 extend through and receive support from opposing sidewalls of the rotor chamber 138 .
[0044] In the embodiment illustrated in FIG. 2C , the shaft is provided as cylindrical portions extending from opposing ends of the hub member 144 .
[0045] In alternate embodiments, the shaft 136 may be realized as a separate component extending through a central portion of the hub member 144 and having a length selected to extend between and receive support from opposing sidewalls of the rotor chamber 138 . In some alternate embodiments, the hub member 144 includes a sufficiently sized bore such that the hub member 144 is free to rotate on the shaft 136 . In other alternate embodiments, the hub member 144 may be fixedly secured to the shaft 136 such that the hub member 144 rotates in unison with the shaft 136 . In this case the shaft 136 is rotatably supported at opposing shaft ends by the opposing sidewalls of the rotor chamber 138 .
[0046] In an aspect of the invention illustrated in FIG. 2C , the fin members 142 are substantially planar and arranged at equal angular increments about the hub member 144 relative to the axis of rotation 146 . Although this is a preferred embodiment, it should be evident that the fin members 142 may be provided with other non-planar shapes without deviating from the principles of the inventive disclosure presented herein.
[0047] In the foregoing specification, specific embodiments of the present invention have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.
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The present invention relates to a self actuating rotary dust valve particularly for discharging dust from an engine air cleaner. The rotary dust valve includes a valve body having an inlet port, an outlet port and a rotor chamber interposed therebetween. A rotary dust ejection member is enclosed in the rotor chamber and supported for rotation about a fixed axis. A plurality of fin members are provided angularly spaced about and secured to the hub member. Adjacent pairs of the fin members define at least one dust pocket therebetween to receive dust from the air cleaner to be ejected. The rotor chamber and the fin members are cooperatively shaped and configured to maintain a continuous air lock closure. The dust valve is operable by any of: gravity and vibration to rotate and thereby to discharge the dust buildup through the outlet port or alternately by other drive means.
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FIELD OF THE INVENTION
[0001] This application relates generally to software modeling and distributed systems.
BACKGROUND OF THE INVENTION
[0002] Modern business information systems are typically structured as multi-tiered distributed systems comprising Web services, application services, databases, enterprise information systems, file systems, and other storage systems. In such environments, data is stored at multiple tiers, each tier associated with a different level of data abstraction. All data entities that map to an information entity owned and used by an application are logically associated, across tiers, and related to the application. Discovery of such relationships in a distributed system is a challenging problem that requires understanding how data is used and transformed. For example, discovering which logical storage volume(s) a business application uses and thus depends on requires first discovering, at a higher level, which data sources the application is using and how these data sources may map to databases; consequently, it requires discovering how database tables transform to file system files and/or logical storage volumes, and so on.
[0003] Discovery of such relationships is complicated by at least two trends in system design today: first, the widespread adoption of virtualization technologies enforces a separation between distributed system tiers. In addition, the traditional tendency to view the “server domain” independently from the “storage domain”, from a systems management perspective, is another factor contributing to this information gap.
[0004] Manual discovery of application-data associations is a difficult and error-prone task. A known technique discovers application-data relationships using online system monitoring and training heuristics for applications and data residing in a single computer system. However, this prior art technique has several drawbacks including: (a) being based purely on heuristic rules, it cannot eliminate the possibility of overlooking some application-data relationships (“false negatives”); (b) it does not relate applications running on one computer with applications and/or data on another computer.
[0005] Another prior art technique builds distributed system dependency graphs using active (e.g., fault injection) or passive (e.g., trace collection and offline analysis) methods. The dependency graphs show how applications on one computer system communicate with applications on another computer system. Antivirus programs, access control systems, disaster recovery management systems, and information lifecycle management systems are other potential consumers of application-data association information. Accordingly, what is desired is an improved system and method for automatic discovery of application-data relationships spanning multiple-tiers.
BRIEF SUMMARY OF THE INVENTION
[0006] A system and method for automatic discovery of application-data relationships spanning multiple tiers is disclosed. The system in one aspect includes system configuration template description that models a system configuration of computer system, for instance, an enterprise system. The system configuration template description includes at least description of one or more software components on the computer system. The system also includes software template description that models at least one of use and transformation of data by one or more software components on a computer system. Each software component on the computer system has a corresponding software template description. A processor is operable to extract information associated with the computer system. The extracted information is used to build the system configuration template description and the software template description. The processor is further operable to traverse the system configuration template description and the software template description to discover application and data associations.
[0007] A method for automatic discovery of application-data relationships in one aspect includes modeling a system configuration of a computer system using a predefined template defining distributed system infrastructure. The modeled system configuration includes at least description of one or more software components in the computer system. The method also includes modeling one or more software components described in the modeled system configuration using a predefined software component template. The modeled one or more software components includes at least description of at least one of use and transformation of data by the one or more software components. The modeled one or more software components are extended to include at least installation-specific information related to the at least one of use and transformation of data by one or more software components. The method further includes traversing the modeled system configuration and the one or more software components to discover application and data associations.
[0008] Further features as well as the structure and operation of various embodiments are described in detail below with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a diagram illustrating an overview of system architecture in one embodiment.
[0010] FIG. 2 is a block diagram illustrating an example of a SC model instantiation in one embodiment.
[0011] FIG. 3 is a block diagram illustrating DLT creation for software components in the SC model in one embodiment.
[0012] FIG. 4 is a block diagram illustrating extending from DLT models to DLI models in one embodiment.
[0013] FIG. 5 is a block diagram illustrating crawling the SC model using the DLI models in one embodiment.
[0014] FIG. 6 illustrates an example of system configuration meta-model instance.
[0015] FIG. 7 illustrates an example of data locations template (DLT) meta-model in one embodiment.
[0016] FIG. 8 illustrates an example of data locations instance (DLI) meta-model in one embodiment.
[0017] FIG. 9 is a flow diagram illustrating a method of discovering application-data relationship.
[0018] FIG. 10 is a block diagram illustrating validation and re-invocation of the discovery actions in one embodiment.
DETAILED DESCRIPTION
[0019] FIG. 1 illustrates an overview of system architecture in one embodiment of the present disclosure. In an exemplary embodiment, three meta-models provide descriptions of distributed system infrastructure and of data consumption and data transformation in software components. In general, a meta-model is a precise definition of the constructs and rules needed for creating semantic models of particular entities. Another way to think about meta-models is as collections of “concepts” (e.g., things, terms, etc.) that make up a vocabulary with which one can talk about a certain domain. It is a similar concept to a “schema” as used in databases or XML, or to the definition of a class in object-oriented languages. One meta-model in an exemplary embodiment of the present disclosure describes models of distributed system infrastructure, and two meta-models describe models of software, for example, application or middleware components.
[0020] In one embodiment, the meta-models may include a System Configuration (SC) meta-model 102 ; the Data Locations Template (DLT) meta-model 104 ; and the Data Locations Instance (DLI) meta-model 106 . The UML diagrams for these meta-models are shown in FIG. 6 , FIG. 7 , and FIG. 8 , respectively. Although the exemplary embodiment is illustrated herein with references to three meta-models, it should be understood that the system and method of the present disclosure does not limit the number of meta-models to only three and that more or less number may be used.
[0021] In one embodiment, these meta-models are instantiated into specific models of the system infrastructure and the software components in the distributed system being considered. Such instantiation in one embodiment are performed as part of a pre-discovery process. A runtime logic 108 , for example, program of instructions or scripts mine or extract system information to build the instantiated models. A crawling algorithm 110 uses the models 112 , 114 , 116 to automatically discover application-data associations in distributed systems. In an exemplary embodiment, the crawling algorithm 110 is distributed but is not limited to such. For example, the crawling algorithm 110 may be run from a centralized system.
[0022] In an exemplary embodiment of the present disclosure, distributed systems are modeled using the System Configuration (SC) meta-model 102 . Each instance of SC model may be represented by a respective instance of the SC meta-model as will be described with reference to FIG. 2 . In one embodiment, each software component in the SC Model is associated with a DLT model.
[0023] In an exemplary embodiment of the present disclosure, Data Locations Template (DLT) meta-model 104 describes software component's consumption and transformation of data, as will be described with reference to FIG. 3 . Examples of software components include but are not limited to applications and middleware. In one embodiment, descriptions of data consumption include lists of names of data-sets, which usually take the form of pathnames in some data namespace. Descriptions of data transformation usually take the form of rules, e.g., a database table with name ‘X’ maps to a set of table space containers {‘Y’}. In one embodiment, a rule is applicable on a range of inputs rather than on a single input. A representation of the DLT meta-model in the Unified Modeling Language (UML) is illustrated in FIG. 7 . In one embodiment of the present disclosure, an instantiation of the DLT meta-model is created for software components present in a distributed system being considered, for example, before the application-data relationship discovery process.
[0024] Descriptions of data consumption by a software component may be created by software modeling tools or specified by human experts, or through dynamic discovery via a variety of information sources or by any other known or will be known methods or combinations thereof. Similarly, descriptions of data transformation by a software component may be created by modeling tools or by human experts, such as software developers or system administration specialists or the like or combinations thereof, and used to dynamically discover relationships between data at different levels of abstraction. DLTs for software components may be stored in a repository and retrieved as needed by the discovery process. In one embodiment, DLTs describing major middleware components, such as Application Servers, Database Servers, or Enterprise Information Systems, may typically be created once and stored in a repository, while DLTs for applications may typically be constructed on-demand at deployment time.
[0025] FIG. 2 is a block diagram illustrating an example of a SC model instantiation in one embodiment. A system configuration (SC) model 204 , for instance, is instantiated at 208 , as an instance of the SC meta-model 202 and describes the distributed system 206 being considered as an example. In one embodiment the SC model 204 forms the substrate upon which a distributed-crawler process operates. The SC model 204 is built from the distributed system being considered, for example, using IT infrastructure discovery systems, such as those populating a configuration management database (CMDB), for example, from existing registries of physical and logical assets typically found in enterprise systems. In one embodiment, the SC model 204 is built using a predefined schema, for example, a UML description shown in FIG. 6 . The schema for the SC Model preferable captures details of all physical and logical elements relevant to the distributed system 206 being considered. The SC Model 204 includes one or more software components 210 , 212 , 214 , which may consume and/or possibly transform data.
[0026] FIG. 3 is a block diagram illustrating DLT creation for software components in the SC model in one embodiment. In one embodiment, each software component 312 , 314 , 316 that consumes and/or transforms data is associated with a Data Locations Template (DLT) model 302 . A DLT model 304 , 306 , 308 for a software component 312 , 314 , 316 is instantiated 318 , for example, by being created on demand at DLT model factory 320 or by being retrieved from a repository 322 . Thus, in one embodiment, a DLT model ( 304 , 306 , 308 ) is instantiated for each software component ( 312 , 314 , 316 ) in the SC model 310 .
[0027] In one embodiment, each DLT model uses a data model shown in FIG. 7 . A DLT instance for each software component in the SC may be created, for example, before the discovery process. The complexity of creating DLTs varies depending on whether the software component represents a simple application or a more complex middleware component. Generally, application DLTs tend to be simpler since applications typically do not transform or export data; such simple DLTs may be automatically created by software modeling tools. Modeling is well suited for such a task due to its ability to capture intended behavior at the time of software design and using it for online analysis. For instance Rational Rose or other model-driven software design tool may be used to produce a DLT from UML. Additional or alternatively, operator input may be used to build DLTs.
[0028] In one embodiment, DLT models do not include any installation-specific details of the data consumption and transformation of software components since, for example, such information is known only after installation time. Examples of installation-specific details are absolute pathnames or machine names. Instead, the DLT models 304 , 306 , 308 , in one embodiment, use variables (bound at a later time) to represent such information. To capture installation-specific information about data consumption and transformation, the disclosed system and method specifies, for example, the Data Locations Instance (DLI) meta-model and model shown in FIG. 4 , which are extensions of the DLT meta-model and model respectively.
[0029] FIG. 4 is a block diagram illustrating extending from DLT models to DLI models in one embodiment. DLT models 410 , 412 , 414 of software components are extended at 416 to corresponding DLI models 404 , 406 , 408 , for instance, by mining installation-specific information 420 from the distributed system 418 . The DLI models 404 , 406 , 408 follow, for instance, the schema of the DLI meta-model 402 shown in FIG. 8 . FIG. 8 illustrates an example of a UML diagram describing the DLI meta-model. DLI model schema includes ref (“reference”) attribute in the DLIComponent and DataSet elements 802 , 804 of the DLI schema. The ref attribute points to entities of the distributed system infrastructure captured in the SC model. The value of each ref attribute is determined during the transformation from the DLT to the DLI model of a software component. The information that is added to the DLI models 404 , 406 , 408 may include, for example, absolute pathnames and machine names, references to deployed software or hardware elements using their names as listed in the SC model, for instance, described in the SC model of the distributed system, names of discovered data sets representing data use of software components, etc., and the like. In one embodiment, transformation rules are copied unmodified from the DLT to the DLI model of the software component.
[0030] In one embodiment, the process of extending DLT models to DLI models uses runtime support, for example, scripts and/or program of machine instructions to mine and extract information from the distributed system. Examples include invoking operating system (OS) registries, application server APIs, file system, other management APIs, other information sources, and the like. For instance, the DLI models and the SC model in one embodiment comprise the inputs to the distributed crawling and discovery process.
[0031] In one embodiment, the DLT and DLI meta-model structures may comprise two section, the Data Consumption section, and the Data Transformation section, as shown in the UML diagrams of FIG. 7 and FIG. 8 . In one embodiment, the data transformation section may comprise one or more ExportedDataType elements (e.g., 702 ). Each ExportedDataType element may comprise a name, a description of the syntactic format of the namespace (“NameSpaceFormat”) of the data type; and a description of the syntactic format of the namespace (“MappingFormat”) of the data type that the exported data type maps to. In addition, each ExportedDataType may be associated with a MappingRule element (e.g., 704 ), which is a method for transforming (at runtime) a given name in the NameSpaceFormat to one or more corresponding names in the MappingFormat. In one embodiment, the MappingRule element method may be implemented by script(s), whose names are provided in the MappingRule element.
[0032] The data consumption section in one embodiment may comprise one or more DataSet elements (e.g., 706 ). Each DataSet may have a name attribute; that name may be specified according to (and thus associated with) the NameSpaceFormat of the ExportedDataType element of the software component exporting that data type. A DataSet element may additionally point to zero or more InformationSources (e.g., 708 ). InformationSources in one embodiment are dynamic sources of information (e.g., scripts whose execution returns information about the distributed system infrastructure) that may be required in order to fully determine the name of a DataSet.
[0033] Data consumption section, for example, describes data consumption of a software component, which in one embodiment may be typically described as a list of dataset names in some namespace and may be discovered in a number of ways. One example method for discovering data consumption is by looking at the application container providing runtime services (e.g., a J2EE application server or an operating system) to an application, to data providers (e.g., file systems, databases) whose services are used by applications, as well as application packaging and registry systems (e.g., J2EE .ear/.rar files, Linux RPMs, Windows registry, etc.). If not automatically discoverable, data consumption may be specified in DLTs by experts in the software components considered. Example cases of data use may include but is not limited to data in shared directories (e.g., /tmp), shared libraries (e.g., in windows\dll), and the like.
[0034] The system and method of the present disclosure uses the following example format to describe DATASETS:
[0000] Data Provider:Data Type l ;Data Name l /(Data Type i ;Data Name i ) i
[0000] where Data Type l ;Data Name l can be null, and i runs from zero up to a finite number. The above dataset name may contain wildcards (e.g., the equivalents of *, % in UNIX) and dynamically derived variables.
An example of a DLT model describing a J2EE application (“MyTrade3App”), which for example is part of the SC model shown in FIG. 6 , is shown in XML format below:
[0000]
<DLTComponent name=“MyTrade3App” dataprovider=“no”
dataconsumer=“yes”>
<DataConsumer>
<DataSet name=“[%dataprovider]:[%pathnames]” >
<InformationSource script=“find-was-app-data” params=“” />
</DataSet>
</DataConsumer>
</DLTComponent>
[0035] This DLT describes that this J2EE application is consuming but not transforming data, for example, may be because data transformation is typically performed by middleware software. The DataSet tag in the above XML file leaves undefined the names of the data providers and pathnames of the data consumed by this component (variables %dataprovider and %pathnames) and instead points to an information source (a script, in this example) that can be used to bind these names to their installed values during the transformation of the DLT model to the DLI model.
[0036] Middleware systems, which often consume and transform/export data, involve somewhat more complex DLT instances, may be specified by human experts such as software developers or systems administration specialists. Additionally or alternatively, they may also be produced automatically, for example, by software modeling tools.
[0037] The data transformation section is described in one embodiment as follows. A middleware system that exports data abstractions (also referred to as a “Data Provider”) describes the data transformation it implements in terms of a mapping between two namespaces, those of a higher and a lower level data abstraction. Typically, before describing such a mapping, the format of the namespaces of each data abstraction is defined. Similar to the format used to describe data sets, the system and method of the present disclosure uses the following regular expression to describe namespaces:
[0000] Data Provider:Data Type l ;Data Name l /(Data Type i ;Data Name i ) i
[0000] where Data Type l , Data Name l can be null, and i runs from zero up to a finite number.
[0038] Examples of namespace formats are
db-instance-name:database;database-name/table;table-name (Relational database) file-system-name:(file-or-directory;file-or-directory-name) i (File System)
[0041] eis-name:repository;repository-name/business-object;business-obj-name (EIS)
controller-name:logical-volume;logical-volume-name (Storage Controller) controller-name:logical-volume;logical-volume-name/block;block-number (Storage Controller)
[0044] Data transformation between a high-level data abstraction A and a low-level data abstraction B may thus be described by the following mapping:
[0000] Data Provider A :Data Type A l ;Data Name A l /(Data Type A i ;Data Name A i ) k → Data Provider B :Data Type B l ;Data Name B l /(Data Type B j ;Data Name B j ) m
where i runs from 0 to k−1 and j runs from 0 to m−1. This naming convention reflects the hierarchical nature of the namespaces. In a hierarchical namespace, the name of a dataset comprises several components (or tree levels, if the namespace is seen as a tree). A typical example of a hierarchical namespace is that of files in modern file systems. The above representation generalizes file system namespaces by associating each level (“Data Type Level number : Data Name Level number ”) in the path with potentially a different data type (denoted by “Data Type Level number ”). The subscripts i and j enumerate the number of levels in the names of data abstractions A and B, respectively. The indexes k and m are their upper bounds.
[0045] In one embodiment, the above mapping is many-to-many and may contain wildcards and dynamically-derived variables. For example, any of the data name and type variables can be dynamically derived by executing scripts. The above transformation rules and associated dynamic scripts may be typically written by middleware developers or by those skilled in data transformation mechanics of the middleware software.
[0046] As an example, consider the following DLT excerpt (Data Consumption section of the DLT omitted) describing the data transformation performed by the DB2 middleware.
[0000]
<DLTComponent name=“db2” dataprovider=“yes” dataconsumer=“yes”>
. . .
<DataProvider>
<ExportedDataType type = “table“
NameSpaceFormat = “db2:\database;[%1]\table;[%2]“
MappingFormat = ”fs:\[%filename]”
MappingRule = “db2fs-mapping“ />
<ExportedDataType type = “jdbcdrivers“
NameSpaceFormat = “db2:\jdbcdrivers;[%1]”
MappingFormat = ”fs:\[%filename]”
MappingRule = “jdbcdriver-mapping“ />
</DataProvider>
</DLTComponent>
[0047] This example describes two exported data types (“table” and “jdbcdrivers”) that are implemented by a database software component. The first exported data type, whose name is “table” (and corresponds to a database table), is described as follows: The namespace format has two levels; the first level corresponds to the name of the database comprising the table; the second level corresponds to the name of the table itself. The exact names of the database and table to map are left as variables (%1 and %2) to be provided at the time of the invocation/execution of the MappingRule described below. The MappingFormat for the “table” data type corresponds to that of a typical file system. In other words, the “table” exported data type maps to one or more files. The MappingRule for the “table” data type points to a script, which encapsulates the runtime knowledge necessary to map any given (existing) database table to the files (in a back-end file system) that the table corresponds to. Similarly, in the “jdbcdrivers” exported data type (which corresponds to a JDBC driver typically needed by database users), the NameSpaceFormat has a single level and includes a single variable (%1), which will be bound to the specific name of a JDBC driver at a later time. The MappingFormat describes the namespace of a file system, just as in the case of the “table” exported data type. The MappingRule points to a script, which can discover at runtime the mapping of a JDBC driver to one or more files by looking up the file system underlying the DBMS.
[0048] As described above, in one embodiment, DLTs are extended to DLIs to include specific references to the system being considered. In transforming DLTs to DLIs, DLI instances may be automatically derived from DLT instances, for example, using appropriate runtime support that mines information from the distributed system considered. As an example, the DLI derived from the DLT of the “MyTrade3App” J2EE application described earlier can be produced automatically to generate the XML shown here:
[0000]
<DLIComponent name=“MyTrade3App” ref=“cmns:MyTrade3”
dataprovider=“no” dataconsumer=“yes”>
<DataConsumer>
<DataSet ref=“cmns:MyTradeCluster” name=“wsas:\app;trade3” />
<DataSet ref=“cmns:DB2-node-wxa8“
name=“db2:\database;trade3db\table;holdingejb” />
<DataSet ref=“cmns:DB2-node-wxa8”
name=“db2:\database;trade3db\table;quoteejb” />
<DataSet ref=“cmns:DB2-node-wxa8”
name=“db2:\database;trade3db\table;keygenejb” />
<DataSet ref=“cmns:DB2-node-wxa8”
name=“db2:\database;trade3db\table;accountejb” />
<DataSet ref=“cmns:DB2-node-wxa8”
name=“db2:\database;trade3db\table;orderejb” />
<DataSet ref=“cmns:DB2-node-wxa8“
name=“db2:\database;trade3db\table;accountprofileejb” />
</DataConsumer>
</DLIComponent>
[0049] In one embodiment, the transformation of DLTs to DLIs is fully automated and thus is performed without human intervention. Additionally or alternatively, operator input may be used to transform DLTs to DLIs. A process of transforming a DLT to a DLI may include, for example, invoking scripts to bind variables in dataset names, which in turn may involve calls to a number of APIs, such as the operation system (“OS”) file system and registry, application service containers (e.g., J2EE AppServer), database configuration managers, and storage or other management systems or the like. Once created, the DLIs may be placed in well-known locations, for instance, at the installation directory of the software component they correspond to.
[0050] FIG. 5 is a block diagram illustrating crawling the SC model using the DLI models in one embodiment. In one embodiment, distributed crawling 510 of the SC model 502 , discovers application-data relationships. The SC model 502 may be represented by a graph. When visiting a software component, one or more appropriate data transformation rules are taken from the DLI model 504 , 506 , 508 and applied as shown at 512 . Traversal of the entire graph representing the SC model 502 and use of all applicable transformation rules provide end-to-end application-data relationships.
[0051] The output of the crawling and discovery process 510 , which in one embodiment is the entire set of discovered application-data relationships, is stored in an application-data relationship registry 516 . The output of the crawling and discovery algorithm stored in a repository 516 may include relationships between data across tiers and linkage of data to applications and identification of services implementing and providing the data. Uses of the discovered application-data relationships include policy-based planning tools 518 , which for example formulate suitable systems management policies and feed them to policy enabling systems 520 . For example, the application-data associations discovered can be used for performing application specific policy-based management. In one embodiment, the ability to reflect business decisions may be expressed at the application level to the level of data. As an example, Information Lifecycle Management (ILM) policies for disaster recovery can be formulated to describe the degree of disaster resiliency desired for data, in terms of the applications or business processes that own the data (e.g., “use a Recovery-Time Objective of 5 minutes for all data owned by Application X”), instead of the data themselves (e.g., “use a Recovery-Time Objective of 5 minutes for data items Y, Z”). Such policy formulation is simpler to compose and reduces the possibility of error in specifying all data items affected by the policy.
[0052] As described above, in one embodiment, the application-data relationship discovery may utilize a crawler algorithm. An example of a crawler algorithm used for the distributed discovery process is shown in FIG. 9 . In one embodiment, inputs to the algorithm include but is not limited to system configuration (SC) model and DLIs for software components, for example, applications and middleware. At 902 , for each application in the SC model, the method considers the dataset descriptions in the software component's DLI model. At 904 , for each dataset D, if D is a file, the method records application-file relationship at 906 . Otherwise the method visits D's data provider P and gets a handle on P's DLI model at 908 . P, for example, is represented by a node in SC. The method in one embodiment may use remote procedure call (RPC) if the node is located on one or more remote machines. At 910 , the rules in P's DLI model are used to transform D to D′. At 912 , steps 904 to 910 are repeated for D′. In one embodiment, the output, discovered application-data relationship is stored in a database.
[0053] In one embodiment, actual remote procedure calls are not necessary if it is always possible to invoke the middleware APIs remotely. This is possible in managed environments with systems like WebSphere and DB2 but may be difficult with lower level APIs such as the OS API on single-machine nodes. However, the use of intermediate management APIs such as TPC (TSRM) or TSM may be used to provide similar information through publicly and remotely accessible APIs.
[0054] In one embodiment, the complexity of the above-described crawling and discovery process may be equal to the complexity of depth-first search (DFS). Its actual cost in practice depends on the cost, for example, delay, of invoking scripts that exercise the needed APIs. For example, if a DB2 instance manager is slow in responding, the overall cost will practically be proportional to the number of DB2 calls, for instance, the number of calls related to the number of database tables that need to be resolved.
[0055] In one embodiment, the system and method of the present disclosure may also provide validating and rediscovering process. FIG. 10 is a block diagram illustrating validation and re-invocation of the discovery actions in one embodiment. In one embodiment, the validation process 1002 may be based on receiving and analyzing system events 1004 , such as I/O and process activity, as shown in FIG. 10 . For example, correlating a business component transaction or a database SQL query (detected via some JDBC log file or callback) with a file access operation can be an indication that a previously found relationship between the business component and that file is indeed valid. In addition, newly discovered relationships may be updated in the relationships database 1010 . For instance, in the event that new applications or newly created data 1006 are detected, a new invocation of the crawling and discovery process 1008 can be triggered. This process can also be triggered either periodically or anytime new applications or data are detected.
[0056] In one embodiment, the system and method may be used to enable management policies that make use of the application-data relationship information. Examples of such policies are “Use a recovery time objective (RTO) of 5 minutes for all data owned or accessed by application APP”, “Use a backup order priority directly proportional to the business value of data”, and the like. In the examples, the application-data relationship information is used to group all data related to an application and to reflect on them the business value of the application.
[0057] In a case of data shared between multiple applications, different policies may be used. An example of sharing may be two applications accessing the same library files. For example, if two application APP 1 and APP 2 having different business values share a data item, that data item may be considered as having high or low value. For instance, a conservative policy may attribute high value to the data since at least one business rated as high value is using the data.
[0058] In one embodiment, the disclosed system and method is extensible. The framework that includes the meta-models and models described above is vendor-independent and general enough to describe any application or middleware system consuming or providing data. Examples of such middleware systems include but are not limited to J2EE application servers, database management systems, SAP, and Adaptive Business Objects (ABO). In an exemplary embodiment, the discovery is preferably from the applications to the lowest levels of the storage hierarchy. In one embodiment, unlike in the prior art systems, the system and method of the present disclosure in one embodiment identifies dependency specifically as it relates to applications' use of data.
[0059] The system and method of the present disclosure may be implemented and run on a general-purpose computer or computer system. The computer system may be any type of known or will be known systems and may typically include a processor, memory device, a storage device, input/output devices, internal buses, and/or a communications interface for communicating with other computer systems in conjunction with communication hardware and software, etc.
[0060] The terms “computer system” as may be used in the present application may include a variety of combinations of fixed and/or portable computer hardware, software, peripherals, and storage devices. The computer system may include a plurality of individual components that are networked or otherwise linked to perform collaboratively, or may include one or more stand-alone components. The hardware and software components of the computer system of the present application may include and may be included within fixed and portable devices such as desktop, laptop, server.
[0061] The embodiments described above are illustrative examples and it should not be construed that the present invention is limited to these particular embodiments. Thus, various changes and modifications may be effected by one skilled in the art without departing from the spirit or scope of the invention as defined in the appended claims.
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Method and system are disclosed for automatically discovering associations between applications and data in multi-tiered distributed systems. The method in one aspect uses a machine-readable specification of a model or template that describes use and transformation of data by software components. The method additionally utilizes a model of system configuration and appropriate runtime support to mine information available from systems management software present in enterprise systems. The application-data association discovery process performs a traversal of the distributed system configuration graph with actions taken during this traversal driven by the contents of the templates for the software components present in the system. The results of the application-data association discovery process are stored in a database and may be used to specify application-specific information lifecycle management (ILM) policy or as input to impact analysis tools in access control and antivirus systems.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to optical systems and, more particularly, to the optical and electro-optical devices used in high power optical systems.
[0003] 2. Description of the Related Art
[0004] Optical fibers are used to transmit light in an optical system. FIG. 1 shows front and side views of a typical optical fiber 5 . Optical fiber 5 includes a cladding 14 and a core 12 . The core 12 is the actual light conduit of the optical fiber. The core 12 and/or the cladding 14 are doped so that the cladding 14 has a different index of refraction than the core 12 . The cladding reflects light back into the core, causing light to propagate through the core 12 for the length of the optical fiber. Generally, an optical fiber 5 is capable of handling high optical powers as long as light is simply propagating through the fiber. However, in places where fiber 5 is terminated, the termination point may be vulnerable to damage that arises due to high power optical signals.
[0005] Light entering or leaving a termination end of an optical fiber 5 is focused into the core 12 . Accordingly, at the point where light enters or leaves the termination end of the fiber 5 , the intensity of the light is related to the diameter of the core 12 . The smaller the core diameter, the smaller the diameter of the light spot formed on the end of the fiber and the greater the intensity of the light entering or leaving the termination end of the optical fiber.
[0006] In high power (e.g., around 1 Watt and higher) systems using single mode fiber (which typically has a relatively small core diameter), the intensity of light entering or leaving the termination end of an optical fiber may be significant. If any contaminants or irregularities are present at the termination end of the fiber, they may act as focusing lenses, creating localized spots of even higher intensities on the fiber end. The end of a fiber 5 may be coated with a dielectric coating to decrease insertion loss due to reflection and other unwanted effects that may occur as light enters or leaves the end of the optical fiber. At high intensities, light may burn the termination end of the fiber, damaging this coating. In extreme situations, burning may also damage the optical fiber itself. In such situations, the damage may increase the insertion loss and reflection of the fiber end. Additionally, the burning may damage the fiber so much that it is unable to operate properly and causes system disruption.
[0007] Typically, the core diameter is one of the points at which light is most focused in an optical system. Accordingly, termination ends of fibers are often the most vulnerable to being damaged in high power systems. It is desirable to be able to reduce the possibility that undesirable effects such as increased insertion loss will arise in high power optical systems. It is also desirable to be able to handle higher powers without a significantly increased potential of optical damage at the termination ends of optical fibers.
SUMMARY
[0008] Various embodiments of methods and systems of using TEC (Thermal-Diffusion Expanded Core) optical fiber to increase the power handling capabilities of an optical device are disclosed. In one embodiment, an optical device includes a TEC optical fiber that includes a first core. The diameter of the first core at the end of the TEC optical fiber is larger than the diameter of the first core in an unexpanded portion of the TEC optical fiber. The optical device also includes a focusing lens configured to focus light into the end of the first optical fiber so that a light spot created by the focused light on a surface of the end of the TEC optical fiber has a light spot diameter that is larger than the diameter of the unexpanded portion of the first core.
[0009] In some embodiments, the TEC optical fiber may be part of an optical fiber pigtail that is permanently affixed in the optical device. The optical device may include an active component such as a laser diode configured to output the light to the focusing lens. The optical device may also (or alternatively) include a passive component configured to process the light and output the light to the focusing lens. An additional TEC optical fiber that includes a second core, where the diameter of the second core at the end of the additional TEC optical fiber is larger than the diameter of the second core in the unexpanded portion of the additional optical fiber, may input the light into the optical device.
[0010] One embodiment of a method of operating an optical device may involve providing light to a lens within the optical device and the lens focusing the light into the end of a TEC optical fiber having a first core and a first cladding. The diameter of the first core at the end of the TEC optical fiber is larger than the diameter of the first core in the unexpanded portion of the TEC optical fiber. A light spot created by focusing the light into the end of the TEC optical fiber has a light spot diameter that is larger than the diameter of the first core in the unexpanded portion of the TEC optical fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A better understanding of the present invention can be obtained when the following detailed description is considered in conjunction with the following drawings, in which:
[0012] [0012]FIG. 1 shows front and side cross-sectional views of a typical optical fiber.
[0013] [0013]FIG. 2 shows front and side cross-sectional views of a thermal-diffusion expanded (TEC) fiber that may be included in one embodiment of an optical device.
[0014] [0014]FIG. 3 shows one embodiment of an optical device that includes TEC fiber.
[0015] [0015]FIG. 4 shows another embodiment of an optical device that includes TEC fiber.
[0016] [0016]FIG. 5 shows the size of a light spot relative to the size of the expanded and unexpanded portions of a TEC optical fiber in one embodiment of an optical device.
[0017] 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 the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims. Note, the headings are for organizational purposes only and are not meant to be used to limit or interpret the description or claims. Furthermore, note that the word “may” is used throughout this application in a permissive sense (i.e., having the potential to, being able to), not a mandatory sense (i.e., must). The term “include” and derivations thereof mean “including, but not limited to.” The term “connected” means “directly or indirectly connected,” and the term “coupled” means “directly or indirectly connected.”
DETAILED DESCRIPTION OF EMBODIMENTS
[0018] [0018]FIG. 2 shows an example of a thermal-diffusion expanded core (TEC) optical fiber 10 that may be used in some embodiments. As shown, TEC optical fiber 10 begins at a termination end and continues to another end (not shown). The other end of the fiber may also have an expanded core in some embodiments. The optical fiber includes an inner core 12 surrounded by an outer cladding 14 . TEC optical fiber 10 is formed by heating a portion of an optical fiber. The heating causes ion movement so that, in the heated portion, the area of the optical fiber that has core-type doping 12 becomes larger and the area that has cladding-type doping 14 becomes smaller. In the example shown in FIG. 2, (at least) one end of the optical fiber 10 has been thermally expanded so that core 12 is larger at the end of optical fiber 10 than it is in other portions of optical fiber 10 . If optical fiber 5 is a single mode fiber used to transmit light with a wavelength between 980 nm to 1650 nm, the diameter of non-expanded portions of the core 12 may be between 6 and 11 μm. At the termination end of the fiber, the expanded portion of the core may have a diameter between 20 to 50 μm. The expanded portion of the fiber may be around 3 mm in length in such an embodiment. The termination end of the optical fiber 10 may be coated with a coating (e.g., a dielectric material) that reduces reflections at the termination end.
[0019] [0019]FIG. 3 shows one embodiment of an optical device 100 . In this embodiment, optical device 100 includes a laser diode 20 , one or more lenses 30 , and a TEC optical fiber 10 . As shown, laser diode 20 outputs light 40 , which is collimated and focused by lenses 30 into the end of optical fiber 10 . Optical device 100 may be packaged in an enclosure (not shown) in order to reduce the amount of contaminants to which the components of optical device 100 are exposed. In many embodiments, optical fiber 10 may be an optical fiber pigtail that is permanently attached to optical device 100 (e.g., so that optical device 100 may be attached and/or detached from other optical devices without having to realign optical fiber 10 ). In such an embodiment, additional optical fiber(s) may be coupled to the other end (not shown) of optical fiber pigtail 10 in order to integrate optical device 100 into an optical system. In some embodiments, the optical device may be configured to handle 1 Watt or more of power. In another embodiment, the optical device may be configured to handle between 3 and 5 Watts.
[0020] [0020]FIG. 5 shows one example of the relative size of the light spot formed on the termination end of optical fiber 10 by light beam 40 . As shown in FIG. 5, the diameter of the light spot formed on the end of optical fiber 10 may be slightly smaller than the diameter of the expanded portion of core 12 at the termination end of optical fiber 10 . In many embodiments, the coupling efficiency of the optical device may increase as the difference between the diameter of the light spot and the diameter of the expanded portion of the core 12 is decreased. Thus, in some embodiments, the diameter of the light spot may be about the same size as the diameter of the expanded portion of the core 12 . The light spot diameter is larger than the diameter of the unexpanded portions of core 12 .
[0021] Since the light spot is larger than it would be if the end of the fiber had not been thermally expanded, the intensity of the light is less than it would be if the light had been focused to have a smaller light spot diameter at the fiber end. The area of the core at the end of fiber 10 is π·r 2 . If, for example, the unexpanded portion of the core has a diameter of 10 μm and the expanded portion of the core has a diameter of 30 μm, the focusing area at the termination end of the TEC optical fiber 10 may be 9 times (i.e., (π·30 2 )/(π·10 2 )) larger than the focusing area at the termination end of a non-expanded fiber. Accordingly, the optical power may be 9 times higher that that used with an unexpanded optical fiber while keeping the same (or a reduced) possibility that the light intensity will damage the termination end of the optical fiber 10 . If the power of the light output from the light source is the same as that used with an unexpanded optical fiber, the larger core focusing area at the termination end of the TEC optical fiber may reduce the possibility that the light intensity will damage the termination end of optical fiber 10 .
[0022] The configuration shown in FIG. 3 may be used in similar optical devices. Instead of a laser, other active optical components that output and/or receive light may be included, and optical fiber 10 may act as either an input or an output into optical device 100 . For example, another embodiment of an optical device may include a receiver that receives light (e.g., via one or more collimating lenses) output from the termination end of a TEC optical fiber 10 . Other exemplary active components that may be included in embodiments of optical device 100 include photosensors, transmitters, receivers, modulators, attenuators, switches, amplifier pumps, and semiconductor optical amplifiers. In some embodiments, both sending and receiving TEC optical fibers may be included in an optical device 100 so that the optical device may receive, process, and output one or more light beams.
[0023] [0023]FIG. 4 shows another embodiment of an optical device 100 . In this embodiment, a first optical fiber 10 A inputs a light beam into optical device 100 . A second optical fiber 10 B receives a light beam output by optical device 100 . A passive component 50 processes the input light beam to produce the output light beam. Two lenses 30 respectively collimate the input light beam and focus the output light beam. Exemplary passive optical components include lenses, glass crystals, gratings, mirrors, etc. such as those used in passive devices like collimators, isolators, couplers, multiplexers, filters, power splitters, etc. Note that in some embodiments, both active and passive components may be included (e.g., as shown in FIG. 3) in an optical device.
[0024] If both the input and output fibers are TEC fibers, as shown in FIG. 4, the light beam that is input to the output optical fiber 10 B will have the same spot size as the light beam that is output from the input optical fiber 10 A so long as lenses 30 are symmetrical lenses that are symmetrically arranged with respect to optical component 50 and the termination ends of optical fibers 10 A and 10 B. If the lenses 30 are not symmetrical or are not symmetrically arranged, the configuration and/or arrangement of the lenses may be such that the light beam input to optical fiber 10 B has a spot size diameter that is larger than the diameter of the non-expanded portion of that fiber's core 12 . Furthermore, if one of the optical fibers is not a TEC optical fiber, the lenses may be configured and/or arranged so that the light spot diameter at the termination end of the TEC optical fiber is larger than the diameter of the unexpanded portion of the TEC optical fiber's core.
[0025] While the embodiments shown in FIGS. 3 - 4 show optical devices that include one or two optical fibers, other embodiments may include multiple input and/or output optical fibers. For example, in some embodiments, optical device 100 may be a device such as a multiplexer, demultiplexer, or combiner that receives one or more inputs and produces one or more outputs. One or more of the optical fibers may be TEC optical fibers in such an embodiment. A component within the optical device is configured to process light so that the diameter of the light spot(s) on the termination end of the TEC optical fiber(s) are larger than the diameter(s) of the unexpanded portion of the core(s) of the TEC optical fiber(s).
[0026] Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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Various embodiments of methods and systems of using TEC (Thermal-Diffusion Expanded Core) optical fiber to increase the power handling capabilities of an optical device are disclosed. In one embodiment, an optical device includes a TEC optical fiber that includes a first core. The diameter of the first core is larger at the end of the TEC optical fiber than it is in the unexpanded portion of the TEC optical fiber. The optical device also includes a focusing lens configured to focus light into the end of the TEC optical fiber so that a light spot created by the focused light on a surface of the end of the TEC optical fiber has a light spot diameter that is larger than the diameter of the first core in the unexpanded portion of the TEC optical fiber.
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This is a continuation of application Serial No. 707,354, filed July 21, 1976 now abandoned.
BRIEF DESCRIPTION OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus used in the expanding of the beads of a tubeless tire such that they will properly seat against a wheel rim and provide leak proof seals as the tire is inflated.
2. Prior Art
With the advent of tubeless tires, it has been necessary to develop apparatus for properly positioning the beads of the tires so that they will seat against wheel rims on which they are mounted as the tires are inflated. The apparatus used has generally comprised a belt that can be placed peripherally around a tire after the tire has been mounted on a wheel, and that includes some means for tightening the belt to increase the peripheral pressure applied to the tire. This increased peripheral pressure, and the constraint of the belt, force the sidewalls of the tire outwardly such that the beads thereof will engage the wheel rims. The belts generally have cinching devices to shorten the belt length and thereby increase the constraint applied by the belt to the periphery of the tire, or they are inflatable such that as air is put into the belts, and they expand, they apply additional constraint to the tire. In using such devices, it is most common for the tire to be lifted into a horizontal position where the weight of the wheel generally moves the rims thereof away from the beads of the tire that are to be sealed to the rims. As a result, it is frequently very difficult to seal the beads to the rims.
SUMMARY OF THE INVENTION
The present invention is concerned with providing apparatus for expanding tire beads into engagement with wheel rims in such a way that the tire beads are more easily seated against the wheel rims than has heretofore been possible and without involving any difficult lifting or handling of a wheel assembly comprising the wheel and a tire mounted thereon.
Principal objects of the present invention are to provide apparatus that can be conveniently used with tubeless tires of all sizes, even including large truck tires; and of all kinds, including belted bias and radial tires; and that can be used to quickly and easily seat the beads of the tires against the rims of wheels during inflation of the tires.
Other objects are to provide such apparatus on which a wheel assembly can be readily positioned without lifting and that will insure proper initial seating of the tire beads of the tire of the wheel assembly against the rims of the wheel of the wheel assembly as the tire is inflated.
Principal features of the invention include a stand or framework onto which a wheel assembly may be rolled and including guide means that will support the wheel assembly in an upright position; a draw strap that extends fully around or that cooperates with a frame member to totally encircle the periphery of the tire of the wheel assembly; cinching apparatus for snugging the draw strap tight around the periphery of the tire; and valve apparatus that provides compressed air to a tire inflation apparatus.
Additional objects and features of the invention will become apparent from the following detailed description, taken together with the accompanying drawings.
THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a first embodiment of the invention, showing a wheel assembly including a tire mounted on a wheel and positioned within the tire bead expander of the invention;
FIG. 2, a vertical section view taken on the line 2--2 of FIG. 1, with the cinching means surrounding the tire, but not snugged up tight;
FIG. 3, a view like that of FIG. 2, but showing the cinching means cinched tight and the tire deformed accordingly;
FIG. 4, a side elevation view of the apparatus without a wheel assembly positioned therein;
FIG. 5, a front elevation view;
FIG. 6, a front elevation view of another embodiment of the invention;
FIG. 7, a side elevation view of the embodiment of the invention shown in FIG. 6;
FIG. 8, a similar view, with a tire positioned therein, but with the draw strap not cinched tight; and
FIG. 9, another such view with the draw strap cinched tight.
DETAILED DESCRIPTION
Referring now to the drawings:
In the illustrated embodiment shown in FIGS. 1-3, the tire bead expander of the present invention comprises a stand and support frame, shown generally at 10; a draw strap, shown generally at 11; a ratchet take up unit 12; a pressure gauge 13; and a control valve 14.
Valve 14 has an inlet line 15 connected thereto and the other end of the inlet line is connected to an air compressor or other source of air under pressure, not shown. An air hose 16 also has one end connected to the valve 14 and its other end has an inflation fitting 17 thereon.
The stand and support frame 10 includes a base platform 18. Side rails 19 and 20 are spaced apart at opposite sides of the platform 18 to serve as guides for a wheel assembly, such as is shown at 11, FIG. 1, to be rolled therebetween. The side rails 19 and 20 include outwardly flared front legs 19a and 20a that extend to the forward end of platform 18 and rear legs 19b and 20b. The side rails extend upwardly at 19c and 20c and rearwardly at 19d and 20d before being interconnected by a cross bar 21. The outwardly flared front legs serve to guide the wheel assembly between the rails and the spacing of the rails is such that the wheel assembly can be readily rolled between them until the wheel assembly comes in contact with the cross bar 21 or is stopped by pipe 25.
Pipe 25 is held positioned above the platform 18 by bar 25a and is located centrally between the side rails 19 and 20 to serve as a central tire support. The pipe 25 is arcuately curved to fit around a tire periphery. Pipe 25 is supported at its upper end by a pair of brackets 26 and 27 that are fixed to the cross bar 21 and an upright stanchion 28 that is mounted on the base platform, and at its lower end by a pair of guide pipes 29 and 30 that extend forwardly and outwardly from the pipe 25 to the base platform 18.
The flexible draw strap 11 is attached to the uppper and lower ends of the pipe 25. The draw strap includes a chain 31 that has one end fixed at 31a within the lower end of pipe 25 and a flexible strap 32 that has one end passed between guide rollers 33 and that is then secured to a take up reel 34 of the ratchet take up unit 12. The other end of the chain 31 is fixed to the other end of the flexible strap 32 by a connector 32a. The ratchet take up unit 12 is conventional and is used to take up the slack and to tighten the draw strap 11 around the tire of a wheel assembly positioned on the support frame 10.
In use, a wheel assembly such as is shown at 33, and including a wheel 34 on which a tubeless tire 35 has been mounted, is rolled into position on the frame 10. In positioning the wheel assembly, it is rolled between the front legs 19a and 20a and the side rails 19 and 20 until it is stopped by the pipe 25 or the cross bar 21. As the wheel assembly is rolled between the guide rails it is directed up the guide pipes 29 and 30 and rests on the lower portion of pipe 25 and partially within the curve of the pipe 25.
After the wheel assembly has been positioned, the draw strap 11, which has been moved from between the side rails during positioning of the wheel assembly, is arranged to peripherally encircle the portion of the tire not within the curve of pipe 25. The ratchet take up unit is then manipulated to roll the flexible strap 32 thereon and to thereby tighten the chain and strap 32 around a portion of the tire, while at the same time compressing the tire against pipe 25. The chain 31 extends from within pipe 25 at one end and below the tire supporting surface of the central tire support and since the strap is taken up by the ratchet at the other end of the pipe 25, the tire is substantially fully encircled by the pipe 25 and draw strap 11, and, as the strap 32 is rolled onto the ratchet take up unit reel, the tire is substantially uniformly compressed around its entire periphery. This expands the tire bead outwardly into close proximity with the rims of the wheel. Thereafter air is forced into the tire through the usual valve stem 36, using the inflation fitting 17 and air hose 16.
In the embodiment of the invention shown in FIGS. 6-9, the tire bead expander comprises a support frame, shown generally at 40; a draw strap, shown generally at 41; a ratchet take up unit 42 that corresponds to the ratchet take up unit 12 previously described; and a pressure gauge 43 and control valve 44 that correspond to the pressure gauge 13 and control valve 14, previously described.
The connections and operations of the gauge 43 and control valve 44 are the same as for gauge 13 and valve 14, previously described and will not be further described in detail.
Frame 40 includes a base platform 48, spaced apart side rails 49 and 50 will outwardly and downwardly extending front legs 49a and 50a. A guide plate 39 extends between the front legs and partially up the legs to guide a wheel assembly 11 upwardly between the side rails, as will be further explained. Rear legs 49b and 50b extend outwardly and rearwardly from the side rails to support them above the base platform 48.
The side rails 49 and 50 extend upwardly at 49c and 50c and rearwardly at 49d and 50d before being interconnected by a cross bar 51.
An upwardly opening channel member 55, positioned above the platform 48 and centrally between the side rails is arcuately curved at 55a to generally follow a portion of the periphery of a tire and extends at its lower end 55b to a location just behind the upper end of the guide plate 39. The channel member thus serves as a central tire support means.
The side flanges of the channel member 55 extend upwardly at 55c beyond the upper end of the channel web and rollers 56 are positioned between the side flanges to guide a belt portion 57 of the draw strap 41 therethrough. One end of the belt portion 57 is connected to the ratchet take up unit 58 and is adapted to be rolled thereon in conventional fashion by pivoting of the handle 59. The other end of the belt portion is securely attached to a chain portion 60 of the draw strap 41. The chain portion 60 is long enough to encircle, with the belt, the tire of any wheel assembly positioned in the tire bead expander. A hook 61 is centrally attached to a short chain 61a, the ends of which are anchored to the upper side flanges of the channel member 55.
In using the tire bead expander of FIGS. 6-9, the draw strap is arranged such that the belt portion hangs downwardly and the chain portion 60 is positioned in the channel member 55, before being draped to one side of the unit. A wheel assembly, with a tire 35 mounted thereon, is rolled up the guide plate 39 and onto the lower end of the channel member. The draw strap is then positioned around the tire periphery, is pulled up as much as possible and the chain portion 60 is connected to the hook 61. Thereafter, the ratchet take up unit 58 is operated to take up the belt portion 57. This pulls the draw strap even more tightly around the tire and expands the tire beads outwardly where they will be more apt to seat against the rims of the wheel 33 of the wheel assembly.
As the draw strap tightens around the tire, the wheel assembly is raised and the draw strap comes out of channel, as shown best in FIG. 9. The draw strap then applies a substantially uniform pressure fully around the tire as the tire beads are expanded outwardly to facilitate their sealing with the rims of the wheel.
While the cinching apparatus herein disclosed comprises a manually manipulated, ratchet operated take up unit, it will be apparent that other types of take up units can be used. For example, such unit can be fluid or electrically operated.
Although preferred forms of my invention have been herein disclosed, it is to be understood that the present disclosure is by of example and that variations are possible without departing from the subject matter coming within the scope of the following claims, which subject matter I regard as my invention.
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Apparatus for expanding the beads on tubeless tires, including a stand into which such a tire is to be rolled, a flexible draw strap adapted to peripherally surround the tire or to cooperate with an arcuate central frame in surrounding the tire, cinching apparatus for substantially uniformly tightening the draw strap around the tire, and valving structure through which compressed air may be supplied to tire inflation apparatus.
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BACKGROUND
The system and method of the present embodiment relate generally to automatically transposing an image from a circular image space to a horizontal image space.
Electronically represented text can be oriented in various ways and, in some cases, parts of the text can be inverted in relation to other parts of the text. One situation in which this can occur is when text is located in a roundel, which is a circle containing text. On a mail piece, a roundel can be located, for example, to the left of a permit block and can contain, for example, text written along an inside edge of the roundel. Additionally, there can be another circle just inside the text. Company name, city and state, or zip code information can be contained in the roundel instead of, for example, in the permit block. Roundels can include, for example, text written in a circle (see FIG. 3A ), and text oriented so that it is never upside-down to the reader (see FIG. 3B ).
SUMMARY
The needs set forth above as well as further and other needs and advantages are addressed by the embodiments set forth below.
The present embodiment can automatically transpose a circular image to a horizontal image. The method of the present embodiment can include, but is not limited to including, the steps of choosing a starting pixel on the circumference of a circular image and choosing an end sampling pixel within the circular image. The method can also include the steps of computing the distance between the location of the starting pixel and location of the end sampling pixel, computing an angle based on the location of the starting pixel and the circumference of the circular image, and computing X and Y coordinates based on the center of the circular image, the angle, and the distance. The method can still further include the steps of copying a sample pixel located at the X and Y coordinates to a position in an image, for example, a horizontal or flattened image, that is based on where the sample pixel was sampled in the circular image, moving the sample point towards the end sampling pixel, and repeating the sampling steps until reaching the end sampling pixel. The method can even still further include the steps of moving to the next pixel along the circumference of the circular image and repeating the sampling steps as above until each pixel along the circumference has been visited, and storing the image in an electronic sink.
The system of the present embodiment can include, but is not limited to including, a pre-sampling processor for choosing a starting pixel on the circumference of a circular image and choosing an end sampling pixel within the circular image, computing the distance between the location of the starting pixel and location of the end sampling pixel, computing an angle based on the location of the starting pixel and the circumference of the circular image, and computing X and Y coordinates based on the center of the circular image, the angle, and the distance. The system can also include a sampler 23 for copying a sample pixel located at the X and Y coordinates to a position in an image, for example, a horizontal or flattened image, that is based on where the sample pixel was sampled in the circular image, moving the sample point towards the end sampling pixel, repeating the sampling steps until reaching the end sampling pixel, moving to the next pixel along the circumference of the circular image and repeating the sampling steps as above until each pixel along the circumference has been visited. The system can still further include an image creator for accessing the image and storing the image in an electronic sink.
For a better understanding of the present embodiments, together with other and further objects thereof, reference is made to the accompanying drawings and detailed description.
DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a schematic block diagram of the system of the present embodiment;
FIG. 2 is a schematic block diagram of the detail of a component of the system of the present embodiment;
FIGS. 3A and 3B are examples of text in roundels;
FIGS. 4A-4C are examples of text of various layouts, for example, flipped ( FIG. 4B ); and
FIGS. 5A and 5B are flowcharts of a method of an embodiment according to the teachings stated herein.
DETAILED DESCRIPTION
The present embodiments are now described more fully hereinafter with reference to the accompanying drawings. The following configuration description is presented for illustrative purposes only. Any computer configuration and architecture satisfying the speed and interface requirements herein described may be suitable for implementing the system and method of the present embodiments.
Referring now to FIGS. 1 and 2 , system 100 ( FIG. 1 ) of the present embodiment can include, but is not limited to including, pre-sampling processor 11 ( FIG. 1 ) for choosing starting pixel 21 ( FIGS. 1 and 2 ) on circumference 13 ( FIGS. 1 and 2 ) of circular image 12 ( FIGS. 1 and 2 ), equating a starting location of starting pixel 21 ( FIGS. 1 and 2 ) to circumference position 43 ( FIGS. 1 and 2 ), equating circumference position 43 ( FIGS. 1 and 2 ) to next location 17 ( FIGS. 1 and 2 ), choosing end sampling pixel 27 ( FIG. 2 ) within circular image 12 ( FIGS. 1 and 2 ), computing distance 35 ( FIG. 1 ) between next location 17 ( FIGS. 1 and 2 ) and end sampling pixel 27 ( FIG. 2 ), computing angle 37 ( FIG. 1 ) based on next location 17 ( FIGS. 1 and 2 ) and circumference 13 ( FIGS. 1 and 2 ), computing X coordinate 39 ( FIGS. 1 and 2 ) and Y coordinate 41 ( FIGS. 1 and 2 ) based on the center of circular image 12 ( FIGS. 1 and 2 ), angle 37 ( FIG. 1 ), and distance 35 ( FIG. 1 ). System 100 ( FIG. 1 ) can further include sampler 23 ( FIGS. 1 and 2 ) for copying sample pixel 33 ( FIG. 1 ) located at X coordinate 39 ( FIGS. 1 and 2 ) and Y coordinate 41 ( FIGS. 1 and 2 ) to a position in target image 29 ( FIGS. 1 and 2 ) that is based on circumference position 43 ( FIGS. 1 and 2 ), X coordinate 39 ( FIGS. 1 and 2 ), and Y coordinate 41 ( FIGS. 1 and 2 ), modifying next location 17 ( FIGS. 1 and 2 ), accessing pre-sampling processor 11 ( FIGS. 1 and 2 ) until distance 35 ( FIG. 1 ) is substantially zero, modifying circumference position 43 ( FIGS. 1 and 2 ), accessing pre-sampling processor 11 ( FIGS. 1 and 2 ) until the next circumference position 43 ( FIGS. 1 and 2 ) is adjacent to the starting location. System 100 ( FIGS. 1 and 2 ) can still further include an image creator 25 ( FIG. 1 ) for accessing target image 29 ( FIGS. 1 and 2 ) and storing target image 29 ( FIGS. 1 and 2 ) in electronic sink 47 ( FIG. 1 ). Image creator 25 ( FIG. 1 ) can further equate the width of target image 29 ( FIGS. 1 and 2 ) to circumference 13 ( FIGS. 1 and 2 ), and equate the height of target image 29 ( FIGS. 1 and 2 ) to the radius of circular image 12 ( FIGS. 1 and 2 ). Circular image 12 ( FIGS. 1 and 2 ) and circumference 13 ( FIGS. 1 and 2 ) and be provided by electronic source 31 ( FIG. 1 ), which can include, but is not limited to including, a scanner, keyboard input, or other means.
Referring now primarily to FIG. 2 , sampler 23 can include, but is not limited to including, sample positioner 53 and pixel copier 51 , and pre-sampling processor 11 can include, but is not limited to including circumference processor 45 and radial processor 49 . Sample positioner 53 can compute angle 37 as
Angle 37=(( A *(360 /C ))*(π/180)) (1)
A is the location of starting pixel 21 and C is circumference 13 of circular image 12 . Sample positioner 53 can further define X coordinate 39 as
X Coordinate 39 =CP +(sin(Angle 37)* D ) (2)
and define Y coordinate 41 as
Y Coordinate 41 =CP +(cos(Angle 37)* D ) (3)
where CP is the center of circular image 12 and D is distance 35 .
Continuing to refer to FIG. 2 , optionally, sample positioner 53 can decrement next location 17 to move towards end sampling pixel 27 . Sample positioner 53 can also optionally determine the pixel location of an adjacent pixel that is adjacent to circumference position 43 , can set circumference position 43 to the pixel location, and can inform circumference processor 45 of the new value for circumference position 43 . Sample positioner 53 can even further optionally compute the position in target image 29 as position (XF, YF), where XF, the image X coordinate, is equal to next location 17 , and where YF, the image Y coordinate, is equal to the location at (X coordinate 39 , Y coordinate 41 ). Optionally, end sampling pixel 27 can be the center of circular image 12 . Radial processor 49 can decide how many points to sample in between starting pixel 21 and end sampling pixel 27 for each radial. Next location 17 falls on a pixel location because X coordinate 39 and Y coordinate 41 can be rounded to integer values after being calculated, for example, in floating point. Sampler 23 can sample grey, bilevel, and/or color pixels. Starting pixel 21 can lie outside circular image 12 , and end sampling pixel 27 can lie inside a circle inside circular image 12 , for example, if an inner circle exists, see FIGS. 3A and 3B . If there is no inner circle in, for example, a mail product, sampler 23 can sample the outer half of the radius (plus some padding on both sides). Sampler 23 can sample points that are one pixel apart on or near circumference 13 and work inwards on an imaginary line towards end sampling pixel 27 . Thus, sometimes sampler 23 can sample the same pixel twice. Pixel copier 51 can store each sample pixel 33 ( FIG. 1 ) in target image 29 at a certain location, thereby forming target image 29 , as sampling proceeds. Target image 29 can contain grey, bilevel, and/or color output, without performing the step of binarization.
Referring to FIGS. 4A-4C , target image 29 ( FIG. 4A ) is shown after the conversion of method 150 ( FIGS. 5A-5B ) is complete. FIGS. 4B-4C illustrate half-flipped layout 59 FIG. 4B ) and flipped layout 61 ( FIG. 4C ).
Referring now primarily to FIGS. 5A-5B , method 150 for automatically converting circular image 12 ( FIG. 1 ) associated with circumference 13 ( FIG. 1 ) to target image 29 ( FIG. 1 ) can include, but is not limited to including, the steps of (a) choosing starting pixel 21 ( FIG. 1 ) on circumference 13 ( FIG. 1 ) of circular image 12 ( FIG. 1 ); (b) equating starting location of starting pixel 21 ( FIG. 1 ) to circumference position 43 ( FIG. 1 ); (c) equating circumference position 43 ( FIG. 1 ) to next location 17 ( FIG. 1 ); (d) choosing end sampling pixel 27 ( FIG. 2 ) within circular image 12 ( FIG. 1 ); (e) computing distance 35 ( FIG. 1 ) between next location 17 ( FIG. 1 ) and end sampling pixel 27 ( FIG. 2 ); (f) computing angle 37 ( FIG. 1 ) based on next location 17 ( FIG. 1 ) and circumference 13 ( FIG. 1 ); (g) computing X coordinate 39 ( FIG. 1 ) and Y coordinate 41 ( FIG. 1 ) based on the center of circular image 12 ( FIG. 1 ), angle 37 ( FIG. 1 ), and distance 35 ( FIG. 1 ); (h) copying sample pixel 33 ( FIG. 1 ) located at X coordinate 39 ( FIG. 1 ) and Y coordinate 41 ( FIG. 1 ) to a position in target image 29 ( FIG. 1 ) that is based on circumference position 43 ( FIG. 1 ), X coordinate 39 ( FIG. 1 ) and Y coordinate 41 ( FIG. 1 ); (i) modifying next location 17 ( FIG. 1 ); (j) repeating steps (d)-(i) until distance 35 ( FIG. 1 ) is substantially zero; (k) modifying next circumference position 43 ( FIG. 1 ); (l) repeating steps (c)-(k) until next circumference position 43 ( FIG. 1 ) is adjacent to the starting location; and (m) storing target image 29 ( FIG. 1 ) in electronic sink 47 ( FIG. 1 ).
Referring now primarily to FIG. 1 , method 150 ( FIGS. 5A-5B ) can optionally include the steps of equating the width of target image 29 ( FIG. 1 ) to circumference 13 ( FIG. 1 ) and equating the height of target image 29 ( FIG. 1 ) to the radius of circular image 12 ( FIG. 1 ). Method 150 ( FIG. 5 ) can further optionally include the steps of computing angle 37 ( FIG. 1 ) as Angle 37 =((A*(360/C))*(π/180)) wherein A=the location of starting pixel 21 ( FIG. 1 ) and C=circumference 13 ( FIG. 1 ) of circular image 12 ( FIG. 1 ), defining X coordinate 39 ( FIG. 1 ) as X Coordinate 39 (FIG. 1 )=CP+(sin(Angle 37 (FIG. 1 ))*D), and defining Y coordinate 41 ( FIG. 1 ) according to Y Coordinate 41 (FIG. 1 )=CP+(cos(Angle 37 (FIG. 1 ))*D), wherein CP=the center of circular image 12 ( FIG. 1 ) and D=distance 35 ( FIG. 1 ). In method 150 ( FIG. 5 ) end sampling pixel 27 ( FIG. 2 ) can be equal to the center of circular image 12 ( FIG. 1 ). Also, in method 150 ( FIG. 5 ), the step of modifying distance 35 ( FIG. 1 ) can include the step of decrementing distance 35 ( FIG. 1 ), and the step of modifying circumference position 43 ( FIG. 1 ) can include the steps of determining the pixel location of an adjacent pixel that is adjacent to circumference position 43 ( FIG. 1 ) and setting circumference position 43 ( FIG. 1 ) to the pixel location. Method 150 ( FIG. 5 ) can further optionally include the step of computing the position in target image 29 ( FIG. 1 ) as position (XF, YF), where XF, the image X coordinate,=circumference position 43 ( FIG. 1 ), and where YF, the image Y coordinate,=(X coordinate 39 ( FIG. 1 ), Y coordinate 41 ( FIG. 1 )).
The methods of the present embodiments can be, in whole or in part, implemented electronically. Signals representing actions taken by elements of system 100 ( FIG. 1 ) can travel over electronic communications media. Control and data information can be electronically executed and stored on computer-readable media. The system can be implemented to execute on a node 20 in a communications network 19 . Common forms of computer-readable media can include, but are not limited to, for example, a floppy disk, a flexible disk, a hard disk, magnetic tape, or any other magnetic medium, a CDROM or any other optical medium, punched cards, paper tape, or any other physical medium with patterns of holes or ink or characters, a RAM, a PROM, and EPROM, a FLASH-EPROM, or any other memory chip or cartridge, a carrier wave, or any other medium from which a computer can read.
Although the teachings have been described with respect to various embodiments, it should be realized these teachings are also capable of a wide variety of further and other embodiments.
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A system and method for automatically transposing an image from a circular image space to another image space, for example, horizontal. Examples of applications include a mail piece a roundel on a mail piece. On a mail piece, company name, city and state, or zip code information can be contained in the roundel instead of, for example, in the permit block. The system implements the methods electronically. Control and data information is electronically executed and stored on computer-readable media.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a Non-Provisional Application based on Provisional Application No. 61/611,212 filed Mar. 15, 2012.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates generally to windbreak type structures. More particularly, the invention concerns a novel, generally V-shaped, foldable structure that protects the user from wind and one that can be easily erected and easily dismantled for storage and transport.
[0006] 2. Discussion of the Prior Art
[0007] A number of different types of windbreak structures have been suggested in the past. These structures range from very simple to unduly complex constructions and typically involve a plurality of hingedly interconnected panels. Exemplary of the typical prior art windbreak structures are those illustrated and described in the following patents:
[0008] U.S. Pat. No. 2,465,147 issued to Butler et al. This patent describes a windbreak comprising a pair of rigid panels, means pivotally interconnecting the panels, collapsible means for bracing the panels in a predetermined angular relation and including a seat portion disposed between the panels.
[0009] U.S. Pat. No. 4,838,525 issued to Snow et al. discloses a barrier shield device, foldable and easily portable, for outdoor use in providing wind-protection or other shielding effects, particularly for use on a sandy beach. A plurality of panels are hinged for a composite shield-effect when folded outwardly for use; and a plurality of spikes, which are supportingly connected to the panels, are movable between an upper position for ease of transport and a lower position in which they are pushed into the ground to hold the panel assembly stable. The connectors for connecting the spikes to the panels, but permitting the movement of the spikes into the sand or ground, are advantageously provided integrally from portions of the panels themselves, and they are located sufficiently low with respect to the bottom edge of the panels so that the spikes are supported in and between both their transport position and their ground-engaging position; and the connectors for the spike or spikes inwardly of the end spikes are formed from the panel-portions adjacent the hinges of the panels, thus achieving the opening for accommodation of the spike by the panel material which would be an outside corner of the panel assembly whether in folded condition for transport or open condition for shield-effect use.
[0010] U.S. Pat. No. 6,240,939 issued to McGee discloses a portable and foldable shelter for use by ice fishermen and other outdoorsmen. A tripod of pole members, hingedly interconnected at one end, is covered with a canvas or plastic cover. A hinged tang is provided on the central pole member which can be secured to the ice and about which the erected shelter can be rotated to keep the open side thereof directly downwind in the event of a wind shift.
SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to provide a windbreak type structure for protecting the user from wind that can be easily erected for outdoor use and can be easily dismantled for storage and transport.
[0012] Another object of the invention is to provide a windbreak type structure of the aforementioned character that can be safely secured in the erected, operable configuration.
[0013] Another object of the invention is to provide a windbreak type structure of the character described in the preceding paragraphs that, when in the erected operable configuration, is quite stable.
[0014] Another object of the invention is to provide a windbreak type structure of the character described that is lightweight and easily portable.
[0015] Another object of the invention is to provide a windbreak type structure of the class described that not only protects the user from the wind, but also protects the user from the sun.
[0016] Another object of the invention is to provide a windbreak type structure in which the foldable panels that make up the sides of the structure can be releasably secured in a coplanar configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a generally perspective view of one form of the windbreak structure of the present invention.
[0018] FIG. 2 is a side elevational view of the windbreak structure shown in FIG. 1 .
[0019] FIG. 2A is a fragmentary top view illustrating the manner in which one side of the windbreak structure is folded into a transport, storage configuration.
[0020] FIG. 2B is a fragmentary top view further illustrating the manner in which the sides of the windbreak structure are folded into a transport, storage configuration.
[0021] FIG. 3 is a fragmentary top view illustrating the operation of the leg brace locking assembly that interconnects the side panels of the windbreak structure and maintains them in an open, erected configuration.
[0022] FIG. 4 is a fragmentary view of the surface bolt assembly that releasably locks the side panels of the windbreak structure in a coplanar relationship.
[0023] FIG. 5 is a generally perspective, exploded view of an alternate form of the windbreak structure of the invention.
[0024] FIG. 5A is a greatly enlarged generally perspective fragmentary, exploded view of the area designated in FIG. 5 as 5 A- 5 A.
[0025] FIG. 5B is an enlarged view taken along lines 5 B- 5 B of FIG. 5A .
[0026] FIG. 5C is a generally perspective fragmentary view similar to FIG. 5A , further illustrating the operation of the cover connecting assembly to interconnect the cover with the upper portion of the windbreak structure.
[0027] FIG. 6 is a generally perspective view of the alternate form of the windbreak structure showing the cover interconnected with the upper portion of the windbreak structure.
[0028] FIG. 7 is a generally perspective view of still another form of the windbreak structure of the present invention.
[0029] FIG. 8 is a side view of still another form of the windbreak structure of the invention.
[0030] FIG. 9 is a greatly enlarged, fragmentary side view of one of the conventional hinges that interconnect the four segments of each of the side panels of the windbreak structure and then maintains them in an open, erected configuration.
[0031] FIG. 10 is a side view of yet another form of the windbreak structure of the invention.
DESCRIPTION OF THE INVENTION
[0032] Referring to the drawings and particularly to FIGS. 1 and 2 , one form of the windbreak structure of the present invention is there shown and generally designated by the numeral 14 . The windbreak structure 14 , which is specially designed for outdoor use to protect the user from the wind, here comprises a first side 16 that comprises a plurality of hingedly interconnected uniquely shaped first panels 18 , 20 and 22 . As indicated in FIG. 1 , windbreak structure 14 also comprises a second side 24 , which is hingedly connected to first side 16 by a hinge assembly 26 ( FIG. 3 ), and is movable between a first collapsed position and a second operable position. More particularly, second side 24 is pivotally movable between a first position proximate first side 16 and a second position wherein the second side extends from the first side at an acute angle of between about 20 degrees and about 40 degrees. First panel 18 is in the shape of a four-sided polygon, or quadrangle, while panels 20 and 22 are generally trapezoid-shaped. Second side 24 also comprises a plurality of hingedly interconnected, second panels 28 , 30 and 32 . Second panel 28 is in the shape of a four-sided polygon, or quadrangle, while panels 30 and 32 are generally trapezoid-shaped. A polygon can be defined as a plane shape having straight sides, while a trapezoid can be defined as a four-sided polygon having exactly one pair of parallel sides. The sum of the angles of a trapezoid is 360 degrees. Panels 18 , 20 , 22 , 28 , 30 and 32 can be constructed from various materials, including metal, wood and plastic. Additionally the panels can be colored, opaque, translucent or transparent as may be desired by the user.
[0033] As illustrated in FIGS. 1 and 3 of the drawings, the first and second sides are releasably locked in the operable position by a leg brace locking, or securement assembly 34 . Both hinge 26 and securement assembly 34 are of conventional construction and are readily commercially available from several sources, including National Manufacturing of Lake Forest, Calif.
[0034] Side panel 22 has spaced apart, generally vertically extending, generally parallel legs 36 and 38 that are interconnected by a ground engaging base member 40 and an upper member 42 . Upper member 42 extends angularly from leg 38 at an angle of between about 15 and about 25 degrees. Side panel 20 has spaced apart, generally vertically extending, generally parallel legs 36 a and 38 a that are interconnected by a ground engaging base member 40 a and an upper member 42 a . Upper member 42 a extends angularly from leg 38 a at an angle of between about 15 and about 25 degrees.
[0035] Side panel 30 has spaced apart, generally vertically extending, generally parallel legs 44 and 46 that are interconnected by a ground engaging base member 48 and an upper member 50 . Upper member 50 also extends angularly from leg 46 at an angle of between about 15 and about 25 degrees ( FIG. 1 ). Side panel 32 has spaced apart, generally vertically extending, generally parallel legs 44 a and 46 a that are interconnected by a ground engaging base member 48 a and an upper member 50 a . Upper member 50 a also extends angularly from leg 46 a at an angle of between about 15 and about 25 degrees ( FIG. 1 ).
[0036] As illustrated in FIGS. 2A and 2B , in the present form of the invention, the panels of each of the first and second sides 16 and 24 are hingedly interconnected by conventional hinges 54 and for ease of storage and transport are movable from the first generally coplanar position shown in FIG. 2A to the second folded position shown in FIG. 2B . In order to releasably hold the panels of each of the first and second sides 16 and 24 of the structure in a coplanar position as shown in FIG. 1 , a panel lock assembly, shown here as a conventional surface bolt 56 , is connected to and spans each of the adjoining panel members. Both, hinges 54 and securement assembly, or surface bolts 56 , are of conventional construction and are readily commercially available from several sources, including National Manufacturing of Lake Forest, Calif.
[0037] Referring now to FIG. 5 of the drawings, an alternate form of the windbreak structure of the invention is there shown and generally designated by the numeral 64 . This structure is somewhat similar, in construction and operation, to the embodiment of the invention shown in FIGS. 1 through 4 of the drawings, and like numerals are used in FIG. 5 to identify like components.
[0038] The primary difference between this latest embodiment of the invention and the earlier described embodiment resides in the fact that the windbreak structure is somewhat longer, having three, rather than two, interconnected trapezoid shaped panels. Additionally, this latest embodiment of the invention is uniquely provided with a flexible cover that covers a portion of the structure and provides protection to the user from rain and from the sun.
[0039] Windbreak structure 64 here comprises a first side 66 that comprises a plurality of hingedly interconnected first panels 68 , 70 , 72 and 74 . First panel 68 is in the shape of a four-sided polygon, or quadrangle, while panels 70 , 72 and 74 are generally trapezoid-shaped. Windbreak structure 64 also comprises a second side 76 , which is hingedly connected to first side 66 by a conventional hinge 26 ( FIG. 3 ) for movement between a first collapsed position and a second operable position. More particularly, second side 76 is pivotally movable between a first position proximate first side 66 and a second position wherein the second side extends from the first side at an acute angle of between about 20 degrees and about 40 degrees. Second side 76 also comprises a plurality of hingedly interconnected second panels 78 , 80 , 82 and 84 . Second panel 78 is in the shape of a four-sided polygon, or quadrangle, while panels 80 , 82 and 84 are generally trapezoid-shaped.
[0040] As in the earlier described embodiment, first and second sides 66 and 76 are releasably locked in the operable position by a leg brace locking or securement assembly 34 .
[0041] Side panel 70 has spaced apart, generally vertically extending, generally parallel legs 86 and 88 that are interconnected by a ground engaging base member 90 and an upper member 92 . Upper member 92 extends angularly from leg 86 at an angle of between about 15 degrees and about 25 degrees. Side panel 72 has spaced apart, generally vertically extending, generally parallel legs 86 a and 88 a that are interconnected by a ground engaging base member 90 a and an upper member 92 a . Side panel 74 has spaced apart, generally vertically extending, generally parallel legs 86 b and 88 b that are interconnected by a ground engaging base member 90 b and an upper member 92 b . Upper member 92 b extends angularly from leg 86 b at an angle of between about 15 degrees and about 25 degrees. Side panel 80 of second side 76 has spaced apart, generally vertically extending, generally parallel legs 94 and 96 that are interconnected by a ground engaging base member 98 and an upper member 100 . Upper member 100 extends angularly from leg 94 at an angle of about 20 degrees. Side panel 82 of second side 76 has spaced apart, generally vertically extending, generally parallel legs 94 a and 96 a that are interconnected by a ground engaging base member 98 a and an upper member 100 a . Upper member 100 a extends angularly from leg 94 a at an angle of about 20 degrees. Side panel 84 of second side 76 has spaced apart, generally vertically extending, generally parallel legs 94 b and 96 b that are interconnected by a ground engaging base member 98 b and an upper member 100 b . Upper member 100 b extends angularly from leg 94 b at an angle of about 20 degrees.
[0042] As in the previously described embodiment and as illustrated in FIGS. 2A and 2B , and as previously described, in this latest form of the invention, the panels of each of the first and second sides 66 and 76 are also hingedly interconnected by conventional hinges 54 and for ease of storage and transport are movable from the first generally coplanar position shown in FIG. 2A to the second folded position shown in FIG. 2B . In order to releasably hold the panels of each of the first and second sides of the structure in a coplanar position as shown in FIG. 5 , a panel-lock assembly shown there as a conventional surface bolt 62 , is connected to and spans each of the adjoining panel members.
[0043] As depicted in FIG. 5 of the drawings, this latest embodiment of the invention uniquely includes a flexible cover 104 having edges 104 a and 104 b that are connected to the upper members of each of the panels of the first and second sides 66 and 76 by uniquely configured connector elements 106 . As illustrated in FIGS. 5A , 5 B and 5 C, each of the generally T-shaped connector elements 106 comprises a locking leg 106 a and a connector leg 106 b that is connected to and extends from the locking leg at an angle of about 90 degrees ( FIG. 5B ). Attached to each connector leg 106 b is a connector cord 107 that interconnects the connector element with the edges of the cover 104 (see FIGS. 5B and 5C ).
[0044] In order to connect the cover 104 with the windbreak structure to form the structure illustrated in FIG. 6 of the drawings, each of the connector legs of each of the connector elements is inserted into a selected one of a plurality of generally vertically extending slots 109 that are formed in the upper members of the panels of the first and second sides 66 and 76 and then turned in the manner depicted in the right hand portion of FIG. 5C . In this manner, cover 104 can be readily removably interconnected with the upper portion of the windbreak structure in the manner illustrated in FIG. 6 .
[0045] Referring now to FIG. 7 of the drawings, still another form of the windbreak structure of the invention is there shown and generally designated by the numeral 114 . This structure is somewhat similar in construction and operation to the embodiment of the invention shown in FIGS. 5 and 6 of the drawings and like numerals are used in FIG. 7 to identify like components.
[0046] The primary difference between this latest embodiment of the invention and the embodiment illustrated in FIGS. 5 and 6 of the drawings resides in the fact that the windbreak structure includes not only a flexible cover that covers a portion of the structure, but also includes a flexible cover that covers portions of the sides of the structure.
[0047] Windbreak structure 114 here comprises a first side 66 that comprises a plurality of hingedly interconnected first panels 68 , 70 , 72 and 74 . Windbreak structure 114 also includes a second side 76 , which is hingedly connected to first side 66 by a conventional hinge 26 ( FIG. 3 ) for movement in the manner previously described, between a first collapsed position and a second operable position. Second side 76 also comprises a plurality of hingedly interconnected second panels 78 , 80 , 82 and 84 . As in the earlier described embodiment, first and second sides 66 and 76 are releasably locked in the operable position by a leg brace locking or securement assembly 34 .
[0048] As depicted in FIG. 7 of the drawings, this latest embodiment of the invention uniquely includes a flexible cover 118 having edges 118 a and 118 b that are, in the manner previously described, connected to the upper members of each of the panels of the first and second sides 66 and 76 by uniquely configured connector elements 106 .
[0049] This latest embodiment of the invention also uniquely includes a flexible side cover 126 having edges that are connected to the side, top and bottom structural members of panel 82 of the second side 76 in the manner previously described, by uniquely configured connector elements 106 (not shown in FIG. 7 ). Additionally, a flexible side cover 130 has edges that are connected to the side, top and bottom structural members of panel 84 of the second side in the manner previously described, by uniquely configured connector elements 106 (not shown in FIG. 7 ). This latest embodiment of the invention also uniquely includes a flexible side cover 134 having edges that are connected to the side, top and bottom structural members of panel 72 of the first side in the manner previously described, by uniquely configured connector elements 106 (not shown in FIG. 7 ). Similarly, a flexible side cover 136 has edges that are connected to the side, top and bottom structural members of panel 74 of the first side in the manner previously described, by uniquely configured connector elements 106 (not shown in FIG. 7 ). With this novel construction, when the user is inside the windbreak structure, cover 118 provides protection from the sun, while side-covers 126 , 130 , 134 and 136 , provide protection from the wind and other outside elements.
[0050] Turning to FIGS. 8 and 9 of the drawings, a side view of yet another form of the windbreak structure of the invention is there shown and generally designated by the numeral 144 . This structure is also somewhat similar in construction and operation to the earlier described embodiments of the invention. The primary difference between this latest embodiment of the invention and the earlier described embodiments resides in the fact that the windbreak structure 144 comprises first and second interconnected sides, each side comprising four hingedly connected segments which together cooperate to define a four-sided polygon, or quadrangle 146 , having a first generally perpendicularly extending side 148 , a second angularly extending side 150 , a top 152 and a bottom 154 . Each four-sided polygonal side comprises a first segment 156 , a second segment 158 , a third segment 160 and a fourth segment 162 .
[0051] The four segments 156 , 158 , 160 and 162 are interconnected in the manner shown in FIGS. 8 and 9 of the drawings by a conventional hinge 164 . This novel construction permits a folding movement of the segments about fold axes 166 , 168 and 170 ( FIG. 8 ) between a first operable position and a second collapsed position. In order to releasably hold the segments of each of the first and second sides of the structure in a coplanar position, a panel lock assembly, shown here as a conventional surface bolt 56 , is connected to and spans each of the adjoining segments in the manner shown in FIG. 8 .
[0052] Each side of the windbreak structure is covered with a substantially transparent, flexible covering 174 so that users of the structure have an uninterrupted view through the sides of the structure. Because of the absence of spaced apart vertical support members between the top and bottom members, the fold lines about which the segments fold, advantageously cannot be seen.
[0053] Referring next to FIG. 10 of the drawings, a side view of still another form of the windbreak structure of the invention is there shown and generally designated by the numeral 178 . This structure is also somewhat similar in construction and operation to the embodiment illustrated in FIGS. 8 and 9 . The primary difference between this latest embodiment of the invention and that illustrated in FIGS. 8 and 9 resides in the fact that the windbreak structure 178 comprises first and second hingedly interconnected sides (not shown—see FIG. 1 ), each side comprising first and second interconnected segments 180 and 182 , which together cooperate to define a four-sided polygon, or quadrangle 184 . As before, the first and second hingedly interconnected sides are connected by a hinge 26 (not shown in FIG. 10 ) and are movable in the manner previously described, between a first collapsed position where the sides are adjacent and a second operable position where the sides extend angularly with respect to each other.
[0054] First segment 180 , which is general trapezoid in shape, has spaced apart, generally vertically extending, generally parallel legs 186 a and 188 a that are interconnected by a ground engaging base assembly 190 a and an upper member assembly 192 a . Second segment 182 has a first generally perpendicularly extending side 192 , a second angularly extending side 194 , a top assembly 196 and a bottom assembly 198 . Second side 194 extends angularly from bottom assembly 198 at an angle of between about 70 degrees and about 80 degrees.
[0055] Each of the first and second segments 180 and 182 comprise two foldable panels. More particularly, first segment 180 has first and second panels 200 and 202 that are interconnected by hinges 164 and are foldable about a fold axes 204 between a first operable position and a second collapsed position. Similarly, second segment 182 has first and second panels 206 and 208 that are interconnected by hinges 164 and are foldable about a fold axes 210 between a first operable position and a second collapsed position. As before, in order to releasably hold the panels of each of the first and second segments of the structure in a coplanar position, a panel lock assembly, shown here as a conventional surface bolt 56 , is connected to and spans each of the adjoining panels.
[0056] Each of the first and second segments 180 and 182 of each side of the windbreak structure is covered with a substantially transparent, flexible covering 212 so that users of the structure have an uninterrupted view through the sides of the structure. Because of the absence of spaced apart vertical support members between the top and bottom members of each of the first and second segments 180 and 182 , the fold lines about which the panels thereof fold, advantageously cannot be seen.
[0057] Having now described the invention in detail in accordance with the requirements of the patent statutes, those skilled in this art will have no difficulty in making changes and modifications in the individual parts or their relative assembly in order to meet specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention.
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A generally V-shaped, foldable structure that protects the user from wind and can easily be erected and dismantled for storage and transport. In certain embodiments of the invention, covers are provided to further protect the user from sun and wind.
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BACKGROUND
[0001] Embodiments of the present invention relate to a method for starting a gas turbine. Such method is potentially applicable to every kind of gas turbine, such as the ones used for mechanical power (compressors or pumps drive) and for power generation (electrical generators).
[0002] A gas turbine is known from the state of the art, comprising a combustion chamber provided with one or more nozzles. Such nozzles are used to inject fuel, which is then burned inside the combustion chamber. The hot exhaust gases that exit the combustion chamber are then used to move an impeller attached to a shaft, thus providing mechanical work.
[0003] An apparatus for regulating the flow of fuel in such gas turbine is also known. The apparatus comprises a fuel line, which in operation is connected with a fuel inlet and with the nozzles of the gas turbine. Indeed, the fuel line has the function of transferring fuel from the inlet to the nozzles. A regulating valve is placed along the fuel line, so that the flow of fuel can be controlled. Thus, in order to start the turbine, the regulating valve is opened to a defined stroke and a small flow of fuel is allowed to enter inside the combustion chamber. A spark then ignites the fuel and, afterwards, the flow of fuel can be increased further, until a desired operating condition is achieved.
[0004] An aspect of the prior art is that, in case of a malfunction of the regulating valve, too much fuel can be allowed inside the combustion chamber before the ignition. This is potentially extremely dangerous, as it can lead to an explosion of the gas turbine or its exhaust duct with high risk of injuries or fatalities of personnel. For this reason, the known turbines are provided with a safety device designed to interrupt the flow of fuel in case of malfunction. Indeed, such safety device may comprise a flow meter placed on the fuel line downstream of the regulating valve
BRIEF DESCRIPTION
[0005] A first embodiment of the present invention therefore relates to a method of starting a gas turbine. Such method comprises the step of providing an apparatus for regulating the flow of fuel in a gas turbine. The apparatus comprises a main line fluidly connectable with a fuel source and with a nozzle array for transferring fuel from the fuel source to the nozzle array. The apparatus also comprises an auxiliary line fluidly connectable with the fuel source and with the nozzle array for transferring fuel from the fuel source to the nozzle array.
[0006] The method comprises the step of keeping the main line sealed while increasing the auxiliary line fuel flow rate. The method also comprises the step of firing the gas turbine while keeping the main line sealed. After the combustion has started in the gas turbine, and when auxiliary line reaches about its maximum capacity, the main line is opened to increase the main line fuel flow rate. The auxiliary line maximum flow rate is less than the main line maximum flow rate.
[0007] In an embodiment, the gas turbine can be started in an intrinsically safe manner, since the auxiliary line alone does not provide enough fuel to enable a catastrophic failure of the gas turbine. Only after the fuel combustion has taken place the main line is opened.
[0008] Another embodiment of the invention relates to an apparatus for regulating the flow of fuel in a gas turbine. Such apparatus comprises a main line that can be connected in fluid communication with a fuel source and with a nozzle array for injecting fuel into a combustion chamber of a gas turbine. The apparatus also comprises a main flow regulator placed on the main line and configured to vary the flow of fuel on the main line up to a main line maximum flow rate.
[0009] An auxiliary line is placed in fluid communication with the fuel source and the nozzle array for transferring fuel from the fuel source to the nozzle array. An auxiliary flow regulator is placed on the auxiliary line and is configured to vary the flow of fuel on the auxiliary line up to an auxiliary line maximum flow rate. The auxiliary line maximum flow rate is less than the main line maximum flow rate.
[0010] A third embodiment of the invention relates to a method of upgrading a previous apparatus for regulating the flow of fuel in a gas turbine. The previous apparatus is connected to a nozzle array and to a fuel source for injecting fuel into a combustion chamber of a gas turbine. The previous apparatus comprises a main line in fluid communication with the fuel source and the nozzle array, so as to transfer fuel from the fuel source to the nozzle array. The previous apparatus also comprises a main flow regulator placed on the main line and configured to vary the flow of fuel on the main line up to a main line maximum flow rate.
[0011] The method of upgrading the previous apparatus itself comprises the steps of providing an auxiliary line and placing it in fluid communication with the fuel source and with the nozzle array, so as to transfer fuel from the fuel source to the nozzle array. The auxiliary is sized so that its maximum flow rate is less than the main line maximum flow rate. An auxiliary flow regulator is then placed on the auxiliary line to vary the flow of fuel on the auxiliary line up to an auxiliary line maximum flow rate.
[0012] In an embodiment, this allows to apply the above described method for starting a gas turbine to an apparatus not specifically designed for it.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Further details and specific embodiments will refer to the attached drawings, in which:
[0014] FIG. 1 is a schematic representation of an apparatus for regulating the flow of fuel in a gas turbine according to a first embodiment of the present invention;
[0015] FIG. 2 is a schematic representation of an apparatus for regulating the flow of fuel in a gas turbine according to a second embodiment of the present invention;
[0016] FIG. 3 is a schematic representation of an apparatus for regulating the flow of fuel in a gas turbine according to a third embodiment of the present invention.
DETAILED DESCRIPTION
[0017] The following description of exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the embodiments of the present invention. Instead, the scope is defined by the appended claims.
[0018] Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
[0019] Therefore, an apparatus for regulating the flow of fuel in a gas turbine will be described by referring to the attached figures, in which will be indicated with the number 1 .
[0020] Such apparatus 1 is designed to transfer the fuel to a combustion chamber “C”, which is provided with a plurality of nozzles 3 . Indeed, the combustion chamber may comprise one or more array “N” of nozzles 3 . As shown for example in FIG. 3 , the nozzle array “N” (itself not part of the invention) comprises a first 3 a and a second set 3 b of nozzles 3 . In the embodiment shown in FIG. 3 the first set 3 a of nozzles 3 comprises the primary nozzles 3 . The second set 3 b comprises the secondary nozzles 3 .
[0021] In further embodiments, not shown, there may be as many set of nozzles 3 as it is deemed necessary by the project specifications.
[0022] The combustion chamber “C” is not considered as part of the present invention, and will not be described in further detail.
[0023] The apparatus 1 comprises a fuel source 2 . Indeed, the fuel source 2 comprises one fuel inlet 2 a , associated with a respective inlet strainer 2 b.
[0024] A main line 4 for the transfer of fuel is placed in fluid communication with the fuel source 2 . Also, the main line 4 is placed in fluid communication with one or more nozzles 3 . Indeed, in the context of the present disclosure the main line 4 is considered to be the path of the fuel between the fuel source 2 and the nozzles 3 . It is to be noted that such path may comprise more than one parallel physical paths between the fuel source 2 and the nozzles 3 .
[0025] Along the main line 4 is placed a sealing device 5 , also referred to as “block and bleed” in the technical field. The sealing device 5 comprises a set of valves 5 a , 5 b , 5 c . A first 5 a and a second valve 5 b are arranged serially along the main line 4 . A third valve 5 c is connected in fluid communication with the main line 4 between the first 5 a and the second valve 5 b so that, when opened, can vent the gas entrapped between the first 5 a and the second valve 5 b . This arrangement is such that during the functioning of the gas turbine, the third valve 5 c is closed while both the first 5 a and the second valve 5 b are kept open. In this way, fuel can flow along the main line 4 . When the gas turbine is not working both the first 5 a and the second valve 5 b are kept closed, and the third valve 5 c is kept open. In this way, any fuel leaks from the first 5 a and the second valve 5 b will be allowed to vent away from the main line 4 by the third valve 5 c , thus preventing any potential accumulation of fuel inside the combustion chamber “C”.
[0026] In an embodiment, a vent valve 6 is present on the main line 4 downstream of the sealing device 5 .
[0027] In the embodiment shown in FIG. 3 , the main line 4 branches to reach the first 3 a and the second set 3 b of nozzles 3 . Indeed, the main line comprises a main branch 4 a which branches into a primary 4 b and into a secondary branch 4 c . The primary branch 4 b is placed in fluid connection with the main branch 4 a and with the first set 3 a of nozzles 3 . Similarly, the secondary branch 4 c is placed in fluid connection with the main branch 4 a and with the second set 3 b of nozzles 3 . In this arrangement, the above described sealing device 5 and vent valve 6 are placed on the main branch 4 a of the main line 4 .
[0028] The main line 4 can comprise an expansion zone 12 . As shown in FIG. 3 , the expansion zone 12 is placed between the main branch 4 a and the primary 4 b and secondary branches 4 c . A divergent portion 13 connects the main branch 4 a to the expansion zone 12 . A convergent portion 14 connects each of the primary 4 b and secondary 4 c branches to the expansion zone 12 . In an embodiment, this helps to dampen any pressure fluctuation on the main line 4 before it reaches the nozzles 3 .
[0029] In an embodiment, a main flow regulator 7 is placed on the main fuel line 4 downstream of the sealing device 5 . Also, the main flow regulator 7 is placed downstream of the vent valve 6 . Such main flow regulator 7 is configured to vary the flow of fuel on the main fuel line 4 up to a main line maximum flow rate. In the embodiment from FIG. 3 , each of the primary 4 b and secondary 4 c branch is provided with its own flow regulator. With more detail, the apparatus 1 may comprise a primary flow regulator 7 a on the primary branch 4 b of the main line 4 . Similarly, the apparatus 1 may comprise a secondary flow regulator 7 b on the secondary branch 4 c of the main line 4 . The primary 7 a and the secondary flow regulator 7 b are substantially similar to the main flow regulator 7 described above. If the specifications require it, the primary 7 a and the secondary 7 b flow regulators may be sized differently. It is to be noted that in this arrangement no main flow regulator 7 is actually present.
[0030] An auxiliary line 8 is placed in fluid communication with the fuel source 2 . The auxiliary line is also placed in fluid communication with at least some of the nozzles 3 , so that it can transfer fuel from the inlet 2 a to the nozzles 3 . The purpose of the auxiliary line 8 is to provide an intrinsically safe way to start the gas turbine, as its maximum flow can be sized so as to be enough to start the gas turbine but not too much as to create the danger of an explosion.
[0031] With more detail, in one embodiment of the invention the pipes of the auxiliary line 8 has a lesser internal diameter than the pipes of the main line 4 . Additionally, in an embodiment, the auxiliary line 8 comprises a convergent portion 10 directly attached to the main line 4 upstream of the main flow regulator 7 . In particular, the auxiliary line 8 branches from the main line 4 upstream of the sealing device 5 .
[0032] In the embodiment shown in FIG. 1 , the auxiliary line 8 connects back to the main line 4 upstream of the main flow regulator 7 .
[0033] In the embodiment shown in FIG. 2 , the auxiliary line 8 connects back to the main line 4 downstream of the main flow regulator 7 .
[0034] In the embodiment shown in FIG. 3 , the auxiliary line 8 connects back to the primary branch 4 b of the main line 4 , in particular downstream of the expansion zone 12 . Similarly to the embodiment shown in FIG. 2 , the auxiliary line 8 connects to the primary branch 4 b downstream of the primary flow regulator 7 a . Another variant is possible (not shown in the drawings) in which the auxiliary line 8 connects to the primary branch 4 b upstream of the primary flow regulator 7 a.
[0035] The auxiliary line 8 comprises a divergent portion 11 directly attached to the main line 4 or, in case of the embodiment from FIG. 3 , to the primary branch 4 b of the main line 4 .
[0036] The auxiliary line 8 is provided with its own auxiliary sealing device 15 . Such auxiliary sealing device 15 is substantially similar to the sealing device 5 described above.
[0037] The auxiliary line 8 is provided with an auxiliary flow regulator 9 , which is configured to vary the flow of fuel on the auxiliary fuel line 9 itself. Indeed, the auxiliary flow regulator 9 ensures that the flow along the auxiliary line 8 can never exceed the auxiliary line 8 maximum flow rate. This maximum flow rate is less than the maximum flow rate of the main line 4 . The auxiliary flow regulator 9 is in particular placed directly downstream with respect to the auxiliary sealing device 15 .
[0038] According to a first embodiment, the auxiliary flow regulator 9 is an orifice. This simplistic embodiment can be employed if the fuel composition is relatively constant (a variation of about 5% of the calorific content of the fuel is admissible). According to another embodiment, the auxiliary flow regulator 9 is a valve. This allows to vary the composition of the fuel without constraints, at the cost of greater complexity.
[0039] In detail, the auxiliary line 8 maximum flow rate is less than the Lower Explosive Limit. The Lower Explosive Limit is defined as the minimum concentration of fuel in a fuel/air mixture such as a spark can ignite the mixture and cause it to explode. In other words, no explosion is possible if the fuel concentration is below the Lower Explosive Limit. Such Lower Explosive Limit generally corresponds to a fuel flow rate of about 15% of the maximum total flow rate. The exact value of the LEL depends on the phisical/chemical properties of the fuel, on the temperature of the air, and on other general phisical properties so that its precise value can easily be computed by the person skilled in the art if all such properties are known or can be reasonably assumed to be inside a specific range (such as is generally the case during the design of a gas turbine).
[0040] The apparatus 1 may also comprise a flame detector (not shown in the drawings) active on the combustion chamber of the gas turbine. In an embodiment, the flame detector is optical, and ensures that a control system of the apparatus 1 can react to any changes in the combustion chamber.
[0041] In order to start the gas turbine, the main shaft of the gas turbine is initially moved by a starting engine (both are not shown in the drawings). Thus an initial air flow is established in the gas turbine and, in particular, in the combustion chamber “C”. In this way, the combustion chamber “C” is purged from eventual residue of fuel which may be still inside.
[0042] After the purging phase, a spark is started inside the combustion chamber “C”. The fuel flow is then slowly increased inside the combustion chamber “C”. With more detail, the main line 4 is kept sealed, while the fuel flow rate in the auxiliary line is increased. In other words, the gas turbine is fired while keeping the main line 4 sealed. Indeed, the gas turbine is fired using only fuel from the auxiliary line.
[0043] With additional detail, in the embodiment shown in FIG. 2 the main flow regulator 7 is opened at a preset stroke. The auxiliary flow regulator 9 is controlled in order to achieve a predetermined pressure value upstream of the main flow regulator 7 . With more detail, the preset pressure value is not constant, but is a function of the rotational speed of the turbomachine. Since the main flow regulator 7 is fixed at this stage, the fuel flow inside the combustion chamber “C” is only a function of the pressure upstream of the main flow regulator 7 .
[0044] The combustion can therefore start in the gas turbine. With additional detail, the method comprises a step of detecting a flame inside the combustion chamber. In an embodiment, such step is performed before the main line 4 opening step. In particular, such step is performed by the above mentioned flame detector.
[0045] Afterwards, the main line 4 is opened in order to increase the main line 4 fuel flow rate. With more detail, after the auxiliary flow regulator 9 is completely opened the gas turbine is warmed up for several minutes. Afterwards, the sealing device 5 is gradually opened, in particular with reference to the first 5 a and second valve 5 b . The main flow regulator 7 can then be controlled in order to further increase the flow of fuel inside the combustion chamber “C”.
[0046] In the embodiments from FIGS. 1 and 3 the startup sequence is similar to the one described above. However, the auxiliary flow regulator 9 is not controlled as a function of a preset pressure, but is placed in sonic condition and targets a predetermined auxiliary line 8 flow rate directly. Additionally, after the auxiliary line 8 maximum flow rate is achieved, the main flow regulator 7 is opened at a preset stroke. Afterwards, the sealing device 5 is gradually opened, in particular with reference to the first 5 a and second valve 5 b . During this phase the auxiliary flow regulator 9 is gradually closed, so that the total flow rate can remain constant. After the auxiliary flow regulator 9 is completely closed, the main flow regulator 7 can be controlled in order to further increase the flow of fuel inside the combustion chamber “C”.
[0047] It is to be understood that even though numerous characteristics and advantages of various embodiments have been set forth in the foregoing description, together with details of the structure and functions of various embodiments, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the embodiments to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. It will be appreciated by those skilled in the art that the teachings disclosed herein can be applied to other systems without departing from the scope and spirit of the application.
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A method of starting a gas turbine is provided, comprising the step of providing an apparatus for regulating the flow of fuel in a gas turbine, the apparatus comprising a main line connecting a fuel source to a nozzle array; and an auxiliary line connecting the fuel source to the nozzle array. The method further comprises the steps of keeping the main line sealed while increasing the auxiliary line fuel flow rate; firing the gas turbine while keeping the main line sealed; and after the combustion has started in the gas turbine, opening the main line for increasing the main line fuel flow rate; wherein the auxiliary line maximum flow rate is less than the main line maximum flow rate.
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FIELD OF THE INVENTION
[0001] The invention relates to method of detecting the presence of a target molecule in a sample, and in particular to a method including contacting the sample with a substrate, the substrate subsequently being washed in a wash step. Moreover, the invention relates to an apparatus for preparing an assay, to an optical detection system for detecting a target molecule in an assay, to a substrate produced according to the method, and to a kit for performing an assay.
BACKGROUND OF THE INVENTION
[0002] Detection methods for particular biological molecules (bio-molecule) are manifold and many different approaches are presently available to the skilled person. The detection of specific biological molecules has a range of important practical applications, including gene identification for diagnostic purposes.
[0003] In general, the detection of biological specimen (the “target”) such as polynucleotides, DNA, RNA, cells, and antibodies can especially be performed on an array for example a so-called bio-array (or micro-array) whereupon corresponding probe molecules are attached at various sites on the array. Target-probe examples include: DNA/RNA-oligonucleotide, antibody-antigen, cell-antibody/protein, hormone receptor-hormone, etc. When the target is bound or hybridized to a corresponding probe molecule, detection of the target bio-molecule may be performed by a variety of optical, electronic and even micromechanical methods.
[0004] A commonly used technique for detection of molecular binding on bio-arrays is optical detection of fluorescent labeled targets also known as a “label” or “marker”. In general, a label may be any agent that is detectable with respect to its physical distribution and/or the intensity of the outgoing signal it gives. Fluorescent agents are widely used, but alternatives include phosphorescent agents, electroluminescent agents, chemiluminescent agents, bioluminescent agents, etc.
[0005] In general a problem of luminescence detection relates to separating the luminescent light with low intensity from the illuminating non-luminescent light, generally with high intensity. The reliability of luminescence detection therefore depends much on the optical characteristics of the spectral filters that are used in the separation process. The spectral filter function may include two steps: a first filter (called the ‘excitation filter’) preferably transmits the rays with a wavelength overlapping with the excitation spectrum of the label and blocks all rays with a wavelength that is inside the spectrum of the detection window. A second filter (called the ‘emitter filter’ or ‘detection filter’) preferably blocks all illumination light and transmits only the luminescent rays. The attenuation (blocking power) of a typical filter set is better than 10 −6 . To this end, also the optical properties of the substrate may be considered.
[0006] US 2005/0048571 discloses a substrate for reducing the auto-fluorescence in connection with optical detection from bio-arrays. In the disclosure, a porous layer of the substrate is tinted with a colorant agent. A drawback of the tinting of the substrate is however that it renders the substrate more expensive, and it may limit the number of different types of substrates that may be used.
[0007] The inventor of the present invention has appreciated that improved means for luminescence detection would be of benefit, and has in consequence devised the present invention.
SUMMARY OF THE INVENTION
[0008] The present invention seeks to provide an improved way of handling luminescence detection, such as in connection with performing a bio-assay, and preferably, the invention alleviates, mitigates or eliminates one or more of the above or other disadvantages singly or in any combination.
[0009] The invention is defined by the independent claims. The dependent claims define advantageous embodiments.
[0010] According to a first aspect of the present invention there is provided, a method of detecting the presence of a target molecule in a sample.
[0011] The target molecules may be bio-molecules conjugated to fluorophores.
[0012] Radiation is typically electromagnetic radiation in the visible or near-visible range, in the infrared (IR) or in the ultraviolet (UV) range.
[0013] In the context of the present invention, the term “fluorescence” and “phosphorescence” are to be understood in a broad sense as the emitted light resulting from a process where light has been absorbed at a certain wavelength by a molecule or atom, and subsequently emitted at the same or other wavelength after the lifetime of the excited molecule/atom in question. The emitted light is often, but need not be limited to, in the visible light spectrum (VIS), the UV spectrum, and the IR spectrum.
[0014] In an embodiment, the target molecules are detected by irradiating the substrate with a beam of radiation and subsequently detect the resulting luminescence beam from the substrate, i.e. the luminescence of the target molecules. The luminescence portion of detected radiation may photoluminescence, in particular fluorescence or phosphorescence.
[0015] The substrate for immobilizing probe molecules may be a bio-array arranged for analysis of biological targets. Typically, the bio-array may comprise a plurality of spots, wherein target molecules are immobilized. In this context, a spot is to be understood as an area having a certain extension. The spot may have a 2D or 3D configuration. The bio-array may comprise a silicon wafer, a glass plate, a porous membrane, such as nylon, nitro-cellulose, etc.
[0016] The optical properties of substrates used for immobilizing probe molecules may be such that the substrates have a very high reflectivity. The amount of scattering depends inter alia on the difference between the index of refraction of air and the substrate. Due to the high reflectivity, the incident radiation may have trouble to penetrate the substrate which reduces the amount of the incident radiation that is able to excite fluorophores that have bound to the substrate, especially within the substrate. Moreover, due to the high reflectivity, a large portion of the reflected light may in some configurations be reflected towards the detector.
[0017] The invention is particularly, but not exclusively, advantageous for reducing the reflectivity of the substrate. By using a substantially index matched fluid during a wash step, the reflectivity of the substrate can be greatly reduced. Moreover, the amount of light penetrating the substrate will be increased, leading to an improvement in the ratio of the incident radiation to the luminescence radiation.
[0018] In an advantageous embodiment, the refractive index of the wash fluid is within the range of the refractive index of the substrate plus/minus 10%. In principle, it is advantageous to obtain as good a match as possible of the refractive indexes, however a trade-off may be advantageous at least in situations where a specific type of wash fluid is required for given probe and/or target molecules and/or substrate. The match of the refractive index of the wash fluid relative to the refractive index of the substrate may be better than plus/minus 8%, plus/minus 6%, plus/minus 4%, plus/minus 2%.
[0019] In an advantageous embodiment, the wash fluid is an aqueous solution of sugar (sucrose) in water, where the weight percentage of sugar is between 50% to 80%. Aqueous solutions of sucrose may be advantageous since many fluorophore-conjugates dissolve easily in such a fluid.
[0020] Embodiments of the invention may advantageously be applied with a porous substrate, since a high reflection from the substrate may be even more problematic for porous substrates due to scattering of the pores.
[0021] In an embodiment of the method according to the invention the target molecules are bio-molecules conjugated to fluorophores.
[0022] In an embodiment of the method according to the invention the substrate is a bio-assay prepared with probe molecules, and the target molecules chemically bind to the probe molecules present in the substrate. In various advantageous embodiments, radiation pass filters, mirrors and possible other optical components may be introduced in the beam path from the radiation source to the detector.
[0023] For example the target molecules are detected by irradiating the substrate with a beam of radiation and subsequently detecting the resulting beam from the substrate.
[0024] The resulting beam may be transmitted through the substrate, or reflected from the substrate.
[0025] In an embodiment a first radiation pass filter ( 2 ) is introduced in the beam path between the radiation source ( 36 ) and the substrate ( 3 , 30 - 32 ).
[0026] In an embodiment a second radiation pass filter ( 4 ) is introduced in the beam path between the substrate ( 3 , 30 - 32 ) and the detector ( 35 ).
[0027] In an embodiment the beam path further comprises a dichroic mirror ( 5 ).
[0028] The method of the present invention may advantageously be at least partly automated, e.g. by implementing the method in an apparatus or a detection system in accordance with other aspects of the invention.
[0029] In a second aspect, the invention relates to an apparatus for preparing an assay.
[0030] In a third aspect, the invention relates to an optical detection system for detecting a target molecule in an assay.
[0031] The second and third aspects of the present invention may provide an apparatus and a detection system for detecting the presence, and optionally quantity, of one or more biological targets, i.e. target molecules in a sample. The system may detect targets that include, but are not limited to, polynucleotides, DNA, RNA, cells, and antibodies. Biological detection systems are often highly complicated and the present invention is advantageous in providing systems with a high reliability of the collected data.
[0032] In a fourth aspect, the invention relates to a substrate produced in accordance with the method of the first aspect.
[0033] In a fifth aspect, the invention relates to a kit for performing an assay.
[0034] In general the various aspects of the invention may be combined and coupled in any way possible within the scope of the invention. These and other aspects, features and/or advantages of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Embodiments of the invention will be described, by way of example only, with reference to the drawings, in which
[0036] FIG. 1 schematically illustrates two general embodiments of the optical setup;
[0037] FIG. 2 illustrates spectral characteristics for the setup of FIG. 1B together with the spectra of the Cy5 dye;
[0038] FIG. 3 illustrates an embodiment of a method of detecting the presence of a target molecule in a sample;
[0039] FIG. 4 shows a graph of the index of refraction, n, of aqueous sucrose solutions, as a function of the weight percent, p.
DESCRIPTION OF EMBODIMENTS
[0040] In biological research and medical diagnostics many biomarkers are detected with the aid of an attached fluorescent label. The apparatus generally used is a fluorescent scanner or microscope, but for specific applications dedicated equipment is made based on the same detection principles.
[0041] In a general embodiment of the present invention, an optical setup is used where at least two spectral filters are applied. FIG. 1 schematically illustrates two general embodiments. FIG. 1A shows a schematic illustration of a fluorescence detection device in a transmission mode where the resultant beam is transmitted through the substrate, whereas FIG. 1B shows a schematic illustration of a fluorescence detection device in a reflection mode where the resultant beam is reflected from the substrate. In FIG. 1A and 1B a light beam 1 A, 1 B is emitted towards a substrate 3 . In order to separate the resultant fluorescent light beam form the illuminating non-fluorescent light spectral filters are applied.
[0042] The spectral filter function consists of two steps: a first radiation filter 2 (called the ‘excitation filter’) being introduced in the beam path between the radiation (light) source and the substrate. The excitation filter preferably transmits the rays with a wavelength overlapping with the excitation spectrum of the label and blocks all rays with a wavelength that is inside the spectrum of the detection window. A second radiation filter 4 (called the ‘emitter filter’ or alternatively a ‘detection filter’) is introduced in the beam path, the emitter filter preferably blocks or at least substantially suppresses the illumination light and transmits only the fluorescent rays. The attenuation (blocking power) of a typical filter set is better than 10 −6 .
[0043] In FIG. 1B a beamsplitter 5 is moreover applied, the beamsplitter may e.g. be applied in a situation where the substrate is not transparent. In an alternative embodiment a dichroic mirror may be applied instead of a beamsplitter, a dichroic mirror reflects excitation light below a certain wavelength and transmits light above this wavelength. A dichroic mirror may therefore also act as an emitter filter 4 , a separate emitter filter may still be used for increased performed, but it may not be necessary.
[0044] In an embodiment, the substrate may be illuminated by a number of high power LEDs, such as 2 to 10 red LEDs, a dark field setup may be applied. The resulting light being detected by a CCD camera (not shown) with the emitter filter mounted in front of the camera. As an example of a fluorophore, the dye Cy5 may be used.
[0045] The substrate 3 may be prepared in any suitable way of preparing a substrate, such as a bio-array substrate for use in a bio-assay. One typical array assay method involves immobilizing probe molecules in discrete locations on the substrate. A solution containing target molecules that bind with the attached probes is placed in contact with the bound probes under conditions sufficient to promote binding of targets in the solution to the complementary probes on the substrate to form a binding complex that is bound to the surface of the substrate. The bio-array may have a dimension in the micrometer range or even in the millimeter range. The number of different spots with distinct hybridization characteristics on the bio-array may vary from around 1 to 1000 per mm 2 on current arrays, and even higher, e.g. up to 10 6 spots per mm 2 . Within a spot on the array typically identical probe molecules are immobilized.
[0046] FIG. 2 illustrates an embodiment of possible involved spectral characteristics for the setup of FIG. 1B together with the spectra of the Cy5 dye. FIG. 2 is generated by use of the Curv-o-matic online application, accessible from the Omega Optical website (www.omegafilters.com). FIG. 2 shows the transmission, T, in percent as a function of the wavelength, λ, in nanometers of the involved spectra, for the Omega filter set XF110-2.
[0047] FIG. 2 shows the excitation spectrum 20 of Cy5 having an excitation peak at 649 nm together with the corresponding emission spectrum 21 having an emission peak at 670 nm. The difference between illumination wavelength and fluorescent wavelength, per photon, is called the ‘Stokes shift’. The Stokes shift of Cy5 is 21 nm.
[0048] The excitation filter is an Omega 630AF50 excitation filter exhibiting the spectrum denoted by 22 (bandwidth 50 nm, center at 630 nm). The emitter filter is an Omega 695AF55 emitter filter exhibiting the spectrum denoted by 23 (bandwidth 55 nm, center at 695 nm). The dichroic mirror is chosen so that the spectrum of the mirror, as denoted by 24, is such that it reflects incident light at the wavelength of the excitation radiation, whereas it transmits the resulting Stoke shifted light. The specific filter set and dichroic mirror are provided as an example, and may not necessarily be applied in a all embodiments. For example, as mentioned in connection with FIG. 1B , an emitter filter may be dispensed when using a dichroic mirror.
[0049] Table 1 shows the results of an experiment, in which the optical properties were measured of porous Nylon substrates (Nytran N and Nytran SPC) 3. The experiment was performed by irradiating the substrate at the incident wavelength of 650 nm and subsequently detecting the resulting beam from the substrate. Two types of experiments were performed, one with a dry substrate, and one which have been exposed to water in a wash step.
[0000]
TABLE 1
Wet
Dry
Nytran N
Transmittance
31.1%
4.2%
Reflectance
68.7%
95.3%
Absorbance
0.1%
0.5%
Nytran SPC
Transmittance
33.8%
5.3%
Reflectance
65.4%
94.4%
Absorbance
0.8%
0.4%
[0050] As can be seen in Table 1, the substrate has a very high reflectivity, especially when dry. The cause for this high reflectivity is scattering due to the high porosity of the substrate. The amount of scattering depends on the difference between the index of refraction of air and substrate. Compared to air, the index of water is much closer to the index of the substrate. This is the reason why a wet substrate has a lower reflection than a dry substrate.
[0051] In accordance with the present invention, a substantially index matching fluid is applied during the wash step of the assay, and thereby the reflectivity of the substrate can be greatly reduced, down to a typical value of 5% reflectivity.
[0052] The improvement in excitation intensity may be at least factor of 3 as compared to water as the washing fluid, but can be as high as 20 compared to a dry substrate.
[0053] The improvement in the ratio of excitation and fluorescence radiation may be at least 14 as compared to water and can be as high as 19 as compared to a dry substrate.
[0054] FIG. 3 illustrates an embodiment of a method of detecting the presence of a target molecule in a sample in accordance with the present invention, where a bio-array is prepared using as a wash-step. FIGS. 3A to 3C illustrates at least some of the involved steps.
[0055] In steps prior to the step of FIG. 3A , a sample fluid has been prepared with target bio-molecules conjugated to fluorophores. In the step 37 of FIG. 3A the sample 6 is contacted with the substrate 30 by flowing the sample fluid through the substrate 30 , causing the target bio-molecules with fluorophores to attach to specific binding locations on the substrate. It is to be understood that target molecules may be contacted to the substrate in alternative ways, e.g. by the application of drop deposition from pulsejets, or by other suitable means.
[0056] During the preparation steps not all fluorophores can be expected to bind to a probe molecule. This means that in addition to fluorophores that have bound to the substrate 30 , there are also unbound fluorophores that are not attached to the substrate, but are still present. A wash step 38 is applied to remove or at least dilute any unbound fluorophore-conjugates, leaving only bound fluorophore-conjugates behind on the substrate, as illustrated in FIG. 3B . During this step a washing liquid 7 is pressed through the substrate 31 . In the current invention, the washing liquid 7 is chosen such, that it has the index of refraction of the wash fluid substantially match the index of refraction of the substrate 31 .
[0057] FIG. 3C illustrate a detection step 39 in order to detect the presence of resultant binding complexes on the substrate, the detection step has been described in connection with FIG. 1 . Because a substantially index matching fluid was used during the washing step ( FIG. 3B ), the reflectivity of the substrate 32 has been reduced considerably, improving the sensitivity of the detection step. The detection is typically applied in direct continuation of the wash step so that the substrate is still wet.
[0058] In different embodiments of the present invention different index matching fluids that can be used. In one embodiment an oils may be used, as an example of a suitable oil; Zeiss Immersol 518F, with n=1.518 at 23° C. may be used. In other embodiments, aqueous solutions of dense materials may be applied. In a specific embodiment an aqueous solution of sugar is used. It may be advantageous to use a solution of 60% to 70% sugar (sucrose, etc.), thereby achieving an index of refraction of 1.45 (see FIG. 4 illustrating the index of refraction, n, of aqueous sucrose solutions, as a function of the weight percent, p). Aqueous sucrose solutions may be a preferred index matching fluid, because fluorophore-conjugates dissolve easily in such a fluid, making the fluid suitable for both the washing step and the detection step.
[0059] It is to be understood that in alternative embodiment, additional washing steps may be applied. Such additional washing steps may be applied with different of same wash fluids, in the situation were different wash fluids are used for different wash steps, at least the last wash step is conducted using a wash fluid being substantially refractive index matched to the substrate.
[0060] The steps of FIG. 3 and possible additional steps may be performed, possibly in an automated or semi-automated manner, in an apparatus for preparing an assay and/or an optical detection system. Such apparatuses and systems may include a handling unit 33 for receiving a substrate, and a wash unit 34 for performing a wash step on the substrate. The handling unit and the wash unit may be embodied in the same unit, or the sample may be moved between units. Embodiments of optical detection systems also comprise a radiation source 36 such as one or more laser diodes and a radiation detector 35 , such as a CCD.
[0061] Kits for use in target detection assays are also provided. The kits at least include a wash fluid, the wash fluid being substantially index matched to a substrate and instructions for using the wash fluid. The kits may further include one or more additional components to be used when carrying out a target detection assay, such as one or more substrates, sample preparation reagents, buffers, labels, etc. The instructions for use may be provided in paper format, be recorded on a suitable recording medium, be provided in the form of directions as how to access the instructions via a remote source, e.g. the Internet, etc.
[0062] Although the present invention has been described in connection with the specified embodiments, it is not intended to be limited to the specific form set forth herein. Rather, the scope of the present invention is limited only by the accompanying claims. In the claims, the term “comprising” does not exclude the presence of other elements or steps. Additionally, although individual features may be included in different claims, these may possibly be advantageously combined, and the inclusion in different claims does not imply that a combination of features is not feasible and/or advantageous. In addition, singular references do not exclude a plurality. Thus, references to “a”, “an”, “first”, “second” etc. do not preclude a plurality. Furthermore, reference signs in the claims shall not be construed as limiting the scope.
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The invention relates to detection the presence of a target molecule in a sample, wherein the sample is contacted with a substrate, the substrate subsequently being washed in a wash step. In particular, the invention relates to a method of detecting the presence of a target molecule in a sample, the method comprising: (a) contacting the sample ( 37 ) with a substrate having immobilized thereon probe molecules that specifically binds to the target molecule; (b) washing the substrate ( 38 ) in a wash step by a wash fluid in order to remove or dilute unbound target molecules; (c) detect the presence of resultant binding complexes (39) on the substrate to determine whether the target molecule is present in the sample. The wash fluid being substantially refractive index matched to the substrate.
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FIELD OF THE INVENTION
The invention relates to a purified proteolytic enzyme and to a method of purifying a proteolytic enzyme, in particular trypsin.
BACKGROUND ART
Commercial proteases, in particular commercial trypsin, even after purification by a special treatment, for example by double crystallization, contains residual lipases, in particular phospholipase A 2 , which is particularly resistant to the heat deactivation to which protease is subjected after its use in a hydrolysis process.
Trypsin is commonly used in the manufacture of protein hydrolysates intended in particular to enter into the composition of infant products. To incorporate the protein portion into a finished product, for example an infant milk, any residual lipolytic enzymatic activity resulting from the protein hydrolysate must be removed. This is necessary in order to avoid the appearance of products of degradation of lecithin which is added to the final formula for technological reasons, for example to enhance the wettability of powders, into lysolecithin, in particular during storage. Such breakdown products may manifest themselves both in liquid products and in powders by the appearance of stability or organoleptic defects, for example spots, poor taste, or by their toxicity leading to side effects, for example of an inflammatory type in breastfeeding infants.
However, it is the case that the complete removal of phospholipases in particular is difficult to achieve. The complete purification of proteases generally requires various precipitation steps, chromatographic separations, heat treatments under well-defined conditions or chemical inactivations. The complete removal of phospholipase A 2 , which is very heat-resistant, requires a prolonged heat treatment which unfortunately also affects the protease.
The aim of the invention is the preparation of a purified protease whose proteolytic activity is quantitatively and qualitatively preserved, but which is free of lipolytic activity, in particular of phospholipase A 2 , by a simple and inexpensive method.
A method of preparing purified trypsin, described for example in U.S. Pat. No. 3,886,043, is known in which a buffer solution of crystallized trypsin is chromatographed by passing over a resin consisting of a dextran gel with grafted sulphonic groups, with the aim of separating the various active forms of porcine trypsin.
It is also known to prepare a lipase-free microbial rennet, for example by the method described in U.S. Pat. No. 4,136,201, by culturing Mucor miehei on an appropriate nutrient medium. The processes of these patents do not achieve the aim of the present invention.
SUMMARY OF THE INVENTION
The invention relates to a purified proteolytic enzymatic preparation and methods for producing the same, characterized in that it possesses a residual phospholipase A 2 activity of at most 20 mU/g of pure enzyme detectable by high performance chromatography analysis of phospholipids after incubating with an infant formula whose phospholipase A 2 activity is not detectable, and in that its protease activity is maintained at not less than 75% of the initial activity of the enzyme.
DETAILED DESCRIPTION OF THE INVENTION
The measurements of the enzymatic activities are detailed in the examples hereinafter. In particular, “nondetectable” is understood to mean a residual phospholipase A 2 activity of <6 mU/g of enzyme.
The enzyme may be any protease of plant, microbial or animal origin or of biogenetic origin. It is preferably a protease of animal origin, such as pancreatin, particularly trypsin of porcine origin.
The method according to the invention is characterized in that:
1) the pH of a solution of the protease is adjusted to a value of between 6 and 9 and in that the solution is kept at this pH and at 20-35° C. for at least 15 min and at most 120 min, so as to use the proteolytic activity of the protease to destroy the lipolytic activity of the lipases and of the phospholipases of the reaction medium, and
2) the pH of the solution is reduced to a value of less than or equal to 3.5, it being possible to reverse the order of steps 1) and 2) above.
In a preferred embodiment which makes it possible to also remove traces of residual lipases other than phospholipase A 2 , the method comprises a final heat treatment step, preferably by ultra high temperature (UHT), as is known in the art and is shown in the examples herein. Traces of heat-sensitive lipases are thus removed.
Preferably, the adjustment of the pH to the alkaline region takes place before the reduction of the pH to the acidic region, since it is thus possible to defer the use of the protease. In the variant where the two steps are reversed, the protease should be used immediately after the treatment.
In a preferred embodiment, there is added to the reaction medium a magnesium salt which is soluble in the latter, preferably at the beginning of the reaction, which makes it possible to stabilize the proteases while promoting the degradation of the phospholipases. Magnesium chloride is preferably added in an amount of 10 to 200 mM/l of the reaction medium, for example 50 to 100 mM/l of reaction medium.
The pure protease concentration in the solution before treatment may be between 0.5 and 6%, and is preferably about 2.5% by weight. The invention also relates to a method of preparing an infant formula based on protein hydrolysate, characterized in that a whey product is enzymatically hydrolysed by means of a purified protease above, in that the hydrolysate is treated at 75-85° C./3-5 min, in that liquid fat and minerals are added thereto, in that a UHT treatment is carried out at 125-135° C./2-3 min, then in that carbohydrates, vitamins and trace elements are added thereto, in that the liquid product is sterilized by UHT and in that it is aseptically packaged.
According to a variant of this method, the liquid is dried, in particular spray-dried, after UHT sterilization treatment.
The purified enzyme according to the invention may be used outside the food area in the applications of proteases, for example in the preparation of a nutritional, cosmetic or pharmaceutical composition.
There may be mentioned, in this regard, anti-inflammatory applications, the treatment of digestive disorders, the treatment of thromboses, the treatment of injuries and wounds and the elimination of necrosed tissues for example.
EXAMPLES
The examples below illustrate the invention. In these examples, the parts and percentages are by weight, unless otherwise stated.
Example 1
1 kg of commercially available porcine trypsin 6.0 S (Novo, Denmark) is dissolved in 10 kg of demineralized water at 25° C., with stirring, in a vessel, the protease concentration being 9.1% and the initial pH 5. To ensure that undissolved protease is not carried over to the next step, the solution is transferred to a new vessel.
A dilute aqueous NaOH solution at 1 M/l is added to adjust the pH of the solution to 8. The pH is then kept constant for 15 min by addition, as required, of the aqueous NaOH solution above, for example by means of a pH-stat, with stirring, so as to hydrolyse the phospholipases.
After this treatment, the proteases are stabilized, that is to say trypsin and chymotrypsin, by reducing the pH of the reaction medium to 3 by addition of an aqueous HCl solution at 1 M/l. The solution of proteases may be used immediately in a hydrolysis reaction or stored, for example, at −25° C. for a deferred use.
The analyses below show the enzymatic activity of the purified proteolytic enzyme obtained according to the invention compared with that of the original commercially available crystallized enzyme (trypsin PTN 6.0 S, Novo, Denmark) which has not been subjected to the treatment according to the invention.
1. Determination of phospholipases:
1.1 Determination of phospholipase A 2 by a radioisotope method.
The method is based on the cleavage of phosphatidylcholine (C14-dioleyl) by phospholipase A 2 and the punctual radiometric detection of the labelled fractions after chromatographic separation.
1.2 Determination of the total phospholipases by titrimetry.
The method is not specific to phospholipase A 2 and detects all phospholipases. It is based on the titration of fatty acids released from egg yolk phospholipids (Fluka, Buchs, Switzerland) by phospholipases at pH 8 (maintained by a pH-stat) and at a constant temperature of 40° C. with 1.4 mM of sodium deoxycholate and 3 mM CaCl 2 . 2 g of purified egg yolk phospholipid are used with addition of 250 mg of turkey egg white trypsin inhibitor (Sigma, St. Louis, USA) per 1 g of trypsin.
2. Determination of lipase and esterase:
2.1 The activity of the lipases is determined by titrimetry using olive oil as substrate in an amount of 100 g/l at a constant pH of 8.9 (pH-stat) in the presence of 1.25 g/l of taurocholate and 82.5 g/l of gum arabic.
2.2 The activity of the esterases is determined using the above method (2.1) but taking medium-chain triglycerides (MCT) as substrate.
3. Determination of proteases:
3.1. For trypsin, the method described by Erlanger et al. in Arch. Biochem. Biophys. 95, 271-278 is used.
3.2. For chymotrypsin, the US Pharmacopoeia XXI (1985) method is used. These methods are conventional and are well known by the skilled artisan. To the extent that further details of these processes are required, the entire content of those documents are incorporated herein by reference.
The results of the analyses of activities in the enzyme preparation are indicated in Table 1 below:
TABLE 1
Phos-
Tryp-
Chymo-
Enzyme
Phospho-
pholi-
Lip-
Ester-
sin
trypsin
prepara-
lipase A 2
pases
ases
ase
(g/
(USP/
tion
(U/g), 1.1
(U/g)
(U/g)
(U/g)
kg)
mg)
Purified
<0.0022
0.79
0.21
0.22
223
41
trypsin
PTN 6.0 S
according
to the
invention
Original
87
14
0.34
0.39
213
42
trypsin
PTN 6.0 S
It is observed that the treatment makes it possible to considerably reduce the activity of enzymes other than proteases, in particular to remove that of phospholipase A 2 , while maintaining intact the proteolytic activity in terms of quality and quantity, in particular the equilibrium between trypsin (93% activity relative to the untreated enzyme) and chymotrypsin (86% activity relative to the untreated enzyme).
Example 2
1 kg of commercially available porcine trypsin 6.0 S (Novo, Denmark) is dissolved in 10 kg of demineralized water at 25° C., with stirring, in a vessel, the protease concentration being 9.1% and the initial pH 5. To ensure that undissolved protease is not carried over to the next step, the solution is transferred to a new vessel.
224 g of magnesium chloride (MgCl 2 .6 H 2 O) are added, the pH is adjusted to 8.5 over 15 min with a dilute aqueous NaOH solution at 1 M/l. The medium is allowed to react or 120 min at 25° C. without controlling the pH, so as to hydrolyse the phospholipases.
After this treatment, the proteases, that is to say trypsin and chymotrypsin, are stabilized by reducing the pH of the reaction medium to 3 by addition of an aqueous HCl solution at 1 M/1 and the solution is allowed to stand for 16 h at 4° C. The purified trypsin solution is then ready for use.
It is observed that the relative activity of the trypsin is 93% of that of the original trypsin and that the relative activity of the chymotrysin is 86% of that of the original chymotrypsin.
Example 3
The purified enzymatic preparation of Example 2 is used to prepare a hypoallergenic infant formula. Whey proteins are hydrolysed and then the hydrolysate is treated at 75-85° C./3-5 min, fat and minerals are added thereto, a UHT treatment is carried out at 125° C./2 min, then maltodextrin and vitamins are added, the liquid product is sterilized by UHT at 148° C./5 s and aseptically packaged.
To test the residual enzymatic activity, 10 ml of purified trypsin solution according to Example 1 are added to 100 ml of the liquid infant formula above whose phospholipase A 2 activity is <6 mU/g trypsin. After mixing, the activities of the lipase and esterase are reduced by a heat treatment at 75-80° C./3-5 min on a water bath. After cooling to room temperature, 55 mg of sodium azide are added and the solution is incubated at 40° C./4 d. After incubation, the phospholipid composition is analysed by high-performance liquid chromatography (HPLC) and the phospholipase A 2 activity calculated, expressed in mU/100 g of product (mU -PL-A 2 ), from the differences in the concentration of the lysophospholipids according to the formula:
mU PL−A 2 =(LPC+LPE) at time t2 minus (LPC+LPE) at time t1 in mg/100 g of product 540 (molecular mass of egg lysolecithins)×(t1−t2)
with LPC=lysophosphatidylcholine and LPE=lysophosphatidylethanolamine,
as well as this value expressed in terms of the concentration of pure trypsin g/100 g, that is to say mU PL-A 2 /g of pure trypsin.
The degradation of trypsin and or chymotrypsin is also evaluated in % relative to the initial activity, as well as the degradation of the phospholipids after 9 months of storage at 20° C. in % of the original phospholipids.
The results are indicated in Table 2 below:
TABLE 2
Degrada-
PL-A 2
tion of
(mU/g of
Chymo-
the phos-
Liquid
pure
Trypsin
trypsin
pholipids
infant
trypsin),
(% of
(% of
(% of
formula
HPLC
initial)
initial)
initial)
Hydro-
16
94
75
<1
lyzed by
purified
trypsin
PTN 6.0 S
according
to the
invention
Hydro-
349000
100
100
100
lyzed by
the
original
trypsin
PTN 6.0 S
Example 4
An infant formula is prepared as in Example 3, except that a phospholipid is added to the liquid mixture before spray-drying it. It observed that the activity of the phospholipases is strongly linked to the degradation of the phospholipids in the product. Large load volumes, an interrupted production, associated with a high phospholipase activity degrades the phospholipids to a certain degree before the product is dried. The products containing the purified trypsin according to the invention show a considerably lower degradation of the added phospholipids, depending on the total quantity of phospholipids added to the formula, <1%, whereas it represents 20 to 90% when the same trypsin is used which has not been subjected to the purification treatment according to the invention.
Furthermore, SDS-PAGE analysis of the residual proteins and analysis of the immunologic ally active antigens by ELISA did not show significant differences using purified trypsin according to the invention compared with production with the unpurified trypsin.
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A purified protease preparation of chymotrypsin and porcine trypsin is prepared by adjusting the pH of a protease solution comprising chymotrypsin and porcine trypsin to a value of between 6 and 9, maintaining the solution at this pH and at 20-35° C. for at least 15 minutes to at most 120 minutes, so as to allow the proteolytic activity of the proteases to destroy the lipolytic activity of the lipases and phospholipases in the solution. Subsequently, the pH of the solution is reduced to a value of less than or equal to 3.5. The purified protease preparation allows the manufacture of infant formulae containing lecithin which are stable during storage and do not exhibit significant degradation of the added lecithin.
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OBJECTS OF THE INVENTION
An object of this invention is to provide an enjoyable mimic tennis game board in which two animated racket-supporting bodies are provided opposedly to each other across a play board, said bodies being moved alternately toward a ball which comes rolling on the board, and when the racket carried by a racket-supporting body catches the ball, said racket is automatically activated to hit the ball.
Another object of this invention is to provide a mimic tennis game board according to which while any of the racket-supporting bodies is being moved, the racket driving mechanism is kept inoperative and the spring for giving driving power to said racket driving mechanism is automatically wound up within the limit of its winding capacity to accumulate the driving power, thereby allowing continuous play of the game.
Still another object of this invention is to provide a mimic tennis game board designed such that the ball hitting force of the racket can be adjusted by operating a lever projecting out from each racket-supporting body.
Yet another object of this invention is to provide a mimic tennis game board of the recited type, in which the bell rings when the racket hits the ball.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1 to 15 show an embodiment of this invention, where
FIG. 1 is a plane view of the game board,
FIG. 2 is a side view thereof, with parts shown in section,
FIG. 3 is an enlarged side elevational view, with parts shown in section, of the driving mechanism for the racket-supporting body,
FIG. 4 is a side elevational view as taken from the right-hand side of FIG. 3, with parts shown in section,
FIG. 5 is a plane view of FIG. 3,
FIG. 6 is a bottom view of FIG. 5,
FIG. 7 is an enlarged frontal view of a cam plate,
FIG. 8 is a left-side view of FIG. 7,
FIG. 9 is an enlarged frontal view of a follower,
FIG. 10 is a left-side view of FIG. 9,
FIG. 11 is a back side view showing a condition where the follower of FIG. 9 was coupled to the cam plate, and
FIGS. 12 to 15 illustrate the process of movements of said cam plate and follower;
FIGS. 16 to 18 show another embodiment of this invention, where
FIG. 16 is a side view thereof, with parts shown in section,
FIG. 17 is an enlarged side elevational view, with parts shown in section, of the driving mechanism for the racket-supporting body, and
FIG. 18 is a side elevational view as taken from the right-hand side of FIG. 17, with parts shown in section; and
FIGS. 19 to 21 show a modification of the play board, where
FIG. 19 is a plane view,
FIG. 20 is a sectional view taken along the line I--I of FIG. 19, and
FIG. 21 is a sectional view taken along the line II--II of FIG. 19.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of this invention is now described in detail with reference to FIGS. 1 to 15 of the accompanying drawings.
In the drawings, numeral 1 indicates a rectangular base board having the fencing walls 2, 2' along the opposing longer sides of the board. The board surface slopes up gently toward the center line connecting the middle points of said respective fencing walls 2, 2', thus forming the slanting surfaces 3, 3'. It will be also seen that a recession 4 (4') is formed in the section defined by the edge of each said slanting surface 3 (3') and the associated shorter side of the board 1. Each of said fencing walls 2, 2' is provided with a ball gutter 5 (5') where the balls 7 are placed in a row so that they may be let out one by one from the outlet 6 onto the board surface near the elevated center region. Secured to the bottom of each said recession 4 (4') is a floor plate 8 (8') formed with an elongated slot 9 (9') extending parallel to the shorter side of the board 1. A rack gear 10 (10') is secured to a top part of each said floor plate 8 (8') such that said rack gear extends along an edge of the associated elongated slot 9 (9'). A block 11 (11') is mounted on each said floor plate 8 (8') so that it is movable reciprocatively along the corresponding slot 9 (9'). Each said block 11 (11'), as shown in FIG. 3, is provided with a block supporting portion 12 which is U-sectioned in the longitudinal direction, opened at both ends in the transverse direction and fitted slidably in the slot 9 (9'), and the protuberances 13, 13 disposed on both sides of said supporting portion 12 are also fitted slidably in the slot 9 (9'). At the end of each said protuberance 13 is secured a washer 14 having a greater diameter than the width of said slot 9 (9'), and a screw 15 is passed into said protuberance 13 through said washer 14 to thereby secure the block 11 against removal from the slot 9. Erected on each said block 11 (11') is an animated hollow racket-supporting body 16. The two animated bodies 16, 16' are so disposed as to oppose to each other across the play board.
Numeral 17 refers to a frame secured on each said block 11 (11') in the inside of each racket-supporting body 16 (16'). Supported by said frame 17 at its middle part is a main shaft 18 which is passed centrally through a lineup of operational members comprising a cam plate 19, a windup spring 20, a ratchet wheel 21, a rubber-made friction plate 22, a gear 23, a pressing spring 24 and a pressing force adjusting plate 25. Of these members, the ratchet wheel 21 alone is fixed to the main shaft 18 so as to turn therewith, and the cam plate 19, friction plate 22, gear 23 and pressing force adjusting plate 25 are so mounted as to be freely rotatable. The outer end 26 of the windup spring 20 is secured to a protuberance 27 disposed close to a peripheral part of the cam plate 19 while the inner end of said spring 20 is secured to a protuberance (not shown) disposed close to the central part of the ratchet wheel 21. The cam plate 19 is provided, on its side opposite from the windup spring 20, with a cam groove 28 connecting a pair of longer-diameter positions A, A' and a pair of shorter-diameter positions B, B' alternately at an angular distance of 90 degrees. At each of the shorter-diameter positions B, B' of said cam groove 28 is provided a stepped portion C (C') designed to change the direction of the groove such that, as viewed in the rotating direction of the cam plate 19 indicated by arrows, the upper side of the groove at the position B (B') will curve outwardly and the lower side will curve inwardly. At the circumferential periphery of said cam plate 19 are provided the stopper pieces 29, 29' disposed at the slightly lower side positions (in the rotating direction of the cam plate) from the line connecting the shorter-diameter positions B, B' of the cam groove 28. The pressing force adjusting plate 25 is tapered on its side opposed to the pressing spring 24 and is also provided with an arcuate protuberance 31 centered by the main shaft 18. An end of the pressing spring 24 is pressed against said protuberance 31 while the other end of said spring 24 is pressed against a side of the gear 23. Secured to said pressing force adjusting plate 25 is an operating lever 32 (32') which is passed through the frame 17 and the racket-supporting body 16 to project out from the backside of said body. Numeral 33 denotes a pawl plate which is secured at its proximal end to a part of the frame 17 opposed to the ratchet wheel 21 while the distal end of said pawl plate 33 is pressed against the notched face of the ratchet wheel 21 so that when the ratchet wheel 21 turns in the same direction as the rotating direction of the cam plate 19 indicated by arrows, the distal end of said pawl plate 33 slides while pressedly contacting with the teeth of the ratchet wheel 21, thus allowing rotation of the ratchet wheel 21, but when the ratchet 21 is urged to turn in the opposite direction, the distal end of said pawl plate 33 is engaged with a tooth of the ratchet wheel 21 to inhibit rotation of the ratchet wheel 21. Mounted at an elevated position across the frame 17 is a racket driving shaft 34 extending parallel to the main shaft 18. Secured to and extending from a middle part of said racket driving shaft 34 is a bar 35 (35') which is passed through the frame 17 and the racket-supporting body 16 (16') to project out from the front side of said body 16 (16'), and a racket 36 (36') is secured to the projecting end of said bar 35 (35') such that said racket pends down therefrom. To an end of said shaft 34 positioned close to the cam plate 19 is secured an end of a follower 37 which is provided at its other end with a protuberance 38 designed to slidably fit into the cam groove 28 and a raised-up portion 39 against which the stopper piece 29 (29') abuts to stop the turning motion of the cam plate 19 with said protuberance 38 being engaged in the stepped portion C (C') of the cam groove 28. Said shaft 34 is also loaded with a spring 40 disposed between the joint with the bar 35 and the end of the shaft 34 opposite from its end mounted with the follower 37. An end 41 of said spring 40 is secured to the frame 17 while the other end 42 is secured to a protuberance 43 provided at a middle part of the driving shaft 34, whereby said driving shaft 34 is elastically supported so that the racket 36 will always maintain its vertical position. Designated by numeral 43 is a bell which is secured by means of a screw 45 and a nut 46 to the inside of an upwardly extended portion 44 of the frame member on the side opposite from the frame member through which the bar 35 is passed. There is also provided a leaf spring 47 of which one end is secured to the upper side of the bar 35 and the other end is positioned close to the bell 43. At the end of the leaf spring 47 positioned close to the bell 43 is provided a protuberance 48 designed to strike the bell 43. Numeral 49 refers to a vertical shaft disposed between the bottom of the block supporting portion 12 and a cut and raised up piece 50 formed by cutting and bending up vertically toward the inside of the frame 17 a part of the frame member positioned slighly lower than the cam plate 19. At the lower end of said vertical shaft 49 is secured a pinion gear 51 having a diameter allowing projection of the gear through the openings at both ends of the block supporting portion 12 and meshed with the rack gear 10, and a crown gear 52 is secured to the top end of said vertical shaft 49. 53 is a transmission gear meshed with said crown gear 52 and the gear 23 mounted on the main shaft 18, said transmission gear 53 being rotatably mounted on a shaft 54 secured to the frame 17.
The mimic tennis game board having the above-described mechanism is now described from its operational aspect. When the player moves his animated racket-supporting body 16 (16') reciprocatively along the elongated slot 9 (9') by holding said body with his hand, the pinion gear 51 meshed with the rack gear 10 (10') is urged to turn correspondingly, and this reciprocative turning motion is transmitted through the vertical shaft 49, crown gear 52 and transmission gear 53 to the gear 23. Said gear 23 is pressed against the fraction disc 22 by the compressed spring 24 and said fraction disc 22 is in turn pressed against the opposing side of the ratchet wheel 21, so that when said gear 23 turns in the same direction as the rotating direction of the cam plate 19 indicated by arrows, that is, when said gear 23 turns forwardly, the ratchet wheel 21 is allowed to turn correspondingly without being checked by the pawl plate 33. Accordingly, the inner end of the windup spring 20 is wound up, and since the outer end 26 thereof is secured to a fixed position by the protuberance 27 on the cam plate 19 which is locked against movement as one of the stepped portions C or C' of the cam groove 28 abuts against the protuberance 38 of the link 37 and also one the stopper pieces 29 or 29' abuts against the end of the protuberance 39, the windup spring 20 is thus wound up to accumulate the rotative power. When the gear 23 turns reversely after said forward rotation, the pawl plate 33 is engaged with the ratchet wheel 21 to lock its movement, keeping the windup spring 20 in said wound up state.
In this way, the spring 20 is wound up progressively by every forward turn of the gear 23, and when the spring is wound up to its limit capacity, the spring force overwhelms the frictional force of the friction disc 22, allowing the ratchet wheel 21 and gear 23 to begin sliding over the friction disc 22, so that no matter how much the gear 23 turns forwardly thereafter, the spring 20 won't be wound up any more and thus over-winding of the spring 20 is prevented.
Under this condition, a ball 7 is brought onto the central part of the surface of the play board 1 from either of the ball gutters 5 or 5', for example from the ball gutter 5. As the ball 7 rolls down on the slant surface 3 toward the recession 4, the player moves his racket-supporting body 16 toward the ball 7 so as to catch the ball with the racket 36. When the racket 36 catches the ball 7, the lower end of the racket 36 is pushed by the force of the ball 7, causing the end of the bar 35 to lower down while propped by the driving shaft 34, whereupon said shaft 34 turns its follower 37 from the position of FIG. 12 to the position of FIG. 13 where the protuberance 38 is disengaged from the stepped portion C of the cam groove 28 against which said protuberance has been pressed under the elastic force of the spring 40 and also the end of the protuberance 39 is disengaged from the stopper piece 29. Consequently, the rotative force accumulated on the windup spring 20 is now exerted to the cam plate 19 to let it turn quickly in the direction of arrow, causing corresponding turn of the cam groove 28 about the main shaft 18, and in the course of movement of the protuberance 38 from the shorter-diameter position B of the cam groove 28 to the longer-diameter position A as shown in FIG. 14, the end of the follower 37 is pushed out sharply and its movement is transmitted through the driving shaft 34 and projecting bar 35 to the racket 36 to let it strike the ball 7. And in the course of movement of the protuberance 38 from said longer-diameter position A to the shorter-diameter position B' on the opposite side as shown in FIG. 15, the end of the follower 37 is pushed back to its original position and its movement is transmitted through the driving shaft 34 and projecting bar 35 to the racket 36 to let it return to its original position. When the racket 36 assumes its original position and the cam plate 15 makes a half-turn from its starting position, the stopper piece 29' on the opposite side abuts against the end of the protuberance 39 as shown in FIG. 15, thus locking the cam plate 19 against movement and creating a situation ready for striking the next rolling-down ball 7. When the ball 7 is hit by the racket 36 during its actuation, the turning motion of the driving shaft 34 is transmitted to the leaf spring 47 so that its ball-striking portion 48 strikes the bell 43 to let go bell ringing upon hitting of the ball.
The ball 7 hit by the racket 36 rolls up on the slant surface 3, and after passing the peak point, it further rolls down on the slant surface 3' on the opposite side toward the recession 4', so that the player on the opposite side moves his racket-supporting body 16' so as to catch the ball 7 with the racket 36'. The racket 36' is actuated in the same way as said above to hit the ball 7, and the hit ball rolls up on the slant surface 3', and after passing the highest point, it further rolls down on the slant surface 3 toward the recession 4. So, the player on this side again moves his racket-supporting body 16 so as to catch the ball 7 with the racket 36. As the racket 36 catches the ball 7, the end of said racket 36 is pushed by the force of the ball 7 to let the end of the bar 35 lower down while propped by the driving shaft 34, whereby said shaft 34 is actuated to turn the follower 37 from the position of FIG. 15 to the position where the protuberance 38 is dislocated from the stepped portion C' of the cam groove 28 while the end of the protuberance 39 is disengaged from the stopper piece 29'. Consequently, the rotative force accumulated on the windup spring 20 is exerted to the cam plate 19 to let it turn quickly in the direction of arrow, causing corresponding turn of the cam groove 28, and in the course of movement of the protuberance 38 from the shorter-diameter position B' of the cam groove 28 to the longer-diameter position A', the end of the follower 37 is pushed out sharply and thereby the racket 36 is actuated in the manner described above to hit back the ball 7, and in the course of further movement of the protuberance 38 from said longer-diameter position A' to the original shorter-diameter position B, the racket 36 is driven in the same way as said above to return to its original position. When the racket 36 thus assumes its original position and the cam plate 19 makes the additional half turn, the first stepped portion C is engaged with the protuberance 38 and the stopper piece 29 abuts against the end of the protuberance 39 to lock the cam plate 19, thereby producing a stand-by situation for striking the next rolling-down ball 7.
If the racket-supporting body 16 (16') is moved reciprocatively along the elongated slot 9 (9') before the ball comes rolling down again, the loosened spring 20 is wound up upon every forward turn of the gear 23 and always maintained in a maximal wound-up condition, thus keeping the rotative power accumulated constantly. In this case, if the pressing force adjusting plate 25 is turned by operating the lever 32 (32') projecting out from the back side of the racket-supporting body 16 (16') so that the raised-up side of the protuberance 31 will be pressed against the pressing spring 24 to strengthen the spring pressure, the spring 20 is wound up faster and stronger, allowing striking of the ball with a stronger force. On the other hand, if the pressing force adjusting plate 25 is turned so that the recessed part of the protuberance 31 will be pressed against the pressing spring 24 to weaken the spring pressure, the spring 20 is wound up more slowly and more weakly, so that the ball 7 is striken with a weaker force.
In this way, two players move their racket-supporting bodies 16, 16' alternately to hit the ball 7 with the racket 36 to return the ball to the player on the opposite side. If any player fails to hit the ball, he allows one point to his opponent. By repeating the above-said operation, two players can continue a mimic tennis game.
The present invention is not limited to the foregoing embodiment but includes the following modifications.
For instance, the rack gear 10, vertical shaft 49, cut and bent up piece 50, pinion gear 51, crown gear 52, transmission gear 53 and shaft 54 in the mechanism of the above-described embodiment may be eliminated, and instead the main shaft 18 may be extended so that it projects out from the racket-supporting body 16 (16'), with a turning grip being fixed to the extended end, or a winding shaft 56 (56') may be provided in the frame 17, said shaft 56 (56') carrying at its end a worm gear 55 meshed with the gear 23 and having its other end projected out from the back side of the racket-supporting body 16 (16'), with a butterfly grip 57 (57') being secured to the other end of said shaft 56 (56').
When one holds and turns said grip 57 (57') and hence the winding shaft 56 secured thereto to let the gear 23 turn in the same direction as the rotating direction of the ratchet wheel 21, said turning motion of the shaft 56 is transmitted to the ratchet wheel 21 as the gear 23 is pressed against the friction disc 22 by the pressing force of the spring 24 and the friction disc 22 is thereby pressed against a side of the ratchet wheel 21. Accordingly, the inner end of the windup spring 20 is wound up, and since the outer end 26 thereof is secured to a fixed position by the protuberance 27 of the cam plate 19 which is kept stationary by the engagement of the protuberance 38 of the link 37 in one of the stepped portions C or C' in the cam groove 28 and by the abutment of one of the stopper pieces 29 or 29' against the end of the protuberance 39, the spring 20 is wound up to accumulate the rotative force. The grip 57 (57') cannot be turned reversely since the pawl plate 33 is engaged with the ratchet wheel 21 to inhibit its rotation in the reverse direction.
In this embodiment of the invention, the spring 20 is gradually unwound as alternate hitting of the ball 7 by the rackets 36, 36' is continued. In this case, the game may be continued until the spring 20 runs down perfectly, or the spring 20 may be wound up properly while continuing the game.
Lines 58 may be directly drawn on the surface of the board 1 to present an actual tennis court lining as shown in FIG. 19, or a mat described with such lines 58 may be pasted to the board surface.
A net plate 59 resembling an actual tennis net may be set centrally across the fencing walls 2, 2' provided on the board 1 as shown in FIGS. 19 to 21. In this case, the support posts 60, 60' provided at both ends of the net plate 59 are so designed that their lower end portions may be detachably fitted into the corresponding holes 61, 61' formed in the top surfaces of the fencing walls 2, 2', with the lower edge of the net plate 59 being sufficiently spaced-apart from the board surface to allow passage of the ball 7 therethrough.
Also, a half-spherical score indicator 63 (63') may be slidably set in an elongated slot 62 (62') formed in the top surface of each fencing wall 2 (2'), and a series of numerical figures 64 for expressing the score may be directly inscribed on the inner side of each fencing wall 2 (2') or a strip of paper bearing such figures 64 may be pasted thereto.
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This invention relates to a game board whereby a mimic tennis game can be played. Two animated racket-supporting bodies disposed opposedly to each other across a play board are moved alternately so as to catch a ball which comes rolling on the board surface toward either side of the board where said racket-supporting body is disposed, and when the racket carried by the racket-supporting body on one side catches the ball and the racket is accordingly displaced, the racket driving mechanism provided in the racket-supporting body is operated to drive the racket so that it will automatically hit the ball. After hitting of the ball by the racket, the racket driving mechanism is inactivated. As the animated bodies are moved across the play board, a pinion gear meshes with a rack gear and ultimately a spring is wound up to accumulate power for driving the simulated tennis ball. Each time a ball is hit, a bell rings. The tennis racket carried by each animated body is actuated by a spring driven mechanism including a cam plate formed with a curved groove and a follower connected to the cam plate. A half spherical member is slidable in a slot marked with numerical figures to provide a score indicator.
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FIELD
[0001] The present patent document relates to apparatus and methods for locking electronics against accidental or unwanted tampering.
BACKGROUND
[0002] Many electronic devices sold today come with a remote control. The remote control that accompanies an electronic device allows users to operate the device from some distance away. For example, a remote control allows a television viewer to change the channel without getting off the couch and walking over to the television. Typically, remote controls can control many of the functions of the electronic device, including but not limited to powering the device on and off, selecting specific functions of the electronic device, and controlling the volume.
[0003] While using a remote control can make operating an electronic device more convenient, remote controls may also pose a hindrance. The buttons of the remote control may get accidentally pushed or pressed and consequently, the electronic device may perform an unwanted function. The buttons may be accidentally or unexpectedly pressed by small children, animals, other users, or the owners themselves. In addition, remote controls may fall into unwanted areas such as between the cushions of a couch. Remote controls may get accidentally stepped on, which could cause the remote control to accidentally activate the electronic device. Furthermore, remote controls may be accidentally bumped or dropped which may also cause the unwanted operation of the electronic device.
[0004] If the buttons of the remote control are accidentally engaged, the electronic device may perform an unwanted function. For example, the electronic device may accidentally turn off in the middle of an important portion of the devices operation. In the case of a television, a television may turn off right before the winning goal is scored or the game winning shot is made. Other examples of unwanted operations include unexpectedly changing the channel or muting the volume at an inopportune time.
[0005] Furthermore, young children are often very inquisitive about remote controls and want to play with the remote control. If the little kid gets to play with the remote control, the child will almost certainly begin pressing buttons and thus cause the electronic device to perform unwanted functions. If the adult prevents the child from playing with the remote control the child may become upset and irritated.
[0006] In addition to the unwanted or accidental operation that may be caused by the buttons on the remote control, similar problems exist with the panel buttons of electronic devices. Front panel buttons are often within the reach of small children and may be bumped or pushed. Similar to the remote, small children are often fascinated with buttons and preventing the small child from pressing the buttons could irritate or upset the child. Furthermore, as explained above, pushing or bumping the buttons on the front panel could cause unwanted operation at inopportune times. Animals may also accidentally brush against or bump the buttons on the front panel causing unwanted activation or operation of the device.
[0007] Unwanted or accidental operation of an electronic device may also have detrimental side effects on the life of the electronic device. Repetitive operation of some electronic device functions could cause damage to the electronic device. For example, turning the device on and off in successive fashion may cause electric surges in the device that are detrimental to the life of the device. By reducing the unwanted or accidental functions of the device, the life of the device may be prolonged.
SUMMARY OF THE EMBODIMENTS
[0008] In view of the foregoing, an object according to one aspect of the present patent document is to provide improved apparatus and methods for providing unwanted or undesired control of electronic devices. Preferably the apparatus and methods address, or at least ameliorate one or more of the problems described above. To this end, a remote control designed to operate an electronic device is provided. In one embodiment the remote control comprises: a housing; and a plurality of buttons arranged on the housing wherein a single button is designed to lock the plurality of buttons on the remote control.
[0009] In at least one embodiment, a single button is designed to lock the plurality of buttons on the remote control with a single push. In certain embodiments, a key combination is required to confirm the unlocking of the remote control and/or electronic device.
[0010] The electronic device may be any number of devices including but not limited to a, display device, Blu-ray® player, DVD player, personal computer (PC), Digital Video Recorder (DVR) or some other electronic device in which tamper prevention is required. In at least one embodiment, the electronic device is a television.
[0011] In yet another embodiment, the single button designed to lock and/or unlock the plurality of buttons may be brightly colored to allow the button to stand out.
[0012] In another embodiment, the single button designed to lock and/or unlock the plurality of buttons is designed to unlock the plurality of buttons by simultaneous pushing the single button with at least one other button. In another embodiment, instead of simultaneously pushing another button, a sequence is subsequently entered after the single lock button is pushed.
[0013] In yet another embodiment, the firmware of the remote control is designed to prevent a transmission of a signal by the remote control when the remote control is locked. In yet another embodiment, the firmware of the electronic device is designed to ignore a signal from the remote control when the remote control is locked.
[0014] In another embodiment, a system for preventing unwanted control of an electronic device is provided; the system comprises: a remote control configured to operate a television, the remote control comprising, a housing; a plurality of buttons arranged on the housing; and a single button designed to lock the plurality of buttons on the remote control.
[0015] In one embodiment of the system for preventing unwanted control of an electronic device, the system further comprises a television. The television further comprises: a television housing; a plurality of television buttons arranged on the television housing; and a single television button designed to lock the plurality of television buttons.
[0016] In another embodiment, the single button designed to lock the plurality of buttons on the remote control is also designed to lock the plurality of television buttons. In yet another embodiment, the single television button designed to lock the plurality of television buttons is also designed to lock the plurality of buttons on the remote control.
[0017] In another embodiment, the television is designed to bring up an on-screen-display for a password when the single button on the remote control is pressed to unlock the remote control or the television.
[0018] In yet another embodiment, a method of preventing unwanted control of a television is provided, the method comprises the steps of: receiving a key combination designed to confirm an unlock signal; receiving a first signal from a single button on a remote control or the television designed to enable a lock state; and disabling the functionality of a plurality of buttons on the remote control and the television.
[0019] In another embodiment the method further comprises the step of receiving a second signal from the single button on the remote control or the television designed to disable the lock state.
[0020] In another embodiment, the method further comprises the steps of receiving an unlock key combination; and comparing the unlock key combination with the key combination designed to confirm an unlock signal. If the key combinations match, the functionality of the plurality of buttons on the remote control and the television are enabled.
[0021] Different key combinations may be used to confirm the unlock signal. In one embodiment, the unlock key combination includes depressing the single button on the remote and simultaneously depressing at least one of the plurality of buttons on the remote. In another embodiment, the unlock key combination includes depressing a sequence of the plurality of buttons on the remote.
[0022] In yet another embodiment, the method further comprises the step of displaying an on-screen-display on the television requesting the unlock key combination after the step of receiving a second signal from the single button on the remote control or the television designed to disable the lock state.
[0023] As described more fully below, the apparatus and methods of the embodiments permit the locking of remote controls and/or electronic devices to prevent accidental or unexpected functioning. Further aspects, objects, desirable features, and advantages of the apparatus and methods disclosed herein will be better understood from the detailed description and drawings that follow in which various embodiments are illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration only and are not intended as a definition of the limits of the claimed embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 illustrates a system with an electronic device including a lock to prevent accidental tampering.
[0025] FIG. 2A illustrates an on screen display of an electronic device including a lock to prevent accidental tampering.
[0026] FIG. 2B illustrates an on screen display for entering a lock code for an electronic device including a lock to prevent accidental tampering.
[0027] FIG. 3A illustrates an on screen display for entering a lock code to lock an electronic device.
[0028] FIG. 3B illustrates an on screen display for entering a lock code to unlock an electronic device.
[0029] FIG. 4 illustrates a method of locking or unlocking an electronic device and/or remote control.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0030] Consistent with its ordinary meaning, the term “lock” or “locked” is used herein to refer to preventing the normal operation of the buttons located on a device and/or the corresponding remote control of the device. “Tamper lock” or “lock out” may also be used in the place of “lock.” When an electronic device is “locked” some or all of the buttons on the remote control and/or electronic device no longer operate normally. For example, the buttons may be pushed, pressed or activated with no apparent result. It is not important how the lock is implemented only that some portion of the buttons may be pushed without effecting their normal result.
[0031] Consistent with its ordinary meaning, the term “button” is used herein to refer to any small knob or disk pressed to activate an electronic circuit or otherwise operate an electronic device, machine, toy or other device. Button also includes areas of a touch screen or other input device design to operate as a button. Buttons may be any shape or design and are not limited to disk or other round shapes. Furthermore, the term button as used herein may also include switches or other devices designed to provide input to an electronic device.
[0032] FIG. 1 illustrates a system 10 with an electronic device 22 , a remote control 12 , and corresponding lock buttons 14 and 24 designed to prevent accidental tampering. The system of claim 10 includes an electronic device 22 and a remote control 12 . While the electronic device 22 of the system 10 is displayed as a display device such as a television, the embodiments of the present patent document include any electronic device and are not limited to a television. For example, the electronic device 22 may be a Blu-ray® player, DVD player, stereo receiver, monitor, personal computer (PC), Digital Video Recorder (DVR) or other electronic device. Furthermore, the electronic device 22 may be designed for home or commercial use.
[0033] The embodiment illustrated in FIG. 1 includes a remote control 12 . The remote control 12 is designed to allow a user to operate the electronic device 22 from some distance away. For example, in the embodiment of FIG. 1 , a user may operate the television while sitting on a couch. Typically, remote controls 12 use infrared technology to communicate with the electronic device 22 and allow a user to control the electronic device 22 from a distance. However, remote controls 12 may use other communication technologies to operate the electronic device 22 including IEEE 802.11 (WiFi), Bluetooth®, or any other communication technology that allows electronic devices to communicate at a distance.
[0034] The remote control 12 may have a number of buttons 16 , 18 , and 20 . The buttons may be of various types including buttons that are assigned to numbers or buttons that increase or decrease a variable such as the volume button 16 or the channel button 20 . The remote control 12 also includes a single lock button 14 designed to lock the buttons on the remote control 12 and/or the electronic device 22 .
[0035] As shown in FIG. 1 , the electronic device 22 may also have a single lock button 24 along with a number of other buttons 26 . The buttons 26 and the lock button 22 are shown on the front panel of electronic device 22 , however, the buttons may be located anywhere on the electronic device 22 including but not limited to the side, behind a panel, or any other location.
[0036] In one embodiment, the lock button 14 and/or 24 may be brightly color or backlit to make the button easily seen or detected. Preferably, the lock button 14 and/or 24 is brightly colored and has “LOCK” written across it in an easy to read lettering. Drawing attention to the lock button 14 and/or 24 suggests to the user that it should be pressed first and helps avoid confusion when the other buttons do not appear to be operating correctly, as is the case when the lock is enabled. However, in other embodiments, the lock buttons 14 and/or 24 are not brightly colored and may match the rest of the buttons on the remote control 12 or the electronic device 22 .
[0037] Providing a single lock button 14 and/or 24 on the remote control 12 or the electronic device 22 to initiate locking allows the user to easily lock the electronic device 22 and/or the remote control 12 without navigating through a number of menu screens. When it is desired to lock the remote control 12 or the electronic device 22 , only a single button push is required to initiate the process. In the preferred embodiment, a single push of the lock button 14 or 24 locks all the other buttons on the remote control 14 and the electronic device 22 .
[0038] Although the system 10 in FIG. 1 is shown with both a electronic device 22 and a remote control 12 , the system 10 is not required to include a remote control 12 and may only include the electronic device 12 with the lock button 24 . In addition, the system 10 may not include the electronic device 22 and may just include the remote control 12 with the lock button 14 . For example, a remote control 12 including a lock button 14 that may be subsequently programmed to work with an electronic device 22 is one example of an embodiment of the system 10 without an electronic device 22 . Preferably, the system 10 includes both the electronic device 22 and the remote control 12 designed to work with and operate the electronic device 22 .
[0039] In embodiments that include both a remote control 12 and an electronic device 22 , preferably both the remote control 12 and the electronic device 22 have a lock button 14 and 24 respectively. However, both are not required to have a lock button 14 and 24 . In one embodiment, only the remote control 12 includes a lock button 14 . In another embodiment, only the electronic device 22 has a lock button 24 .
[0040] When the lock button 14 on the remote control 12 is activated or pressed, preferably the buttons on both the remote control 12 and the electronic device 22 are locked. Similarly, when the lock button on the electronic device 22 is pressed, preferably the buttons on both the remote control 12 and the electronic device 22 are locked. However, in other embodiments the locking function may operate in other ways. For example, pressing the lock button 14 on the remote control 12 may lock just the remote control 12 or just the electronic device 22 . In addition, pressing the lock button 24 on the electronic device 22 , may lock just the electronic device 22 or just the remote control 12 .
[0041] When the remote control 12 or the electronic device 22 is locked, preferably all of the buttons except for the single lock button 14 and/or 24 , which may be used to unlock, are disabled or not functioning. However, not all the buttons need to be disabled. In one embodiment, pressing the lock button 14 or 24 may only disable the button that controls power to the device. In another embodiment, pressing the lock button 14 or 24 disables all the buttons except for the button(s) that control the volume of the electronic device 22 . In certain embodiments, even the lock button 14 and/or 24 itself may be disabled. Numerous other combinations of enabled and disabled buttons are possible in the embodiments of the present patent document.
[0042] The system 10 may implement the locking feature in a number of ways. For example, the remote control 12 may include firmware that disables transmissions when the remote control 12 is in a locked state. Consequently, when the remote control 12 is in a locked state and the user accidentally presses buttons on the remote control, no signal is dispatched from the remote control 12 and the electronic device 22 does not perform the unwanted or unexpected function.
[0043] In yet another embodiment, the electronic device 22 may have firmware that is programmed to ignore a signal received from the remote control 12 and/or a button on the electronic device 22 when the remote control 12 or the electronic device 22 or both are in a locked state. Other implementations of locking the electronic device 22 and/or the remote control 12 are possible, including combinations of firmware on both the remote control 12 and the electronic device 22 that implement the locking feature, without departing from the scope of the embodiments of the present patent document.
[0044] FIG. 2A illustrates an on screen display of an electronic device including a lock to prevent accidental tampering. In FIG. 2A , the electronic device 100 includes lock button 24 . The electronic device 100 is depicted in FIG. 2A as a television having display 102 . The firmware of the electronic device 100 may contain software configured to display an on-screen-display (OSD) 110 , which allows the user to perform tasks related to the locking feature. For example, in at least one embodiment, the OSD allows the user to set the lock code and turn the lock on and off.
[0045] FIG. 2B illustrates the OSD for setting the lock code 120 . As just one example, a four character/digit lock code may be entered to prevent accidental locking or unlocking of the electronic device 100 . As shown in FIG. 2B , the characters may be replaced with an asterisk as they are entered to prevent visual display of the lock code to those in viewing range of the display 102 .
[0046] While FIGS. 2A and 2B show one embodiment contemplated by the present patent document that includes OSD's to setup the tamper lock and allow a user to enter a password, OSD's are not required in other embodiments. For example, pressing the lock button 14 or 24 alone, without entering a password, may lock and/or unlock the electronic device 100 and/or remote control 12 . In another embodiment, the lock button 14 and/or 24 may be used in combination with another user selected button to lock the device. For example, the lock button 14 and/or 24 may be held down in combination with one of the other buttons 16 , 18 , 20 or 26 . The user may press both the lock button 14 and/or 24 and another button simultaneously to enable or disable the lock. Pressing an additional button simultaneously with the lock button 14 or 24 to enable or disable the lock makes it unlikely that the locking feature is accidentally activated or deactivated. Depressing both the lock button and another button simultaneously due to an accident would be a rare occurrence.
[0047] As yet another example, the lock button 14 or 24 may be pressed followed by a key sequence to lock or unlock the electronic device 22 and/or remote control 12 . For example, the user may be required to press the lock button 14 and/or 24 followed immediately by some combination of other keys to change the lock state of the remote control 12 and/or electronic device 22 . The key sequence may or may not include pressing the lock button 14 and/or 24 again. In embodiments including OSD's, an OSD may be displayed to prompt the user to enter the key sequence after the lock or unlock state change is initiated by pressing the lock button 14 and/or 24 .
[0048] As mentioned above, OSD's are not required and the user may set up a password, key combination, or a key to simultaneous press in conjunction with the lock button 14 and/or 24 using other methods. For example, the lock button may be held down for a period of time to indicate a setup operation. In an embodiment with backlit buttons, the buttons may begin to blink to indicate to the user that a setup operation may be performed. The user may then enter the key combination or select the simultaneous key to act as a password for enabling or disabling the locking feature. In one embodiment, the lock button 14 and/or 24 may be depressed for a second time to indicate that the key combination constituting the password has been complete. The remote control 12 and electronic device 22 will then be setup to require the particular key combination entered by the user to follow the depression of the lock button 14 and/or 24 to lock and/or unlock the remote control 12 and/or electronic device 22 .
[0049] FIG. 3A illustrates an on screen display for entering a lock code to lock an electronic device 100 . In an embodiment where the electronic device includes a display 102 , it is preferable to use an OSD to provide feedback to a user when entering a key combination. In embodiments requiring a password or some key combination, once the password or key combination is setup, the user will be required to enter the key combination after depressing the lock button to enable and/or disable the lock. For example, in the embodiment shown in FIG. 3A , once the lock button 14 and/or 24 is depressed, an OSD 130 appears on the screen to provide feedback to a user to let them know to enter the password or key combination to lock the remote control 12 and/or electronic device 100 .
[0050] As long as the correct password or key combination is entered, the device locks. If the wrong password or key combination is entered a new message may be displayed indicating the wrong password has been entered and asking the user to try again.
[0051] FIG. 3B illustrates an on screen display for entering a lock code to unlock an electronic device 140 . Unlocking the device preferably operates using the same method that is used for locking the device. However, in one embodiment the same password is used to lock and unlock the electronic device and/or remote control. In another embodiment, different passwords are used. In yet another embodiment, a password is only needed to unlock the electronic device and/or remote control. Once the lock button 14 and/or 24 is depressed, an OSD 140 may appear asking the user to enter the previously setup password or key combination to deactivate the lock. If the wrong combination is entered, the electronic device and/or remote control remains locked and a message may be displayed to try again.
[0052] In the preferred embodiment including an OSD, the user may enable the lock by simply pressing lock button 14 or 24 without entering any key combination. Once the lock is enabled, all the buttons on both the remote control 12 and the electronic device 22 are locked, except lock buttons 14 and 24 . Consequently once the lock is enabled in the preferred embodiment, the only functional buttons are the lock buttons 14 and 24 .
[0053] In the preferred embodiment including an OSD, a key combination is required to unlock the system 10 . To unlock the system 10 in the preferred embodiment, lock button 14 or 24 is pressed to initiate the unlocking sequence. The system 10 then displays an OSD 140 to prompt the user to enter the key combination to disable the lock. If the correct key combination is entered, the system 10 is unlocked. If the incorrect key combination is entered, the system 10 remains locked and the user is prompted to try again.
[0054] While preferably a system with a display device designed to provide OSD's is powered on when the state of the lock is being changed, the locking feature may still be enabled or disabled without the OSD's being displayed, for example if the system is powered off. If the system is powered off, the lock feature may work exactly as described above except that the OSD prompting for a key combination would not be displayed. In another embodiment, initiating a change in the lock state may power on the electronic device 22 to display the OSD requesting a key combination.
[0055] Preferably some type of feedback such as a message saying wrong password is given when the password or key combination is entered incorrectly. However, no feedback is required and simply not enabling or disabling the lock may be the only result of an incorrect password or key combination. In addition, methods of feedback other than a OSD may be used. For example, in embodiments with backlit buttons, the buttons may blink or all turn on at the same time to indicate an incorrect entry. Remote controls 12 may also be made to vibrate for incorrect entries.
[0056] FIG. 4 illustrates one embodiment of a method of locking and unlocking an electronic device and/or remote control. In the embodiment of FIG. 4 , the system is setup by first entering a key combination 200 to act as a password to unlock the electronic device and/or remote control. Once the lock feature is setup it may be activated by pressing a single button on the remote control and/or the electronic device 202 . This allows the electronic device and/or remote control to be locked from any place or during any phase or state of operation of the electronic device by pressing only a single button 202 .
[0057] After the single button is pressed the system enters the lock enabled state 204 and all the buttons on the remote control and the electronic device are disabled except the lock buttons. To exit the lock enabled state 204 , either the single lock button on the remote control or the single lock button on the electronic device may be pressed 206 . After pressing the lock button to remove the remote control and the electronic device from the lock enabled state a key combination may be entered 208 .
[0058] The key combination entered in 208 is then verified against the key combination entered in step 200 to verify the key combination is correct 210 . If the key combination is correct, the system enters the lock disabled state 212 and all the buttons on both the remote control and the electronic device resume their full functionality.
[0059] If the key combination entered in 208 does not match the key combination entered in 200 , than the key combination must be reentered 208 and the system remains in the lock enabled state.
[0060] Although the embodiments have been described with reference to preferred configurations and specific examples, it will readily be appreciated by those skilled in the art that many modifications and adaptations of the methods, and systems for locking an electronic device and/or remote control described herein are possible without departure from the spirit and scope of the embodiments as claimed hereinafter. Thus, it is to be clearly understood that this description is made only by way of example and not as a limitation on the scope of the embodiments as claimed below.
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A remote control designed to operate an electronic device comprising: a housing, a plurality of buttons arranged on the housing, and a single button is designed to lock the plurality of buttons on the remote control.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional Patent Application Ser. No. 60/602,117, filed Aug. 17, 2004 for “Using a Polaron Interaction Zone as an Interface to Integrate a Surface Plasmon Layer and a Semiconductor Detector” and U.S. provisional Patent Application Ser. No. 60/602,061, filed Aug. 17, 2004 for “Utilizing an Integrated Plasmon Detector to Measure a Metal Deposit Roughness on a Semiconductor Surface,” both by David T. Wei and Axel Scherer, the disclosures of which are incorporated in their entirety herein by reference thereto. This application is filed on the same day as U.S. patent application No. ______ Attorney Docket No. 622688, for “Utilizing an Integrated Plasmon Detector to Measure a Metal Deposit Roughness on a Semiconductor Surface”, also incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] The present invention was supported in part by grant no. F49620-03-1-0418 from the United States Air Force Office of Scientific Research. The U.S. Government may have rights in any patent issuing on this application.
BACKGROUND
[0003] 1. Field
[0004] The present disclosure relates to integrated plasmon detectors.
[0005] 2. Related Art
[0006] When a species of atoms (whether gas, liquid, or solid) is ionized into an equal number of free electrons and ionized atomic cores known as ions, the atoms are said to be in a plasma state. In an ideal undisturbed gaseous plasma, the density of free electrons is equal to that of the positively charged ions and the overall distribution of charge is equal, and thus neutral, throughout the plasma. When this distribution is disturbed, the electrons seek to restore their neutral positions through the combined effect of repulsion from other electrons and attraction from the uniform positive charge background of the ions. This will induce an oscillation in the electrons as they attempt to return to their neutral positions known as plasma oscillation. [The Feynman Lectures of Physics, R. P. Feynman et al., Addison Wesley, Reading, Mass. 1964, the entire contents of which are incorporated herein by reference.]
[0007] In a metal, the density of free electrons is much higher, and their temperature much lower, than in a gaseous plasma. These free electrons are thus a quantum gas and, when oscillating, form what is termed a plasmon. Free electrons oscillating at a common frequency are oscillating at plasmon frequencies that are generally very high, having a typical value on the order of 3×10 15 Hz (corresponding to a charge of about 12 eV). [Elementary Excitation in Solids, D. Pines, Benjamin, N.Y. 1964; and Statistical Mechanics, R. P. Feynman, Addison Wesley, Reading, Mass. 1972; the entire contents of both of which are incorporated herein by reference.] For purposes of discussion and with reference to FIG. 1 ( a ), whereas a plasmon is understood herein to refer to the state of quantum plasma in a solid, a jellium 2 is understood to mean a quasiparticle consisting of a negatively charged core 4 shielded by positive charges 6 gathered from the surrounding ions within a Fermi-Thomas radius λ FT , which is comparable to the radius of a host atom in a metal lattice. The electron thus oscillates within this atom-sized sphere of positively-charge volume, evincing a high frequency and thus displacement that is small relative to the size of the sphere. When all such electrons oscillate in phase with one another, a standing plasmon wave arises (k=0), whereas a linear series of electrons having a definite phase relationship to one another correspond to a traveling plasmon wave having definite direction and mode numbers k (k≠0).
[0008] A quantum plasma in a solid also contains individual “hot” electrons that tend to interact (i.e. collide) with each other and with jelliums much more frequently that with the host ion lattice. When a hot electron 4 ′ penetrates a jellium 2 , as shown in FIG. 1 ( b ), there are two negative electron charges 4 , 4 ′ inside a volume 6 of a unit of positive charge. This imbalance of charge leads the jellium to disintegrate by the expulsion of both electrons such that total momentum is conserved. Conversely, when two such hot electrons collide, as shown in FIG. 1 ( c ), the result is a stationary jellium 2 at the point of impact and one free electron 4 ′. Molecular physics teaches us that the probabilities of these two opposite processes are equal.
[0009] When a metal is impinged upon by a laser pulse beam having a frequency below the plasmon frequency of the metal, electrons begin to be set in motion at randomly distributed frequencies lying between the laser beam and the plasmon frequencies (between 10 15 and 3×10 15 Hz). Initially most of these electrons are free hot electrons, with few jelliums. These hot electrons tend to favor the creation of jelliums through their collisions, and thus the subgroup of collective electron plasmonic oscillations begins to build up in jelliums as energy is transferred from the laser beam to the plasmon system. Depending on the length of the laser pulse and the thickness of the metal, the plasmon oscillations may reach a peak maximum range, with free electron density as high as 10 23 /cm 3 . These collective oscillations have a natural frequency or plasma frequency determined by the density of electrons in the neutral distribution n 0 , and can be expressed as
f = ( 1 2 π ) ⅇ 2 n 0 ɛ 0 m e ( 1 )
where e is the unit electron charge, n 0 is the neutral density of electrons in a plasma, ε 0 is the permittivity of vacuum, and m e is the unit electron mass.
[0010] When the laser beam ceases to impinge onto the metal, most jelliums continue to oscillate at their respective plasmon frequency characteristic of concentration and movement (mood number). When a jellium falls out of step with the whole class collective modes of existing plasmon oscillations, it drops out and an ‘individual’ hot electron (as opposite to a ‘collective class’ hot electron) results that eventually cools down to room temperature to become a thermal electron. However, if it does not pass through an adaptor layer to cool down quickly, the remaining heat will make detecting it functionally difficult.
[0011] Currently known methods and devices for measuring the decay of a plasmon all rely on photodetectors of various types to detect the emitted decay photons. This approach is limited by the fact that the decay photons have to travel a relatively long path from the surface to the detector, a path over which they undergo angular spreading misalignment, and environment influences. Thus, collection and detection of decay photons as a means of studying plasmon effects can be difficult and prone to inaccuracies. The present disclosure addresses these difficulties with a novel approach to plasmon detection: monitoring the hot electrons internally created by plasmon decay.
SUMMARY
[0012] According to one embodiment described herein, a plasmon detector comprises a top layer of material with a surface adapted to generate a plasmon when excited by an incident beam of light; an interface layer joined to the top layer opposite from the surface of the top layer and adapted to slow polarons emitted by the plasmon to thermal electrons; and a collector layer joined to the interface layer opposite from the top layer and adapted to collect the thermal electrons from the interface layer.
[0013] According to another embodiment described herein, a method for detecting a plasmon comprises selecting a top layer of material with a surface adapted to generate a plasmon when excited by an incident beam of light; joining an interface layer to the top layer opposite from the surface of the top layer, the interface layer adapted to slow polarons emitted by the plasmon to thermal electrons; joining a collector layer to the interface layer opposite from the top layer, the collector layer adapted to collect the thermal electrons from the interface layer; impinging a beam of light onto the surface of the top layer; and detecting the thermal electrons collected in the collector layer.
[0014] In further embodiments, the interface layer may comprise a substantially non-conductive n region, and the interface layer may comprise any one or more of the group comprised of ZnSe, GaP, GaAs, and Si. In yet further embodiments, the collector layer may comprise a semiconductor, and the top layer may comprises any one or more of the group comprised of Au and Ag. In a still further embodiment, an electric circuit may be connected between the collector layer and the top layer to conduct thermal electrons collected in the collector layer to the top layer.
[0015] According to a still further embodiment described herein, a method for detecting a plasmon comprises impinging a beam of light onto the surface of a metal to generate a plasmon that decays through Raman scattering photons and emitted electrons, and counting the emitted electrons.
[0016] In another embodiment described herein, a plasmon detector comprises means for generating a plasmon on a metal; means for reducing the energy of electrons emitted by decay of the plasmon; and means for counting the reduced energy electrons.
[0017] In still another embodiment described herein, a method for detecting a plasmon comprises impinging photons onto a first material to generate a plasmon that decays through Raman scattering photons and free electrons having a first energy state; causing the free electrons to form polarons in a second material and slow down to thermal electrons having a second energy state through the emission of phonons; and counting the thermal electrons.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1 ( a )- 1 ( c ) are diagram representation of a jellium particle, and the formation and destruction mechanisms for a jellium particle;
[0019] FIG. 2 is a Feynman diagram representation of a polaron decay scheme employed in embodiments described in the present disclosure; and
[0020] FIG. 3 is a functional block diagram, not drawn to scale, of a detector according to the present disclosure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring to FIG. 2 , a Feynman diagram depicts the decays scheme of a jellium or plasmon particle. An incident photon laser pulse that strikes a conductive mass of material (such as silver, gold, or other metal) excites free electrons to set up a plasmon, which then decays by emitting a high-energy electron and a Raman scattering photon that is reflected back from the mass. Thus, conservation of momentum dictates that the matching high-energy electron travels in a generally opposite direction from that of the Raman photon, and away from the surface. As the plasmon decays after the pulse, and accumulation underneath the surface of such high-energy “hot” electrons of energy between 0.04 eV and 12 eV begins to collapse towards the interior of the conductive material and proceed to interact with the ionic lattice atoms of this material. If this material is polar (that is, strongly ionic in nature), these high-energy electrons are quickly quenched. This stream of high-energy electrons traveling at high velocity through such a polar lattice has a distortion affect upon the lattice that takes the form of a wave (similar, on a broad conceptual level, to a breeze flowing through a grass field). As each high-energy electron moves through the atomic lattice, it drags the lattice disturbance with it and interacts with the ionic charges in the lattice, thereby forming a new composite particle known as a polaron.
[0022] More specifically, polarons are formed by the charge coupling of a high-energy electron with the ionic charges from the solid atomic lattice, taking the form of a hot and heavy composite particle, or eigenstate, moving through the lattice. Through the charge coupling between the hot electron and the lattice ions, the electron sheds its kinetic energy to the ionic lattice one quantum per each interaction. Each such quantum of energy imparted to the lattice causes the lattice to vibrate in unison, thereby giving rise to a “wake” behind the high-energy electron. Each quantum of such lattice vibration is known as a phonon, and a high-energy electron dragging a wake of phonons behind it forms a polaron. As each phonon breaks away from the polaron, the polaron loses a quantum of energy and recoils at a random angle until it eventually loses all of its kinetic energy and becomes a “cold,” or thermal, electron (having energies on the order of 0.04 eV, or room temperature). [“Oscillatory and Excitation Spectra of CdS and ZnSe,” Proc. 3 rd . Int. Conf. On Photoconductivity, D. T. Y. Wei et al., pp. 343-350, edited by E. M. Pell, Pergamon, N.Y., 1973, the entire contents of which are incorporated herein by reference.]
[0023] With continued reference to FIG. 2 , there are four basic types of phonons, as defined in Table I below.
TABLE I Wave Polarization Direction/Displacement of Ions in Unit Cell Longitudinal Transverse Along each other LA TA (Acoustic) Opposite (Optical) LO TO
[0024] The relative electron coupling strength of each of the above four types of phonons depends on the band structure and how polar the host material is (increasing across the Group IV, III-V, and II-VI sequence of semiconductors). For most popular optical crystals, the shortest emission time is for LO phonons (about 10 −13 sec) and the longest emission time is for TA phonons (>10 −9 sec). The emission of any one of the four types of phonons is possible, but the ones with the shortest interaction times are favored, and the natural priority in typical semiconductors is therefore LO, TO, LA, TA. In the plasmon decay curve, LO phonon emission characterizes the initial sharp drop and TA phonon collision accounts for the slow tailing off. LA and TO phonon emissions are not important with respect to characterizing this curve.
[0025] With reference now to FIG. 3 , the present disclosure addresses solutions to the problems encountered by conventional plasmon detectors by detecting the high-energy electrons produced by the decay of the plasmon instead of the Raman photons. Thus, with continued reference to FIG. 3 , one embodiment of a detector 10 according to the present disclosure includes a “plasmon” layer 100 of metal with an exposed surface 102 upon which a laser beam 106 may impinge. The metal layer 100 is selected to give rise to a plasmon when excited by a laser beam, and thus preferred materials include, among others, gold (Au) and silver (Ag).
[0026] Joined to the plasmon layer of material 100 and generally opposite from the exposed surface 102 is a “polaron” layer 110 that is selected to slow the high-energy electrons emitted by the decay of the plasmon to thermal electrons through the generation of polarons. The polaron layer 110 is most preferably a so-called pi (n) region, that is, an electric insulator substantially void of conducting host electrons or holes. Thermal electrons cannot travel across this region by drift (also called ohmic conduction), but the high-energy decay electrons can traverse such a region as polarons by diffusion, due to their high momentum concentration gradient and the random nature of polaron movements. Materials suitable for use in the polaron layer include, among others, ZnSe, GaP, GaAs, and Si. Assuming an average polaron velocity of 10 6 m/sec, the thickness of the polaron layer 110 would typically need to be about 1 μm for LO phonon emission. The choice of materials will be dictated by, among others, the type of phonons emitted, the energy of the decay electrons, and the purity and perfection of the crystals used.
[0027] With continued reference to FIG. 3 , an electrically conductive “collector” layer 120 is joined to the polaron layer 110 opposite from the plasmon layer 100 . As polarons are slowed down in the polaron layer 110 , the resulting thermal electrons arrive to be collected in the collector layer 120 , where they can be detected and the initial incident laser beam 106 can thus be quantified. A practical material for the collector layer is a semiconductor substrate, which can be either homo or hetero junction. The thermal, or “cold” electrons that arrive in the conductive layer 120 can thus be counted in any manner known to those skilled in the art and may further be “recycled” through an external circuit 140 that sends them back to the plasmon layer 100 to form new plasmons and decay in the next cycle of plasmon decay. It is understood that the individual thermal electrons in this flow do not need to be counted, as the response of a detector measuring the thermal electron flow or current, and particularly the decay shape following each laser pulse, can provide all the information desired.
[0028] It will be appreciated by the skilled reader that the present disclosure is directed to a novel method and device for detecting and quantifying plasmons that avoid the problems found in current state of the art methods and devices. The presently disclosed embodiments detect the plasmon decay electron instead of the Raman photon and, through the provision of an interface region that slows such decay electrons to thermal levels through the generation of polarons, provide for an integrated device that unites the plasmon generation layer with the thermal electron collector layer. The thermal electrons collected in the collector can then be detected and measured with conventional electronics, and may be recycled back to the plasmon conductive layer to give rise to a subsequent plasmon and the attendant generation of decaying polarons.
[0029] While several illustrative embodiments of the invention have been shown and described, numerous variations and alternative embodiments will occur to those skilled in the art. The relative thicknesses of the various layers in FIG. 3 , for instance, are not to be understood as disclosing a preferred or necessary thickness ratio among these layers. Such variations and alternative embodiments are contemplated, and can be made without departing from the scope of the invention as defined in the appended claims.
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An integrated plasmon detector includes a top layer of material adapted to generate a plasmon when excited by a beam of light incident onto a surface of the top layer, an interface layer joined to the top layer opposite from the surface of the top layer and adapted to slow polarons emitted by the plasmon to thermal electrons, and a collector layer joined to the interface layer opposite from the top layer and adapted to collect the thermal electrons from the interface layer.
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BACKGROUND OF THE INVENTION
This invention relates generally to gravure proofing and correction and more particularly to a simple trial proof-printing method for use in the proofing and correction of gravure printing.
In the printing of printed matter, ordinarily, it is the common practice to carry out beforehand trial proofing of the printed matter; that is, making a trial impression, for the purpose of enabling the customer or the person in charge of the printing to determine whether or not the printed matter desired by the customer will be properly produced. This is generally referred to as "proofing" "proving", or "proofing and correcting", but the number of trial impressions or proofs is very small, being of the order of a few sheets to ten and a number of sheets. This trial proofing is carried out for correcting errors of the printing plate surface, unsightly appearance, nonuniformity, and coloring. Accordingly, it must be assumed, as a premise, that a printing plate used for proofing will be corrected. Furthermore, if the proofing impression were to be different from the printed matter to be delivered to the customer, i.e., the main job impressions or the edition impressions, it would be meaningless as a proof, of course. On the other hand, from the object of proofing, it is not necessary that the proof be an impression which has been made as a result of exactly the same process and the same work as the edition impression. Accordingly, so-called proof presses for making proof impressions are being widely used.
However, in the case of gravure printing, differing from typographic printing and offset printing, the making of proofs cannot be easily carried out, and corrections during or after completion of the process of preparing the plate is difficult. For this reason, so-called blue printing or cyanotype, wherein a blue print is made from the gravure continuous-tone positive prior to the plate fabrication is substituted for proofing. While it is possible with blue-print proofing to examine the dimensions and layout of the image or characters and the like, the photographic gradation, and other features after the plate preparation, the tonal effect in the case of color gravure cannot be examined. Consequently, in such a case, it has been disadvantageously necessary to print with the main printing press or with a proof press having a construction similar to that of the main press.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a very simple gravure proof-printing method in order to solve the above described problems. I have observed that, in spite of the fact that gravure printing expresses tone by means of half-tone dots, a blue printing can withstand proofing to a certain degree. Furthermore, I have developed a novel process for offset printing with the use of a gravure continuous-tone positive instead of an offset screen positive and have noted the identicality of these positives.
Gravure printing and offset printing differ in their printing methods, and their dot compositions are also different. However, this difference in these two printing methods merely means that the processes for reproducing an image identical to the original are different and does not mean that the anticipated image cannot be reproduced. Furthermore, I have noted that the difference between the dot compositions merely indicates that a difference exists in a microscopic observation, and the image of the printed matter is usually observed, as a matter of course, by naked eye, and that the proof-printing need not be carried out according to the same process and under the same work conditions as the edition printing. In fact, I have found that the proof impression for gravure printing may be made by offset printing without any adverse effect on the proofing, and this discovery constitutes a basis of this invention.
More specifically, according to this invention there is provided a gravure proof-printing method which is characterized by the steps of superposing a contact screen upon the photosensitive layer of a plate blank for offset printing, superposing further thereon a continuous-tone positive for gravure printing, exposing the plate to light from the side of the positive thereby to carry out photoprinting, developing this plate to produce a printing plate, and using this plate to make a proof for gravure proofing and correction.
The nature, utility, and further features of this invention will be more clearly apparent from the following detailed description.
DETAILED DESCRIPTION
First, for the plate for offset printing, any of those of ordinary type can be used. Examples of such offset-printing plates are polymetal plates, deep-etch plates, dry offset plates, and presensitized plates, each of which has a photosensitive layer on either of its two sides. Of these, a presensitized plate is the most desirable because of its features such as its convenience in use in view of its intended application to proofing.
For the contact screen, also, those for gravure printing and for offset printing can be used. Of these, those for offset printing are preferable.
The continuous-tone positive for gravure printing is made to specified dimensions, similarly as in an ordinary gravure printing method, from an original by photographing it to obtain a color separated continuous-tone negative through the use of a color scanner, a camera, or the like.
After the contact screen and the continuous-tone positive have been superposed in this order on and caused to closely contact the photosensitive layer of the offset printing plate, exposure to light is carried out from the positive side. This exposure can be carried out in the same manner as in the photoprinting of a halftone positive in offset printing.
After the exposure and photoprinting, the resulting plate is subjected, similarly to the case of an ordinary offset printing plate, to process steps such as, for example, developing, water washing, sensitizing treatment, water washing, removing, water washing, gumming up, and drying, whereupon a printing plate is obtained. The above mentioned developing can be carried out by an ordinary method such as the brush developing method or the spray developing method.
Next, with the use of the printing plate thus obtained, trial printing is carried out by offset printing, as in ordinary offset proofing, thereby to produce a printed matter. In this proof-printing, the hue of the ink for offset proof printing is, of course, caused to approach the hue of the gravure ink, and the use of an ink of high transparency is desirable.
In the fabrication of the printing plate used in the method of this invention, supplementary auxiliary measures and means such as the additional use of a spacer or spacers, a no-screen exposure, and flash exposure are effective. Furthermore, the continuous tone sensation reproducable by gravure printing can be made to appear by using a contact screen of fine lines such as, for example, more than 200 lines/inch.
As will be apparent from the above description, this invention provides a completely new and very simple gravure proof-printing method which, in comparison with the presently used gravure proof-printing methods, affords substantially rationalization and improvement such as a considerable shortening of the work time and lowering of the production cost. It is to be noted that this invention is effective in its application not only to ordinary gravure printing by the chemical erosion or etching method but also to gravure printing by electronic engraving.
In order to indicate more fully the nature and utility of this invention, the following specific example of practice representing a preferred embodiment of the invention is set forth below.
EXAMPLE
A contact screen of positive type (150 lines/inch) was superposed with its surface facing downward on the photosensitive layer of a presensitized plate, and, over this screen, a continuous-tone positive for gravure printing was superposed and caused to contact closely with its surface facing downward. Exposure was carried out for photoprinting by irradiation from the side of the continuous-tone positive for 10 minutes by means of a single metal-halide lamp of 2 kW.
Thereafter, the resulting presensitized plate was developed by spraying for one minute (at a running speed of the plate of 30 seconds/meter) with the use of a solution obtained by diluting 5 or 6 times a stock solution of a developer (caustic soda, sodium silicate) for presensitized plates. The plate was then washed with water, subjected to sensitizing treatment with developing ink (manufactured by Fuji Shashin Film Kabushiki Kaisha (Fuji Photographic Film Company) Japan), and then washed with water. Unwanted parts were removed with a removing solution, and the plate was again washed with water.
The plate was then subjected to gumming up and drying, whereupon a printing plate was obtained.
With this printing plate, multicolor printing was carried out on a proof press (produced by J. G. Mailander Druckmaschinenfabrik, West Germany) in cyan, black, magenta, and yellow, in this order, with process inks for proofing (manufactured by Morohoshi Ink Kabushiki Kaisha, Japan) thereby to produce printed matters, which were effective for gravure proofing.
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A gravure proof-printing method is described which comprises superposing a contact screen upon the photosensitive layer of a plate blank for offset printing, superposing further thereon a continuous-tone positive for gravure printing, exposing the plate to light from the side of the positive for photoprinting, developing the resulting plate to produce a printing plate, and using this plate to make a proof for gravure proofing and correction.
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[0001] This application claims the benefit of U.S. Provisional Application No. 61/103,998, filed Oct. 9, 2008. The entire content of this application is incorporated by reference herein.
[0002] The present invention relates to cultured cell lines that have been transfected with adenoviral expression vectors so that they express one or more functional cytochrome P450 enzymes and optionally a reporter gene, the invention includes inter alia methods of producing the cells, products and methods of their use, especially in toxicology screens.
BACKGROUND
[0003] Cell lines currently used for toxicity testing have limited utility because they lack the ability to metabolise the drug or chemical, which overlooks the generation of a more toxic metabolite. Alternatives to animal experimentation for toxicity in drug development need to provide greater reliability in predicting human toxicity. Use of cell lines for prediction of drug metabolism or toxicity in a human subject is limited by the fact that cell lines currently available have lost differentiated cell functions and do not reproduce the characteristics of organs, such as the liver, where toxic effects are most often seen. In particular, most available human cell lines fail to express the cytochrome P450 enzymes (which determine the metabolism and toxicity of many drugs and chemicals) at levels comparable to those found in intact tissues. The cytochromes P450 (P450s), a family of enzymes catalysing oxidation of a great number of xenobiotic chemicals, are usually absent or expressed at only low levels in cultured cells. Moreover, metabolism of xenobiotics can either increase the toxicity through generation of more toxic metabolites, or abrogate the toxic effects through rapid metabolism of the toxin. Existing cell lines therefore do not replicate the influence of cellular metabolism on the toxic effects of chemicals and cannot be taken to be reliable indicators of compound metabolism and toxicity in vivo. To overcome the limitations of cultured cell lines, P450 metabolism needs to be reintroduced. It will generally be desirable to express several P450s and also in many cases cytochrome P450 reductase (CPR) since P450 enzymes are themselves not metabolically active without appropriate reductase activity being present. Cell lines which could be engineered so that they had the ability to metabolise a drug or chemical would offer immediate improvements to the art.
[0004] In general, restoration of P450 metabolism requires expression of P450 and CPR transgenes simultaneously at appropriate levels. Many methods have been developed to introduce functioning transgenes into cells. However, when attempting to restore P450 metabolism by expressing several transgenes, the problem remains of obtaining cells in which all transgenes are expressed simultaneously and at the desired levels.
[0005] A number of strategies have been developed to express multiple genes, including internal promoters, fusion proteins and internal ribosomal entry site (IRES). The most commonly used strategy in the construction of two gene vectors is the insertion of an IRES element between the two genes. These two genes are transcribed under the control of a single promoter within the vector. However, a disadvantage of this system is that a gene transcribed upstream of an IRES is expressed strongly whereas a gene placed downstream is expressed at lower levels.
[0006] A method of restoring the cellular levels of key metabolic enzymes would therefore be valuable in improving the ability of cultured cell lines to predict the in vivo metabolism and toxicity of applied chemicals.
[0007] The present invention provides a novel method of restoring the functions of xenobiotic metabolism in cultured cell lines by using an adenoviral-based multiple P450 expression system. This invention advantageously allows the expression of human P450s of choice in a wide variety of mammalian cell lines, thereby replicating any chosen profile of P450-mediated metabolism and providing in vitro prediction of compound metabolism and metabolically activated toxicity.
BRIEF SUMMARY OF THE DISCLOSURE
[0008] According to a first aspect of the invention there is provided a cell derived from a cultured cell line that expresses one or more metabolically active cytochrome P450s, the cell containing an adenovirus expression vector that comprises nucleic acid sequences encoding one or more different cytochrome P450s, the nucleic acid sequences encoding the one or more different cytochrome P450s being positioned in tandem and separated from one another by self-processing cleavage sequences.
[0009] This present invention provides cell lines capable of predicting toxicity of drugs or other chemicals in humans that could be used as a replacement for animals in safety testing. Our approach has been to generate transgenic cell lines that provide good prediction of human toxicity by introducing expression of multiple human P450s into cells carrying “reporter” genes. The reporter genes are artificial transgenes designed to signal early stages of various types of toxicity such as oxidative stress, hypoxia, DNA damage, onset of programmed cell death (apoptosis), inflammation or abnormal cell division. Their ability to reliably predict toxicity of an applied compound often depends on appropriate metabolism of the compound which is assured by the presence of the P450s.
[0010] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises”, means “including but not limited to”, and is not intended to (and does not) exclude other moieties, additives, components, integers or steps.
[0011] Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
[0012] Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.
[0013] Preferably, the cell derived from the cell line is transfected with the adenovirus expression vector. Preferably, the cell is stably transfected with the vector.
[0014] Preferably the cell line is a mammalian cell line and more preferably is a human cell line.
[0015] A “cell line” is cells grown in tissue culture and representing generations of a primary culture. A cell line is a permanently established cell culture that will proliferate indefinitely given appropriate fresh medium and space, cell lines are distinct families of cell types grown in culture and cells in the same line are typically clones. Different cell lines have different features which are useful in molecular biological applications, examples of cell lines that can be used in the present application include but are not limited to the ARE, CHO, MCF-7, HeLa, A2780, HepG2 cell lines.
[0016] Preferably, the cell is a cell that in vivo is associated with having an endogenous P450 function. For example the cell maybe derived from a kidney, brain, lung, heart, skin, liver or placental cell line. More preferably the cell is from a hepatic cell line. In other embodiments of the invention the cell line may be a tumour cell line or maybe a cell line derived from a tissue that is not associated with P450 metabolism.
[0017] The NADPH-dependent cytochrome P450 reductase (CPR) is a membrane bound protein localized in the ER membrane. CPR donates electrons from the two-electron donor NADPH to the heme of P450. A functional requirement for cytochrome P450s to be expressed is that it receives electrons from CPR. Accordingly, in some embodiments of the invention where the cells from the cultured cell line do not have an inherent electron donating CPR capacity the adenoviral expression vector further includes a nucleic acid sequence encoding CPR, the CPR being positioned in tandem with the nucleic acid sequences encoding the one or more different cytochrome P450s and separated therefrom by further self-processing cleavage sequence. Thus preferably, the cell derived from the cell line also expresses a P450 reductase that is either inherent in the cell or is included and added to the adenoviral expression vector. In this way, by either the cell having an inherent CPR or by having one manufactured thereinto, the cell is capable of expressing functional P450 with a metabolic capability. It will be appreciated that some cell lines that already have CPR will be transfected with adenovirus expression vectors that do not have a CPR and associated self processing sequence whilst cell lines deficient of CPR will be transfected with adenovirus expression vectors that do contain a CPR and associated self processing sequence. Accordingly, the transfected expression vector is selected according not only to the cell line but also the type and number of functional P450s which it is desired to express.
[0018] Preferably, the cell derived from a cell line expresses multiple P450s. In embodiments of the invention the cell expresses 2, 3, 4, 5, 6, 7, 8 or more P450s.
[0019] Cytochrome P450 includes the CYP1 family (CYP1A1; CYP1A2; CYP1B1), CYP2 family (CYP2A6; CYP2A13; CYP2B6; CYP2C8; CYP2C9; CYP2C19; CYP2D6; CYP2E1; CYP2F1; CYP2J2; CYP2R1; CYP2S1; CYP2W1), CYP3 family (CYP3A4; CYP3A5; CYP3A7; CYP3A43), CYP4 family (CYP4A11; CYP4A22; CYP4B1; CYP4F2) and CYP>4families (CYP5A1, CYP8A1, CYP19A1, CYP21A2, CYP26A1). The P450S that can be expressed by the cells of the following invention include any one or more of the aforementioned P450s.
[0020] Preferably, the P450s are human P450s. Representative P450 include but are not limited to CYP2D6, CYP2E1, CYP1B1 and CYP3A4.
[0021] Preferably, the expression of each of the P450s is driven by a self-processing cleavage sequence. Thus in embodiments of the invention in which the cell expresses 2, 3, 4, 5, 6, 7, 8 or more P450s the number of self-processing cleavage sequences will be commensurate as each P450 has its own dedicated self-processing cleavage sequence.
[0022] Preferably, the adenovirus expression vector further includes at least one reporter sequence or transgene and an associated self-processing cleavage sequence.
[0023] Preferably, the cell derived from the cell line co-expresses the reporter transgene that is responsive to drug or chemical induced toxicity. For example and without limitation, the reporter transgene comprises regulatory sequences responsive to oxidative stress (haemoxygenase 1 promoter); antioxidant response (ARE); inflammation (NF-kB); cell cycle advance (AP-1); DNA damage (p53); apoptosis (p21/Waf1); hypoxia (HRE) and other cell stress responsive sequences (XRE, Hsp70, GRE). The readout from these reporter genes are either luciferase or CXR's proprietary epitope-tagged β-hCG.
[0024] A “self-processing cleavage site” or “self-processing cleavage sequence” is defined herein as a post-translational or co-translational processing cleavage site sequence. Such a “self-processing cleavage” site or sequence refers to a DNA or amino acid sequence, exemplified herein by a 2A site, sequence or domain or a 2A-like site, sequence or domain. As used herein, a “self-processing peptide” is defined herein as the peptide expression product of the DNA sequence that encodes a self-processing cleavage site or sequence, which upon translation, mediates rapid intramolecular (cis) cleavage of a protein or polypeptide comprising the self-processing cleavage site to yield discrete mature protein or polypeptide products.
[0025] Preferably, the self-processing cleavage sequence is a 2A sequence and is derived from a mammalian virus selected from the group comprising foot and mouth disease virus (FMDV), cardiovirus encephalomyocarditis virus (EMCV), Theiler's murine encephalitis virus (TMEV), equine rhinitis A virus (ERAV), equine rhinitis B virus (ERAV) and porcine teschovirus-1 (PTV-1; formerly porcine enterovirus-1).
[0026] Alternatively, the 2A sequence is derived from an insect virus selected from the group comprising Thoseaasigna virus (TaV), infectious flacherie virus (IFV), Drosophila C virus (DCV), acute bee paralysis virus (ABPV) and cricket paralysis virus (CrPV).
[0027] The adenovirus vectors carry DNA coding sequences for the P450s of choice and optionally P450 reductase if required in tandem, each component being separated by a dedicated 2A sequence. In some embodiments the adenovirus vectors further include a reporter transgene and dedicated 2A sequence so that the reporter transgene can be co-expressed with the P450s.
[0028] The major challenge addressed by the present invention has been to achieve co-expression of multiple P450s in cultured cells. Previously, this might have required many time-consuming transfection and cloning operations. In the present invention an innovative strategy has been developed to allow expression of multiple P450s in almost any cell line of interest. This exploits the availability of adenovirus vectors for transient expression of transgenes in cell lines and the properties of the 2A peptide sequence coded by the Foot and Mouth Disease Virus which causes a break in peptide chains produced during gene translation. Combined, these two features allow the simultaneous expression of multiple proteins from a single viral gene transfer.
[0029] According to a further aspect of the invention there is provided a cell from a cultured cell line that expresses one or more metabolically active cytochrome P450s, the cell comprising an adenovirus expression vector and one or more nucleic acid sequences encoding cytochrome P450s selected from the CYP1, CYP2, CYP3, CYP4 and CYP>4 families each selected cytochrome P450 being positioned in tandem with interposed 2A self processing sequences separating them and wherein the cell has a CPR function that is either inherent to the cell line or is provided by a nucleic acid sequence encoding CPR and 2A self-processing sequence.
[0030] Preferably, the cell is a human hepatocyte and preferably the expressed functional P450s are human P450s. In this way human metabolism in human cells in vitro may be assessed.
[0031] According to a yet further aspect of the invention there is provided a method of producing the cells of the first aspect of the invention, the method comprising stably transfecting a cell derived from a cultured cell line with an adenovirus expression vector that comprises nucleic acid sequences encoding one or more different cytochrome P450s, the nucleic acid sequences encoding the one or more different cytochrome P450s being positioned in tandem and separated from one another by self-processing cleavage sequences, the vector optionally further including a nucleic acid sequence encoding CPR, the CPR being positioned in tandem with the nucleic acid sequences encoding the one or more different cytochrome P450s and separated therefrom by further self-processing cleavage sequence.
[0032] According to a yet further aspect of the invention there is provided use of the cells derived from a cell line as herein before described, as models for drug metabolism and/or for screening candidate compounds for toxic effects via metabolic activation. A drug or candidate compound can be any compound, agent, or molecule that is known to have or may have a therapeutic, diagnostic or other use when administered to an animal, e.g., a human.
[0033] According to a yet further aspect of the invention there is provided a method of assessing human P450 metabolism of a candidate therapeutic or other compound in vitro in a cell, comprising exposing the cell of the first aspect of the invention to the candidate therapeutic or other compound and measuring metabolite production.
[0034] According to a yet further aspect of the invention there is provided a method of assessing potential toxicity of a candidate therapeutic or other compound in vitro as a result of human P450 metabolism of the candidate therapeutic, comprising exposing the cell of the first aspect of the invention to the candidate therapeutic or other compound and measuring cytotoxic effects.
[0035] In the embodiment of the invention where the adenovirus expression vector further includes a reporter transgene the expression of the transgene products may be used as an indicator of the metabolic status and/or cytotoxicity.
[0036] It will be appreciated that the methods of the present invention advantageously improve the relevance of in vitro studies of screens to human metabolism.
[0037] Preferred features ascribed to each and every aspect of the invention apply mutatis mutandis to each and every aspect of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 shows the strategy for construction of bicistronic adenoviral vectors. FIG. 1A shows the modification of FMDV 2A (F2A) sequence (SEQ ID NOS: 1 and 2) and FIG. 1B shows the bicistronic construct.
[0039] FIG. 2 shows constructs used to generate recombinant adenoviruses which were then infected into the developed reporter cells individually or in a group of different P450s to express various combinations of P450s and reporters in cultured cells.
[0040] FIG. 3 shows expression of multiple P450s and P450 reductase in CHO cells by immunoblotting. Each lane was loaded with 30 μg total cell lysate protein from cells infected with: (1) adenovirus only; (2) CYP2D6(His)CPR fusion vector; (3) CYP2A6.F2A.CPR vector; (4) CYP2A6.F2A.CYP1A1; (5) CYP3A4. F2A.CPR; (6) CYP3A4.F2A.CPR+CYP2D6(His)CPR fusion; (7) CYP3A4.F2A.CPR+CYP2A6. F2A.CYP 1 A1; (8) CYP3A4.F2A.CPR+CYP2A6.F2A.CYP1A1+CYP2D6(His) CPR fusion; (9) 10 μg mouse liver microsomal protein
[0041] FIG. 4 shows ARE induction by viral transduction and BaP.
[0042] FIG. 5 shows ARE induction in MCF-7/ARE cells infected with P450s.
[0043] FIG. 6 shows adenovirus-mediated co-expression of human CYP3A4 and CPR in CHO cells.
[0044] FIG. 7 shows human CYP3A4 activity in transduced CHO cells. Adenovirus was transduced into CHO cells and enzyme activity was measured 2 days after transduction. Activity is shown in pmol/min/10 6 cells.
[0045] FIG. 8 shows induction of ARE by viral transduction and antioxidants.
[0046] FIG. 9 shows cytotoxicity of acetaminophen (APAP) and tamoxifen in human hepatocytes expressing CYP3A4.
[0047] FIG. 10 shows ATP assay for acetaminophen (APAP) in viral-transduced HepG2 cells.
[0048] FIG. 11 shows ATP assay for tamoxifen in viral-transduced HepG2 cells.
DETAILED DESCRIPTION
Chemicals and Cell Culture
[0049] Unless otherwise stated, all chemicals and all media supplements for cell culture were purchased from Sigma-Aldrich Co. Ltd. (Dorset, United Kingdom). HepG2 (human hepatoblastoma), MCF7 (human breast carcinoma), and Chinese hamster ovarian carcinoma (CHO) cell lines were purchased from ECACC. The growth medium for MCF7 and HepG2 cells was DMEM supplemented with 10% fetal bovine serum and antibiotics. The growth medium for CHO cells was RPM-1640. All cells were cultured at 37′C in 5% CO 2 , and passaged every 3 to 4 days.
Bicistronic Expression Constructs
[0050] Plasmid pET32hCGZsGreen Final is already available and contains a cassette of hCG-F2A-ZsGreen. This cassette was cut off from plasmid pET32hCGZsGreen Final by using restriction enzymes KpnI/PmeI and generated 2 kb fragment was inserted into KpnI/EcoRV double digested vector pcDNA3 to construct plasmid pcDNA/hCG-ZsGreen. The F2A sequence was cut off from plasmid pcDNA/hCG-ZsGreen by BamHI/EcoRI digestions and the generated 0.37 kb fragment was cloned into BamHI/EcoRI sites in plasmid pUC18. The F2A was modified by site directed mutagenesis to remove an internal ApaI site 60 base pairs upstream 5′-end of F2A sequence with oligo pair P56F/R, and then a XhoI site was introduced upstream of first codon of F2A (oligos P53F/R). This plasmid was named as pUC18/F2A, and was ready to be cut off for cloning ( FIG. 1A ). CPR cDNA was cut off from plasmid pcDNA/HR with enzymes KpnI/XbaI, the 2 kb fragment was cloned into the KpnI/XbaI sites of pUC18. Then the 5′-half of CPR (from ATG start codon to 50 base pairs downstream the PmII site) was amplified by PCR with primers P52F/P52R. The primer P52F contains an ApaI site upstream of ATG codon of CPR and the ApaI site was introduced into the predicted product (1.0 kb) of PCR. After being separated by electrophoresis on an agarose gel, the DNA fragment was extracted from the agarose gel, and then cloned into vector pCR2.1-TOPO by using TOPO TA Cloning kit (Invitrogen Corp. Cat. no. K4575-01) to generate a plasmid pCR2.1/5′-half CPR. The 1.0 kb fragment of 5′-half CPR was cut off from the plasmid pCR2.1/5′-half CPR by ApaI/HindIII and inserted into the ApaI/HindIII sites of pUC/F2A to generate the plasmid pUC18/F2A-5′-Half CPR ( FIG. 1B ).
[0051] The CYP1A1 and CYP2A6 cDNAs used were obtained as Image Clones 5123393 and 40006068 respectively and were sequenced to confirm no mutation in the sequence.
[0052] Adenovirus Production. The recombinant adenoviral constructs containing bicistronic P450 coding sequences or containing a fused P450-CPR and a control pShuttle/CMV were linearized with PmeI and were transformed into BJ5183-AD-1 cells. The recombinant adenoviral constructs were identified by PacI digestion. Adenoviruses were produced by transfection of PacI digested adenoviral constructs into AD-293 cells. The recombinant adenovirus and the control virus Ad-mock were amplified in Ad293 cells to generate stocks of adenovirus according to the Manufacture's protocols (ViralPower Adenoviral Expression System, Invitrogen). The titer of each viral stock was determined by plaque assay (AdEasy XL Adenoviral Vector System, Instruction Manual, Stratagene) or immunology assay (AdEasy Viral Titer Kit, Instruction Manual, Stratagene). Titers of the stocks were at the range of 1×10 8 to 1×10 9 plaque-forming units (pfu)/ml or infection units (ifu)/ml.
Adenoviral Transduction and Effects on Luciferase Reporter Activity in ARE32 Cells
[0053] ARE32 cells were seeded in 24-well plates at 2×10 5 cells per well and cultured overnight. Cells were transduced for 2 h with up to three Adeno-P450s at MOI value of 27 pfu/cell in 0.5 ml of culture medium, after which the medium was removed and replaced with fresh medium. Cells were incubated for an additional 48 h and then were treated with chemicals in serum-free medium for 1 day. Then cells were harvested and lysed. The Luciferase Reporter Assay System (Promega) was used to examine reporter gene activity in cell lysates.
CYP3A4 and CYP2D6 Activity Assays—Midazolam and Bufuralol Hydroxylation
[0054] Samples were analyzed by LC-MS/MS for 1-OH-bufuralol and 1-OH-midazolam using a CTC PAL autosampler, an Agilent 1100 pump and a PE Sciex API 3000 mass spectrometer. An electro spray was used as the ionization source. An Agilent Zorbax SB-C18 column (2.1×50 mm, 5 μm) was used for the separation. The chromatography was performed with a mobile phase A (CH 3 OH:1 M CH 3 COONH 4 :HCOOH:H 2 O, 50:2:0.755:950 v/v/v/v) and mobile phase B (CH 3 OH:1 M CH 3 COONH 4 :HCOOH:H 2 O, 900:2:0.755:100 v/v/v/v) using a linear gradient from 0 to 100% B in 3 min, at 100% B until 3.1 min and from 3.1-3.5 min back to 100% A with a flow-rate of 0.3 ml/min. The column temperature was maintained at 60° C. LOQs were determined relative to baseline noise (S/N=10).
Cytochrome P450 Reductase Activity Assay—Cytochrome C Reduction
[0055] Activity of CPR was assayed under aerobic conditions at 37° C. in 1 mL incubation mixtures containing 0.3 M potassium phosphate (pH 7.7), 50 μM cytochrome c, and total cellular protein (10 μg). Reactions were initiated by the addition of 10 μL 5 mM NADPH, and the rate of cytochrome c reduction was determined spectrophotometrically at 550 nm based on extinction coefficient for cytochrome C ε=21.4 mM cm −1 . The rate of the enzyme-catalyzed reaction was determined by subtracting the rate of the reaction occurring in the absence of protein. Product formation was linear with respect to protein concentration and incubation time.
CYP2A6 Activity Assay—Coumarin 7-Hydroxylation
[0056] Coumarin (50 μM) was added into the adenoviral transducted HepG2 cells in 24-well plate with 4×10 5 cells in 0.5 ml medium and incubated with cells for 4 hrs. Then 25 μL of the medium were mixed with 75 μL of H 2 O and 5 μl of 1M Tris (pH 9.0). The fluorescence was measured in 96-well plates by using ELISA reader (Fusion, Packard) with excitation at 365 nm and emission at 460 nm (bandwidth of 40 nm). All assays were performed in duplicate, and eight concentrations of 7-Hydroxycoumarin (0 to 100 pmol/well) were included to construct a standard curve. Activity of CYP2A6 is expressed as picomoles of 7-Hydroxycoumarin formed per minute, per 10 6 cells or mg protein (pmol/min/10 6 cells or pmol/min/mg protein).
CYP1A1 Activity Assay—Ethoxyresorufin Deethoxylation
[0057] Ethoxyresorufin (5 μM) and salicylamide (3 mM) were added into the adenoviral transducted HepG2 cells in 24-well plate with 4×10 5 cells in 0.5 ml medium and incubated with cells for 4 hrs. Then 25 μL of the medium were mixed with 75 μL of H 2 O. The fluorescence (in 100 μL) was measured by using ELISA reader (Fusion, Packard), with excitation at 530 nm and emission at 590 nm. All assays were performed in duplicate, and seven concentrations of resorufin (0 to 32 pmol/well) were included to construct a standard curve. Activity of CYP1A1 is expressed as picomoles of resorufin formed per minute, per 10 6 cells or mg protein (pmol/min/10 6 cells or pmol/min/mg protein).
Immuno Blot Assay of CPR and CYP Protein Expression
[0058] Polyclonal antibody raised in sheep against human CYP3A4 (NF14) and CYP2D6; rabbit anti-CPR were obtained from Biomedical Research Centre, Dundee University, UK. Polyclonal antibody raised in rabbit against human CYP1A1 and CYP2A6 were from CXR Biosciences Ltd. Dundee, UK. Horseradish peroxidase (HRP) conjugated ECL anti-rabbit and anti-sheep antibodies were purchased from GE Healthcare, UK limited (Little Chalfont Buckinghamshire, UK). For the whole-cell extracts, cells were harvested by cell lifter and lysed in lysis buffer containing 10 mM sodium phosphate (pH 8.0), MgCl 2 (2 mM), EDTA (1 mM) and dithiothreitol (2 mM). Cells were lysed by sonication using an MSE Soniprep (two 5 second bursts at amplitude microns of 12 with sample kept on ice). Protein concentrations were determined using a commercially available protein assay kit (DC Protein Assay, Bio-Rad). Total cellular proteins were separated on a 10% SDS-polyacrylamide gel and electroblotted onto nitrocellulose membranes and probed with primary antibody. Antibody binding was visualized on X-ray film by enhanced chemiluminescence using the ECL kit from Amersham Pharmacia Biotech.
[0059] Recombinant adenoviral vectors containing FMDA 2A peptide conferring efficient bicistronic gene expression in cultured cells were generated. FIG. 1 shows an example of the structure of an expression construct and FIG. 2 shows a variety of constructs utilised for multiple P450s and P450 reductase expression.
EXAMPLE 1
[0060] Next we explored the possibility of co-expression of multiple P450s and CPR by co-transduction with the multiple recombinant adenoviruses. Adenovirus vectors were generated carrying DNA coding sequences for the P450s of choice and cytochrome P450 reductase (CPR) in tandem, separated by 2A sequences. Altogether, six recombinant adenoviruses were generated expressing CPR and different P450s with up to three P450 genes in one adenovirus. An adenovirus containing CYP2A6 and CYP1A1 (Ad2A6.F2A.1A1) and an adenovirus containing a fused gene of CYP2D6 and CPR (Ad2D6(His)CPR) were generated. Three recombinant adenoviruses at total MOI value of 27 were used to transduce CHO cells and successfully achieved co-expression of up to four P450s (CYP3A4, CYP2D6, CYP2A6, & CYP1A1) together with CPR ( FIG. 3 ). By infecting cell lines with multiple adenoviruses, we were able to achieve high levels of simultaneous expression of up to four P450s (CYP3A4, CYP2D6, CYP2A6 and CYP1A1) ( FIG. 3 ). P450 transgene function was confirmed by immunoblot analysis of cell lysates. Immunoreactive bands corresponding to CPR and each of the P450s demonstrated that adenovirus infection did indeed result in expression of each of the desired proteins. Results therefore confirmed co-expression of multiple P450s and CPR in cells.
EXAMPLE 2
[0061] In cell line ARE32, the antioxidant responsive element (ARE), activated by Nrf2, is used to drive a luciferase gene as reporter. A functional ARE is found in the 5′ flanking region of genes encoding NQO1, multiple GST isozymes and many other anticarcinogenic/antioxidant genes. Induction of these genes confers cytoprotection against carcinogenesis and acts to minimize the effects of the toxic insult. Therefore, measurement of ARE induction provides useful information into the particular mechanism of toxicity. We tested whether multiple P450s and P450 reductase were capable of expression in ARE32 cells. Table 1 shows the levels of P450 activity obtained in transduced ARE32 cells, indicating that up to four P450s and CPR were introduced and expressed in cells. ARE32 control values are from ARE32 cells without virus infection. ARE32 Transduced values are from ARE32 cells infected with three viruses: Ad3A4.F2A.CPR; Ad2D6(His)CPR; and Ad2A6.F2A.1A1 at a total MOI value of 27.
[0000]
TABLE 1
ARE32
ARE32
Enzyme activity
Control
Transduced
CPR: cytochrome c reduction (nmol/min ·
23.1
79.1
mg protein)
CYP3A4: 1′-hydroxymidazolam formation
0.1
4.4
(pmol/min/mg protein)
CYP2D6: 1′-hydroxybufuralol formation
0
16.2
(pmol/min/mg protein)
CYP2A6: 7′-hydroxycoumarin formation
0
58.2 ± 1.5
(pmol/min/10 6 cells)
CYP1A1: Resorufin formation (pmol/min/10 6
0
73.7 ± 0.9
cells)
[0062] Benzo(a)pyrene (BaP), a carcinogen found in coal tar, diesel exhaust fumes and charred food. It is toxic after metabolic activation by CYP1A1. We tested the effects of transduced CYP expression on ARE induction following application of BaP. P450s were introduced into the ARE reporter cells as indicated in FIG. 4 , and then the cells were exposed to BaP (4 μM). Results showed that BaP treatment provoked a strong induction of ARE (>20-fold) in cells that express both human CYP1A1 and CYP2A6 cDNAs, but showed no induction in cells expressing CYP3A4 and CYP2D6.
[0063] Infection of MCF-7 human breast cancer cells with the CYP3A4-CPR and CYP2A6-CYP1A1 vectors and the CYP2D6/CPR fusion vector and incubation with appropriate P450 substrates in the culture medium for one hour resulted in substantial rates of metabolism of the substrate compounds compared to little or no metabolism in uninfected MCF-7 cells. We believe that this is the first time that cell lines simultaneously expressing high levels of multiple human P450s has been achieved. Accordingly results show that a model has been generated for testing chemical metabolism and the toxic effects of inter-mediated metabolites simultaneously.
EXAMPLE 3
[0064] Toxic responses are complex, but in their early stages are often associated with increased expression of ‘stress induced’ genes. Artificial reporter genes whose expression is under the control of regulatory DNA elements associated with such ‘stress induced’ genes can therefore be used as ‘engineered biomarkers’ of developing toxic responses. Reporter genes can be designed to act as biomarkers of a variety of cellular stress responses associated with early stages of toxicity. These include regulatory sequences responsive to oxidative stress (haemoxygenase 1 promoter); antioxidant response (ARE); inflammation (NF-kB); cell cycle advance (AP-1); DNA damage (p53); apoptosis (p21/Waf1); hypoxia (HRE) and other cell stress responsive sequences (XRE, Hsp70, GRE). The readout from these reporter genes are either luciferase or CXR's proprietary epitope-tagged β-hCG.
[0065] P450-mediated metabolism of chemicals can either increase or decrease their toxicity through generation of more toxic metabolites or metabolism of the toxic compounds respectively. To establish the importance of co-expressed P450s in determining toxicity reporter responses, we compared the effects of various compounds on reporter gene expression with various co-expressed P450s.
[0066] First, we examined the effects of benzo(a)pyrene (BaP), a highly toxic carcinogen, on expression of a reporter gene consisting of the antioxidant response element (ARE) driving expression of a luciferase readout gene in MCF-7 cells. BaP provoked a more than 20-fold induction of the reporter gene in cells expressing both human CYP1A1 and CYP2A6, but showed no induction in cells expressing CYP3A4 or CYP2D6.
[0067] In further experiments, we examined induction of the ARE reporter in MCF-7 cells expressing CYP3A4 and CPR, CYP2A6 and CPR, CYP2D6 and CPR or CYP2A6 and CYP1A1 by either butylated hydroxyanisole, an antioxidant widely used as a food preservative (BHA-20 μM) or 7-ethoxycoumarin, an antioxidant (7-E-100 μM). We found that treatment with either compound provoked a more than 32-fold induction of the reporter in cells that express human CYP1A1 and CYP2A6, but that little or no induction was present in control cells or in the presence of CYP3A4 or CYP2D6.
[0068] With reference to FIG. 5 , expression of the luciferase reporter readout is evaluated in comparison to control MCF-7/ARE cells not expressing P450 transgenes (first bar=1).
EXAMPLE 4
[0069] In order to achieve a high level of P450 activity the appropriate amount of adenoviruses used for transducing cells should be optimised to give ˜100% of transduction. However, the amount of adenovirus cell surface receptors varies greatly among different cell types. If too much virus is used, it will cause cytotoxicity or other undesired effects in cells. Therefore, we first tested the optimal multiplicity of infection (MOI) value in CHO cells. In the experiment shown in FIG. 6 , CHO cells were transduced with Ad3A4.F2A.CPR at MOI values of 8, 15 and 38 pfu/cell and adenovirus Ad3A4(His)CPR, which generates a fused CYP3A4(His)CPR protein (˜120 Kda), used as a control. After additional 60 h incubation, the level of P450 protein in transduced cells were determined by Western blot analysis and results showed that fusion adenovirus produced a fused CYP3A4(His)CPR protein of ˜120 KDa and the bicistronic construct (Ad3A4.F2A.CPR) produced two processing products corresponding to the individual ‘cleaved’ proteins CYP3A4-F2A and CPR. There was no uncleaved CYP3A4-2A-CPR protein found in the cell lysate. 1′-hydroxylation of midazolam in transduced CHO cells was also measured ( FIG. 7 ). Results indicated that addition of the 2A peptide to CYP3A4 protein did not affect the function of CYP3A4 and enzyme activity of CYP3A4 was gradually elevated with the increase of MOI value. Results confirm that FMDV 2A peptide confers efficient bicistronic gene expression and cleavage in cultured cells.
EXAMPLE 5
[0070] Butylated hydroxyanisole (BHA) is an antioxidant used as a food additive (E320). We tested whether BHA and 7-ethoxycoumarin were capable of inducing ARE reporter activity in these cells because it is necessary for them to be metabolized by P450s into compounds that induce ARE-driven gene promoters. For example, BHA is O-demethylated by cytochrome P450 to yield tert-butylhydroquinone which is a more potent inducer of ARE than BHA. We examined induction of the ARE reporter in ARE32 cells expressing CYP3A4 and CPR, CYP2A6 and CPR, CYP2D6 and CPR or CYP2A6 and CYP1A1 by either butylated hydroxyanisole (BHA) at 20 μM or 7-ethoxycoumarin (7-EC) at 100 μM ( FIG. 8 ). Significant ARE reporter induction was seen with CYP2A6 but not with CYP3A4 or CYP2D6. Greatest induction (>35-fold) was seen when CYP2A6 was co-expressed with CYP1A1. Results show that induction of ARE by P450-dependent metabolites of butylated hydroxyanisole & 7-ethoxycoumarin.
EXAMPLE 6
[0071] This study aimed to evaluate the adenovirus-mediated expression of CYP3A4 and to test the toxicity of two compounds (acetaminophen and tamoxifen) and their CYP3A4-dependent metabolites in HepG2 cells. CYP3A4 and P450 reductase were delivered into HepG2 cells (Hep-3A4) by adenoviral transduction at Multiplicity of Infection (MOI)=8. Data confirmed that CYP3A4 was active. The adenovirus Ad-mock was used to transduce HepG2 cells at MOI=8 as control (Hep-mock). CYP3A4 activity was determined and compared in Hep-3A4 cells and cryopreserved human hepatocytes. The level of activity (1′-Hydroxylation of midazolam) in Hep-3A4 cells was ˜30-40% of those in cryopreserved human hepatocytes. The level of activity observed in Hep-3A4 cells compared to human hepatocytes is within the normal population range.
[0000]
TABLE 2
P450 Activities in Hep-3A4, Human Hepatocytes and HepG2 cells
CYP3A4 Activity
Cells
1′-Hydroxymidazolam
4′-Hydroxymidazolam
HepG2
<Detection Limit
<Detection Limit
Hep-3A4
1.99 ± 0.23
0.37 ± 0.05
(MOI = 8)
pmol/min/mg protein
pmol/min/mg protein
1.45 ± 0.06
0.27 ± 0.02
pmol/min/10 6 cells
pmol/min/10 6 cells
Cryopreserved Human
4.59 ± 0.55
0.36 ± 0.06
Hepatocytes
pmol/min/mg protein
pmol/min/mg protein
4.64 ± 0.08
0.37 ± 0.02
pmol/min/10 6 cells
pmol/min/10 6 cells
[0072] The cytotoxicities of acetaminophen and tamoxifen were determined by the ATP depletion assay. A dose-dependent decrease in cell viability was observed following treatment with the Test Items in adenoviral transduced HepG2 cells (Hep-3A4 and Hep-mock) and cryopreserved human hepatocytes ( FIG. 9 ). CYP3A4-related toxic activation of acetaminophen was observed at concentration of 10 mM ( FIG. 10 ). Depletion of glutathione by simultaneously exposing the cells to 100 μM of BSO resulted in a significant sensitisation of both Hep-3A4 and Hep-mock cells to acetaminophen, shifting the concentration-response to the left such that there was no apparent additional CYP3A4 related cytotoxic effect observed at the concentrations used. P450-related toxic activation of tamoxifen was not observed in this study ( FIG. 11 ). Depletion of glutathione by pre-treatment with BSO had no effect on the cytotoxicity of tamoxifen in either Hep-3A4 or Hep-mock cells. This suggests that tamoxifen cytotoxicity is not P450-dependent.
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The present invention provides cell lines that have been transfected with adenovirus expression vectors so that they express at least one metabolically competent or functional cytochrome P450 enzyme. The invention also includes methods of their use, especially in toxicology screens.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of co-pending application Ser. No. 370,664, filed Apr. 22, 1982, and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of fireproof coverings for protecting heat-sensitive parts, and in particular, to protecting electrical cables, supporting means and the like in potentially dangerous environments such as found in petro-chemical plants.
2. Prior Art
Most electrical cables are now insulated with a plastics material. Most of the plastics materials used for cable coverings are heat-sensitive, readily flammable materials. Therefore, numerous proposals for making cables fireproof have been made. Thus, for example, it has been proposed to apply a self-quenching fireproofing agent to such cables, for example that known from German Pat. No. 2,039,969, corresponding to U.S. Pat. No. 3,642,531. However, this process is relatively complicated and costly, particularly in those cases where several juxtaposed cables must be protected against fire risks.
U.S. Pat. No. 4,064,359 discloses soft, flexible mats made of fiberglass, which possesses a relatively low heat resistance, for wrapping directly around pipes. By contrast, a coating on the flexible mat possesses a higher heat resistance. In other words, a coating containing high-melting fibers is used to compensate for the technically deficient fire-proof characteristics of fiberglass mats. The invention herein uses a similar coating, but in conjunction with rigid mineral wool panels made from hard, massive, relatively heavy, molded mineral fiber sheets. The fiber sheets are made of a hot-melting fiber material and have a much higher resistance to fire than fiberglass. The coating also improves resistance to chemical damage, impact damage and weatherproofing. However, the coating has yet another function, in that it sinters at temperatures between 700° C. and 900° C. (1290° F. and 1650° F.) and thereby provides a mechanical reinforcement of fiber structure at the surface of the mineral wool panels, the coating forming a substitute for the organic binder of the panels which decomposes when heated. Moreover, the sintered coating tends to be smoke-tight. Therefore, such a coating offers additional fire protection because it prevents or at least retards disintegration (dimmunition of volume, leaks at joints and a tendency to crumble) of the binding agent as it decomposes at temperatures above 300° C. U.S. Pat. No. 4,064,359 mentions that the glass may be mixed with a suitable molding resin to form specific shapes. It also mentions that maximum fire protection properties are obtained when the inner layer is made up entirely of glass. Apart from this general statement, which is not further elaborated or supported, the disclosure does not contain even further hints regarding the mechanical and heat resistance properties of such molded fiberglass parts.
In German Utility Model No. 73 17 104 a panel element for sealing openings in walls and ceilings is disclosed. The panel elements are made of a fiber sheet, about 3 cm. to 6 cm. thick, made of mineral wool or glass fibers, and containing a resinous binder which vaporizes at about 200° C. The panel elements are coated on both sides with a fire resistant coating. The composition of the coating can be compared with that of U.S. Pat. No. 4,064,359. No data is supplied in the Utility Model regarding the mechanical properties of the panel elements. The panel elements are not intended for forming channels for electrical ducts, but only for closing the openings.
A cable covering with a duct-like protective sheath has been proposed, which comprises two sheet steel layers, the gap between which is filled with mineral wool. However, in order to prevent corrosion in the construction of such protective sheaths, it is necessary to use stainless steel layers, or at least galvanized steel, which is expensive. In addition, metal protective sheaths require retaining devices as a result of their own weight. Such devices are relatively complicated and cannot always be properly fitted.
SUMMARY OF THE INVENTION
The object of this invention is to provide a fireproof covering, which is less expensive to manufacture and easier to fit and install, but which nevertheless protects against fire, weathering, chemical attach and mechanical impact.
According to the invention, this object is achieved by a fireproof covering comprising rigid mineral wool components with a fireproof coating, at least on the outside. Suitable mineral wool has a high softening point. Suitable examples include rock wool made from a basalt/dolomite melt or a basalt/limestone melt as well as slag wool and/or ceramic wool. The fireproof coating can advantageously be formed from an inflammable or not readily flammable fireproofing agent, which is highly resistant to weathering, chemical damage and degradation and mechanical impact. A suitable fireproof coating is disclosed in German Pat. No. 2,039,969, corresponding to U.S. Pat. No. 3,642,531, the teachings of which are incorporated herein by reference.
A fireproof covering according to this invention can be adapted to the conditions prevailing on-site, because it comprises self-supporting components requiring no separate supporting framework. Although the necessary protection is not provided by either mineral wool alone or by a fireproof coating alone, quite surprisingly, it has been found that there is a special interaction between the two components which leads to the protection necessary against high temperatures, even if the mineral wool and/or fireproof coating contains a certain percentage of organic binders, which decompose in a fire. As the temperature rise in the case of a fire is a dynamic process, it is not absolutely necessary for the covering to withstand the highest temperatures, which can be in the range of 1,000° C. It is in fact a question of delaying the heat penetration to such an extent that for the necessary time, the electrical cables or other structure disposed inside of the covering remain operative.
In the case of a fire, the mineral wool is protected by the fireproof coating. Due to its relatively high thermal conductivity, the fireproof coating more particularly compensates for local temperature differences, as well as for any inhomogeneities of the mineral wool boards or plates. In addition, heat convection through the mineral wool is prevented by the blocking fireproof coating. Surprisingly, it has been found that the mineral wool is in a position to serve as an adequately stable supporting structure for the prior fireproof coating even in the case of the binder of the coating decomposing, leading to a reduction in the mechanical stability thereof. Detailed research has not yet been conducted on the interaction, but tests under correspondingly severe conditions have revealed this reciprical assisting action between the mineral wool and the coating as the latter sinters on the surface of the panels.
Without great technical expenditure and effort, such a fireproof coating makes it possible for the cables therein to retain their operating characteristics at least until the signals for operating the safety devices, for example, safety valves, have been transmitted.
Preferably, at least some of the mineral wool components of the fireproof covering according to the invention are curved or bent in at least one direction, which largely obviates the sealing problems occurring in the case of plate-like components disposed at an angle to one another. Thus, a fireproof covering according to the invention can comprise, for example, at least two, preferably four cross-sectionally, substantially L-shaped or at least one, preferably two cross-sectionally, substantially U-shaped mineral wool components in which the object to be protected from thermal damage is placed or with which the object is covered. Such objects can include, for example, cables, supply pipes and supports. In fact, such fireproof coverings can surround almost any space in which lines are to be placed which must be protected from thermal damage.
The mineral wool components of the fireproof covering according to the invention are preferably extruded or molded parts, which are preferably molded prior to the final setting of the binder. The mineral wool components are preferably compressed in the connecting area. A stepped profile is advantageously formed. The latter more particularly applies in the case of longitudinally directed connecting areas.
The mineral wool components of the fireproof covering according to the invention are preferably impermeable, for example with respect to liquids, and in particular with respect to gases. For this purpose, such fireproof coverings preferably incorporate a metal foil layer, which preferably extends substantially over the entire component surface.
According to a preferred embodiment of the fireproof covering according to this invention, the mineral wool components have outwardly bent, flange-like borders extending at least along the longitudinal ledges. The mineral wool components can also have, in plan view, substantially rectangular plates, all of the edges or borders of which are constructed in flange-like manner and bent outwardly. The longitudinal edges are preferably bent at an angle of 45°, so that the individual components can be easily assembled into duct covers of rectangular or square cross-section, in which the flange-like borders of the components engage with one another over a large area, which helps to provide a mutual seal. The edges, which can be connected to the corresponding edge of a further component for extending duct, can be bent by an angle of 90°.
In the case of the fireproof covering according to this invention, angle and/or corner pieces can be provided, which cover the areas adjacent to the covering edges or corners, preferably in a width corresponding to at least double the covering wall thickness, thereby insuring a good seal of the corner areas. At least certain of the components can have a tray and/or trough-like construction for producing covered ducts.
The mineral wool components of the covering according to this invention can, as stated above, incorporate a metal foil layer. However, instead of such a layer, or in addition thereto, the components can have a metal netting reinforcement, preferably arranged in the center or inner path of the wall. Such a metal reinforcement has a double function, namely the stabilization of the covering and increasing the insulating action of the covering, due to the fact that it distributes heat laterally, reducing the effect of local hot spots.
The mineral wool components can have recesses, particularly stamped portions for the mounting and fixing correspondingly shaped fastening and support elements.
The individual mineral wool components are preferably interconnected under contact pressure. Preferably, disks or clips are used, being arranged on either side of interconnected mineral wool components or panels and pressed against the latter by fastening elements such as screws and nuts. The mineral wool components or panels according to this invention are solid, hard, self-supporting structural elements which can not only be glued together, but can also be connected by means of nails, screws and bolts. It is also possible to provide plates or rails, which preferably extend over the entire connecting area and uniformly distribute the contact pressure of interconnected mineral wool components. The connecting areas can be in different planes and can be constructed in labyrinth-like manner.
The aforementioned metal foil preferably extends over the entire covering area of the associated component and is preferable incorporated to the latter prior to the setting of the binder. Preferably, the metal foil does not extend to the edges or borders of the mineral wool components, so that their contact faces and at least the edges and borders on the surface are free from metal foil. This reduces heat conduction through the metal foil to the interior of the duct.
The fireproof covering according to the invention can be in the form of one or several layers, particularly for the covering area. The multi-layer construction is advantageous in several respects. Firstly, the covering can be formed from thinner and consequently more readily deformable individual elements. Secondly, intermediate layers can be provided between the individual mineral wool components. Such an intermediate layer is preferably formed from a thin metal foil. In addition to such a foil, or in place thereof, it is also possible to provide a separate fireproof coating. Thirdly, sealing problems can be significantly reduced by a reciprocal displacement (staggering) of the components adjacent to the connecting areas.
The mineral wool of the components preferably has a bulk density between 200 kg/m 3 and 700 kg/m 3 , preferably between 300 kg/m 3 and 600 kg/m 3 .
The individual layers can be formed by identically shaped mineral wool components, at least in the corner and edge areas. The inner layer preferably has a higher density than the outer layer, so that the covering remains effective even if its outer layer is subjected to high thermal loads.
At temperatures of about 900° C. the mineral wool has a tendency to sinter. However, even at such high temperatures, heat penetration can be prevented for a sufficiently long time if the density of the outer layer is matched to an optimum thermal insulation, while an inner more highly compacted layer fulfills the supporting function. The higher temperatures are then no longer likely to penetrate the inner layer.
The softening point of the mineral wool components is preferably above 900° C. Such components preferably comprise: 42% to 50% by weight of SiO 2 ; 12% to 18% by weight of Al 2 O 3 ; 12% to 20% by weight of CaO; 8% to 15% by weight of MgO; and, 4% to 10% by weight of iron oxides. The average diameter of the mineral wool fibers of the mineral wool components is preferably between 2 μm and 6 μm.
The binder used in producing the mineral wool components is preferably a thermal setting polymer, and in particular, a phenolic or formaldehyde resin. The proportion of binder to mineral wool can be in the range of 1.5% to 8% by weight, and is preferably in the range of 2% to 6% by weight. Suitable binders may be chosen from the group consisting of phenol formaldehyde resin, urea formaldehyde resin and melamine formaldehyde resin.
The fireproof coating can be applied after the final fitting of the mineral wool components. However, it is preferably applied prior to fitting, including the areas of the contacting surfaces. It has proved particularly advantageous to use components provided on their contacting faces with an inflammable or not-readily flammable protective coating, and it is especially advantageous to join them together by an adhesive having such properties. The adhesive coating may comprise: 1% to 25% inorganic incombustible glass fibers; 10% to 50% terpolymer binder; 2% to 20% inert inorganic filling material; 5% to 15% plasticizer; 35% to 70% inorganic flame retarder; and be free of antimony compounds.
The mineral wool components for the assembly of a fireproof covering according to this invention are preferably constructed in such a way that they can be stacked upon one another, preferably without forming gaps, which greatly facilitates their transportation and storage.
The associated flanges of adjacent components preferably have a width which is at least double the wall thickness of the components.
According to a preferred embodiment, a supporting structure is provided, to which the components can be fixed. This supporting structure preferably comprises a plurality of vertically arranged frames, which are fixed to and surround cable troughs. These frames can comprise U-shaped rails and connecting bends are provided for the connection thereof. According to a preferred embodiment, the frames comprise in each case four flat iron straps, interconnected by means of connecting bends connecting the flat iron straps of the individual frames. The flat strap irons and the connecting bends are provided with screw holes, which are preferably in the form of elongated slots. If necessary, the individual frames can be additionally interconnected by rails running parallel to the cable, the rails also being provided with screw holes. The mineral wool boards or plates can be fixed to the supporting structure by retaining members which are inserted through or into the plates and which in each case are associated with a securing member.
According to a preferred embodiment, the mineral wool plates are fixed by means of fastening elements which can be pressed into the end face thereof and screwed to the supporting structure. The fastening elements have in each case two legs, one of which has a terminal tip which can be pressed into a mineral wool plate and the other of which has an elongated slot used for threaded attachment to the supporting structure. The strength of the structure elements is so high that screws can be threaded into the structural elements and fixed therein. A metal screw of 40 mm. in length and 5 mm. in diameter, as is usually used for wood, was screwed into a structural element 30 mm. deep. The screw was inserted parallel to the fiber direction and then loaded with 15 kg. in a pulling test. No changes in the position of the screw in the structural element were apparent during several days of testing with variations in temperature of from approximately +70° C. to -40° C. (+158° F. to - 40° F.). A pulling force of 32 kg. was necessary to remove the screw from the structural element.
Connecting elements can be provided for the purpose of fixing the mineral wool plates together, which elements are anchored in recesses in the plates. These connecting elements can be constructed in a strap or spring-like manner. The connecting elements are preferably made from asbestos cement and can be fixed by an adhesive, such as the self-quenching fireproofing agent disclosed in U.S. Pat. No. 3,642,351.
The protective coating on the mineral wool components preferably consists of a mechanically strong and weatherproof material.
A further embodiment of the invention is a cable duct held by supports. The channel is formed like a through-bore or chute in which cables may be placed. The upper inner structural element is simply placed on the upper edge of the side walls of the duct to insulate the cable duct. The lower inner structural element can be fixed to the upper inner structural element by means of nails. Following this, the upper outer structural element, which is correspondingly larger, can be put in place and the lower outer structural element can be screwed to the upper outer structure element. Thus, no additional supporting elements are necessary. The longitudinal joints of the inner structural elements lie in the corners of the L-shaped cross-section of the outer structural elements and are therefore covered. The cross-sectional joints of the inner structural elements are also covered by the outer structural elements. The cross-sectional joints of the outer structural elements are covered by a sleeve of sheet metal which is provided in two parts, and therefore mechanically strengthens the structure.
Although the structural elements are made of compressed mineral wool, the covering of the cable ducts offers good insulation. It is possible with a one layer covering, with structural elements of 30 mm. thick, that objects in the interior of the ducts can be protected for at least 30 minutes against fire (F30). A double-layered construction will provide protection for objects inside the duct for at least 60 to 90 minutes (F60 to F90). The F values are established according German Norm DIN 4102, which in principle corresponds with ISO R 834 or ASTM E 119.
It is an important advantage of this invention that coverings according to the invention can be retrofitted to existing cable ducts in such a way that no additional support structure is necessary. Duct inserts for supporting cables and the like can also be easily provided.
Preferably at least one molded mineral wool component of the fireproof covering or the fireproof duct has at least one 90° right angle in cross section.
Preferably at least one molded mineral wool component has an L-shaped cross section or a U-shaped cross section. The molded mineral wool components are shaped advantageously from a flat mat of high thickness and low density by compressing under heat to the desired shape, thickness and density. If the fireproof covering or duct consist of more than one layer the different layers are preferably of different thickness and density, whereby layer with the higher thickness has preferably the lower density. The layer with higher density has preferably a density of 400 to 700 kg/m 3 and the layer of lower density has preferably a density of 200 to 400 kg/m 3 . The thickness of the thinner layer is preferably 10 to 15 mm and the thickness of the thicker layer is preferably 30 to 50 mm. At least one part of the layer with lower density is U-shaped or L-shaped in cross section and may be combined with a flat or shaped cover. The parts of the layer of high density may or may not be shaped in cross section.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there are shown in the drawings forms which are presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a perspective view of a portion of a preferred embodiment of a fireproof covering according to this invention.
FIG. 2 is a cross-section through the fireproof covering shown in FIG. 1.
FIGS. 3 to 5 illustrate other embodiments of fireproof coverings according to this invention, in cross-section.
FIGS. 6 to 9 illustrate successive stages for the fitting of a fireproof covering according to this invention.
FIG. 10 illustrates a cutaway portion of the fireproof covering of FIG. 4, shown from the side.
FIG. 11 is a partial perspective view of another embodiment of a fireproof covering according to this invention.
FIG. 12 is a partial perspective view of yet another embodiment of a fireproof covering according to this invention, as equipped with a supporting structure.
FIG. 13 is yet another embodiment of a fireproof covering according to this invention, shown in perspective.
FIG. 14 is a partial perspective view of a portion of a fireproof covering according to this invention illustrating interlocking structure of inner panels.
FIG. 15 illustrates the supporting structure of the fireproof covering shown in FIG. 14.
FIG. 16 illustrates various embodiments of fastening elements used in the assembly shown in FIG. 14.
FIG. 17 illustrates a first assembly stage of the supporting structure shown in FIG. 15.
FIG. 18 illustrates a second assembly stage of the supporting structure shown in FIG. 15.
FIG. 19 is a partial perspective view illustrating the manner in which the cover plate is fixed to the supporting structure.
FIG. 20 is a side elevation of another embodiment of a fireproof covering according to this invention, including duct supports.
FIG. 21 is a section view taken along the line XXI--XXI in FIG. 20.
FIG. 22 is a front elevation of the fireproof covering and support structure shown in FIG. 20.
FIG. 23 is a diagram of the bending strength.
FIG. 24 is a diagram of the tensile strength.
FIG. 25 is a diagram of the depth of indentation with a conus of 90°.
FIG. 26 is a perspective view of another embodiment of the fireproof duct for electrical cables.
FIGS. 27, 27a and 27b show the construction of a curve of the embodiment of FIG. 26.
FIGS. 28, 28a, 28b and 28c show details of the embodiment of FIG. 27.
FIG. 29 shows the construction of the corner of the embodiment of FIG. 26.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention is described through reference to many embodiments of the invention, each of which shares the novel and nonobvious characteristics which distinguish the invention over the prior art. The various embodiments incorporate and illustrate adaptive features, which in many instances, can be advantageously incorporated into many other of the embodiments. It is simply not possible to illustrate each and every adaptive feature in conjunction with each and every embodiment.
A portion of a preferred embodiment of a fireproof covering according to this invention is shown in FIG. 1. The covering has a substantially U-shaped component 1 formed from molded mineral wool material. Component 1 has a downwardly directed side, as the drawing is oriented, with a fireproof coating, and is arranged in such a way that its flange-like borders 2 are located in a horizontal plane. Sidewalls sloping at an angle of approximately 45° are connected onto and pass into a planer base. The base width corresponds essentially to three times the component depth. The flange-like borders 2 have equidistantly facing stamped recesses 3 into which the lateral ends of cable clips can be inserted. These cable clips can in each case be formed from a straight web, but can also have undulating depressions for receiving individual cables. Thus, the cables are carried by the components and are surrounded on all sides by air in duct so formed. A separate supporting structure for the cables is unnecessary.
The trough formed by a plurality of successively arranged components 1 is covered by a plurality of successively arranged components 4, only one of which is shown in FIG. 1 for purposes of facilitating the explanation.
The shape and dimensions of the components 4 correspond to those of the components 1. They are also made from molded mineral wool material and have on their outside, that is, the side directed upwardly in the drawing, a fireproof coating. The borders 5 of components 4 rest on the borders 2 of component 1 and are displaced or staggered with respect to the underlying components in a manner similar to that in which brick walls are constructed. Metal clips 6 having a U-shaped cross-section are provided at the transition points between the components 1 and 4, which are clipped onto the borders 2 and 5. However, in some instances, it has proved advantageous to provide separate fastening elements, for example screws, in place of the clips 6.
FIGS. 3 to 5 illustrate cross-sections through alternative embodiments of fireproof coverings according to this invention, although each essentially corresponds to that shown in FIGS. 1 and 2, in that each comprises successively arranged lower components 1 and upper components 4. In the embodiment of FIG. 3, ledge or strip-like intermediate pieces 7 are disposed between the lower components 1 and the upper components 4, serving as spacers. In the embodiment of FIG. 4, successively arranged components 8 are provided beneath the lower components 2 and tightly engage on the latter and are displaced relative thereto, as may be seen more clearly in FIG. 10. Thus, the fireproof covering of the embodiment of FIG. 4 is in double-layer form in the lower area.
The fireproof coverings shown in FIGS. 3 and 5 are provided with U-shaped rails 9 and fastening screws 10 for fixing the upper components 4 to the lower components 1 and/or 8. The base of each U-shaped rail 9 rests on the edge or border of the component and is preferably longer than the latter, so that they may also be used for simultaneously fixing a plurality of successively arranged components to one another. The rails extend over the entire length of the fireproof duct.
The spacer 7 of the embodiment of FIG. 3 and the components 8 of the embodiment of FIG. 4, each of which is disposed below an upper component 1, are in each case preferably made from a molded mineral wool material, provided at least on the outside with a fireproof coating.
The embodiment of FIG. 9 illustates that the fastening screws can, if desired, also pass through cable clips 11. However, in order to avoid the formation of heat bridges, it is preferable to make the clips 11 shorter, so that they do not come into contact with the fastening screws 10, as illustrated in the embodiment of FIG. 5.
In the embodiment of the fireproof covering shown in FIG. 4, it is possible to provide a separate fireproof coating between components 1 and the underlying components 8. This makes it possible to provide a thin metal foil 21, for example an aluminum foil, between the two component layers. Such a metal foil can also be embedded in components 1, 4 and 8, providing additional reinforcement for the components and additional sealing against gas and liquid penetration.
In each case, the individual components 1, 4 and 8 are preferably profiled in such a way that they can be stacked or nested inside of one another, in the same way as the components 1 and 8 are shown in cross-section in FIG. 4. This considerably facilitates the transportation and storage of such components.
FIGS. 6 to 9 show how a fireproof covering according to this invention can be fitted or installed. FIG. 6 shows a column post 12 onto which a bracket 13 is fixed. A substantially ladder-shaped frame 15, comprising a plurality of individual segments which can be screwed together at their end faces is fixed to the bracket 13 by means of clamps 14. A layer of successively arranged, lower components 1 is placed from above onto frame 15 as shown in FIG. 7. The lower components 1 can have cooperating profiles for mutual sealing purposes. The same also applies with respect to the upper components 4, which can be subsequently placed on the borders 2 of the lower components 1 if loose cabling, that is cabling without cable clips, is desired in the duct formed by the lower components 1 and the overlying components 4. After installing the upper components 4, metal clips 6 may be fitted as shown in FIG. 8. After the metal clips 6 have been fitted, the U-rails 9 may be attached by fastening screws 10. Cables can be laid in prior to the application of the upper components 4, or can be subsequentially drawn through the duct thereafter.
If cable clips 11 are used, as shown in FIG. 9, they must be inserted prior to attachment of the upper components, fitting into the stamped recesses provided in the lower components 1. The individual clips 11 can be interconnected before or after by means of a trough 16, preferably made from sheet metal, into which the cable 17 to be protected may be laid. The troughs are then covered by upper components 4. As can also be seen in FIG. 9, lower rails 9 can be attached by separate screws than those which fix upper rails 9 to the upper components 4. With this arrangement, the upper components 4 can be raised if necessary, without having to disassemble the lower rails 9.
FIG. 10 illustrates the manner in which the individual components 1, 4 and 8 of the embodiment shown in FIG. 4 are preferably arranged in a displaced or staggered manner with respect to one another.
FIG. 11 is a partial perspective view of a fireproof covering comprising four components 18, which like components 1, 4 and 8, can also be rigid and formed from a molded mineral wool material. At least on the outside, the components 18 also have a fireproof coating. Borders of component 18 are bent over outwardly in flange-like manner, so that they tightly engage with the border flange of the adjacent component and can be interconnected by means of clips corresponding to clips 6 and/or U-rails 9. In still another embodiment which is not illustrated in the drawings, but which is structurally analogous to that shown in FIG. 11, the fireproof covering comprises individual components, all of whose border edges are bent outwardly, so that the edges of adjacent succeeding components in the longitudinal direction of the covering engage one another and can be interconnected by means of the clips and/or the U-rails.
Coverings according to this invention can also be used for protecting objects other than cables, particularly constructional components, for example, steel supports, as well as for the protection of hydraulic control and supply lines.
The embodiment shown in FIG. 12 comprises a supporting structure of individual rails 19 and 20, to which the individual components can be fixed. The components comprise two-layered corner, edge and plate-like intermediate pieces.
The embodiment of the fireproof covering shown in FIG. 13 is a protective device for a cable route in which a cable trough 101 is provided for a plurality of juxtaposed cables and which is secured to a support 103 fixed to a wall 102. The protective device comprises a protective cover 104 fixed to vertically directed frames 105, which are in turn fixed to the cable trough 101, preferably by means of screws 106 using intermediate pieces 121.
Each of the frames 105 comprises two horizontally directed rails 107, 108, two vertically directed rails 109, 110 and four connecting bends 111, which connect the horizontal rails 107, 108 to the vertical rails 109, 110. Each of the rails 107 through 110 can comprise a plurality of mutually axially adjustable parts, so that they can be adapted to the particular volume proportions. In the drawing, only the two vertical rails 109, 110 are shown in multipart form. In each case, they comprise two short rail portions 112, 113 and a central portion 114 in which portions 112, 113 are axially displaceable and secured by means of connecting elements, for example screws.
The protective cover 104 has a rectangular cross-section, its walls consisting of joined-together planar mineral wool plates approximately 30 mm to 80 mm thick, and preferably 50 mm thick, namely a base plate 115, a top plate 116 and two side plates 117, 118.
In the embodiment, plates 115 through 118 are shown in multipart form, i.e. they comprise a plurality of rectangular individual plates, whose narrow sides abut. For fixing plates 115 through 118 to the frames 105, fastening elements 119 are provided, which are essentially in nail-like form.
The following procedure is adopted for assembling plates 115 through 118. Firstly, a base plate 115 is fixed to two frames 105 by means of in each case two fastening elements 119, which are driven through the plate from the inside of the frame. The protruding ends of the fastening elements 119 can then be secured by clamping disks 120 or by bending over. When base plate 115 has been fixed to the two frames 105, it is possible to fix the two side plates 117, 118 to the two frames 105, for which purpose fastening elements 119 are again used. However, before this takes place, the ends of side plates 117, 118 facing base plate 115 are preferably coated with a heat-resistant adhesive containing inorganic fibers with a melting point of 700° C. to 800° C., and being free of antimony compounds.
A suitable adhesive coating preferably comprises, by weight: 1% to 25% inorganic, incombustible fibers; 10% to 50% binder; 2% to 20% inert, inorganic filling material; 5% to 15% plasticizer; and 35% to 70% inorganic flame retarder. The inorganic, incombustible fibers may be glass chosen from the group consisting of soda-lime glass, potash-lime glass, and boron-alumina glass, each with a melting point in the range of 700° C. to 800° C. The binder may be a terpolymer, made from monomeres chosen from the group consisting of vinyl alcohol, vinyl chloride, vinyl acetate, ethylene, propylene, styrene, methacrylic acid, methacrylic acid methyl ester, butadiene and vinyl laurate. The inert, inorganic filling material may be chosen from the group consisting of calcium carbonate, titanium dioxide, quartz sand, calcium sulfate and barium sulfate. The plasticizer may be chosen from the group consisting of diisotridecylphthalate, di-2-ethylhexylphthalate, diphenylcresylphosphate, trioctylphosphate, orthophosphoric acid-tri-(2-chlorethyl)ester and tributylphosphate. The flame retarder may be chosen from the group consisting of aluminiumhydroxide, hydrated aluminiumphosphate and hydrated zeolite.
It is also possible to use additional connecting elements, which can be in strap or spring form and are associated with the recesses or slots in base plate 115 for fixing the side plates 117, 118 to the base plate. When the two side plates 117, 118 are assembled, it is possible to start with the assembly of top plate 116, which is performed in the same way.
The structure formed from two frames 105, base plate 115, two side plates 117, 118 and a top plate 117 forms a unitary component, which can be prefabricated in the factory or, if desired, assembled on site. On site, this component can be terminally joined to other, correspondingly constructed components. In addition to or in place of a heat-resistant adhesive, it is possible to use connecting elements constructed in dowel pin, strap or spring-like manner and for which correspondingly dimensioned receptacles must be provided in the adjacent component.
The fireproof covering according to the invention has the advantage that it can be retrofitted, for example to existing cable routes and can also be used when they are laid for the first time. The covering is characterized by a particularly good insulating action. Construction is easy and no special supports are required for the frames 105 during the assembly thereof.
The protective cover 104 and preferably the two side plates 117, 118 can be provided with ventilating flaps 122 ensuring a good circulation and ventilation of the protective cover interior and consequently the cooling of the cables inserted therein. The ventilating flaps 122 can be directly articulated to the protective cover plates. However, it is also possible to articulate them onto frame-like inserts 123, which can be fixed in correspondingly dimensioned plate recesses. The ventilating flaps 122 and the optionally associated inserts 123 are preferably made from a heat-resistant hard material, more specifically mineral wool plates, in whose production a cement-like binder is used.
FIG. 14 shows a portion 154 of a cable covering having a base plate 150, two side plates 151, 152 and a top plate 153 and which can be terminally connected to correspondingly constructed and dimensioned portions. In order to bring about a tight terminal connection between adjacent portions 154, the individual portions have on one end face in each case an inner frame, which can be terminally inserted into the adjacent portion. The frame comprises individual strips 155 through 160, preferably made from the same material as plates 150 through 153 of the individual cable covering portions 154.
Unlike the embodiment of FIG. 13, the supporting structure associated with plates 150 to 153 can advantageously comprise individual frames 161 (see FIG. 15) interconnected by means of angle rails 162, provided with elongated slots 163. In the embodiment of FIG. 15, the frames 161 in each case comprise four flat strap irons 164, which are also provided with elongated slots 165 and are attached by screws 166 to angle rails 162. Downwardly directed U-shaped bearing rails 168 are provided between the two vertically directed flat strap irons 164, and are fixed to straps 164 by bends 169 and screws 170 (See FIG. 18). Bearing rails 168 are attached by screws 171 to the bottom of the cable trough (See FIG. 17).
Unlike the embodiment of FIG. 13, the cover plates 150 to 153 can be fixed to the supporting structure by means of fastening elements 172, 173 screwed to the latter and which are terminally pressed into the said plates. FIGS. 16a and 16c show such fastening elements 172, 173 made from a stable sheet metal and having an essentially U or Z-like configuration. In each case, they have a member provided with an elongated slot 174 by means of which they can be fixed to the supporting structure, while also having a member provided with a tip 175. As a result of such fastening elements, the following procedure can be adopted for assembling the cover plates. Firstly, a plurality of the U-shaped fastening elements 172 are screwed to the lower angle irons 163 of the supporting structure in such a way that the member provided with a top 175 is directed upwards. When this has taken place, a side plate 151 or 152 can be introduced into the tips 175 of fastening elements 172 from above. The substantially Z-shaped fastening elements 173 can then be used for fastening to frame 161 and/or to the vertical rails 164 of frame 161. The tips of elements 173 are to be pressed into the end faces of the plates, followed by the screwing of elements 173 to frame 161. In addition to the substantially U or Z-like fastening elements 171, 173, it is also possible to use for plate fixing purposes through-fastening elements, an embodiment of which is shown in FIG. 16d. Fastening element 176 in FIG. 16d has a large and substantially disk-shaped head 177, to which a shank 178 is fixed. At the free end of shank 178, there is a thread 179, onto which a nut can be screwed, after previously inserting shank 178 with thread 179 through a cover plate and an elongated slot in the supporting structure.
In the case of the supporting structure of FIG. 15, if necessary, the individual frames 161 are not only interconnected by angle rails 162, but also by parallel perforated rails 180 (See FIG. 19) having elongated slots 181, which contribute to the stabilization of the supporting structure and are preferably always provided if the individual cover plates are formed by plates juxtaposed in the longitudinal direction of the cover.
A further embodiment of the invention, which relies in particular upon the ability of the mineral wool components to form a secure seat for conventional fasteners, such as nails and screws. A fireproof covering in the form of a cable duct 24 is shown in FIGS. 20, 21 and 22. The duct 24 is held between two supports 26, in the nature of those supports described hereinbefore. The duct 24 comprises inner and outer structural elements, each of which has a L-shaped cross-section as shown in FIG. 21. An upper, inner structural element 28 is joined to a lower, inner structural element 30 so as to form a closed chute or channel therebetween. Two metal side wall brackets 36 and 38 run between supports 26, the cable duct being constructed therearound. The inner structural elements are connected to one another by common nails 40. The inner structural elements are surrounded and covered by an upper, outer structural element 32 and a lower, outer structural element 34. It will be appreciated that the respective seams of the inner and outer structural elements are at opposite corners of the rectangular-cross-section of the cable duct. The outer structural elements are connected to one another by common screws 42.
With reference to FIG. 20, the cable duct is formed by a plurality of inner and outer structural elements, extending in the desired direction. The inner structural elements abut one another at joints 54 and the outer structural elements abut one another at joints 56. It will be appreciated that these joints are also staggered relative to one another in order to enhance sealing of the cable duct. The joints 54 are well covered by the outer structural elements. The joint 56 of the outer structural elements is covered and reinforced by a sleeve 44, comprising two L-shaped brackets 46 and 48. Each of the brackets 46 and 48 have angled flanges 50, whereby the sleeve brackets may be attached to one another by nut and bolt assemblies 52. No additional supporting elements are necessary.
The inner and outer structural elements may be constructed from the same mineral wall panels or covers utilized in the other embodiments disclosed herein. The inner and outer brackets are preferably sheet metal.
Certain applications may require shorter durations of heat resistance, in which case fireproof coverings of only one layer will suffice, wherein a moisture-proof putty, which produces a coal-foam coating under fire conditions, is packed into and fills the transverse and longitudinal joints of the mineral wool components for sealing the joints. Such an intumescent putty should be weatherproof, and preferably comprises, by weight: 10% to 50% binding agent; 0.1% to 10% inert, inorganic filling material; 0.5% to 5% thicknener; 3% to 12% inorganic fiber; 5% to 15% plasticizer; and, 25% to 60% active filling material.
The binding agent may be a terpolymer made from monomeres chosen from the group consisting of: vinyl alcohol, vinyl chloride, vinyl acetate, ethylene, propylene, styrene, methacryl acid, methacryl acid methyl ester, butadiene and vinyl laurate. The inert, inorganic filling material may be chosen from the group consisting of calcium carbonate, titanium dioxide, calcium sulfate, aluminium silicate and barium sulfate. The thickener may be chosen from the group consisting of pyrogenic silicic acid, hydroxyethylcellulose and hydroxymethylcellulose. The inorganic fiber may be a glass fiber chosen from the group consisting of soda-lime glass, potash-lime glass and boron-alumina glass. The plasticizer may be chosen from the group consisting of diphenylcresylphosphate, tributylphosphate, orthophosphoric acid-tri-(2-chlorethyl)ester and trioctylphosphate. The active filling material may be chosen from the group consisting of melamine, melamin-phosphate, dimelaminpyrophosphate, corn starch, pentaerythrite, dipentaerythrite and cellulose.
This invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. Accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
FIGS. 23 and 24 show that the bending strength and tensile strength are increasing more than proportional in comparison with the density. Therefore, according to a preferred embodiment it is provided a combination of a fireproof covering or fireproof duct of two layers of different density, whereby the more dense layer provides more strength and the less dense layer provides more heat insulation. Applicant has found that the depth of indentation beginning with a density of about 300 kg/m 3 and above is decreasing less (see FIG. 25). Therefore, the fireproof mineral wool components have advantageously a density of at least 300 kg/m 3 , whereby the less dense as well as the more dense fireproof mineral wool components may be used on the outer surfaces. Surprisingly it has been found that a fireproof mineral wool component with increasing binding agent content has an increasing heat stability. Therefore, the binding agent content is preferably at least 3% per weigth and especially 4 to 5 and more percent. This is surprising, because the binding agent is combustible and decomposes when heat is applied. The fireproof mineral wool components with L-shaped cross sections are used preferably for the covering of already mounted cables, whereas fireproof mineral wool components with U-shaped cross sections are preferably used as ducts for cables and other heat sensible objects which are laid into the duct of the fireproof mineral wool components after they have been arranged. The U-shaped components can also be used for covering of already mounted objects such as for cables which are mounted transversely along a wall, whereby objects can wholly be covered by the U-shaped components.
FIGS. 26 to 29 show the various possibilities of a channel or duct system made of two different layers of fireproof mineral wool components. A series of U-shaped components 200 of mineral wool are arranged one behind another on two angle bars 201 which are mounted transversely on supporting means 202 of vertical carriers 203. The U-shaped components 200 are covered with cover panels 204. The cover panels and the U-shaped components have the same thickness of 30 mm and a density of 300 kg/m 3 . Their length is 900 mm. Their width is 400 mm. The interior surfaces of the so formed channel are lined with flat mineral wool components of a thickness of 10 mm and of a density of 600 kg/m 3 . The length of the panels is 1500 mm. The flat panels 205 are inserted into the channel in such a way that the joints of the U-shaped components are covered on the inner side by the flat panels. The flat panels are fixed to the inner surfaces of the U-shaped components and their covers by means of pins of metal (not shown). However, they can also or additionally be bonded to the U-shaped components by means of an adhesive. The inner surface of the flat panels 205 at the bottom of the U-shaped component may have transversely ribs or corrugations in order to provide a free distance between the objects to be inserted and the bottom of the channel.
FIGS. 27 to 29 show the possibilities of a construction system of this embodiment to provide a curve of 90° by means of two angles of 45° (angles of 30° or different angles are possible, too).
The end of the U-shaped components may be cut along preprinted lines 206. There are provided angle pieces of 45° and 30° resp. of the flat insert components 207 and 208 which can be used to cover the cut joints 206 of the bottom and the cover of the channel inside. FIG. 28 shows side wall inserts 209 and 210 of the flat material with angles of 45° and 30° resp. for covering the vertical joints of the U-shaped components, too.
FIG. 29 shows the possibility of a 90° angle of the channel. For the covering of the joints at the inner and outer corner of the angle there may be used sections 211 and 212 of the U-shaped components which are insered additionally (212) or in substitution (211) of corresponding pieces of U-shaped components 200.
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A fireproof covering for protecting heat-sensitive material and structures, said covering comprising: pre-shaped mineral wool components, molded to rigid, substantially self-supporting forms with a binder, for surrounding the heat-sensitive material and structures; and, a fireproof coating at least on the outside of the rigid mineral wool components, the coating progressively sintering onto the surface of the rigid mineral wool components under fire conditions and supporting the components as the binder progressively decomposes, whereby heat-sensitive material and structures can be protected from fire conditions for extended periods of time.
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[0001] REFERENCE TO RELATED APPLICATION
[0002] This is a continuation application of U.S. patent application Ser. No. 15/004,453, filed Jan. 22, 2016, now pending, which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0003] The present invention relates generally to stringed instruments.
BACKGROUND OF THE INVENTION
[0004] FIG. 1 shows a prior art musical instrument 100 . The musical instrument 100 shown in FIG. 1 is a six stringed electrical guitar. The musical instrument 100 shown in FIG. 1 includes a body 112 , a neck 114 extending from the body 112 and a nut 116 extending transversely across the neck 114 . A headstock 124 extends from the neck 114 , and is shown in FIG. 1 . The stringed musical instrument 100 also includes a bridge 118 . A plurality of strings 120 is supported between the nut 116 and the bridge 118 . FIG. 1 also shows a plurality of frets 122 extending perpendicular across the neck 114 .
[0005] As shown in FIG. 1 , conventional stringed musical instruments are typically equipped with a neck or fingerboard which is used to control the length, and therefore the vibrational frequency of the strings 120 being plucked, strummed, bowed, or otherwise activated.
[0006] In the conventional fretted stringed musical instrument, the string length is achieved through the fingers of the fretting hand pressing them against pieces of wire, the fret 122 , imbedded in slots in the fingerboard. The string, being pressed against the hard surface of the fret 122 and thereby stopped, is effectively shortened by the amount of distance of the fret to the bridge 118 , which defines the effective vibrating length of the string, thus altering its pitch (or ‘frequency of vibration’).
SUMMARY OF INVENTION
[0007] The invention includes a musical instrument having a body and a neck slidably mounted for movement longitudinally of the body between a first position and a second position. A head portion is disposed on the distal end of the neck. A depression in the neck extends along a least a portion of the neck and receives a trolley that moves therein between a first position and a second position.
[0008] The instrument also includes a tailpiece having a plurality of tuning machines affixed to the trailing end (bottom) of the body. The strings having a first end and a second end wherein the first end of each of the plurality of strings is attached to the trolley and the second end of each of the plurality of strings is attached to one of the plurality of tuning machines on the tailpiece.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
[0010] FIG. 1 is a stringed instrument of the prior art;
[0011] FIG. 2A is a front view of an illustrative embodiment of a stringed instrument having a slidable neck in an extended position;
[0012] FIG. 2B is a back view of an illustrative embodiment of a stringed instrument having a slidable neck in an extended position;
[0013] FIG. 3A is a front view of an illustrative embodiment of a stringed instrument having a slidable neck in retracted position;
[0014] FIG. 3B is a back view of an illustrative embodiment of a stringed instrument having a slidable neck in retracted position;
[0015] FIG. 4 is an orthogonal top view of a slidable neck according to an illustrative embodiment;
[0016] FIG. 5 is an orthogonal bottom view of a slidable neck according to an illustrative embodiment;
[0017] FIG. 6 is a side view of a slidable neck according to an illustrative embodiment;
[0018] FIG. 7 is a front view of the body of an illustrative embodiment of a stringed instrument;
[0019] FIG. 8 is a perspective view of the body and tail piece of a stringed instrument according to an illustrative embodiment of the invention;
[0020] FIG. 9 is an exploded view of the body and neck of a stringed instrument according to an illustrative embodiment of the invention;
[0021] FIG. 10 shows a view of the proximal portion of the neck with the fret board removed;
[0022] FIG. 11 shows a view of the distal portion of the neck with the fret board removed;
[0023] FIG. 12 shows a view of the distal portion of the neck with the fret board attached;
[0024] FIGS. 13A and 13B are detail views of the tailpiece;
[0025] FIG. 14 is a rear view of the proximal portion of the neck illustrating the locking mechanism;
[0026] FIG. 15 is an isometric view of a first stand for use with the inventive instrument;
[0027] FIG. 16 is an isometric view of a first stand for use with the inventive instrument;
[0028] FIGS. 17A through 17C are plan view of an alternate means of applying tension to the device according to an alternate embodiment of the invention; and
[0029] FIG. 18 is a plan view of an alternate means of applying tension to the device according to an alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] The device will now be described with reference to the accompanying Figures. In all Figures, like numerals correspond to like elements. The device is directed to an apparatus and method for providing a hand-held stringed instrument that can vary in length between and extended and retracted state. Specific details of the device and its use are disclosed more completely below.
[0031] By way of background, the term “stringed instrument” is intended to be directed to a wide variety of hand-held stringed instruments. Suitable, non-limiting examples include the acoustic guitar, electric guitar, acoustic bass guitar and electric bass guitar, banjo, mandolin, and similar type instruments. Although the Figures depict a six stringed electric guitar, the scope of this disclosure includes instruments with more or fewer strings
[0032] Terms of location such as “upper” and “lower” are used merely for convenience. As are relative terms such as “proximal” and “distal.” Unless otherwise specified the terms “upper,” “lower,” “above” and “below” are used in the context of the instrument as if it were standing upright, such as in FIGS. 2A and 2B . The terms “proximal” and “distal,” generally, refer to parts of the inventive instrument in relation to an intended user as the device would be during ordinary use. “Leading” and “trailing” are used to describe a relation as though the device where moving in a path of travel along an axis from its lower to upper end. Notwithstanding the foregoing, all terms (including those of relative location) are to be construed in the context in which they are presented and are not restricted to the guiding principles set forth above.
[0033] Turning now to FIGS. 2A through 3B , a general embodiment of the inventive retractable stringed instrument is shown. In these figures, instrument 10 is depicted as an electric guitar. As with traditional guitars, instrument 10 includes body 20 with neck 60 attached to the upper end thereof. Neck 60 further includes head 80 at its distal end, relative to body 20 . Instrument 10 further includes tailpiece 40 located on its lower end , relative to neck 60 . In a preferred embodiment, tailpiece 40 is affixed to the surface of body 20 . Other arrangements are, however, possible. For example, tailpiece 40 could be attached to the sidewall of body 20 at its lower end and thereby extend outward. As shown in FIG. 2B , instrument 10 also includes integrated stand 90 for use in extending neck 60 (as discussed below) or when the instrument is not in use.
[0034] As more closely seen in FIGS. 4 through 6 , neck 60 includes a base section 62 positioned at the proximate end thereof and opposite head 80 . As discussed in further detail below, it is base section 62 of neck 60 that engages with, and moves within, body 20 .
[0035] Proximal end 60 a of neck 60 with base section 62 thereof. A standard pickup 61 is affixed to the surface of base section 62 at the proximal end thereof. As shown, rails 64 extend outwardly from the sidewalls of base section 62 . Rails 64 are received by, and slidably move within, channels 28 of body 20 (discussed below). Locking palls 88 extend outwardly from rails 64 to fix neck 60 in predetermined locations and are part of the locking mechanism (discussed below).
[0036] Neck 60 includes depression 63 which extends from a location adjacent head 80 to a location adjacent pickup 61 . Depression 63 is preferably uniform in width along its length is substantially coincident with the longitudinal axis of neck 60 .
[0037] Body 20 , shown in FIG. 7 with tailpiece 40 removed, has a leading end ( 20 a ) adjacent neck 60 and trailing end ( 20 b ). Tailpiece 40 , in a preferred embodiment, is affixed to the upper surface of center block 22 as shown in FIG. 8 . Body 20 further includes wing elements 24 a and 24 b . Each wing is connected to center block 22 at its lower end, at least, to form body 20 . This arrangement forms interior space 26 which is defined by sidewalls 26 a and lower wall 26 b . Each side wall 26 a includes a channel 28 extending at least partially between leading end 20 a of body 20 and bottom wall 26 b . Interior space 26 receives base section 62 of neck 60 and it is within interior space 26 that base section 62 travels as it moves between the extended and retracted positions. Channels 28 further include apertures 29 to receive palls 88 of the locking mechanism (discussed below) to selectively secure neck 60 in desired positions.
[0038] FIG. 9 is an exploded view of body 20 and neck 60 . Also shown are recess A and B which receive electronics associated with the instrument. For example, recess A could house a speaker (not shown) that is covered by speaker cover A 1 . Recess B can hold additional electronics common in the industry (not shown) that are in turn covered by pickguard B 1 .
[0039] An important feature of the inventive instrument is the ability to maintain tension on the strings whether the neck of the instrument is in the extended or retracted position. This is accomplished by an intricate tensioning mechanism as discussed below.
[0040] Referring now to FIG. 10 , a portion of neck 60 is shown with fret board 16 removed. Trolley 70 moves longitudinally within depression 63 and is substantially rigid. The distal ends of strings 12 are connected to trolley 72 . In one embodiment, flange 72 extends upward from trolley 70 and received strings 12 . In such an embodiment the overall height of trolley 70 and flange 72 do not exceed the depth of depression 63 . Trolley 70 is secured within depression 63 by means of flanges extending therefrom which are received by groves 65 formed in the sidewalls of the depression.
[0041] A first end of spring 74 attached to trolley 70 opposite flange 72 . Spring 74 provides the biasing force needed to maintain tension on strings 12 regardless of the relative position of neck 60 . The second end of spring 74 is attached to an anchoring point 76 affixed within the proximal end of depression 63 . As shown in FIG. 10 , slip rings 75 can be used to adjust the tension of spring 74 as well as facilitate the attachment thereof to anchor 76 . Slip rings 75 can also be used to attach spring 74 to trolley 70 (see also FIG. 11 below).
[0042] FIG. 11 shows trolley 70 within depression 63 of neck 60 at the distal end thereof (adjacent head 70 ). This indicates the instrument is in the extended position. A metal stop 66 adjacent the distal end of depression 63 . As it can be seen, the distal ends of strings 12 are attached to trolley 70 via flange 72 . The strings extend upward from flange 72 toward head 80 and around rollers 82 disposed therein. Rollers 82 can rotate on an axle ( 83 ) extending across head 80 . Alternatively, strings can simply lie over a transverse member having a sufficient radius to allow the strings to move there over as neck 60 travels between an extended and retracted position (and vice versa).
[0043] FIG. 12 shows the distal end 60 a of neck 60 with fret board 16 attached thereto. Strings 12 on the upper side of rollers 82 extend downward toward trailing end 20 ( b ) of body 20 passing under keeper 84 . Nut 86 includes numerous slots 86 a through which strings 12 pass to aid in maintaining string alignment.
[0044] As shown in FIG. 12 , the tensioning mechanism of instrument 10 is hidden during use by removable fret board 16 . Tines extending from fret board 16 are received by and engage receptacles 67 on neck 60 (see FIGS. 7 and 8 ). Fret board lock 78 ( FIG. 7 ) holds fret board 16 in place when it is in position.
[0045] The proximal ends of strings 12 connect to various tuning machines 46 on tail piece 40 (see FIGS. 13A and 13B ). Tuning machines 46 work in much the same manner as those on traditional stringed instrument, with the exception of their placement. As discussed above, tailpiece 40 (which includes tuning machines 46 ) is located on the lower (proximal) end of body 20 and not a headstock on the distal end of neck 60 . This arrangement provides numerous advantages in combination with the retractable neck of the instant invention. This placement also, however, provides numerous advantages when used with a traditional stringed instrument as will be appreciated by the skilled artisan.
[0046] Tailpiece 40 has proximal 42 and distal ends 44 . In the embodiment shown in FIG. 13 , the tailpiece has a stepped shape and substantially hollow center. This allows strings 12 to remain as straight as possible in their path between head 80 and the respective tuning machine 46 . Similar to nut 86 , leading end 42 of tailpiece 40 has numerous slots 42 a to accommodate strings 12 . Cap 48 covers leading end 42 of tailpiece 40 to prevent strings 12 from leaving slots 42 a if tension on the strings is lost. Leading end 42 serves the same function as a bridge found on standard string instruments. One advantage of placing the bridge structure in the manner shown in FIGS. 13A and 13B is that the bridge has a fixed position and does not need to be displaced during retraction as in some instruments of the prior art. It should be noted that the use of tailpiece 40 can be used in conjunction with a retractable instrument, as described herein, or on a standard instrument of the prior art. Cover 42 b serves to help retain strings 12 in slots 42 a .
[0047] Movement of the neck relative to the body (extension and retraction) is controlled by the locking mechanism shown in FIG. 14 . As previously discussed, locking palls 88 extend from rails 64 on the base section 62 of neck 60 to engage apertures 29 in channels 28 on body 20 . Extension and retraction (locking and unlocking) of palls 88 are controlled by dial 82 located on the back (underside) of base section 62 . Turning dial 82 causes coincident rotation of locking base 84 . This movement translates to joined arms 86 which are attached to palls 88 .
[0048] Also shown in FIG. 14 is bracket 28 which holds wings 24 a and 24 b in fixed relative position as well as providing an inward bias to help secure base section 62 within interior space 26 . Bracket 28 also serves as a positive stop, preventing over extension of neck 60 . Removal of neck 60 from body 20 can be achieved by removing bracket 28 and sliding base section 62 upwardly (distally, in a leading direction) until it is clear of interior space 26 .
[0049] Additionally, instrument 10 includes stand 90 attached to trailing end 20 ( b ) of body 20 . Stand 90 not only provides a means to hold instrument 10 in an upright position when not in use, but also provides leverage when extending neck 60 . Alternate embodiments of stand 90 are shown in FIGS. 15 and 16 .
[0050] Referring to FIG. 15 , stand 90 is attached to the instrument (shot shown) via mechanical fasteners extending through plate 92 . Plate 92 is connected to base 94 through hinge 96 . Support 98 is hingidly connected to plate 92 and swings outwardly when in use. Support 98 contacts and engages base 94 to provide the structural integrity to support the instrument.
[0051] FIG. 16 shows an alternate embodiment of stand 90 a . The instrument (not shown) is received by the cradle portion 92 a of the stand. Frame 94 a extends upwardly and in contact with the back (underside) of body 20 . Support arm 96 is pivotally connected to frame 94 a and swings outwardly to provide the structural integrity to support the instrument.
[0052] Lastly, with reference to FIGS. 17A, 17B and 17C an alternate embodiment is shown which provides an alternative to stand 90 of FIG. 15 to provide the leverage needed to extend neck 60 when it is under tension. In this embodiment bracket 28 of FIG. 14 is replaced by a similar device comprising upper bracket 28 a which is hingidly connected to lower bracket 28 b . Handle area 28 c provides a gripping surface so that the necessary force can be safely placed on neck 60 during extensions and retraction. Once lower bracket 28 b is depressed and comes in contact with segmented plates 28 d the back of the instrument, the mechanism pushes the neck up one step at a time and ultimately into position and not require the manual process of standing on the hinge and extending the neck manually.
[0053] FIG. 18 shows yet another embodiment wherein the neck is advance through use of a ratcheting mechanism. Manipulation of handle 28 e causes a corresponding toothed cog 28 f to engage segmented plates 28 g . The motion of which causes the neck of the instrument to extend or retract (dependent upon which of the paired ratcheting devices is actuated).
[0054] Those ordinarily skilled in the art will appreciate that the present invention could be applied to many types of stringed instrument in many different forms. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall there between. Relative terminology, such as “substantially” or “about,” describe the specified materials, steps, parameters or ranges as well as those that do not materially affect the basic and novel characteristics of the claimed inventions as whole (as would be appreciated by one of ordinary skill in the art). Now that the invention has been described,
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The present invention includes a retractable stringed musical instrument; specifically a stringed musical instrument having a tailpiece, a body coupled to the tailpiece, a neck coupled to the body and a fingerboard coupled to the neck. The fingerboard and the neck extends and retracts relative to the body. The retractable stringed instrument further comprises a mechanism to maintain tension on the strings of the instrument regardless if the neck is in the extended or retracted position.
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BACKGROUND
U.S. Pat. No. 4,482,347 discloses a peristaltic pump which, because of its compactness and simplicity of construction, and its precise, accurate, and reliable operation, is particularly suitable for medical use in a fluid infusion or administration system or in a system for withdrawing fluids, such as wound, urine, pleura, or other drainage systems. The pump includes a series of bearing assemblies each having concentric inner and outer members capable of free rotation with respect to each other. The inner members are concentrically mounted upon a power-driven shaft with the centers of the inner members equidistant from the axis of the shaft and spaced at uniform angular distances thereabout to describe a helix about the axis of the drive shaft. A resilient tube extends along a line parallel with the shaft and is supported by a platen so that the tube is sequentially compressed by each of the outer bearing members of the series, thereby driving fluid through the resilient tube. A thin elastomeric membrane is interposed between the outer bearing members and the tube with the membrane in continuous contact with the tube during pump operation.
Such a pump is of positive action in its operation and is capable of generating substantial outlet pressures. While maximum discharge pressure may be controlled by simply discontinuing pump operation, situations exist in arthroscopic surgery and other medical and non-medical operations where interrupting pump operation, and the resultant decreases in pressure which then occur, are undesirable. What is instead needed is some means that operates independent of flow rate for insuring that a selected maximum discharge pressure is not exceeded. A further objective would be to attain such control over maximum outlet pressure while at the same time providing a unit which is simple and reliable in operation, is relatively compact, and utilizes relatively inexpensive tubing that may be economically discarded after a single interval of use.
Other types of peristaltic pumps are disclosed in the references cited in the aforementioned patent and are further represented by U.S. Pat. Nos. 4,373,525, 3,990,444, 3,542,491, and 4,029,441. U.S. Pat. No. 4,373,525 discloses a peristaltic pump with slidable fingers that engage a tube supported by a spring-loaded pressure plate, with the addition of a pivotal arm having "pressing parts" at its opposite ends for detecting pressure changes and triggering a suitable alarm; U.S. Pat. No. 3,990,444 ws a pump having a tube similarly supported by a spring-loaded pressure plate and with multiple rollers carried by a wheel that rotates in the same plane as the tubing; U.S. Pat. No. 3,542,491 discloses a pump also having rollers that are moved along a section of resilient tubing to drive fluid through that tubing; U.S. Pat. No. 4,029,441 discloses tubing formed by a folding operation which is held in place by jaws and saddle elements to insure a desired pumping action by rollers as they are advanced along the tube.
SUMMARY OF THE INVENTION
One aspect of this invention lies in the discovery that pressure regulation of a peristaltic pump of the type disclosed in the aforementioned and co-owned U.S. Pat. No. 4,482,347 may be achieved simply and effectively, and independently of rate of flow, by supporting the straight section of tubing by means of a platen which automatically moves away from the axis of the bearing assemblies when back pressure exceeds a predetermined maximum level, thereby reducing pumping efficiency to just the extent necessary for maintaining, but not exceeding, such maximum pressure. Specifically, the platen assembly takes the form of a support frame which is fixed in relation to the pump axis when the pump is in operation, a rigid platen plate having an elongated channel or trough that supports the straight section of resilient tubing to be compressed by the bearing assemblies and compression means interposed between the frame and the floating rigid plate for holding the tubing section in position for sequential compression by the bearing assemblies. The compression means may take the form of an elastomeric foam pad or a series of compression springs disposed between the frame and floating plate. In either case, the compression means is only slightly or partially compressed during normal pump operation but is more fully compressed to permit substantial displacement of the plate when a predetermined maximum back pressure is exceeded.
The trough or channel of the floating plate has a radius of curvature, when viewed in cross section, that is only slightly greater than the outside radius of the outer bearing members of the pump. Such a relationship permits the use of resilient tubing that has a relatively large diameter in relation to the size of the bearing assemblies, without risk that unintended backflow might occur through the tubing during normal pumping operation. The result is a pump of relatively high capacity for its size and operating speed. Ideally, an elastomeric membrane is disposed between the bearing assemblies of the pump and the resilient tubing, and, if desired, a resilient liner may be provided along the trough or channel of the rigid plate of the platen assembly.
Other features, advantages, and objects of the invention will become apparent from the specification and drawings.
DRAWINGS
FIG. 1 is a longitudinal sectional view of a pumping apparatus embodying this invention.
FIG. 2 is an exploded perspective view of the platen assembly for such apparatus.
FIG. 3 is an enlarged sectional view taken along line 3--3 of FIG. 1.
FIG. 3A is a sectional view similar to FIG. 3 but illustrating alternate pressure-limiting compression means.
FIG. 4 is a sectional view similar to FIG. 3 but showing displacement of the floating plate for regulating back pressure.
FIG. 5 is a somewhat schematic view illustrating the relationship of one bearing assembly, the resilient tubing, and the platen assembly when the pump shaft has rotated approximately 90° from the position of FIG. 3.
FIG. 6 is a schematic view similar to FIG. 5 but illustrating the relationship of parts when the pump shaft has rotated approximately 180° from the position shown in FIG. 3.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawings, the numeral 10 generally designates a peristaltic pump for metering fluid through resilient tubing 11. The tubing may be formed of an elastomeric material such as, for example, silicone rubber; however, it is not necessary, at least in all cases, that the tubing material be elastomeric but only that it be sufficiently resilient to permit full collapse and recovery upon the application and removal of compressive forces. Resilient polyvinyl chloride tubing has been found effective, and it is believed that any of a wide variety of resilient similar polymeric but non-elastomeric materials might be used.
Except for the differences described herein, the peristaltic pump 10 is essentially the same as the pump shown and described in Borsanyi U.S. Pat. No. 4,482,347, the disclosure of which is incorporated by reference herein. The pump includes a housing 12 composed of a pair of sections 13 and 14 which are locked together in the relationship shown in FIG. 1 when the pump is operated but which are hingedly or otherwise separably connected to permit insertion and removal of tubing 11. In the illustration given, sections 13 and 14 are depicted as upper and lower sections, respectively, and while reference may be made to such orientation for clarity of description it is to be understood that the orientation is not critical and that the pump may be operated effectively in any suitable position.
The pump mechanism includes a series of bearing assemblies 15 each having inner and outer bearing members 16 and 17, respectively. Preferably, the inner bearing member 16 takes the form of an inner bearing race, the outer member 17 constitutes an outer race, and anti-friction bearing elements 18 are disposed therebetween. Such anti-friction bearing elements would normally consist of ball bearings, but the use of various types of roller bearings is possible. Furthermore, other types of bearing assemblies, such as self-lubricating sleeve bearings, might be advantageously used.
Each inner race or member 16 is mounted eccentrically upon a drive shaft 20, and the shaft is in turn journaled in brackets or mounting elements 21 and 22. One end of the shaft is operatively connected to power means in the form of stepping motor 23.
Each inner race or member 16 is eccentrically mounted upon shaft 20 with the centers of all such races being equidistant from the axis 24 of the drive shaft and with the angular spacing between all of such centers being essentially the same and the sum of the angular spacing being 360°. Where a series of seven bearing assemblies is provided as shown, the incremental angular distance between the centers of the inner races should be 360° divided by 7, or approximately 51.43°. A greater or smaller number of bearing assemblies may be provided, although the preferred range is believed to be 3 to 30 such assemblies. Of particular importance is the fact that the series of bearing assemblies must be mounted upon the drive shaft 20 so that the centers of the inner races describe a spiral or helix of at least 360° about the drive shaft axis.
The inner races 16 may be secured upon the shaft 20 in any suitable manner. In the embodiment illustrated, shaft 20 has a central portion of non-circular (heptagonal) cross sectional outline and the eccentrically-disposed openings 16a in the respective inner races 16 are of the same configuration so that the eccentric bearings may be incrementally positioned upon the shaft with their centers helically oriented. The inner races are thereby secured against independent relative rotation with respect to shaft 20, and locking elements 25 are secured to the shaft at opposite ends of the series of bearing assemblies 15 to hold the series against axial displacement.
A portion of the resilient polymeric tube 11 is supported with its longitudinal axis parallel with the rotational axis 24 of shaft 20 and with a linear zone of one surface of an elastomeric membrane 30 in contact with the tube. Tube retaining means in the form of a pair of mounting brackets or clamps 31 are provided by one of the housing sections (the lower section 14 in FIGS. 1 and 2) for frictionally retaining the tubing in place and for insuring that the portion of the tube disposed between the brackets is straight and is in parallel alignment with the rotational axis of the drive shaft.
The imperforate elastomeric membrane 30 is interposed between tube 11 and the cylindrical surfaces of the outer bearing members or races 17 as illustrated in FIGS. 1 and 3. The membrane is planar in an untensioned state and assumes the configuration shown in these figures because of the distortions developed by bearing assemblies 15. Ideally, the membrane is secured to the upper housing section 13 and separates or isolates the pump mechanism from tubing 11. Any suitable means may be used to secure the periphery of the membrane to casing or housing section 13.
A platen assembly supports the tube in contact with the underside of membrane 30 and in proper position for compression by bearing assemblies 15. The platen assembly includes housing section 14, a rigid platen element or plate 32, and compression means 33 which, in FIGS. 1 and 3, takes the form of an elastomeric foam pad or cushion. The plate 32 is rectangular in outline and elongated in the direction of tubing 11. Similarly, the compression pad or cushion 33 has a rectangular outline similar to that of rigid plate 32 although, as shown in FIGS. 1 and 3, the pad may be shorter and narrower than plate 32. Both the compression pad and the lower portion of the rigid plate are received within a rectangular recess 34 formed in housing section 14. The housing section therefore defines a frame for retaining plate 32 and compression pad 33 and for maintaining the plate in proper supporting relation with respect to tubing 11. The plate 32 and its facing 32a are depicted as being slightly shorter than recess 34 to allow the plate to float more freely, even rock slightly, upon pad 33 in that recess. As shown most clearly in FIG. 2, the mounting brackets 31 are located at opposite ends of the elongated rectangular recess 34.
Each bearing assembly 15 has its inner race 16 eccentrically mounted so that its center moves between one extreme position in which it is spaced maximally from the platen and the lumen 11a of the tube is substantially fully open (FIG. 6) and the other extreme position in which the center of the inner race is spaced minimally from the platen and the lumen of the tube is closed (FIG. 3). To reduce torque peaks that develop as each bearing assembly sweeps through the lumen-occluding position of FIG. 3, especially when two such assemblies (the first and last of the series) simultaneously compress and substantially close the tube, the plate 32 may be provided with a resilient facing 32a engaging and supporting tube 11. The facing must not be so compliant that it will allow outward displacement of the tube in preference to complete occlusion of that tube. The tube should close as shown in FIG. 3 with the resilience of facing 32a serving the primary purpose of reducing the torque peak once such occlusion has taken place. It is to be understood that facing 32a, although highly advantageous, is optional, and that its presence does not alter the fact that plate 32 of the platen assembly is rigid and provides firm support for tubing 11.
The upper surface of plate 32 (and the upper surface of facing 32a, if provided), is arcuate when viewed in transverse section. Specifically, the upper surface 35 defines an elongated channel or trough for receiving and supporting tubing 11. The radius of transverse curvature of the trough is slightly greater than the radius of curvature of the outer surface of each outer bearing race or member 17. Ideally, the radius of curvature of the trough should equal the sum of the radius of each bearing assembly, plus the extent of its eccentricity, plus double the wall thickness of tube 11, plus the thickness of membrane 13 (where the membrane is included). Since the membrane is relatively thin (its thickness is exaggerated in the drawings for clarity of illustration), it may be stated that the radius of curvature of the trough approximates the radius of each bearing assembly, plus its eccentricity, plus 2 times the wall thickness of the tube. The result is that when tube 11 is fully compressed and its lumen is occluded by a bearing assembly as depicted in FIG. 3, the curvatures of the bearing assembly, the collapsed wall portions of the tubing 11, and the trough or upper surface of the floating plate (whether faced or not) are all concentric.
Such a curvature of the trough has a number of important advantages. It insures that when the tubing is compressed, as shown in FIG. 3, its lumen 11a is fully closed or occluded. The lumen appears as a tightly closed slit without any lateral bypass channels that might otherwise be present at opposite ends of that slit if the platen were flat rather than transversely curved. Furthermore, the curvature of the trough permits usage of relatively large diameter resilient tubing 11 (in relation to the diameter of bearing assemblies 15) without risk that undesirable leakage might occur when the tube is in its compressed state. Because of the relatively large size of the tubing in relation to the diameter of the bearing assemblies, the pump has high pumping capacity for its size and operating speed. In addition, the curvature of the trough contributes significantly in retaining tube 11 in proper position during a pumping operation, even when the support plate 32 shifts in its position because of pressure fluctuations near the maximum level. The curvature thus reduces the need for elastomeric membrane 30. While the presence of the thin membrane is still highly advantageous to insure against lateral displacement of the tube during pump operation and to isolate the pump mechanism from tubing 11 and the platen assembly, thereby protecting the pump mechanism from contact with fluids, particulates, and, in general, outside contaminants, the membrane may nevertheless be omitted in some cases because of the stabilization of the tube provided by the arcuate trough.
Although the plate 32 is slidably received in recess 34 for upwardly and downward movement therein, such plate is normally held stationary in the operative position illustrated in FIG. 3 by the compression means (pad) 33. As each bearing assembly urges tube 11 into its fully closed position, only slight or partial compression of pad 33 occurs. In other words, the material of pad 33 is selected so that its resistance to compression generally exceeds the resistance of tube 11 against becoming fully collapsed. Therefore, during normal pump operation, or at least until resistance to outflow from the pump exceeds a predetermined maximum level, pad 33 is no more than partially compressed.
The material and dimensions of the pad are selected so that its resistance to compression will be overcome when a predetermined maximum fluid pressure develops in tube 11 downstream of the pump. For example, for a pump to be used in arthroscopic surgery, it has been found that a maximum discharge pressure of 20 psig is appropriate. Greater pressures might result in rupture of the tubing and possibly produce other complications in the operative procedure. The compression pad is therefore dimensioned and formed of an elastomeric material (foam rubber) that cannot maintain the platen plate 32 in its upwardly extended position (FIG. 3) when fluid pressures within tubing 11 on the downstream side of the pump exceed 20 psig. When such a condition arises, the floating plate 32 is forced downwardly in the direction of arrows 40, compressing pad 33 and allowing the lumen 11a of the resilient tube 11 to open (FIG. 4). Pumping efficiency drops sharply since liquid in the tube may flow in a reverse direction to the extent permitted by retraction of the floating platen plate 32. Such retraction is modulating and self-correcting; that is, the plate 32 retracts only to the extent necessary to keep fluid pressure from substantially exceeding a preselected maximum pressure (20 psig in the example given above), and once the downstream pressure drops below the selected maximum level the floating plate will return to its original position, thereby restoring pumping efficiency (FIG. 3).
FIGS. 5 and 6 schematically depict a bearing assembly of the pump in different stages of operation. Thus, FIG. 5 shows the bearing assembly 15 when the drive shaft has rotated clockwise, in the direction of arrow 41, 90° from the position shown in FIG. 3. It will be observed that the trough contributes in retaining the tube 11 in its original position despite the fact that bearing assembly 15 is displaced laterally because of the eccentric mounting of its inner race 16 on drive shaft 20. When that shaft has rotated 180° from its original position, the parts assume the relationship depicted in FIG. 6. Continued rotation of the shaft results in compressive action of the bearing assembly 15 until full compression is again achieved (FIG. 3).
The compression means 33 has been shown and described as being formed of compressible elastomeric material with low hysteresis such as silicone foam rubber. It is to be understood that similar results may be achieved by utilizing spring means or any other compressible elements that resist compression until the discharge pressure in the line exceeds a preselected maximum level and that restore the floating platen plate to its extended position when the discharge pressure drops below that level. FIG. 3A depicts a construction identical to the one already shown ahd described except that the compression means takes the form of a multiplicity of helical compression springs 33' arranged in a uniform pattern in recess 34 beneath platen plate 32. The springs are shown in an arrangement of spaced rows, it being understood that each row includes a plurality of such springs.
While in the foregoing I have disclosed embodiments of the invention in considerable detail for purposes of illustration, it will be understood by those skilled in the art that many of these details may be varied without departing from the spirit and scope of the invention.
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Controlling maximum fluid pressure at the outlet end of a peristaltic pump of the general type disclosed in U.S. Pat. No. 4,482,347 is achieved by supporting the resilient tubing of the pump in the trough of a rigid but movable platen mounted upon a compression pad or spring arrangement that resists platen movement until a back pressure of predetermined magnitude occurs, at which time the plate is displaced to reduce pumping efficiency and prevent further increases in outlet pressure.
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BACKGROUND OF THE INVENTION
The prior art discloses various clock radios and alarms incorporating timing mechanisms, or devices to turn a radio on, or off, at present times, or to actuate the alarm. Certain radios of these prior types included a light which was adapted to be flashed on and off and thereby function as a wake-up signal to a sleeping person. Other types of prior art radios included a so-called "slumber switch" which was utilized to turn the radio on and then after the expiration of a selected period of time, when the user presumably has fallen asleep, to turn the radio off. The slumber switch on such radios was adapted to be utilized without affecting the alarm setting on the radio. It was known too, in clock radios, that multiple sets of volume and station selector controls might be utilized, so that when a timer mechanism activated the radio it would operate at the preselected station and at the chosen volume and which operation could be obtained independently of a separate set of tuning and volume controls. One type of prior clock radio was known which provided a timer mechanism that activated the radio for a certain period of time and during this time period uniformly decreased the volume level, to zero, and after which period to radio was turned off. When the radio was turned on again, automatically, as a wake-up alarm, the mechanism caused the volume gradually to increase from the zero position, or volume level, to its previous setting.
Another prior patent disclosure reveals a light alarm system associated with an electric clock so that the light was activated at a preset time as a wake-up alarm controlled by the clock mechanism. When activated, the light operated at a low light level and gradually increased in brightness from this minimun setting until full brightness was attained as a simulation of daylight. Another patent from the prior art utilizes a timer cam which functions on a twenty four hour basis and utilizies a gear that turns a radio on or off. Another prior art inventor uses two switches, one to turn his system on and one to turn on a dimming device. Certain of such prior arrangements were not controllable manually and where both audible alarm and lights were used they were directed through the same control device.
SUMMARY OF THE INVENTION
This invention provides a timing mechanism in assoication with a tape deck, or the like and a lamp to control the sound output level of the tape deck as well as the light level of the lamp automatically and whereby the volume level of the tape deck and the light level may be varied simultaneously, or individually, over a predetermined or preset period of time. The output of the tape deck and the brightness of the lamp may be preset to diminish simultaneously, or to raise the volume and increase the light level together, but also affording independent operation of either the tape deck, or the lamp. The invention utilizes a potentiometer for regulating the volume of the tape deck and/a dimmer device for controlling the light level of the lamp mounted at opposite ends of an operating shaft with mechanism for operatively connecting either the potentiometer or the dimmer, or both, to a dimmer mechanism and having individual solenoids in an electrical circuit for effecting such connections. The operating shaft mechanism also includes means for actuating the potentiometer and the dimmer manually and independently of each other and the electrical circuitry affords means for operating the system fully automatically whereby the timing mechanism may be utilized with the tape deck and the lamp to enable either to be set for automatic operation for any preset period of time within the capacity of the timer mechanism. The volume, or audio output, of the tape deck and the brightness of the lamp will be regulated according to the setting of the controls. However, the arrangement is such that is may be used as a continuous tape player with manual volume control, or it may be used strictly as a night light, with manual control. Either the tape deck or the lamp may be used independently of the other on fully automatic operation, if desired.
OBJECTS OF THE INVENTION
It is the primary purpose of the invention to provide an electromechanical system of controlling the sound level of an audio device and the light level of a lamp in a child's room for regulating such levels during periods of sleep and when the child is awakening.
The principal object of the invention is the provision of an electromechanical control arrangement for automatically or manually regulating the sound and light levels of an audio device and a lamp.
An important object of the invention is to provide an audio device and a lamp under control of a timer mechanism operating in conjunction with a potentiometer and a dimmer device for regulating the audio and light output thereof and operable manually independently of the timer mechanism.
Another object of the invention is the provision of potentiometer and dimmer means for regulating the output levels of an audio device and a lamp in association with a timer mechanism which permits of manual operation thereof, or provides for automatic operation of one, or both, in combination with electrical circuitry, including solenoids for operatively connecting the potentiometer and dimmer with the timer, or disconnecting one, or both, from the timer.
A further object of the invention is to provide an arrangement for regulating the sound and light levels of an audio device and a lamp including a potentiometer and a dimmer operatively connected by mechanism which provides for connection of either one, or both, the potentiometer and dimmer to a timer device for automatic operation of one, or both, and which provides for manual operation of either, with solenoids in an electrical circuit for effecting the connection, or disconnection.
A still further object of the invention is the provision of an arrangement for regulating the sound and light levels of an audio device and a lamp including a potentiometer and a dimmer operatively connected by a shaft with means on the shaft actuated by separate solenoids to connect the potentiometer and/or the dimmer with a timer mechanism and having means associated with the shaft for actuating the potentiometer and dimmer manually and independently of each other.
DESCRIPTION OF THE DRAWINGS
The foregoing and other and more specific objects of the invention are attained by the mechanism and arrangement illustrated in the accompanying drawings wherein
FIG. 1 is a generally schematic illustration of a mechanism for operatively connecting a potentiometer and a dimmer with a timer mechanism and operable automatically, or manually, with separate solenoids for effecting the connections, or disconnections; and
FIG. 2 is a schematic wiring diagram of an electrical circuitry for effecting the complete operation of the system for regulating the sound and light levels.
DESCRIPTION OF PREFERRED EMBODIMENT
In the drawings, as best shown in FIG. 1, a potentiometer 10 and a dimmer 11 are mounted in axial alignment on supporting brackets 12 and 9, respectively. The potentiometer and dimmer are operatively connected by a shaft mechanism including a central shaft 13 which serves also as a control shaft for manually actuating the dimmer 11. The potentiometer 10 may be actuated manually by means of a control shaft 14 which is of tubular section, fitting over the shaft 13 and rotatable relative thereto. The tubular shaft 14 passes through the potentiometer and is operatively connected thereto as at 15 so that when the shaft 14 is rotated, independently of the shaft 13, the potentiometer is also rotated. Operating handle 16 on the shaft 14 provides means for rotating the shaft while handle 17 on the shaft 13 provides means for rotation of that shaft.
It will be seen that the central shaft 13 extends entirely through the shaft mechanism for connection directly to the dimmer 11 as at 18 and passes through the dimmer with a similar connection 18 at the outer side thereof whereby the dimmer may be readily rotated by means of the operating handle 17. It will be seen that the potentiometer control shaft 14 extends inwardly to a position approaching a median point of the mechanism, but stopping short of the actual middle of the shaft 13, as at 14a. A sleeve 19 is slidably mounted on shaft 14 for movement axially of the shaft but which is prevented from rotating relative to the shaft 14 by means of a keyway (not shown) which permits relative sliding movement axially but positively locks the tubular shaft 14 and the sleeve 19 encircling the shaft, against relative rotation. At its inner end the sleeve 19 is provided with a bevel gear 20 more fully hereinafter to be described.
A sleeve 21 is mounted on the dimmer control shaft 13 and is axially slidable thereon but is prevented from relative rotation with respect thereto by means of a keyway (not shown) which positively locks the sleeve 21 and shaft 13 against relative rotation but permits the sleeve to slide axially of the control shaft. A bevel gear 22 is provided on the inner end of the tubular sleeve 21 similar to the gear 20 on the tubular sleeve 19 but in opposite relation thereto. Centrally between the potentiometer 10 and the dimmer 11 a timer mechanism 23, including a bevel gear wheel 24, is mounted on a bracket 25 in position for the gear wheel to mesh with one or the other, or both of the bevel gears 20 and 22 whereby the potentiometer 10 and the dimmer 11 can be placed under the control of the timer and their operation regulated thereby.
The bevel gears 20 and 22, mounted on the respective sliding sleeves 19 and 21, are adapted to be moved into meshing engagement with the gear wheel 24 by means of solenoids 26 and 27 respectively, whereby the potentiometer 10, or the dimmer 11, can be placed under the control of the timer 23. The respective solenoids are mounted on the brackets 12 and 9 directly below the associated potentiometer or the dimmer, as shown in FIG. 1 and actuate the sliding sleeves 19 and 21 through suitable lever mechanisms which move the sleeves axially on the shafts 14 and 13 to engage, or disengage, the gears 20 and 22 with respect to the gear wheel 24. The solenoid arm 28 is pivotally connected with a lever 29 which is fulcrummed intermediate its ends on a pivot member 30 projecting from a mounting bracket 31 secured to the solenoid 26. The pivot member 30 is rigidly secured to the bracket 31 which is located adjacent to the inner end of the solenoid.
A link 32 connects the opposite end of the lever 29 to a freely rotative ring, or collar member 33, encircling the sleeve 19 and which enables the sleeve member to be moved axially on the shaft 14 while the sleeve and the shaft are left free to be rotated by means of the operating handle 16, or by the gear 20 when it is operatively meshed with the gear wheel 24. The ring 33 rides in a groove 34 which encircles the sleeve 19 and enables the sleeve to be rotated freely in the ring but enables the sleeve to be moved axially on the shaft 14 by means of the solenoid actuated lever mechanisms 29/32. Thus the solenoid 26 can act to engage the gear 20 with the gear wheel 24 to operate the potentiometer from the timer 23 or, the gears may be disengaged by the operation of the solenoid whereby the potentiometer may be adjusted manually through the medium of the operating handle 16.
A lever 35 operatively connects the solenoid arm 36 of the solenoid 27 with a ring, or collar 37 on the sleeve 21, through a connecting link 38, whereby the solenoid can operate to move the sleeve and the associated bevel gear 22 axially on the shaft 13. The ring 37 rides in a groove 39 that encircles the sleeve 21 similarly to the groove 34 in the sleeve 19, so that the sleeve 21 is free to rotate in the ring 39 under the impetus of the timer mechansim 23 through the gears 24 and 22 or, when the gears are disengaged the shaft 13 and the associated sleeve 21 can be rotated manually by means of the operating handle 17 to adjust the dimmer 11. The lever 35 fulcrums intermediate its ends on a pivot member 40 rigidly secured to a mounting bracket 41 secured adjacent the inner end of the solenoid 27. Thus, this solenoid can function similarly to the opposite solenoid, to move the bevel gear 22 on the sleeve 21 into and out of operating engagement with the timer actuated gear 24 to place the dimmer 11 under the control of the timer mechanism or, the dimmer can be left free to be adjusted manually be means of the through shaft 13 and operating handle 17.
The solenoids 26 and 27 are disposed in an electrical circuit powered from a source of A.C. current 44 as shown schematically in FIG. 2. As shown in this diagram it will be seen that a single pole, double throw switch 45 is in circuit with a tape deck 46, the potentiometer 10 and the solenoid 26, while a similar single pole, double throw switch 47 is in circuit the dimmer 11 and the solenoid 27. Switches 45 and 47 are operable independently of each other and when the switch 45 is in the off position at 0 the tape deck 46, potentiometer 10 and solenoid 26 will not be operative so that audio production will not be available while the switch is disposed in this position. However, when the switch 45 is placed in its active position at 1 the tape deck 46 and potentiometer 10 will be activated so that audio production is had and in this position of the switch, volume control is obtained by manual adjustment of the potentiometer 10 through operation of the shaft 14 by means of the handle 16, the solenoid 26 being inactive in position 1 of the switch 45. Under these conditions the potentiometer control shaft 14 is free to be rotated manually with the bevel gear 20 disengaged from the timer gear wheel 24, as shown in FIG. 1. A speaker 48 is disposed in the audio circuit with the tape deck 46 and potentiometer 10 and projects sound generated at the tape deck under volume control exerted by the potentiometer.
Position 1 of switch 47 also is the manual operating position for the dimmer 11 and lamp 49 and when the switch is disposed in the off position 0 the dimmer 11 and the solenoid 27 are deactivated so that no light is to be had at the lamp 49. However, in position 1 of switch 47 the dimmer is activated and brightness of the light given by lamp 49 can be adjusted manually by rotating the dimmer through the medium of through operating shaft 13 by the handle 17, solenoid 27 being deactivated in this position of the switch 47. In FIG. 1 the bevel gears 20 and 22 are shown in positions as though the switch 45 is in its position 1 with switch 47 in its position 2, where the gear 22 will be engaged with gear wheel 24 on the timer, but in position 1 of switch 47 the gears will be disengaged just as in the case of gear 20 in this Figure to provide for manual operation.
When either switch 45 or switch 47 is disposed in its position 2 a double-pole double-throw switch 50 will be activated, but since this switch is a double-pole double-throw type of switch the power continues to be directed independently to the respective functions of switches 45 and 47. The double-pole double-throw switch 50 is opened by activating the timer 23. When switch 45 is placed in its position 2 the double-pole double-throw switch 50 is entergized but remains open. However, when timer 23 is activated switch 50 closes thereby directing power to tape deck 46, potentiometer 10 and solenoid 26. The solenoid 26, as indicated in FIG. 1 and hereinbefore described, then engages the potentiometer bevel gear 20 with the gear wheel 24, actuated by the timer, so that as the timer slowly rotates to its deactivated condition, the timer gear 24 turn the potentiometer gear 20 thereby automatically reducing the volume gradually at the speaker 48 until the timer 23 is totally deactivated thus opening the double-pole double-throw switch 50 and thereby deactivating the system.
The lighting system functions similarly with the power being directed through the double-pole double-throw switch 50 to the dimmer 11 and the solenoid 27 to regulate the operation of lamp 49. When switch 47 is placed in its position 2 the double-pole double-throw switch 50 is activated but remains open as described in reference to the audio phase of the system. However, when the timer mechanism 23 is activated, the switch 50 closes and thereby directs power to the dimmer 11 and associated lamp 49 and the solenoid 27. Solenoid 27 operates to engage the bevel gear 22, which is operatively associated with the dimmer 11, with the timer actuated gear wheel 24 so that as the timer mechanism slowly rotates to its deactivated position the timer gear 24 turns the dimmer gear 22, thereby automatically and gradually reducing the brightness of the lamp 49 by rotating the dimmer 11, and continues to reduce the lamps brightness until the timer 23 is fully deactivated thus opening the switch 50 and thereby deactivating the entire system.
Both of the switches 45 and 47 can be activated to cause the tape deck 46 and the lamp 49 to be operated at the same time under the control of the timer mechanism 23 whereby the volume control of the tape deck 46 and speaker 48 and the brightness control of the lamp 49 can be regulated simultaneously and at the same rate. If desired, relays may be installed between the potentiometer 10 and its solenoid 26 and between the dimmer 11 and its associated solenoid 27 so that when the potentiometer or the dimmer become completely deactivated the associated solenoids 26 and 27 will also be deactivated whereby to afford the timer mechanism 23 its freedom to deactivate the system.
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A child's lamp and sound source including a light and a tape deck, or the like, controlled by a timer mechanism mechanically actuating either a dimmer for the light or a potentiometer for varying the sound level of the tape deck. Electrical circuitry including solenoids for controlling the tape deck and light automatically also provides for manual control of the potentiometer and dimmer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/565,699, filed on Aug. 2, 2012, now U.S. Pat. No. 8,819,752, which is a continuation of U.S. patent application Ser. No. 11/064,280, filed on Feb. 23, 2005, now U.S. Pat. No. 8,261,311, which claims the benefit of earlier filing date and right of priority to Korean Application No. 10-2004-0012388, filed on Feb. 24, 2004, the contents of which are all hereby incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method for transmitting video data from a mobile communication terminal.
2. Description of the Related Art
With the increase in the availability of highly integrated memory and the transmission speed of large-scale data, a mobile communication terminal (“terminal”) may store and transmit a text message, a still image or a melody, and record, store, edit and transmit video.
Users are increasingly recording video through the terminal or transmitting stored video to other terminals.
During transmission of video data or an audio signal synchronized with a video signal between terminals, a conventional terminal cannot transmit the video data when the video data is being reproduced. A user must stop reproducing the video data, write a message, attach the video data to be transmitted to the message, and transmit the message to another terminal. In other words, conventional terminals transmit video data by separately implement reproduction of video data and transmission of a message to which the video data file is attached.
FIGS. 1A and 1B illustrate a conventional terminal apparatus, including signal flow through the apparatus, for transmitting video data from a terminal.
As shown in FIGS. 1A and 1B , the apparatus for transmitting the video data includes a key input unit 110 , an event processing unit 120 , a video data reproduction unit 130 , a message transmission unit 140 , a data storage unit 150 , an output processing unit 160 , and a call processing unit 170 . The descriptions for these units are given below.
Upon a user pressing an option key, the key input unit 110 recognizes the pressed key. The key input unit 110 determines, for example, if the pressed key is a video data reproduction start key, a video data reproduction stop key, or a message transmission start key. The key input unit 110 transmits the result of the determination to the event processing unit 120 .
The event processing unit 120 notifies the video reproduction unit 130 and the message transmission unit 140 of an event. Examples of an event include a video data reproduction start event, a video data reproduction stop event, and a message transmission start event.
The video data reproduction unit 130 reads video data selected by the user from the data storage unit 150 and reproduces the video data.
The message transmission unit 140 writes a message, attaches a selected video data file to the written message, and attempts to transmit the message attached to a video data file according to a data transmission protocol.
The video data file and related information are stored in the data storage unit 150 .
The output processing unit 160 audiovisually notifies a user of reproduction information of the video data and terminal information.
The call processing unit 170 transmits the message to a receiving terminal in accordance with directions from the message transmission unit 140 .
Hereinafter, a method for transmitting video data from a conventional terminal will be described with reference to signal flow diagram of FIGS. 1A and 1B .
A user presses a video data reproduction key after selecting the video data to be reproduced from a list of videos stored in the data storage unit 150 . The key input unit 110 determines that the pressed key is a video data reproduction start key. The key input unit 110 notifies the event processing unit 120 of the determination. The event processing unit 120 notifies the reproduction unit 130 of a video data reproduction start event corresponding to the determination. The event processing unit 120 activates the video data reproduction unit 130 and notifies the video data reproduction unit 130 of selected video data information.
The video data reproduction unit 130 reads the selected video data from the data storage unit 150 and reproduces the read video data.
To transmit the video data currently being reproduced, the user stops reproducing the video data.
The user presses a key to stop reproduction of the video data currently being reproduced. The key input unit 110 determines the pressed key is intended to stop video data reproduction, and notifies the event processing unit 120 of the determination. The event processing unit 120 notifies the video data reproduction unit 130 to stop reproducing video data and deactivates the video data reproduction unit 130 .
The video data reproduction unit 130 stops reproducing the video data and notifies the event processing unit 120 that reproduction has stopped. The event processing unit 120 notifies the output processing unit 130 that the video data reproduction unit 130 is deactivated. The output processing unit 160 indicates, on a terminal screen the video data reproduction unit 130 is deactivated.
To transmit the video data for which reproduction of has stopped, the user presses a message transmission key. The key input unit 110 determines the pressed key is for message transmission and notifies the event processing unit 120 . The event processing unit 120 notifies the message transmission unit 140 of a message transmission event corresponding to the pressed key and activates the message transmission unit 140 .
The user writes a message utilizing the message transmission unit 140 . The message transmission unit 140 attaches the written message to a selected video data file, and attempts to transmit the message through the call processing unit 170 .
Upon complete transmission of the message, the message transmission unit 140 notifies the event processing unit 120 and the event processing unit 120 notifies the output processing unit 160 .
The output processing unit 160 audiovisually notifies the user that transmission of the message, and the video data file has been completed.
In summary, a user of a conventional terminal desiring to transmit a video data currently being reproduced must stop reproducing the video data and transmit a message to which the entire video data file is attached. To transmit a portion of the video data, the user is required to edit the video data using editing software before transmission. An edited version of the video data and the editing software require separate storage locations.
Therefore, there is a need for an improved apparatus and method for transmitting video data that provides additional advantages over conventional terminals and increases user convenience.
SUMMARY OF THE INVENTION
Features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
In one embodiment, an apparatus for transmitting video data to a receiving terminal is disclosed. The apparatus comprises an event processing unit for outputting a signal to store a selected portion of the video data that is currently being reproduced and a video data reproduction unit for receiving the signal from the event processing unit and storing the selected portion of the video data that is currently being reproduced in response to a signal from the event processing unit during reproduction of the video data. A message transmission unit is further provided for attaching the stored selected portion of the video data that is currently being reproduced to a message and transmitting the message to the receiving terminal. A data storage unit stores the video data and the selected portion of the video data.
A user may designate the selected portion of the video data. The video data reproduction unit preferably, upon completion of storing the selected portion of the video data, temporarily stops reproducing the video data.
In another embodiment, a method of transmitting video data to a receiving terminal is disclosed. The method comprises storing a selected portion of the video data while the video data is being reproduced, attaching the stored selected portion of video data to a message, and transmitting the message to the receiving terminal.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
These and other embodiments will also become readily apparent to those skilled in the art from the following detailed description of the embodiments having reference to the attached figures, the invention not being limited to any particular embodiments disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
Features, elements, and aspects of the invention that are referenced by the same numerals in different figures represent the same, equivalent, or similar features, elements, or aspects in accordance with one or more embodiments.
FIGS. 1A and 1B illustrate a structure and signal flow of an apparatus for transmitting video data to a receiving terminal according to the conventional art.
FIGS. 2A-2C illustrate a structure and signal flow of an apparatus for transmitting video data to a receiving terminal according to a first embodiment of the present invention.
FIGS. 3A-3C illustrate a structure and signal flow of an apparatus for transmitting video data to a receiving terminal according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to an apparatus and method for efficiently transmitting video data while minimizing the resources required by a mobile communication terminal.
Although the invention is illustrated with respect to a mobile terminal, it is contemplated that the invention may be utilized wherever it is desired to efficiently transmit data, such as video data, that requires editing in a communication system while minimizing the size of a data storage location and reducing user inconvenience. Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
The preferred embodiments transmit video data facilitating increased user convenience and data storage efficiency. More specifically, the preferred embodiments specify a portion of the video data for transmission from currently reproduced video data. The preferred embodiment transmits the specified portion of the video data including an attached message.
FIGS. 2A-2C illustrate a structure and signal flow of an apparatus for transmitting video data to a receiving terminal according to a first embodiment of the present invention.
Referring to FIGS. 2A-2C , an apparatus for transmitting the video data from the terminal includes a key input unit 210 , an event processing unit 220 , a video data reproduction unit 230 , a message transmission unit 240 , a data storage unit 250 , an output processing unit 260 , and a call processing unit 270 . Functions of each of these constituent elements are discussed below.
When a user presses an option key, the key input unit 210 recognizes that the option key has been pressed. The key input unit 210 determines the pressed key. The pressed key, for example, may be a video data reproduction start key, a video data storage start key, or a video data storage termination key. The key input unit 210 transmits the determination to the event processing unit 220 .
The event processing unit 220 notifies the video data reproduction unit 230 and the message transmission unit 140 of an event. The event, for example, may be a video data reproduction start event, a video data storage start event, or a video data storage termination event corresponding to the pressed key.
The video data reproduction unit 230 reads video data selected by the user from the data storage unit 250 , and reproduces the read video data. The video data reproduction unit 230 stores a selected portion of the video data specified by a user while the selected video data is being reproduced. The data storage unit 250 temporarily stores position information of the video data that is currently being reproduced.
The message transmission unit 240 writes a message and attaches the video data selected for transmission to the message. The message transmission unit 240 , in accordance with a data transmission protocol, attempts transmission of the message.
The data storage unit 250 stores the video data, the selected portion of the video data specified by the user, the stop position information of the video data currently being reproduced, and any related information.
The output processing unit 260 audiovisually notifies the user regarding information related to reproducing the video data and information about the terminal.
The call processing unit 270 transmits the message attached to the video data to a receiving terminal in accordance with instructions from the message transmission unit 240 .
A method for transmitting video data to a receiving terminal according to the first embodiment of the present invention will be described with reference to the signal flow diagram shown in FIGS. 2A-2C .
Upon a user pressing a video data reproduction start key, the key input unit 210 recognizes the pressed key. The event processing unit 220 transmits a video data reproduction event, corresponding to the recognized pressed key, and video data reproduction information to the video data reproduction unit 230 . The video data reproduction unit 230 reads the corresponding video data from the data storage unit 250 . The video data reproduction unit 230 reproduces the read video data in accordance with the transmitted video information and the video data reproduction event. The user designates a start position and a stop position for a portion of the video data selected for transmission while the video data is being reproduced.
The video data reproduction unit 230 temporarily stores, from the start position to the stop position, video data in the data storage unit 250 , temporarily stops reproduction of the video data upon completion of video data storage, and temporarily stores the stop position information of video data currently being reproduced in the data storage unit 250 . The event processing unit 220 recognizes the reproduction of the video data temporarily stopped and reactivates the message transmission unit 240 .
The message transmission unit 240 attaches the temporarily stored video data to a user message. The call processing unit 270 transmits the message attached to the video data to a receiving terminal. The output processing unit 260 , upon complete transmission of the message, audiovisually notifies a user of message transmission. The reproduction unit 230 resumes reproducing the video data based on the stored stop position information.
Hereinafter, the method of transmitting video data from a terminal according to the first embodiment of the present invention will be described in more detail.
After searching a list of the video data stored in the data storage unit 250 , a user presses the video data reproduction start key, and video data is selected. The key input unit 210 determines that the video data reproduction start key has been pressed. The key input unit 210 notifies the event processing unit 220 . The event processing unit 220 notifies the video data reproduction unit 230 of a video data reproduction start event and information regarding the selected video data, and reactivates the video data reproduction unit 230 .
The video data reproduction unit 230 reads the selected video data from the data storage unit 250 and reproduces the selected video data.
When a portion of the selected video data is reproduced, a user designates, via the key input unit 210 , a start position used for transmitting a portion of the selected video data. The key input unit 210 notifies the event processing unit 220 that a video data storage start key has been pressed. The event processing unit 220 notifies the video processing unit 230 that a portion of the video data currently being reproduced is the start position for transmission.
The video data reproduction unit 230 continues reproducing the video data and stores the video data from the start position in the data storage unit 250 .
The user designates, via a key stroke, a stop position for the portion of the video data for transmission. The key input unit 210 notifies the event processing unit 220 that the designated stop position of the video data is to be transmitted. The event processing unit 220 notifies the video data reproduction unit 230 upon completion of storing the video data.
The video data reproduction unit 230 stops storing the video data and temporarily stops reproduction of the video data. The video data reproduction unit 230 temporarily stores stop position information of the video data currently being reproduced in the data storage unit 250 , and notifies the event processing unit 220 that reproduction of the video data has stopped.
The event processing unit 220 activates the message transmission unit 240 . The message transmission unit 240 attaches the video data temporarily stored in the data storage unit 250 to a message. The message transmission unit 240 attempts to transmit the message to a receiving terminal.
Upon complete transmission of the message, the message transmission unit 240 deletes the video data temporarily stored in the data storage unit 250 . The message transmission unit 240 notifies the event processing unit 220 that the temporarily stored video data has been deleted upon completion of message transmission.
The event processing unit 220 reactivates the video data reproduction unit 230 . The video data reproduction unit 230 resumes reproduction of the video based on the stop position information stored in the data storage unit 250 .
FIGS. 3A-3C illustrate a structure and signal flow of an apparatus for transmitting video data to a receiving terminal according to a second embodiment of the present invention.
Referring to FIGS. 3A-3C , the apparatus includes a voice input unit 310 , an event processing unit 220 , a video data reproduction unit 230 , a message transmission unit 240 , a data storage unit 250 , an output processing unit 260 , and a call processing unit 270 . Functions of each of the units are described below.
Upon a user issuing an optional voice command, the voice input unit 310 recognizes the voice command and determines the contents of the voice command. The voice command may be a video data reproduction start command, a video data storage start command, or a video data storage termination command. The voice input unit 310 transmits the result of the determination to the event processing unit 220 .
The event processing unit 220 notifies the video data reproduction unit 230 and the message transmission unit 240 of the event corresponding to the voice command.
The video data reproduction unit 230 reads the video data selected by the user from the data storage unit 250 and reproduces the read video data. The video data reproduction unit 230 stores a selected portion of a video data specified by the user during reproduction of the selected video data and stop position information of the video data currently being reproduced in the data storage unit 250 .
The message transmission unit 240 writes a message, attaches the video data selected for transmission to the written message, and attempts to transmit the message according to a data transmission protocol.
The data storage unit 250 stores the video data, the selected portion of the data specified by the user, the temporarily stored stop position information of the video data currently being reproduced, and related information.
The output processing unit 260 notifies the user regarding reproduction information regarding the video data and terminal information.
The call processor 270 transmits the message and the selected portion of the video data to the receiving terminal in accordance with instructions from the message transmission unit 240 .
A method of transmitting video data to a receiving terminal according to the second embodiment of the present invention will be described with reference to the signal flow as shown in FIGS. 3A-3C .
The user issues a video data reproduction start voice command and the voice input unit 310 recognizes the voice command. The event processing unit 220 transmits a video data reproduction event corresponding to the recognized voice command along with video reproduction information to the video data reproduction unit 230 . The video data reproduction unit 230 reads the video data from the data storage unit 250 , reproduces the read video data, and stores a specified portion of the video data. While the video data is being reproduced, the user designates a start position and a stop position for transmission of a selected portion of the video data.
The video data reproduction unit 230 temporarily stores the video data, from the designated start position to the designated stop position, in the data storage unit and temporarily stops reproducing the video data until completion of video data storage. The video data reproduction unit 230 temporarily stores stop position information of the video data currently being reproduced in the data storage unit 250 . The event processing unit 220 recognizes that reproduction of the video data has been temporarily stopped and activates the message transmission unit 240 . The message transmission unit 240 attaches the temporarily stored video data to a message.
The message is attached to the video data for transmission through a call processing unit to the receiving terminal. The output processing unit 260 audiovisually notifies the user that message transmission is complete. The video data reproduction unit 230 resumes reproducing the video data based on the stored stop position information of the video data currently being reproduced in the data storage unit 250 .
Hereinafter, the method of transmitting the video of the terminal according to the second embodiment of the present invention will be described in detail.
The user searches a list of the video data stored in the data storage unit 250 , selects video data, and issues a video data reproduction voice command. The voice input unit 310 determines the voice command indicates video data reproduction start and notifies the event processing unit 220 of the result. The event processing unit 220 notifies the video data reproduction unit 230 of a video data reproduction start event corresponding to the determination along with information regarding the selected video data and activates the video data reproduction unit 230 .
The video data reproduction unit 230 reads the selected video data from the data storage unit 250 and reproduces the read video data.
A portion of the selected video data being reproduced is selected for transmission. If a start position of the portion to be transmitted is designated by a user issuing a voice command, the voice input unit 310 notifies the event processing unit 220 that a video data storage start voice command has been issued. The event processing unit 220 notifies the video data reproduction unit 230 that the portion currently being reproduced is the start position of the portion to be transmitted.
The video data reproduction unit 230 continues reproducing the video data and stores the video data from the designated start position in the data storage unit 250 .
The user designates a stop position for a portion of the video data selected for transmission by issuing a voice command. The voice input unit 310 notifies the event processing unit 220 that the designated stop position is for the video data to be transmitted. The event processing unit 220 notifies the video data reproduction unit 230 upon termination of video data storage.
The video data reproduction unit 230 terminates video data storage and temporarily stops reproducing the video data. The video data reproduction unit restores stop position information of the video data currently being reproduced in the data storage unit 250 . The video data reproduction unit notifies the event processing unit 220 upon temporarily stopping reproduction of the video data.
The event processing unit 220 activates the message transmission unit 240 . The message transmission unit 240 attaches the video data stored in the data storage unit 250 to a message the user has written, and attempts transmission through the call processing unit 270 .
When transmission of the message is completed, the message transmission unit 240 deletes the video data temporarily stored in the data storage unit 250 . The message transmission unit 240 notifies the event processing unit 220 upon completion of message transmission and deletion of the temporarily stored video data.
The event processing unit 220 reactivates the video data reproduction unit 230 . The video data reproduction unit 230 resumes reproducing the video data based on the stored stop position information of the video data currently being reproduced and completes processing of the video transmission.
The present invention provides video data reproduction whereby a user can select a selected portion of the video data for transmission to a specific terminal. After transmission is completed, the video data temporarily stored but previously transmitted is automatically deleted. A separate video editing software and an editing process are not required. Accordingly, a user's convenience is increased, and storage space required for a terminal is reduced.
As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to be embraced by the appended claims.
Although the present invention is described in the context of a mobile terminal, the present invention may also be used in any wired or wireless communication systems using mobile devices, such as PDAs and laptop computers equipped with wired and wireless communication capabilities. Moreover, the use of certain terms to describe the present invention should not limit the scope of the present invention to certain type of wireless communication system, such as UMTS. The present invention is also applicable to other wireless communication systems using different air interfaces and/or physical layers, for example, TDMA, CDMA, FDMA, WCDMA, etc.
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An apparatus and method for transmitting video data to a receiving terminal is disclosed. The apparatus comprises an event processing unit for outputting a signal to store a selected portion of the video data that is currently being reproduced, a video data reproduction unit for receiving the signal from the event processing unit and storing the selected portion of the video data that is currently being reproduced in response to the outputted signal while reproducing the video data. A message transmission unit is further provided for attaching the stored selected portion of the video data that is currently being reproduced to a message and transmitting the message to the receiving terminal. A data storage unit stores the video data and the selected portion of the video data.
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OBJECT OF THE INVENTION
[0001] As stated in the title of this descriptive specification, the present invention relates to a process for reduction of the common mode current for power line communications equipment, which has the object of reducing the level of common mode signal in order to satisfy the standards of different countries on power line communications equipment, all of which without having to reduce the injected power, which would worsen the coverage and the efficiency of the communications system.
[0002] In general, the invention is applicable to any electric circuit in which the common mode current needs to be reduced and more particularly in electric circuits used in telecommunications equipment which use the mains network as transmission medium.
[0003] Defined below are some terms which are used in this document. Let a signal source be formed from an electric generator, a circuit via which the generated current flows and an additional circuit suitable for passing current coming from the generator and connected to the circuit in some way. Common mode current is defined as being that current which flows through the conductor and returns via the circuit or the source.
[0004] Moreover, common mode choke is described as being that device capable of attenuating or reducing the level of the common mode current in an electric circuit.
[0005] Power line communications equipment is likewise defined as the type of communication by means of electrical defined as the type of communication by means of electrical signals that use the low, medium or high tension electrical mains network as communications channel.
PRIOR ART OF THE INVENTION
[0006] In the majority of electrical systems, common mode currents need to be attenuated due to their actual functioning, with the aim of reducing the electromagnetic interference with other devices.
[0007] The state of the art already contains devices for reducing common mode currents, as an example of which one can cite switched power supply sources which use common mode filters for reducing their conducted and radiated electromagnetic emissions [which can be found in many different documents such as AN 15 on POWER INTEGRATIONS]. Another example is communications by means of Ethernet cable, fitted with common mode chokes for reducing their conducted and radiated emission levels in the corresponding frequency band.
[0008] There currently do not exist devices for reducing in any effective way common mode levels in power line communications systems, and the devices existing and used in other applications are of no use for this type of communications on account of their limitations regarding working voltages and attenuations in differential mode. Moreover, in order for the reduction in common mode current to be effective, both the way in which the common mode choke is constructed and its location in the communications circuit are of overriding importance.
DESCRIPTION OF THE INVENTION
[0009] In order to achieve the objectives and avoid the drawbacks stated in the above sections, the invention consists of a process for reduction of the common mode current for power line communications equipment, where the mains network is used as the communications medium, and which at least comprises applying the signal transmitted by the communications equipment via a common mode choke circuit; characterised in that the signal (transmitted by the communications equipment via a common mode choke circuit) is applied on braided signal cables belonging to the common mode choke circuit mounted around a toroidal magnetic core. In this manner, the differential mode inductance is minimised.
[0010] The common mode choke can be located internally or externally to the communications equipment. If it is internal, its position will be as an output element from the power line communications equipment. If it is external, its position will be between the communications equipment and the injection point into the mains network.
[0011] One particular case is to locate the special common mode choke at the injection point of the communications signal to the mains network, which has the added advantage of increasing the impedance of the common mode loop.
[0012] Below, in order to facilitate a better understanding of this specification and forming an integral part thereof, some figures are attached in which, on an illustrative rather than limiting basis, the object of the invention has been represented.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 .—Represents a type of choke circuit of those known conventionally, which presents impedance in common and differential mode.
[0014] FIG. 2 .—Shows the choke used by the invention for reducing the common mode signal.
[0015] FIG. 3 .—Shows an example of the location of the choke of the invention in the power supply cable for the power line communications device, in which the choke is located at the injection point of the signal to the mains.
DESCRIPTION OF AN EXAMPLE OF EMBODIMENT OF THE INVENTION
[0016] A description is made forthwith of an example of the invention, making reference to the numbering adopted in the figures.
[0017] In order to introduce PLC (power line communications) products in the market, it is necessary to satisfy the regulations concerning electromagnetic emissions on PLC devices. One of the most important requirements is the limit of common mode current which, on a standard basis, is measured with a device known as a T-shaped Impedance Stabilisation Network, or T-ISN, in a controlled environment. With this measurement, the common mode is obtained coming from the Device Under Test (DUT). In this measurement, part of the differential signals coming from the DUT are converted into common mode signals, owing to the longitudinal conversion loss or LCL.
[0018] Power line communications equipment usually has a switched mode power supply or SMPS source connected to the mains network at the same point where the communications signal is injected. This SMPS represents an unbalanced load connected in parallel with the PLC signal source, with which, when starting to transmit, a certain amount of differential signal will be converted into common mode, owing to parasite capacities, and the result of the measurement with the T-ISN will be a larger common mode than expected.
[0019] One solution to this problem is to reduce the power transmitted by the PLC equipment, but this entails various drawbacks, such as worse coverage and a lower transmission capacity (throughput).
[0020] Even in the case that the injected PLC signal were to be completely balanced (in other words, purely differential), measurement with T-ISN imposes a certain quantity of common mode current on the probe, which can only be reduced by decreasing the power of the signal. If the injected signal has a certain amount of common mode current, this will be measured additionally on top of that of the current probe, which makes it important to maintain the signal output from the PLC equipment as balanced as possible.
[0021] The objective of the present invention is to succeed in reducing the level of common mode signal in order to satisfy the regulations of different countries, in such a way that it is not necessary to make a sudden reduction in the injected power, which would worsen the coverage and the efficiency of the communications system.
[0022] The method employed for this consists of using a special common mode choke at the output from the PLC equipment which reduces common mode emissions as much as possible. This choke can be located both internally and externally to the communications equipment, depending on the type of equipment it is wished to develop.
[0023] In the state of the art, conventional common mode chokes are used to suppress electromagnetic interference (or EMI) in switched sources. These chokes are designed for achieving a powerful attenuation on the common mode signal without saturating its magnetic cores and, ideally, they can be represented as high impedance for common mode signals and a short-circuit for differential signals.
[0024] In FIG. 1 one can see one of these conventional chokes, where ( 1 ) represents the input, ( 2 ) the output, ( 3 ) the path of the current and ( 4 ) the direction of the field within the choke. Chokes of this kind are valid for the purpose for which they were created, namely, attenuating the noise in common mode coming from the power supply source and permitting the passage of 50 Hz currents without saturating the magnetic core, but they are not suitable for PLC technology on account of their impedance characteristics.
[0025] In the state of the art there exist two types of common mode (CM) chokes for EMI purposes. On the one hand there are toroidal CM chokes which perform well at high frequency, in other words, with high self resonance frequency or SRF, but which present low impedance in common mode. On the other hand, there exist common mode chokes that are spool wound, which perform well at low frequencies, namely they have high impedance in low frequency common mode, but perform badly at high frequencies (due to having a low SRF). Both types of commercial chokes present impedance in common mode and in differential mode.
[0026] For PLC equipment the impedance has to be in common mode only, so neither toroidal CM chokes nor spool wound chokes can be used due to the presence of a residual inductance.
[0027] In order to achieve the stated objective, the proposed method consists of injecting the signal through a special common mode choke consisting of braided signal cables mounted around a toroidal magnetic core, which minimises the dispersion inductance. This special choke can be seen in FIG. 2 , where ( 5 ) indicates the signal input (output of the PLC equipment), ( 6 ) the signal output (to the mains network) and ( 7 ) the magnetic torus.
[0028] In the majority of cases, in order to reduce common mode currents from the signal source, this special common mode choke needs to be included at the output from the PLC equipment. In the case of tabletop communications equipment the common mode signal can be reduced further by placing the choke between the PLC equipment and the injection point to the mains. The optimum location point for the special common mode choke is the injection point of the communications signal to the mains, which the special choke can achieve at the end of the power supply cable for the equipment which can be seen in FIG. 3 as ( 8 ).
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It permits common mode currents to be reduced in communications equipment using the mains network as transmission medium, in order to adapt the emission values of common mode to standards on power line communications corresponding to each country.
The reduction in emission levels in common mode of signals transmitted by power line communications equipment permits the transmitted signal to be optimised in a way that manages to satisfy the existing regulations without sacrificing either coverage or performance of the communications system.
It is characterised by the use of a special common mode choke at the outlet from the communications system which minimises the inductance in differential mode.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a National Stage filing of PCT International Application Serial No. PCT/GB2007/004658, filed Dec. 5, 2007, which claims the benefit of GB Application Serial No. 0625061.7, filed Dec. 15, 2006, the disclosures each of which are expressly incorporated herein by reference.
TECHNICAL FIELD
This invention relates to a connector for use in terminating communications cables.
SUMMARY OF THE INVENTION
In a first aspect the present invention provides a connector for use in terminating communications cables including: electrical contacts arranged to receive wires of a communications cable; at least one cover pivotally associated with the connector; wire receiving spaces for guiding the wires are associated with the at least one cover; and the at least one cover is arranged to move pivotally to bring the wires into engagement with the electrical contacts.
The electrical contacts will preferably be insulation-displacing or -piercing contacts, but other kinds of contacts may be used, for example when stripped wire ends are provided for connection to the contacts. The electrical contacts may be provided on a removable contact carrier, for example on opposed faces of the carrier, and the carrier may be retained in the connector by the at least one cover. The carrier may at least partly shield the inside of the connector from external electromagnetic radiation, and may at least partly prevent emission of electromagnetic radiation from the interior of the plug to the outside. Preferably the carrier will include cross-shaped or other internal shielding to prevent or reduce cross-talk radiation between respective wire pairs within the plug. The carrier may include at least one recess that aligns with the at least one cover to position the carrier in the connector. The recess may receive a cam portion of the at least one cover to position the carrier.
The at least one cover may be pivotally moveable from a first position to a second position, the cable terminated by the connector has a longitudinal axis and in the first position the wire receiving spaces extend away from the longitudinal axis of the cable and in moving to the second position the wire receiving spaces are brought closer to aligning with the axis. The at least one cover may at least partly shield the inside of the connector from external electromagnetic radiation and may at least partly prevent or reduce emission of its internal electromagnetic radiation to the outside. The connector may be in the form of a plug or a jack, and may include two covers, which may be provided on opposite sides of the connector.
The connector may include two (or more) shells which fit about the cable, the shells preferably including resilient flanges, which flanges press against the cable to grip the cable, and which flanges may establish electrical contact with foil, braid, or other electromagnetic shielding carried by the cable. The resilient flanges may be provided on a removable insert of the shell. The shells may be a snap-fit together, the snap-fit preferably being achieved by way of a lug which runs run for substantially the entire length of at least one of the shells.
In preferred embodiments of the invention, at least one, more preferably all, of the resilient flanges is/are provided with teeth having sharp points that pass through the folded-back braid or foil shield of the cable and sink into the cable jacket, to both retain the connector on the cable and make electrical continuity between the cable shield and the connector. Designs having all of the flanges toothed to provide cable retention and electrical continuity are superior to designs in which one flange provides electrical continuity, and the rest of the flanges are untoothed continuous ridges that must grip the cable beyond the folded-back braid/foil shield in order to resist sliding along the cable jacket. The more preferred toothed flange design thus achieves better cable retention and simplifies installation since the length of the braid/foil shield that is folded back over the cable jacket is not critical, whereas for untoothed flange designs the folded-back shield length must be adjusted to be engaged by only the first electrical-continuity flange but not by the other cable-gripping flanges.
A second aspect the present invention accordingly provides a cable clamp for a connector, the cable clamp including the aforementioned two or more shells which fit about a cable, wherein the shells further include resilient flanges which press against the cable to grip the cable and which may establish electrical contact with the usual shielding braid or foil of the cable. The resilient flanges may be provided on a removable insert of the shell. The cable clamp preferably includes two shells which snap-fit together fit about the cable. The snap-fit may be achieved by way of a lug which runs for substantially the entire length of at least one of the shells.
In a third aspect the present invention provides a contact carrier for use with a connector including: electrical contacts for interengagement with wires of a communications cable are provided on a body portion of the carrier; the carrier includes at least one recess that may be engaged with the connector to retain the carrier in the connector when the carrier is correctly inserted in the connector. The carrier may at least partly shield the inside of the connector from external electromagnetic radiation, and may at least partly prevent emission of electromagnetic radiation from the interior of the plug to the outside. Preferably the carrier will include cross-shaped or other internal shielding to prevent or reduce cross-talk radiation between respective wire pairs within the plug. The electrical contacts may be provided on opposed faces of the carrier.
The carrier and the cover or covers of the connector are preferably provided with snap-engageable formations, for example groove and recess formations, to retain the cover(s) in closed position about the carrier.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a first sub-assembly which forms part of an embodiment of a connector according to the present invention;
FIG. 2 shows a second sub-assembly for use with the sub-assembly of FIG. 1 ;
FIGS. 3A to 3G illustrate the snap-fitting together of the first and second sub-assemblies;
FIG. 4 shows the first and second sub assemblies assembled together with a cable to be terminated;
FIG. 4A shows the assembly of FIG. 3 with wire ends trimmed;
FIGS. 5 & 6 show a thirdsub-assembly being fitted to the assembly of FIG. 4 ;
FIG. 7 shows an assembled connector according to the invention;
FIGS. 8 & 9 illustrate components of the connector of FIG. 7 in more detail;
FIG. 10 shows an alternative embodiment of a connector according to the invention partly assembled;
FIGS. 11 and 12 show the connector of FIG. 10 being further assembled;
FIGS. 13 and 14 show the connector of FIG. 10 fully assembled;
FIG. 15 shows the preferred toothed spring flanges of the cable-enclosing half-shell sub-assemblies; and
FIG. 16 shows the preferred snap-fit slot and rib formations for securing the hinged covers in the closed position on the contact carrier.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 a first sub-assembly 10 of a connector is shown which includes a shell in the form of casing 11 and an electrically-conductive cover 12 , both of which are formed from a metallic alloy known in this field of technology as “Zamak”. Cover 12 is pivotally connected to casing 11 and may pivot about axis A. Wire-receiving spaces 14 are provided in a plastic lacing fixture 16 which is affixed to the inside of cover 12 . Referring to FIG. 2 , a second sub-assembly 20 is shown which is complementary to the first sub-assembly and is similar in construction. Cover 22 and casing 21 are formed from Zamak and are pivotally connected about axis B. Wire-receiving spaces 24 are provided in lacing fixture 26 . Casing 21 is identical to casing 11 .
The casings 11 and 21 both include removable inserts 13 which include resilient flanges 15 . The casings 11 and 21 are arranged to be snap-fitted together about a cable to be terminated to form a cable clamp around the cable. A foil-shielded cable is typically used. A length of outer insulation is removed from the end of the cable to be terminated and a section of the exposed foil shield is folded back over the cable outer insulation. The resilient flanges 15 become compressed about the cable when casings 11 , 21 are snap-fitted together to grip the cable and provide strain relief. Inserts 13 are made of electrically conductive material and press against the folded back section of foil to achieve electrical continuity between the foil shield in the cable and the connector. Casing 11 includes a lug 17 and a recess 18 . Casing 21 includes complementary recess 28 and lug 27 . To snap-fit the casings together lug 17 is snap-fitted into recess 28 and lug 27 is snap-fitted into recess 18 .
Referring to FIGS. 3A to 3G , the operation of snap-fitting together the two casings is illustrated. In these figure the cable is not shown for simplicity. At FIG. 3A , casings 11 , 21 are brought together until they touch (see FIG. 3B ). Casings are then manipulated so that lugs 17 , 27 align with recesses 18 , 28 (see FIG. 3C ). At FIG. 3D , casings are aligned so that recesses 81 , 71 line up with lugs 80 , 70 which are visible in FIGS. 1 and 2 . Casings 11 , 21 are then pressed together to arrive at the arrangement shown in FIGS. 3E and 3F . Casings 11 , 21 are snap-fitted together by way of the lug and groove formation shown in FIG. 3G .
Termination of a cable by way of the connector will now be described. Referring to FIG. 4 , sub-assemblies 10 , 20 are shown having been snap-fitted together about a cable 60 and wires 30 of cable 60 have been positioned in wire receiving spaces 14 and 24 . Cable 60 is generally cylindrical and has a central axis C. Excess wire is then trimmed from the ends of wires 30 (see FIG. 4A ).
Referring to FIG. 5 , a third sub-assembly 40 is shown which includes a carrier 41 formed from Zamak. Eight insulation-displacing contacts 42 are mounted in the carrier and are insulated from the carrier by plastic inserts. The insulation-displacing contacts are in electrical connection with plug contacts 43 which are housed in insulating contact holder 49 , which may be integral with the aforementioned plastic inserts. Carrier 41 is to be assembled with the first and second sub-assemblies to form a connector. Note that lug 45 will locate in groove 46 . Also, four lugs 47 will engage with four grooves 48 , which serve both to align sub-assembly 40 with the casings 11 , 21 already assembled on the cable, and to resist unintentionally disengagement of the casings 11 , 21 . Carrier 41 also includes recesses 44 which are used to retain the carrier in the assembled connector as will now be described.
Referring to FIG. 6 the connector is shown partially assembled. Carrier 41 is shown passing by flat portions 51 , 52 of covers 22 , 12 . To ensure right-way-around assembly, the distance between flat portions 51 and 52 and the relevant lug width are different on the opposite sides of carrier 41 , so that sub-assembly 40 will be assemblable only in its correct position. After complete insertion of carrier 41 , covers 12 and 22 are free to pivot about their respective axes to bring the wires towards the insulation-displacing contacts. As the covers 22 , 12 rotate, cam portions 54 , 53 of the covers come into engagement with recesses 44 of carrier 41 . The covers 22 , 12 are moved towards their closed position by hand and are pushed to their closed position by gripping about the entire assembly with pliers and squeezing so that the wires are properly engaged with the insulation-displacing contacts.
Referring to FIG. 7 , the connector is shown fully assembled. The covers, casings and carrier serve to completely surround the inside of the connector, thus shielding the wires inside the connector from electromagnetic interference.
Referring to FIGS. 8 and 9 , lacing fixture 16 and contact holder 49 are shown. When the covers of the connector are closed, the lip 84 of lacing fixture 16 snaps into the recess 85 on the contact holder, thus helping to keep the covers in the closed position.
FIGS. 10 to 14 show a female or jack type connector, which is similar in construction to the male or plug type connector shown in FIGS. 5 to 7 , and is intended to mate with the plug type connector. The main difference of the jack connector from the plug connector is found in the contact carrier 140 . It can be seen that contact carrier 140 provides a female type connection in the form of a recess generally indicated by arrow 160 which accommodates the male type connector previously described. Recess 160 may be protected by dust cover 150 .
FIG. 15 illustrates the aforementioned preferred toothed spring flanges 15 in the upper and lower cable-gripping sub-assemblies 11 , 21 .
FIG. 16 illustrates the addition of ribs 410 in the carrier 41 and slots 120 , 220 in the hinged covers 12 , 22 , which ribs snap-fit into the slots to hold the covers 12 , 22 releasably in the closed position around the contact carrier 41 .
In the above described embodiments, the end of the finished connector which bears the plug contacts extends away from the cable substantially in line with the axis of the cable. However, alternative constructions where the plug contacts extend at an angle to the axis of the cable may be employed.
In the embodiments described above, the electrically shielding parts are formed from Zamak, but other metals or electrically conductive materials could be used. A mould-over process may be used to form these components from a metal sheet surrounded by a moulded plastics material. Parts made of plastics in the embodiments described above could alternatively be made of other dielectric materials. In the embodiments described above, connectors with eight sets of contacts are described, but other numbers of contacts could be used, even odd numbers, and the insulation-displacing contacts described could be replaced by other types of contacts as previously mentioned. The cable may include a foil shield or a braided shield, or both foil and braided shields could be present.
In the embodiments described above the cable-surrounding casings were of identical (“mirror image”) construction. Alternatively, casings of dissimilar construction could be used, provided that they are dimensioned to mate together in an appropriate manner. The casings may be provided as separate components, or could be provided as a hinged component including two half shells joined along one side of their length.
Finally, it is to be appreciated that various alterations or additions may be made to the parts previously described without departing from the spirit or ambit of the present invention. The present invention includes connectors having the convenient pivoting structure of the present invention wherein some or all of the shielding parts described above may be replaced by plastics parts or other electrically insulating parts when less-shielded or unshielded connectors are required.
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A connector for use in terminating communications cables including electrical contacts ( 42 ) arranged to receive wires ( 30 ) of a communications cable ( 60 ), at least one cover ( 12, 22 ) pivotally connected with the connector and having wire-receiving spaces ( 14, 24 ), wherein the cover is arranged to move pivotally to bring wires positioned in its wire-receiving spaces into engagement with the contacts ( 42 ).
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FIELD OF THE INVENTION
[0001] The present invention relates to synthesis of suitably substituted chalcone derivatives which exhibit pronounced antihyperglycemic activity in conjunction with antidyslipedemic activity. More particularly the invention relates to synthesis of compound having formula I and pharmaceutical composition containing these compounds, as described in the following description.
BACKGROUND OF THE INVENTION AND PRIOR ART
[0002] Type II diabetes mellitus accounts for 90-95% of all diabetes. Changed sedentary life style has contributed towards affliction of the disease to adult population also. The main force driving this increasing incidence is a staggering increase in obesity, the single most important contributor to the pathogenesis of diabetes mellitus. Prolonged disease condition leads to chronic macrovascular complications such as retinopathy and nephropathy. The disease is collectively referred, as metabolic syndrome encompasses type II diabetes and common constellation of closely linked clinical features. Characteristic factors include insulin resistance per se, obesity, hypertension and a common form of dyslipidemia and low high-density lipoprotein cholesterol. Metabolic syndrome is associated with marked increased incidence of coronary, cerebral and peripheral artery disease [Executive summary of the third report of the National Cholesterol Program Expert Panel on detection, evaluation and treatment of high blood cholesterol in adults (2001), J. Am. Med. Asso. 285, 2486-2496.].
[0003] The role of peripheral and hepatic insulin resistance in the pathogenesis of diabetes mellitus is undisputed. Insulin resistance can be due to multiple defects in signal transduction such as impaired activation of insulin receptor-tyrosine kinase and reduced activation of insulin-stimulated phosphatidyl inositol-3-hydroxy kinase. The resistance of insulin due to diet-induced obesity [Elchebly, M. et al. (1999), Science, 283, 1544.] has given the critical role of obesity in the development of insulin resistance and other features of the metabolic syndrome. Successful approaches attenuating appetite and/or enhancing energy expenditure will prove of great benefit in preventing and treating type H diabetes. Abnormalities of fatty acid metabolism are increasingly recognized as key components of the pathogenesis of the metabolic syndrome and type I diabetes. A critical player in potentiating the promoting effect of hyperinsulinaemia on hepatic lipid accumulation is the anabolic transcription factor SREBP-1, which upregulates genes such as that for fatty acid synthase [Shimomura, 1. et al. (2000), Mol. Cell, 6, 77-86.]. These observations support a unified “lipotoxicity” hypothesis, which states that metabolic syndrome and type II diabetes can be caused by the accumulation of triglycerides and long chain fatty-acyl-CoA in liver and muscle. The third causal factor of metabolic syndrome is oxidative stress. Excess levels of oxygen in the living body can also pose a serious health threat; the so-called oxygen toxicity is brought about by oxygen species such as hydrogen peroxide and oxy radicals and damage living tissue. The active oxygen species are associated with diabetes mellitus and are destructive towards various tissues as occurring in diabetes mellitus. There have been many reports discussing relationships between peroxidation and diseases such as diabetes mellitus, atherosclerosis and myocardial ischemia in terms of radical oxidation. Glucose is oxidized under oxidative stress to highly reactive species, which ultimately reacts with proteins. Glucose, like other alpha hydroxy aldehydes, can enolize and thereby reduce molecular oxygen under physiological conditions, catalyzed by transition metals, yielding alpha keto aldehydes and oxidizing intermediates. These secondary compounds are more reactive than monosaccharides and can react with proteins to form cross-linked Maillard products (Simon P. Wolff et al. (1991); Free Radical Biology and Medicine, 10, 339-352.).
[0004] Oxidative stress also modifies lipids. Like glucose, LDL also undergoes oxidative modification to form modified LDL (oxidized LDL). The actual oxidation process is believed to begin with lipid peroxidation, followed by fragmentation to give short chain aldehydes. These aldehydes in turn react with the lysine residues of apo-B, creating a new epitope, which is recognized by the scavenger receptor of macrophages. During this same process, lecithin is converted to lysolecithin, which is a selective chemotactic agent for monocytes. The monocytes enter the subendothelium and undergo a phenotypic change to a macrophage, which avidly take up the oxidized LDL via the scavenger receptor. The uptake of oxidized LDL continues until the macrophage is so engorged with cholesteryl esters that it transforms into a foam cell. Groups of these foam cells constitute a fatty streak, the earliest hallmark of atherosclerosis. By inhibiting the oxidation of LDL, it is hoped that the modification of apo B and the production of chemotactic lysolecithin can be prevented and inturn the atherosclerosis.
[0005] At present, therapy for type II diabetes relies mainly on several approaches intended to reduce the hyperglycemia itself: sulphonylureas which increase insulin secretion from pancreatic beta cells; metformin which acts to reduce hepatic glucose production, peroxisome proliferator activated receptors agonists which enhance insulin action and α-glucosidase inhibitors which interfere with gut glucose absorption. These therapies have limited efficacy, limited tolerability and mechanism-based toxicity. Of particular concern is the tendency for most treatments to enhance weight gain. A problem particular to the sulphonylureas is that many patients who respond initially become refractory to treatment overtime.
[0006] The increasing prevalence of obesity and its associated comorbidities including type II diabetes and related cardiovascular disorders has stimulated efforts to develop effective new approaches in the treatment of this condition. While most therapeutic approaches involve altering the balance of metabolic energy by reducing energy intake, an alternative approach for the management of obesity is to affect an increase in the rate of energy expenditure. In 1984, compounds of the phenethanolamine class (as shown below), having thermogenic properties in rodents were first disclosed. Despite their structural similarity to known β 1 and β 2 adrenoceptor ligands, pharmacological studies indicated that these compounds stimulated a third or ‘atypical’ β-adrenergic receptor (β-AR) that is now described as ⊖ 3 -AR. β 3 agonist also increased insulin sensitivity and glucose utilization. Later studies suggested that Tyr 64 Arg β 3 -AR mutation in the human population plays a role in the development of diabetes mellitus and/or obesity in some individuals possessing this genetic variant [Turner, N. C.; (1996), DDT, 1, 109-116].
[0007] A family of transcription factors, known as PPAR-γ plays a crucial role in regulating the storage and catabolism of dietary energy producing materials. There are three PPAR subtypes that are the products of distinct genes and are commonly designated as PPPAR α, γ and δ. PPAR-γ affect body weight through regulation of fatty acid catabolism or energy expenditure. PPAR-γ expressed mainly in adipose tissue plays a pivotal role in regulation of glucose and lipid homeostasis [Willson, T. M. et al. (2000), J. Med. Chem. 43, 527-550].
[0008] Troglitazone effectively reduces hyperglycemia, hyperinsulinaemia and hypertriglyceridemia in patients with type II diabetes. The mechanism of pharmacological effects has been shown to involve increased insulin sensitivity effects in skeletal muscle, liver and adipose tissue via the activation of PPAR-γ. As vitamin-E analogue, troglitazone has been demonstrated to be an effective antioxidant; oxidative ring opening and subsequent quinone metabolite formation is believed to be the cause of hepatotoxicity and withdrawal of the drug [Kan He, et al. (2001), Biochemical Pharmacology, 62, 191-198.]. This has led to the modification and resulted in several new molecules.
[0009] Grafting of pharmacophores on systems own or very close metabolites may exhibit some times undesired effects. For example first generation of statins though derived from fungal metabolite, is very close analogue of mevalonic acid and therefore function as HMG-CoA reductase inhibitors, block mevalonate production which is involved in cholesterol biosynthesis and hence cholesterol synthesis is inhibited in the cell. Mevalonate is a common precursor for all isoprenoids such as ubiquinones (co enzyme Q 10), the dolichols, and isopentenyl tRNA etc. Therefore, there is a decrease in the synthesis of non-sterol constituents, which may contribute significantly to the side effects, observed with HMG-CoA reductase inhibitors. Similarly in designing of troglitazone, vitamin-E component was used which metabolized to quinonoid intermediate after one electron oxidation. This intermediate is speculated to be the cause of toxicity of troglitazone.
[0010] Flavonoids are among the most ubiquitous groups of polyphenolic compounds in foods of plant origin. Chalcones and flavones are among various subgroups of flavonoids. As integral constituents of the diet, they may exert a wide range of beneficial effects on human health. Flavonoids produce such biological effects through their free radical scavenging antioxidant activities and metal ion chelating abilities. (Cotelle, N. et al, Free Rad. Biol. Med. 1992, 13, 211.). These properties led us to utilize chalcones for the synthesis of hybrid molecules as antidiabetic and antidyslipidemic agents by substitution with thermogenic as well as insulin sensitizing pharmacophores.
OBJECTS OF THE PRESENT INVENTION
[0011] The main objective of the present invention is to provide a substituted chatcone derivative of formula I or a pharmaceutically acceptable salt thereof.
[0012] Another object of the present invention is to provide a pharmaceutical composition comprising these chalcone derivatives and a pharmaceutically acceptable carrier or diluent thereof.
[0013] Yet another object of the present invention is to provide a pharmaceutical composition comprising the chalcone derivatives of the present invention with a lipid lowering agent and a sugar lowering agent.
[0014] Still another object of the present invention is to provide a process for preparation of compound of formula I.
[0015] Yet another object of the present invention is to provide a method for controlling type II diabetes and associated hyperlipidemic conditions in a mammal by administering a pharmaceutically acceptable amount of compound I with or without other diabetic and lipid lowering agents.
[0016] Still another object of the present invention is to provide a method of controlling macrovascular conditions such as retinopathy and nephropathy in mammals by administering a pharmaceutically acceptable amount of the compound I with or without other diabetic and lipid lowering agents.
SUMMARY OF THE INVENTION
[0017] Accordingly, the present invention provides novel chalcone derivative of formula I which exhibit antihyperglycemic and antidyslipedemic activity. The invention also provides a method for controlling ‘type II’ diabetes and associated hyperlipidemic conditions in a mammal by administering composition containing these derivatives.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention provides novel chalcone derivatives, which exhibits antidiabetic and antidyslipidemic activities in different model systems. More particularly, this invention relates to compound having the formula I and pharmaceutically acceptable salts thereof. Where in the groups R 1 , R 2 and R 3 are as herein after defined.
[0019] Wherein
[0020] R 1 , R 2 and R 3 are selected from H, OH, O-alkyl, O-phenyl, O-substituted phenyl or combination thereof;
[0021] Where Z is an alkane having upto 5 carbon atoms;
[0022] R is propanolamine wherein amino groups are selected from t-butyl amine, n-butyl amine, i-butyl amine, i-propyl amine, 4-phenyl piperazine-1-yl amine, 4-(2-methoxy phenyl)-piperazin-1-yl amine, and 3,4-dimethoxy phenethyl amine and
[0023] Ar is thiazolidinedione methylene phenoxy
[0024] Another embodiment of the present invention provides a pharmaceutical composition comprising the compound of formula I and pharmaceutically acceptable quantities of a conventional pharmaceutically acceptable carrier or diluent thereof.
[0025] Yet another embodiment of the present invention provides a pharmaceutical composition comprising the compound of formula I along with pharmaceutically acceptable quantities of conventional lipid lowering agents and/or conventional sugar lowering agents.
[0026] Yet another embodiment of the present invention provides a method for treating type II diabetes and associated hyperlipidemic conditions in mammals by administering a pharmaceutically effective amount of compound of formula I, optionally with other diabetic and lipid lowering agents.
[0027] Yet another embodiment of the present invention provides a method for treating type II diabetes and associated hyperlipidemic conditions in mammals by administering a pharmaceutically effective amount of compound of formula (18), optionally with other diabetic and lipid lowering agents.
[0028] Yet another embodiment of the present invention provides a method for treating type II diabetes and associated hyperlipidemic conditions in mammals by administering a pharmaceutically effective amount of compound of formula (34), optionally with other diabetic and lipid lowering agents.
[0029] Yet another embodiment of the present invention provides a method for treating type II diabetes and associated hyperlipidemic conditions in mammals by administering a pharmaceutically effective amount of compound of formula (46), optionally with other diabetic and lipid lowering agents.
[0030] Yet another embodiment of the present invention provides a method of treating macrovascular conditions such as retinopathy and nephropathy in mammals by administering a pharmaceutically effective amount of the compound of formula I, optionally with other diabetic and lipid lowering agents.
[0031] Yet another embodiment of the present invention provides a method of treating macrovascular conditions such as retinopathy and nephropathy in mammals by administering a pharmaceutically effective amount of the compound of formula (18), optionally with other diabetic and lipid lowering agents.
[0032] Yet another embodiment of the present invention provides a method of treating macrovascular conditions such as retinopathy and nephropathy in mammals by administering a pharmaceutically effective amount of the compound of formula (34), optionally with other diabetic and lipid lowering agents.
[0033] Yet another embodiment of the present invention provides a method of treating macrovascular conditions such as retinopathy and nephropathy in mammals by administering a pharmaceutically effective amount of the compound of formula (46), optionally with other diabetic and lipid lowering agents.
[0034] Yet another embodiment of the present invention provides the range of pharmaceutically effective dose of 50-200 mg/Kg body weight of the compound to be administered in mammals.
[0035] Still another embodiment of the present invention provides a compound of formula (18).
[0036] Yet another embodiment of the present invention provides a compound of formula (34)
[0037] Yet another embodiment of the present invention provides a compound of formula (46)
[0038] Still another embodiment of the present invention provides a process for preparing a compound of formula I, comprising the steps of:
(i) reacting hydroxy acetophenone and substituted benzaldehyde using aqueous sodium hydroxide in methanol at room temperature to obtain chalcones; (ii) reacting chalcones obtained in step (i) with epichlorohydrin using sodium hydride as base in dry dimethyl formamide to obtain epoxide ; and (iii) heating epoxide obtained in step (ii) under reflux at room temperature with suitable amines in methanol to yield corresponding propanolamines.
[0042] Yet another embodiment of the present invention provides a process for preparing a compound of formula I (43-46), comprising the steps of:
(i) reacting chalcone with dibromo alkane in presence of K 2 CO 3 and acetone at room temperature to get bromo alkoxy chalcone; and (ii) reacting bromo alkoxy chalcone obtained in step (i) with 4-(Thiazolidin-2,4-dione-5-ylidinemethyl)-phenol, in presence of K 2 CO 3 and dimethyl formamide at room temperature to obtain corresponding chalcone derived thiazolidinediones.
Synthesis of Chalcone Derived Propanolamines
[0045] All the chalcones [7-12] were prepared using the Claisen-Schmidt condensation, which has been previously reported (Sogawa, S.; Nihro, Y.; Ueda, H.; Izumi, A.; Miki, T.; Matsumosa, H.; Satoh, T. J. Med. Chem. 1993, 36, 3904). Hydroxy acetophenone [1-3] and appropriately substituted benzaldehyde [4-6] were reacted using aqueous sodium hydroxide in methanol at room temperature to provide corresponding chalcones [7-12]. Chalcones 10-12 were prepared under reflux. Yields ranged from 65% to quantitative. The chalcones were always obtained as transalkenes (E-form) as judged by 1 H NMR spectroscopy. The chalcones thus obtained were reacted with epichlorohydrin using sodium hydride as base in dry dimethyl formamide. The purified epoxide [13-17] was heated under reflux with various amines in methanol to yield corresponding propanolamines [18-35] as presented in Scheme 1 (Table 1).
[0046] Reagents and Conditions: (i). 50% aq.NaOH, Methanol, RT (ii). NaH, Epichlorohydrin, DMF, RT (iii). Amine, Methanol, RT.
Synthesis of 4-(Thiazolidin-2,4-dione-5-ylidinemethyl)-Phenol
[0047] 4-(Thiazolidin-2,4-dione-5-ylidinemethyl)-phenol (38) was synthesized by the condensation of 4-hydroxy benzaldehyde (36) with commercially available 2,4-thiazolidinedione (37) using piperidine as base in refluxing ethanol, according to a known procedure (Momose, Y.; Meguro, K.; Ikeda, H.; Hatanaka, C.; Oi, S.; Sohda, T. Chem. Pharm. Bull. 1991, 39, 1440.) (Scheme 2)
[0048] Reagents and Conditions: (i). Ethanol, Piperidine, Reflux.
Synthesis of Chalcone Derived Thiazolidinediones
[0049] Bromo alkoxy chalcone (39-42) were prepared by the reaction of chalcone (8&12) with dibromo alkane. Reaction of 38 with dibromo alkoxy chalcone in dry dimethyl formamide provided the target compounds (43-46). (Scheme 3, Table 2).
[0050] Reagents and Conditions: (i). 50% aq.NaOH, Methanol, RT (ii). Dibromo alkane, K 2 CO 3 , Acetone, RT (iii). 38, K 2 CO 3 , DMF, RT.
TABLE 1 Compd. Posi- No. tion R1,R2,R3 Amine Formula 18 4′ 3,4-dimethoxy 4-phenyl C 30 H 34 N 2 O 5 piperazine-1-yl 19 4′ 3,4-dimethoxy t-butyl C 24 H 31 NO 5 20 4′ 4-methoxy 4-phenyl C 29 H 32 N 2 O 4 piperazine-1-yl 21 4′ 4-methoxy i-butyl C 23 H 29 NO 4 22 4′ 4-methoxy t-butyl C 23 H 29 NO 4 23 4′ 4-methoxy i-propyl C 22 H 27 NO 4 24 4′ 4-methoxy 4-(2-methoxy C 30 H 34 N 2 O 5 phenyl)- piperzin-1-yl 25 4′ 4-methoxy 3,4-dimethoxy C 29 H 33 NO 6 phenethyl 26 4′ 4-methoxy methyl C 20 H 23 NO 6 27 4′ 4-methoxy n-butyl C 23 H 29 NO 4 28 3′ 4-methoxy 4-phenyl C 29 H 32 N 2 O 4 piperazine-1-yl 29 3′ 4-methoxy i-propyl C 22 H 27 NO 4 30 3′ 4-methoxy t-butyl C 23 H 29 NO 4 31 2′ 4-methoxy n-butyl C 23 H 29 NO 4 32 2′ 4-methoxy i-propyl C 22 H 27 NO 4 33 4′ 3,4-methylenedioxy 4-phenyl C 29 H 30 N 2 O 5 piperazine-1-yl 34 4′ 3,4-methylenedioxy t-butyl C 23 H 27 NO 5 35 4′ 3,4-methylenedioxy i-butyl C 23 H 27 NO 5
[0051]
TABLE 2
Compd. No.
n
R
Formula
43
4
4-methoxy
C 30 H 27 NO 6 S
44
5
4-methoxy
C 31 H 29 NO 6 S
45
4
3,4-methylenedioxy
C 30 H 25 NO 7 S
46
5
3,4-methylenedioxy
C 31 H 27 NO 7 S
[0052] The invention is further elaborated with the help of following examples. However, these examples should not be construed to limit the scope of the invention.
EXAMPLES
4′-Hydroxy-4-methoxy-chalcone [7]
[0053] To a well-stirred solution of 4-hydroxy acetophenone, 1 (10 g, 73.5 mmol) and 4-methoxy benzaldehyde, 4 (8.9 mL, 73.5 mmol) in methanol (140 mL) was added 50% w/v aqueous sodium hydroxide solution (70 mL). The reaction mixture was stirred at room temperature for 12 h and then evaporated in vacuo. Water was added and acidified with hydrochloric acid (1N) and extracted with ethyl acetate. The organic layer was separated, washed with water, dried over sodium sulphate, filtered and evaporated in vacuo. The residue yielded pure 7 after purification by column chromatography. Yield 16.8 g (90%); mp 184-185° C. MS (EI) m/z 254 (M + , 100%), 253 (34.7%), 239 (32.3%), 161 (36.8%), 121 (79.5%); IR (KBr) 3371, 1654; 1 H NMR (200 MHz, CDCl 3 ) δ 7.99 (d, J=8.6 Hz, 2H), 7.78 (d, J=15.6 Hz, 1H), 7.60 (d, J=8.6 Hz, 2H), 7.41 (d, J=15.6 Hz, 1H), 6.93 (d, J=7.2 Hz, 4H), 5.85 (s, 1H), 3.86 (s, 3H).
3′-Hydroxy-4-methoxy-chalcone [8]
[0054] 3-Hydroxy acetophenone, 2 (6.8 g, 50 mmol), 4-methoxy benzaldehyde, 4 (6.0 mL, 50 mmol) and 50% aqueous sodium hydroxide (50 mL) in methanol (110 mL) were reacted as in 7 to yield 8. Yield 12.5 g (98%); mp 93-94° C.; MS (FAB) 255 (M + +1); IR (KBr) 3366, 1649; 1 H NMR (200 MHz, CDCl 3 ) δ 7.80 (d, J=15.6 Hz, 1H), 7.62 (d, J=7.8 Hz, 1H), 7.58 (d, J=8.7 Hz, 2H), 7.55 (d, J=2.3 Hz, 1H), 7.38 (d, J=15.6 Hz, 1H), 7.36 (t, J=7.8 Hz, 1H), 7.04 (d, J=7.9 Hz, 1H), 6.92 (d, J=8.6 Hz, 2H), 3.85 (s, 3H).
2′-Hydroxy-4-methoxy-chalcone [9]
[0055] 2-Hydroxy acetophenone, 3 (6 mL, 50 mmol), 4-methoxy benzaldehyde, 4 (6 mL, 50 mmol) and 50% aqueous sodium hydroxide (50 mL) in methanol (100 mL) were reacted as in 7 to yield 9. Yield 11.7 g (92%); mp 81-83° C. (lit. 93-94); 227 MS (FAB) 255 (M + +1); IR (KBr) 3450, 1639; 1 H NMR (200 MHz, CDCl 3 ) δ 7.92 (dd, J=8.7 Hz, 1.4 Hz, 1H), 7.90 (d, J=15.4 Hz, 1H), 7.62 (d, J=8.7 Hz, 2H), 7.53 (d, J=15.5 Hz, 1H), 7.49 (t, J=7.4 Hz, 1H), 6.95 (d, J=8.6 Hz, 2H), 7.03-6.89 (m, 2H), 3.86 (s, 3H).
3,4-Dimethoxy-4′-hydroxy-chalcone [10]
[0056] 4-Hydroxy acetophenone, 1 (13.6 g, 100 mmol), 3,4-dimethoxy benzaldehyde, 5 (16.6 g, 100 mmol) and 50% aqueous sodium hydroxide (80 mL) in methanol (200 mL) were reacted under reflux as in 7 to yield 10. Yield 19.6 g (69%); mp 193-195° C.; MS (FAB) 285 (M + +1); IR (KBr) 3443, 1643; 1 H NMR (200 MHz, CDCl 3 ) δ 10.45 (s, 1H), 8.10 (d, J=8.5 Hz, 2H), 7.81 (d, J=15.5 Hz, 1H), 7.66 (d, J=15.5 Hz, 1H), 7.52 (s, 1H), 7.36 (d, J=8.2 Hz, 1H), 7.01 (d, J=8.4 Hz, 1H), 6.93 (d, J=8.5 Hz, 2H), 3.95 (s, 3H), 3.92 (s, 3H).
4′-Hydroxy-3,4-methylenedioxy-chalcone [11]
[0057] 4-Hydroxy acetophenone, 1 (2.7 g, 20 mmol), 3,4-methylenedioxy benzaldehyde, 6 (3 g, 20 mmol) and 50% aqueous sodium hydroxide (5 mL) in methanol (40 mL) were reacted under reflux as in 7 to yield 11. Yield 3.5 g (65%); mp 191-193° C.; MS (FAB) 269 (M + +1); IR (KBr) 3410, 1646; 1 H NMR (200 MHz, CDCl 3 ) δ 9.15 (s, 1H), 7.98 (d, J=8.7 Hz, 2H), 7.72 (d, J=15.5 Hz, 1H), 7.37 (d, J=15.5 Hz, 1H), 7.16 (s, 1H), 7.12 (d, J=8.1 Hz, 1H), 6.99 (d, J=8.8 Hz, 2H), 6.82 (d, J=7.9 Hz, 1H), 6.02 (s, 2H).
3′-Hydroxy-3,4-methylenedioxy-chalcone [12]
[0058] 3-Hydroxy acetophenone, 2 (2.7 g, 20 mmol), 3,4-methylenedioxy benzaldehyde, 6 (3 g, 20 mmol) and 50% aqueous sodium hydroxide (5 mL) in methanol (40 mL) were reacted under reflux as in 7 to yield 12. Yield 4.1 g (76%); mp 188-189° C.; MS (FAB) 269 (M + +1); IR (KBr) 3389, 1659; 1 H NMR (300 MHz, DMSO-d 6 ) δ 9.84 (s, 1H), 7.73 (d, J=15.6 Hz, 1H), 7.64 (d, J=15.9 Hz, 1H), 7.63 (s, 1H), 7.62 (d, J=5.4 Hz, 1H), 7.45 (s, 1H), 7.36 (t, J=7.9 Hz, 1H), 7.30 (d, J=7.8 Hz, 1H), 7.05 (dd, J=7.9 Hz, 2.4 Hz, 1H), 6.98 (d, J=7.8 Hz, 1H), 6.09 (s, 2H).
4′-(2,3-Epoxy-propoxy)-4-methoxy-chalcone [13]
[0059] To a well-stirred solution of 4′-hydroxy-4-methoxy-chalcone, 7 (15 g, 59 mmol) in dry dimethyl formamide (170 mL) was added 50% sodium hydride (5.6 g, 236 mmol) at 0-5° C. and after 30 minutes, excess of epichlorohydrin (13.8 mL, 177 mmol) was added and stirred at room temperature for overnight. The reaction mixture was concentrated under reduced pressure, diluted with water and extracted with chloroform. The combined organic layers were dried over sodium sulphate, filtered and evaporated to dryness. The crude product was purified by column chromatography to afford 13. Yield 11 g (60%); mp 85-87° C.; MS (FAB) 311 (M + +1); IR (KBr) 1655; 1 H NMR (200 MHz, CDCl 3 ) δ 8.02 (d, J=8.8 Hz, 2H), 7.77 (d, J=15.6 Hz, 1H), 7.59 (d, J=8.7 Hz, 2H), 7.41 (d, J=15.6 Hz, 1H), 6.99 (d, J=8.8 Hz, 2H), 6.93 (d, J=8.7 Hz, 2H), 4.32 (dd, J=11.1 Hz, 2.9 Hz, 1H), 4.01 (dd, J=11.1 Hz, 5.7 Hz, 1H), 3.84 (s, 31H), 3.40-3.35 (m, 1H), 2.92 (t, J=4.5 Hz, 4.5 Hz, 1H), 2.77 (dd, J=4.8 Hz, 2.6 Hz, 1H).
3′-(2,3-Epoxy-propoxy)-4-methoxy-chalcone [14]
[0060] By a similar procedure as described for 13, compound 14 was obtained from 3′-hydroxy-4-methoxy-chalcone, 8 (5 g, 19.7 mmol), epichlorohydrin (4.7 mL, 59 mmol) and 50% sodium hydride (2.83 g, 118 mmol) in dry dimethyl formamide (110 mL). Yield 4.6 g (75%); mp 64-65° C.; MS (FAB) 311 (M + +1); IR (KBr) 1658; 1 H NMR (200 MHz, CDCl 3 ) δ 7.79 (d, J=15.5 Hz, 1H), 7.60 (d, J=8.7 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.56 (d, J=1.3 Hz, 1H), 7.41 (t, J=7.9 Hz, 1H), 7.39 (d, J=15.5 Hz, 1H), 7.15 (dd, J=8.1 Hz, 1.4 Hz, 1H), 6.94 (d, J=8.6 Hz, 2H), 4.34 (dd, J=11.0 Hz, 2.8 Hz, 1H), 4.01 (dd, J=11.0 Hz, 5.8 Hz, 1H), 3.86 (s, 3H), 3.40-3.38 (m, 1H), 2.93 (t, J=4.5 Hz, 4.4 Hz, 1H), 2.79 (dd, J=4.7 Hz, 2.6 Hz, 1H).
2′-(2,3-Epoxy-propoxy)-4-methoxy-chalcone [15]
[0061] By a similar procedure as described for 13, compound 15 was obtained from 2′-hydroxy-4-methoxy-chalcone, 9 (6 g, 23.6 mmol), epichlorohydrin (7.4 mL, 94.5 mmol) and 50% sodium hydride (2.76 g, 94.5 mmol) in dry dimethyl formamide (120 mL). Yield 3 g (42%); mp 57-58° C.; MS (FAB) 311 (M + +1); IR (KBr) 1644; 1 NMR (200 MHz, CDCl 3 ) δ 7.64 (dd, J=8.5 Hz, 1.8 Hz, 1H), 7.63 (d, J=15.8 Hz, 1H), 7.60 (d, J=8.6 Hz, 2H), 7.45 (t, J=7.5 Hz, 1H), 7.34 (d, J=15.8 Hz, 1H), 7.10-6.95 (m, 2H), 6.92 (d, J=8.8 Hz, 2H), 4.36 (dd, J=1.0 Hz, 2.6Hz, 1H), 4.08 (dd, J=11.0 Hz, 5.1 Hz, 1H), 3.84 (s, 3H), 3.34-3.31 (m, 1H), 2.85-2.77 (m, 2H).
3,4-Dimethoxy-4′-(2,3-epoxy-propoxy)-chalcone [16]
[0062] By a similar procedure as described for 13, compound 16 was obtained from 3,4-dimethoxy-4′-hydroxy-chalcone, 10 (14.2 g, 50 mmol), epichlorohydrin (7.8 mL, 100 mmol) and 50% sodium hydride (4.8 g, 200 mmol) in dry dimethyl formamide (150 mL). Yield 7 g (41%); mp 95-96° C.; MS (FAB) 341 (M + +1); IR (KBr) 1655; 1 H NMR (200 MHz, CDCl 3 ) δ 8.03 (d, J=8.8 Hz, 2H), 7.75 (d, J=15.5 Hz, 1H), 7.39 (d, J=15.5 Hz, 1H), 7.23 (dd, J=8.3 Hz, 1.5 Hz, 1H), 7.16 (s, 1H), 7.00 (d, J=8.8 Hz, 2H), 6.89 (d, J=8.3 Hz, 1H), 4.32 (dd, J=11.1 Hz, 2.9 Hz, 1H), 4.01 (dd, J=11.1 Hz, 5.8 Hz, 1H), 3.95 (s, 3H), 3.93 (s, 3H), 3.40-3.36 (m, 1H), 2.93 (t, J=4.5 Hz, 4.6 Hz, 1H), 2.79 (dd, J=4.8 Hz, 2.6 Hz, 1H).
4′-(2,3-Epoxy-propoxy)-3,4-methylenedioxy-chalcone [17]
[0063] By a similar procedure as described for 13, compound 17 was obtained from 4′-hydroxy-3,4-methylenedioxy-chalcone, 11 (6.4 g, 24 mmol), epichlorohydrin (5.6 mL, 72 mmol) and 50% sodium hydride (2.9 g, 120 mmol) in dry dimethyl formamide (120 mL). Yield 6.2 g (80%); mp 83-84° C.; MS (FAB) 325 (M + +1); IR (KBr) 1650; 1 H NMR (200 MHz, CDCl 3 ) δ 7.98 (d, J=8.8 Hz, 2H), 7.72 (d, J=15.5 Hz, 1H), 7.36 (d, J=15.5 Hz, 1H), 7.16 (s, 1H), 7.12 (d, J=8.1 Hz, 1H), 6.99 (d, J=8.8 Hz, 2H), 6.83 (d, J=7.9 Hz, 1H), 6.02 (s, 2H), 4.32 (dd, J=11.1 Hz, 3.0 Hz, 1H), 4.02 (dd, J=11.1 Hz, 5.7 Hz, 1H), 3.38-3.36 (m, 1H), 2.93 (t, J=4.4 Hz, 4.3 Hz, 1H), 2.78 (dd, J=4.8 Hz, 2.6 Hz, 1H).
3,4-Dimethoxy-4′-[2-hydroxy-3-(4-phenylpiperazin-1-yl)-propoxyl-chalcone [18]
[0064] A solution of 3,4-dimethoxy-4′-(2,3-epoxy-propoxy)-chalcone, 16 (1 g, 2.9 mmol) and 1-phenyl piperazine (0.45 mL, 3 mmol) in dry methanol (90 mL) was stirred at reflux for 6 h. Reaction mixture was concentrated on rotavapor and crude product purified by column chromatography to afford 18.Yield 870 mg (60%); mp 126-127° C.; MS (FAB) 503 (M + +1); IR (KBr) 3426, 1652; 1 H NMR (200 MHz, CDCl 3 ) δ 8.03 (d, J=8.8 Hz, 2H), 7.76 (d, J=15.5 Hz, 1H), 7.39 (d, J=15.5 Hz, 1H), 7.31-7.20 (m, 3H), 7.16 (d, J=1.3 Hz, 1H), 7.01 (d, J=8.8 Hz, 2H), 6.93 (d, J=7.8 Hz, 1H), 6.95-6.87 (m, 3H), 4.19-4.08 (m, 3H), 3.95 (s, 3H), 3.92 (s, 3H), 3.23 (t, J=4.7 Hz, 4H), 2.90-2.85 (m, 2H), 2.69-2.61 (m, 1H); 13 C NMR (50 MHz, CDCl 3 ) δ 189.2, 162.8, 151.8, 151.6, 149.7, 144.6, 132.1, 131.1, 129.6, 128.5, 123.4, 120.3, 116.6, 114.8, 111.7, 110.7, 70.9, 65.9, 60.8, 56.5, 53.8, 49.7. Analyses calculated for C 30 H 34 N 2 O 5 : C, 71.69; H, 6.82; N, 5.57. Found: C, 71.18; H, 6.93; N, 5.32.
4′-[-tert-Butylamino-2-hydroxy-propoxyl-3,4-dimethoxy-chalcone [19]
[0065] In a similar manner to the preparation of 18, compound 19 was obtained from 3,4-dimethoxy-4′-(2,3-epoxy-propoxy)-chalcone, 16 (1 g, 2.9 mmol) and tert-butyl amine (0.94 mL, 9 mmol) in dry methanol (80 mL). Yield 1.1 g (94%); mp 62-64° C.; MS (FAB) 414 (M + +1); IR (KBr) 3450, 1650; 1 H NMR (200 MHz, CDCl 3 ) δ 8.03 (d, J=8.8 Hz, 2H), 7.76 (d, J=15.5 Hz, 1H), 7.40 (d, J=15.5 Hz, 1H), 7.26 (s, 1H), 7.17 (dd, J=8.2 Hz, 1.6 Hz, 1H), 7.0 (d, J=8.8 Hz, 2H), 6.90 (d, J=8.3 Hz, 1H), 4.07-4.05 (m, 3H), 3.95 (s, 3H), 3.93 (s, 3H), 2.88 (dd, J=11.9 Hz, 4.0 Hz, 1H), 2.68 (dd, J=11.9 Hz, 7.5 Hz, 2H), 1.13 (s, 9H). Analyses calculated for C 24 H 31 NO 5 : C, 69.71; H, 7.56; N, 3.39. Found: C, 69.82; H, 7.41; N, 3.16.
4′-[2-Hydroxy-3-(4-phenylpiperazin-1-yl)-propoxy]-4-methoxy-chalcone [20]
[0066] In a similar manner to the preparation of 18, compound 20 was obtained from 4′-(2,3-epoxy-propoxy)-4-methoxy-chalcone, 13 (1.3 g, 4.2 mmol) and 1-phenyl piperazine (0.64 mL, 4.2 mmol) in dry methanol (120 mL). Yield 1.4 g (70%); mp 165-167° C.; MS (FAB) 473 (M + +1); IR (KBr) 3392, 1652; 1 H NMR (200 MHz, CDCl 3 ) δ 8.03 (d, J=8.8 Hz, 2H), 7.78 (d, J=15.6 Hz, 1H), 7.60 (d, J=8.6 Hz, 2H), 7.42 (d, J=15.5 Hz, 1H), 7.31-7.24 (m, 2H), 7.01 (d, J=8.7 Hz, 2H), 6.94 (d, J=8.7 Hz, 2H), 6.96-6.84 (m, 3H), 4.19-4.09 (m, 3H), 3.86 (s, 3H), 3.24 (t, J=4.9 Hz, 4H), 2.89-2.84 (m, 2H), 2.74-2.64 (m, 4H). Analyses calculated for C 29 H 32 N 2 O 4 : C, 73.70; H, 6.83; N, 5.93. Found: C, 73.32; H, 6.41; N, 5.69.
4′-[3-iso-Butylamino-2-hydroxy-propoxy]-4-methoxy-chalcone [21]
[0067] In a similar manner to the preparation of 18, compound 21 was obtained from 4′-(2,3-epoxy-propoxy)-4-methoxy-chalcone, 13 (1 g, 3.2 mmol) and iso-butyl amine (1.6 mL, 16 mmol) in dry methanol (100 mL). Yield 900 mg (74%); mp 76-77° C.; MS (FAB) 384 (M + +1); IR (KBr) 3423, 1653; 1 H NMR (200 MHz, CDCl 3 ) δ 8.02 (d, J=8.6 Hz, 2H), 7.78 (d, J=15.6 Hz, 1H), 7.60 (d, J=8.5 Hz, 2H), 7.42 (d, J=15.6 Hz, 1H), 6.99 (d, J=8.8 Hz, 2H), 6.93 (d, J=8.6 Hz, 2H), 4.21-3.97 (m, 3H), 3.85 (s, 3H), 2.91-2.72 (m, 2H), 2.48 (d, J=6.7 Hz, 2H), 1.83-1.66 (m, 1H), 0.93 (d, J=6.6 Hz, 6H). Analyses calculated for C 23 H 29 NO 4 : C, 72.04; H, 7.62; N, 3.65. Found: C, 72.12; H, 7.43; N, 3.52.
4′-3-tert-Butylamino-2-hydroxy-propoxy]-4-methoxy-chalcone [22]
[0068] In a similar manner to the preparation of 18, compound 22 was obtained from 4′-(2,3-epoxy-propoxy)-4-methoxy-chalcone, 13 (1 g, 3.2 mmol) and tert-butyl amine (1.67 mL, 16 mmol) in dry methanol (80 mL). Yield 1 g (85%); mp 70-71° C.; MS (FAB) 384 (M + +1); IR (KBr) 3391, 1640; 1 H NMR (200 MHz, CDCl 3 ) δ 8.02 (d, J=8.7 Hz, 2H), 7.78 (d, J=15.7 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.41 (d, J=15.6 Hz, 1H), 6.99 (d, J=8.9 Hz, 2H), 6.93 (d, J=8.7 Hz, 2H), 4.13-4.05 (m, 3H), 3.86 (s, 3H), 2.95-2.73 (m, 2H), 1.21 (s, 9H). Analyses calculated for C 23 H 29 NO 4 : C, 72.04 H, 7.62; N, 3.65. Found: C, 72.09; H, 7.13; N, 3.72.
4′-[2-Hydroxy-3-iso-propylamino-propoxy]-4-methoxy-chalcone [23]
[0069] In a similar manner to the preparation of 18, compound 23 was obtained from 4′-(2,3-epoxy-propoxy)-4-methoxy-chalcone, 13 (1 g, 3.2 mmol) and iso-propyl amine (1.36 mL, 16 mmol) in dry methanol (100 mL). Yield 700 mg (59%); mp 105-106° C.; MS (FAB) 370 (M + +1); IR (KBr) 3420, 3289, 1654; 1 H NMR (200 MHz, CDCl 3 ) δ 8.02 (d, J=8.6 Hz, 2H), 7.78 (d, J=15.7 Hz, 1H), 7.60 (d, J=8.5 Hz, 2H), 7.42 (d, J=15.6 Hz, 1H), 6.99 (d, J=8.9 Hz, 2H), 6.93 (d, J=8.7 Hz, 2H), 4.23-4.09 (m, 3H), 3.85 (s, 3H), 2.96-2.74 (m, 3H), 1.11 (d, J=6.2 Hz, 6H). Analyses calculated for C 22 H 27 NO 4 : C, 71.52; H, 7.37; N, 3.79. Found: C, 71.33; H, 7.42; N, 3.63.
4′-[2-Hydroxy-3-{4-(2-methoxyphenyl)-piperazin-1-yl}-propoxy]-4-methoxy-chalcone [24]
[0070] In a similar manner to the preparation of 18, compound 24 was obtained from 4′-(2,3-epoxy-propoxy)-4-methoxy-chalcone, 13 (500 mg, 1.6 mmol) and 1-(2-methoxyphenyl)piperazine (0.3 mL, 1.7 mmol) in dry methanol (80 mL). Yield 530 mg (66%); mp 97-98° C.; MS (FAB) 503 (M + +1); IR (KBr) 3451, 1652; 1 H NMR (200 MHz, CDCl 3 ) δ 8.03 (d, J=8.3 Hz, 2H), 7.78 (d, J=15.5 Hz, 1H), 7.60 (d, J=8.1 Hz, 2H), 7.43 (d, J=15.4 Hz, 1H), 7.03-6.85 (m, 8H), 4.13-4.09 (m, 3H), 3.87 (s, 3H), 3.86 (s, 3H), 3.14-3.10 (m, 4H), 2.90-2.88 (m, 2H), 2.67-2.63 (m, 4H).
[0071] Analyses calculated for C 30 H 34 N 2 O 5 : C, 71.69; H, 6.82; N, 5.57. Found: C, 71.62; H, 6.91; N, 5.42.
4′-[3-{2-(3,4-Dimethoxyphenyl)-ethylamino}-2-hydroxy-propoxy]-4-methoxy-chalcone [25]
[0072] In a similar manner to the preparation of 18, compound 25 was obtained from 4′-(2,3epoxy-propoxy)-4-methoxy-chalcone, 13 (1 g, 3.2 mmol) and 3,4-dimethoxyphenethylamine (2.65 mL, 16 mmol) in dry methanol (80 mL). Yield 930 mg (59%); mp 120-121° C.; MS (FAB) 492 (M + +1); IR (KBr) 3431, 1654; 1 H NMR (200 MHz, CDCl 3 ) δ 8.01 (d, J=8.8 Hz, 2H), 7.78 (d, J=15.6 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.42 (d, J=15.5 Hz, 1H), 6.97 (d, J=8.6 Hz, 2H), 6.93 (d, J=9.1 Hz, 2H), 6.78-6.73 (m, 3H), 4.09-4.01 (m, 3H), 3.87 (s, 3H), 3.85 (s, 6H), 2.91-2.77 (m, 6H). Analyses calculated for C 29 H 33 NO 6 : C, 70.86; H, 6.77; N, 2.85. Found: C, 70.81; H, 6.72; N, 2.91.
4′-[2-Hydroxy-3-methylamino-propoxy]-4-methoxy-chatcone [26]
[0073] In a similar manner to the preparation of 18, compound 26 was obtained from 4′-(2,3-epoxy-propoxy)-4-methoxy-chalcone, 13 (1 g, 3.2 mmol) and methylamine (5.5 mL, 64 mmol) in dry methanol (80 mL). Yield 470 mg (43%); mp 114-115° C.; MS (FAB) 342 (M + +1); IR (KBr) 3487, 3344, 1652; 1 H NMR (200 MHz, CDCl 3 ) δ 8.01 (d, J=8.6 Hz, 2H), 7.77 (d, J=15.6 Hz, 1H), 7.59 (d, J=8.5 Hz, 2H), 7.41 (d, J=15.6 Hz, 1H), 6.98 (d, J=8.9 Hz, 2H), 6.93 (d, J=8.7 Hz, 2H), 4.07-4.05 (m, 3H), 3.85 (s, 3H), 2.93-2.82 (m, 2H), 2.50 (s, 3H). Analyses calculated for C 20 H 23 NO 4 : C, 70.36; H, 6.79; N, 4.10. Found: C, 70.40; H, 6.72; N, 4.13.
4′-[3-n-Butylamino-2-hydroxy-propoxy]-4-methoxy-chalcone [27]
[0074] In a similar manner to the preparation of 18, compound 27 was obtained from 4′-(2,3-epoxy-propoxy)-4-methoxy-chalcone, 13 (1 g, 3.2 mmol) and n-butyl amine (1.26 mL, 12.8 mmol) in dry methanol (100 mL). Yield 880 mg (72%); mp 163-164° C.; MS (FAB) 384 (M + +1); IR (KBr) 3367, 1629; 1 H NMR (200 MHz, CDCl 3 ) δ 8.02 (d, J=8.7 Hz, 2H), 7.77 (d, J=15.3 Hz, 1H), 7.59 (d, J=8.7 Hz, 2H), 7.41 (d, J=15.5 Hz, 1H), 6.99 (d, J=8.9 Hz, 2H), 6.93 (d, J=8.7 Hz, 2H), 4.20-3.95 (m, 3H), 3.86 (s, 3H), 2.93-2.55 (m, 2H), 2.55 (t, J=5.9 Hz, 2H), 1.57-1.39 (m, 4H), 0.93 (t, J=6.9 Hz, 3H). Analyses calculated for C 23 H 29 NO 4 : C, 72.04; H, 7.62; N, 3.65. Found: C, 71.97; H, 7.58; N, 3.61.
3′-[2-Hydroxy-3-(4-phenylpiperazin-1-yl)-propoxy]-4-methoxy-chalcone [28]
[0075] In a similar manner to the preparation of 18, compound 28 was obtained from 3′-2,3-epoxy-propoxy)-4-methoxy-chalcone, 14 (500 mg, 1.6 mmol) and 1-phenyl 107° C.; MS (FAB) 384 (M + +1); IR (KBr) 3430, 3295, 1644; 1 H NMR (200 MHz, CDCl 3 ) δ 7.60 (d, J=8.9 Hz, 1H), 7.58 (d, J=15.8 Hz, 1H), 7.56 (d, J=8.4 Hz, 2H) 7.45 (t, J=7.1 Hz, 1H), 7.28 (d, J=15.8 Hz, 1H), 7.08-7.01 (m, 2H), 6.91 (d, J=8.6 Hz, 2H), 4.15-4.04 (m, 3H), 3.84 (s, 3H), 2.84-2.68 (m, 2H), 2.52 (t, J=5.9 Hz, 2H), 1.40-1.25 (m, 4H), 0.87 (t, J=6.9 Hz, 3H). Analyses calculated for C 23 H 29 NO 4 : C, 72.04; H, 7.62; N, 3.65. Found: C, 71.96; H, 7.57; N, 3.61.
2′-[2-Hydroxy-3-iso-propylamino-propoxy]-4-methoxy-chalcone [32]
[0076] In a similar manner to the preparation of 18, compound 32 was obtained from 2′-(2,3-epoxy-propoxy)-4-methoxy-chalcone, 15 (1 g, 3.2 mmol) and iso-propyl amine (1.6 mL, 19.3 mmol) in dry methanol (100 mL). Yield 870 mg (73%); mp 88-89° C.; MS (FAB) 370 (M + +1); IR (KBr) 3450, 3284, 1645; 1 H NMR (200 MHz, CDCl 3 ) δ 7.60 (d, J=8.9 Hz, 1H), 7.58 (d, J=15.6 Hz, 1H), 7.55 (d, J=8.4 Hz, 2H), 7.44 (t, J=7.5 Hz, 1H), 7.28 (d, J=15.8 Hz, 1H), 7.08-6.97 (m, 2H), 6.91 (d, J=8.6 Hz, 2H), 4.14-3.95 (m, 3H), 3.84 (s, 3H), 2.83-2.61 (m, 3H), 0.97 (d, J=6.0 Hz, 6H). Analyses calculated for C 22 H 27 NO 4 : C, 71.52; H, 7.37; N, 3.79. Found: C, 71.48; H, 7.41; N, 3.71.
4′-[2-Hydroxy-3-(4-phenylpiperazin-1-yl)-propoxy]-3,4-methylenedioxy-chalcone [33]
[0077] In a similar manner to the preparation of 18, compound 33 was obtained from 4′-(2,3-epoxy-propoxy)-3,4-methylenedioxy-chalcone, 17 (500 mg, 1.5 mmol) and 1-phenyl piperazine (0.23 mL, 1.5 mmol) in dry methanol (60 mL). Yield 540 mg (72%); mp 153-154° C.; MS (FAB) 487 (M + +1); IR (KBr) 3396, 1651; 1 H NMR (200 MHz, CDCl 3 ) δ 8.02 (d, J=8.8 Hz, 2H), 7.71 (d, J=15.5 Hz, 1H), 7.38 (d, J=15.5 Hz, 1H), 7.27 (t, J=7.9 Hz, 2H), 7.16 (s, 1H), 7.12 (d, J=8.0 Hz, 1H), 7.01 (d, J=8.8 Hz, 2H), 6.97 (d, J=7.2 Hz, 1H), 6.91-6.82 (m, 3H), 6.02 (s, 2H), 4.17-4.09 (m, 3H), 3.23 (t, J=4.8 Hz, 4H), 2.89-2.81 (m, 2H), 2.69-2.62 (m, 4H). Analyses calculated for C 29 H 30 N 2 O 5 : C, 71.59; H, 6.21; N, 5.76. Found: C, 71.62; H, 6.30; N, 5.81.
4′-[ 3 -tert-Butylamino-2-hydroxy-propoxy]-3,4-methylenedioxy-chalcone [34]
[0078] In a similar manner to the preparation of 18, compound 34 was obtained from 4′-(2,3-epoxy-propoxy)-3,4-methylenedioxy-chalcone, 17 (1 g, 2.9 mmol) and tert-butyl amine (0.93 mL, 9 mmol) in dry methanol (80 mL). Yield 1 g (84%); mp 122-piperazine (0.26 mL, 1.7 mmol) in dry methanol (75 mL). Yield 620 mg (82%); mp 153-154° C.; MS (FAB) 473 (M + +1); IR (KBr) 3485, 1652; 1 H NMR (200 MHz, CDCl 3 ) δ 7.79 (d, J=15.6 Hz, 1H), 7.60 (d, J=8.8 Hz, 1H), 7.60 (d, J=8.8 Hz, 2H), 7.58 (d, J=2.9 Hz, 1H), 7.41 (t, J=7.8 Hz, 1H), 7.39 (d, J=15.6 Hz, 1H), 7.31-7.23 (m, 2H), 7.16 (dd, J=8.1 Hz, 1.9 Hz, 2H), 6.94 (d, J=8.7 Hz, 2H), 6.96-6.83 (m, 2H), 4.19-4.08 (m, 3H), 3.86 (s, 3H), 3.23 (t, J=4.9 Hz, 4H), 2.89-2.81 (m, 2H), 2.70-2.62 (m, 4H). Analyses calculated for C 29 H 32 N 2 O 4 : C, 73.70; H, 6.83; N, 5.93. Found: C, 71.63; H, 6.54; N, 5.91.
3′-[2-Hydroxy-3-iso-propylamino-propoxy]-4-methoxy-chalcone [29]
[0079] In a similar manner to the preparation of 18, compound 29 was obtained from 3′-(2,3-epoxy-propoxy)-4-methoxy-chalcone, 14 (1 g, 3.2 mmol) and iso-propyl amine (1.36 mL, 16 mmol) in dry methanol (80 mL). Yield 910 mg (76%); mp 102-103° C.; MS (FAB) 370 (M + +1); IR (KBr) 3391, 3131, 1650; 1 H NMR (200 MHz, CDCl 3 ) δ 7.79 (d, J=15.7 Hz, 1H), 7.60 (d, J=8.6 Hz, 1H), 7.60 (d, J=8.6 Hz, 2H), 7.55 (d, J=1.9 Hz, 1H), 7.40 (t, J=7.9 Hz, 1H), 7.38 (d, J=15.6 Hz, 1H), 7.14 (dd, J=7.6 Hz, 1.6 Hz, 2H), 6.94 (d, J=8.7 Hz, 2H), 4.09-4.01 (m, 3H), 3.86 (s, 3H), 2.92-2.74 (m, 3H), 1.10 (d, J=6.2 Hz, 6H). Analyses calculated for C 22 H 27 NO 4 : C, 71.52; H, 7.37; N, 3.79. Found: C, 71.13; H, 7.29; N, 3.81.
3′-[3-tert-Butylamino-2-hydroxy-propoxy]-4-methoxy-chalcone [30]
[0080] In a similar manner to the preparation of 18, compound 30 was obtained from 3′-(2,3-epoxy-propoxy)-4-methoxy-chalcone, 14 (1 g, 3.2 mmol) and tert-butyl amine (1.34 mL, 12.8 mmol) in dry methanol (120 mL). Yield 850 mg (69%); mp 83-84° C.; MS (FAB) 384 (M + +1); IR (KBr) 3387, 1653; 1 H NMR (200 MHz, CDCl 3 ) δ 7.78 (d, J=15.6 Hz, 1H), 7.60 (d, J=8.7 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.56 (d, J=2.5 Hz, 1H), 7.40 (t, J=7.9 Hz, 1H), 7.38 (d, J=15.6 Hz, 1H), 7.14 (dd, J=7.6 Hz, 1.7 Hz, 1H), 6.94 (d, J=8.7 Hz, 2H), 4.09-4.01 (m, 3H), 3.86 (s, 3H), 2.92-2.81 (m, 3H), 1.14 (s, 9H). Analyses calculated for C 23 H 29 NO 4 : C, 72.04; H, 7.62; N, 3.65.
[0081] Found: C, 72.08; H, 7.57; N, 3.58.
2′-[3-n-Butylamino-2-hydroxy-propoxy]-4-methoxy-chalcone [31]
[0082] In a similar manner to the preparation of 18, compound 31 was obtained from 2′-(2,3-epoxy-propoxy)-4-methoxy-chalcone, 15 (450 mg, 1.45 mmol) and n-butyl amine (0.72 mL, 7.26 mmol) in dry methanol (70 mL). Yield 480 mg (86%); mp 106-124° C.; MS (FAB) 398 (M + +1); IR (KBr) 3401, 1660; 1 H NMR (300 MHz, CDCl 3 ) δ 8.00 (d, J=8.7 Hz, 2H), 7.71 (d, J=15.6 Hz, 1H), 7.37 (d, J=15.6 Hz, 1H), 7.16 (s, 1H), 7.11 (d, J=8.1 Hz, 1H), 6.99 (d, J=8.7 Hz, 2H), 6.83 (d, J=7.8 Hz, 1H), 6.01 (s, 2H), 4.07-3.98 (m, 3H), 2.87 (dd, J=12.0 Hz, 3.9 Hz, 3.3 Hz, 1H), 2.69 (dd, J=12.0 Hz, 7.5 Hz, 7.5 Hz, 1H), 2.42 (bs, OH, NH), 1.13 (s, 9H); 13 C NMR (50 MHz, CDCl 3 ) δ 188.9, 162.9, 150.1, 148.8, 144.8, 131.9, 131.1, 129.9, 125.4, 120.3, 114.8, 109.0, 107.1, 101.9, 71.2, 68.9, 45.0, 29.4. Analyses calculated for C 23 H 27 NO 5 : C, 69.50; H, 6.85; N, 3.52. Found: C, 68.84; H, 6.94; N, 3.42.
4′-[3-iso-Butylamino-2-hydroxy-propoxy]-3,4-methylenedioxy-chalcone [35]
[0083] In a similar manner to the preparation of 18, compound 35 was obtained from 4′-(2,3-epoxy-propoxy)-3,4-methylenedioxy-chalcone, 17 (1 g, 2.9 mmol) and iso-butyl amine (0.89 mL, 9 mmol) in dry methanol (100 mL). Yield 1 g (84%); mp 122-123° C.; MS (FAB) 398 (M + +1); IR (KBr) 3325, 1657; 1 H NMR (200 MHz, CDCl 3 ) δ 8.00 (d, J=8.8 Hz, 2H), 7.72 (d, J=15.5 Hz, 1H), 7.36 (d, J=15.5 Hz, 1H), 7.15 (s, 1H), 7.10 (dd, J=8.7 Hz, 1.3 Hz, 1H), 6.98 (d, J=8.8 Hz, 2H), 6.83 (d, J=7.9 Hz, 1H), 6.01 (s, 2H), 4.09-4.03 (m, 3H), 2.85-2.76 (m, 2H), 2.47 (d, J=6.5 Hz, 2H), 1.78-1.72 (m, 1H), 0.93 (d, J=6.6 Hz, 6H). Analyses calculated for C 23 H 27 NO 5 : C, 69.50; H, 6.85; N, 3.52. Found: C, 69.53; H, 6.71; N, 3.14.
4-(Thiazolidin-2,4-dione-5-ylidinemethyl)-phenol (38)
[0084] A mixture of 4-hydroxy benzaldehyde, 36 (3 g, 24.6 mmol), 2,4-thiazolidinedione, 37 (2.9 g, 24.8 mmol), pipieridine (2.5 mL) and methanol (100 mL) was refluxed for 18 h. The reaction mixture was poured into water and acidified with acetic acid to give 38, which was recrystallised from methanol. Yield 4.7 g (86%); mp 296-298° C.; MS (FAB) 222 (M + +1); IR (KBr) 3404, 3123, 1723, 1678; 1 H NMR (200 MHz, DMSO-d 6 ) δ 7.70 (s, 1H), 7.46 (d, J=8.6 Hz, 2H), 6.93 (d, J=8.6 Hz, 2H).
3′-(4-Bromo-butoxy)-4-methoxy-chalcone [39]
[0085] Potassium carbonate (2.2 g, 15.8 mmol) was added to a stirred solution of 3′-hydroxy-4-methoxy-chalcone, 8 (2 g, 7.87 mmol) in dry acetone (100 mL) at room temperature. After the mixture was stirred for 30 min, dibromo butane (4.7 mL, 39.4 mmol) was added and the resultant was stirred at room temperature for 12 h. Reaction mixture was filtered through celite, concentrated under reduced pressure and extracted with chloroform. The extract was washed with water, dried over sodium sulphate, filtered and concentrated in vacuo. The residue was purified by column chromatography to afford 39. Yield 2.8 g, (91%); mp 91-92° C.; MS (FAB) 389/391 (M + +1); IR (KBr) 1654; 1 H NMR (200 MHz, CDCl 3 ) δ 7.79 (d, J=15.6 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.59 (d, J=7.6 Hz, 1H), 7.52 (d, J=2.0 Hz, 1H), 7.39 (t, J=7.8 Hz, 1H), 7.38 (d, J=15.6 Hz, 1H), 7.10 (dd, J=8.1 Hz, 2.3 Hz, 1H), 6.94 (d, J=8.7 Hz, 2H), 4.08 (t, J=5.7 Hz, 2H), 3.86 (s, 3H), 3.50 (t, J=6.3 Hz, 2H), 2.16-1.94 (m, 4H).
3′-(5-Bromo-pentyloxy)-4-methoxy-chalcone [40]
[0086] This compound (40) was prepared from 3′-hydroxy-4-methoxy-chalcone, 8 (2 g, 7.87 mmol), dibromo pentane (5.4 mL, 39.4 mmol) and potassium carbonate (2.2 g, 15.8 mmol) in dry acetone (100 mL) using the identical procedure as described for 39. Yield 2.7 g (85%); mp 83-84° C.; MS (FAB) 403/405 (M + +1); IR (KBr) 1650; 1 H NMR (200 MHz, CDCl 3 ) δ 7.78 (d, J=15.6 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.58 (d, J=7.4 Hz, 1H), 7.52 (d, J=2.2 Hz, 1H), 7.39 (t, J=7.8 Hz, 1H), 7.39 (d, J=15.6 Hz, 1H), 7.10 (dd, J=8.0 Hz, 2.3 Hz, 1H), 6.93 (d, J=8.7 Hz, 2H), 4.04 (t, J=6.2 Hz, 2H), 3.85 (s, 3H), 3.44 (t, J=6.7 Hz, 2H), 1.99-1.81 (m, 4H), 1.71-1.60 (m, 2H).
3′-(4-Bromo-butoxy)-3,4-methylenedioxy-chalcone [41]
[0087] This compound (41) was prepared from 3′-hydroxy-3,4-methylenedioxy-chalcone, 12 (2.7 g, 10 mmol), dibromo butane (3.6 mL, 30 mmol) and potassium carbonate (2.76 g, 20 mmol) in dry acetone (100 mL) using the identical procedure as described for 39. Yield 3.6 g (89%); mp 97-98° C.; MS (FAB) 403/405 (M + +1); IR (KBr) 1654; 1 H NMR (200 MHz, CDCl 3 ) δ 7.73 (d, J=15.6 Hz, 1H), 7.58 (d, J=7.6 Hz, 1H), 7.51 (s, 1H), 7.39 (t, J=7.8 Hz, 1H), 7.34 (d, J=15.6 Hz, 1H), 7.16 (s, 1H), 7.14-7.07 (m, 2H), 6.84 (d, J=7.9 Hz, 1H), 6.02 (s, 2H), 4.07 (t, J=5.6 Hz, 2H), 3.50 (t, J=6.3 Hz, 2H), 2.16-1.94 (m, 4H).
3′-(5-Bromo-pentyloxy)-3,4-methylenedioxy-chalcone [42]
[0088] This compound (42) was prepared from 3′-hydroxy-3,4-methylenedioxy-chalcone, 12 (2.7 g, 10 mmol), dibromo pentane (4.1 mL, 30 mmol) and potassium carbonate (2.76 g, 20 mmol) in dry acetone (100 mL) using the identical procedure as described for 39. Yield 2.7 g (64%); mp 87-88° C.; MS (FAB) 417/419 (M + +1); IR (KBr) 1652; 1 H NMR (200 MHz, CDCl 3 ) δ 7.73 (d, J=15.6 Hz, 1H), 7.57 (d, J=7.6 Hz, 1H), 7.51 (d, J=2.1 Hz, 1H), 7.39 (t, J=7.8 Hz, 1H), 7.34 (d, J=15.6 Hz, 1H), 7.16 (s, 1H), 7.14-7.10 (m, 2H), 6.02 (s, 2H), 4.05 (t, J=6.2 Hz, 2H), 3.50 (t, J=6.7 Hz, 2H), 2.02-1.78 (m, 4H), 1.71-1.59 (m, 2H).
4-Methoxy-3′-{4-[4-(thiazolidin-2,4-dione-5-ylidinemethyl)-phenoxy]-butoxy}-chalcone [43]
[0089] A mixture of 3′-(4-bromo-butoxy)-4-methoxy-chalcone, 39 (1.2 g, 3.1 mmol), 4-(thiazolidin-2,4-dione-5-ylidinemethyl)-phenol, 38 (1 g, 4.62 mmol) and potassium carbonate ( 600 mg, 4.34 mmol) in dry dimethyl formamide (80 mL) was stirred at room temperature for 8 h. The reaction mixture was filtered through celite, diluted with water and acidified with dilute hydrochloric acid and filtered. The crude product was purified by column chromatography to yield 43. Yield 800 mg (49%); mp 186-187° C.; MS (FAB) 530 (M + +1); IR (KBr) 3429, 1729, 1688, 1657; 1 H NMR (200 MHz, DMSO-d 6 ) δ 8.33 (s, 1H), 7.88 (d, J=8.7 Hz, 2H), 7.81 (d, J=17.8 Hz, 1H), 7.75 (s, 1H), 7.75 (d, J=7.7 Hz, 1H), 7.62 (s, 1H), 7.56 (d, J=8.8 Hz, 2H), 7.54 (t, J=9.3 Hz, 1H), 7.49 (d, J=17.6 Hz, 1H), 7.25 (dd, J=7.9 Hz, 2.1 Hz, 1H), 7.12 (d, J=8.7 Hz, 2H), 7.03 (d, J=8.7 Hz, 2H), 4.16 (s, 4H), 3.84 (s, 3H), 1.94 (s, 4H), Analysis Calcd for C 30 H 27 NO 6 S: C, 68.04; H, 5.14; N, 2.64; S, 6.05. Found: C, 68.25; H, 5.37; N, 2.69; S, 5.89.
4-Methoxy-3′-{5-[4-(thiazolidin-2,4-dione-5-ylidinemethyl)-phenoxy]-pentyloxy}-chalcone [44]
[0090] A mixture of 3′-(5-bromo-pentyloxy)-4-methoxy-chalcone, 40 (1.4 g, 3.47 mmol), 4-(thiazolidin-2,4-dione-5-ylidinemethyl)-phenol, 38 (800 mg, 3.62 mmol) and potassium carbonate (500 mg, 3.62 mmol) in dry dimethyl formamide (80 mL) were reacted in a similar way as described for 43 to yield 44. Yield 970 mg (52%); mp 182-183° C.; MS (FAB) 544 (M + +1); IR (KBr) 3288, 1736, 1682, 1654; 1 H NMR (200 MHz, DMSO-d 6 ) δ 7.75 (d, J=8.7 Hz, 2H), 7.67 (d, J=17.1 Hz, 1H), 7.63 (s, 1H), 7.61 (d, J=7.7 Hz, 1H), 7.47 (s, 1H), 7.43 (d, J=9.1 Hz, 2H), 7.40 (t, J=9.6 Hz, 1H), 7.36 (d, J=17.0 Hz, 1H), 7.11 (d, J=8.1 Hz, 1H), 6.98 (d, J=8.9 Hz, 2H), 6.92 (d, J=8.7 Hz, 2H), 3.96 (s, 4H), 3.72 (s, 3H), 1.71-1.33 (m, 6H). Analysis Calcd for C 31 H 29 NO 6 S: C, 68.49; H, 5.38; N, 2.58; S, 5.90. Found: C, 68.37; H, 5.46; N, 2.67; S, 6.08.
3,4-Methylenedioxy-3′-{4-[4-(thiazolidin-2,4-dione-5ylidinemethyl)-phenoxy]-butoxy}-chalcone [45]
[0091] A mixture of 3′-(4-bromo-butoxy)-3,4-methylenedioxy-chalcone, 41 (3 g, 7.44 mmol), 4-(thiazolidin-2,4-dione-5-ylidinemethyl)-phenol, 38 (1.8 g, 8.14 mmol) and potassium carbonate (2.2 g, 16 mmol) in dry dimethyl formamide (125 mL) were reacted in a similar way as described for 43 to yield 45. Yield 800 mg (20%); mp 173-175° C.; MS (FAB) 544 (M + +1); IR (KBr) 3373, 1726, 1664; 1 H NMR (200 MHz, DMSO-d 6 ) δ 10.39 (s, 1H), 7.84 (s, 1H), 7.77 (s, 1H), 7.73 (d, J=16.9 Hz, 1H), 7.70 (d, J=6.2 Hz, 1H), 7.62 (s, 1H), 7.50 (d, J=8.5 Hz, 2H), 7.48 (t, J=8.4 Hz, 1H), 7.48 (d, J=16.7 Hz, 1H), 7.34 (d, J=7.9 Hz, 1H), 7.23 (d, J=6.5 Hz, 1H), 7.00 (d, J=8.1 Hz, 1H), 6.94 (d, J=8.5 Hz, 2H), 6.12 (s, 2H), 4.10 (s, 2H), 3.75 (s, 2H), 1.78 (s, 4H). Analysis Calcd for C 30 H 25 NO 7 S: C, 66.29; H, 4.64; N, 2.58; S, 5.90. Found: C, 66.35; H, 4.57; N, 2.34; S, 6.13.
3,4-Methylenedioxy-3′-{5-[4-(thiazolidin-2,4-dione-5-ylidinemethyl)-phenoxy]-pentyloxy}-chalcone [46]
[0092] A mixture of 3′-(5-bromo-pentyloxy)-3,4-methylenedioxy-chalcone, 42 (2.5 g, 5.9 mmol), 4-(thiazolidin-2,4-dione-5-ylidinemethyl)-phenol, 38 (1.6 g, 7.24 mmol) and potassium carbonate (2.2 g, 16 mmol) in dry dimethyl formamide ( 125 mL) were reacted in a similar way as described for 43 to yield 46. Yield 1.4 g (42%); mp 159-161° C.; MS (FAB) 558 (M + +1); IR (KBr) 3316, 1736, 1679, 1655; 1 H NMR (200 MHz, DMSO-d 6 ) δ 10.41 (s, 1H), 7.85 (s, 1H), 7.74 (d, J=16.7 Hz, 1H), 7.73 (s, 1H), 7.71 (d, J=5.4 Hz, 1H), 7.63 (s, 1H), 7.50 (d, J=8.9 Hz, 2H), 7.48 (t, J=8.9 Hz, 1H), 7.48 (d, J=17.9 Hz, 1H), 7.36 (d, J=7.9 Hz, 1H), 7.23 (d, J=5.9 Hz, 1H), 7.01 (d, J=8.2 Hz, 1H), 6.95 (d, J=8.4 Hz, 2H), 6.13 (s, 2H), 4.08 (t, J=5.7 Hz, 2H), 3.70 (t, J=6.6 Hz, 2H), 1.80-1.66 (m, 4H), 1.49-1.46 (m, 2H); 13 C NMR δ 189.0, 167.9, 166.2, 160.5, 159.3, 149.9, 148.5, 144.5, 139.5, 133.8, 132.9, 130.2, 129.6, 126.4, 124.3, 121.2, 120.4, 119.6, 117.0, 116.7, 114.1, 108.9, 107.1, 102.0, 67.8, 41.7, 28.5, 27.3, 23.0. Analysis Calcd for C 31 H 27 NO 7 S: C, 66.77; H, 4.88; N, 2.51; S, 5.75.
[0093] Found: C, 66.96; H, 4.91; N, 2.40; S, 5.46.
[0000] Biological Screening
[0094] The biological screening of the synthesized compounds for antihyperglycemic and antidyslipidemic activities were carried out in Biochemistry Division, Central Drug Research Institute. Sucrose loaded rat model was used for primary screening followed by streptozotocin induced beta cell damaged diabetic model of Sprague Dawley strain male albino rat model. The compounds, which exhibited significant activity repeatedly in STZ model, were subjected to screen in db/db mice. The serum of the mice was also analyzed for lipid profile of the compounds exhibiting antihyperglycemic activity. All the compounds were also screened for antidyslipidemic activity in triton model.
[0000] Evaluation of Antihyperglycemic Activity
[0000] Sucrose Loaded Rat Model (SLM)
[0095] Male albino rats of Charles Foster/Wistar strain of average body weight 160±20 g were selected for this study. The blood glucose level of each animal was checked by glucometer using glucostrips (Boehringer Mannheim) after 16 h starvation. Animals showing blood glucose levels between 3.33 to 4.44 mM (60 to 80 mg/dl) were divided into groups of five to six animals in each. Animals of experimental group were administered suspension of the desired synthetic compound orally (made in 1.0% gum acacia) at a dose of 100-mg/kg-body weight. Animals of control group were given an equal amount of 1.0% gum acacia. A sucrose load (10.0 g/kg) was given to each animal orally exactly after 30 min post administration of the test sample/vehicle. Blood glucose profile of each rat was again determined at 30, 60, 90 and 120 min post administration of sucrose by glucometer. Food but not water was withheld from the cages during the course of experimentation. Quantitative glucose tolerance of each animal was calculated by Area Under Curve (AUC) method (Prism Software). Comparing the AUC of experimental and control groups determined the percentage antihyperglycemic activity. Statistical comparison was made by Dunnett's test.
[0000] Sucrose-Challenged Streptozotocin-Induced Diabetic Rats (STZ-S)
[0096] Male albino rats of Sprague Dawley strain of body weight 160±120 g were selected for this study. Streptozotocin (Sigma, USA) was dissolved in 100 mM citrate buffer pH 4.5 and calculated amount of the fresh solution was injected to overnight fasted rats (45 mg/kg) intraperitoneally. Blood glucose level was checked 48 h later by glucostrips and animals showing blood glucose values between 144 to 270 mg/dl (8 to 15 mM) were included in the experiment and termed diabetic. The diabetic animals were divided into groups consisting of five to six animals in each group. Animals of experimental groups were administered suspension of the desired test samples orally (made in 1.0% gum acacia) at a dose of 100-mg/kg-body weight. Animals of control group were given an equal amount of 1.0% gum acacia. A sucrose load of 2.5-g/kg body weight was given after 30 minutes of compound administration. After 30 minutes of post sucrose load blood glucose level was again checked by glucostrips at 30, 60, 90, 120, 180, 240, 300 min and at 24 h, respectively. Animals not found diabetic after 24 hours post treatment of the test sample were not considered and omitted from the calculations and termed as non-responders. The animals, which did not show any fall in blood glucose profile in a group while the others in that group, showed fall in blood glucose profile were also considered as non-responders. Food but not water was withheld from the cages during the experimentation. Comparing the AUC of experimental and control groups determined the percent antihyperglycemic activity. Statistical comparison between groups was made by Student's ‘t’ test.
% Antihyperglycemic Activity = 100 - Average blood glucose level of test substance treated group at test time Average blood glucose level of control group at test time × 100
Evaluation of Antidyslipidemic Activity
Triton Model
[0097] Male Charles foster rats weighing 200-225 g were divided into control, hyperlipidemic and hyperlipidemic plus drug treated groups containing six animals in each group. Hyperlipidemia was induced by administration of triton WR-1339 (200 mg/kg i.p.). All animals were maintained on a special pellet diet and water ad libitum. Compounds and standard drug were macerated with 0.2% aqueous gum acacia suspension. The suspension was fed orally at the dose of 100 mg/kg simultaneously with triton in drug treated group. The animals of control group received the same amount of gum acacia by similar route of administration. At the end of the experiment, after 18 h, blood was withdrawn from retro orbital plexus and plasma was used for the assay of total cholesterol, phospholipid and triglycerides.
[0000] Lipid Estimation
[0000] Cholesterol
[0098] Cholesterol was estimated using the kit provided by Roche Diagnostics. Cholesterol esters are enzymatically hydrolyzed by cholesterol esterase (CE) to cholesterol and free fatty acids. Free cholesterol, including that originally present, is then oxidized by cholesterol oxidase (CO) to cholest-4-en-3-one and hydrogen peroxide. The hydrogen peroxide combines with hydroxy benzoic acid (HBA) and 4-aminoantipyrine (4AAA) in the presence of peroxidase (POD) to form a chromophore (quinoneimine dye), which may be quantitated at 500-505 nm. The intensity of red colour formed is directly proportional to the concentration of total cholesterol in the specimen and measured spectrophotometrically (Searcy, C. L. Diagnostic Biochemistry, 1969, McGraw Hill, New York; Ellefson, R. D.; Caraway, W. T. Fundamentals of clinical chemistry, 1976, Ed Tietz N W, 506-515.)
[0000] Triglycerides
[0099] Triglycerides were estimated using the kit provided by Roche Diagnostics.
[0100] Lipoprotein lipase hydrolyses triglycerides to yield glycerol and fatty acids. Glycerol kinase converts glycerol to glycerol-3-phosphate, which is oxidized by glycerol phosphate oxidase to dihydroxy acetone phosphate and hydrogen peroxide. In the presence of peroxidase, hydrogen peroxide oxidatively couples with 4-aminoantipyrine and 4-chloro phenol to produce red quinonimine dye. The intensity of red colour formed is directly proportional to the concentration of triglycerides in the specimen and is measured by photometrically (Wahlefeld, A. W.; Bergmeyer, H. U. Ed. Methods of enzymatic analysis, 2 nd English edition, New York, N.Y., Academic press inc, 1831-1840.).
[0000] Phospholipids
[0101] Serum (0.2 mL) and perchloric acid (1.0 mL) was digested at 180° C. for 1-1.5 h till the solution became colorless. The liberated inorganic phosphate (Pi) was measured by the method of Fiske and Subbarow (Fiske, C. H.; Subbarow, V. J Biol. Chem. 1925, 66, 375.). 1 m]L of 2.5% ammonium molybdate (prepared in 5 N sulphuric acid) and 0.5 mL reducing agent (4-amino naphthol sulphonic acid, 0.2%), sodium metabisulphite (2.4% w/v in distilled water) was added to the above tubes and mixed well. The reaction mixture was distilled with 2.5 mL of triple distilled water and kept at 60° C. in water bath for 20 min. For standard, an appropriate amount of potassium dihydrogen phosphate dissolved in triple distilled water containing 2-10 μg phosphorus (Pi) was run simultaneously with the experiment tubes. The optical density of the blue colour was recorded at 620 nm against reagent blank. The values of Pi were converted into phospholipid by multiplying with 25 (a constant calibrated from Pi value of lecithin).
TABLE 3 Antihyperglycemic and antidyslipidemic activity in SLM, STZ-S and triton models % Fall in blood glucose levels (SLM&STZ-S models) % Fall in lipid levels Compd. STZ-S (Triton model) No. SLM 5 h 24 h TC PL TG 18 15.4 — 20.3 20 08 12 19 11.2 NIL NIL 21 22 19 20 7.78 NIL NIL 11 11 10 21 5.67 ND ND 05 14 12 22 11.8 NIL NIL 16 11 21 23 1.41 ND ND 17 12 22 24 10.8 — 6.18 24 15 14 25 NIL ND ND 04 10 33 26 NIL ND ND 37 28 39 27 38.0 NIL NIL 25 22 20 28 4.41 ND ND 40 26 17 29 6.85 NIL NIL 33 27 27 30 20.0 — 11.3 27 25 30 31 33.1 NIL NIL — 03 — 32 47.0 — 2.77 22 15 29 33 5.03 ND ND 22 21 16 34 21.1 — 23.0 26 20 18 35 23.8 — 11.6 13 09 13 43 NIL ND ND 04 14 31 44 NIL ND ND 06 13 19 45 0.13 ND ND 23 21 14 46 13.4 11.8 7.18 13 20 20
Evaluation of Antihyperglycemic and Antidyslipidemic Activity in db/db Mice
[0102] The db/db mouse is a well-characterized model of type H diabetes. The background for the db/db mouse is the C57BL/Ks strain. The major deficiency of the C57BL/KsBom-db mouse (db/db) is lack of a functional leptin receptor. This leads to defective leptin signaling and a complete lack of feedback from leptin. Both hypothalamic NPY content and secretion are consequently elevated, and this result in hyperphagia and decreased energy expenditure, obesity, insulin-resistance, hyperinsulinaemia, hyperglycemia and dyslipidemia. The db/db mouse develops NIDDM from around week 10. The disease is stable until week 20, where destruction of pancreatic β-cells can be recognized clinically as decreasing levels of plasma insulin and very severe hyperglycemia. The male mice are more diabetic than female and will normally die earlier. The advantage of using male mice for experimental purposes is that the fluctuations in plasma parameters are less than in the females where the estrogen cycle affects the clinical diabetes mellitus. The optimal age of db/db mice used for experiments will be from week 12 to 18 when they have developed NIDDM with diabetic dyslipidemia but still have functional β-cells in the pancreas. C57BL/KsBom-db mice 12-18 weeks, 40-50 g bred in the animal house of CDRI, Lucknow. 10 male mice were used in the experiments. The mice were housed in groups of 5 individuals in a room controlled for temperature (23±2° C.) and 12/12 hours light/dark cycle (lights on at 6.00 am). Body weight was measured daily from day 1 to day 10. All animals had free access to fresh water and to normal chow except on the days of the postprandial protocol day 6 and during the overnight fast before the OGTT on day 10. Blood glucose was checked every morning up till day 5. On day 6 postprandial protocol was employed, in this method blood glucose was checked at—0.30 min and 0 h. Test compounds were given to the treatment group whereas control group received only gum acacia (1.0%); the blood glucose was again checked at 1, 2, 3, 4 and 6 h post test compound treatment. Finally on day 10 an oral glucose tolerance test (OGTT) was performed after an overnight fasting. Blood glucose was measured at −0.30 min and test drugs were fed, blood glucose was again measured at 0.0 min post treatment, at this juncture glucose solution was given at a dose of 3 gm/kg to all the groups including control group; the profile of blood glucose was checked at 30 min, 60 min, 90 min and 120 min post glucose administration. Quantitative glucose tolerance of each animal was calculated by Area Under Curve (AUC) method (Prism Software). Comparing the AUC of experimental and control groups determined the percentage antihyperglycemic activity. Statistical comparison was made by Dunnett's test.
[0000] Lipid Cholesterol
[0103] Cholesterol and triglycerides were estimated using the same procedures as given above.
[0000] HDL-Cholesterol
[0104] HDL-Cholesterol was estimated using the kit provided by the Roche Diagnostics. Cholestest N HDL is a liquid reagent that directly measures the HDL-cholesterol concentration in serum by a new method that is based on the selective solubilising effect of proprietary detergent to the different lipoproteins. In the assay system, only HDL is solubilised by a special detergent; other lipoproteins are not disturbed. After HDL is selectively disrupted, HDL cholesterol is measured enzymatically (Gordon, T.; Casstelli, W. P.; Hjortland, M. C.; Kannel, W. B.; Dawber, T. R. High density lipoproteins as a protective factor against coronary heart disease, Am. J. Med. 1977, 62, 707-714.).
TABLE 4 Antihyperglycemic activity in db/db mice % Fall in blood glucose levels Compound number 6 days 10 days 18 29.9 18.9 34 NIL 32.0 46 1.76 23.1
[0105] TABLE 5 Antidyslipidemic activity in db/db mice % Fall in lipid levels Compound number TG Chol. HDL 18 +5.20 1.36 11.8 34 +7.44 40.3 +1.76 46 6.76 18.9 21.4
Results:
[0106] The activity of chalcones in SLM and STZ models are given in table 3 and compounds 18 and 34 showed significant results. Compound 46 in this series was also taken up for detailed study and showed significant lowering of blood glucose in db/db mice (Tables 3-5).
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The present invention provides novel substituted chalcone derivatives which exhibit anti-hyperglycemic and anti-dyslipedemic activity. The invention also provides a method for treating type II diabetes and associated hyperlipidemic conditions in a mammal by administering the compounds of the present invention and compositions containing these derivatives.
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TECHNICAL FIELD
[0001] The present invention relates to a piston for an internal combustion engine, the piston being movable back and forth in a cylinder of the internal combustion engine.
BACKGROUND ART
[0002] Automobiles travel by causing tires to rotate with a rotational drive force, which is converted from a drive force that is generated by an internal combustion engine supplied with a fuel. Recently, various attempts have been made to improve the fuel consumption ratio (gas mileage) of internal combustion engines on such automobiles. Since an improved fuel consumption ratio reduces the amount of fuel consumed, energy savings and protection of the global environment can be realized.
[0003] One such attempt is directed toward reducing the resistance to sliding movement between inner wall surfaces of cylinders (inner wall surfaces of bores or sleeves) of the internal combustion engine and pistons that move back and forth in the cylinders. If resistance to sliding movement is reduced, the pistons move back and forth more easily in the cylinders. Therefore, the drive force applied to move the pistons back and forth is reduced, resulting in a reduction in the amount of fuel consumed.
[0004] It is known in the art to deposit a layer including a lubricant-rich material on the inner wall surfaces of cylinders or piston skirts in order to reduce resistance to sliding movement of the pistons, for improving the lubrication properties of the inner wall surfaces of the cylinders or the piston skirts. For example, as disclosed in International Publication No. WO 2011/115152, the present applicant has proposed providing ridges on the sliding surface of a piston skirt, and covering the ridges with a lubricating film made of silver, silver alloy, copper, or copper alloy.
[0005] As disclosed in International Publication No. WO 2011/115152, it is preferable to interpose an intermediate layer made of a heat-resistant resin material between the film and the piston skirt, in order to ensure that the film is firmly bonded to the piston skirt by the intermediate layer. Specific examples of such a heat-resistant resin material include polyimide resin, polyamide-imide resin, epoxy resin, nylon-6 resin, and nylon-6,6 resin, etc.
[0006] The existence of the film on the piston of the internal combustion engine is effective to suitably maintain a lubricant between the inner wall surface of the cylinder, e.g., the inner wall surface of the sleeve, and the piston skirt. The existence of the film also serves to spread or transfer frictional heat quickly, so that the piston skirt and the inner wall surface of the cylinder can be prevented from becoming adhered to each other.
SUMMARY OF INVENTION
[0007] Vehicles that travel in severe environments, such as racing cars or the like, which are driven at high speeds over a long period of time, are required to be powered by a highly durable internal combustion engine as compared to general vehicles. For example, the piston used in the internal combustion engine disclosed in International Publication No. WO 2011/115152 desirably makes the film less liable to come off the piston skirt insofar as possible, thereby preventing the piston skirt and the inner wall surface of the cylinder from becoming adhered to each other over a long period of time.
[0008] The present invention has been made in connection with the technology disclosed in International Publication No. WO 2011/115152. A major object of the present invention is to provide a piston for use in an internal combustion engine, which is capable of making a solid lubricator less liable to come off for thereby suitably maintaining a lubricant between a piston skirt and the inner wall surface of the piston.
[0009] Another object of the present invention is to provide a piston for use in an internal combustion engine, which is capable of preventing the inner wall surface of a cylinder and a piston skirt from becoming adhered to each other.
[0010] According to an embodiment of the present invention, there is provided a piston for use in an internal combustion engine, which is movable back and forth in a cylinder of the internal combustion engine, comprising:
a base layer disposed on a sliding contact surface of a piston skirt, the base layer containing a resin material; a solid lubricator disposed on the base layer; and fibrous fillers that reside within and extend between the base layer and the solid lubricator.
[0014] The fibrous fillers exist across a boundary between the base layer and the solid lubricator, such that the fibrous fillers extend from the base layer into the solid lubricator. In other words, the fibrous fillers have ends that are embedded in the solid lubricator and other ends that are embedded in the base layer. Hence, the fibrous fillers develop an anchoring effect in both the base layer and the solid lubricator. Therefore, the base layer and the solid lubricator are firmly joined to each other via the fibrous fillers. As a result, it is difficult for the solid lubricator to peel off and separate away from the base layer.
[0015] The internal combustion engine in which the piston is incorporated remains highly durable even if the internal combustion engine is used in cars that travel in severe environments, such as racing cars or the like.
[0016] Assuming that a weight of the resin material is given as 100% by weight, the proportion of the fibrous fillers lies within a range from 10% to 65% by weight. The proportion of the fibrous fillers, which is 10% or greater by weight, allows the fibrous fillers to develop a sufficient anchoring effect, thereby making it possible to sufficiently increase the bonding strength between the base layer and the solid lubricators. The proportion of the fibrous filler, which is 65% or less by weight, is effective to cause the resin material to sufficiently hold the solid lubricator on the piston skirt. Stated otherwise, the fibrous fillers, which are contained in the resin material in the above range, make it possible to prevent the solid lubricator from coming off, suitably maintain the lubricant between the inner wall surface of the cylinder and the piston skirt, and are capable of avoiding adhesion from occurring between the inner wall surface of the cylinder and the piston skirt.
[0017] The solid lubricator preferably comprises at least one of silver, silver alloy, copper, or copper alloy. Each of such materials exhibits an excellent lubricating capability when the piston skirt is held in sliding contact with the inner wall surface of the cylinder.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is a perspective view showing in its entirety a piston according to an embodiment of the present invention;
[0019] FIG. 2 is a side elevational view of the piston shown in FIG. 1 ;
[0020] FIG. 3 is a fragmentary cross-sectional view of a surface layer region of a piston skirt of the piston;
[0021] FIG. 4 is an enlarged cross-sectional view of a boundary region between a base layer and a solid lubricator, which are deposited on a sliding contact surface in a surface layer region of the piston skirt;
[0022] FIG. 5 is a side elevational view of a piston according to another embodiment of the present invention;
[0023] FIG. 6 is an enlarged cross-sectional view of a surface layer region of a piston skirt of a piston according to yet another embodiment of the present invention;
[0024] FIG. 7 is a view showing a test piece according to an Inventive Example and the result of a peel test;
[0025] FIG. 8 is a view showing a test piece according to a Comparative Example 1 and the result of a peel test;
[0026] FIG. 9 is a view showing a test piece according to a Comparative Example 2 and the result of a peel test;
[0027] FIG. 10 is a view showing a test piece according to a Comparative Example 3 and the result of a peel test; and
[0028] FIG. 11 is a view showing a test piece according to a Comparative Example 4 and the result of a peel test.
DESCRIPTION OF EMBODIMENTS
[0029] Pistons for use in internal combustion engines (hereinafter referred to simply as “pistons”) according to preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
[0030] FIG. 1 is an overall perspective view showing the entirety of a piston 10 according to an embodiment of the present invention. FIG. 2 shows the piston 10 in side elevation. The piston 10 includes a pair of piston skirts 12 , 12 in a lower portion thereof, and a pair of walls 14 , 14 , which extend substantially vertically and are disposed between the piston skirts 12 , 12 . The walls 14 , 14 have respective pin bosses 16 , 16 that project horizontally. The pin bosses 16 , 16 have respective piston pin holes 17 , 17 defined respectively therethrough for insertion of a non-illustrated piston pin. The piston pin extends through a penetrating hole, which is defined in a smaller end of a non-illustrated connecting rod, thereby pivotally supporting the connecting rod on the piston 10 .
[0031] The piston 10 includes an oil ring groove 18 , a first piston ring groove 20 , and a second piston ring groove 22 , which are defined above the piston skirts 12 , 12 and arranged successively upward in this order. The oil ring groove 18 , the first piston ring groove 20 , and the second piston ring groove 22 extend circumferentially around a head portion of the piston 10 .
[0032] The piston 10 , which is constructed in the foregoing manner, is made of an aluminum alloy such as AC2A, AC2B, AC4B, AC4C, AC4D, AC8H, or A1100 (aluminum alloys defined according to JIS), an Al—Cu alloy, or the like.
[0033] As shown at an enlarged scale in FIGS. 3 and 4 , each of the piston skirts 12 has a sliding contact surface formed as a smooth surface, and a base layer 24 that is fixed to the smooth sliding contact surface. The base layer 24 covers the entirety of the sliding contact surface of each of the piston skirts 12 and has a substantially uniform thickness.
[0034] The base layer 24 contains a heat resistant resin material 26 , which increases the bonding strength between solid lubricators 30 , to be described below, and the piston skirts 12 . Preferred examples of the resin material 26 include polyimide resin, polyamide-imide resin, epoxy resin, nylon-6 resin, and nylon-6,6 resin, etc.
[0035] The base layer 24 also contains fibrous fillers 28 in the resin material 26 . The fibrous fillers 28 are in the form of metal fibers, the lengths of which lie within a range from several tens to several hundreds μm, for example, and have ends that project from the surface of the base layer 24 . A specific example of the metal fibers is Fe whiskers, although fibers of Fe—Ni—Cr alloy or fibers of tin (Sn) may be used. Alternatively, for example, the fibrous fillers 28 may be in the form of ceramic fibers made of silicon carbide (SiC) or the like, carbon nanotubes, or fibrous graphite.
[0036] Assuming that the weight of the resin material 26 is given as 100% by weight, the proportion of the fibrous fillers 28 preferably lies within a range from 10% to 65% by weight. The proportion of the fibrous fillers 28 , which is 10% or greater by weight, allows the fibrous fillers 28 to be embedded suitably in the base layer 24 and the solid lubricators 30 , thereby making it possible to sufficiently increase the bonding strength between the base layer 24 and the solid lubricators 30 . The proportion of the fibrous fillers 28 , which is 65% or less by weight, is effective to cause the resin material 26 to sufficiently hold the solid lubricators 30 on the piston skirts 12 .
[0037] Stated otherwise, the fibrous fillers 28 , which are contained in the resin material 26 in the above range, make it possible to prevent the solid lubricators 30 from coming off, maintain a lubricant suitably between the inner wall surface of a cylinder and the piston skirts 12 , and avoid the occurrence of adhesion between the inner wall surface of the cylinder and the piston skirts 12 .
[0038] Although the base layer 24 may contain only the resin material 26 and the fibrous fillers 28 , additionally, the base layer 24 may include a solid lubricant. The solid lubricant may be of a known nature. Preferred examples of the solid lubricant include molybdenum disulfide (MoS 2 ), boron nitride (BN), and graphite (C), etc.
[0039] The solid lubricators 30 , which extend in a linear manner circumferentially around the piston skirts 12 , are disposed on the base layer 24 (see FIGS. 1 and 2 ). Each of the solid lubricators 30 is raised horizontally from the base layer 24 . Therefore, each of the linearly shaped solid lubricators 30 is shaped in the form of a ridge.
[0040] Ends of the fibrous fillers 28 are embedded in the solid lubricators 30 and project from the base layer 24 in the vicinity of a contact surface, which is held in contact with the base layer 24 . In other words, the fibrous fillers 28 are contained in such a manner that the fibrous fillers 28 lie within and extend between the base layer 24 and the solid lubricators 30 . Since ends of the fibrous fillers 28 are embedded in the solid lubricators 30 and other ends thereof are embedded in the base layer 24 , the fibrous fillers 28 develop an anchoring effect both in the solid lubricators 30 and in the base layer 24 . Therefore, the base layer 24 and the solid lubricators 30 are firmly joined to each other. As a result, it is difficult for the solid lubricators 30 to peel off or become separated from the base layer 24 .
[0041] According to the present embodiment, the solid lubricators 30 are made of any one of silver, silver alloy, copper, and copper alloy. Each of such materials exhibits an excellent lubricating capability when the piston skirts 12 are held in sliding contact with the inner wall surface of a bore in a cylinder block or the inner wall surface of a cylinder sleeve. Preferred examples of silver alloy include Ag—Sn alloy and Ag—Cu alloy. Preferred examples of copper alloy include Cu—Sn alloy, Cu—Zn alloy, and Cu—P alloy, etc.
[0042] If the solid lubricators 30 are made of silver or silver alloy, the purity of silver preferably is 60% by weight or greater. If the purity of silver is less than 60% by weight, the thermal conductivity of the solid lubricators 30 is slightly low, and hence the solid lubricators 30 cannot easily form a smooth wearing surface, resulting in a tendency to lessen the ability to reduce the frictional loss (Psf) of the internal combustion engine. More preferably, the purity of silver is 80% by weight or greater.
[0043] If the solid lubricators 30 are made of copper or copper alloy, the purity of copper preferably is 70% by weight or greater, for the same reasons as described above, and more preferably, is 80% by weight or greater in particular.
[0044] The purity of silver is defined as the “% by weight of silver contained in the solid lubricators 30 ”. For example, if the solid lubricators 30 are made of silver alloy, the purity of silver is determined as the % by weight of silver contained in the solid lubricators 30 . If the solid lubricators 30 are in the form of sintered bodies produced from a paste after being coated with silver particles, the purity of silver is defined as the proportion of the silver particles in the paste. The purity of copper is defined similarly.
[0045] It is not required that all of the solid lubricators 30 are made of the same metal. The solid lubricators 30 may be made of different metals, for example, in such a manner that one of the solid lubricators 30 is made of silver, while another of the solid lubricators 30 adjacent thereto is made of copper alloy.
[0046] The solid lubricators 30 are not limited to having a particular thickness. However, if the thickness of the solid lubricators 30 is excessively small, the solid lubricators 30 become worn in a relatively short period of time. Conversely, if the thickness of the solid lubricators 30 is excessively large, the solid lubricators 30 become so heavy that a large driving force is required to move the piston 10 back and forth. In order to avoid such problems, the thickness of the solid lubricators 30 preferably lies within a range from 0.5 to 100 μm.
[0047] When the internal combustion engine, which is equipped with such a piston 10 , is assembled and operated, the solid lubricators 30 essentially are held in sliding contact with the inner wall surface of the cylinder (the inner wall surface of the cylinder bore or the inner wall surface of the cylinder sleeve) with a lubricating oil interposed therebetween. If the solid lubricators 30 are held in sliding contact with the inner wall surface of a sleeve that is made of FC (gray cast iron) or Al, for example, the sum of the thermal conductivity of the solid lubricators 30 and the thermal conductivity of the sleeve of FC or Al is determined to be 350 W/m·K or greater. In addition, the absolute value of the difference between the Young's moduli of the solid lubricators 30 and the sleeve of FC or Al is 10 GPa or greater.
[0048] According to an intensive study by the inventors, in this case, the lubricating oil is retained suitably in the small clearance between the sleeve and the piston skirts 12 , thereby preventing adhesion from taking place between the sleeve and the piston skirts 12 . Therefore, the sleeve and the piston skirts 12 are effectively prevented from suffering from seizure, whereby the frictional loss of the internal combustion engine is significantly reduced.
[0049] According to the present embodiment, furthermore, the solid lubricators 30 and the base layer 24 are firmly joined to each other as a result of the fibrous fillers 28 that are interposed therebetween.
[0050] Consequently, it is difficult for the solid lubricators 30 to peel off from the base layer 24 . Stated otherwise, the solid lubricators 30 are held on the sliding contact surfaces of the piston skirts 12 over a long period of time. Therefore, due to the existence of the solid lubricators 30 , the piston 10 can maintain the above-described advantages over a long period of time.
[0051] Since it is difficult for the solid lubricators 30 to peel off from the base layer 24 , the above advantages are obtained by the action of the solid lubricators 30 , even if the piston 10 is moved back and forth intensively in the cylinder. More specifically, the internal combustion engine in which the piston is incorporated remains highly durable, even if the engine is used in cars that travel in severe environments, such as racing cars including Formula 1 type racing cars or the like, for example.
[0052] According to the present embodiment, the piston requires only the addition of a plurality of linear solid lubricators 30 . The above-described solid lubricant and the resin material 26 are inexpensive and lightweight. Even though the sliding contact surfaces of the piston skirts 12 overall are covered with the base layer 24 having the solid lubricators 30 disposed thereon, the piston 10 is prevented from becoming high in cost or excessively heavy. In other words, the piston 10 is capable of carrying out a sufficient lubricating action, even though the weight of the piston 10 is prevented from increasing.
[0053] Even if a sleeve of Al, which tends to experience seizure in comparison with a sleeve of FC, is used in combination with the piston 10 , which is made of aluminum alloy, the piston 10 effectively avoids seizure and is capable of significantly reducing frictional loss in the internal combustion engine. Further, if the base layer 24 contains a solid lubricant, the solid lubricant can ensure a lubricating capability.
[0054] The base layer 24 and the solid lubricators 30 can be provided on the sliding contact surfaces of the piston skirts 12 in the following manner.
[0055] First, the resin material 26 , which is to be made into the base layer 24 , is prepared and melted. The fibrous fillers 28 are mixed with the melted material. In the resin material 26 , the content of the fibrous fillers 28 preferably lies within a range from 10% to 65% by weight. A solid lubricant may also be added to the resin material 26 and the fibrous fillers 28 .
[0056] Next, the melted material is supplied to the sliding contact surfaces of the piston skirts 12 . The melted material may be sprayed onto the sliding contact surfaces of the piston skirts 12 , or alternatively, the sliding contact surfaces of the piston skirts 12 may be coated with the melted material. The melted material preferably is applied so that the sliding contact surfaces of the piston skirts 12 are covered entirely with the melted material. It is easier and simpler to cover the sliding contact surfaces of the piston skirts 12 entirely with the melted material. Stated otherwise, rather than selectively coating portions of the sliding contact surfaces of the piston skirts 12 with the melted material, the base layer 24 can be formed with greater ease.
[0057] The melted material, which has been supplied as described above, is cooled and solidified in a state in which the contained fibrous fillers 28 project from the surface of the material. In this manner, the base layer 24 is formed on the sliding contact surfaces of the piston skirts 12 .
[0058] Meanwhile, fine particles of silver, silver alloy, copper, or copper alloy, preferably having an average particle diameter in a range from 1 to 80 nm, and more preferably from 30 to 80 nm, or stated otherwise, nanoparticles of silver, silver alloy, copper, or copper alloy, are dispersed in a dispersion medium in order prepare a paste. Preferred examples of the dispersion medium are polar solvents including aromatic alcohols such as benzylic alcohol, propylene glycol monomethyl ether acetate (PEGMEA), polyethylene glycol monomethacrylate (PEGMA), terpineol, etc. An unsaturated fatty acid ester may be added as a dispersant to such polar solvents.
[0059] For forming the solid lubricators 30 , the base layer 24 is coated with the paste containing the dispersion medium, using a known coating process such as a screen printing process, a pad printing process, or the like. Thereafter, the paste together with the piston 10 is heated to a temperature preferably within a range from 160° C. to 240° C. The dispersion medium in the paste is volatilized and the nanoparticles are fused together. In other words, the nanoparticles are sintered, thereby producing the solid lubricators 30 in the form of sintered bodies made up of nanoparticles.
[0060] The solid lubricators 30 are obtained by coating the base layer 24 with a paste, at a location where the ends of the fibrous fillers 28 project from the surface of the base layer 24 . Consequently, the solid lubricators 30 have ends of the fibrous fillers 28 embedded therein, in the vicinity of a contact surface that is held in contact with the base layer 24 . Accordingly, the fibrous fillers 28 are contained in such a manner that the fibrous fillers 28 lie within and extend between the base layer 24 and the solid lubricators 30 .
[0061] As described above, the solid lubricators 30 are obtained by a coating process, such as a screen printing process, a pad printing process, or the like. Since the coating process is carried out after the melted material has been cooled and solidified into the base layer 24 , the printing plate is prevented from becoming clogged with the melted material. In other words, the solid lubricators 30 can be obtained in an efficient manner.
[0062] If the solid lubricators 30 are formed from nanoparticles, the solid lubricators 30 are sintered in a relatively low temperature range from 160° C. to 240° C., thereby producing a coating. Therefore, the piston skirts 12 , which are made of an aluminum alloy, are prevented from being heated to a high temperature, and the mechanical strength thereof, etc., is prevented from being adversely affected.
[0063] The present invention is not limited to the embodiment described above. Various changes may be made to the embodiment without departing from the scope of the invention.
[0064] For example, although according to the present embodiment, the solid lubricators 30 are provided in a linear shape, as shown in FIG. 5 , the solid lubricators 30 may be provided in a dot shape. Recesses, which are defined between the dot-shaped solid lubricators 30 , are effective to fulfill a role of maintaining the lubricating oil.
[0065] According to the arrangement shown in FIG. 5 , the amount of paste used to form the solid lubricators 30 , i.e., the amount of metal (silver, silver alloy, copper, or copper alloy) used, is reduced. Thus, the cost of the piston is further reduced and the weight of the piston 10 is prevented from increasing.
[0066] The base layer 24 may be formed selectively only on portions of the piston skirts 12 where the solid lubricators 30 are to be formed. Alternatively, the entire sliding contact surfaces of the piston skirts 12 may be coated with the base layer 24 , together with the entirety of the base layer 24 being coated with the solid lubricators 30 .
[0067] A plurality of linear marks may be provided on the sliding contact surfaces of the piston skirts 12 . In addition, the base layer 24 may be provided selectively on the linear marks, whereas the solid lubricators 30 may be provided selectively only on the base layer 24 . Alternatively, as shown in FIG. 6 , a plurality of protrusive linear ridges 32 , which extend around the sliding contact surfaces, may be provided on the base layer 24 , and the solid lubricators 30 may be provided in a linear shape or a dot shape on the ridges 32 .
[0068] In the above embodiment, the base layer 24 is formed by supplying the melted material to the sliding contact surfaces of the piston skirts 12 , and then cooling and solidifying the melted material, after which the base layer 24 is coated with the paste in order to form the solid lubricators 30 . However, the present invention is not limited to such a process. Alternatively, before the melted material is cooled and solidified, the melted material may be coated with the paste in order to form the solid lubricators 30 .
EXAMPLES
Inventive Example
[0069] A test piece 34 shown in FIG. 7 was fabricated, and a peel test was conducted on the test piece 34 . The test piece 34 had a laminated body 42 made of a base layer 38 and a solid lubricator 40 . The laminated body 42 was disposed on the surface of an aluminum alloy sheet 36 , which was formed in a sheet-like shape having a length of 25 mm, a depth of 25 mm, and a height of 5 mm. An aluminum alloy sheet 46 , which was formed in the same manner as the aluminum alloy sheet 36 , was joined to the laminated body 42 by an interposed adhesive 44 .
[0070] More specifically, a melted material, which was produced by melting a resin material 48 of polyamide imide (PAI), was mixed with fibrous fillers 50 made of iron. At this time, the content of the fibrous fillers 50 in the resin material 48 was 10% by weight.
[0071] The surface of the aluminum alloy sheet 36 was treated by shot peening, and thereafter, the surface was coated with the melted material made up of the mixture of the resin material 48 and the fibrous fillers 50 , which was supplied by spray coating. Using radiative cooling, the melted material was solidified into the base layer 38 .
[0072] A paste, which was prepared by dispersing fine particles of silver in benzylic alcohol containing an unsaturated fatty acid ester as a dispersant, was supplied to the base layer 38 by screen printing, after which the entire piece was sintered at 210° C. for 2 hours. Thus, the laminated body 42 , in which the base layer 38 and the solid lubricator 40 were joined together by the fibrous fillers 50 , was obtained. The thickness of the base layer 38 was 10 μm, whereas the thickness of the solid lubricator 40 was 9μm.
[0073] The solid lubricator 40 of the laminated body 42 was coated with the adhesive 44 , and the aluminum alloy sheet 46 was joined thereto, thereby fabricating the test piece 34 .
[0074] The peel test was conducted by applying forces in the directions of the arrows X 1 and X 2 in FIG. 7 to the aluminum alloy sheets 36 , 46 of the test piece 34 , and confirming which one of the layers between the aluminum alloy sheets 36 , 46 was peeled off. As a result, as indicated by the broken line in FIG. 7 , it was confirmed that peel-off occurred between the solid lubricator 40 and the adhesive 44 , whereas the base layer 38 and the solid lubricator 40 remained suitably joined to each other.
Comparative Example 1
[0075] As shown in FIG. 8 , a test piece 52 was fabricated, and a peel test was conducted on the test piece 52 , in the same manner as the peel test that was performed on the test piece 34 . In FIG. 8 and subsequent figures, components which are identical to those shown in FIG. 7 are denoted by identical reference characters, and such features will not be described in detail below.
[0076] The test piece 52 included a lubricating layer 54 instead of the laminated body 42 of the test piece 34 . In other words, the test piece 52 was fabricated in the same manner as in the Inventive Example, except for the process of fabricating the lubricating layer 54 . The lubricating layer 54 was obtained using a melted material, which was produced by melting a resin material of polytetrafluoroethylene (PTFE) and PAI, mixing the melted material with a solid lubricant of MoS 2 and C, supplying the mixed melted material to the aluminum alloy sheet 36 in the same manner as in the Inventive Example, and thereafter sintering the entire piece at 190° C. for 90 minutes. The content of the solid lubricant in the resin material was 10% by weight, and the thickness of the lubricating layer 54 was 22 μm.
[0077] A peel test was conducted on the test piece 52 . As indicated by the broken line shown in FIG. 8 , peel-off occurred between the lubricating layer 54 and the adhesive 44 .
Comparative Example 2
[0078] As shown in FIG. 9 , a test piece 56 was fabricated, and a peel test was conducted on the test piece 56 in the same manner as the peel test described above. More specifically, shot peening was not performed on the surface of the aluminum alloy sheet 36 , and a melted material, which was produced by melting a PAI resin, was supplied to the aluminum alloy sheet 36 by screen printing, thereby producing a base layer 58 . Next, a paste of fine particles of silver and a dispersant, which was prepared in the same manner as in the Inventive Example, was supplied to the base layer 58 by screen printing. Thereafter, the test piece 56 was fabricated by the same process used in the Inventive Example. The thickness of the base layer 58 was 3 μm.
[0079] A peel test was conducted on the test piece 56 . As indicated by the broken line shown in FIG. 9 , peel-off occurred between the base layer 58 and the solid lubricator 40 .
Comparative Example 3
[0080] As shown in FIG. 10 , a test piece 60 was fabricated, and a peel test was conducted on the test piece 60 in the same manner as the peel test described above. The test piece 60 included a base layer 62 instead of the base layer 38 of the test piece 34 . The test piece 60 was fabricated in the same manner as the test piece 34 , except for the process of forming the base layer 62 . More specifically, in order to form the base layer 62 of the test piece 60 , a melted material produced by melting a resin material of PAI was mixed with a solid lubricant of MoS 2 and C, and thereafter, the mixture was supplied to the surface of the aluminum alloy sheet 36 , which had been treated by shot peening. The content of the solid lubricant in the resin material was 10% by weight.
[0081] A peel test was conducted on the test piece 60 . As indicated by the broken line shown in FIG. 10 , peel-off occurred between the base layer 62 and the solid lubricator 40 .
Comparative Example 4
[0082] As shown in FIG. 11 , a test piece 64 was fabricated, and a peel test was conducted on the test piece 64 in the same manner as the peel test described above. The test piece 64 included a base layer 66 instead of the base layer 38 of the test piece 34 . The test piece 64 was fabricated in the same manner as the test piece 34 , except for the process of forming the base layer 66 . More specifically, in order to form the base layer 66 of the test piece 64 , a melted material produced by melting a resin material of PAI was mixed with a solid lubricant of C, and thereafter, the mixture was supplied to the surface of the aluminum alloy sheet 36 , which had been treated by shot peening. The content of the solid lubricant in the resin material was 10% by weight.
[0083] A peel test was conducted on the test piece 64 . As indicated by the broken line shown in FIG. 11 , peel-off occurred between the base layer 66 and the solid lubricator 40 .
[0084] In peel tests performed on the Inventive Example and on Comparative Examples 1 through 4, shear strengths upon the occurrence of peel-off were measured. The shear strengths of the Inventive Example and Comparative Examples 2 through 4, which included the base layer and the solid lubricator, were substantially twice the shear strength of Comparative Example 1, which included PTFE but did not include a base layer.
[0085] As can be understood from a comparison of FIGS. 8 through 11 , Comparative Examples 2 through 4, which are free of fibrous fillers between the base layer and the solid lubricator, exhibited the occurrence of peal-off between the base layer and the solid lubricator, whereas in the Inventive Example, which includes the fibrous fillers 50 , the base layer 38 and the solid lubricator 40 remained in a suitably joined condition while exhibiting substantially the same shear strength as in Comparative Examples 2 through 4.
[0086] Accordingly, it was confirmed that the bonding strength between the base layer 38 and the solid lubricator 40 is increased by the fibrous fillers 50 , which are provided between the base layer 38 and the solid lubricator 40 . Such a feature implies that the existence of the fibrous fillers 50 fortifies the bond between the base layer 38 and the solid lubricator 40 , so that it is extremely difficult for interlayer peel-off to occur between the base layer 38 and the solid lubricator 40 .
[0087] From the foregoing description, it is clear that the fibrous fillers 50 , which lie within and extend between the base layer 38 and the solid lubricator 40 , make it less likely for the solid lubricator to come off from the piston skirts, and as a result, the lubricant can be maintained suitably between the inner wall surface of the cylinder and the piston skirts.
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A piston that maintains excellent lubricating performance even when the internal combustion engine is operated in severe environments. A primer layer including a resinous material is disposed on the sliding surface of the skirt of a piston, and solid lubricating parts, preferably including silver (Ag), a silver alloy, copper (Cu), or a copper alloy are disposed on the primer layer. In the primer layer and the solid lubricating parts, a fibrous filler including metallic fibers, etc., is present so as to extend across the boundary between the primer layer and the solid lubricating parts.
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FIELD OF THE INVENTION
[0001] The present invention concerns improvements in and relating to roller subs for use downhole in oil or gas wells as part of the tool string or drill string to reduce friction between the string and the wellbore.
BACKGROUND TO THE INVENTION
[0002] Roller subs are used widely throughout the oil industry but especially in wireline toolstrings, which rely on gravity alone to advance the toolstring, and are especially useful down wells that deviate substantially from the vertical.
[0003] Conventional roller subs are generally substantially solid circular cylindrical bodies that are milled to provide radial slots at intervals therearound and therealong. These slots each accommodate a respective roller wheel. Two example prior art configurations of multi-roller wheel sub are illustrated in FIGS. 1 and 2 below.
[0004] In the FIG. 1 example the cylindrical body 1 , formed with the plurality of slots 2 , holds each roller wheel 3 in place in its respective slot by means of a grub screw 4 which locks down onto a radius groove machined into the head of a caphead screw 5 that serves as the axle of the respective roller wheel 3 .
[0005] In the FIG. 2 example, the roller sub has substantially the same configuration but in this case the axle 6 of each roller wheel 3 has an undercut into which a fixing grub screw 7 locks.
[0006] A number of practical problems arise from the use of such conventional designs of multiroller wheel sub, perhaps the most important of which is that the axles and the grub screws and other locking fixtures for holding the roller wheels 3 in place are vulnerable to mechanical failure which may lead to jamming of roller wheels or their loss downhole. Loss of mechanical components such as these downhole is, of course, extremely undesirable since they may interfere with operation of the well and necessitate costly interruption of production to attempt to locate and fish them out.
SUMMARY OF THE INVENTION
[0007] According to the present invention there is provided a roller sub for use downhole in oil or gas wells as part of a toolstring or drill string to reduce friction between the string and wellbore, which roller sub carries at least one roller wheel, wherein the roller sub is a modular assembly of parts which assemble together to trap the at least one roller wheel in place between them.
[0008] Preferably the modular assembly comprises a body formed of segments.
[0009] Suitably the modular assembly body of the roller sub comprises six segments.
[0010] Advantageously each roller wheel has integral (i.e. integrally formed or assembled) pivot pin means.
[0011] Preferably the pivot pin means of each roller wheel comprise axle stubs that are domed or substantially hemispherical in shape to co-operatively engage with correspondingly shaped recesses in the body of the roller sub.
[0012] Suitably each roller wheel has a circumferential groove whereby the roller wheel has a dumbell-like shape in profile.
[0013] Advantageously a channel is provided extending longitudinally through the roller sub to serve as a conduit for fluids or electric line.
[0014] Preferably part of the channel is defined by the circumferential grooves of the roller wheels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a side elevation view of a first example of prior art roller sub and with insets showing transverse sections.
[0016] [0016]FIG. 2 is a side elevation view of a second example of prior art roller sub and with insets showing transverse sections.
[0017] A preferred embodiment of the present invention will be now more particularly described, by way of example, with reference to FIGS. 3 to 6 of the accompanying drawings, wherein:
[0018] [0018]FIG. 3 is a perspective view of a preferred embodiment of roller sub fully assembled;
[0019] [0019]FIG. 4 is a perspective view similar to FIG. 3 but with two roller-mounting body segments of the roller sub disassembled therefrom.
[0020] [0020]FIGS. 5A and B are, respectively, a plan view of a body segment of the roller sub and a side elevation view of the same;
[0021] [0021]FIG. 5C is a transverse section along the line A-A of the body segment of FIGS. 5 A/B and shown schematically in-situ assembled with the other body segments and with a roller wheel shown in ghostline mounted thereto;
[0022] [0022]FIG. 5D is a transverse section of view of the body segment of FIGS. 5 A/B taken along the line B-B in FIGS. 5 A/B and again shown assembled together with the other segments;
[0023] [0023]FIG. 6A is a general assembly diagram of the roller sub, as fully assembled, and showing the top sub and bottom sub part cut away; and
[0024] [0024]FIGS. 6B and 6C are, respectively, a transverse sectional view taken along the line A-A in FIG. 6A and along the line B-B in FIG. 6A.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] Referring to FIGS. 3 to 6 , the roller sub of the present invention does not comprise a one-piece cylindrical body with machined slots for roller wheels as in the prior art. Instead, it comprises a modular assembly of body segments 12 a - 12 f with the roller wheels 30 each having integrally formed pivot pin means 31 and being substantially encased and thereby locked within the roller sub body 1 ′ during assembly of the body 1 ′.
[0026] The sub body 1 ′ comprises a top sub 100 , a bottom sub 200 and an intermediate body part 300 . The intermediate body part 300 encases the roller wheels 30 in use and is composed of the body segments 12 a - 12 f that fit together. In the illustrated form it is composed of six body segments 12 a - 12 f , two of which are seen disassembled from the sub body 1 ′ in FIG. 4.
[0027] The body segments 12 a - 12 f are formed as metal bars that are of cross sectional shape that is generally a segment of a circle, whereby the assembled sub intermediate part 300 is substantially circular cylindrical. The bars 12 a - 12 f are suitably cast, but may be machined to have a pair of longitudinally spaced apart recesses 40 a , 40 b , angled at different radial orientations. Each recess 40 a , 40 b defines half of a cavity to receive a roller wheel 30 and which mates with a recess 40 a ′, 40 b ′ of an adjacent one of the bars 12 a - 12 f to define a full cavity.
[0028] The six body segments 12 a - 12 f between them define six cavities, each to accommodate a respective one of six roller wheels 30 , each wheel 30 oriented radially outwardly at a different orientation from each other and the wheels 30 between them substantially covering the full 3600 circumference around the sub.
[0029] Each of the roller wheels 30 is seated within a respective cavity and is held within the cavity by co-operative engagement of the axle stubs 31 of the roller wheel 30 with corresponding sockets 32 in the wall of each opposing recess 40 a , 40 a ′ defining the mounting cavity for the roller wheel 30 . Each axle stub socket 32 is suitably a substantially hemispherical recess to receive a corresponding hemispherical shape of axle stub 31 .
[0030] The simple act of assembling two adjacent body segments 12 a , 12 b together around a roller wheel 30 traps it in place between the two. When all six body segments 12 a - 12 f are assembled together as the intermediate body part 300 trapping all six wheels 30 in place, they are secured together in assembled state by screw thread mounting of the top sub 100 to the upper end of the intermediate body part 300 , and with the lower end of the intermediate body part 300 being threadedly coupled with the bottom sub 200 .
[0031] By screw threaded engagement of the intermediate body part 300 with the top and bottom subs 100 , 200 it is possible to completely avoid use of any grub screws or other means of locking the parts together. However, individual grub screws may additionally or alternatively be used for this purpose while still achieving a very marked improvement over the prior art arrangement of roller sub, using only a pair of grub screws 34 , one for coupling with the intermediate part 300 with the top sub 100 , and the other for coupling with the bottom sub 200 .
[0032] The provision of the roller wheels 30 with their own integrally formed pivot pin means, i.e axle stubs 31 confers a number of technical benefits. The axle stubs 31 of the roller wheels 30 occupy little volume in comparison to the axles and locking grub screws of the prior art. This provides the opportunity of forming the roller wheel 30 with a broader profile than the conventional wheel, and which suitably has a pulley-like shape, as illustrated, with a prominent rim portion 35 at each end separated by a median groove portion 33 .
[0033] This profile of the wheel 30 provides for a wide stable wheel while minimising surface contact area. The wheel 30 configuration as a whole is more robust and more stable and spans a greater proportion of the circumference of the roller sub 1 ′, enabling provision of roller wheel 30 contact with the well bore around the full circumference of the roller sub with as few as six wheels 30 and, therefore, within a relatively short length of roller sub, making the whole device far more compact in all respects than the prior art roller sub and utilising less roller wheels 30 as well as avoiding the need for the various other fixing components.
[0034] With six wheel-mounting segments and between them carrying six wheels 30 , each of wide span, substantially any orientation around the full circumference presents at least a part of a roller wheel 30 to the well bore. This enables, at the simplest level, a tool string to be supported by the one short roller sub at each end of the tool string, avoiding the need for many subs or subs of extended length.
[0035] Through avoiding use of separate axles and locking screws and the like, a number of yet further technical benefits ensue. In particular, not only does the assembly of the present invention avoid risk of loss of components down hole but maintenance is also made much simpler. In the prior art configuration great trouble has to be taken in the assembly of the roller wheels to the roller sub to minimise the risk of their falling out, in use, and the locking screws are commonly bonded into place with adhesive, whereby stripping of the tool for maintenance is made awkward and often leads to damage to the screw threads and the need to clean and replace not only the roller wheels, but also the axles and screws. In the case of the present invention the roller sub is disassembled very easily, simply by unscrewing the top and bottom end subs 100 , 200 and the service engineer need only clean and replace the roller wheels 30 , where necessary.
[0036] By forming the axle stubs 31 of the roller wheel 30 to be domed and suitably substantially hemispherical in shape, they are able to support the roller wheel 30 effectively under heavy lateral loads, further enhancing the substantial improvement in strength of the axles.
[0037] The roller wheels 30 by virtue of their ‘pulley-like’ or ‘dumbell-shaped’ profile, are able to more easily traverse debris downhole. Furthermore, the manner of mounting of the roller wheels within the connector body provides a wheel cavity with better clearance for egress of any debris that might otherwise enter and interfere with operation of the wheel.
[0038] The pulley-like or dumbell-shaped profile of the roller wheels 30 has a yet further benefit in that where the roller wheels 30 come together back-to-back in the roller sub, the median groove portion 33 of each wheel 30 combines with the groove 33 of each of the adjacent two wheels 30 to define a substantially sized generally circular or polygonal space 41 which may form part of a conduit that extends through the length of the roller sub. This can best be seen in FIGS. 6B, 6C and may be exploited for a number of purposes including accommodating an electric line extending the length of the sub. Indeed, in one embodiment the roller sub may be adapted specifically for this purpose and have a male electrical connector at one end and a female electrical connector at the other end, linked by electrical wire extending between the ends through the conduit 41 . Such a configuration is original and is facilitated through the existence of the median grooves 33 of the roller wheels to define the basis for the passage/conduit 41 without wastage of space and enabling maintenance of the compact design of the whole assembly.
[0039] The roller sub of the present invention has been tested and established to work efficiently to angles of well bore deviation as much as 88°—e.g. where the toolstring extends initially substantially vertically but turns to extend substantially horizontally downhole.
[0040] The compact configuration of the roller sub of the present invention enables it to be scaled down to a diameter as small as 2 inches, if necessary, and still be effective.
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The present invention provides a roller sub for use downhole in oil or gas wells as part of a toolstring or drill string to reduce friction between the string and wellbore. The roller sub is a modular assembly of parts which assemble together to trap the roller wheels in place between them, avoiding need for grub screws to fasten the individual wheels and rendering the roller sub very compact.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to simulation of the operation of electronic circuits, especially integrated circuits. The invention relates more particularly to a technique for reducing the amount of time and difficulty of accurately simulating circuit performance in cases wherein the various parameters for mathematical simulation models of devices/components in a simulator experience or assume “out-of-range” values during simulation of the operation of circuits containing the devices/components.
[0002] “Compact” (i.e., sufficiently simple to be incorporated in circuit simulators) semiconductor device models are mathematical descriptions or equations of semiconductor devices in a circuit used in circuit simulators, and serve as an important vehicle for achieving suitable communication between integrated circuit designers and integrated circuit fabrication facilities or “foundries”. When characterizing a semiconductor process, foundries fabricate a number of devices with various geometric sizes and physical parameters on test wafers. Those devices are then measured over a normal operating range, and the measured data are used to extract the compact device models. The compact device models are made available to circuit designers as a part of a process design kit (PDK).
[0003] Circuit analysis software based on or similar to the well-known public domain simulation engine SPICE (Simulation Program with Integrated Circuit Emphasis) is widely used in the semiconductor industry. However, strong-nonlinear (e.g., exponential) device characteristics in some compact models are known to cause convergence problems in a SPICE or SPICE-like circuit simulator employing the well known Newton-Raphson numerical analysis algorithm. Limiting algorithms (e.g., by Bhattacharya & Mazumd) have been used to deal with the convergence problems by limiting the magnitudes of the changes between Newton-Rapson iterations. Since compact semiconductor device models are generally designed using different modeling equations characterizing different operating regions of nonlinear devices (such as transistors and diodes), discontinuities of equations and derivatives thereof may exist in boundaries between the different regions. Various techniques (e.g., as subsequently described in the Liu et al. reference) are known for dealing with such discontinuities. It should be noted that the above mentioned limiting algorithms are used to deal with “strong” nonlinear characteristics, but not with discontinuities.
[0004] The accuracy of circuit simulation results that correspond to various variables and parameters of a circuit design depends on the accuracy of the compact device models. Note that the term “parameters” herein refers to intrinsic constants or coefficients (for example, constants representative of the width and length of a MOSFET) for a “device instance” that does not change during a DC sweep or a transient run of a simulator. The term “device instance” as used herein refers to an individual device in a circuit. (It is referred to as a “device instance” (rather than just a “device”) because sometimes system engineers refer to the entire integrated circuit chip as a “device”.) It should be understood that many device instances can be modeled by the same device model. For example, a circuit may include half of a million device instances even though the circuit is simulated using only 200 device models. Note that device currents and voltages are referred to herein as “variables” rather than “parameters”.
[0005] The semiconductor device models typically are accurate over particular “normal ranges” of the voltages applied to the “terminals” of device models used during simulation of circuit performance. However, during a DC simulation or transient simulation of the operation of a circuit including a particular semiconductor device, the model of that device may operate with variables such as electrode voltages and currents that are outside of its normal range. Some device models, such as models for diodes or bipolar transistors, exhibit strongly “non-physical” nonlinear behaviors which do not accurately correspond (during simulation of circuit operation) to the behavior of an actual physical device when operating outside of its normal modeling range.
[0006] There are many reasons for a device instance to be out-of-range during a simulation run. For example, large swings and overshoots during “less-accurate top-level” runs of the simulator for a particular circuit may cause out-of-range device instances. As another example, some behavioral models can be used to represent certain parts of the circuit for simulation. Those models could output very large currents or voltages that are “nonphysical” (i.e., would not be present in a real physical device of the kind being modeled), causing device instances connected to them to be out-of-range. Use of an unsuitable mathematical model for a device such as a diode or transistor may cause the simulator computations to fail to suitably converge.
[0007] The prior methods of voltage or current limiting (or other device parameter limiting) and the prior methods of discontinuity removal for device models have not been as effective as is desirable. For example, strongly nonlinear (i.e., strongly non-physical) behaviors of the circuit device occurring during a simulation typically cause various numerical computational difficulties for a circuit simulator. This typically causes longer simulation times, and sometimes causes the results of simulator computations to completely fail to converge, thereby causing the entire simulation run to fail. For example, the current in a diode having a large forward bias increases exponentially, and this may cause convergence difficulties for the simulator. In any case, when a simulation fails, integrated circuit designers often are forced to modify the options of the circuit simulation program or to even redesign the circuit. This is usually very time-consuming and costly.
[0008] Prior Art FIG. 1 is a copy of FIG. 5 in United States patent application “Continuous Parametric Model for Circuit Simulation” by Liu et al., Ser. No. 09/754,811 filed Jan. 4, 2001, published Jan. 31, 2002 as Publication Number US 2002/0013932, and entirely incorporated herein by reference. Prior Art FIG. 1 indicates a method of generating an enhanced continuous parametric device model for use in various SPICE simulators. The device model begins with the acquisition of a “base parametric model”, as indicated in block 505 . The base parametric model is analyzed to determine whether the model is continuous over the desired full range of device variables, as indicated in decision block 510 . If the base parametric model is not continuous, at least one compensation function is applied to “fix” or eliminate the discontinuity, as indicated in block 515 . If the base parametric model is continuous, the method advances through a logical connector 520 to determine whether the derivatives of the base parametric model are continuous, as indicated in decision block 525 . If the derivatives are not continuous, a compensation constant is applied to the parametric model to eliminate the derivative discontinuity, as indicated in block 530 . After the derivatives have been found to be continuous or have been “fixed” or compensated to be continuous, the method concludes with the result being an enhanced or modified or replaced continuous parametric model, as indicated in label 540 . The enhanced/modified/replaced continuous parametric model can be stored in model library for use by simulation/analysis engine software.
[0009] Thus, in accordance with Prior Art FIG. 1 , a discontinuous, but not necessarily “strongly” nonlinear, base parametric model is “fixed” so as to change it into an enhanced/modified/replaced continuous parametric model. Note that the Liu et al. method “fixes” discontinuities, but does not fix strong nonlinearities in model equations. Known limiting algorithms deal with strong nonlinearities by limiting changes between Newton-Raphson iterations, but the model equations remain strongly nonlinear. (In contrast, the new technique of the present invention fixes strong nonlinearities by dynamically modifying or replacing strongly nonlinear equations with linear or “weakly nonlinear” equations, but does not fix discontinuities.)
[0010] In addition to the above mentioned Liu et al. published patent application, the most relevant prior art is believed to include material in Chapter 2 of “The Designer's Guide to SPICE and Specter” by Kundert, 1995, and the article “Augmentation of SPICE for Simulation of Circuits Containing Resonant Tunneling Diodes”, by Mayukh Bhattacharya, et al., IEEE transactions on computer-aided design of integrated circuits and systems, vol. 20, No. 1, January, 2001. (An introduction to the Newton-Raphson analysis method and convergence may be found in Kundert's above mentioned book.)
[0011] Thus, there is an unmet need for a simulator and technique for reducing the amount of time required to accurately simulate performance of circuits including strongly nonlinear device models.
[0012] There also is an unmet need for a simulator and technique which avoid the need for integrated circuit designers to modify options of a circuit simulation program as a result of a failure of computations in the simulation program to converge suitably.
[0013] There also is an unmet need for a simulator and technique which avoid the need for integrated circuit designers to modify the design of an integrated circuit as a result of a failure of simulation computations to converge suitably.
[0014] There also is an unmet need for a simulator and technique which reduce the time and overall cost required in the design of integrated circuits.
[0015] There also is an unmet need for a simulator and technique which avoid the need for “fixing” convergence problems associated with strongly nonlinear device models.
SUMMARY OF THE INVENTION
[0016] It is an object of the invention to provide a simulator and technique for reducing the amount of time required to accurately simulate performance of circuits including strongly nonlinear device models.
[0017] It is another object of the invention to provide a simulator and technique which avoid the need for integrated circuit designers to modify options of a circuit simulation program as a result of a failure of computations in the simulation program to converge suitably.
[0018] It is another object of the invention to provide a simulator and technique which avoid the need for integrated circuit designers to modify the design of an integrated circuit as a result of a failure of simulation computations to converge suitably.
[0019] It is another object of the invention to provide a simulator and technique which reduce the time and overall cost required in the design of integrated circuits.
[0020] It is another object of the invention to provide a simulator and technique which avoid the need for “fixing” convergence problems associated with diode and bipolar transistor device models with exponential characteristics.
[0021] Briefly described, and in accordance with one embodiment, the present invention provides a simulation system ( 1 ) that prevents failure of simulation computations to converge due to out-of-range conditions of a first device model including a first equation (Eqn.(1)) utilized in simulation computations involving the first device model by identifying an out-of-range condition (e.g., v d >V 0 ) which is likely to prevent convergence of simulation computations involving the first equation during a simulation run, and by automatically providing a second equation (Eqn.(6) or Eqn.(9)) in place of the first equation (Eqn.(1)), wherein the second equation defines a simpler mathematical function than the first equation and is more likely than the first equation to allow simulation computations to converge to a desired solution during the simulation run. The method includes automatically determining any time at which the out-of-range condition no longer exists and automatically modifying the first device model by replacing the second equation with the first equation.
[0022] In one embodiment, the invention provides a method for operating a simulation system ( 1 ) to prevent failure of simulation computations to converge due to out-of-range conditions of a first device model being simulated. The first device model includes a first equation (e.g., Eqn.(1)) utilized in simulation computations involving the first device model. The method includes: identifying an out-of-range condition (e.g., v d >V 0 ) which is likely to prevent convergence of simulation computations involving the first equation during a simulation run; automatically providing a second equation (e.g., Eqn.(6) or Eqn.(9)) in place of the first equation (Eqn.(1)), wherein the second equation defines a simpler mathematical function than the first equation and is more likely than the first equation to allow simulation computations to converge to a desired solution during the simulation run; and also includes continuing the simulation run to obtain the desired solution.
[0023] In a described embodiment, the method includes automatically determining any time at which the out-of-range condition no longer exists and also includes automatically modifying the first device model by replacing the second equation with the first equation and then continuing the simulation run.
[0024] In one embodiment, the first equation is an exponential equation and the second equation is either a linear equation or a second order polynomial equation.
[0025] In one embodiment, the first equation represents a characteristic of a diode and is given by the expression
[0000]
I
d
=
I
s
(
v
d
V
te
-
1
)
,
[0000] where v d is the voltage across the diode, I d is diode current, I s is the saturation current, V te =K*q/T, K is Boltzman's constant, q is the electronic charge, and T is temperature in degrees Kelvin.
[0026] In one embodiment, the second equation is selected from the group including linear (or first order polynomial) equations and second order polynomial equations.
[0027] In one embodiment, the method includes using the first equation during the simulation run whenever the first device model is not in an out-of-range condition and using the second equation during the simulation run whenever the first device model is in an out-of-range condition.
[0028] In one embodiment, the simulation system ( 1 ) is operated to prevent failure of simulation computations to converge due to out-of-range conditions of a plurality of device models in a circuit being simulated.
[0029] In one embodiment, the method includes forming a system of linearized equations representing a configuration of a circuit being simulated and using a Newton-Raphson analysis to perform the simulation computations. In one embodiment, values of parameters of the first device model are extracted parameters obtained by measurement of a physical implementation of the first device, and the method includes using the extracted parameters to identify the out-of-range condition.
[0030] In one embodiment, the method includes operating a SPICE circuit simulation program ( 3 ) included in the simulation system ( 1 ).
[0031] In one embodiment, the invention includes a simulation system ( 1 ) for preventing failure of simulation computations to converge due to out-of-range conditions of a first device model being simulated, the first device model including a first equation (e.g., Eqn.(1)) utilized in simulation computations involving the first device model. The simulation system ( 1 ) includes computing circuitry ( 2 , 3 , 18 , 26 , 27 , 30 ) for identifying an out-of-range condition (e.g., v d >V 0 ) which is likely to prevent convergence of simulation computations involving the first equation during a simulation run; computing circuitry ( 18 , 20 , 22 ) for automatically providing a second equation (e.g., Eqn.(6) or Eqn.(9)) in place of the first equation (Eqn.(1)), wherein the second equation defines a simpler mathematical function than the first equation and is more likely than the first equation to allow simulation computations to converge to a desired solution during the simulation run; and computing circuitry ( 14 , 16 , 17 , 18 , 20 , 22 ) for continuing the simulation run to obtain the desired solution. In one embodiment, the second equation is either a linear equation or a second order polynomial equation, and the first equation is an exponential equation.
[0032] In one embodiment, values of parameters of the first device model are extracted parameters obtained by measurement of a physical implementation of the first device. In one embodiment, the simulation system ( 1 ) includes a SPICE circuit simulation program ( 3 ).
[0033] In one embodiment, the invention provides a simulation system ( 1 ) for operating a simulation system ( 1 ) to prevent failure of simulation computations to converge due to out-of-range conditions of a first device model being simulated, the first device model including a first equation (e.g., Eqn.(1)) utilized in simulation computations involving the first device model. The system includes means ( 2 , 3 , 18 , 26 , 27 , 30 ) for identifying an out-of-range condition (e.g., v d >V 0 ) which is likely to prevent convergence of simulation computations involving the first equation during a simulation run; means ( 18 , 20 , 22 ) for automatically providing a second equation (e.g., Eqn.(6) or Eqn.(9)) in place of the first equation (Eqn.(1)), wherein the second equation defines a simpler mathematical function than the first equation and is more likely than the first equation to allow simulator computations to converge to a desired solution during the simulation run; and means ( 14 , 16 , 17 , 18 , 20 , 22 ) for continuing the simulation run to obtain the desired solution.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a copy of FIG. 5 in published United States Patent Application US 2002/0013932 published Jan. 31, 2002.
[0035] FIG. 2 is a block diagram of a circuit modeling and simulation system.
[0036] FIGS. 3A-E constitute a flowchart of a program for simulating circuits with out-of-range parameters and/or variables occurring in a device model.
[0037] FIG. 4A is a graph of the current through a simulated diode as a function of its voltage.
[0038] FIG. 4B is a graph of the conductance of the simulated diode represented by FIG. 4A as a function of its voltage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] In a described embodiment of the invention, if an operating parameter such as a voltage between two terminals of a modeled device such as a diode or transistor in a circuit simulation system is “out-of-range”, then the model is considered to no longer accurately describe its behaviors. To ensure numerical stability of the circuit simulator, the simulator automatically operates to identify any out-of-range variables which are likely to prevent convergence of simulation computations to a meaningful solution. If an out-of-range parametric condition or variable condition is detected, then the simulator automatically and dynamically substitutes a simpler mathematical function for the model which allows the simulation computations to converge suitably to a meaningful desired solution.
[0040] FIG. 2 is essentially similar to FIG. 1 in commonly assigned U.S. Pat. No. 8,200,461 entitled “Small-Signal Stability Analysis at Transient Time Points of Integrated Circuit Simulation” by the present inventor, filed Sep. 24, 2009 (published as US Publication 2011/0071812 on Mar. 24, 2011), and incorporated herein by reference. FIG. 2 is a simplified block diagram illustrating an exemplary computer simulation system 1 which can be used both to generate and utilize modified (or enhanced or replaced) device models to simulate electronic circuits and systems. System 1 includes a workstation 10 including a CPU (central processing unit) 2 which is operatively coupled by means of a bus 11 , a network interface 21 A, another bus 11 A, and a server 21 B to one or more computer-readable mass storage devices in a model library 5 . Model library 5 may include disk drives and CD-ROM drives and the like, and stores both “base parametric models” and modified, replaced, or enhanced parametric models of circuit devices. Workstation 10 also includes a program memory 3 A, a data memory 3 B, and an input/output interface 7 each coupled to bus 11 . Input/output interface 7 is coupled via a bus 8 to a peripheral function unit 4 which may include a keyboard, a digital pointer device such as a mouse, trackball, light pen, touch screen input device or the like, and a display device such as a LCD screen.
[0041] In FIG. 2 , workstation 10 executes software instructions that are stored in one of its memory resources to represent an integrated circuit which is to be simulated. As is known for SPICE and similar simulation systems, the simulation of an electronic circuit is based on a set of circuit elements that are associated with selected “nodes” in an overall “netlist” that specifies the circuit which is to be simulated. Each circuit element is specified by a model which specifies the simulated behavior of that circuit element in response to input stimuli applied to the circuit element. Initial conditions to be applied at nodes of the modeled circuit for the purpose of simulating the transient response of that circuit may be input by the user via peripheral devices 4 or may be initial state data stored in model library 5 . (For example, the time interval over which the transient response is to be analyzed is input via peripheral devices in block 4 or by retrieving a previously stored interval.) Conventional transient analysis is performed by time discretization over the selected time interval, wherein a system of equations descriptive of the modeled circuit is then solved in a piece-wise fashion at each of a sequence of discrete time points. The discrete transient time points within that interval are generally chosen by a time-stepping method (e.g., based on local truncation errors, break points, and the like).
[0042] As previously indicated, circuit components or devices used in conventional SPICE circuit modeling are described by mathematical models which generally are a collection of mathematical representations, such as input/output transfer functions, of various device parameters that characterize the devices/components. Such mathematical representations are referred to herein as “parametric models”. A particular circuit component/element may be represented by various base parametric device models. Data to be associated with a “base parametric device model” typically is collected or “extracted” by measurement of corresponding physical devices and is utilized in generating the device model, for example by “curve-fitting” of actual device data to equations utilized in the base parametric models. During a simulation run, if a base parametric device model operates outside of the range of the extracted physical device data utilized to generate that base parametric device model, it is considered to be “out-of-range” and therefore no longer valid. When that occurs, the base parametric device model equation is dynamically modified, i.e., enhanced or replaced, by a simpler equation that allows the simulator computations to converge.
[0043] There are many causes for the base parametric model of a semiconductor device in a circuit to be “out-of-range” during the simulation. At some point during the simulation, a base parametric device model may receive or generate very large representations of currents or voltages (or of parameters) that cause it to be “out-of-range” and therefore inaccurate. For example, sometimes designers run “top-level simulations” with very loose parameter tolerances, and this may cause the base parametric device model to experience large, out-of-range voltage swings or “overshoots”. In some cases, improper device models might be used for “less important” devices in the circuit being simulated. In some cases, “out-of-range” operation of a base parametric device model may be the result of a design error. In any case, whenever a base parametric device model is undergoing out-of-range of operation, it no longer can be considered to accurately describe the behavior of the corresponding actual physical device in the circuit being simulated.
[0044] FIG. 3A shows a top-level flowchart wherein a START label 12 indicates the beginning of the overall process of simulating DC or transient operation of a particular circuit to be simulated (the structure of which has been entered by the user into simulation system 1 ). For example, the simulation program executed by simulation system 1 ( FIG. 2 ) may receive a circuit netlist that includes a description of the appropriate circuit component model connections, and also may receive a “control statement”, as indicated in block 13 . The control statement typically includes various device parameter tolerances, and also typically includes the desired number of circuit analyses and indicates whether they are AC analyses or DC analyses.
[0045] Referring to block 14 , the simulation process modifies or enhances or replaces a base parametric device model as needed to provide a suitable simplified device model that allows simulation computations to converge whenever simulation system 1 finds that the base parametric device model is operating out-of-range. The simulation program evaluates all of the base parametric device models that are strongly nonlinear whenever they are operating out-of-range, so that the out-of-range device models can be modified or replaced by a linear or less nonlinear models for out-of-range of operation. Specifically, simulation system 1 dynamically modifies base parametric device models that exhibit strong nonlinearity beyond their normal operating range. Highly nonlinear device functions, such as exponential functions, are replaced by simpler functions such as first order linear or second order polynomial functions with more simulator-friendly numerical properties. Simulation system 1 then performs one or multiple DC and/or transient analyses as specified by the user. For example, during each specified analysis simulation system 1 repeatedly evaluates/computes instances of nonlinear device conditions (i.e., evaluates/computes current through a diode, forward voltage across the diode, and/or conductance of the diode) in the circuit being simulated. If a nonlinear device goes into an out-of-range condition at some point during the simulation, then simulation system 1 switches from the original nonlinear base parametric model to a specified linear function or second order function and uses it for as long as the modified device model remains in the out-of-range condition, and then returns to the original nonlinear base parametric model. (An “out-of-range condition” of a device model is defined such that the device model's terminal parameters and/or variables fall outside of the actual physical device values that have been utilized in the base parametric device model.) Details of steps performed in accordance with block 14 are described with reference to subsequently described FIG. 3B . (Various other operations performed by simulation system 1 are well known.)
[0046] Referring to block 16 , the modified or enhanced or replaced device model (hereinafter referred to simply as “modified device model”) then is utilized to perform one or multiple DC and/or transient analyses using the modified/replaced device model. Specifically, the presently selected user-specified analysis is performed in accordance with the transient analysis process of subsequently described FIG. 3C . While an analysis is being performed, if a device model needs to be evaluated for an AC analysis, it is necessary to compute a DC operating point. That requires evaluating the nonlinear device models. To perform an AC analysis, it is necessary to linearize the associated device models at the DC operating point. (The operating point analysis can be (but does not need to be) a stand-alone analysis.) As indicated by decision block 17 in FIG. 3A , the simulation program next determines if the present analysis performed in accordance with block 16 is successful and if any further analyses are required. If the determination of decision block 17 is affirmative, the simulation program returns via flowchart path 17 A to block 16 and performs the next user-specified analysis. If the determination of decision block 17 is negative, the overall simulation of the circuit under consideration is complete, as indicated by “END” label 24 .
[0047] Details of the process of evaluating a device model as indicated in block 14 of FIG. 3A are shown in FIG. 3B , wherein the device evaluation program goes via path 13 A from the start label to block 26 and acquires one of the device models from device library 5 (for example, a device model represented by subsequently described Equations (1) and (2)) used for the circuit being simulated from model library 5 ; that device model may show strong nonlinearity when operating out-of range. The program then goes to block 28 and receives specified controlling parameters. A controlling parameter can be at the circuit level or at the device level. For example, one circuit-level controlling parameter could be the maximum conductance for all the devices in the circuit. Another controlling parameter could be the maximum current for certain diode model.
[0048] The program then goes to block 30 and determines a boundary of the normal operating range for the device model under consideration, for example by using subsequently described Equation (3). Next, the program goes to decision block 32 and determines, on the basis of a user specified option, whether the present nonlinear base parametric device model should be modified or enhanced or replaced by a first order linear polynomial or a second order polynomial. If the determination of decision block 32 is that a first order polynomial should be used, the program goes to block 34 and computes appropriate parameters for out-of-range device mathematical functions, while maintaining continuity of the device functions and their first order derivatives. This results in a desired modified or enhanced or replaced device model, as indicated by path 10 and label 38 . If the determination of decision block 32 is that a second order polynomial should be used, the program goes to block 36 and computes appropriate parameters for the out-of-range device. This results in the modified device model, as indicated by path 10 and label 38 . The modified device model then is used in accordance with the process of block 16 in FIG. 3A .
[0049] In one example, a diode model represented by Equations (1) and (2) below illustrates an original base parametric device model. Referring to block 26 , simulation/analysis system 1 acquires this diode model from model library 5 ( FIG. 2 ), with its current-voltage characteristics determined by Equation (1) and its conductance characteristics determined by Equation (2):
[0000]
I
d
=
I
s
(
v
d
V
te
-
1
)
,
and
Eqn
.
(
1
)
g
d
=
∂
I
d
∂
v
d
=
I
s
V
te
v
d
V
te
Eqn
.
(
2
)
[0000] where v d is the forward voltage across the diode, I d is the diode current, g d is the diode conductance, and I s and V te are model parameters. I s is the saturation current. V te =K*q/T, K is Boltzman's constant, q is electronic charge, and T is temperature in degrees Kelvin. ( FIG. 4A shows a representative graph of diode current I d according to Equation (1), and FIG. 4B shows a graph of the corresponding diode conductance g d . The solid-line curves in FIGS. 4A and 4B represent Equations (1) and (2), respectively. The dashed line sections of the curves represent sections of the curves which have been dynamically modified in accordance with the present invention. Although both I d and its derivative are continuous, they are strongly nonlinear for large values of v d . For example, in FIG. 4A it may be seen that at approximately v d =0.75 V (volts) the exponential diode model may be considered to be out-of-range, and from that point on the equation of a suitable “easy-to-converge” linear or polynomial function may be substituted in place of the original exponential function.)
[0050] Referring to block 28 in FIG. 3B for this example, note that simulation/analysis system 1 receives controlling parameters for modifying the diode model, including values for voltage, current, and conductance (e.g., Vmax=0.7 V, Imax=1 A (ampere), gmax=(1×10 +3 ) mhos, as well as the choice (e.g., first-order or second order polynomial equation) of a substitute for the exponential expression in Equation (1).
[0051] Referring to block 30 in FIG. 3B , simulation/analysis system 1 in this example determines a boundary voltage V 0 of a “normal” operating range of forward voltage v d for Equation (1) of the diode model, given by
[0000]
V
0
=
min
(
V
max
,
V
te
ln
(
I
max
I
s
)
,
V
te
ln
(
g
max
V
te
I
s
)
)
,
Eqn
.
(
3
)
[0000] where V 0 is the smallest or minimum among the three voltages indicated within the brackets.
[0052] If operation beyond the boundary voltage V 0 is detected, simulation/analysis system 1 then computes corresponding modified device model parameters for the selected linear or second order out-of-range current equations for the diode model. If linear approximation is chosen in accordance with decision block 34 , simulation/analysis system 1 uses Equations 4, 5, 6 and 7 (below) to compute the following parameters based on the continuity conditions of the diode current and diode conductance, as indicated in block 34 :
[0000]
a
0
=
I
s
(
v
d
V
te
-
1
)
,
Eqn
.
(
4
)
a
1
=
I
s
V
te
V
0
V
te
,
Eqn
.
(
5
)
I
d
=
a
0
+
a
1
(
v
d
-
V
0
)
,
and
Eqn
.
(
6
)
g
d
=
a
1
.
Eqn
.
(
7
)
[0053] However, if simulation/analysis system 1 determines in decision block 32 that second-order polynomial approximation is to be used to model I d for out-of-range operation of the diode, then simulation/analysis system 1 computes the following model parameters as indicated in block 36 based on the continuity conditions of current, conductance, and second order derivative of the current equation,
[0000]
a
0
=
I
s
(
v
0
V
te
-
1
)
,
Eqn
.
(
4
)
a
1
=
I
s
V
te
V
0
V
te
,
Eqn
.
(
5
)
a
2
=
I
s
2
V
te
2
V
0
V
te
,
Eqn
.
(
8
)
I
d
=
a
0
+
a
1
(
v
d
-
V
0
)
+
a
2
(
v
d
-
V
0
)
2
,
and
Eqn
.
(
9
)
g
d
=
a
1
+
2
a
2
(
v
d
-
V
0
)
.
Eqn
.
(
10
)
[0000] Note that if the base model is continuous, then the continuity of the current and its derivative of the modified device model remains continuous.
[0054] FIG. 3C is identical to FIG. 2A of commonly assigned Published patent application “Method and System for Processing of Threshold-Crossing Events” filed Jun. 26, 2009 by the present inventor, published Dec. 31, 2009 as Publication No. 2009/0326882, and incorporated herein by reference. FIG. 3C is a flow diagram of a method for transient analysis of a circuit model in circuit simulation system 1 in FIG. 2 . The transient analysis is performed over a time interval (0,T) that is computationally divided into discrete time points t m , where the time index m is the number of time points generated during the analysis. The start time and stop time for the time interval may be specified by the user. Modified nodal analysis of the modeled circuit is used to construct differential algebraic equations, and the time derivative terms of the differential algebraic equations are discretized to generate a system of nonlinear algebraic equations. The initialization may include predicting an initial time step h 1 for time index m=1 and generating a solution v 0 of the circuit equations for the first time point t 0 of the analysis for time index m=0. For ease of description, the assumption is made that the analysis begins at t 0 =0 (or any other user-specified time point).
[0055] In FIG. 3C , the START label goes via path 14 A from block 14 in FIG. 3A to block 200 . In block 200 , the simulation program first performs an initialization for the transient analysis in the present example. For example, a starting point (at which set the initial time might be set to zero) may be determined for a transient analysis that is to be performed. After the transient analysis is initialized, time points are generated (i.e., the nonlinear algebraic equations are solved) for each time index m and the transient analysis is terminated when the stop time T is reached. A time-varying input source provides an input stimulus signal, e.g., a voltage or current, having a value that is a function of time, so that the value of the input source may need to be adjusted when the current time point changes. To generate a solution at a time point t m , the time-varying input sources are updated to generate the input stimulus values, and an initial guess for the solution v m of the nonlinear algebraic equations at time point t m is “projected”, based on these updates and the solution(s) at previous time point(s). Note that at this point in the method, the time point t m is at a time step h m which is predicted either during the initialization process of block 200 or after acceptance of the previous time point t m-1 either as indicated in block 212 or as modified in block 210 if the solution to the nonlinear algebraic equations for the predicted time step fails to converge or is not acceptable.
[0056] Then, as indicated in block 202 , the next time point for the varying input stimulus is updated and an initial “guess” at a reasonable value of the simulated solution for the next time step is determined. The initial guess for the solution v m may be determined by any suitable means, e.g., by extrapolation. As indicated in block 206 , the circuit equations are solved at each time point. (Once the initial guess for the solution v m is determined, the nonlinear algebraic equations are solved at the current time point t m using a Newton-Raphson iterative method that is described below in more detail with reference to FIG. 3D . In general, the Newton-Raphson iterative method takes the initial guess for the solution and refines it iteratively making the guess more and more accurate in each iteration.)
[0057] If the iterative method converges on a solution v m and the solution v m satisfies any user-specified requirements according to block 208 , the solution v m for the time point t m is accepted in accordance with block 212 . The acceptance of a time point in accordance with block 212 includes outputting any information, i.e., results, a user has requested for a time point. The outputting may involve, for example, storing the requested results and/or providing the results to another software application and/or displaying the results in human readable form (e.g., on paper or on a display). Any data structures used for generating time points are updated based on the current time point.
[0058] The time step is then predicted for the next time point in accordance with block 214 . The next time point and the solution at the next time point are then generated based on the new time step in accordance with blocks 202 - 214 unless some criterion for terminating the analysis (such as the stop time for transient analysis has been reached in accordance with decision block 215 ) has been met.
[0059] If the iterative method does not converge on the solution v m , or the solution v m does not satisfy any user-specified requirements according to block 208 , the current time step h m is reduced, i.e., the current time point t m is moved closer to the previous time point. Another attempt is then made to generate the current time point t m unless some criterion for terminating the analysis has been met, such as the current time h m step being too small. If the simulated solution converges and is acceptable, as indicated by a “YES” determination by decision block 208 , the current time point is accepted, as indicated in block 212 . That predicts or determines the time step for the next time point, as indicated in block 214 . If the determination of decision block 208 is “NO”, the program goes to block 210 and reduces the current time step. The program then goes to decision block 215 , and if that determination is negative the program returns to updating the time varying input source(s) and determining another initial guess for the solution, as indicated in block 202 . An affirmative decision by decision block 215 results in the program following path 16 A to decision block 17 in FIG. 3A . (More details for blocks 200 - 206 are set forth in subsequently described FIG. 3D .)
[0060] FIG. 3D is a simplified version of FIG. 2B of the above-mentioned (and incorporated herein by reference) Publication No. 2009/0326882. FIG. 3D illustrates a simplified Newton-Raphson numerical analysis process flow, and shows a flowchart of a method for solving the system of nonlinear algebraic circuit equations at the current time point t m . The method is an iterative method based on the Newton-Raphson approach for solving nonlinear algebraic equations. In essence, the method attempts to converge on the solution v m at the time point t m . As previously explained (with reference to block 202 of FIG. 3C ), the method begins with the projected initial guess for the solution v m at the current time point t m and iterates until there is convergence to a solution as determined in accordance with decision block 236 .
[0061] In FIG. 3D , the START label comes from block 206 of FIG. 3C and evaluates all of the nonlinear models as described below with reference to FIG. 3E . After the nonlinear devices are evaluated, the linear system of equations is formed (typically represented in a matrix) that represent the integrated circuit being simulated, as indicated in block 226 . More specifically, the nonlinear algebraic equations are linearized around the current solution v m k . (Any suitable technique for forming the linear system of equations may be used.) The linear system of equations is then solved, as indicated in block 228 of FIG. 3D , to determine an update Δv m k+1 for the current solution v m k . The solution v m k+1 for the next iteration k+1 is then computed as the sum of the current solution v m k and the update Δv m k+1 . Then, in accordance with block 226 , simulation system 1 forms a linear system. Then, in accordance with block 228 , simulation system 1 solves the system of linearized equations.
[0062] The solution Δv m k+1 and other convergence criteria (e.g., Kirchoff's current law) are checked for convergence in accordance with decision block 236 . If the decision of block 236 is affirmative, the solution has converged, and the program of FIG. 3D terminates and returns to block 208 of FIG. 3C . If the determination of decision block 236 is negative because solution has not converged, another iteration through blocks 224 - 228 is performed.
[0063] The flowchart of FIG. 3E illustrates the device evaluation process of block 224 of FIG. 3D . The START label in FIG. 3E therefore is the same starting point as in FIG. 3D , i.e., is the entry point of block 206 in FIG. 3D . The simulation program determines, in accordance with decision block 15 , whether any more device models need to be evaluated. If that determination is affirmative, the program goes to decision block 18 and determines whether both the present device instance (i.e., device model) is operating out-of-range and a corresponding suitable modified device model is available. If the determination of decision block 18 is affirmative, then the simulation program goes to block 22 and evaluates (i.e., calculates) the modified out-of-range device model equations. If the determination of decision block 18 is negative, the simulation program goes to block 20 and evaluates the original base device model equations. In either case, the simulation program returns to decision block 15 . If the determination of decision block 15 is negative, then the program returns to block 226 of FIG. 3D .
[0064] Thus, simulation system 1 ( FIG. 2 ) automatically finds and identifies out-of-range conditions of the base parametric models of devices in the circuit being simulated and, if necessary, replaces or enhances or modifies highly nonlinear (and hence inaccurate) device functions (e.g., exponential functions) of the original base parametric models with linear and/or second order polynomial functions so as to preserve continuity and monotonicity of the original base parametric model. This technique greatly improves numerical stability of simulation system 1 and avoids convergence failures, and reduces simulator runtimes, thereby improving the robustness and the performance of the SPICE (or other) circuit simulation system 1 .
[0065] This is in contrast to prior solutions such as changing simulator settings and/or modifying the circuit being simulated, which in effect are manual trial and error processes and are inherently highly inefficient, time-consuming, and costly. For example, the described technique of determining whether a device model is in an out-of-range condition does not require determining if the mathematical function in the model and/or its derivative are continuous, and does not try to “fix” such discontinuities as required by the prior art (as in the above mentioned published Liu et al. patent application). Instead, the described embodiment of the invention automatically replaces or modifies the original base parametric model by a simple first or second order polynomial function or the like so as to make the model less nonlinear. However, the described embodiment of the invention does not “fix” discontinuities of a device model.
[0066] While the invention has been described with reference to several particular embodiments thereof, those skilled in the art will be able to make various modifications to the described embodiments of the invention without departing from its true spirit and scope. It is intended that all elements or blocks which are insubstantially different from those recited in the claims but perform substantially the same functions, respectively, in substantially the same way to achieve the same result as what is claimed are within the scope of the invention.
|
A simulation system ( 1 ) prevents failure of simulation computations to converge due to out-of-range conditions of a first device model including a first equation (Eqn.(1)) utilized in simulation computations involving the first device model by identifying an out-of-range condition (e.g., v d >V 0 ) which is likely to prevent convergence of simulation computations involving the first equation during a simulation run, and by automatically providing a second equation (Eqn.(6) or Eqn.(9)) in place of the first equation (Eqn.(1)), wherein the second equation defines a simpler mathematical function than the first equation and is more likely than the first equation to allow simulation computations to converge to a desired solution during the simulation run. The method includes automatically determining any time at which the out-of-range condition no longer exists and automatically modifying the first device model by replacing the second equation with the first equation.
| 6
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates principally to a conical sweep array antenna and a radar comprising such an antenna.
2. Description of the Prior Art
The book "Les Antennes, application aux radars et aux techniques spatiales" by Leo Thourel, second edition published by Dunod in 1971 describes, on pages 409, a flat antenna with a conical sweep. This book describes an antenna having groups of radiating slit guides. These guides are grouped in four identical quadrants fed by four excitation wave guides situated behind. Each of the quadrants forms an equiphase group, whose phase center is at the barycenter of the excitation amplitudes of said slits. Because of the identity of the four groups, the phase barycenters form the apex of a square whose center is the center of the antenna. If the four quadrants are fed in phase, the whole of the antenna is equiphase and the maximum radiation appears along the axis normal to the plane of the antenna, passing through its center. The conical sweep is achieved by feeding each of the quadrants through a phase shifter. The successive phase shift of the different quadrants allows a slope of the energy beam to be obtained.
The author emphasizes two serious defects of this device, first the level of the distant secondary loads is always very high and the gain factor is low. In fact, the diagram obtained is the product of the diagram of a quadrant multiplied by the alignment factor of the four barycenters which are always distant by more than a wave length. Second order lobes therefore inevitably appear (lobe of the arrays). In addition, the gain is reduced by the presence of these lobes and is affected by the losses in the phase shifters, which are often of the order of half a decibel, and which is deducted from the gain of the antenna alone.
SUMMARY OF THE INVENTION
The present invention relates to a conical sweep flat antenna having, in addition to the four quadrants whose radiation is likely to be phase shifted, radiation sources placed for example at the center of the antenna whose phase shift with respect to the supply energy is constant.
The conical sweep allows high accuracy to be obtained in determining the direction of a target. Conical sweep antennae are used more particularly for tracking radar and for trajectory calculation radar. Directional antennae of the Cassegrain type, with a beam opening at half power of the order of 1°, are used more particularly in a trajectory calculation radar. The great directivity of these antennae provides high precision tracking. On the other hand, target acquisition at the outset is fairly difficult. In addition, the problem of initial acquisition may arise again after a loss, after said target has been masked by obstacles such for example as a building or trees.
The present invention provides a wide beam conical sweep antenna, having for example a beam opening at half power of the order of 10°. This antenna has low precision, but a great probability of initial detection. The wide opening beam antenna of the invention performs particularly well and may form a secondary antenna associated with a primary conical sweep antenna with small beam opening, the main antenna being for example of the Cassegrain type.
The invention provides principally a flat antenna comprising elementary sources, the circular permutation in the plane of the antenna of the phase shift of some of said sources with respect to the others allowing a conical sweep to be obtained, wherein at least one elementary source is provided whose phase shift is constant.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from the following description of the accompanying Figures given by way of non limitative examples, in which:
FIG. 1 is a front view of a first embodiment of the antenna of the invention;
FIG. 2 is a front view of a second embodiment of the antenna of the invention;
FIG. 3 is an illustration of a first embodiment of radiating sources used in the antenna of the invention;
FIG. 4 is an illustration of a second embodiment of radiating sources used in the antenna of the invention;
FIG. 5 is an illustration of a third embodiment of radiating sources used in the antenna of the invention;
FIG. 6 is an illustration of a fourth embodiment of radiating sources used in the antenna of the invention;
FIG. 7 is an illustration of a fifth embodiment of radiating sources used in the antenna of the invention;
FIG. 8 is an illustration of a sixth embodiment of radiating sources used in the antenna of the invention;
FIG. 9 is an illustration of the principle of the phase shift by switching;
FIG. 10 is a perspective view of the feed lines used in the antenna of the invention;
FIG. 11 is a diagram illustrating the relative arrangement of the flat conical phase shift antenna with respect to a conical sweep antenna of Cassegrain type with which it is associated;
FIG. 12 shows radiating curves of the antenna of known type; and
FIG. 13 shows curves of the antenna of the invention.
In FIGS. 1 to 13 the same references have been used to designate the same elements.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, an improved conical sweep array network has been shown.
Antenna 4, illustrated in FIG. 1, has four quadrants 3. In the non limitative examples shown, each quadrant 3 comprises three elementary sources 2. The points A, B, C, D represent the phase centers of the quadrants 3 situated at the barycenters of the amplitudes emitted by the sources 3. Antenna 4 further includes, in addition to the sources belonging to quadrants 3, a source 1, placed for example in the center of the antenna. The sources 2 of the four quadrants 4 and the source 1 are fed with energy for example from a single oscillator. The sources 2 of quadrants 3 are fed through a variable phase shifter, having for example two states. The phase shift of the central source 1 with respect to the energy fed by the oscillator is fixed. By effecting the circular permutation of the phase shifts applied to the different quadrants 3, the conical sweep is obtained.
In a first embodiment of the antenna of the invention, a phase shift is applied to one of the quadrants 3 with respect to the other three. This phase shift is permuted in a circular fashion. For example, in a first stage the phase shift is applied to the quadrant whose phase center is point A. In a second stage, the phase shift is applied to the quadrant 3 whose phase center is point B. In a third stage, the phase shift is applied to the quadrant 3 whose phase center is point C. In a fourth stage, the phase shift is applied to the quadrant 3 whose phase center is point D. In a fifth stage, the phase shift is applied to the quadrant 3 whose phase center is point A and so on.
Advantageously, the same phase shift is applied to two successive quadrants 3. Similarly, circular permutation of these phase shifts is provided. Thus, for example, in a first stage of phase shift is applied to the quadrants 3 whose phase centers are point A and point B. In a second stage a phase shift is applied to the quadrants 3 whose phase centers are point B and point C. In a third stage a phase shift is applied to the quadrants 3 whose phase centers are point C and point D. In a fourth stage, a phase shift is applied to the quadrants 3 whose phase centers are point D and point A. In a fifth stage, a phase shift is applied to the quadrants 3 whose phase centers are point A and point B, and so on.
It is obvious that the circular permutation may be effected in the opposite direction.
In a third variant of the phase shift of the antenna 4 of the invention, the phase of the elementary sources 2 varies with the abscissa and the ordinate of these sources on the surface of antenna 4. The phase shift is for example the greatest for the endmost sources 2 of the quadrant 3 whose phase center is point A, the phase shift decreasing the closer to the endmost elementary sources 2 of the quadrant 3 whose phase center is point C. Then, circular permutation of these phase shifts is carried out similarly to one of the two preceding examples of phase shift on the antenna.
Advantageously, the fixed phase shift of the central source 1 is between the phase shift of the source belonging to a phase shifted quadrant 3 and that of the sources belonging to a non phase shifted quadrant 3.
Advantageously, the phase shift of the central source 1 is equal to half the value of the relative phase shift of the sources 2 belonging to a phase shifted quadrant 3 with respect to a source 2 of a non phase shifted quadrant 3.
The use of an elementary source 1 radiating a phase shift which is constant with respect to the oscillator appreciably improves the quality of the radiating diagram of the antenna 4, particularly by lowering the coma lobes.
In FIG. 2, another arrangement of the elementary radiating sources 1 and 2 can be seen. The antenna includes five elementary sources 1 placed in the form of a cross in the center of antenna 4. The sources are spaced apart evenly over the surface of antenna 4.
In the example illustrated in FIG. 2, the four quadrants 3 each have four elementary sources 2. A variant of the antenna 4 of the invention has four additional sources 10 phase shifted for example with respect to the constant feed oscillator, placed at the ends of the cross formed by the assembly of the elementary sources 1. The phase shift is obtained in the same way as for the device of antenna 4 shown in FIG. 1. The variation of phase shift with the abscissa and the ordinate of sources 2 on the surface of antenna 4 is obtained in the case of antenna 4 shown in FIG. 2, for example, by using digital two bit phase shifters providing four phase shift positions.
FIGS. 3 to 8 show different embodiments of the elementary radiating sources 1, 2 or 10.
The sources illustrated in FIGS. 3 to 8 are known per se.
In FIG. 3, two elementary sources 5 are shown of the patch type. The patch sources 5 are fed by a distribution tree 6. The sources are formed using the so called microstrip technology, which consists in depositing metallizations on a dielectric 70 whose opposite face comprises a metallized ground plane 7. The patch sources 5 are widened portions of the supply metallization whose width is for example equal to λ/2, λ being the wave length of the radiations in free space.
In FIG. 4, an elementary source 5 has been shown formed by a radiating slit.
In FIG. 5, an elementary source has been shown formed by a horn. The horn illustrated in the non limiting example of FIG. 5 is a rectangular horn.
In FIG. 6, an elementary source 5 has been shown of the dielectric candle type 12. Source 5 is fed by a strip 6 coupled through a wall 8 to a circular wave guide 9. At the end of the wave guide is placed a dielectric piece 12 of an elongate shape giving the name of candle to the whole of the elementary source 5.
In FIG. 7 a helix type elementary source 5 can be seen.
In FIG. 8, is shown a double logarithmic spiral wound on a cone 6. Arrow 61 shows the direction of radiation of source 5.
In FIG. 9, a phase shifter 40 is shown called switching phase shifter. Phase shifter 40 includes two paths 41 and 46 of different lengths. Depending on whether the signal follows, between an input 30 and an output 31, the longest path 46 or the shortest path 41 the phase shift of the signal present at output 31 of the phase shifter 40 will be more or less great with respect to the signal present at the input 30 of phase shifter 40. Switching between the two paths 41 and 46 is obtained by switching from the saturated state to the disabled state of the PIN diodes 32, 33 and 34. In the example illustrated in FIG. 9, path 41 has a length equal to λ/2, diode 32 is placed half way, at an equal distance λ/4, from the input 30 and from the output 31. Path 46 comprises two PIN diodes 33 and 32 placed respectively at a distance equal to λ/4 from the input 30 and from the output 31 of phase shifter 40. The device, not shown in FIG. 9, for switching the PIN diodes for example diode 34 in its saturated state and diodes 32 and 33 in their disabled state, allows the signal to pass through leg 41. Similarly, a disabling of diodes 34 and enabling of diodes 32 and 33 allows the signal to pass through leg 46.
In FIG. 9, the phase shifter 40 has two legs 41 and 46 providing two different phase shifts. The phase shifter 40 shown in FIG. 9 is called a one bit phase shifter. Of course, phase shifter 40 may have a larger number of legs providing a larger number of phase shifts. Similarly, the invention is not limited to the use of switching phase shifts. Other types of phase shifts may be used for constructing the flat conical sweep antenna of the invention.
In FIG. 10, a three plate feed line is shown. The three plate line may be particularly advantageous for feeding and/or phase shifting the energy supplied to the elementary sources. A three plate line is described in the French Pat. No. 2,496,996 filed by the applicant.
In FIG. 10 a detail has been shown of a three plate line providing the balanced division of energy between an input 63 and two output 53. The energy distribution is provided by a metal strip, made for example from copper. The copper strip is placed between two metal plates 51 and 52. The dielectric supports 50 provide constant spacing between the metal strip and plates 51 and 52. The air present between plates 51 and 52 plays the role of dielectric, without for all that generating power losses.
Advantageously, the antenna of the invention has a wide energy beam. For example, the antenna illustrated in FIG. 1, whose elementary souces are dielectric candles such as illustrated in FIG. 6, has an opening at half power of the beam of the order of 10°. It is therefore advantageous to associate it with a trajectory calculation radar antenna of Cassegrain type.
In FIG. 11, an example is shown of associating a Cassegrain antenna 112 with an antenna 4 such as described above. The Cassegrain antenna has a radiating source 13 placed facing an auxiliary mirror 15 and passing through a main mirror 14.
Advantageously, the flat antenna 4 is placed on the face opposite the source 13 of the auxiliary mirror 15. Arrow 61 shows the main directions of the radiation of antenna 4 and of the Cassegrain antenna 112.
The example shown in FIG. 11 is of course in no way limiting. Antenna 4 may be placed for example beside the Cassegrain antenna 112. It is however important for antenna 4 not to disturb the radiation emitted and received by the Cassegrain antenna 112.
The association of a conical sweep antenna 4 with a radar having a conical sweep Cassegrain antenna 112 allows the radar processing chain of the main antenna 112 to be used for processing the signals received in antenna 4.
The invention is not limited to wide beam flat antennae. The invention also allows conical sweep flat antennae to be constructed of low cost and with the desired beam opening.
In FIG. 12, curves showing the performances of the antennae of known type can be seen. For facilitating comparison with the curves of FIG. 13, the same radiating sources have been used as for the construction shown in FIGS. 12 and 13. These radiating sources are dielectric candles such as shown in FIG. 6.
As abscissa 16 has been shown the azimuth in degrees and as ordinates 15 has been shown the power in decibels.
Curve 17 shows the radiating diagram of an antenna whose four quadrants 13 radiate in phase. Curve 18 shows the radiating diagram of the same antenna whose conical sweep is obtained by phase shifting two quadrants 3 with respect to the other two quadrants 3.
In FIG. 13, the performance of the antennae of the invention such as illustrated in FIG. 1 can be seen. Curve 17 shows a radiating diagram of all the sources 2 and 1 emitting in phase. Curve 17 shows the radiating diagram when two quadrants 3 have a phase shift with respect to the other two, the central source 1 having a phase shift smaller by half. As can be seen the antenna of the invention has perfomances superior to the known type antenna, particularly in that the secondary lobes are smaller.
The invention applies particularly to the construction of conical sweep antennae with wide beam for the acquisition of targets in a trajectory calculation radar, tracking being provided by a Cassegrain antenna with narrow beam conical sweep.
The invention also applies to the construction of low cost conical sweep antennae.
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A conical sweep array antenna has a flat antenna structure having a plurality of microstrip sources disposed in a plurality of sections. Preferably, each section includes a plurality of sources. The flat antenna also has at least one source disposed outside any of the sections. A phase-shifting device phase-shifts the plurality of sources to cause a conical sweep pattern of the flat antenna. Also, the phase-shifter device provides a constant phase-shift to the one source which is not disposed in any section. The presence of the nonphase-shifted source improves the radiating diagram of the antenna of the invention, particularly by reducing the coma lobe.
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BACKGROUND OF THE INVENTION
Numerous studies have demonstrated the importance of in vivo animal models in the study of mammalian organ systems, especially with respect to immune systems. Unfortunately, researchers studying the human immune system have been without such a model. Recently, several groups have reported the engraftment of human bone marrow cells or human fetal liver cells into mice exhibiting severe combined immunodeficiency (SCID). Lapidot et al., Science 255:1137 (1992); Mosier et al., Nature 335:256 (1988); McCune et al., Science 241:1632 (1988). Another report used immunodeficient bg/nu/xid mice to achieve similar results. Kamel-Reid et al., Science 242:1706 (1988). None of these studies was able to establish long-term proliferation and differentiation of human tissues in the host. Additionally, transient differentiation was achieved only by the addition of exogenous human growth factors. Lethally-irradiated mice have also been used as recipients for human bone marrow cells. Lubin et al., Science 252:427 (1991). This study also failed to produce continued, normal human cell differentiation.
Hematopoiesis is a hierarchial process involving cells at various stages of differentiation and development. In the murine system, it is well-established that hematopoietic stem cells are capable of reconstituting the hematopoietic system of lethally-irradiated recipients. Jones et al., Blood 73(2) :397 (1989). The most reliable assay for such activity is a transplantation assay demonstrating the reconstitution of primary and secondary recipients. Such an assay provides a valuable tool for the examination of the mouse immune system. However, because of the absence of a comparable model for humans, the understanding of human hematopoiesis is severely limited.
As mentioned above, there are reports of successful engraftment of human cells into immunodeficient mice. One of these studies, by Lapidot et al. (1992), used SCID mouse recipients for transplant of human bone marrow cells. When stimulated with combinations of erythropoietin (EPO) and human mast cell growth factor (hu-MGF), and/or PIXY321 (human IL-3 fusion protein), 76% of recipients showed engraftment of human cells in recipient bone marrow of 10 or more times that seen in animals receiving no growth factor treatment. Human tissue was of lymphoid, erythroid and myeloid character, indicating differentiation of transplanted tissue occurred. Without the addition of exogenous human growth factors, however, the relative amount of engraftment was low (0.01 to 1.0%). Moreover, it was unclear what effect extended discontinuation of growth factor treatment might have on subsequent stimulation. While this, and other previous studies represent important steps forward, they fall far short of a complete, functioning model of human hematopoiesis.
To date, however, no successful long-term engraftment, proliferation and differentiation of normal hematopoietic stem cells in a non-human mammal has been reported. As a result, no adequate animal model exists for the study of human hematopoiesis.
SUMMARY OF THE INVENTION
It is, therefore, the object of the present invention to provide a closed, non-human model for the human hematopoietic system that is complete with respect to maintenance, proliferation and differentiation of human hematopoietic tissues.
Another object of the present invention is to provide a method by which non-human mammals, capable of supporting the maintenance, proliferation and differentiation of human hematopoietic tissue without the addition exogenous factors, can be produced.
Another object of the present invention is to provide human tissue that is produced in a non-human mammal.
Another object of the present invention is to provide a method by which human tissue is produced in a non-human mammal.
In satisfying the foregoing objects, there has been provided, in accordance with one aspect of the present invention a non-human, genetically-immunocompetent mammal, the hematopoietic system of which consists essentially of cells that are of human origin, wherein some non-lymphoid hematopoietic cells are syngeneic to said mammal.
There also is provided a process for producing the non-human mammal as described above comprising the steps of
(A) providing a non-human mammal in which immunologic genotype comports with the norm for the species of said mammal;
(B) exposing said mammal to a level of x- or gamma-radiation that is sufficient to destroy substantially all bone marrow of said mammal; then
(C) transplanting into said mammal syngeneic spleen colony cells and human cells comprising passaged bone marrow stromal cells.
There also is provided a non-human mammal that is the product of a process comprising the steps of
(A) providing a non-human mammal in which immunologic genotype comports with the norm for the species of said mammal;
(B) exposing said mammal to a level of x- or gamma-radiation that is sufficient to destroy substantially all bone marrow of said mammal; then
(C) transplanting into said mammal syngeneic spleen colony cells and human cells comprising passaged bone marrow stromal cells.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention provides the first closed, long-term model for human hematopoiesis in a non-human mammal, and methods for production thereof. A closed model, for the purpose of this application, is defined such that the system of interest is capable of normal function without the addition of elements exogenous to the model organism. As a result of this capability, human hematopoietic systems can be studied more effectively, not only in general, but also in individual human patients. In addition, it permits the production of human tissues for diagnosis and treatment of human disease.
The present invention demonstrates that engraftment, proliferation and differentiation of human hematopoietic stem cells can be achieved in a non-human transfer recipient. Engraftment is detected by human cell-specific colony assay. Proliferation is confirmed by the presence of committed progenitors long after transplant in the colony assay. Differentiation is confirmed by the finding of human cells of myeloid, erythroid and lymphoid nature. Active hematopoiesis is maintained without the addition of exogenous factors. And surprisingly, recipients of transplanted cells are not recognized as foreign by transferred human cells capable of such recognition.
Experiments conducted up to nine months after transfer of human cells show that both early and committed progenitor cells were maintained by recipients. Such cells could only be found in the presence of continued proliferation and maturation of the transplanted material. Therefore, these experiments, described in detail below, demonstrate the first long-term maintenance of human hematopoietic cells in significant numbers in a non-human recipient. It is also the first example of a complete, closed model of human hematopoiesis.
It is well-known that bone marrow-derived stromal cells provide a microenvironment able to support and regulate hematopoiesis in long-term bone marrow culture. Singer et al., ADVANCES IN HAEMATOLOGY, Vol. 4, pp. 1-34 (Hoffbrand, V., ed., Churchill Livingston, London, 1985); Dexter et al., J. Cell Physiol. 82:461 (1977). Investigators have reported that stromal cells regulate hematopoiesis by providing cell-cell contact as well as by producing hematopoietic cytokines. Albertson et al., EMBO 7:2801 (1988); Gualtieri et al., Exp. Hematol. 15:883 (1987); Naparstek et al., J. Cell Physiol. 126:407 (1986). As one might suspect, the lack of such factors in non-human recipients of human hematopoietic tissue markedly reduces or prevents the proliferation and differentiation of such tissues. Lapidot et al. (1992). In the present invention, this difficulty is avoided by the co-infusion of passaged stromal cells. Because these cells also successfully engraft, as reported by Wu and Keating, Exp. Hematol. 19:485 (1991), the factors necessary for proper development of human hematopoietic tissues are produced within the transfer recipient. This obviates the need for time-consuming and expensive addition of exogenous growth factors as reported elsewhere.
As will become evident, when transplanting human tissue into non-human hosts, it is highly desirable to use immunologically normal recipients. In this context, "immunologically normal" denotes an individual that displays immune system characteristics typical for the species to which the individual belongs. These characteristics would typically include, among others, functioning B-cells and T-cells as well as structural cell components, called cell surface antigens, which act as the immunologic signature for a particular organism.
Typically, the use of such immunologically normal recipients poses the following problem. The recipient's immune system, via its B- and T-cells, will identify the cell surface antigens of the engrafted tissue as foreign. This recognition leads ultimately to an immune response against the tissue, resulting in destruction or non-engraftment. This response is known as host-versus-graft rejection.
One way to circumvent host-versus-graft rejection is to use immunologically compromised recipients. Such animals exhibit two general types of deficiency, genotypic and phenotypic. Some researchers have employed genotypically-immunodeficient mice in order to circumvent this problem. These animals have genetic defects which result in the inability to generate either humoral or cell-mediated responses and include SCID mice and bg/nu/xid mice. Kamel-Reid et al. (1988); Lapidot et al. (1992). Therefore, they are unable to react against engrafted tissue. As a general proposition, however, the use of such animals is severely limited by the availability of an appropriate, immune-deficient organism as a recipient. In addition, these animals require housing in sterile environments and/or constant prophylactic antibiotic treatment.
The second category of immunodeficient recipients are those which are genetically capable of generating an immune response, yet have been phenotypically altered such that no response is seen. Typically, such phenotypically-immunodeficient recipients are generated by irradiation and this technique has been used extensively. See Jones et al. (1989). Such an approach is not without its difficulties, however. Irradiation sufficient to render the recipient incapable of mounting a response to the engrafted tissue usually results in death of the recipient due to destruction of the hematopoietic system.
The present invention obviates the need to create and/or identify genetically-immunodeficient organisms as tissue transfer recipients because immunodeficiency is achieved via irradiation of the recipient organism, and is therefore, phenotypic. Thus, any non-human mammal may be a recipient for human cells, permitting selection of the most favorable recipient, depending on the particular phenomenon to be examined. In addition, by selecting recipient organisms capable of supporting quantitatively greater human cell growth, the potential for increased human tissue proliferation is enhanced. Such non-human mammals will include, but are not limited to, mice, rats, rabbits, cats, dogs, pigs, sheep and non-human primates including baboons and chimps. It will also be unnecessary to maintain special colonies of potential recipients under sterile conditions or antibiotic maintenance.
The present invention also obviates the difficulties associated with irradiation by providing a replacement hematopoietic system following the destruction of the resident one. Specifically, by employing a set of human bone marrow stem cells capable of directing proliferation and differentiation stem cells, transfer of a stable and functioning hematopoietic system is accomplished. Thus, animals that are successfully engrafted can survive the normally lethal radiation treatment.
A second problem results when, as in the present invention, the engrafted tissues are themselves capable of mounting an immune response. Such a response is called graft-versus-host phenomenon. This effect is mediated by T-cells within the transferred cell population. Only through elaborate, expensive, and time-consuming procedures can T-cells be eliminated from the transferred cell population. Previous studies of human cells transferred into non-human hosts have not directly addressed this issue. In fact, it is unclear whether graft-versus-host reactions actually occur in SCID mice. Lapidot et al. (1992).
The present invention, by way of contrast, employs a system where one expects graft-versus-host reactions. Yet here, there is a surprising lack of immune response by the grafted human cells against the host. This suggests a fundamental difference in human T-cell development and/or function following transfer into a non-human host. Regardless of the mechanism, the absence of graft-versus-host reactions in the present invention allows the use of normal human tissues without concern for the presence of T-cell activity.
Another important aspect of the present invention is the co-infusion of human cells with syngeneic non-lymphoid spleen colony cells. These cells are known to have profound effects on hematopoietic reconstitution and, to a limited extent, exhibit hematopoietic potential. Kitamura et al., Nature 291:159 (1981).
In addition to providing the first general animal model for human hematopoiesis, the present invention permits the study of the hematopoietic system of a particular patient. Thus, abnormal hematopoietic systems can be examined on an individual basis and compared to model systems derived from normal patients. The medical conditions which could be examined in this manner might include, but are not limited to acute and chronic leukemias of myeloid, lymphoid or multilineage cell origin, the myelodysplastic syndromes, myeloproliferative disorders, aplastic anemia, disorders involving deficiencies of single hematopoietic lineages such as pure red cell aplasia, thrombocytopenia or neutropenia and AIDS. As a result, subtle differences in both the pathology and responsiveness to treatment in a given patient can be examined outside that patient's body. The benefits of having such "custom-made" experimental vessels at the organismal level are apparent.
The present invention also provides for the use of non-human recipient organisms as "factories" for human tissues. One previous limitation in human biological and medical research has been the lack of human tissues on which to conduct research. If appropriate tissues are not available in a timely fashion, or in sufficient quantities, the ability of the investigator to conduct meaningful experiments can be impaired.
However, if small amounts of human tissue could be propagated outside the human body, the potential for producing relatively large quantities of human tissues could be realized. There have been two general approaches employed to solve this problem. The first, tissue culture of human cells in vitro, is generally limited by the mortality of cells outside the human body. The exception to this rule is the propagation of transformed cells. These cells, however, are generally not representative of normal cells and are only available on a fortuitous basis.
The other method used to produce human tissues is by grafting into non-human hosts. Yet this technology is limited by the immunologic reactions, by and against grafted tissue, described more fully above. One way to circumvent this phenomenon is to use hosts which are unable to mount an immune response to grafted tissues, such as genetically or phenotypically immunodeficient recipients. As mentioned, the use of genetically immunodeficient organisms is less than ideal due to the total immunodeficiency of the organism and the limitation as to the size and type of animal that may be used. The irradiated recipient, while circumventing these problems, faces the alternative difficulty of surviving radiation sufficient to knock out its immune function.
By practicing the present invention, one skilled in the art can overcome all the difficulties described above in the production of human tissue. Employing irradiated animals, one may select an appropriate host exhibiting any given desirable biologic characteristic. Further, repopulating the irradiated recipient with an bone marrow stem cells results in the reestablishment of both immunocompetency and hematopoiesis in the host organism, thus obviating health concerns. Thereafter, hematopoietic cells, or any other co-infused, non-hematopoietic human tissues which engraft and proliferate, can be harvested. Such non-hematopoietic cells might include, but are not limited to liver, pancreas, brain, intestine, bone and cartilage. In many cases, the irradiation and engraftment may be performed on fetuses after removal from the womb, followed by reimplantation. In this way, the recipient organism (i.e., the fetus) can be protected by the mother's immune system prior to the establishment of the transferred human immune system. In addition, it may be possible to replace entire recipient organs or organ systems with tissue derived from a single human patient, effectively creating an "ersatz" human in the non-human recipient.
Due to the complexity of the human system, it was found more instructive to initially use enriched or purified cell populations to study hematopoietic stem cells. Cell purification can be based upon the presence of the cell surface antigens mentioned previously. The CD34 antigen is one of the best-characterized human hematopoietic stem cell antigens, being expressed in 1%-3% of normal human bone marrow cells. Bone marrow cells that express CD34 include colony-forming cells of all lineages, as well as their precursors. Experiments show that the CD34+ marrow cell fraction is enriched for a variety of primitive, multipotent, and committed progenitors (Civin et al., J. Immunol. 133:157 (1984); Saeland et al., Blood 72:1580 (1988)) which, in the presence of appropriate stimuli, can differentiate into myeloid or erythroid colonies in vitro and are capable of reconstituting normal marrow function in lethally irradiated primates. Berenson et al., J. Clin. Invest. 81:951 (1988).
In one version of the present invention, lethally-irradiated mice are co-infused with syngeneic mouse spleen colony cells, human marrow cells enriched for the CD34+ fraction, and passaged human bone marrow stromal cells. Surviving transplant recipients are screened by PCR and found to contain human DNA sequences. Examination of transplant recipients' bone marrow cells four months after engraftment detects from 11.9 to 68.3 percent human hematopoietic progenitors using a human hematopoietic colony assay. In contrast, engraftment of human hematopoietic progenitors in transplant recipients who do not receive co-infused human marrow stromal cells is 2.9 percent or less. Confirmation of human origin of hematopoietic progenitors is established by analysis of individual colonies using PCR amplification of human X-chromosome specific sequences and corroborated by in situ hybridization of marrow cells with a human X-chromosome specific biotinylated probe. Southern blot analysis of DNA extracted from the spleen, thymus and bone marrow of the transplanted animals indicates that human cells were evenly distributed in these tissues. Transplant recipients tested nine months after co-infusion show significant numbers of mature human granulocytes, demonstrating sustained hematopoiesis of human immune cells.
The preceding paragraph underscores the importance of the inclusion of stromal cells with transplanted tissues. When transplanting non-hematopoietic tissues, other stromal cells or the relevant analogue can be used. Liver stroma (Kupfer cells, etc.) would be used when transplanting liver tissue, pancreatic stroma would be used when transplanting islet cells and microglial cells would be used when transplanting brain tissue.
The finding that stromal cells play an important role in facilitating engraftment of foreign tissues comports with other recent findings. For example, stromal cells from malignant tissues have been shown to mediate attachment, metastasis and growth in Hodgkin's and non-Hodgkin's lymphoma, breast cancer and prostate cancer.
Furthermore, human marrow stromal cells can be readily transfected with foreign genes using physical methods. Therefore, genetically modified stroma could be used to modify the recipient further. Keating et al., Exp. Hematol. 18:99 (1990); Matthews et al., Exp. Hematol. in press (1993).
In light of the preceding description, one skilled in the art can use the present invention to its fullest extent. The following examples therefore are to be construed as illustrative only and not limiting in relation to the remainder of the disclosure.
EXAMPLE 1
Human CD34+ Cell Isolation
Cells from normal human bone marrow bearing the CD34 antigen are isolated using an enrichment method which gave 99% pure CD34+ cells, according to an immunofluorescent assay as follows. Light-density mononuclear cells are isolated by Ficoll-Hypaque gradient separation at a density of 1.077 g/ml. Cells bearing the CD34 antigen are isolated from a non-adherent mononuclear fraction by positive selection using indirect immune panning with an anti-CD34 monoclonal antibody (HPCA-1; Becton-Dickinson, Mountain View, Calif.) as reported by Saeland et al., Blood 72:1580 (1988). A second purification step is performed using immunomagnetic beads. The CD34+ cells are resuspended at 10 7 cells/ml with immunomagnetic beads (10 7 beads/ml) coated with anti-mouse immunoglobulins for 30 minutes (Dynal Inc.). The beads are removed using a magnet, and the CD34+ cells were recovered in suspension. In all experiments, the isolated cells are 95% to 99% CD34+, as judged by staining with the anti-CD34 MoAb.
EXAMPLE 2
CFU-S Assay
For co-infusion experiments with human cells, mouse spleen colonies are induced by the intravenous injection of Balb/c BM cells (1×10 5 /mouse) into irradiated Balb/c mice (900 cGy) as described by Till and McCulloch, Rad. Res. 14:213 (1961). On day 12, the nodules developed on the spleen surface are harvested and single cell suspensions are prepared.
EXAMPLE 3
Human Stromal Cell Culture
For co-infusion experiments with CD34+ cells and mouse spleen cells, human bone marrow stromal cell cultures are generated as described by Keating et al., Blood 64(6):1159-1162 (1984) and Keating et al., Exp. Hemtol. 18:99-102 (1990). Fresh human bone marrow mononuclear cells are placed into a 25 cm 2 tissue culture flask containing 7 ml McCoy 5A medium supplemented with 10% horse serum and 10% fetal bovine serum and 10 -6 M hydrocortisone. The culture is incubated at 37° C. in a humidified atmosphere containing 5% CO 2 in air; once a week, half the culture medium and non-adherent cells is removed until the adherent layer became confluent. After two to three weeks, the adherent layer is removed by treatment with trypsin, recultured in the same medium, and passaged a total of 3-4 times.
EXAMPLE 4
Transplantation
In order to investigate if human CD34+ cells can be engrafted into normal murine recipients, one million such CD34+-enriched cells, the equivalent of 10 8 bone marrow cells, were transplanted into lethally-irradiated BALB/c mice (Jackson Laboratory, Bar Harbor, Me.) in each of two groups--Groups I and II. Animals in both groups were transplanted with syngeneic mouse spleen colony cells in the amount of 3×10 6 per mouse in order to ensure murine hematopoietic reconstitution of the irradiated animals, but only animals in Group II received passaged human stromal cells in the amount of 1×10 7 cells per mouse. A total of 26 mice were transplanted with CD34+ cells and syngeneic spleen colony cells, of which 12, constituting Group II, are also transplanted with human marrow stromal cells. Of the 26 mice transplanted, 15 survived for more than four months. Eight of the 26 mice died during the first month, while three died during the 3 to 4 months after transplantation.
EXAMPLE 5
Polymerase Chain Reaction (PCR)
Four months after transplantation, peripheral blood of the recipients was collected and examined for the presence of human cells by polymerase chain reaction (PCR) analysis. Individual colonies were picked from culture dishes. After washing once with distilled water, the spleen colony cells were digested in 100 μl of buffer [containing 200 μg/ml proteinase K, 50 mmol./L Tris-chloride (pH 8.5), 1 mmol/L EDTA, and 0.5% Tween 20] at 56° C. for 1 hour with shaking. After digestion, the samples were boiled for 10 minutes to inactive proteinase K. For amplification, 5 μl of the sample was subjected to PCR amplification using 2.5 units Taq enzyme (Boehringer Mannheim, FRG), 250 ng of each primer, and 100 μmol/L of each DNTP (Boehringer) in a final reaction volume of 100 μl buffer. For the amplification of the human X alphoid repeat sequence, the primers of the sense and antisense were: 5'-AATCATCAAATGGAGATTTG-3' (SEQ ID NO: 1), 5'GTTCAGCTCTGTGAGTGAAA-3' (SEQ ID NO: 2), respectively (Witt et al., Human Genetics 82:271-274 (1989). Amplification was at 94° C. for 30 seconds, 54° C. for 30 seconds, and 72° C. for 1.5 minutes for 30 cycles. Amplified products were electrophoresed on 2.5% agarose (FMS) and stained by ethidium bromide. As shown in Table I, recipients in both experimental groups (with or without human stromal cells) contained human cells.
EXAMPLE 6
Colony Assay
In order to further characterize these human cells, single cell suspensions of the recipient bone marrows were plated and colony assays, optimized either for the growth of a human multilineage colony (CFU-GEMM) or mouse granulocyte-macrophage progenitors (CFU-GM), were performed:
Human CPU-GEMM. Semisolid cultures in methylcellulose are produced according to a standard method (Keating and Toor, [reference]), and modified by plating 1×10 5 cells per tissue culture grade 35 Petri dish, in the presence of 10% human plasma, 10% fetal bovine serum, 1-4 units/ml erythropoietin, rhSCF (CytoMed, MA) and rhIL-3 (Amersham). Duplicate dishes are plated in each experiment after 12 days of incubation at 37° C. in 5% CO 2 in air. The colonies are counted using an inverted phase-contrast microscope.
Murine CFU-GM. Bone marrow cells are gently dispersed into a single cell suspension in Iscove's Modified Dulbecco's Medium (IMDM) containing 10% fetal bovine serum. To measure granulocyte-macrophage colony-forming cells (CFU-GM), bone marrow cells (1×10 5 ) are cultured in 1 ml IMDM containing 0.3% Difco agar and IL-3 (as produced from an IL-3-producing cell line provided by G. Mills, Toronto). After incubation for 7 days at 37° C. in 5% CO 2 in humidified air, granulocyte-macrophage colonies (CFU-GM) containing >50 cells are counted. All cultures were performed in duplicate.
Since murine IL-3 does not stimulate the growth of human hematopoietic progenitor cells, and human IL-3 has no effect on murine cells, the differing culture conditions allow a determination of cross-stimulation to be made. The results, set forth in Table II, show that no cross-stimulation was observed. Table II also contains a summary of the information gained from an analysis of colonies obtained from the marrow cells of recipient mice.
In Group II, a large proportion of early myeloid progenitors were detected under culture conditions suitable to human hematopoietic progenitors. Comparing this result to the colonies detected under culture conditions suitable for murine progenitors, the ratio of human:mouse colonies varied from 11.9% to 68.3%. In terms of colony formation, results were similar to those observed with normal human marrow controls. In contrast, the Group I recipient mice which did not receive human stromal cells contained very few human hematopoietic progenitors detected with the granulocyte-macrophage colony assay examined after 12 days in culture. No committed erythroid progenitors (BFU-E) were detected in this group.
Some of the Group II recipients were followed for 9 months after transplantation. An analysis of human hematopoietic progenitors present in the bone marrow of these recipients using an in vitro colony assay is shown in Table III. Human committed progenitors (3.8% to 23%) were found in three of the four mice. The human origin of individual colonies was confirmed by PCR analysis. The sustained maintenance of committed human hematopoietic cells in the recipient mice suggests that the engrafted CD34+ cells developed in the bone marrow of recipients and showed sustained proliferation and differentiation.
EXAMPLE 7
PCR Analysis of Individual Hematopoietic Colonies
In order to demonstrate that the colonies detected under CFU-GEMM culture conditions are indeed human hematopoietic cells, PCR is used to amplify and detect the human X chromosome α-satellite repeat in individual human multi-lineage colonies. PCR amplification of normal human DNA results in a 130 bp band (Witt and Erickson, Human Genetics 82:271 (1989). PCR was performed essentially as described above. To measure background amplification in the PCR assay, 100 ng of DNA from Balb/c granulocyte-macrophage colonies is used as a negative control.
The results indicate that all the colonies generated under culture conditions suitable for animal or human hematopoietic cells contained the 130 bp specific human DNA product, while no PCR amplification product was seen in the negative controls. Lane designations are as follows: lane 1, 1 kB molecular marker; lane 2, colony DNA from human male cells; lane 3, colony DNA from human female cells; lane 4, colony DNA from Balb/c mice; lanes 5-10, individual colonies from recipients transplanted with CD34+ cells, spleen colony cells and human stromal cells for 4 months. For example, for recipient #4, 10 colonies were isolated and individually analyzed (Table I); all 10 were positive for the human sequence.
EXAMPLE 8
Isolation of Genomic DNA and Southern Blot Analysis
In order to examine the tissue distribution of human hematopoietic cells in transplant recipients, Southern blot analysis is performed. Standard procedures (Maniatis et al.) for the preparation of genomic DNA samples are used. Ten μg of genomic DNA is digested with the appropriate restriction enzyme and then electrophoresed through a 0.7% agarose gel. Following Southern transfer to Hybond-N (Amersham) nylon membranes and subsequent baking, membranes are placed in a bag containing phosphate buffer prehybridization solution containing 5× SSC, 0.45% skim milk power, 0.1% SDS, pH 7.2. Blots are hybridized overnight at 42° C. using the same prehybridization solution containing 9% dextran sulfate. After hybridization, the blots are extensively washed in 2× SSC, 0.1% SDS for 20 min. at room temperature, and in 0.1× SSC, 0.2% SDS for 10-30 min. at 65° C. The autoradiograph is exposed at -70° C. using an intensifying screen.
A human Factor 1×probe (McGraw et al., Proc. Nat'l. Acad. Sci. USA 82(9): 2847-2851 (1985), linear and gel purified, was labelled (>6×10 8 cpm/μg DNA) with 32 P using the random primer method. All four recipients examined contained human cell DNA in thymic, splenic, and marrow tissues. DNA was extracted from recipient mice 18 weeks after engraftment with CD34+ cells. Mouse numbers correspond to those in Table II (Group II). Lane designations are as follows: HBM, normal human bone marrow; MBM, Balb/c mouse bone marrow; THY, recipient thymus; SPL, recipient spleen; BM, recipient bone marrow.
EXAMPLE 9
In Situ Hybridization
Fluorescent in situ hybridization has become an important technique for visualizing genetic material in fixed cells. A major advantage of this method is that interphase human hematopoietic cells, including immature hematopoietic cells, can be distinguished from murine cells using a human-specific probe. The in situ hybridization method can be used to further confirm the presence of human hematopoietic cells in the transplant recipients. For in situ hybridization, bone marrow cells are incubated in 75 mM KCl for 15 min. at 37° C. The cells are spun down and fixed with two changes of methanol/acetic acid (3:1 v/v). Cells are centrifuged on cleaned slides, allowed to air dry overnight, and gradually dehydrated with ethanol. Before use, slides are treated with RNase A (100 μg/ml) in 2× SSC for one hour at 37° C., with proteinase K (0.1 μg/ml in 20 mM Tris-HCl, 2 mM CaCl2, pH 7.4), for 7.5 min. at 37° C. and are post-fixed with 4% paraformaldehyde for 10 min. dehydrated, and kept at room temperature until used. DNA is denatured by immersion of the slides in 70% formamide in 2× SSC, pH 7, for two minutes at 70° C. This is followed by immersion in ice-cold 70% ethanol, and by continued dehydration with ethanol.
The probe is denatured by heating the hybridization mixture, followed by quick cooling on ice, and added to slides. After a coverslip is added and sealed with rubber cement, the slides are incubated in a moist chamber for 12 to 16 hours at 37° C. After hybridization, the slides are washed in two changes of 50% formamide, 2× SSC and in three changes of 2× SSC at 40° C. for twenty min. each.
For detection of hybridization, the slides are overlayed with 10 μl fluorescein-labelled avidin (Vector Laboratories) in 2× SSC plus 1% BSA. After incubation of 45 min. at R.T. in the dark, the slides are washed in two changes of 2× SSC, 1× SC and 0.5× SSC, for 5 min. each, and then counterstained with propidium iodide (PI, 0.5 μg/ml) in anti-fade solution.
The probe, a human X-chromosome α-satellite DNA (Oncor Inc.) that does not hybridize with murine DNA (Waye et al., Nucleic Acids Res. 13(8):2731-2734 (1985)) (20 ng/μl), was added to hybridization mixture which contained 50% formamide, 2× SSC, and 500 μg/ml of carrier salmon sperm DNA. Regions to which the probe bound appear yellow, whereas the remaining DNA appears red in the microphotographs due to the superposition of green FITC-and red PI-fluorescence. The mouse numbers correspond to those in Table II (Group II). Panel A cells are normal human bond marrow cells (positive control). Panel B cells are normal Balb/c bone marrow cells (negative control). Magnification is 630×. Hybridization results indicate the presence of human hematopoietic cells in the bone marrow of murine transplant recipients and confirm results obtained with Southern blots of marrow DNA and PCR analysis of individual hematopoietic colonies.
These results are the first to show the presence of very early as well as terminally-differentiated human hematopoietic cells. Because donor human cells were enriched for early hematopoietic progenitors and lacked terminally differentiated cells, the appearance of significant numbers of mature human granulocytes as well as the detection of human multi-lineage colonies in mice reconstituted nine months previously, indicates that human donor cells not only engrafted, but proliferated and differentiated in vivo as well.
EXAMPLE 10
Analysis of Bone Marrow Cells from Murine Recipients Investigated Nine Months after Transplantation of Human CD34+ Cells and Human Passaged Marrow Stromal Cells
Cell sorting experiments can determine levels of murine and human lymphoid cells in long-term reconstituted recipients. Analysis with a FACScan instrument was performed using the following monoclonal antibodies:
1. goat•anti-human IgG Fc: human B cells (affinity purified F(ab')2 preparation, mouse Ig adsorbed and FITC labeled)
2. mouse•anti-human CD3: human T cells (phycoerythrin labeled IgG2a)
3. goat•anti-mouse IgG: murine B cells (affinity purified F(ab')2 human Ig adsorbed and P-PE labeled)
4. hamster•anti-mouse CD3: murine T cells (FITC labeled IgG)
Three color sorting with biotin/streptavidin-PerCP labeled anti-CD45 (T200) antibody, recognizing human/murine and human nucleated hematopoietic cells, was used. The frequency of cells was established as follows: human B cells--9%; human T cells--12%, murine B cells 2%; murine T cells--3%.
EXAMPLE 11
PCR Analysis of Recipient Bone Marrow Cells for Human and Murine T and B Cells Nine Months after Transplantation
Human/murine lymphoid subpopulations were sorted using the monoclonal antibodes as described in Example 9. The sorted subpopulations were subjected to PCR analysis for specific human and murine T and B cell sequences. PCR analysis was performed according to our modification of standard methods. Wu and Keating, (1993).
The following primers were used to detect Ig mRNA (i.e., B cell message):
sense--Igh-J primer recognizing, human and murine J regions
antisense--CH1 region of murine IgG, recognizing all IgG isotypes
antisense--CH2 region of human IgG, recognizing all IgG isotypes
The following primers were used to detect T cell receptor mRNA:
sense--TCR β-chain-J regions recognizing, human and murine J regions
antisense--CH1 region of murine TCR β-chain, recognizing all murine TCR β-chain isotypes
antisense--CH2 region of human TCR β-chain, recognizing all human TCR β-chain isotypes
For each set of primers, amplification was seen, thus confirming the presence of both human and murine B and T cells.
TABLE I______________________________________PCR amplification of human DNA from reconstituted Balb/c miceusing human X-chromosome α repeat primers. Colonies in humanPeripheral Bone CFU-GEMMblood Thymus Spleen Marrow assay______________________________________GROUP Imouse #1 + + + + 1/1 #2 + + + + 1/1 #4 + + + + 1/2Total: 3/4GROUP IImouse #1 + + + + 7/7 #2 + + + + 10/10 #3 + + + + 10/10 #4 + + + + 10/10 #5 + + + + 10/10 #6 + + + + 4/4Total: 51/51______________________________________ Group I Lethallyirradiated Balb/c mice were injected with CD34+ cells and spleen colony cells. Group II Lethallyirradiated Balb/c mice were injected with CD34+ cells, spleen colony cells, and human stromal cells.
TABLE II__________________________________________________________________________Hematopoietic colonies from Balb/c bone marrow reconstituted with CD34+cellsNCC Mouse Humanper femur CFU-GM.sup.a CFU-GEMM.sup.a Human:Mouse1 × 10.sup.6 1 × 10.sup.5 cells per femur 1 × 10.sup.5 cells per femur ratio__________________________________________________________________________GROUP I.sup.bmouse #1 6.3 78 ± 6.0 4914 ± 37.8 1 ± 0.2 63 ± 3.2 1.2% #2 3.9 71 ± 3.4 2769 ± 22.6 0.5 ± 0.2 18 ± 1.2 0.6% #3 5.8 47 ± 2.4 2726 ± 13.9 0 -- -- #4 8.2 69 ± 3.4 5658 ± 27.8 2 ± 1.0 164 ± 7.8 2.9% #5 4.2 58 ± 4.2 2436 ± 17.6 0 -- --GROUP II.sup.cmouse #1 12.2 22 ± 3.2 2684 ± 24.2 6 ± 0.4 732 ± 12.1 27.2% #2 6.9 48 ± 2.4 3312 ± 34.8 22 ± 1.4 1518 ± 16.2 45.8% #3 9.4 28 ± 1.4 2632 ± 22.4 16 ± 2.4 1504 ± 12.4 57.1% #4 7.7 41 ± 2.2 3157 ± 34.4 28 ± 3.2 2156 ± 28.2 68.4% #5 14.6 68 ± 3.4 9928 ± 42.3 16 ± 3.7 1088 ± 14.2 23.5% #6 8.2 42 ± 2.1 3444 ± 26.6 5 ± 1.2 410 ± 8.4 11.9%Control-1.sup.d 9.8 88 ± 4.2 8674 ± 35.8 0Control-2.sup.e 0 75 ± 2.4__________________________________________________________________________ .sup.a Results are the mean ± SE from duplicate. .sup.b Lethallyirradiated Balb/c mice were transplanted with CD34+ cells and spleen cells. .sup.c Lethallyirradiated Balb/c mice were transplanted with CD34+ cells, spleen cells, and human stromal cells. .sup.d Normal Balb/c bone marrow cells were cultured for CFUGM. .sup.e Normal human bone marrow cells were cultured for CFUGEMM.
TABLE III__________________________________________________________________________CFU-GEMM from the bone marrow of Balb/c mice reconstituted with CD34+cells,mouse spleen cells, and human marrow stromal cellsNCC Mouse Human Human: PCR(+)per femur CFU-GM.sup.a CFU-GEMM.sup.a Mouse (by human1 × 10.sup.6 1 × 10.sup.5 cells per femur 1 × 10.sup.5 cells per femur % × primer)__________________________________________________________________________mouse.sup.b #1 1.3 72 ± 3.2 936 ± 9.6 11 ± 2.2 143 ± 8.2 14.5% 5/5 #2 1.1 65 ± 1.4 715 ± 10.2 2 ± 1.4 22 ± 2.2 3.8% 2/2 #3 0.5 78 ± 2.6 390 ± 6.3 4 ± 1.4 20 ± 2.1 5.1% 4/4 #4 2.1 65 ± 1.8 1365 ± 7.4 15 ± 2.3 975 ± 4.4 23.0% 10/10Control-1.sup.c 8.9 84 ± 3.2 7476 ± 18.8 0Control-2.sup.d 0 75 ± 4.1__________________________________________________________________________ .sup.a Results are the mean ± SE from duplicate cultures. .sup.b Lethallyirradiated Balb/c mice, reconstituted by transplantation with CD34+ cells, syngeneic mouse spleen cells, and human stromal cells, were viable. .sup.c Normal Balb/c bone marrow cells were cultured for CFUGM. .sup.d Normal human bone marrow cells were cultured for CFUGEMM.
__________________________________________________________________________# SEQUENCE LISTING- (1) GENERAL INFORMATION:- (iii) NUMBER OF SEQUENCES: 2- (2) INFORMATION FOR SEQ ID NO:1:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 20 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA- (iii) HYPOTHETICAL: NO- (iv) ANTI-SENSE: NO- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:# 20 TTTG- (2) INFORMATION FOR SEQ ID NO:2:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 20 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA- (iii) HYPOTHETICAL: NO- (iv) ANTI-SENSE: YES- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:# 20 GAAA__________________________________________________________________________
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A chimeric, non-human, genetically-immunocompetent mammal is disclosed. The hematopoietic system of the mammal has human passaged bone marrow stromal cells and human hematopoietic stem cells obtained from a CD34 + -enriched bone marrow fraction, and also contains transplanted syngeneic non-lymphoid spleen colony cells. The mammal may be a mouse, a rat, a rabbit, a cat, a dog, a pig, a sheep or a non-human primate. The mammal can be produced by providing a non-human, genetically-immunocompetent mammal in which its immunologic genotype comports with the norm for the species of the mammal, exposing the mammal to a level of x- or gamma-radiation that is sufficient to destroy substantially all bone marrow in the mammal to render the mammal phenotypically immunodeficient, then transplanting into the mammal syngeneic non-lymphoid spleen colony cells and human passaged bone marrow stromal cells, and transplanting into the mammal human hematopoietic stem cells obtained from a CD34 + -enriched bone marrow fraction. Human hematopoietic cells may be obtained from the chimeric, non-human mammal.
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BACKGROUND
[0001] The present disclosure relates to the field of joist and truss construction. In particularly the disclosure relates to a broad spectrum of joist's or trusses having T-shaped chords with the benefits of adjustable length.
[0002] Current joist designs offer different design types and can fall into two general categories, open web truss or closed web joist. Both have disadvantages for the consumer.
[0003] One type of conventional open web truss which is used for supporting building floor and roof structures and the like is formed by two parallel wooden chords, such as 2×4 or 2×3 dimensions, or the use of composite lumber such as Laminated Veneer Lumber (LVL), arranged one over the other interconnected by webs of steel or wood. The webs may be attached by gluing or by sheet metal connector plates having tamped teeth protruding out allowing them to embed into the wooden chords. Such a truss is generally manufactured in a factory and transported to a construction site for installation as a component of the building. This type of truss is known in the art of trusses as an open web truss and has the ability to be designed with the chord being oriented either in the flat or wide direction or vertically or the narrow direction. While the truss with the flat lumber suffers from not enough material for strength the vertically assembled truss suffers from too narrow of a nailing surface.
[0004] It is also known in the art of joist design to build a solid web joist consisting of two parallel wooden chords connected by a continuous solid web such as plywood or Oriented Strand Board (OSB). Such a joist suffers from having the solid web which doesn't leave any area for utilities such as plumbing, electrical or duct work to pass through them.
[0005] There are current designs combining both features of the solid web joist and an open web truss. These combinations are limited in production due to difficulty in manufacturing or to weaknesses due to lumber orientation.
[0006] Therefore there is a need for a joist that can combine the strength of a solid web joist with the capabilities of an open web truss and the flexibility of an adjustable length which prior art has not addressed.
SUMMARY
[0007] The disclosed device is directed towards a strong open web truss formed from an upper chord and a lower chord that are interconnected by diagonal and/or vertical webs. The chords are T-shape providing strength in the vertical direction and giving a wider nailing surface in the horizontal direction. An extension portion is coupled to the upper chord and lower chord with a self-locking bulbous rabbet proximate the web at each end allowing the length of the truss to be adjusted. Typically the truss is assembled from wooden components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The embodiments of the truss of the prescribed invention are shown in detail below with reference to attached drawings.
[0009] FIG. 1 is a partial elevation view of an exemplary truss.
[0010] FIG. 2 illustrates a complete isometric view of an exemplary truss.
[0011] FIG. 3 is a perspective view of a T-shaped chord.
[0012] FIG. 4 is a cross sectional end view of the T-shaped chord and connection to the end adjustable block using a self-locking bulbous rabbet.
[0013] FIG. 5 is an exploded cross sectional view of the self-locking bulbous rabbet in detail.
DETAILED DESCRIPTION
[0014] Persons of ordinary skill in the art will realize that the following disclosure is illustrative only and not in any way limiting. Other embodiments of the invention will readily suggest themselves to such skilled persons having the benefit of this disclosure.
[0015] This disclosure describes a truss with T-shaped chords. The T-shaped chord includes a horizontal section connected to a vertical leg section approximate the center of the horizontal section forming a T. The chords will be interconnected by webs connected to the vertical section of the T-shaped chord. The truss includes extension sections at opposite ends of the chords. The extension sections extend beyond the webbing. The extension sections are configured to be adjustable allowing for proper fit upon installation of the truss. The extension sections generally having an I-beam cross sectional shape. Particularities for the adjustable sections are described below in more specific detail.
[0016] FIG. 1 illustrates a partial elevation view of an exemplary truss. The truss 10 comprises an upper chord 21 combining a horizontal section 111 with a vertical section 11 A and a lower chord 21 combining a horizontal section 11 with a vertical section 11 A. In an exemplary embodiment, the upper and lower horizontal sections 11 can be made of solid lumber, such as 2×3 or 2×4 lumber or from composite lumber such as Laminated Veneer Lumber (LVL), GluLam, Laminated Strand Lumber (LSL) other types of composite lumber. The vertical section 11 A can be made of thinner lumber such as 1×3 or 1×4 or from the same thickness lumber as the horizontal section 11 is made. The vertical section may be made of solid lumber or composite lumber such as Laminated Veneer Lumber (LVL), GluLam, or Laminated Strand Lumber (LSL) or other types of composite lumber. The upper vertical section 11 A is coupled with a strut or web 13 to the lower vertical section 11 A. In an exemplary embodiment, the horizontal sections 11 and the vertical sections 11 A may be comprised from a single part or from individual parts.
[0017] The web members 13 are generally arranged in a Warren or V type truss pattern. In another exemplary embodiment, the webs 13 may be arranged in a fan type arrangement where a vertical web 14 and a diagonal web 13 intersect at the vertical chord section 11 A. The web members 13 , 14 may be connected to the vertical section of the chord 11 A by metal connector plates or by finger type adhesive joints or by some other fashion. The web members 13 , 14 may be comprised of solid lumber, composite lumber or by metal, either stamped sheet metal or tubular. It will be appreciated by others in the art that other materials may be used while still embodying the spirit of the present invention.
[0018] The adjustable truss 10 is constructed with an adjustable end block 12 at each end having a bulbous tenon 16 machined on the top and bottom edge allowing it to lock itself into the vertical sections 11 A. In the exemplary embodiment the truss 10 will have a similar bulbous rabbet 16 machined into the vertical sections at the extension to accept the adjustable end block 12 . The connection between the adjustable end block will be accomplished with glue. The adjustable end block 12 may be comprised of solid lumber or of composite lumber. The first web 13 may comprise a Bulbous rabbet 16 on one edge to receive a bulbous tenon 17 from one edge of the adjustable end block 12 . Those skilled in the art will appreciate that the bulbous tenon 17 and rabbet 16 is a self-locking connection and that it requires no clamping time for gluing, speeding up production time.
[0019] FIG. 2 illustrates a complete isometric view of the invention in an exemplary form. In this exemplary embodiment, truss 10 includes an upper chord 21 comprised of a horizontal section 11 with a vertical section 11 A and a lower chord 21 comprised of a horizontal section 11 with a vertical section 11 A. The upper chord 21 is interconnected to the lower chord 21 by way of webs 13 , 14 configured in a v-shape configuration with multiple spans. An opening 15 approximate the center of the span can be used to facility additional space needed for placement of plumbing or duct work. The opening 15 can be facilitated by a web 14 placed vertically at each end of the opening 15 . In another alternative exemplary truss, the web 14 maybe placed at the beginning of the webs 13 and the adjustable end block 12 . In this alternative embodiment the vertical web 14 may also include a bulbous rabbet 16 to receive the bulbous tenon 17 . It will be appreciated by others skilled in the art that other web configurations may be used.
[0020] FIG. 3 is an illustration of a perspective view of the T-shaped chord. The T-shape chord 21 will be comprised of a flat horizontal section 11 and a vertical section 11 A. In an alternative exemplary form, the T-shaped chord 21 may be comprised of a horizontal section 11 and multiple vertical sections 11 A. Those skilled in the art will recognize that the T-shape offers strength in two directions, horizontally and vertically without the waste of using a larger solid piece of lumber and therefore making more efficient use of our timber resources.
[0021] FIG. 4 is a cross sectional end view of the connection between the chords 21 and the adjustable end block 12 . In the exemplary truss 10 the chords 21 are connected to the adjustable end block 12 with a bulbous rabbet 16 and tenon 17 and facilitated with an adhesive. The vertical section 11 A of the chord 21 will have a bulbous rabbet 16 at the end of the truss 10 to accept the bulbous tenon 17 of the adjustable end block 12 . An adhesive may be applied between the bulbous rabbet 16 and the bulbous tenon 17 .
[0022] FIG. 5 illustrates an exploded cross sectional View of the connection between the adjustable end block 12 and the chord 21 . The chord 21 comprised of the horizontal section 11 and the vertical section 11 A. The vertical section 11 A having a bulbous rabbet 16 to accept the bulbous tenon 17 . The bulbous tenon 17 comprised of a bulbous end 20 tapers to a narrower neck 18 and a chamfered section 19 . Likewise, the bulbous rabbet 16 comprised identically to accept the bulbous tenon 17 .
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The disclosed device is directed towards a truss comprising an upper T-shaped chord. A lower T-shaped chord is coupled to said upper chord. A plurality of web members are coupled to said T-shaped chords. An extension section is coupled to said upper T-shaped chord and said lower T-shaped chord approximate the web. Said extension section is configured to by adjustable by trimming.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
Escherichia coli 0157:H7, also known as enterohemorrhagic E. coli (EHEC), has been associated with recent outbreaks of foodborne diseases. Sporadic cases of hemorrhagic colitis and hemolytic uremic syndrome have occurred worldwide. These outbreaks have been attributed to the presence of the pathogenic microorganism in ground beef since beef and dairy cattle are known to carry the organism in their intestinal tracts and carcasses are frequently contaminated during the slaughter process. The most visible outbreak in the United States occurred in the Western states and involved over 500 cases and several deaths of young children. Investigations by the Centers for Disease Control indicate that EHEC is the third most important cause of foodborne illness in the U.S., and the incidence of the disease is increasing. There is thus a strong incentive to develop a quick and sensitive assay method for the detection of the microorganism in beef products such as ground beef, on beef carcasses during inspection and in cattle fecal specimens. This invention relates to novel primers which can be used to detect pathogenic E. coli by specifically amplifying a fragment of a plasmid found in all strains tested by polymerase chain reaction (PCR).
2. Background of the Invention
EHEC has emerged as a foodborne pathogen of considerable public health importance. Present detection methodologies for this pathogen in foods, however, are either expensive, time-consuming cumbersome, have low specificity and sensitivity or require extensive training to perform. Since most methods require prior enrichment steps, the amount of time needed to obtain final confirmatory results is prolonged.
Virtually all EHEC harbor a large ˜60-MDa plasmid (Fratamico et al. 1993. J. Med. Microbiol. vol. 39, pp. 371-381). It is currently unknown whether the presence of the plasmid plays a role in virulence. Known virulence factors include the production of one or more types of bacteriophage-encoded Shiga-like toxins, SLTs or verotoxins (Strockbine et al. 1986. Infect. Immun. vol. 53, pp. 135-140; Karmali, M. A. 1989. Clin. Microbiol. Rev. vol. 2, pp. 15-38), and the ability of the bacteria to intimately adhere to the intestinal mucosa by an attaching and effacing mechanism (Tzipori et al. 1989. Infect. Immun. vol. 57, pp. 1142-1150).
It has been suggested that the protein product of the EHEC eaeA gene may be necessary for attaching and effacing adhesion (Yu and Kaper. 1992. Mol. Microbiol. vol. 6, pp. 411-417). The gene has been cloned and sequenced and the product determined to be a 97-kDa outer membrane protein, called intimin 0157 (Louie et al. 1993. Infect. Immun. vol. 61, pp. 4085-4092). The genes encoding SLT-I and SLT-II have also been cloned and sequenced (Jackson et al. 1987. FEMS Microbiol. Lett. vol. 44, pp. 109-114), and immunological and DNA-based methods such as DNA hybridization have been developed for the detection of SLT-producing E. coli (Gannon et al. 1992. Appl. Environ. Microbiol. vol. 58, pp. 3809-3815; Paton et al. 1993. J. Clin. Microbiol. vol. 31, pp. 3063-3067; Begum et al. 1993. J. Clin. Microbiol. vol. 31, pp. 3153-3156; Hull et al. 1993. vol. 31, pp. 1167-1172), for EHEC having the eaeA gene (Gannon et al. 1993. J. Clin. Microbiol. vol. 31, pp. 1268-1274) and for the large 60-MDa plasmid (Levine et al. 1987. J. Infect. Dis. vol. 156, pp. 175-182). These methods suffer from the drawbacks mentioned above, however, and the search for an improved method has continued in an effort to provide a rapid and sensitive assay for the detection of the microorganism.
SUMMARY OF THE INVENTION
We have discovered oligonucleotide sequences which specifically amplify a DNA fragment of the plasmid found in all EHEC strains tested. In accordance with this discovery, it is an object of the invention to provide the novel oligonucleotides as primers for polymerase chain reaction (PCR) assays for the specific detection and identification of EHEC.
It is also an object of the invention to provide PCR assay methods utilizing the novel primers.
Other objects and advantages of the invention will become readily apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a and 1b show the sensitivity of PCR for the detection of a 60-MDa plasmid of E. coli 0157:H7 (EHEC): FIG. 1a: PCR amplification of 10-fold dilutions of E. coli 0157:H7, lanes 1-11 at 1×10 9 cfu/ml-1×10 -1 cfu/ml; lane 12, negative control (H 2 O instead of bacterial suspension). FIG. 1b) Southern blot of gel in FIG. 1a).
FIGS. 2a and 2b show the results of the multiplex PCR procedure using selected bacterial strains: FIG. 1a: agarose (1.6%) gel followed by ethidium bromide staining. FIG. 2b) Southern blot of gel in FIG. 2a).
DETAILED DESCRIPTION OF THE INVENTION
A portion of an EcoRI-HindIII DNA fragment of the 60-MDa plasmid harbored by virtually all EHEC strains was sequenced, and 20-mer single-stranded primers were designed. Plasmid pCVD419 (PBR325 containing a 3.4-kb fragment of the 60-MDa plasmid, provided by James Nataro, Center for Vaccine Development, Baltimore, Md.; Levine et al., supra) was digested with HindIII, and the isolated 3.4-kb fragment was then digested with EcoRI, yielding fragments of approximately 1.4 and 1.9 kb in size. The 1.4-kb fragment was subcloned into M13 mp19 using the M13 cloning kit (Boehringer Mannheim Corporation, Indianapolis, Ind.) according to the manufacturer's instructions. A portion of the 1.4-kb fragment was then sequenced using the Sequenase® version 2.0 kit (United States Biochemical Corporation, Cleveland, Ohio).
PCR primers, designed from the 1.4-kb fragment, are 5'-ACGATGTGGTTTATTCTGGA-3' (SEQ ID NO: 1) and 5'- CTTCACGTCACCATACATAT-3' (SEQ ID NO: 2) and have been designated MFS1F and MFS1R, respectively. The primers have been used to generate a 166-bp amplification product.
To confirm the identity of the 166-bp PCR product, amplified DNA was analyzed. Following agarose gel electrophoresis, Southern blots were prepared using a 3' end-labeled (digoxigenin-11-ddUTP) oligonucleotide probe (Genius 5 kit, Boehringer Mannheim), 5'-CCGTATCTTATAATAAGACGGATGTTGG-3' (SEQ ID NO: 3), which is internal to the primer pairs on the plasmid DNA fragment. A 166-bp hybridization signal was visible with all of the strains in which the amplification product was detectable on agarose gels.
To determine the sensitivity of the PCR, serial dilutions were prepared from a 4 h culture of EHEC strain B1409 grown in brain heart infusion broth (Difco). Following PCR amplification, the products were subjected to agarose (1.6%) gel electrophoresis. A 166-bp PCR product was generated with as little as 1.2 cfu (FIG. 1a). The PCR products were transferred to nylon membranes by Southern blotting (Sambrook et al. 1994. Molecular cloning: a laboratory manual, 2nd ed. Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.) and hybridized with the internal probe 3' tailed with digoxigenin-11-dUTP/dATP prepared using the Genius 6 kit (Boehringer Mannheim) according to the manufacturer's instructions. Sensitivity of the PCR by colorimetric detection was 1.2-0.12 cfu (FIG. 1b).
The primers were tested with crude cell lysates from 148 bacterial strains (Table 1). PCR results of all of the E. coli 0157:H7, 0157:NM and 0157:H- strains tested showed a 166-bp amplification product on agarose gels. PCR of several other E. coli serotypes such as 026:H11 and 0103:H2 also resulted in a 166-bp product. All the the non 0157 strains which were PCR-positive for the 60-MDa plasmid also possessed SLT DNA sequences.
Samples for the amplification process may be prepared by suspending a test sample in buffer and heating the suspension at a temperature and for a time sufficient to lyse the bacteria. For E. coli, heating at about 100° C for about 10 min is effective. Crude lysate is then added to reaction buffer comprising dNTPs, Taq DNA polymerase (Gibco/BRL, Gaithersburg, Md.) and the primers. Due to the sensitivity of the method, a preliminary step for culturing the samples in order to expand the number of microorganisms is generally unnecessary, thereby considerably reducing the amount of time required to process test samples. Preliminary concentration steps such as centrifugation and/or filtration may carried out, however, if desired.
Amplification is carried out according to conventional procedures well-known in the art (described by Mullis, U.S. Pat. No. 4, 683,202, herein incorporated by reference). The amplified products may be visualized by ethidium bromide staining of
TABLE 1______________________________________PCR results of bacterial strains tested in this study PCR using MFS1F and No. of MFS1R Multiplex PCRbacterial strain strains plasmid plasmid SLTs eaeA______________________________________E. coli0157:H7 31 12/12 12/12 12/12 12/120157:H7 P.sup.-(a) 3 0/4 0/4 4/4 4/40157:NM (SLT.sup.+) 6 6/6 6/6 6/6 6/60157:NM (SLT.sup.-) 1 0/1 0/1 0/1 0/10157:H 1 1/1 1/1 1/1 1/1026:H11 5 4/5 4/5 5/5 0/50111:NM 4 1/4 1/4 1/4 0/40145:NM 2 1/2 1/2 1/2 0/205:NM 3 1/3 1/3 1/3 0/304:NM 2 0/2 0/2 0/2 0/20125:NM 1 0/1 0/1 1/1 0/10103:H2 3 3/3 3/3 3/3 0/3045:H2 1 1/1 1/1 1/1 0/1022:H8 1 1/1 1/1 1/1 0/1091:H21 1 0/1 0/1 1/1 0/10113:H21 1 0/1 0/1 0/1 0/1055:H7 3 0/3 0/3 1/3 3/3078:K80:H12 1 0/1 NT.sup.h NT NT029:NM 1 0/1 NT NT NTK12 C600 1 0/1 0/1 0/1 0/1HB101 + pCVD419 1 1/1 NT NT NTHS 1 0/1 NT NT NTJM109 1 0/1 NT NT NTJM103 1 0/1 NT NT NTV517 1 0/1 NT NT NTJ53 (R16) 1 0/1 NT NT NTML35 1 0/1 NT NT NTB ATCC 11303 1 0/1 NT NT NT078:H11 1 0/1 0/1 0/1 0/1078:H12 1 0/1 0/1 0/1 0/1025:NM 1 0/1 0/1 0/1 0/1Shewanella putrefaciens 1 0/1 0/1 0/1 0/1Pseudomonas aeruginosa 5 0/5 0/1 0/1 0/1Pseudomonas fluorescens 3 0/3 0/3 0/3 0/3Shigella dysenteriae 1 0/1 NT NT NTShigella flexneri 2 0/2 NT NT NTShigella sonnei 1 0/1 NT NT NTSalmonella typhimurium 5 0/5 NT NT NTSalmonella enteriditis 4 0/4 NT NT NTSalmonella arizonae 1 0/1 NT NT NTSalmonella anatum 1 0/1 NT NT NTSalmonella seftenberg 1 0/1 NT NT NTSalmonella dublin 2 0/2 NT NT NTSalmonella poona 1 0/1 NT NT NTAeromonas hydrophila 1 0/1 NT NT NTAeromonas pappu 1 0/1 NT NT NTStaphylococcus aureaus 4 0/4 NT NT NTVibrio parahemolyticus 1 0/1 NT NT NTYersinia enterocolitica 4 0/4 NT NT NTSerratia marcescens 1 0/1 NT NT NTSerratia liquefaciens 1 0/1 NT NT NTRhodococcus equis 1 0/1 NT NT NTListeria monocytogenes 18 0/18 NT NT NTListeria innocua 1 0/1 NT NT NTCarnobacterium piscicola 1 0/1 NT NT NTStreptococcus faecium 2 0/2 NT NT NTBacillus subtillis 2 0/2 NT NT NTBacillus cereus 1 0/1 NT NT NTBacillus thuringiensis 1 0/1 NT NT NT______________________________________ (a) 60 MDa Plasmidcured strains (4) (b) NT, not tested by multiplex PCR
agarose gels or by Southern or dot-blot hybridization techniques utilizing DNA sequences internal to the oligonucleotide primers. Effective amplification conditions are described in Example I.
The primers may also be used in combination with primers directed to other sequences of significance in a multiplex reaction, i.e. an amplification procedure where more than one set of primers amplifying more than one target DNA sequence are used simultaneously. Three sets of primers which have been found advantageous are those primers which amplify sequences of SLTs, the eaeA gene and the 60-MDa plasmid, already described. These primers have been reported to be highly specific for E. coli serogroup 0157. Primers used for amplification of conserved sequences of SLT-I and SLT-II are 5'-TTTACGATAGACTTCTCGAC-3' (SEQ ID NO: 4) AND 5'-CACATATAAATTATTTCGCTC-3' (SEQ ID NO: 5) and have been designated MK1 and MK2, respectively (Karch and Meyer. 1989. J. Clin. Microbiol. vol. 27, pp. 2751-2757). They amplify fragments of 227- and 224-bp of the SLT-I and SLT-II genes, respectively. Primers used for amplification of the eaeA gene are 5'-CAGGTCGTCGTGTCTGCTAAA-3' (SEQ ID NO: 6) and 5'-TCAGCGTGGTTGGATCAACCT-3' (SEQ ID NO: 7) and have been designated AE19 and AE20, respectively (Gannon et al., supra). They amplify a 1,087-bp fragment of the EHEC eaeA gene. An exemplary method of utilizing the three sets of primers is presented in Example II.
The specificity of the multiplex PCR for EHEC was evaluated with 62 bacterial strains comprising 16 E. coli 0157:H7, 8 E. coli 0157 (NM and H-), E. coli of other serotypes, Shewanella putrefaciens and Pseudomonas aeruginosa (Table 1). Amplification of the expected sizes for plasmid, SLT and eae genes were obtained with all E. coli of serotype 0157:H7, 0157:NM and 0157:H- except for one nontoxigenic 0157:NM strain which was negative for all three products. It is not surprising that there were no amplification products using the nontoxigenic 0157:NM strain since it has been reported that SLT-negative E. coli 0157 did not hybridize with gene probe CVD 419 (Levine et al., supra), and therefore did not possess the EHEC 60-MDa plasmid. Using a primer pair specific for the EHEC eae gene, they obtained an amplification product only with SLT-positive E. coli 0157. Toxigenic E. coli 0157:NM are frequently associated with cases of hemorrhagic colitis and hemolytic uremic syndrome (Bopp et al. 1987. J. Clin. Microbiol. vol. 25, pp. 1486-1489; Gunzer et al. 1992. J. Clin. Microbiol. vol. 25, pp. 1486-1489), therefore a method for specific detection of E. coli 0157:H7 and nonmotile toxigenic 0157 strains is extremely useful.
The 166-bp product obtained by amplification of the plasmid gene is generated with as little as 1.2 cfu. However, in the multiplex PCR, the detection limit of the eaeA gene product is about 100 cfu and of the SLT gene is about 1,000 cfu.
PCR results showed that all strains in which the plasmid sequence was amplified also possessed SLT sequences (Table 1). E. coli 091:H21, 0125:NM, one 026:H11 and one 055:H7 isolate possessed SLT sequences but were negative in the PCR using plasmid primers alone. Both plasmid sequence and SLT gene sequences were amplified in several E. coli serotypes including 0111:NM (1/4), 026:H11 (4/5), 0145:NM (1/2), 05:NM (1/3), 0103:H2 (3/3), 045:H2 (1/1) and 022:H8 (1/1). In none of these strains was the eaeA sequence amplified.
Multiplex PCR results showed an amplification product of the expected size (1,087 bp) with the 3 E. coli 055:H7 strains tested using primers AE19 and AE20 which are specific for the EHEC eaeA gene. These results are not surprising since it has been reported that by multilocus enzyme electrophoresis the 0157:H7 clone was most closely related to E. coli 055:H7 which has been recognized as a cause of diarrheal disease (Whittam et al. 1993. Infect. Immun. vol. 61, pp. 1619-1629). It was suggested that these two serotypes may have very similar eae genes since both form attaching and effacing lesions on intestinal epithelial cells. It has also recently been reported that serotypes 0157:H7 and 055:H7 strains have almost identical nucleotide and amino acid sequences in regions where the eaeA gene and protein product of enteropathogenic E. coli and EHEC differ (Louie et al. 1994. Epidemiol. Infect. vol. 112, pp. 449-461).
The amplified fragments obtained following multiplex PCR using several bacterial strains are shown in FIG. 2a. Following Southern blotting of the gel and hybridization with labeled internal probe (oligonucleotide internal to MFS1F and MFS1R primers 3' tailed with digoxigenin-11-dUTP/dATP), a hybridization signal was visible only in strains in which the 166-bp fragment was amplified (FIG. 2b). The probe did not hybridize with the SLT or eaeA products.
The value of screening clinical specimens or food samples for the presence of SLTs alone is questionable since other E. coli serotypes produce SLTs and many may not be clinically significant. Furthermore, it has been reported (Karch et al. 1992. Infect. Immun. vol. 60, pp. 3463-3467) that clinical E. coli isolates may lose SLT genes upon subcultivation. Screening for the EHEC eaeA gene may give rise to false-positive results as occurred with E. coli 055:H7 and, although virtually all EHEC 0157 strains possess the 60-MDa plasmid, several other toxigenic E. coli serotypes also harbor this plasmid. The multiplex PCR therefore should prove to be a very useful method for specific identification of EHEC 0157 since simultaneous detection of virulence genes (SLT and eaeA) and the 60-MDa plasmid is made possible. Additionally, using the multiplex PCR it is possible to determine whether the sample tested contains EHEC 0157 or other SLT-producing E. coli serotypes.
The following examples are intended only to further illustrate the invention and are not intended to limit the scope of the invention as defined by the claims.
EXAMPLES
Example I
Amplification of the 60-MDa Plasmid Fragment.
For PCR amplification of the plasmid fragment, a bacterial colony was transferred from nutrient agar (Difco Laboratories, Detroit, Mich.) to 200 μl of a solution consisting of 0.5% Triton X-100, 20 mM Tris, pH 8.0 and 2 mM EDTA, and the bacterial suspensions were heated at 100° C. for 10 min. The PCR reaction (total volume of 100 μl ) consisted of 5 to 10 μl of the crude cell lysate, 1.5 mM MgCl 2 , 20 mM Tris (pH 8.0), 50 mM KCl, 0.001% gelatin, 200 μM (each) of dNTPs, 2.5 U of Taq DNA polymerase (Gibco/BRL, Gaithersburg, Md.) and 50 pmol of each primer. PCR reactions were performed in a thermal cycler (MJ Research, Inc., Watertown, Mass.) using the following cycling conditions: initial denaturation of 94° C. for 5 min and 94° C. for 30 sec, 55° C. for 30 sec and 72° C. for 90 sec for a total of 35 cycles. Following PCR amplification, the products were subjected to agarose (1.6%) gel electrophoresis followed by ethidium bromide staining.
Example II
Multiplex PCR.
The PCR reaction mixture was prepared as described in Example I with the exception that three sets of primers, MFS1F and MFS1R, MK1 and MK2, and AE19 and AE20 were added in equal concentrations. When the cycling conditions described in Example I were employed, however, only the plasmid and eaeA products were visualized by gel electrophoresis. Modifications in the cycling protocol were therefore made as follows: an initial denaturation at 94° C. for 5 min followed by 35 cycles of 94° C. for 1 min, 48° C. for 3 min and 72° C. for 4 min. Following PCR amplification, the products were subjected to agarose (1.6%) gel electrophoresis followed by ethidium bromide staining.
All references cited above are herein incorporated by reference.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 7(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: double(D) TOPOLOGY: circular(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Escherichia coli(B) STRAIN: 0157:H7(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:ACGATGTGGTTTATTCTGGA20(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: double(D) TOPOLOGY: circular(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Escherichia coli(B) STRAIN: 0157:H7(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:CTTCACGTCACCATACATAT20(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: double(D) TOPOLOGY: circular(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Escherichia coli(B) STRAIN: 0157:H7(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:CTTCACGTCACCATACATAT20(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: double(D) TOPOLOGY: circular(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Escherichia coli(B) STRAIN: 0157:H7(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:TTTACGATAGACTTCTCGAC20(2) INFORMATION FOR SEQ ID NO:5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 21 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: double(D) TOPOLOGY: circular(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Escherichia coli(B) STRAIN: 0157:H7(xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:CACATATAAATTATTTCGCTC21(2) INFORMATION FOR SEQ ID NO:6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 21 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: double(D) TOPOLOGY: circular(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Escherichia coli(B) STRAIN: 0157:H7(xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:CAGGTCGTCGTGTCTGCTAAA21(2) INFORMATION FOR SEQ ID NO:7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 21 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: double(D) TOPOLOGY: circular(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Escherichia coli(B) STRAIN: 0157:H7(xi) SEQUENCE DESCRIPTION: SEQ ID NO:7:TCAGCGTGGTTGGATCAACCT21__________________________________________________________________________
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Primers specific for enterohemorrhagic Escherichia coli (EHEC) 0157:H7 bacteria have been designed which are useful for detecting the bacteria by polymerase chain reaction methods. The primers were derived from DNA sequences contained within a 60-MDa plasmid which is present in most EHEC. The primers may also be used in combination with primers derived from other sequences of significance, the conserved sequences of Shiga-like toxins I and II and the eaeA gene, in a single simultaneous amplification reaction to specifically identify EHEC serotype 0157.
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TECHNICAL FIELD
[0001] The invention relates to manifolds for controlling the flow of an aerosol in a defined manner. The invention is described primarily with reference to the introduction of a sterilant aerosol into a closed sterilisation chamber for the purpose of sterilising medical articles such as ultrasonic probes, although it will be appreciated that it is not limited to such a use.
BACKGROUND ART
[0002] Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.
[0003] Sterilizers are used in the medical, food and packaging industries to kill and thereby prevent the transmission of transmissible agents such as spores, fungi, and bacteria. A typical sterilizer creates a set of physical conditions in a sterilisation chamber that effectively kills nearly all of these transmissible agents.
[0004] Contacting articles in need of sterilisation with sterilant aerosols is one known method of sterilisation. A conventional aerosol sterilisation apparatus has a sterilisation chamber with an aerosol inlet valve and an aerosol outlet valve, an aerosol generator (typically an ultrasonic nebulizer) in fluid communication with the chamber via the inlet valve and a fan upstream of, and in fluid communication with, the aerosol generator.
[0005] In use, an article requiring sterilisation is placed in the chamber, which is then sealed. The aerosol inlet valve is opened and the aerosol outlet valve is closed. The fan is engaged, which creates a gas stream through or the past the aerosol generator into the chamber. A passive vent in the sterilisation chamber allows for pressure equalization as required, to permit gas flow in and out of the sterilisation chamber. The aerosol generator, which contains the desired sterilant, is then activated, putting a large number of small sterilant droplets into gas stream. The droplets are carried by the gas stream to create an aerosol which travels into the sterilisation chamber. The sterilant concentration in the aerosol stream can be adjusted by changing either the flow rate of the gas stream, the productivity of the aerosol generator, or the concentration of the liquid sterilant used.
[0006] The passive waste vent allows some flow to pass through it, allowing the sterilisation chamber to remain at approximately room pressure. This passive system may include a pathway for flow to the outside air past catalytic elements that react with the sterilant and break the sterilant down into a safer chemistry suitable for disposal.
[0007] After a period of time, the fan and the aerosol generator are deactivated and the air inlet valve is closed, hence completing the sterilant delivery phase. The exit valve is then opened and aerosol is actively removed, typically by way of a pump that pulls aerosol and vapour out of the sterilisation chamber at a high rate. The removal system may include a pathway for flow between the sterilisation chamber and outside air past catalytic elements that react with the sterilant and break the sterilant down into a safer chemistry suitable for disposal. The passive vent allows a source of fresh air to be drawn into the sterilisation chamber from the outside air.
[0008] It is generally desirable for the total sterilisation cycle time to be as short as possible. Short reprocessing durations increases the number of times the sterilised article can be used in a given period, which in turn increases the number of patients per day that can be treated. In the case where the article to be sterilised is a high-cost medical device, short cycle times can generate significant financial savings for a health care provider.
[0009] One of the limitations of using an aerosol-based sterilizer is that in order to gain the required level of microbiological reduction in a short sterilisation time a high concentration (ie a high mist density) of aerosol sterilant is required. During sterilisation, a high concentration of aerosol sterilant causes droplets to coalesce on the surface of the article. This can be particularly prevalent at a location on the article that is subject to a direct mist stream from the chamber inlet. This can also lead to multilayer B.E.T.-like absorption on the surface of the sterilized article. Coalesced and absorbed droplets can be difficult to remove from the article at the end of the sterilisation process. Large levels of residual sterilant left on the sterilised article can be harmful to operators and patients and as such are undesirable in a fully automated sterilisation device.
[0010] While the residual sterilant may be removed by washing, this is an expensive feature to add to an automated sterilisation device, and requires sterile water and fresh water supplies that cannot always be easily obtained. Alternatively, it is also undesirable to have staff hand-washing articles, as this requires the use of safety apparatus which can be expensive (such as fume hoods), can take up valuable time and space and moreover increases the risk of harmful sterilant coming into contact with an operator or patient.
[0011] A washing phase also requires a subsequent drying phase which adds considerably to apparatus turn-around times.
[0012] In conventional sterilization apparatus, the aerosol is usually introduced into the sterilization chamber at a single point, via a single chamber inlet port. As a result, the distribution of the aerosol particles tends to fan out from that single point. More droplets contact the article to be sterilised at a point close to the aerosol inlet port, and contact the article at higher velocity, leading to splattering on the surface and the build up of condensate. Similarly, the areas of the article to be sterilised which are more remote from the aerosol inlet may receive a smaller dose of aerosol. In such cases, in order to ensure sterilization of the entire article, it becomes necessary to increase the total sterilant dose to compensate for areas of the article that may receive a smaller dose.
[0013] Increasing sterilant dose may be achieved by increasing the length of time to carry out the sterilisation or by increasing the amount of sterilant delivered in a given time. Both methods can exacerbate the splattering and condensation effect in areas close to the single chamber inlet port.
[0014] One method to reduce the level of condensation and splattering near the inlet port is to move the article to be sterilized further away from the inlet port, allowing it to better disperse before contacting the article. However, greater distances require larger sterilization chambers, and this is undesirable for a number of reasons. Due to space limitations in many medical healthcare facilities, it is desirable for sterilisers to be as small as possible while still being capable of housing the article to be sterilized. Small sterilization chambers are also advantageous because they are both faster to fill with sterilant and faster to remediate than larger chambers. However, a small sterilization chamber increases the difficulty of introducing aerosol into the chamber while having it contact the article in an evenly-distributed fashion.
[0015] Maintaining an even mist distribution inside a sterilization chamber is important to ensure that there is even sterilization of the article to be sterilized. Once introduced into the sterilization chamber, aerosol droplets tend to fall due to gravity which results in a greater mist concentration at the bottom of the chamber than at the top of the chamber. In order to maintain an even distribution top to bottom, a high aerosol flow rate can be used to provide droplet lift. In this case the gas stream moves in an upward direction at a faster rate than droplets fall. A downside of using such a method is that the gas stream velocities used result in greater velocities for smaller droplets, and as there is typically a wide range of droplet sizes in an aerosol it is difficult to optimise such a system. Additionally, the smaller and higher-velocity droplets can collide with the article to coalesce on its surface, thus making removal of residual sterilant difficult.
[0016] Using a dense mist is desirable, as it provides fast sterilization, which in turn can enable short sterilization cycles. However, in practice, dense mists are susceptible to condensation. Prior art sterilizers often require noisy, large and expensive apparatus to remove condensation in a time-effective manner. Thus, in prior art sterilizers, in order to avoid condensation, the density of mist needs to be limited, meaning that short sterilization times cannot be realized.
[0017] Accordingly, there is a need to find improved methods of delivery of the aerosol to a sterilisation chamber, particularly a small chamber, so that the aerosol is delivered to the article to be sterilised in an even manner and at a relatively low velocity to minimise the possibility of condensation.
SUMMARY OF THE INVENTION
[0018] According to a first aspect the invention provides a manifold for introducing a sterilant aerosol to a sterilization chamber for the disinfection of an article, the manifold defining the terminal portion of a fluid pathway from an aerosol generator to the sterilization chamber; the manifold comprising at least one chamber inlet port for introducing aerosol into the sterilizing chamber and being configured to provide directional aerosol flow tangential to at least part of the surface of the article.
[0019] Preferably the manifold is configured to provide directional aerosol flow tangential to at least part of the surface of an article maintained in a predetermined position with respect to the manifold. It is also preferred that the manifold is configured to provide directional aerosol flow such that the article does not receive a direct flow of aerosol from the manifold. Preferably, the aerosol is directed not at the article.
[0020] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.
[0021] References to “sterilisation” and “disinfection” as used herein may be used interchangeably, and are also intended to include other levels of microbial reduction, to including but not limited to sterilisation, high and low level disinfection.
[0022] An aerosol is a large number of discrete particles suspended in a gas. When the gas is directed into a stream or jet, the particles are entrained in the gas and move in a generally cohesive manner about the mean path. However there will be a number of particles that follow pathways deviating from the mean path. The more significantly any given path deviates from the mean path, the smaller the number of particles that follow such a path. Additionally, the further that a group of aerosol particles travel from a common source, the more they disperse. Those skilled in the art will be well aware of such dispersive behaviour and will appreciate that in the present case, where a “direct”, “directed”, “tangential” or the like flow of an aerosol is disclosed, what is being referred to is the mean path taken by the droplets. In terms of the overall flow of aerosol under those circumstances, a skilled person will interpret terms such as “direct”, “directed”, “tangential” and the like as meaning “substantially direct”, “substantially directed”, “substantially tangential” and so on.
[0023] Preferably the article is of a predetermined shape.
[0024] Preferably each chamber inlet port includes a nozzle or duct to direct the aerosol flow. The manifold preferably comprises at least two chamber inlet ports, and more preferably at least four chamber inlet ports.
[0025] The manifold can be a continuous manifold, or can comprise a number of discrete sub-manifolds in fluid connection.
[0026] Preferably, the manifold defines a manifold plane and the chamber inlet ports are directed away from the manifold plane. In one embodiment, the manifold is a simple linear manifold that directs aerosol flow tangential to at least part of the surface of the article to be sterilized. In further embodiments, the manifold is in more than one plane and surrounds the article to be sterilised. The manifold can have any suitable configuration, with regard to the size and shape of the sterilizing chamber and/or the size, shape and nature of the article to be sterilized. In all cases though, the manifold has chamber inlet ports configured to direct aerosol flow tangential to at least part of the surface of the article to be sterilized.
[0027] More preferably the manifold is configured to distribute aerosol from around the article to be sterilized and tangential to at least part of the surface thereoff for example, via a U-shaped, square, circular or semi-circular, manifold.
[0028] Most preferably the manifold is U-shaped and defines a manifold plane and comprises diametrically opposed paired chamber inlet ports, such that a first port directs aerosol flow a first side of the manifold plane and a second port directs aerosol flow to a second side of the manifold plane.
[0029] Preferably the manifold comprises diametrically opposed paired chamber inlet ports, such that a first port directs aerosol flow to a first side of the manifold plane and a second port directs aerosol flow to a second side of the manifold plane.
[0030] In one preferred configuration the manifold is U shaped and preferably has two, three or four vertically spaced apart chamber inlet ports, along each arm. Alternatively, the manifold is bifurcate and preferably has two, three or four vertically spaced apart chamber inlet ports, along each arm. However, any number of chamber inlet ports may be present, depending upon the size of the chamber and the degree of aerosol particle size separation required.
[0031] The manifold can be formed from a single length of tubing. Alternatively, the manifold can be constructed such that is formed from two mated portions that have been engaged with each other to form a complete manifold. For example, the manifold may be formed from a channel which mates with a corresponding seal, such as when a channel in the body of a sterilizing chamber mates with a corresponding seal on the door of the sterilizing chamber, and where both come into engagement when the door of the sterilizing chamber is shut.
[0032] The manifold is preferably in the form of an elongate tub, and is more preferably of square cross section.
[0033] Preferably the manifold includes diametrically opposed paired chamber inlet ports which direct flow at a difference of angle of between 100 and 260 degrees. Preferably the diametrically opposed paired chamber inlet ports create a circular motion of aerosol in the chamber that moves around the article.
[0034] Preferably the minimum distance between the article to be sterilized and the manifold is less than 10 cm, more preferably less than 7 cm and even more preferably less than 5 cm.
[0035] Preferably the manifold inlet is located at the top of the manifold. In one particularly preferred configuration the manifold inlet is bifurcated and splits aerosol flow into the top of the two arms of the U shaped manifold.
[0036] According to a second aspect the invention provides sterilization apparatus including a manifold according to the preceding aspect, a sterilization chamber and detent means to maintain an article to be sterilized at a predetermined position in the chamber, whereby the aerosol flow is tangential to at least part of the surface of the article. Preferably, the manifold does not direct the aerosol at the article to be sterilized.
[0037] Preferably the sterilization chamber defines a chamber volume and aerosol is admitted to the chamber at a rate of between one and three times the chamber volume per minute.
[0038] The sterilization apparatus preferably further includes a passive vent. More preferably, there is at least one aerosol exit point positioned above the central vertical position of the chamber
[0039] The sterilization chamber is preferably adapted to hold an ultrasound probe.
[0040] The article is preferably an ultrasound probe, in which case the sterilization apparatus also preferably comprises a collar to sealingly engage a portion of the article in the chamber and to restrain the predetermined article from contact with the chamber walls. The chamber is elongate with a collar at the top to hold the probe in such a way that the functional region of the probe is suspended substantially in the middle of the chamber, and so that the functional region of the probe is not in contact with the chamber walls. The manifold is located in a plane along the long axis of the ultrasound probe.
[0041] Preferably the chamber wall is heated. The manifold and chamber in combination are preferably configured to provide a vortexing aerosol flow. Preferably the article to be sterilized is at a point central to the vortexing aerosol flow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIG. 1 shows a sterilization apparatus including a manifold of the present invention.
[0043] FIG. 2 shows a sterilization apparatus including a manifold of the present invention, in which is placed an ultrasonic probe for sterilization.
[0044] FIG. 3 is a closer view of FIG. 2 , with the sterilization apparatus door removed for clarity.
[0045] FIG. 4 is a close up view of the chamber inlet located on the manifold.
[0046] FIG. 5 is a cross sectional view of the gas flow from the manifold.
[0047] FIG. 6 is a cross sectional view of the gas flow from the manifold in a chamber of substantially circular cross section.
[0048] FIG. 7 is a cross sectional view of the gas flow from a single sided manifold.
[0049] FIG. 8 is a cross sectional view of the gas flow from a single sided manifold in a chamber of substantially circular cross section.
[0050] FIG. 9 is a cross sectional view of the gas flow from an offset manifold in a chamber of substantially circular cross section.
[0051] FIG. 10 is a cross sectional view of the gas flow from a single sided manifold in a chamber of substantially circular cross section, showing vortex separation of aerosol droplets on the basis of momentum.
DESCRIPTION
[0052] The present invention provides a means for creating and maintaining a dense and even mist distribution in a sterilization chamber that is marginally larger than the article (or articles) to be sterilized while greatly reducing condensation on the surface of the article.
[0053] These ends are met by directing aerosol tangential to the article to be sterilized. The tangential flow reduces the likelihood of condensation when high aerosol velocities are present by using droplet deflection. It has been observed that droplets are less likely to adhere to a surface if they contact it at a shallow angle compared to contacting an article in a perpendicular approach.
[0054] The manifold configuration of the present invention also provides a longer travel path for aerosol droplets, allowing aerosol to more fully disperse before coming into contact with the article, hence improving aerosol distribution in the sterilization chamber. The longer travel path provided allows aerosol to reduce in velocity before coming into contact with the article, hence reducing the likelihood of condensation.
[0055] The offset nature of the chamber inlet ports also allows them to be positioned very close to the article without the threat of condensation forming on the surface of the article, hence facilitating a smaller sterilization chamber.
[0056] By using multiple sterilant inlet ports, it is possible to more evenly control the distribution of aerosol in the sterilization chamber.
[0057] By controlling the flow rate of aerosol into the sterilization chamber, the aerosol can be maintained at approximately equal concentrations at across the vertical dimension of the chamber. An optimal flow rate is between one and three times the chamber volume per minute. Using higher flow rates may cause condensation on the surface of the article, and lower flow rates do not provide sufficient gas speed to allow droplets to overcome gravitational effects.
[0058] Preferably, the aerosol inlet ports are directed away from each other such that the direction of flow from each port pair varies by between 100 and 260 degrees. This provides an aerosol motion within the chamber that is directed around the article to be sterilized that is largely parallel or tangential to the surfaces on the device to be sterilized. The inlet ports need not be paired, ie on the same vertical plane, but can be offset vertically. The nozzles can also be placed so that they alternate in respect of which side of the article they are directed towards.
[0059] The tangential flow can also be achieved by having the manifold or manifolds offset from the central axis of the chamber.
[0060] Additionally, this tangential motion provides a means for separating larger droplets from smaller droplets. Larger droplets have higher linear momentum and are more likely to collide with the heated chamber wall, rather than be carried around inwards with the gas flow toward the article to be sterilised. This reduces the possibility of large droplets colliding with and condensing on the article. Providing a largely smooth chamber shape can help facilitate the vortex action (i.e. by rounding the corners of the chamber to prevent the disruption of the vortex). Thus, vortex droplet separation can be achieved.
[0061] It is possible to heating the chamber walls to between 40 and 80 degrees Celsius in order to rapidly evaporate off any droplets that may have condensed on the chamber walls due to the separation process, hence reducing the likelihood of a person coming into contact with condensed sterilant at any stage.
[0062] It is believed to be particularly advantageous to have the combination of vortex droplet separation and heated chamber walls. The larger droplets contact the chamber walls and evaporate, hence removing residual droplets from the chamber wall, reducing the chance that the operator could come into contact with harmful sterilant.
[0063] The invention will now be described with reference to the drawings.
[0064] FIG. 1 shows a steriliser 1 which has a sterilising chamber 2 which incorporates the nebuliser manifold 3 . The chamber comprises a rear portion 4 , which is housed in the body of the sterilizer 5 . The chamber also has a front portion 6 , in a mateable arrangement with the body. Closing the door 7 brings the front and rear portions of the chamber together.
[0065] Closing the door causes the chamber front to mate with the chamber rear to seal the sterilization chamber.
[0066] Turning to FIG. 2 , the sterilising chamber 2 is adapted to receive an elongate probe, for example, an ultrasound probe 10 , that is inserted into the open chamber, and held in a sealingly engaged manner by means of a collar 11 , such that the head of the probe 12 is not in contact with any surface. When the chamber door 7 is closed and ultrasonic probe 10 is in place, a sealed chamber results which has the probe 10 suspended inside. The work surfaces of the probe are thus not in contact with any surface.
[0067] Whilst collar 11 is shown as detent means for positioning the article to receive a tangential flow, any suitable means such as brackets, mounting pins, clips etc may be used to maintain the article (such as an ultrasound probe) in a position where it will receive only a tangential aerosol flow, not a direct aerosol flow from the manifold. That is, the manifold directs the aerosol to the void space around the article, and not at the article itself. Preferably the article is suspended in the chamber, which is as small as possible with regards to the article to be sterilized—for example it is preferred if the distance between probe 10 and chamber wall 2 or manifold 8 is less than a few centimetres.
[0068] FIG. 3 shows the sterilizer with the door 7 removed. The sealed sterilising chamber 2 is heated prior to use, along with the manifold 8 . A fan not shown, in fluid connection with the manifold inlet ports 13 and 14 (see FIG. 1 ), is then started. The air flows into the manifold via inlet ports 13 and 14 , and into the manifold. The air flow exits the manifold by the chamber inlet ports 15 , 16 , 17 , 18 , 19 , 20 , 21 and 22 , and enters the sterilization chamber. The manifold 8 is a continuous tubular tube, of square cross section as shown, although it can be of any cross section, with a number of ports for introducing sterilising agent to the chamber. The manifold is substantially U shaped, with the upper portion of the parallel arms 23 and 24 being stepped apart further than the lower portion of the parallel arms 25 and 26 .
[0069] Once the desired flow conditions are achieved, the ultrasonic nebulizer (not shown), which is in-line between the fan and the sterilization chamber 2 , is activated. A sterilant liquid, most typically hydrogen peroxide, is supplied to the nebuliser and is nebulised. The aerosol exits the nebuliser and joins the air flow. The aerosol is then moved via the same path as the air flow, preferably a short path, to the manifold inlet ports 13 and 14 at the top of the manifold. Because the aerosol is under positive pressure, caused by the fan, and because the chamber has a passive exit vents 27 and 28 to allow the air pressure to be equalised, the nebulant flows through the manifold 8 , out of the chamber inlet ports 15 , 16 , 17 , 18 , 19 , 20 , 21 and 22 and into the sterilization chamber 2 .
[0070] A typical nebulant mist as produced in the nebulizer contains a distribution of aerosol particle sizes. Although the average particle size or MMAD, (Mass Median Aerodynamic Diameter) can be controlled, and the spread of particle sizes can be reduced by varying the nebulization conditions, the particles themselves are inevitably spread over a range of sizes.
[0071] Manifold 8 is preferably heated at a temperature sufficient to cause evaporation from the droplets, the aerosol particles become somewhat smaller as they transit through the manifold 8 . Those particles that exit the manifold through the first chamber inlet ports 15 and 16 , closest the manifold inlet, have a MMAD which is not significantly smaller than that which enters the manifold through manifold inlets 13 and 14 . However, the particles that exit the manifold at the chamber inlet ports 21 and 22 distal to the manifold inlet have spent a longer time in the manifold 8 and there has been evaporation and a consequent reduction in particle size. As a result, the MMAD of these particles is reduced relative to its initial size. This will apply regardless of the initial size of the particles.
[0072] Thus, as the chamber inlet ports are moved further away from the manifold inlet, the droplet size issuing from that inlet port decreases. That is the aerosol particle size at outlet 21 , 22 <the aerosol particle size at outlet 19 , 20 <the aerosol particle size at outlet 17 , 18 <the aerosol particle size at outlet 15 , 16 .
[0073] The temperature of the droplets as they exit the manifold increases as a function of the amount of time spent in the manifold. For example, the droplets entering chamber 2 through chamber inlets 21 and 22 are not only smaller than the droplets exiting through chamber inlets 15 and 16 , they are also at a higher temperature.
[0074] The resultant small droplets tend to move upwards, especially as a result of the air flow towards passive outlet vents 27 and 28 at the top of the chamber. However, the device still operates viably if the passive vent is located elsewhere in the chamber, including at the bottom of the sterilization chamber 2 .
[0075] Thus, in the present invention the velocity of the aerosol droplets in the chamber is rather low. This is advantageous, since high velocity droplets tend to splatter on the surface, leading in some cases to an uneven build up of sterilant. A large build up of droplets is problematical as it means that either longer drying time is required to dry the article, or that there is an increased risk of residual material being left on the article. Residual sterilant, such as peroxide, can be injurious to users or patients.
[0076] To further reduce the velocity of the droplets, the chamber inlet ports as shown in FIG. 4 are in the form of ducts 29 (or nozzles) having an off centre orifice 30 which leads to the aerosol being directed away from the object to be sterilised. In the present invention, the aerosol is directed to the side of the ultrasound probe. This is shown in FIG. 5 , which is a horizontal cross section through the chamber. The gas flow 31 a and 31 b is to either side of the plane 32 defined by the manifold 8 . The nozzles 29 and outlets 30 cause the flow to be away from plane 32 at an angle such that the probe 10 is contacted only at a shallow or tangential angle.
[0077] FIG. 6 shows the arrangement in a chamber 2 of substantially circular cross section. The chamber wall 2 causes the gas flows 33 a and 33 b to begin to circulate in a smooth manner near the chamber wall. The droplets are thus aimed at the void space in the chamber 2 around the sides of probe 10 , rather than being directed at the probe itself. The droplets thus enter the chamber 2 at velocity, but because of the longer path available to the droplets they have the opportunity to slow and then diffuse around the chamber (downwards for large droplets, upwards for small droplets) until they contacting the probe 10 at low velocity. Larger droplets will be more inclined to take a more linear path, with less inward vortexing. Accordingly, larger particles will take a path that leads them into contact with chamber wall 2 , which is heated and thus causes the larger droplets to evaporate.
[0078] FIGS. 5 and 6 have the chamber enlarged and simplified for clarity. In actuality, the chamber 2 is preferably conformed as closely as possible to the shape of the article. Whilst sufficient space needs to be present in the chamber to allow the mist to lose velocity, the chamber is otherwise sized as small as practicable.
[0079] FIG. 7 shows a horizontal cross section of a manifold arrangement where the aerosol is introduced from one side only. The gas flow 31 b is directed to one side of the plane 32 defined by the manifold 8 . The nozzles 29 and outlets 30 cause the flow to be away from plane 32 at an angle such that the probe 10 is contacted only at a shallow or tangential angle.
[0080] FIG. 8 shows an arrangement similar to FIG. 6 , but where the manifold is configured along one side of the chamber only. A single chamber inlet port can be used as shown, configured in such a way that the flow is tangential to the surface of an object (usually an object of a known predetermined shape) in the chamber. A single chamber inlet port is sufficient to create a vortexing flow. The chamber wall 2 still directs gas flow 33 b to begin circulating in a smooth manner near the chamber wall. The droplets are thus aimed at the void space in the chamber 2 around the sides of probe 10 , rather than being directed at the probe itself. The droplets thus enter the chamber 2 at velocity, but because of the longer path available to the droplets they have the opportunity to slow and then diffuse around the chamber (downwards for large droplets, upwards for small droplets) until they contact the probe 10 at low velocity.
[0081] The tangential flow can also be achieved by having the manifold or manifolds offset from the central axis of the chamber. FIG. 9 shows how a manifold 8 may be positioned offset from the axis 32 . In such a case, it is not necessary to have duct 29 direct flow away from the article. It can be seen that this configuration maintains flow 33 b tangential to the article, while still providing vortex separation.
[0082] FIG. 10 shows a similar configuration to FIG. 8 , but illustrates in a simplified form the different paths taken by varying sized droplets. Smaller droplets follow the gas flow around the chamber, as shown by path 34 . Larger droplets have a higher linear momentum than smaller droplets as they exit from manifold 8 . The largest droplets will have the most linear path 35 , which leads them to collide with chamber wall 2 at point 36 . Because the chamber is heated, the larger droplets evaporate. Thus, the vortexing is a means of separating and selectively removing larger droplets from the chamber. A more even, dense mist of smaller droplets is thus available for sterilization.
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A manifold which introduces sterilant aerosol to a sterilization chamber for the disinfection of an article. The manifold defines the terminal portion of a fluid pathway from an aerosol generator to the sterilization chamber and comprises at least one chamber inlet port for introducing aerosol into the sterilizing chamber. The manifold is configured to provide directional aerosol flow tangential to the surface of the article, which is preferably of a known configuration and maintained in a predetermined position with respect to the manifold, such that it does not receive a direct flow of aerosol from the manifold. Preferably, the manifold is U-shaped, or bifurcate and defines a plane and with a chamber inlet ports are directed away from that plane. The chamber inlet ports are preferably paired so they create a circular motion of aerosol that moves around the article. Also sterilization apparatus including the manifold.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending application Ser. No. 11/336,685, filed Jan. 20, 2006, which is a continuation of Ser. No. 10/202,220, filed Jul. 24, 2002, the disclosures of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] This invention relates to 3-dimensional computer graphics systems and in particular to systems of the type described in our British patent numbers 2282682 and 2298111.
BACKGROUND OF THE INVENTION
[0003] British patent number 2282682 describes a system that uses a ray casting method to determine the visible surfaces in a scene composed of a set of infinite planar surfaces. An improvement to the system is described in UK Patent Application number 2298111, in which the image plane is divided into a number of rectangular tiles. Objects are stored in a display list memory, with ‘object pointers’ used to associate particular objects with the tiles in which they may be visible. The structure of this system is shown in FIG. 1 .
[0004] In FIG. 1 , the Tile Accelerator 2 is the part of the system that processes the input data, performs the tiling calculations, and writes object parameter and pointer data to the display list memory 4 . The layout of data in the display list memory is as shown in FIG. 2 . There are numerous possible variations on this, but essentially, there is one list of object pointers per tile, and a number of object parameter blocks, to which the object pointers point. The layout of objects in the display list memory is shown in FIG. 2 , The top part of the diagram shows the basic system, with parameters stored for two objects, A and B. Object A is visible in tiles 1 , 2 , 5 , 6 , and 7 , and so five object pointers are written. Object B is visible only in tiles 3 and 7 , so only two object pointers are written. It can be seen that the use of object pointers means that the object parameter data can be shared between tiles, and need not be replicated when the objects fall into more than one tile. It also means that the Image Synthesis Processor 6 of FIG. 1 (ISP) is able to read the parameters for only the objects that may be visible in that tile. It does this using the ISP Parameter Fetch unit 8 . In the example of FIG. 2 , the ISP would read only the parameters for object B when processing tile 3 , but would read the parameters for both objects when processing tile 7 . It would not be necessary to read data for tile 4 . The lower part of FIG. 2 shows the memory layout that is used with the macro tiling Parameter management system, which is described later.
[0005] When the Tile Accelerator has built a complete display list, the Image Synthesis Processor (ISP) 6 begins to process the scene. The ISP Parameter Fetch unit 8 processes each tile in turn, and uses the object pointer list to read only the parameter data relevant to that tile from the display list memory 4 . The ISP then performs hidden surface removal using a technique known as ‘Z-buffering’ in which the depth values of each object are calculated at every pixel in the tile, and are compared with the depths previously stored. Where the comparison shows an object to be closer to the eye than the previously stored value the identity and depth of the new object are used to replace the stored values. When all the objects in the tile have been processed, the ISP 6 sends the visible surface information to the Texturing and Shading Processor (TSP) 10 where it is textured and shaded before being sent to a frame buffer for display.
[0006] An enhancement to the system described above is described in UK Patent Application number 0027897.8. The system is known as ‘Parameter Management’ and works by dividing the scene into a number of ‘partial renders’ in order to reduce the display list memory size required. This method uses a technique known as ‘Z Load and Store’ to save the state of the ISP after rendering a part of the display list. This is done in such a way that it is possible to reload the display list memory with new data and continue rendering the scene at a later time. The enhancement therefore makes it possible to render arbitrarily complex scenes with reasonable efficiency while using only a limited amount of display list memory.
[0007] As 3D graphics hardware has become more powerful the complexity of the images being rendered has increased considerably, and can be expected to continue to do so. This is a concern for display list based rendering systems such as the one discussed above because a large amount of fast memory is required for the storage of the display list. Memory bandwidth is also a scarce resource. Depending upon the memory architecture in use, the limited bandwidth for writing to and reading from the display list memory may limit the rate at which data can be read or written, or it may have an impact on the performance of other subsystems which share the same bandwidth, e.g. texturing.
[0008] Embodiments of the present invention address these problems by examining the depth ranges of objects and tiles, and culling objects from the scene that can be shown not to contribute to the rendered result.
[0009] Embodiments of the invention use the depth values stored in the ISP to compute a range of depth values for the whole tile. By comparing the depths of objects with the range of stored depth values it is possible to cull objects that are guaranteed to be invisible without needing to process them in the ISP.
[0010] The Parameter Management system referred to above allows renders to be performed in a limited amount of memory, but it can have a significant impact on performance compared to a system with a sufficient amount of real memory.
[0011] Embodiments of the invention mitigate the inefficiencies of the Parameter Management system by culling objects before they are stored in the display list. Reducing the amount of data stored in the display list means that fewer partial renders are required to render the scene. As the number of partial renders is reduced, the significant memory bandwidth consumed by the Z Load and Store function is also reduced.
[0012] To perform this type of culling the Tile Accelerator compares incoming objects with information about the range of depths stored in the ISP during previous partial renders.
[0013] FIG. 3 , shows a graph illustrating the depths for a previous partial render and for a new object to be rendered. The new object lies within a depth range of 0.7 to 0.8, and during the previous partial render all pixels in a tile were set to values between 0.4 and 0.6. There is no way that the object can be visible since it is further away and therefore occluded by the objects drawn previously. Therefore the object need not be stored in the display list memory since it cannot contribute to the image.
[0014] A second stage of culling, in the parameter fetch stage of the ISP, occurs in a further embodiment. This is at the point at which object pointers are dereferenced, and parameter data is read from the display list memory. This works on a very similar principle to the first stage culling shown in FIG. 3 . By storing a little additional information in the object pointer, and by testing this against depth range information maintained in the ISP, it is possible to avoid reading the parameter data for some objects altogether. This type of culling reduces the input bandwidth to the ISP, and the number of objects that the ISP must process, but it does not reduce the amount of data written into the display list memory.
[0015] Unlike the first stage of culling, the second stage works with object pointers that correspond to the tile that is currently being processed by the ISP. The ISP's depth range information can be updated more quickly, and more accurately, than the range information used in the first stage culling, and this allows objects to be culled that were passed by the first stage.
[0016] The invention is defined in its various aspects in the appended claims to which reference should now be made.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Specific embodiments of the invention will now be described in detail by way of example with reference to the accompanying drawings in which:
[0018] FIG. 1 shows a known system;
[0019] FIG. 2 shows schematically the layout of the display list memory;
[0020] FIG. 3 shows a graph illustrating the differences between previously stored depths and the depth of an incoming object;
[0021] FIG. 4 is a block diagram of an embodiment of the invention;
[0022] FIGS. 5 a ) and b ) shows graphically how stored depth range changes as objects are processed;
[0023] FIG. 6 shows a block diagram of the comparator arrays required to derive the depth range in an embodiment of the invention;
[0024] FIG. 6A shows enlarged views of certain cells from FIG. 6 ;
[0025] FIG. 7 shows schematically various depth compare modes of operation;
[0026] FIG. 8 shows the effect of pipeline delay; and
[0027] FIG. 9 shows the effect of movement of the depth range during pipeline delay.
DETAILED DESCRIPTION
[0028] FIG. 4 is an expanded and modified version of the block diagram of FIG. 1 . The ISP Z range generation unit 12 computes the range of Z values stored in the ISP 6 and feeds it back to the first stage of culling, located in the TA2, via the Z range memory 14 . A second feedback path sends Z range data to the second stage of culling, located in the ISP parameter fetch unit 8 .
[0029] ISP Range Generation
[0030] The embodiment described uses a range of depths that represent the minimum and maximum depths of the objects stored in the ISP 6 . This range is computed in the ISP as objects are processed, and represents the actual range of depth values that are stored in the tile at that moment. This range has to be updated constantly, as stored values are continually being replaced and the range may grow and shrink as the scene is rendered. FIG. 5 a ) and b) show respectively before and after a situation in which an incoming object is rendered into the pixels which previously determined the maximum Z value of the tile, thus causing both the minimum and maximum depth values to be reduced.
[0031] The ISP 6 contains storage for each pixel in the tile, which may vary in size depending on the particular implementation of the technology. A typical tile size might be 32.times.16 pixels. The ISP also contains a number of PEs (Processor Elements) which are hardware units which operate in parallel to perform the functions of the ISP by determining depth values at each pixel. Typically there are fewer PEs than there are pixels in the tile. For example, there may be 32 PEs arranged as a grid of 8.times.4 pixels. In this case 32 (8.times.4) pixels can be computed simultaneously, and the PEs will perform the computations up to 16 (4.times.4) times at fixed locations within the tile in order to process an entire object. FIG. 6 shows a possible arrangement of PEs 16 within a tile, as well as the comparator structures described below.
[0032] To compute the range of depths the PEs compute the range of depths for the set of pixels on which they are currently working. This range, together with range information from the other possible PE positions, is then used to update the overall depth range for the tile. A typical implementation would use comparators in tree structures to find the range of values stored in a set of pixels. For example, a set of 32 PEs would require 16+2.times.(8+4+2+1)=46 comparators to calculate both the maximum and minimum values. This tree structure can be seen at the bottom of FIG. 6 . In this diagram, blocks marked “Min/Max” 18 contain one comparator to determine the minimum and maximum of two input values from two PEs 16 , and blocks marked “Min/Max 2 ” 20 contain a pair of comparators, in order to compute the minimum and maximum of two input ranges. The output of the comparator tree is a pair of values representing the minimum and maximum set of depth values in those 32 pixels, which is stored in memory associated with that particular set of pixels.
[0033] Each Min/Max block 18 is coupled to the outputs of two of the PEs 16 and compares the minimum and maximum values output by these elements and stores these in its memory, passing a range to the Min/Max 2 unit 20 . The Min/Max 2 unit 20 receives input from a second Min/Max unit 18 and passes the output to the next Min/Max 2 unit 20 in the tree. All PE ranges ultimately feed into a single Min/Max 2 unit 20 at the bottom of the tree. This gives a PE Z range output 22 for the array of 32 PEs 16 .
[0034] Once the PEs have computed a polygon in all areas of the tile, i.e. at every pixel, it is necessary to combine the stored depth values into a single value for the whole tile. Again, a tree of comparators may be used. In the case of the 32.times.16 tile, there are 16 sets of ranges to be reduced to one, and so 2.times.(8+4+2+1)=30 comparators are required. This structure is shown at the top-right of FIG. 6 , where each “Min/Max 2 ” block 20 contains a pair of comparators. The output of the final pair of comparators 26 gives the range of depth values for the whole tile, updated with the depths of the triangle that has just been processed. The inputs to the tree are the block Min/Max range memories 24 which store range information corresponding to each of the PE array positions. These memories are updated with the PE Z range data 22 after the PE array has been processed.
[0035] The comparators 18 , 20 , 26 of FIG. 6 and the other Z range generation circuiting are all contained within the ISP Z range generation unit 12 in FIG. 4 . Thus, this generates and stores the Z range for the whole tile.
[0036] It is also necessary to know whether a valid depth value has been stored at every pixel in the ISP. Normally there is a polygon near the beginning of each frame that is used to initialize the values in the Z buffer, however this cannot be relied on. Any uninitialised depth value will obviously affect the validity of any range information, and so this condition must be detected and the range marked as being invalid. Depth based object culling must be avoided until the range information becomes valid.
[0037] Precision
[0038] The large number of comparators used in the ISP's Z range generation hardware 12 is expensive to build, as it will use a considerable amount of silicon area. In order to reduce the size of the hardware 12 the precision of the calculations can be reduced. For example, while the Z values coming into the ISP can be stored as floating point values with 24 bit mantissas, the Z range comparators can operate on shorter words, e.g. 8 or 16 bit mantissas.
[0039] As values are truncated to the smaller word length it is important that the values are rounded appropriately, since it is unlikely that the shorter word will be able to represent the value of the long word precisely. When dealing with ranges, the minimum value must be rounded to the nearest value that is smaller than the original, and the maximum value must be rounded to the nearest value that is larger than the original. In this way, the truncation errors always cause the Z range to expand. Expansion of the Z range reduces the efficiency slightly since fewer objects are found to lie entirely outside the range, but it maintains the correctness of the generated image. If the range is allowed to contract it is found that objects close to the edge of the range are discarded when in fact they should be visible in the image. This is obviously not desirable.
[0040] In order to maintain the required precision at the output of a comparator tree it is necessary to use progressively higher levels of precision at higher levels in the tree.
[0041] The use of full precision Z range values is also impractical in other parts of the system. For example, in the discussion of the ISP parameter fetch culling stage, it will be seen that at least one value representing the Z range of the object is stored inside the object pointer. For reasons of space efficiency it may be desirable to store a reduced precision value here also. In this case there is little point in the ISP generating a range using more precision than is available in the object pointer values. On the other hand, the culling stage in the tile accelerator benefits from higher precision ranges from the ISP, since it does not have the same storage constraints.
[0042] In practice the benefits of higher precision Z range calculations are small, and typically a reduced mantissa length of between 8 and 16 bits will be found to be optimal. The exact sizes used will be determined by the requirements of the particular device being implemented.
[0043] Z Range Testing
[0044] The minimum and maximum Z values of a polygonal object can be determined easily by examination of the vertex coordinates. When valid range information is available from the ISP in the Z range generation unit 12 it is possible to conditionally cull the object based on comparison of the two ranges of values.
[0045] Each object in the score has a “Depth Compare Mode” (DCM) which takes one of eight values and is an instruction that tells the ISP's depth comparison hardware how to decide whether the object passes the depth test at a pixel. The culling test must be modified according to the DCM of the object. The eight possible values of DCM, and the appropriate culling test for each, are shown in Table 1.
[0000]
TABLE 1
Depth Compare Modes
DCM
Condition
Culling Test
DCM_ALWAYS
The object always
N/A
passes the depth
test, regardless of
Z values.
DCM_NEVER
The object never
N/A
passes the depth
test, regardless of
Z values.
DCM_EQUAL
The object passes
Cull if
the depth test if
(Obj: Max < ISP: Min)
its z value is equal
OR
to the z value
(Obj: Min > ISP: Max)
stored in the ISP.
DCM_NOT_EQUAL
The object passes
N/A
the depth test if
its z value is not
equal to the z value
stored in the ISP.
DCM_LESS
The object passes
Cull if (Obj: Min >=
the depth test if
ISP: Max)
its z value is less
than the z value
stored in the ISP.
DCM_LESS_EQ
The object passes
Cull if (Obj: Min >
the depth test if
ISP: Max)
its z value is less
than or equal to the
z value stored in
the ISP.
DCM_GREATER
The object passes
Cull if (Obj: Max <
the depth test if
ISP: Min)
its z value is
greater than the z
value stored in the
ISP.
DCM_GREATER_EQ
The object passes
Cull if (Obj: Max <=
the depth test if
ISP: Min)
its z value is
greater than or
equal to the z value
stored in the ISP.
[0046] Depth comparisons in the ISP are performed for every pixel in the object for each tile being processed, with depths being iterated across the surface of the polygon. Depth based culling performs a single test per object, and must therefore perform appropriate comparison between suitable ranges of values.
[0047] The depth compare mode must be taken into account when performing the depth based culling tests. The diagrams in FIG. 7 show three of the simple conditions that correspond to DCM modes DCM_EQUAL, DCM_LESS, and DCM_GREATER. The shaded areas indicate the range of depths stored in the ISP, which are made available by the Z range generation unit 12 to the culling stages, and the triangles indicate candidates for culling. Triangles marked ‘OK’ would be passed while triangles marked ‘X’ would be culled.
[0048] In the DCM_EQUAL example, objects will only be stored in the ISP if they have a depth value equal to one of the currently stored depth values. This means that any object with a depth range that intersects the stored range (objects marked ‘OK’) may pass the depth test and so must not be culled. The objects that do not intersect the stored range (objects marked ‘X’) cannot possibly pass the depth test, and can therefore be safely culled.
[0049] In the DCM_LESS example, objects will be stored in the ISP if they have depth values that are less than the corresponding stored value. Objects with depths that are entirely less than the stored range are very likely to be visible, and are therefore not culled. Objects with depth ranges that intersect wholly or partly with the stored range may also be visible, and are not culled. Only objects whose range is entirely greater than the stored depth range are guaranteed to be completely occluded, and may therefore be culled. These objects are marked with ‘X’.
[0050] The DCM_GREATER example is the opposite of the DCM_LESS example. Objects with depth ranges entirely greater than the stored range can be culled, while those with depths that intersect or have depth values greater than the stored range cannot be culled.
[0051] The DCM modes DCM_LESS_EQ and DCM GREATER_EQ are very similar to DCM_LESS and DCM_GREATER respectively, but differ in whether an equality condition is considered to be an intersection of the ranges or not.
[0052] For the remaining modes, DCM_ALWAYS, DCM_NEVER, and DCM_NOT_EQUAL, it is not possible to use depth based culling. It is clear that there is no comparison of depth values that can be used to indicate whether the object can be culled in these cases.
[0053] Notice that four of the DCM modes, (the LESS and GREATER modes) require only one value from each of the ranges, while the test for DCM_EQUAL requires both values from each range.
[0054] The DCM_NEVER mode appears to be of somewhat limited usefulness as it will never pass the depth test, and will never be visible in the scene. We have to assume that such objects have been added to the scene for a good reason, and therefore should not be culled. One possible reason would be if the object has a side-effect, such as performing stencil operations. In fact, it is essential that any object that may have side-effects should not be culled.
[0055] Handling Changes in Depth Compare Mode
[0056] The design of 3D rendering hardware relies heavily on pipelining, which is a technique in which the processing that is required is divided up into a large number of simpler stages. Pipelining increases the throughput of the system by keeping all parts of the hardware busy, and allows results to be issued at the rate achieved by the slowest stage, regardless of the length of the pipeline itself.
[0057] Pipelining is a useful technique, and it is essential in the design of high performance rendering systems. However, it presents some problems to the z based culling system, where the culling ideally happens at an early stage in the pipeline, but the ISP depth range generation happens much later. The effect is that of a delay, between determining that an object can be culled, and the time when that object would actually have been rendered in the ISP. Any change in the state of the ISP between the culling test and the actual rendering time could cause the culled object to become visible again, and thus cause an error in the rendered image. The things that can, and will, cause changes in the state of the ISP are the other non-culled objects already in the pipeline.
[0058] For an example of a situation in which the delay caused by the pipeline causes a problem, consider a large number of objects with a DCM of DCM_LESS. This is a typical mode for drawing scenes, where objects closer to the viewpoint obscure the view of those further away Now consider a single object in the middle of the scene, with a DCM of DCM_ALWAYS. This situation in shown in FIG. 8 , where all objects except ‘B’ are DCM_LESS, and the object marked ‘B’ is DCM_ALWAYS. Object ‘C’ is currently being processed in the ISP, object ‘A’ is being culled, and there are eight objects (including ‘B’) at intermediate stages in the pipeline.
[0059] As object ‘C’ is processed, the range of values in the ISP is between 0.5 and 0.6. This is the range that is fed back to the culling unit and used for the culling of object ‘A’. Object A has a Z value of 0.8, which when compared with the ISP's Z range, means that it will be culled. Now suppose that object ‘B’ covers the entire tile, and has a Z value of 0.9. The DCM_ALWAYS mode means that it will replace all the stored depths in the ISP with 0.9, and so object ‘A’, if it had not been culled, would actually be closer to the viewpoint than the stored object ‘B’, and should therefore be rendered as a visible object. It can be seen that the use of depth based culling produces incorrect results when the Z range feedback is delayed, either by a pipeline, or for any other reason.
[0060] This problem occurs due to the pipeline length between the ISP parameter fetch and ISP depth range generation hardware units, and also due to the delay between processing an object in the Tile Accelerator, and that object being rendered in the ISP. In the latter case the delay is considerably larger, and the problem is exacerbated if the Z range information from the ISP is updated only at the end of each partial render. Solutions to these problems are described below.
[0061] In the majority of cases, objects are grouped such that objects with a constant depth compare mode occur in long runs. In a typical application, a single depth compare mode, such as DCM_LESS or DCM_GREATER will account for the majority of the objects in the scene, since it is these modes that allow hidden surface removal to occur. Where other modes are used, these tend to be for special effects purposes, and the objects are few in numbers and are often grouped together at the end of the display list. It is fortunate that delayed Z range feedback is not a problem in the case where the DCM does not change.
[0062] As an example of correct behaviour, consider the case of a number of DCM_LESS objects, shown in FIG. 9 . The objects will replace the objects stored in the ISP only if their Z value is less than the currently stored value. This means that the numbers in the ISP can only ever become smaller, and because objects are replaced it is possible that both the minimum and maximum stored depth values will be reduced. The appropriate culling test for a DCM_LESS object is to discard the object if the minimum Z value of the object is greater than the maximum extent of the ISP's Z range. Since the delay can only cause the ISP's maximum value to be larger than it would otherwise be, the culling is safe. Slightly fewer objects will be culled than in the ideal case, but the conservative culling behaviour does not cause errors in the rendered output.
[0063] Z Range Culling in the Tile Accelerator
[0064] Culling in the Tile Accelerator operates when parameter management is active. That is, when the system begins to render small parts of the screen (called macro tiles) before the whole image has been stored in the display list memory. The rendering of a macro tile is known as a “partial render” and typically renders only a fraction of the number of objects that will eventually be rendered in that macro tile. The parameter management system allows the display list memory associated with the macro tile to be released and used for the storage of further objects. This allows scenes of arbitrary complexity to be rendered in a finite amount of memory space. Parameter management is described fully in UK Patent Application number 0027897.8.
[0065] A small amount of memory is used, shown as “Z Range Memory” 14 in FIG. 4 , in a feedback loop to store the Z range information generated by the ISP. A separate memory location is used for each tile, and it contains the Z range generated at the end of the partial render that occurred most recently in that tile.
[0066] The tile accelerator works by calculating the set of tiles in which each object must be rendered, and adding the object to each of those tiles by writing an object pointer into the appropriate list. In a basic system a single copy of the parameter data is written to the display list memory, but in a system using parameter management a copy of the data must be written for each macro tile in which the object is to be rendered. This arrangement is shown in the lower part of FIG. 2 .
[0067] Z range culling works by reducing the set of tiles to which the objects are added. This is done by comparing the Z range of the object with the stored Z range for the tile, for each tile in which the object occurs. Tiles can then be removed from the set when the test fails. The comparison test must of course be chosen according to the DCM of the object.
[0068] The reduction in memory consumption occurs because the reduced set of tiles also tends to use fewer macro tiles, and therefore fewer copies of the object parameter data must be made.
[0069] As described above, changes in the depth compare mode have to be dealt with in order to prevent errors occurring. The situation is slightly more complicated than that shown in FIG. 8 , because the Tile Accelerator and ISP are unlikely to be working on the same tile at the same time. The parameter management system makes the interval between processing an object in the TA and it being rendered in the ISP unpredictable, and there will be an unknown number of DCM changes stored in the display list.
[0070] In order to deal with changes of DCM it is necessary to depart a little from ideal behaviour and update the stored range values in Z range memory 14 from within the TA as objects are processed. The disadvantage of this method is that although the system begins with the range generated by the ISP, the updated range will be a worst case estimate based on the vertex coordinates of all the objects processed by the TA. The range generated in this way will tend to be larger than the range that the ISP would generate itself since it is not possible to take into account objects that overdraw each other. Table 2 shows the range updates required for objects with different DCMS. The stored range cannot shrink, but always grows, and is replaced again by the ‘accurate’ values from the ISP at the end of the next partial render.
[0071] An advantage of this type of operation is that the stored Z range, although larger than necessary, is not delayed by the pipeline, and so changes in DCM do not cause problems.
[0000]
TABLE 2
Range updates in the TA
DCM
Condition
DCM_ALWAYS
Extend range min/max to include
object min/max.
DCM_NEVER
Do not modify range.
DCM_EQUAL
Do not modify range.
DCM_NOT_EQUAL
Extend range min/max to include
object min/max.
DCM_LESS
Extend range min to include
object min.
DCM_LESS_EQ
Extend range min to include
object min.
DCM_GREATER
Extend range max to include
object max.
DCM_GREATER_EQ
Extend range max to include
object max.
[0072] Z Range Culling in the ISP Parameter Fetch Unit
[0073] Culling objects in the ISP parameter fetch is slightly simpler than culling in the tile accelerator, since the parameter fetch hardware and ISP are always operating on the same tile at the same time. The situation is exactly as illustrated in FIG. 8 , and an appropriate comparison on minimum and maximum Z values can be used to cull objects.
[0074] The ISP's Z range values can be taken directly from the Z range generation unit, and fed back to the parameter fetch unit as shown in FIG. 8 . The Z range of the object itself is more problematic, since it would defeat the purpose of culling if it were necessary to read the object parameters from memory in order to compute the Z range. Instead, all appropriate information (the Z range and DCM) must be read from the object pointer, by the parameter fetch unit 8 .
[0075] To store Z range information in the object pointer the range must be computed in the tile accelerator. This is not a problem, since the TA culling stage also requires hardware to compute the Z range, and the same hardware can be used for both purposes.
[0076] Free space is scarce in the object pointer word, and it is desirable to keep the length of the word as short as possible. The DCM code requires the storage of three bits. Once the DCM is known, the culling tests for DCM_LESS and DCM_LESS_EQ require only the minimum Z value of the object, and culling tests for DCM_GREATER and DCM_GREATER_EQ require only the maximum Z value of the object. In these cases is therefore possible to store the one value, maximum or minimum, whichever is appropriate to the DCM of the object.
[0077] The DCM_EQUAL culling test, as shown in Table 1, does need both values and therefore requires the storage of two depth values in the object pointer. The increase in size of the object pointer necessary to store the second value may not be desirable, particularly since the DCM_EQUAL mode is not commonly used for large numbers of objects. In this case it is possible to perform incomplete culling by performing only one half of the full test, and thus using only one value from the object pointer.
[0078] As discussed previously, it is not necessary to store full precision values in the object pointer, provided that care is taken in rounding. Additional space savings can be gained in this way.
[0079] To deal with the problem of changing depth compare modes, a simple counter is employed in the parameter fetch unit. The length of the pipeline is known in advance, as is the maximum number of objects which it can possibly contain. In order to ensure correct operation it is required that the triangle being fetched and the triangle being processed in the ISP both belong to one run of triangles, all with the same DCM. The counter is reset to zero when the DCM changes, and is incremented as each triangle is fetched. Culling is disabled when the counter is less than the maximum possible number of objects in the pipeline, thus ensuring that the object in the ISP is part of the same run of objects as the object currently being fetched. Efficiency is reduced slightly because a number of objects at the beginning of each run cannot be culled, but correctness is guaranteed. With a pipeline length of approximately 20 objects, and typical applications in which the DCM does not change frequently, the number of objects that cannot be culled is only a small proportion of the total scene. With scene complexity expected to rise in the future, the resultant reduction in efficiency will become less significant.
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An apparatus and a method for generating 3-dimensional computer graphic images. The image is first sub-divided into a plurality of rectangular areas. A display list memory is loaded with object data for each rectangular area. The image and shading data for each picture element of each rectangular area are derived from the object data in the image synthesis processor and a texturizing and shading processor. A depth range generator derives a depth range for each rectangular area from the object data as the imaging and shading data is derived. This is compared with the depth of each new object to be provided to the image synthesis processor and the object may be prevented from being provided to the image synthesis processor independence on the result of the comparison.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the discovery of a specific class of plasticizers for poly(iminoimidazolidinediones) and poly(parabanic acid) resins.
2. Prior Art
Both the poly(iminoimidazolidinediones) and poly (parabanic acids) and their methods of preparation are known and described in detail in commonly assigned U.S. Pat. No. 3,661,859, which is incorporated in its entirety herein. The poly(parabanic acids) may also be prepared by other processes, such as shown in U.S. Pat. No. 3,609,113.
The poly(iminoimidazolidinediones) may be formed by the reaction of hydrogen cyanide with a diisocyanate or mixture of diisocyanates, the reaction of a dicyanoformamide with a diisocyanate or mixtures of diisocyanates, or the polymerization of a cyanoformamidyl isocyanate and contain a 1,3-imidazolidinedione-1,3-diyl ring of the following structures in the repeat units: ##STR2## wherein NH is in the 4 or 5 position.
The poly(parabanic acids) also designated as poly(1,3-imidazolidine-2,4,5-triones) may be prepared, for example, by the acid hydrolysis of poly(iminoimidazolidinediones) and contain the imidazolidinetrione ring in the repeat unit: ##STR3## U.S. Pat. No. 3,609,113 and German Patent No. 1,770,146 describe other methods for preparing polymers which contain the poly (parabanic acid) ring.
The polymers may contain both imino-1,3-imidazolidinedione-1,3-diyl rings and imidazolidinetrione rings, thus the present polymers may be broadly characterized as having the repeating unit: ##STR4## wherein Q is ##STR5## wherein X is O or NH, provided that at least one X is O, R is an organic moiety which may be aliphatic, alicyclic, aromatic or mixtures thereof, and n is sufficiently large to produce a solid product.
The R is the organic moiety of the diisocyanate when the polymer is produced according to the procedure in U.S. Pat. No. 3,661,859. Thus, the diisocyanates may be selected from a broad group having a large variety of organic moieties. The organic moieties of the diisocyanate may be substituted with groups such as alkyl, aryl, halogens, sulfoxy, sulfonyl, alkoxy, aryloxy, oxo, ester, alkylthio, arylthio, nitro and the like which do not react with the isocyanate group. Functional groups which have active hydrogen atoms, (e.g., carboxylic acids, phenols, amines, etc.) should not be present. Specific diisocyanates which may be used are set out in U.S. Pat. No. 3,661,859, other patents, articles or organic textbooks as known in the art.
Some of the parabanic acid polymers have been found to have high glass transition temperatures, and thus, are especially suitable as magnetic tapes (where good dimensional stability at high temperatures is required), films for use in flexible printed circuits, cable wraps, etc., for fibers such as tire cord fibers (where tensile strength and modulus are required), for moldings for electrical connectors, bearings, magnetic wire insulation, coatings for cables, cookware, glass fabrics, industrial belts (where high temperatures are required) and the like.
However, many of the present polymers decompose when they are heated at or above their glass transition temperatures and as a result they can not be molded or extruded. Previously these polymers could be processed only by solution methods or by a powder coating technique which also requires a solvent.
It is an advantage of the compositions of the present invention that the poly(iminoimidazolidinediones), poly(imidazolidine-2,4,5-tiones) or mixed poly(iminoimidazolidine-1,3-dione/imidazolidine-2,4,5-triones) or as defined above the polymers ##STR6## may be processed by extrusion and molding techniques, when plasticized according to the present invention. Also films of the compositions of the present invention can be heat-sealed whereas films of the same pure polymers can not be sealed with heat. It is a particular advantage of the present plasticizers in that they are not detrimental to copper chelate thermal stabilizers frequently employed in the films, whereas many other materials investigated as plasticizers do adversely effect the thermal stability.
SUMMARY OF THE INVENTION
Briefly, the present invention is a plasticized composition comprising heterocyclic polymers characterized in the repeating unit by the tri-substituted 1,3-imidazolidine-1,3-diyl ring: ##STR7## wherein X=O or NH, provided at least one X is O or more specially polymers having the repeating unit: ##STR8## wherein Q is ##STR9## and X has the significance set out above, R is an organic moiety which may be aliphatic, alicyclic, aromatic or mixtures thereof and n is sufficiently large to produce a solid product and a plasticizing amount of aromatic sulfones or aromatic sulfoxides.
More particularly, the polymers may be poly(iminoimidazolidinediones) characterized by a tri-substituted 1,3-imidazolidine-1,3-diyl ring of the following structure: ##STR10## poly(parabanic acids) characterized by a tri-substituted 1,3-imidazolidine-1,3-diyl ring of the following structure: ##STR11## or more specifically, polymers of the general structure: ##STR12## wherein R and n have the significance given above.
The plasticized compositions of the present invention are capable of being melted without decomposition. The polymers may be films, powders or the like.
The term "plasticizing amount" as used herein means that amount of aromatic sulfone or aromatic sulfoxide, which is incorporated in and compatible with the polymer to form a homogeneous composition. Generally, the plasticizer incorporated into the polymer will comprise from 10 to 50 weight percent of the total weight of polymer and plasticizer, although the plasticizers may be used in slightly smaller amounts, i.e., about 5% and in somewhat larger amounts, e.g., up to about 60%. Preferably up to about 30 weight percent of the plasticizer will be employed.
DETAILED DESCRIPTION OF THE INVENTION
The plasticizers useful for the present invention are aromatic sulfones and aromatic sulfoxides and more specifically diaromatic sulfones and diaromatic sulfoxides represented by the formulas:
R'--SO.sub.2 --R" or R'--SO--R"
wherein R' and R" are like or unlike aryl radicals, alkaryl radicals and araryl radicals. Preferably, R' and R" radicals have 6 to 12 carbon atoms and include derivatives of benzene, diphenyl, naphthalene, toluene, xylene, and the like. Some specific compounds which may be used as plasticizers in the present invention include diphenyl sulfone, phenyl tolyl sulfone, ditolyl sulfone, xylyl tolyl sulfone, dixylyl sulfone, tolyl paracymyl sulfone, phenyl biphenyl sulfone, tolyl biphenyl sulfone, xylyl biphenyl sulfone, phenyl naphthyl sulfone, tolyl naphthyl sulfone, xylyl naphthyl sulfone, diphenyl sulfoxide, phenyl tolyl sulfoxide, ditolyl sulfoxide, xylyl tolyl sulfoxide, dixylyl sulfoxide, tolyl paracymyl sulfoxide, phenyl biphenyl sulfoxide and aromatic sulfones and sulfoxides of substituted aromatic compounds which substituents do not inhibit the plasticizing effect of the material nor react to degrade the polymer. In particular, substituent groups which have active hydrogen atoms (e.g., carboxylic acids, phenols, amines, etc.) should not be present. Examples of substituent groups which do not interfere with the plasticizing effect include alkoxy or aryloxy carbonyl groups, halogens such as bromine, chlorine or fluorine, aryloxy or alkoxy groups, and sulfur containing groups.
The presence of a plasticizer in the polymers described herein will, as is the known effect of plasticizers, result in different film properties at elevated temperatures, compared to unplasticized polymer film, that is, polymer films not containing plasticizer. Generally, plasticizers are incorporated in the polymer in amounts of about 10 to 30 weight percent which will produce lower softening points than the polymer without the plasticizer incorporated therein.
The plasticized polymer is thus desirably softened at high temperatures so that films of these compositions may be sealed by heat. Films of the present unplasticized polymers are however difficult to heat seal because of their very high softening temperatures, because the polymer does not flow enough to coalesce into a single phase. Moreover, other materials employed in conjunction with the polymer may be damaged by the high temperatures required to seal the unplasticized polymer.
It was found that conventional plasticizers such as mixtures of N-ethyl-o-toluene sulfonamide and N-ethyl-p-toluene sulfonamide and mixtures of o-toluene sulfonamide and p-toluene sulfonamide were not useful for plasticizing the present polymers in melts. Generally, the compositions containing these plasticizers melted but were subject to decomposition at the temperatures required to melt the blends if normal mixing procedures were used, i.e., adequate blending time of the polymer and plasticizer. Those blends which were melted in small batches for only a few minutes exhibited poor thermal stability when heating and mixing were continued.
These problems are substantially overcome by the use of aromatic sulfones or aromatic sulfoxides as plasticizers according to the present invention.
The present plasticizers may be incorporated into the polymers in solution, such as dimethylformamide solutions of polymer used for casting or coating or in dry polymer compositions for melt extrusion.
The polymer-plasticizer compositions according to the present invention are stable meltable composition and may be extruded without degradation. The extrusions may be carried out at temperatures in the range of 250° to 330° C. The extrudates of the invention compositions were tough, smooth clear and yellow to amber colored.
ILLUSTRATIVE PREFERRED EMBODIMENTS
For purpose of illustration, but not for exclusion, the majority of the examples illustrating the invention will be described in specific with respect to a particular polymer. That is, a poly(parabanic acid) prepared from diphenylmethane diisocyanate in accordance with proprietary techniques well described in patents assigned to Exxon Research and Engineering Company to result in a high performance polymer having the repeating unit shown below: ##STR13## which is also designated as poly[1,4-phenylenemethylene-1,4-phenylene-1,3-(imidazolidine-2,4,5-trione)] which is also designated in chemical abstracts as poly [(2,4,5-trioxo-1,3 imidazolidinediyl)-1,4-henylenemethylene-1,4-phenylene]. It has a high glass transition temperature of 290° C. and can not be extruded or molded.
For purposes of convenience, these polymer species will be referred to as PPA-M. It will be recognized that other polyparabanic acids (PPA) can be prepared from other monomers so that the diphenyl methane group will be replaced by other organic moieties.
In general, the preferred polymers of the polymer-plasticizer compositions are those which have sufficient repeating units at room temperature to be solids.
In addition to the polymer and plasticizers, it is contemplated that other appropriate additives which are not detrimental to the compositions such as those employed to stabilize against oxidation or ultraviolet light, flame retardants, pigments, fillers and the like may be present.
As noted above, a particular advantage to the use of the present plasticizers is that they are not detrimental to the effectiveness of copper/chelate oxidation stabilizers as disclosed in commonly assigned U.S. Pat. No. 4,022,751.
The chelating compounds are illustrated by dicarboxylic, acids, e.g., malonic acid; hydroxy acids, hydroxy aldehydes, e.g., salicylaldehyde; β-diketones, e.g., acetylacetonates; keto esters, e.g., ethylacetoacetate and diphenyl ketones, e.g., 2-hydroxyphenonls.
The various organic moieties of the chelating agents may be substituted with various radicals such as alkyls having up to 12 carbon atoms, alkoxy radicals having up to 12 carbon atoms, aryl, and arloxy having up to 12 carbon atoms and groups pendant thereon capable of forming a salt with copper such as carboxylics, sulfonics or the like, such as sulfo or carboxy.
Suitable radicals include methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, methoxy, ethoxy, propoxy, butoxy, pentyloxy, hexoxy, heptoxy, octyloxy, nonoxy, decoxy, undecoxy, dodecoxy, phenyl, benzyl, tolyl, napthyl, phenyloxy, benzyloxy and napthyloxy.
Some other specific copper chelates include the copper chelate of 2-hydroxybenzophenone, 2-hydroxy-4-methoxy-5-sulfobenzophenone, 2-hydroxy-4-methoxy-2'-carboxybenzophenone, 2,2'-dihydroxy-4-methoxybenzophenone, 2-hydroxy-4-methoxy-benzophenone, 8-quinolinolate and benzoyl acetonate (cupric).
The following examples illustrate the present invention and should not be construed as limiting the scope thereof.
EXAMPLES 1-5
Films were prepared by dissolving PPA-M in dimethyl formamide and adding the designated plasticizer in an amount to provide the corresponding weight percent in the dried film. The solutions were cast and dried to produce 1 mil films which were heat sealed and then tested for peel strength. The compositions, heat seal preparation and test results are shown in TABLE I.
TABLE I______________________________________ Diphenyl Minimum Sulfone Heat Peel Wt % in dry Sealing StrengthExample PPM-Film Temperature* Lbs/Inch______________________________________1 0 290° C. 1.2.sup.a2 5 260° C. 4.0.sup.a3 10 250° C. 2.9.sup.a4 15 240° C. 3.9.sup.a5 5 260° C. 4.0.sup.b______________________________________ *Sealed in platen press for 30 seconds at 400 psi. .sup.a Sealed filmto-film .sup.b Sealed filmto-Yates Atreated copper foil. Film tore at 4.0 lbs/inc to stress instead of peeling.
EXAMPLE 6
This example demonstrates that there is substantially little loss of strength of the films plasticized in accordance with this invention.
A film was made in the same manner as in Examples 1-5, by forming a solution of 400 grams of PPA-M in 1,600 grams of dimethyl formamide at room temperature and adding 20 grams of diphenylsulfone plasticizer thereto. The solution was cast and dried to produce a 3.5 mil thick film. The film had a tensile strength of 14,604 psi and a % elongation of 41. The tensile strength compares favorably with the PPA film in the absence of the plasticizer which had a tensile strength of 14,750 psi.
EXAMPLE 7-11
PPA-M resin and N N-dimethylformamide, DMF, were weighed into a stirred vessel in the ratio to yield 20% weight percent of resin in the film casting solution. Two weight percent of the copper salt/chelate of 2-hydroxy-4-methoxybenzophenone-5-sulfonic acid (an oxidation stabilizer) and the plasticizer, if any, as shown in TABLE III, to be evaluated were added and the resulting mixture was stirred until resin, stabilizer and plasticizer were completely dissolved.
The resulting film casting solutions were used to prepare film (1 mil) by coating a wet film onto a continuously moving stainless steel belt which conveyed the film through a drying oven after which the film was stripped from the belt and taken up as a roll. The residual DMF left in the film was less than 0.5%.
The films were aged in a circulating air at 230° C. for the time indicated in Table III after which the percent tensile elongation was measured using ASTM procedure D-638-72. The results are reported in TABLE III. It is evident from the results that the three commercial plasticizers severely reduced the oxidative stability of PPA-M to an unacceptable level compared to the unplasticized film A.
Example 8 contains neither copper chelate nor plasticizer and serves, by comparison to Example 9, to illustrate the normal high stability achieved with the copper chelate in the absence of plasticizer.
TABLE II______________________________________ Percent Retention of Tensile ElongationPlasticizers Days AgedExample Compound Wt. % 0 21 35 49 63______________________________________7 None*0- 1000-0-0-0-8 None0- 100 79 77 54 359 Triphenylphosphate 15 100 42 260-0-10 Tricresylphosphate 15 100 50 390-0-11 N-ethyl-mixed o,p- 15 100 55 50 130- toluenesulfonamide______________________________________ *Does not contain copper chelate stabilizer
EXAMPLES 12-17
The same procedure as Examples 8-12 was used to produce the films evaluated here. The compounds tested as plasticizers are not considered to be commercial plasticizers but which effectively plasticize PPA-M. The oxidation stabilizer (copper salt/chelate of 2-hydroxy-4-methoxy-benzophenone-5-sulfonic acid) was present at 1.5 weight percent. The films were aged at 215° C. in a circulating air oven for the time intervals indicated in TABLE IV after which the propagating tear strengths were measured using ASTM procedure D 1938-67. The test results are reported in TABLE IV. From the results diphenyl sulfone is clearly superior in that essentially no loss of oxidative stability is observed compared to the unplasticized PPA-M film, whereas the other compounds tested resulted in substantial degradation of the effectiveness of the stabilizer.
TABLE III______________________________________ Percent Retention of Propating Tear StrengthPlasticizers Days AgedExample Compounds Wt % 0 14 28 42 56______________________________________12 None 0.0 100 75 56 47 3613 Diphenyl Sulfone 10.0 100 77 61 33 2914 Diphenyl Sulfone 15.0 100 86 71 50 3715 Hexamethyl- 10.0 100 50 300-0- phosphoramide16 Triphenylphosphine 15.0 100 420-0-0-17 Triphenylphosphite 15.0 100 45 260-0-______________________________________
EXAMPLES 18-20
The same procedure was employed as in Examples 8-12. The copper salt/chelate of 2-hydroxy-4-methoxybenzophenone-5-sulfonic acid was employed at 1.5 weight percent. The two compounds were found to plasticize PPA-M film to make it heat sealable. The films were aged at 215° C. in a circulating air oven for the period of time indicated in TABLE V. The propagating tear strength were measured after each aging interval using ASTM procedure D 1938-67 to determine the degree to which the plasticizer reduced the oxidative stabilizing effectiveness of the copper salt/chelate oxidation inhibitor. The results are reported in TABLE V. The results show that the diphenyl sulfoxide was essentially as good as the diphenyl sulfone in not degrading the oxidation inhibitor.
TABLE IV______________________________________ Percent Retention of Propatating tear StrengthPlasticizers Days AgedExample Compounds Wt % 0 14 28 42 56______________________________________18 None0- 100 70 55 45 3619 Diphenyl Sulfoxide 10 100 69 56 43 2720 Mixed o,p-toluene 10 1000-0-0-0- sulfonamide______________________________________
EXAMPLE 21
850 grams of PPA-M (ηinh=0.98) dry mix composition with 150 grams of diphenyl sulphone was prepared and the conditions for extrusion determined.
The Brabender extruder which was used had a 0.75 inch barrel with an L/D ratio of 20:1. It was fitted with either a 1/8 inch heated rod die or a heated 2" wide adjustable thickness ribbon die. The barrel had two heated zones. The screw had 10 flights feed, 5 flights compression, and 5 flights metering. The compression ratio was 3:1.
______________________________________ExtrusionZone 1: 285° C.; Zone 2: 290° C.Die: 275° C. 40-80 rpm; Die pressure: 3500-4500psi; color of extrudate: yellow with greenishtinge; appearance of extrudate: relativelysmooth with some roughness, tough weightchange of extrudate (milled powder at 190° C.,four samples)Sample A B C D______________________________________Original wt. grams 5.00127 5.00203 5.00127 5.00203Wt. after 36 hours 4.89649 4.90545 4.89131 4.90173Wt. loss % -2.10 -1.93 -2.20 -2.00______________________________________
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Normally intractable polymers of the structure: ##STR1## wherein X is O or NH, provided at least one X is O, R is an organic moiety, such as poly(parabanic acids) are plasticized by composition with from 15 to 60 weight percent of an aromatic sulfone or aromatic sulfoxide such as diphenyl sulfone, diphenyl sulfoxide or dibutyl-4,4'-sulfonyl dibenzoate.
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TECHNICAL FIELD
This application relates generally to the manufacture of semiconductor integrated circuits and, more particularly, to methods for producing dielectric layers in such circuits.
BACKGROUND OF THE INVENTION
It is customary in the manufacture of integrated circuits, to form dielectric layers between conductors which interconnect various portions of the circuit. The conductive interconnections, known as "runners," may be made from a metal, such as aluminum or tungsten, or may be made from doped poly-silicon, perhaps with an overlaying layer of silicide. In some applications, the entire runner may be made from silicide.
It is sometimes desired, for example, in certain SRAM applications, to have a comparatively thin dielectric layer between the second- and the third-level conductors. One method for providing such an inter-level dielectric is to use low-pressure chemical vapor deposition (LPCVD) of silicon dioxide from an appropriate precursor gas, such as TEOS. However, the relatively high (approximately 720° C.) deposition temperature of LPCVD TEOS may cause degradation of silicided runners.
Plasma-enhanced TEOS processes (PETEOS) utilize a lower deposition temperature (approximately 390° C.), but are often too fast (i.e., deposit material too quickly) and produce material layers of uneven quality. Typical standard PETEOS processes can produce a comparatively thick (10,000 Å) dielectric film at a rate of approximately 125 Å per second. However, this deposition rate is too fast for situations in which a thin (approximately 1000 Å) or ultra-thin (approximately 100 Å) dielectric is desired because the deposition process is not completely stable in the first few seconds after startup.
SUMMARY OF THE INVENTION
Illustratively, the present invention provides a manufacturable process for depositing a thin layer of high quality, uniform dielectric in a reactor by utilizing a deposition rate which is slower than standard processes. Applicant has found that by reducing the ratio of precursor gas flow rate to oxygen flow rate, a dielectric with the aforementioned characteristics can be produced.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a cross-sectional view showing a portion of a product (e.g., a semiconductor integrated circuit) produced by an illustrative embodiment of the present invention.
DETAILED DESCRIPTION
Turning to FIG. 1, a semiconductor product is shown including runners 13, 15, and 17, and dielectric material 11 and 19. Dielectric material 11 may be formed by a conventional PECVD deposition process described in greater detail below. Typically, there may be located beneath dielectric 11 a body, a material which may include, for example, a silicon substrate, another dielectric layer, or both. Conductive runners 13 and 15 are formed upon dielectric layer 11. Runners 13 and 15 may be made from a metal, such as aluminum or tungsten, or may be made from doped polysilicon or amorphous silicon. Alternatively, runners 13 and 15 may be a silicide, such as titanium silicide. Runners 13 and 15 may be only partially silicide, i.e., only the upper portions of runners 13 and 15 may contain silicide, while the lower portions comprise polysilicon or amorphous silicon. Runners 13 and 15 may be connected to the active regions of transistors, such as sources, gates, or drains. Windows or vias through which the connections may be made are not depicted in the figure. Alternatively, runners 13 and 15 may be connected to other lower-level runners. Dielectric 19 covers and surrounds runners 13 and 15. Runner 17 is located atop dielectric layer 19. Runner 17 may be connected through vias or windows to lower runners, such as 13 or 15, through openings not illustrated. In many applications, it is desired that dielectric 19 be comparatively thin (e.g., approximately 800 Å). For example, a comparatively this dielectric may be used when runner 17 and runners 13 and 15 are at the same or nearly the same voltage which may occur, for example, in certain SRAM cells.
As mentioned before, formation of dielectric 19 by prior art LPCVD TEOS processes requires a temperature of approximately 720° C. The comparatively high temperature of 720° C. may cause degradation of any silicide material in runners 13 and 15.
Alternatively, dielectric 19 may be formed by a prior art PETEOS process. The PETEOS process requires a lower deposition temperature (approximately 390° C.). However, typical PETEOS processes are very fast--they may produce approximately 125 Å of material per second. Consequently, a mere 6 seconds, or so is required for deposition of approximately 800 Å of dielectric 19 thickness. Furthermore, when dielectric 19 is produced by PETEOS process, the resulting layer is often of uneven quality.
It is hypothesized that the uneven quality obtains because the plasma utilized to form layer 19 by the prior art PETEOS process does not become fully stabilized until approximately three or more seconds after initiation. Dielectric formed during the initial unstable phase of plasma creation has poor dielectric properties. However, if dielectric 19 is to be comparatively thin (i.e., 800 Å), it is essential that the dielectric should be of high quality. It is hypothesized that the dielectric layer formed during the first 3 seconds contains, in addition to silicon dioxide, impurities such as carbon and Si--OH.
Applicant has discovered processes for producing a comparatively uniform high-quality dielectric layer which is formed in a plasma-enhanced reaction using a precursor, such as TEOS. The deposition process is comparatively slower, i.e., 60-5 Å per second than conventional PETEOS deposition which is typically 125 Å /second. The inventive processes adapt well to deposition equipment, such as the AMI 5000, manufactured by Applied Materials Corporation, Santa Clara, Calif. Furthermore, the teachings of the present invention are also applicable to apparatus made by other manufacturers, such as Novellus.
Applicant's processes for producing a dielectric layer utilizing a precursor gas, such as TEOS, is detailed below in Table 1. The table includes three embodiments in columns A, B, and C. For comparison, conventional PETEOS process parameters are also listed in Table 1.
TABLE 1__________________________________________________________________________ Conventional A B C Processes__________________________________________________________________________Typical 500-3000 Å 200-600 Å 50-200 Å >10,000 ÅThicknessesPressure 8 torr ± 10% 6 torr ± 10% 6-8 torr 9 torrPower 350 w ± 10% 100-200 w 200-300 w 350 wTEOS flow 200 sccm ± 10% 100 sccm ± 10% 50 sccm ± 10% 380 sccmO.sub.2 flow 600 sccm ± 10% 700 sccm ± 10% 750 sccm ± 10% 425 sccmSuscept. Temp. >390-410° C. >390-410° C. >390-410° C. 390° C.Spacing 200-300 mil 300 mil ± 10% 300 mil ± 10% 190 milDeposition Rate 50-60 Å/min. 20-30 Å/sec. 5-10 Å/sec. 125 Å/sec.Uniformity (1σ) ±3% ±2% ±7% ±3%__________________________________________________________________________
Applicant hypothesizes that the deposition process involving a precursor, such as TEOS, involves two types of reactions: (1) a gas-phase reaction in the plasma and (2) a surface reaction upon the substrate. In the gas-phase reaction, TEOS and oxygen combine in the plasma. Oxygen radicals assist in the dissociation of TEOS and the burning-off of carbon and helium carrier-gas. The surface reaction may be described as providing a final landing place for silicon dioxide species where they may combine and form bonds. Furthermore, the surface reaction permits the desorption of undesirable species, such as carbon, silicon carbides, and Si--OH.
Applicant's process (especially for embodiments A and C) provides for an increase in the ratio of total plasma power to TEOS flow rate. The increased power makes the gas-phase reaction more efficient and provides for the "burning off" of undesired species. Furthermore, applicant's process provides for an increase in the oxygen to TEOS flow rate ratio. Naturally, one might expect to decrease the amount of TEOS if a slower deposition rate were desired. However, the decreased TEOS flow also means that undesirable carbonaceous materials inherent in the TEOS chemistry are provided to the reaction more slowly. Thus, the undesired materials may be more efficiently burned off, thus enhancing the quality of the deposited dielectric. It should be noted that in all three embodiments the total gas flow (TEOS plus oxygen) is approximately constant (carrier gas, such as helium, is not considered). One might be tempted to simply decrease both TEOS and oxygen in order to get a lower deposition rate. However, the resulting layer has been found to be not uniform. Alternatively, one might be tempted to decrease the flow of both gases and add an inert gas such as argon to maintain a total gas flow near 800 sccm. However, the argon may be incorporated in the resulting layer and degrade its properties.
The increased ratio of oxygen flow rate to TEOS flow rate is believed by applicant to be one of the most significant changes from standard process parameters for producing the desired layers. Thus, in a standard process, the ratio of TEOS flow rate to oxygen flow rate is approximately 425/380=1.1, whereas, the same ratio for applicant's process is no higher than ##EQU1## Furthermore, in applicant's process, the temperature of the substrate is slightly increased. A temperature increase to approximately 400°-410° C. is not generally significant in LPCVD reactions. However, the temperature increase is significant in PETEOS reactions. The increased temperature has been found to assist in converting Si--O to silicon dioxide. Furthermore, the increased temperature enhances the desorption reaction which facilitates elimination of Si--OH and carbonaceous materials. Applicant's process is also characterized by an increased wafer-to-showerhead spacing. (The showerhead is the multi-hole apparatus through which the TEOS, oxygen and carrier gas are dispensed.) The increased wafer-to-showerhead spacing means that species arriving at the substrate surface are less likely to contain undesired by-products of the TEOS dissociation.
Examination of Table 1 shows that the thickness uniformity of at least embodiments A and B is comparable to conventional processes. Such uniformity enhances manufacturability of the process. The somewhat poorer uniformity of embodiment C may be due to the presence of native oxide (of uneven thickness) which becomes a more significant part of the resulting oxide than in other embodiments. The present invention is applicable to the formation of dielectrics, not only between conductive runners, but also between active transistor regions and first-level runners. Furthermore, the inventive principles are applicable to deposition of dielectrics from other precursors such as tetramethylcyclotetrasiloxane (C 4 H 16 Si 4 O 4 ) with the acronym "TMCTS," sold under the trademark "TOMCATS" by J. C. Schumacher, a unit of Air Products and Chemicals, Inc.
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A method for forming a thin high quality interlevel dielectric is disclosed. The dielectric is produced in a plasma reactor utilizing a precursor gas such as TEOS. Pressure, power, temperature, gas flow, and showerhead spacing are controlled so that a dielectric of TEOS may be deposited at 60-5 Å / sec, thus making formation of thin (800 Å) high quality dielectrics feasible.
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BACKGROUND OF THE INVENTION
This invention relates generally to ultra filtration and, in particular, to tubular membranes coupled in series to present a filtration module and to a method of preparing such a module.
Semi-permeable ultra filtration membrane devices have long been employed in both high pressure reverse osmosis and low pressure ultra filtration processes and systems. Typically, the membranes are formed into tubules and grouped together inside of a cylindrical vessel. Support members hold the tubules in spaced relationship and the assembly is referred to as a module. One or more modules may be used to concentrate or separate a wide variety of liquids and solids including polymeric emulsions or latices, body fluids, aqueous emulsions and low molecular weight solids such as urea and liquid solid systems such as a whey solution containing proteinaceous components. A typical material for constructing the semi-permeable tubular membranes is cellulose acetate.
The afore-mentioned modules may be arranged with their tubules in either series or parallel relationship depending upon the demands of the filtering process for which the module is used. Typically, a number of modules are joined together to accomplish the desired filtration.
There are known advantages to modules having their tubules arranged in series as opposed to a parallel arrangement. For example, where pressure drop is not a limiting factor, the pump sizing requirements for a given number of tubules arranged in series is substantially less than for the same number of tubules arranged in parallel. Another advantage of a series module is that cleaning of the inner surface of the filtration membrane may be accomplished by inserting properly sized spong balls into the fluid stream for passage through the tubules which make up the module. This sponge ball cleaning technique cannot be utilized reliably with a parallel arranged module since there is no assurance that fluid flow will carry sponge balls to each of the individual tubules.
There are, however, known disadvantages associated with a series arranged filtration module. The series arrangement requires a number of grommets and/or expanders as well as headers or U-bends, backup plates, and clamps. A typical series arranged ultra filtration module is shown and described in U.S. Pat. No. 4,309,287 issued Jan. 5, 1982. The large number of components which has heretofore been required for a series arranged filtration module not only increases the manufacturing cost of the module significantly over comparable parallel arranged modules, but also results in substantially increased potential for leakage with attendant increased maintenance costs. Another disadvantage of prior art constructions for series arranged ultra filtration modules is that the use of grommets, expanders and U-bends create uneven surfaces along the fluid path which can cause "hangup" of sponge balls utilized to clean the module. In applications where periodic sponge ball cleaning is required, however, the series arranged module is employed.
OBJECTS OF THE INVENTION
It is, therefore, a primary object of the present invention to provide an ultra filtration module and method of preparing same wherein the ultra filtration tubules are series arranged to minimize pumping requirements, but a single unitary header together with a single end plate is employed to accomplish the series arrangement as opposed to the much larger number of components needed to present headers of the prior art.
Another important objective of my invention is to provide a series arranged filtration module and method of constructing same wherein the filtration tubules are joined by casting a potting compound in place around the tubules to assure a fluid tight seal without the need for multiple coupling components as has characterized prior art series arranged filtration modules.
Still another one of the objects of this invention is to provide a series arranged filtration module which has a much smaller number of components than previous series arranged modules thereby decreasing the opportunities for leakage within the module and reducing maintenance costs.
A very important aim of my invention is also to provide a series arranged filtration module and method of producing same which, by reason of the relatively small number of components which make up the module, is significantly less expensive to manufacture than series arranged modules of the prior art.
Other objects of the invention will be made clear or become apparent from the following description and claims when read in light of the accompanying drawing.
DESCRIPTION OF THE DRAWINGS
In the drawings, FIG. 1 is a top plan view of a mold for use in constructing a filtration module according to the present invention;
FIG. 2 is a side elevational view of the mold shown in FIG. 1;
FIG. 3 is a vertical cross-sectional view of a portion of the mold shown in FIG. 1 as it would appear in conjunction with two associated ultra filtration tubules;
FIG. 4 is a vertical cross-sectional view taken along line 4--4 of FIG. 1 together with the vessel and tubules which form the filtration module;
FIG. 5 is a side elevational view with portions broken away and shown in cross-section of a filtration module constructed according to the method of the present invention;
FIG. 6 is a vertical cross-sectional view taken along line 6--6 of FIG. 5;
FIG. 7 is a vertical cross-sectional view taken along line 7--7 of FIG. 6; and
FIG. 8 is a cross-sectional view of one of the end plugs utilized in the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In cross-flow membrane filtration where the present invention finds particular applicability, a solid tubular filtration vessel is provided with a plurality of ultra filtration tubules which extend lengthwise of the vessel. These tubules are held in spaced apart relationship for passage of the feed stream therethrough. Oppositely extending inlet and outlet ports in the filtration vessel sidewall provide a passageway for permeate to pass out of the module. It is to be understood that a plurality of modules may be arranged in interconnected relationship, but in the interest of brevity only a single module will be described herein.
Referring initially to FIG. 5 of the drawings, a filtration module constructed according to the present invention is designated generally by the numeral 10. Module 10 includes an elongated generally cylindrical filtration vessel 12, a plurality of ultra filtration tubules 14, end plugs 16 and end plates 18.
With reference to FIGS. 4 and 5, vessel 12 comprises an elongated rigid cylindrical member 20 that is open-ended and includes end couplings 22. Each end coupling 22 is identical and includes an outwardly flared bell end for receiving one end of member 20. An appropriate adhesive or other bonding means is employed to rigidly secure the couplings 22 to the member 20. Bell end 24 of coupling 20 is integral with a cylindrical body portion 26 having an integral arm 28 which extends from the longitudinal axis of vessel 12 at an angle of 90° . Arm 28 has a flared end 30 which defines an opening 32 (FIG. 4). A groove 30a is provided in the outwardly facing surface of flared end 30. At the end of coupling body 26 opposite bell end 24 is outwardly flared and provided with a thickened wall section 34 to provide additional structural strength. A sealing groove 34a provided in the end surface of the thickened wall 34.
With reference to FIGS. 1-3, the mold member which forms end plug 16 will now be described. It is to be understood, of course, that in the method of the present invention two mold members will be employed, but as they are identical only one will be described in detail at this time. A mold member is designated generally by the numeral 36 in FIG. 2 and includes a generally planar section 38 having opposed circumferentially extending sealing rings 38a and 38b. Integral with planar section 38 and extending therefrom at an acute angle are coupler components 40 one of which is shown in detail in FIG. 3. Each component 40 includes a generally cylindrical base portion 42 from which extends two integral generally conical sections 44 that are connected by a bight section 46. Each conical section 44 has a base end 44a which is generally cylindrical and is positioned immediately on top of base portion 42. As is apparent from viewing FIG. 3, the entire coupler component 40 is of an open or hollow construction.
A modified coupler component 140 (FIGS. 1 and 2) comprises a base portion 142 and a single conical section 144. Conical section 144 has a generally cylindrical base section 144a that is positioned immediately on top of base portion 142. Base portion 142 is substantially identical to the base portion 42 previously described except slightly less than half the diameter and conical section 144 is substantially identical to the section 44 previously described. There being only a single conical section 144 on base 142, there is no need for any component corresponding to bight section 46 of component 40. A plurality of tabs 48 extend from planar section 38 in the opposite direction from components 40 and 140 and provide means for grasping the mold to extract it from vessel 12 after use.
In carrying out the method of the present invention, vessel 12 is provided along with two mold members 36 which are sized to be received in the open ends of the vessel with a sealing ring 38a received in a groove 34a. After one mold member 36 has been placed in position, the ultra filtration tubules 14 (FIGS. 4 and 5) are positioned with one end being received by the conical sections 44 and 144. The tubules are sized to provide a close friction fit between the tubule and the base portion of the generally conically shaped sections 44 and 144 as best illustrated in FIG. 3. Once all of the tubules are in place, the second mold member 36 is brought into position to close the opposite end of vessel 12 in the same manner as previously described for tne first mold member. It should be noted that care is taken in positioning both mold members to align the single conical section 144 with the inlet tubule at one end and the outlet tubule at the opposite end.
Next, vessel 12 is oriented to a vertical position. As shown in FIG. 4, a nozzle 50 is positioned inside of vessel 12 through opening 32 and a moldable material 52 is injected through the nozzle into the bottom of the vessel. An epoxy resin is preferred for the moldable material because of its many desirable properties including bonding and compressive strengths, relatively fast hardening time and inert characteristics relative to most materials to which ultra filtration techniques are applied. Other moldable materials can, of course, be utilized. Material 52 is injected into the vessel until it completely covers mold member 36 and extends upwardly along the tubules 14 a sufficient distance to assure that a fluid tight seal will be formed when the material hardens Once material 52 hardens, an end plug 16 is presented. As best understood from viewing FIGS. 6, 7 and 8, end plug 16 partially presents a plurality of distinct unitary U-shaped conduit couplings 56 between adjacent pairs of tubules 14. Each coupling includes generally cylindrical leg sections 58 separated by a partition wall section 60 and joined together by a bight section 62. End plug 16 also surrounds inlet tubule 14 and presents an inlet opening 64 in communication therewith. After material 52 has hardened and end plug 16 has been formed, mold member 36 may be immediately removed or it may be left in place until the second end plug is formed and the two mold members removed substantially simultaneously.
In any case, after forming the first end plug, vessel 12 is oriented to a second vertical position wherein the two ends are rotated 180° from the first position previously described. Thus, the second end will be in the identical position shown in FIG. 4 for the first end and again a moldable material 52 is introduced into the bottom of the vessel through opening 32 by means of nozzle 50. The moldable material is again added so as to completely cover the second mold member 36 as well as the ends of tubules 14 over a sufficient portion of their length so as to assure formation of a fluid tight seal.
Material 52 is allowed to harden to present a second end plug 16 identical to the end plug previously described. In the case of the second end plug, the unitary opening 64 previously designated as an inlet opening serves as an outlet opening and is coupled with the outlet tubule 14. In this regard, it is to be noted that, by carefully selecting the spatial orientation of coupler components 40 in mold 36, and by rotating the position of the second mold member in the vessel approximately 15° relative to the rotational position of the first mold member in the opposite end of the vessel, the same mold configuration can be employed for both molds.
After the second end plug 16 has been formed, the second mold member 36 is removed from vessel 12. The exposed ends of the plugs 16 are then covered by first and second solid end plates 18. A gasket seal 66 of elastomeric material seats on the end surface of thickened wall section 34 and the end plate is held in place by conventional means such as an appropriate clamp (not shown). Each end plate 18 has an outwardly projecting nipple 68 which presents an opening 70 which registers with opening 64 and thus serves as either an inlet or an outlet opening depending upon which end of vessel 12 is involved. As best appreciated from viewing FIG. 7, each end plate 18 cooperates with an end plug 16 to complete the U-shaped conduit couplings 56 by providing an end wall or cover for each of the conduit bight sections 62.
In a typical installation, the feed stream of a fluid to be filtered enters vessel 12 through opening 70 at the right-hand side of FIG. 5 and passes through each of the individual tubules connected in series before ultimately passing out of the vessel as concentrate through the outlet opening presented by nipple 68 in the second and opposite end plate 18. Permeate exits vessel 12 through arm 28.
During utilization of module 10, the interior surface of the ultra filtration membrane will become clogged with foulants which will reduce the throughput of the module. To maintain maximum flow-through volume as well as the efficiency of the filtration process, small balls of sponge-like material 72 (FIGS. 5 and 7) are periodically introduced into the module to scour the inner membrane surface. Manifestly, the diameter of the sponge ball is carefully selected so that it will gently but effectively engage the inner surface of the tubule to scour it and remove foulants. Because of the unitary construction of the filtration module, the sponge balls 72 move through the filtration path with reduced danger of becoming trapped in one of the U-couplings 56 when compared with prior U-shaped connections for series arranged modules.
From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth as well as other advantages which are likely to become apparent upon utilization of the invention in commercial applications.
It will be understood that certain features and subcombinations of the invention disclosed are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
Since many possible embodiments may be made of the invention without departing from the scope thereof, it is understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
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A filtration module of tubular members in series and method of preparing same. The tubules are arranged in series and are joined by a unitary header plate together with a single end plate. This construction eliminates the need for multple components used in the prior art devices thus reducing construction and maintenance costs and opportunities for leakage, and provides for faster and more effective cleaning.
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FIELD OF THE INVENTION
This invention relates to a novel safety shield for land based rotary drilling rigs. More particularly, the invention pertains to a portable, clam-shell style extendible leg safety shield which can be readily installed in the bottom of the cellar below the drilling floor and around the drill stem of an operational land based drilling rig, such as an oil or gas well drilling rig, when drilling the surface hole section of an oil or gas well when no conductor pipe has been preset.
BACKGROUND OF THE INVENTION
Drilling oil or gas wells with a drilling rig is a hazardous activity. One of the components of the drilling rig which creates a safety hazard to the workmen (roughnecks) is the exposed rapidly rotating drill stem. Regulators in certain jurisdictions have passed regulations which require employers to safeguard their workmen from accidentally coming into contact with moving parts of machinery or equipment that may be hazardous.
When an oil well is being drilled, it is customary, if the top layer of the formation to be drilled is gravel or if exceptional pressures are to be encountered, to set a conductor pipe in the hole extending the depth of the gravel to hold the gravel away from the drill stem or deal with the excess pressure. In other cases, however, where top formation gravel or exceptional pressures are not encountered, and to save time and money, the drill hole is started directly in the ground (spudded) and continues downwardly through the successive strata formations without a conductor pipe being set, until a suitable depth is reached to set the surface casing. The surface casing must be set in a competent formation and successfully cemented full length so that blow out preventers can be installed.
When an oil or gas well is being drilled, drilling mud is used to control formation pressures, cool the drill bit and remove formation cuttings (shale) generated by the rotating drill bit as it cuts downwardly through the strata formations. As the well is being drilled, the drilling mud is pumped downwardly through the interior of the rotating drill stem, which is hollow, and exits from the bottom of the rotating drill bit, which is of a diameter larger than the drill pipe. The drilling mud with shale cuttings returns to the surface in the annular space between the formation and the rotating drill stem. Since the returned drilling mud contains cuttings, the shale contaminated mud is pumped by a trash pump to a shale shaker where the shale is separated from the drilling mud. The mud from the shale shaker, with cuttings removed, is pumped by a mud pump to the top of the drill stem where it is again pumped down the interior of the rotating drill stem to the drill bit. The drilling mud is thus in continuous circulation while the well is being drilled.
When a drill hole is spudded without a conductor pipe being set, an annular space is created between the rotating drill stem and the surrounding ground. This annular space is usually filled with drilling mud which is being returned from the bottom of the hole. The drilling mud obscures the fact that there is an annular hole between the rotating drill stem and the surrounding ground.
While the well is being drilled, the rapidly rotating drill stem of the drilling rig and the annular hole in the ground around the rotating drill stem, as obscured by drilling mud, creates a potential safety hazard. Conditions under the platform floor are often wet and slippery from drilling mud and other debris that is spilled on the ground. Not infrequently, it is necessary for a rig worker to go below the drill deck and shovel or hose away debris and other unwanted materials from the area around the rotating drill stem. In such conditions, it is easy for the rig worker to lose his footing and fall, in some cases against the rotating drill stem and support apparatus. In other cases, the rig worker may inadvertently step into the obscured annular hole and contact the rotating drill stem or get his clothing caught in the rotating drill stem. Serious injury to the worker can then result. Sometimes, electrical equipment with electrical cord has to be taken below deck. The cord can become entangled in the rotating drill stem. Another problem that can occur in the drilling of oil wells is that unwanted articles can fall down the well bore. In such cases, drilling has to undergo a costly shut down while the unwanted articles are fished from the well bore.
U.S. Pat. No. 3,322,198, W. L. McHendry, issued May 30, 1967, discloses a safety device for enclosing a blowout preventer that has been fitted with a rotating head (pack-off). It is a second shield for venting any dust particles or gas that may get by the pack-off unit in the event of expiry of the rubber pack-off element. A blowout preventer is used while drilling the main section of an oil or gas well and can only be installed after the surface hole section (a larger diameter hole) is drilled and the surface casing is set and cemented full length. The surface casing is then cut and a casing head (flange) is welded on. The blowout preventer is then installed on the casing head. The McHendry device is useful only when air or mist drilling is being done on the main drill hole section. Air or mist drilling reduces drilling costs by increasing penetration rates but can only be done in areas that are known not to have a risk of formation water entering the wellbore. When drilling with air or mist and water is encountered, the well must be then filled with drilling mud which is circulated back to the shale shaker in a conventional procedure. In such cases, the air or mist drilling method cannot be continued. The device disclosed by McHendry comprises a split closable hood adapted to be mounted on the drilling head. The hood has a pair of open end portions. One of the end portions includes a mechanism for clamping the hood in a substantially sealed relation about a portion of the drilling head. The other of the end portions includes a collar and a flexible baffle inwardly directed from the interior surface of the collar. The baffle has a hole therein for accepting the drill string of the well drilling apparatus and for permitting entry of air into the hood. Means for withdrawing air and particles from the interior of the hood for controlled disposal is also included. The safety device is designed to fit around the blowout preventer at a fixed elevation and does not have legs which enable the height of the safety device to be adjusted.
Canadian Patent Application No. 2,395,963, N. D. Denis, filed Sep. 6, 2002, discloses a mesh-like percussive or rotary rock drill guard that is designed to keep a driller or operator away from the rotating drill rod of a seismic drilling rig. The guard is mounted on a rock drill mast and is connected to the rotation lever of the drill. Doors mounted on the mast will automatically encase the complete drill and drill rod upon activating any rotation lever. The guard does not have extendible legs which enable the elevation of the guard to be adjusted or plumbed. Seismic drilling rigs are small and portable compared to oil well drilling rigs which employ heavy and massive equipment.
The foregoing examples of the general art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
SUMMARY OF THE INVENTION
The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
The invention is directed to a safety shield for use in association with rotary drilling rigs comprising: (a) a first protective shield; (b) a second protective shield associated with the first shield; (c) a first leg assembly connected to the exterior of the first shield; (d) a second leg assembly secured to the exterior of the second shield; and (e) a securing mechanism for securing the first shield to the second shield.
The first protective shield and the second protective shield can be formed in the shape of hollow conical half shells, which when placed together form a hollow truncated cone. The first protective shield and the second protective shield can be hinged together.
The first and second leg assemblies can be extendible. The first leg assembly and the second leg assembly can be secured to the exterior of the first and second half shells by a series of mounts.
The safety shield can include a pair of leg assemblies secured to the exterior of the first shell and a pair of leg assemblies secured to the exterior of the second shell. The safety shield can include a handle mounted on the exterior of the first shell and a handle mounted on the exterior of the second shell.
The first and second leg assemblies can be formed of an outer component and an inner second component which can be moved relative to the outer component. The outer component can have a slot therein and the inner component can have a handle which can protrude through the slot and enable the inner component to be moved in the slot relative to the outer component. The handle can be locked into position in the outer component. The outer component can have a lock slot therein in which the handle of the inner component can be locked.
In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.
BRIEF DESCRIPTION OF DRAWINGS
Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.
FIG. 1 illustrates a perspective view of the safety shield in a semi-open position.
FIG. 2 illustrates a front view of the hinged side of the safety shield, in a closed position.
FIG. 3 illustrates a side view of the safety shield.
FIG. 4 illustrates a top view of the safety shield.
FIG. 5 illustrates a bottom view of the safety shield.
FIG. 6 illustrates a front view of an inner and outer extendible leg assembly.
FIG. 7 illustrates a section of A-A taken through FIG. 6 .
FIG. 8 illustrates a cut-away view of an inner leg fitted inside an outer leg housing.
FIG. 9 illustrates an isometric view of an inner leg with handle.
FIG. 10 illustrates an isometric view of an outer leg housing with linear slot and lock openings.
FIG. 11 illustrates a detail taken of A-A of FIG. 10 of a part of an outer leg housing with slot and lock opening.
DETAILED DESCRIPTION OF THE INVENTION
Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
The device safety shield, according to the invention has a two part conical clam-shell construction and with adjustable length legs is adapted to be readily installed on the ground around the rotating drill stem below the floor of the oil well drilling rig. The shield provides a protective cover around the drill stem and ancillary drilling equipment and prevents a drilling rig worker (roughneck), when he goes below the drilling rig platform, from being injured by inadvertently stepping into the annular hole around the rotating drill stem, as obscured by the drilling mud, and contacting the rotating drill stem or contacting the drill stem with a shovel or other instrument and getting injured. The shield, particularly with an optional top screen, can prevent objects from falling down the drill hole, thereby avoiding an expensive “fishing” operation.
As seen in FIG. 1 , the rotary drill stem safety shield 2 is constructed of a first upright conically shaped half shell 4 and a second upright conically shaped half shell 6 , which are hinged together along one upright elongated side. Mounted on the exterior of the first conical half shell 4 are a pair of extendible leg assemblies, the first leg assembly 8 being fully visible, with the lower leg 22 of the second leg assembly also being shown. A pair of extendible leg assemblies are also mounted on the second conical half shell 6 , the second leg assembly 10 being fully visible and the leg 14 of the other assembly also being visible. The first leg assembly 8 is mounted on the exterior of the first conical half shell 4 by a short leg mount 16 at the top, a longer leg mount 18 at the bottom, and a pair of intermediate length leg mounts in between. As seen in FIG. 1 , the first leg assembly 8 extends outwardly in a downward direction at an angle to the first conical half shell 4 in a quadrapodal manner. The first leg assembly 8 is constructed of a hollow cylindrical outer first leg housing 20 with an extendible leg 12 protruding from the interior of the bottom of the first tubular leg housing 20 . The construction of the second leg assembly 10 is similar and includes a second hollow cylindrical leg housing 24 and a downwardly extendible leg 26 . The second leg assembly 10 is connected to the exterior of the second conical half shell 6 by a series of mounts 17 , 19 and intermediate mounts similar to mounts 16 and 18 and the intermediate mounts connecting the first leg assembly 8 to the first conical half shell 4 . The bottoms of the extendible legs 14 and 22 of the other two leg assemblies are secured to the first and second conical half shells 4 and 6 in the same manner as the first and second leg assemblies 8 and 10 .
The first conical half shell 4 and the second conical half shell 6 are hinged together along a vertical elongated side in clamshell-like manner by a series of hinges 28 . Alternatively, the hinges 28 can be latches with pins and receptacles. The vertical elongated sides of the first and second conical half shells 4 and 6 opposite the hinges 28 can be secured together by a series of latches 30 with extendible pins 32 arranged above one another on the free vertical side of shell 6 . When the shells 4 and 6 are closed together, the pins 32 fit within receptacles 34 which are arranged above one another on the free vertical side of shell 4 . One hand hold 36 is secured to each respective leg 12 , 14 , 22 and 26 . Hand holds are also secured to the exterior of the first and second conical half shells 4 and 6 , one of which is partially visible in FIG. 1 .
FIG. 2 illustrates a front view of the hinged side of the safety shield, in a closed position. As seen in FIG. 2 , the two half shells 4 and 6 and closed together and the vertical series of pins 32 are respectively secured in the corresponding series of receptacles 34 . A safety lock 38 , which can be closed and padlocked, is also shown between the top and middle latches and pins. FIG. 2 also shows the leg assemblies 20 and 24 , with legs 12 and 26 mounted on the exterior of the two half shells 4 and 6 by the series of mounts 16 , 17 , 18 and 19 . Handles 36 are also visible. The leg assemblies 20 and 24 are secured to the mounts 16 , 17 , 18 and 19 and intermediate mounts by a series of bolts 39 .
FIG. 3 illustrates a side view of the exterior of conical shell 4 of the safety shield. While FIG. 3 illustrates the same basic components that are shown and discussed in FIGS. 1 and 2 above. FIG. 3 also shows a lifting lug 40 at the top region of the half shell 4 , and a horizontal handle 42 at the bottom region of the half shell 4 . FIG. 3 is also notable for illustrating how the extendible inner legs 12 and 22 can be secured at various desired elevations in the interior of the cylindrical outer housings 20 by the handles 36 of inner legs 12 and 22 being moved in elongated slots 44 and rotated into lock slots 46 .
FIG. 4 illustrates a top view of the safety shield. FIG. 5 illustrates a bottom view of the safety shield. In particular, FIGS. 4 and 5 show the two half shells 4 and 6 , the four leg assemblies, the lifting lugs 40 and handles 36 on the two half shells. FIG. 4 also shows a variation of the safety shield where two sets of latches 30 , pins 32 and receptacles are used, one set replacing the hinges on one side. This configuration enables the two half shells to be separated from one another for shipping, storage or other purposes.
FIG. 6 is a front view of an inner and outer leg assembly. As seen in FIG. 6 , the cylindrical outer leg housing 20 is secured to one side of an elongated plate 48 by welding or other securing techniques. The inner extendible leg 12 is square in cross-section and extends out of the interior of the outer cylindrical leg housing 20 . FIG. 7 is a section view taken along section lines A-A of FIG. 6 and shows outer housing 20 , plate 48 and bolts 39 .
FIG. 8 is a cut-away view of an inner leg 12 with protruding handle 36 . FIG. 9 is an isometric view of the inner leg 12 with handle 36 , showing the square cross-section.
FIG. 10 is an isometric view of an outer leg housing 20 with linear slot and lock openings. FIG. 11 is a detail A-A of FIG. 10 showing a part of an outer leg housing with slot and lock opening. FIGS. 10 and 11 illustrate the longitudinal slot 44 that extends the length of the outer leg 20 and enables the handle 36 of the inner leg 12 to be moved longitudinally in the outer leg 20 . When the inner leg 12 is positioned within outer leg 20 at the desired degree of protrusion by moving handle 36 , the handle 36 is rotated 90° into the pair of L-shaped slots 46 to lock the inner leg 12 into position.
EXAMPLE
A prototype of the safety shield has been constructed and tested on an oil rig. The prototype safety device is 4 ft. tall, has a 14 in. inside diameter top and a 20 in. inside diameter bottom with the appearance of an inverted hollow cone. The safety device was constructed in the form of two conical half shells which are hinged together for installation around the drill string of the oil or gas drilling rig when drilling the surface hole stage of the procedure and a conductor pipe has not been preset. The two half shells were secured together by pins through pin pockets. Once installed, the four legs were extended down to elevate the device two feet above ground level. This leaves a space which is necessary for enabling return drilling fluid (mud) to flow under the device to the trash pump to the shale shaker.
The prototype was constructed of aluminum alloy material for lightness, with the only exception being the securing pins, which are of stainless steel to resist corrosion.
The safety device, when installed on the ground below the drill rig platform, provides a protective wall between any worker in the area, the rotating drill string and the annular hole between the drill string and the surrounding ground.
As an option, a 17 inch wide “pipe wiper (stripper)” was installed over the drill string to prevent undesired iron or articles from being dropped down the wellbore, therefore avoiding costly “fishing operations”. The safety device is ideal for use on new wells that have not previously been drilled and cased with a cemented in “conductor pipe”.
While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.
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This invention relates to a novel safety shield for rotary drilling rigs. More particularly, the invention pertains to a portable, clam-shell style extendible leg safety shield which can be readily installed on the ground around the drill stem of an operational drilling rig, such as an oil well drilling rig. A safety shield for use in association with rotary drilling rigs comprising (a) a first protective shield; (b) a second protective shield hinged to the first shield; (c) a first leg assembly connected to the exterior of the first shield; (d) a second leg assembly secured to the exterior of the second shield; and (e) a securing mechanism for securing the first shield to the second shield.
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RELATED APPLICATIONS
This application claims the benefit of Korean Patent Application No. 10-2013-0074203, filed on Jun. 27, 2013, which is hereby incorporated by reference as if fully set forth herein.
FIELD OF THE INVENTION
The invention relates to a voltage clamp step-up boost converter, and more specifically, to a voltage clamp step-up boost converter that removes the configuration of a dissipative snubber using a resonant clamp capacitor.
This work was supported by the MSIP (Ministry of Science, ICT and Future Planning) and NIPA (National IT Industry Promotion Agency) in Korea under Project 2013-H0301-13-2007 [Technology Research for Energy-IT Convergence].
BACKGROUND OF THE INVENTION
Recently, various power supply units used to boost a low DC voltage are being developed for electronic devices based on a fuel cell or battery. In particular, a boost converter using a tapped inductor is launched in the market in order to satisfy a high boost ratio, high power conversion efficiency, and low manufacturing cost.
The boost converter using the tapped inductor is manufactured by adding the tapped inductor serving as a transformer to the boost converter. In connection with the boost converter using the tapped inductor, Korean Patent Publication No. 2010-0082084 A (laid-open published on Jul. 16, 2010) discloses a method of embodying a zero-voltage turn-on and zero-current turn-off function by using a tapped inductor of the boost converter.
In the boost converter using tapped inductor, it is possible to obtain a high boost ratio, but an inductor and a capacitor of a switch causes an occurrence of resonance when the switch is turned off. As a result, a surge voltage is generated across the switch, which incurs an excessive stress on the switch. Hence, the boost converter using tapped inductor needs to use a high withstand voltage diode and a dissipative snubber.
SUMMARY OF THE INVENTION
In view of the above, the present invention provides a voltage clamp step-up boost converter that is capable of reducing voltage stress on a switch and a diode of the boost converter without using a dissipative snubber and that is capable of reducing a switching loss while maintaining a high input-to-output boost ratio. However, the technical subject of the embodiment of the present invention is not limited to the foregoing technical subject, and there may be other technical subjects.
In accordance with an aspect of the embodiment, there is provided an apparatus for a voltage clamp step-up boost converter comprising: a leakage inductor having a first end connected to a power supply unit; a tapped inductor having a first end connected to a second end of the leakage inductor; a magnetizing inductor having a first end connected to the second end of the leakage inductor and a second end connected to a second end of the tapped inductor; a switch having a first end connected to the second end of the tapped inductor and a second end connected to a second end of the power supply unit; a first diode having a first end connected to the second end of the tapped inductor; a second diode having a first end connected to a second end of the first diode and a second end connected to a third end of the tapped inductor; a resonant clamp capacitor having a second end connected between the second end of the first diode and the first end of the second diode and a first end connected between the first end of the power supply unit and the first end of the leakage inductor, the resonant clamp capacitor being configured to perform the clamping of the voltage across the switch and zero-voltage switching thereof when the switch is turned-off; an output capacitor having a first end connected to the second end of the second diode and a second end connected to the second end of the switch; an output load resistor having a first end connected to the first end of the second end of the output capacitor and a second end connected to the output capacitor; and a blocking capacitor having a first end connected to the third end of the tapped inductor and a second end connected to the second end of the second diode, wherein when the switch is turned-on, the voltage clamp step-up boost converter is configured to form a conductive path through the power supply unit, the resonant clamp capacitor, the blocking capacitor, the tapped inductor, and the switch and cause resonance through the resonant clamp capacitor and the leakage inductor with each other to decrease the voltage applied to the resonant clamp capacitor to a negative (−) voltage, thereby making the switch to be zero-current turned-on; and wherein when the switch is turned-off, the voltage clamp step-up boost converter is configured to form a conductive path through the leakage inductor, the tapped inductor, the first diode, and the resonant clamp capacitor to increase the voltage applied to the resonant clamp capacitor to a positive (+) voltage, thereby making the switch to be zero-voltage turned-off.
In accordance with any one of solutions to the aforementioned subject of the present invention, it is possible to reduce the voltage stress on a switch and a diode of the boost converter without using a dissipative snubber and to reduce a switching loss while maintaining a high input-output boost ratio.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent from the following description of the embodiments given in conjunction with the accompanying drawings, in which:
FIG. 1 is a circuit diagram of a voltage clamp step-up boost converter in accordance with an embodiment of the present invention;
FIGS. 2A to 2C are circuit diagrams illustrating other embodiments of a voltage clamp step-up boost converter shown in FIG. 1 ;
FIGS. 3A to 3N are circuit diagrams and timing diagrams of waveforms explaining the operation of the voltage clamp step-up boost converter shown in FIG. 1 ; and
FIGS. 4A and 4B illustrates experimental waveforms of the voltage clamp step-up boost converter of FIG. 1 and a prior art for the comparison between them.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings so that they can be readily implemented by those skilled in the art. However, the present invention may be embodied in different forms, but it is not limited thereto. In drawings, further, portions unrelated to the description of the present invention will be omitted for clarity of the description, and like reference numerals and like components refer to like elements throughout the detailed description.
In the entire specification, when a portion is “connected” to another portion, it means that the portions are not only “connected directly” with each other but they are electrically connected” with each other by way of another device between them. Further, when a portion “comprises” a component, it means that the portion does not exclude another component but further comprises other component unless otherwise described. Furthermore, it should be understood that one or more other features or numerals, steps, operations, components, parts or their combinations can be or are not excluded beforehand.
Hereinafter, the embodiments of the present invention will be described in detail with reference to the accompanying drawings.
FIG. 1 is a circuit diagram of a voltage clamp step-up boost converter in accordance with an embodiment of the present invention, and FIGS. 2A to 2C are circuit diagrams illustrating other embodiments of the voltage clamp step-up boost converter shown in FIG. 1 .
Before describing the embodiment of the present invention, a voltage clamp step-up boost converter 1 shown in FIG. 1 is defined functionally as follows.
The voltage clamp step-up boost converter 1 may include a boost converter, a tapped inductor, a resonant clamp capacitor, a blocking capacitor, and an output load resistor. Herein, reference numerals would not be assigned to the respective components of the voltage clamp step-up boost converter 1 because of a mere functional definition of them.
The boost converter serves to store current applied from a power supply unit in at least one inductor, add energy stored in the at least one inductor to the energy of the power supply voltage to deliver the added energy to an output end in accordance with on/off operations of a switch, and then output a boosted voltage through the output end.
The tapped inductor outputs an increased voltage based on a conversion factor, and the blocking capacitor is charged with the voltage in accordance with the on/off operations of the switch. In addition, the boosted voltage is applied to the output load resistor in accordance with the outputs from the boost converter, the tapped inductor, and the blocking capacitor. In the aforementioned configuration, the output load resistor may be incorporated into the boost converter, however, for the sake of convenience of explanation, the description thereof will be made separately.
Accordingly, the voltage clamp step-up boost converter 1 of the embodiment may have a high boost ratio by totaling all of the boost ratio of the boost converter itself, the boost ratio based on the turn ratio of the tapped inductor and the voltage charged in the blocking capacitor.
Hereinafter, the connection of the components in the voltage clamp step-up boost converter will be described in detail.
Referring to FIG. 1 , the voltage clamp step-up boost converter 1 may include a power supply unit 100 , a leakage inductor 210 , a magnetizing inductor 230 , a tapped inductor 300 , a switch 400 , a first diode 510 , a second diode 520 , a resonant clamp capacitor 600 , an output capacitor 710 , an output load resistor 730 , a DC blocking capacitor 800 , and an output diode 900 .
The leakage inductor 210 has a first end connected to the power supply unit 100 and a second end connected to the tapped inductor 300 and the magnetizing inductor 230 . The magnetizing inductor 230 has a first end connected to a second end of the leakage inductor 210 and a second end connected to a second end of the tapped inductor 300 .
The tapped inductor 300 has a first end connected to the second end of the leakage inductor 210 , a second end connected to a first end of the switch 400 , and a third end connected to a first end of the blocking capacitor 800 . The tapped inductor 300 may have a conversion factor of 1:N, where the first end of the tapped inductor becomes the primary side and the third end thereof becomes the secondary side. Like a transformer, the input-to-output conversion ratio of the tapped inductor 300 may be determined based on a coupling coefficient.
The switch 400 has the first end connected to the second end of the tapped inductor 300 and a second end connected to the second end of the power supply unit 100 . The switch 400 may be, for example, any one of a BJT (Bipolar Junction Transistor), a JFET (Junction Field-Effect Transistor), a MOSFET (Metal-Oxide Semiconductor Field-Effect Transistor), and a GaAs MESFET (Metal Semiconductor FET).
The first diode 510 has a first end that is connected to the second end of the tapped inductor 300 and a second end that is connected to a second end of the resonant clamp capacitor 600 and a first end of the second diode 520 . Further, the second diode 520 has the first end connected to the second end of the first diode 510 and a second end connected to the third end of the tapped inductor 300 .
The resonant clamp capacitor 600 has a second end connected between the second end of the first diode 510 and the first end of the second diode 520 . The resonant clamp capacitor 600 may be interposed for the voltage clamping across the switch 400 and the zero-voltage switching when the switch 400 is turned off. In this case, the first end of the resonant clamp capacitor 600 may be connected to a node to ensure that a constant voltage level is maintained. That is, the first end of the resonant clamp capacitor 600 is used as a clamp node, which may be connected to any node at which the constant voltage level is maintained. This will be explained with reference to FIGS. 2A to 2C .
Referring now to FIG. 2A , a resonant clamp capacitor 600 has a second end that is fixed between a first diode 510 and a second diode 520 . The resonant clamp capacitor 600 also has a first end that is freely connected to any one of points A, B, and C. The embodiment shown in FIG. 1 is defined as a case where the first end of the resonant clamp capacitor 600 is connected to a point A; an embodiment shown in FIG. 2A is defined as a case where the first end of the resonant clamp capacitor 600 is connected to a point B; and an embodiment shown in FIG. 2C is defined as a case where the first end of the resonant clamp capacitor 600 is connected to a point C.
When the first end of the resonant clamp capacitor 600 is connected to the point A, the arrangement corresponds to that illustrated in FIG. 1 . In this case, the first end of the resonant clamp capacitor 600 is connected between the first end of the power supply unit 100 and the first end of the leakage inductor 210 . When the first end of the resonant clamp capacitor 600 is connected to the point B, the arrangement corresponds to that illustrated in FIG. 2B . In this case, the first end of a resonant clamp capacitor 600 is connected between the second end of a power supply unit 100 and the second end of a switch 400 . When the first end of the resonant clamp capacitor 600 is connected to the point C, the arrangement corresponds to that illustrated in FIG. 2C . In this case, the first end of the resonant clamp capacitor 600 is connected between the second end of an output diode 900 and the first end of an output capacitor 710 .
The overall operations of the voltage clamp step-up boost converters illustrated in FIGS. 2A to 2C are substantially same one other, except the difference in the offset voltages applied to the resonant clamp capacitor 600 . Specifically, the offset voltage applied to the resonant clamp capacitor 600 of FIG. 2A may be lower than that of the resonant clamp capacitor 600 of FIGS. 2B and 2C . Therefore, the voltage clamp step-up boost converter 1 of the embodiment illustrated in FIG. 2A may exhibit the lowest withstand voltage property.
Referring back to FIG. 1 , the output capacitor 710 has a first end connected to the second end of the second diode 520 and a second end connected to the second end of the switch 400 . In addition, the output load resistor 730 has a first end connected to the first end of the output capacitor 710 and a second end connected to the second end of the output capacitor 710 .
The DC blocking capacitor 800 has a first end connected to the third end of the tapped inductor 300 and a second end connected to the second end of the second diode 520 . The output diode 900 has a first end connected to the second ends of the blocking capacitor 800 and the second diode 520 and a second end connected to the first end of the output capacitor 710 .
FIGS. 3A to 3N illustrate circuit diagrams and timing diagrams of waveforms explaining the operation of the voltage clamp step-up boost converter shown in FIG. 1 . Hereinafter, the operation of the voltage clamp step-up boost converter 1 having the foregoing configuration will be explained in detail with reference to FIG. 1 and FIGS. 3A to 3N .
Before explaining the operation, it is assumed for the convenience of the interpretation of the operation modes as follows:
i) the magnetizing inductor 230 has inductance as large as to ignore a current ripple caused by the magnetizing inductor 230 ; ii) the components of the voltage clamp step-up boost converter 1 of the embodiments are ideal; iii) the output capacitor 710 has capacitance as large as to ignore the voltage ripple of an output voltage Vo; iv) the blocking capacitor 800 has capacitance as large as to ignore the voltage ripple of a voltage V C applied to the blocking capacitor 800 ; and V) all operations are in steady-states.
Hereinafter, two terms in pairs will be designated as the same component such as the power supply unit 100 and V in ; the leakage inductor 210 and L Lk ; the magnetizing inductor 230 and L m ; the switch 400 and M; the first diode 510 and D 1 ; the second diode 520 and D 2 ; the resonant clamp capacitor 600 and Cs; the output capacitor 710 and Co; the output load resistor 730 and R O ; the blocking capacitor 800 and Cc; and the output diode 900 and D 3 .
Moreover, i pri means the primary side current of the tapped inductor 300 ; V LK means the voltage applied to the leakage inductor 210 ; V Lm means the voltage applied to the magnetizing inductor 230 ; i ds means current flowing to a drain and source of the switch 400 ; V sec means the secondary side voltage of the tapped inductor 300 ; V C means the voltage applied to the blocking capacitor 800 ; i sec means the secondary side current of the tapped inductor 300 (the waveform of i sec will be represented in an inverted form throughout FIGS. 3A to 3N for the sake of convenience); V D1 the voltage applied to the first diode 510 ; i D1 means the current flowing to the first diode 510 ; V S means the voltage applied to the resonant clamp capacitor 600 ; i CS means the current flowing to the resonant clamp capacitor 600 ; V D2 means the voltage applied to the second diode 520 ; i D2 means the current flowing to the second diode 520 ; V D3 means the voltage applied to the output diode 900 ; and i D3 means the current flowing to the output diode 900 .
FIG. 3A represents a conductive path in accordance with the operation of the voltage clamp step-up boost converter at t0˜t1. Referring to FIG. 3B , the switch 400 is in a turned-off state prior to t0, and the energy stored in the magnetizing inductor 230 is passed to the output end through the output diode 900 . At t0˜t1, the switch 400 become a turned-on state, a conductive path of the voltage clamp step-up boost converter is illustrated as in FIG. 3A .
As illustrated in the FIG. 3B , the voltage V ds across the switch 400 rapidly decreases from V o /(1+N) to 0V and at the same time the primary side current i pri of the tapped inductor 300 increases and the secondary side current i sec decreases (in view of its inverted waveform). Specifically, the secondary side current i sec slowly decreases to 0 A by the leakage inductor 210 (in view of its inverted waveform) and the magnetizing inductor 230 and the primary side current i pri slowly increases.
Therefore, because the current i pri -i sec which flows through the switch 400 gradually increases, when the switch 400 is turned on, the voltage V ds and the current i ds have a phase reversal relation enough not to overlap with each other in their waveforms, thereby reducing the switching loss.
FIG. 3C represents a conductive path in accordance with the operation of the voltage clamp step-up boost converter at t1˜t2. Referring to FIG. 3D , the operation of the voltage clamp step-up boost converter at t1˜t2 is started when the primary side current i pri gradually increases to become equal to the current i Lm of the magnetizing inductor 230 and the secondary side current i sec of the magnetizing inductor 230 becomes equal to 0 A. At this time, the output diode 900 is turned off and the second diode 520 is turned on, thereby forming the conductive path illustrated in FIG. 3C . Accordingly, the voltage applied to the blocking capacitor 800 becomes to reduce to −V in due to the resonance of the resonant clamp capacitor 600 and the leakage inductor 210 .
FIG. 3E represents a conductive path in accordance with the operation of the voltage clamp step-up boost converter at t2˜t3. Referring to FIG. 3F , the operation of the voltage clamp step-up boost converter at t2˜t3 is started when the voltage applied to the resonant clamp capacitor 600 reaches −V in . At this time, the first diode 510 is conducted, thereby forming the conductive path illustrated in FIG. 3E . In this case, because the switch 400 is in a turned-on state, the input voltage V in is applied to both of the leakage inductor 210 and the magnetizing inductor 230 . Accordingly, energy is stored in the magnetizing inductor 230 and simultaneously, NV in is charged in the blocking capacitor 800 with the turn ratio of the tapped inductor 300 .
FIG. 3G represents a conductive path in accordance with the operation of the voltage clamp step-up boost converter at t3˜t4. Referring to FIG. 3H , when the blocking capacitor 800 is fully charged, the first diode 510 and the second diode 520 are turned off as illustrated in FIG. 3G . Since the switch 400 is still turned on, the input voltage V in is applied to the leakage inductor 210 and the magnetizing inductor 230 as similar to FIG. 3C and thus energy is stored in the magnetizing inductor 230 .
FIG. 3I represents a conductive path in accordance with the operation of the voltage clamp step-up boost converter at t4˜t5. Referring to FIG. 3I , when the switch 400 is turned off, the conductive path is formed as illustrated in FIG. 3I and the current i Lm of the switch 400 is rapidly reduced to 0 A as illustrated in FIG. 3J . At the same time, the energy stored in the leakage inductor 210 and the magnetizing inductor 230 is charged in the resonant clamp capacitor 600 through the first diode 510 . Therefore, the voltage applied to the resonant clamp capacitor 600 begins to gradually increase from −V in . Further, the voltage across the switch 400 , which is represented as V in +V CS , gradually begins to increase from 0V. Accordingly, when the switch 400 is turned-off, the voltage V ds and the current i ds have a phase reversal relationship enough not to overlap with each other in their waveforms, whereby it is possible to reduce the switching loss.
FIG. 3K represents a conductive path in accordance with the operation of the voltage clamp step-up boost converter at t5˜t6. Referring to FIG. 3L , when the voltage V ds across the switch 400 reaches V O /(1+N), the output diode 900 is conducted and the resonant clamp capacitor 600 and the leakage inductor 210 cause resonance together. Therefore, the voltage V S of the resonant clamp capacitor 600 and the voltage V ds of the switch 400 increase as illustrated in Fig. L, and the current in of the first diode 510 becomes 0 after ¼ resonance cycle. Simultaneously, when the secondary side current i sec reaches i Lm /(N+1), the operation at the t5˜t6 is finished.
FIG. 3M represents a conductive path in accordance with the operation of the voltage clamp step-up boost converter at t6˜t7. Referring to FIG. 3N , when the secondary side current i sec reaches the i Lm /(N+1), the conductive path is formed as illustrated in FIG. 3M and the energy stored in the leakage inductor 210 and the magnetizing inductor 230 is passed to the output end. Thereafter, when the switch 400 is again turned on, the operation at t6˜t7 is finished.
The voltage relational expressions are derived in accordance with the aforementioned operations as follows.
First, let the operations at t0˜t2 and t4˜t6 be ignored for the convenience of deriving the voltage relational expressions related to the respective components off the voltage clamp step-up boost converter in accordance with the embodiment of the present invention.
The voltage V C is applied to the secondary side of the tapped inductor 300 for the duration DT S where the switch 400 is in a turned-on state whereas the voltage −(V o −V c −V in )N/(N+1) is applied to the secondary side of the tapped inductor 300 for the duration (1−D)T S where the switch 400 is in a turned-off state. Therefore, the following Equation can be derived by applying a voltage-time balanced condition to the secondary side of the tapped inductor 300 .
[EQUATION 1]
DT
S
V
C
=
(
1
-
D
)
T
S
N
N
+
1
(
V
O
-
V
C
-
V
in
)
By rearranging the Equation 1, V C can be expressed as the following Equation 2.
[EQUATION 2]
V C =NV in
In the meantime, the voltage V in is applied to an voltage V LM of the primary side of the magnetizing inductor 230 for the duration DT S where the switch 400 is in a turned-on state whereas the voltage −(V o −V in −V C )/(1+N) is applied to the voltage V LM of the primary side of the magnetizing inductor 230 for the duration (1−D)T S where the switch 400 is in a turned-off state. Therefore, the following Equation can be derived by applying voltage-time balanced condition to the primary side of the tapped inductor 300 .
[EQUATION 3]
DT S V in =(1 −D ) T S ( Vo−V in −V C )/(1 +N )
By substituting the Equation 3 with the Equation 2, the following Equation 4 can be derived.
[EQUATION 4]
V O = N + 1 1 - D V in
where V o represents an output voltage, V in represents an input voltage, N represents the conversion factor (or, turn ratio) of the tapped inductor, and D represents a duty ratio.
FIGS. 4A and 4B shows experimental waveforms of the voltage clamp step-up boost converter of FIG. 1 and a prior art for the comparison between them. Specifically, FIG. 4A shows an experimental result on the voltage clamp step-up boost converter of the present invention using a simulation tool.
The specification used in the simulation is as follows: the input voltage is 24V; the output voltage and electricity are 250V and 100 W, respectively; the inductance of the leakage inductor 210 is 10 μl; the inductance of the magnetizing inductor 230 is 100 μH; the turn ratio of the inductors is 1:4; and the capacitance of the resonant clamp capacitor 600 is 47 nF.
Referring to FIG. 4A , it can be known that regardless of the resonance caused by the inductor component of the tapped inductor and the parasitic capacitor, the voltage of each component is clamped by the input and output voltages. Further, the current of the switch 400 increases with a slow inclination when the switch 400 is turned on. Therefore, the waveforms of the voltage V ds across the switch 400 and the current i ds of the switch 400 are not overlap with each other. Meanwhile, the voltage of the switch 400 also increases with a slow inclination when the switch 400 is turned off. Therefore, the waveforms of the voltage V ds across the switch 400 and the current I ds of the switch 400 are also not overlap. Consequently, a very low switching loss is achieved in the actual implementation.
On the other hand, FIG. 4B shows an experimental result on the voltage clamp step-up boost converter of the prior art under the same condition. It can be seen from FIG. 4B that the diode and switch have high voltage stress with the resonance of the inductor component of the transformer and the parasitic capacitor. Particularly, it is observed that the magnitude of current of the magnetizing inductor in the tapped inductor is 7.5 A which is higher than the embodiment of the present invention with respect to the same output load. In addition, the prior art requires the winding number more than usual and a magnetic core having a large air gap and large size in order to prevent the saturation of the tapped inductor.
As set forth above, the voltage clamp step-up boost converter in accordance with the embodiments can be ensured to get the input-to-output boost ratio which is higher than the conventional tapped inductor boost converter by combining all of the turn ratio of the transformer, the voltage of the blocking capacitor, and the boost ratio of the boost converter itself. Especially, the voltage clamp step-up boost converter enables to make the zero current switching by means of the leakage inductance when switch is in a turned-on state and to make the zero-voltage switching by means of the resonant clamp capacitor when the switch is in a turned-off state, thereby significantly reducing the switching loss. Accordingly, the voltage clamp step-up boost converter of the embodiments enables to improve the system efficiency and heat generation.
Description of the present invention as mentioned above is intended for illustrative purposes, and it will be understood to those having ordinary skill in the art that this invention can be easily modified into other specific forms without changing the technical idea and the essential characteristics of the present invention. Accordingly, it should be understood that the embodiments described above are exemplary in all respects and not limited thereto. For example, respective components described to be one body may be implemented separately from one another, and likewise components described separately from one another may be implemented in an integrated type.
The scope of the present invention is represented by the claims described below rather than the foregoing detailed description, and it should be construed that all modifications or changes derived from the meaning and scope of the claims and their equivalent concepts are intended to be fallen within the scope of the present invention.
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An apparatus provides a soft-switched voltage clamp tapped-inductor step-up boost converter that is capable of reducing voltage stress on a switch and a diode of the boost converter without using a dissipative snubber and that is capable of reducing a switching loss while maintaining a high input-to-output boost ratio.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is generally directed to loudspeaker systems and more particularly to loudspeaker systems which use sound chambers which progressively propagate entering annular mid frequency sound waves concentrically about high frequency sound waves to an output wherein the mid frequency sound waves are substantially parallel on opposite sides of the high frequency sound waves.
2. Brief Description of the Related Art
Most loudspeaker systems for commercial or professional applications require more than one transducer. There are two common reasons for this that stem from the limits of transducer technology: limited bandwidth; and/or limited sound power output of individual transducers.
The limited bandwidth of transducers, when compared with the wide bandwidth of the human ear dictates the need for multi-way loudspeaker systems. The wavelengths of sound audible to us range from nearly sixty feet to less than three quarters of an inch in length. No single transducer can reproduce this range of frequencies with acceptable levels of both distortion and efficiency.
The limited sound power capacity of a single multi-way loudspeaker unit when compared to the sound power and distribution required for large venues, dictates the need for multi-unit loudspeaker groups or arrays. This is the case in nearly all commercial use or professional loudspeaker systems. For the purposes of this discussion, multiple units of multi-way loudspeakers will be considered.
Clarity, referred to also as intelligibility and speech intelligibility, is affected by the degree to which the loudspeaker reconstructs the temporal and spectral response of the reproduced wavefront. Interference in the perception of that wavefront can be caused by environmental reflections of sound waves bearing the same spectral information which arrive near in time to the beginning of the wavefront.
Coherence of a wavefront refers to the degree to which the loudspeaker reconstructs the temporal response of the reproduced wavefront.
Uniformity of distribution refers to the similarity in the temporal and spectral nature of the reproduced sound when considered spatially.
Correction of the sound spectrum through equalization is easily achieved with signal processing equipment. Correction of the temporal aspects of sound referred to as impulse response equalization is considerably more complex. Correction of the spatial distribution of sound energy, after the sound has exited the loudspeaker system is not possible.
To fully understand all aspects concerning clarity in large loudspeaker systems, it is necessary to consider issues beyond those limited to the temporal and spectral performance of individual transducers and their related enclosures or waveguides. Wavefront coherence and uniformity must be considered concerning several aspects of the multi-way structure and the multi-unit array. In the multi-way loudspeaker the additional issues are twofold; the reconstruction of complex waveforms from two or more transducers not physically occupying the same location that reproduce different parts of the spectrum; and the temporal interference that occurs in the region of spectral overlap between transducers. In the multi-unit array a further consideration is added: the temporal interference between multiple transducers working together to reproduce the same part of the spectrum.
Complete and uniform energy summation occurs when two or more simple cone loudspeakers produce sound waves of the same frequency which propagate into the same space, where the wavelength propagated is approximately equal to or greater than the spacing of the loudspeakers. In cases such as this the devices are said to be mutually coupled; multiple devices work nearly as a single device.
Complex patterns of summation result in reduced spatial uniformity and lost efficiency when two or more transducers produce sound waves of the same frequency which propagate into the same space, where the wavelength propagated is smaller than the spacing of the transducers. These patterns are not easily integrated in systems and most often, the result is reduced coherence of the wavefront and therefore reduced sound quality.
It is evident that a useful approach to the problem of summation is to physically limit or eliminate the negative interaction between adjacent transducers through the design of wavefront modifying or directivity controlling mechanical geometry through which the sound waves are propagated. The mechanical control of such interactions are therefore of great interest in the development of better loudspeaker arrays.
From the ideal loudspeaker system, sound would appear to the listener as though it came from a point source floating in space. This goal is approachable in a single multi-way loudspeaker, but impossible in a large sound system. Nevertheless, audio engineers have sought over the years to come as close to the goal as possible through a number of interesting innovations.
In small systems, it can be said generally that for best coherency, the physical spacing between transducers of differing frequency ranges should be kept as small as possible. Whereas in large systems, more attention should be paid to the physical relationship between transducers operating in the same frequency range due to the overall size of the array.
The evolution of the co-axial loudspeaker has resulted in improved coherency in two-way systems. A typical variation is a two-way device consisting of a high frequency compression driver mounted on the back plate of a woofer magnet, so configured to allow the sound from the high frequency driver to pass through the woofer and emerge at the center of the cone of the woofer. The passageway through the low frequency magnet combined with the woofer cone, or other small horn device, serve to guide the high frequency energy. The addition of time compensation in the signal path to correct for the physical displacement of the two sound sources produces something very close to the ideal. In this described configuration a direct radiator is combined with a horn loaded driver.
However, the directivity cannot be controlled to the extent that might be desired at all frequencies in such a loudspeaker. Furthermore, a substantial part of the benefit of point source approximation is lost when multiple co-axial speakers are configured in an array spaced on the centers of the woofer. The larger size of the woofer may result in the space between high frequency drivers increasing beyond the dimension allowed by the smaller high frequency drivers, thus aggravating the interference problem between the high frequency components. It is evident that the co-axial driver can improve coherence in a small system, but where large multiples are deployed, no significant gain is likely to occur.
The recently introduced co-entrant horn disclosed in U.S. Pat. No. 5,526,456 to Heinz is a two way, mid frequency and high frequency horn loaded variation on the co-axial loudspeaker. In this variation, the high frequency compression driver is mounted on the back plate of a mid frequency compression driver magnet, so configured to allow the sound from the high frequency driver to pass through the mid frequency device and emerge through the center of the diaphragm of the mid frequency driver. The energy from the mid frequency diaphragm enters the throat of the horn through an annular slot adjacent to the high frequency opening. With suitable time compensation to align the acoustic output of the two devices in the time domain, the result is similar to the co-axial loudspeaker, but with the added advantages of increased mid frequency efficiency and control of mid frequency directivity through the horn loading of that band of energy. However, the discontinuity in the high frequency throat caused by the mid frequency entrance to the throat of the waveguide is quite close to the high frequency driver diaphragm. If the discontinuity is within one quarter wavelength of a given frequency, energy reflected back to the diaphragm will arrive at the half wave interval fully out of phase and cause disruptions in response.
The improvement in the relationship between the two elements within the device, is offset by increased spacing between the high frequency drivers in an array caused by the size of the mid frequency horn. In large arrays therefore, no improvement in high frequency coherence or uniformity of distribution is likely to occur.
Coherency in loudspeaker arrays is a far more complex problem than that of coherency in the single multi-way loudspeaker. Firstly because of the potential size and number of elements to be found in arrays and secondly because of the more difficult acoustic environment and listener configuration in which arrays are typically applied.
Large numbers of transducers are required in large and small auditoria, compounding the problems of spatial distribution and coherence. Where the system design specifies such loudspeakers to be widely distributed throughout the environment, the state of the art with respect to loudspeakers seems sufficient.
Wide distribution throughout the listening space is generally not acceptable where a large public sound system is oriented to music or speech performance. The acoustical focus of the audience, is in most cases, the stage. It is then a primary requirement that an array of multiple speaker enclosures will be placed in close proximity with one another in front of and facing the audience in order to complement that focus. Generally there are at least two arrays of loudspeakers flanking the stage. It is equally inevitable that the interactions between loudspeakers within each array will play a significant role in the outcome.
The consideration of wavelength is preeminent in the science of sound: all sound phenomena are at least in some aspect wavelength dependent. Design considerations with respect to loudspeaker interaction in large arrays are in fact dominated by consideration of wavelength.
First, the wavelength of any frequency under consideration in the array will determine in which frequency range the individual transducers are coupled with one another and in what range they are interfering. Secondly, the directivity of any device is wavelength dependant; the directivity will determine the degree of angular overlap of adjacent wavefronts and therefore the degree of potential acoustical interference.
Wavelength variation of three orders of magnitude over the audio spectrum assures us that no one transducer can possess the same radiation characteristics over the whole audio spectrum. In fact, even when the spectrum is divided into three separate frequency ranges, most transducers operating even within these reduced bandwidths demonstrate a continuous change in the radiation pattern of their acoustic energy with changing frequency.
While a phenomenon can be useful in one frequency range, it may be detrimental in another. One effect, destructive interference, is generally just that. However, this phenomenon can also be used to limit unwanted energy beyond the edge of an area of desired coverage, such as with a di-pole radiator.
Another effect, mutual coupling, while generally regarded as a positive with respect to efficiency and wavefront coherence, can also be a hindrance when beam width narrows excessively. Coupling between drivers, combined with electrically induced phase shift is also responsible for the undesirable effect of beam tilting through the crossover region between two drivers. Mutual coupling occurs when drivers are placed within approximately one wavelength of one another. See Olson, Elements of Acoustical Engineering, 1944 Van Nostrand and Co.
In a line array (Olson et al) in its simplest form, a row of closely spaced direct radiators, is dependant on mutual coupling of one driver to the next. Historically, line arrays have consisted of multiple small direct radiating transducers arranged in a vertical row. Typically the drivers are chosen to be sufficiently small to allow mutual coupling to the highest frequency of concern. For example four inch diameter drivers permit coupling to above 3 Khz, which is sufficient to allow good speech intelligibility. This approach yields a system with a controlled vertical coverage and correspondingly wide horizontal coverage.
Another variation on the line array is a vertical column of high frequency compression drivers mounted on horns with narrow vertical beam width. However, the mutual coupling is limited to a small portion of the lower range of the high frequency transducer.
The ribbon tweeter can be considered a line array of nearly infinite elements, with all the attendant benefits. However, limits in sensitivity and power handling capacity have not permitted the ribbon tweeter to replace the preeminent position of the high frequency compression driver in systems for large spaces.
Spatial distribution of energy within the listening environment has increasingly become the focus of efforts by practitioners of the audio arts. The result of this effort is a number of novel innovations.
Very old established principles which define the line source of Olson et al. are now being combined with significant new trends including new geometry for the purpose of modifying high frequency wavefronts. See for example U.S. Pat. Nos. 5,163,167 to Heil and 5,900,593 to Adamson.
In the interests of improved coherence, spatial distribution and frequency response, a number of high power, high fidelity line array variations have recently been introduced. These multi-way systems all approach the different frequency bands with different technology. While most of these new concepts rely on prior art in the direct radiator portion of the array, several new concepts have emerged in the effort to create line arrays to the highest discernable frequency.
The prior art patents to Heil and Adamson reveal high frequency acoustic sound chambers (that are sometimes referred to as waveguides) capable of wavefront transformation to the highest audio frequencies, for use with compression drivers and waveguides. The output of such devices provide an essentially continuous ribbon of coherent high frequency sound. When placed end to end, even in large arrays, high frequency coherency is maintained. This high frequency solution is seen in curved horizontal and vertical arrays in Adamson and flat vertical arrays in Heil.
Other high frequency sections of new line arrays consist of a previously described simple vertical row of conventional high frequency horn and driver units.
In the mid frequency range significant unresolved problems are apparent. Two general categories of solution are now in use: horn loaded and direct radiator systems. The benefits and limitations of these solutions must be considered with respect to vertical and horizontal arrays.
When direct radiators are used in a mid frequency vertical array, it is not regarded as a suitable solution to place a single mid frequency line array beside a high frequency array. The lack of horizontal symmetry will result in undesirable variations in frequency response across a horizontal section of the array. A more likely solution is to place two vertical line arrays spaced equidistant from a central high frequency line array.
However, due to upper frequency requirements of the mid frequency direct radiators, a maximum size limitation is imposed. This size limitation is incompatible with the demand for substantial acoustic power in the mid band. In such applications, the direct radiating mid frequency devices cannot match the acoustic output of the more efficient high frequency combination of waveguide and compression driver.
Furthermore, the horizontal spacing between the two vertical line arrays of mid frequency devices introduces a special set of limits due to the behavior of the two sound sources. When the two line arrays are spaced at the half wavelength of a given frequency, the energy from one line array arrives at the other 180 degrees out of phase and a cancellation of energy occurs. At higher frequencies the wavefront is divided into a number of narrow lobes due to variable summation between the two sources. While some control of directivity is achieved the gain is offset by losses due to the cancellations, which further reduce the efficiency of the direct radiators.
Much higher efficiencies can be achieved with horn loaded mid frequency, but the typical horn loaded horizontal or vertical arrays results in significant increases in driver to driver spacing. In such systems the mid section behaves as a coupled line array only in the lower half of the spectrum handled by the transducer. Above that frequency the array performs somewhat like a row of point source radiators with all the associated patterns of interference.
When the mid frequency is horn loaded in two columns placed symmetrically about the high frequency array, off axis problems arise due to the differing acoustic centers of the midrange and high frequency arrays. These problems arise due to the physical size of such devices.
In the case of three-way systems where a low frequency section is employed, there are few problems with conventional horizontal and vertical line arrays since these long wavelengths permit mutual coupling with conventional 12″, 15″ and 18″ woofers in the appropriate frequency ranges. Acoustic efficiencies and wavefront shape present few problems.
SUMMARY OF THE INVENTION
The present invention is comprised of a plurality of loudspeaker enclosures arranged in a horizontal or vertical array, where each enclosure must contain at least one high frequency compression driver and at least one inner sound chamber similar to that disclosed in U.S. Pat. No. 5,163,167 to Heil or as disclosed in U.S. Pat. No. 5,900,593 to Adamson or other high frequency throat piece as required to connect a high frequency driver to a waveguide, and at least one mid frequency driver and at least one outer mid frequency sound chamber so shaped to substantially enclose the inner high frequency sound chamber within the mid frequency sound chamber, whereby the inner surface of the outer sound chamber and the outer surface of the inner sound chamber form an acoustic passageway whose input orifice is annular and whose output orifices approximates two parallel slots of approximately uniform width which may be curved or flat. The enclosure may contain an extension of the high frequency sound chamber and the mid frequency sound chamber to further direct the sound waves after the exit of the sound waves from the high frequency and mid frequency sound chambers.
Where the loudspeaker enclosures are arranged in a vertical array the vertical cross section of the enclosure may be trapezoidal or rectangular and where the loudspeaker enclosures are arranged in a horizontal array the horizontal cross section of the enclosure may be trapezoidal or rectangular.
In the present invention there are no differences in principle or geometry between a horizontal array and a vertical array. The horizontal array is a simple 90 degree transformation of the vertical array and vice versa. Depending on the desired application, various embodiments may be constructed and oriented in any desired angle to suit the desired application.
In the typical embodiment the high frequency driver is fixed to the back plate of the magnet assembly of the mid frequency driver and is so placed to be concentric with and axially aligned to the mid frequency driver and the high frequency sound chamber is aligned axially and affixed concentrically to the front side of the mid frequency magnetic assembly which is so constructed to allow high frequency sound to pass through the magnetic structure of the mid frequency driver and to enter into the entrance of the high frequency sound chamber.
The mid frequency sound chamber is fixed to the front side of the mid frequency driver and is so placed to be concentric with and axially aligned to the mid frequency driver and is so shaped to form at least one passageway which is defined by the outer surfaces of the outer walls of the high frequency sound chamber and the inner surfaces of the inner walls of the mid frequency sound chamber with the at least one passageway extending from the annular input orifice to the rectangular output orifice of the mid frequency sound chamber.
The at least one passageway may be divided into at least two passageways which extend the full length of the high frequency sound chamber extending from the annular input orifice to the rectangular output orifice so configured to divide the annular input orifice into at least two arc segments and to shape the output orifices as two equal and parallel rectangular slots, defined by the outer surface of the high frequency sound chamber and the inner surface of the mid frequency sound chamber. A further aspect of the present invention is that the outer surface of the high frequency sound chamber and the inner surface of the mid frequency sound chamber provide a smooth and continuous transition in the cross sectional shape of the passageways to permit a gradual transformation of the shape of the mid frequency wavefront from an arc segment at the entrance to rectangular at the exit.
In the preferred embodiment, the outer surface of the inner high frequency sound chamber is modified to assist in the smooth transition from the annular input orifice to the rectangular output orifice. To facilitate this, a wedge shaped body of material is added to the sides of the high frequency sound chamber so shaped that the thin edge of the wedge divides the annular input orifice into two arc segments. The wedge shaped body of material expands in width as the distance from the input orifice increases thus changing the shape of the passageway according to the width of the wedge.
Furthermore in some embodiments the wedge shaped body is flattened and tapered in thickness and so shaped to conform to the inner surface of the mid frequency sound chamber to provide mating surfaces whereby the outer surface of the high frequency sound chamber is fixed to the inner surface of the mid frequency sound chamber.
In the preferred embodiment the outer surface of the inner high frequency sound chamber is extended at the output orifice to provide an additional high frequency acoustic load and to further guide the high frequency sound wave in a beam width of the desired angle. The outer surface of the inner sound chamber is further modified to provide a smooth passageway for the mid frequency sound wave propagated in the outer sound chamber as it passes out from the output orifice of the outer sound chamber.
A further aspect of the present embodiment is that the dimension of the outermost width of the dual rectangular output orifices of the mid frequency sound chamber is limited to less than one wavelength of the highest frequency that is expected to be propagated solely by the mid frequency sound chamber. The mid frequency sound chamber is therefore capable of propagating a wavefront into the cabinet waveguide to which it is connected to the highest frequency of concern without undesired narrowing of the beam width. Because of the close proximity of the two mid frequency exits, the mid frequency energy appears acoustically at the center of the waveguide. Because the exit of the high frequency sound chamber is located in the center of the two mid frequency sound chamber exits and thus at the center of the waveguide, both the mid and high frequency sound appear to originate acoustically from the same location. This geometry can be extended in a line, vertically or horizontally, with as many devices as required. An array of such sound chambers can be considered therefore, to be co-linear.
In the present embodiment the co-linear exit of the mid frequency and high frequency sound chambers is preferably joined to the entrance of the waveguide constructed according to the teachings of Adamson, U.S. Pat. No. 5,900,593 or according to the practice of Heil, U.S. Pat. No. 5,163,167.
In some embodiments, the enclosure may contain one or more low frequency loudspeakers, which may be configured to radiate sound in any manner which is deemed acceptable to provide the required low frequency sound power to complement the mid frequency and high frequency drivers.
Another distinct aspect of the preferred embodiment is that acoustical interference is created at the exits of the mid frequency sound chamber and the high frequency sound chamber due to discontinuities in reflected impedance and acoustic cancellations. These negative effects occur where the sound waves merge at the entrance to the waveguide, and are limited to a controlled bandwidth.
The interference is caused because the mid frequency wavefront encounters a discontinuity in acoustical resistance due to the space occupied by the high frequency sound chamber exit. Likewise, the high frequency wavefront encounters a discontinuity in acoustical resistance due to the space which is occupied by the exit of the mid frequency sound chamber. Both these discontinuities cause acoustical reflections and cancellations which result in degraded frequency response. These discontinuities are encountered by either the high frequency or mid frequency wavefront when propagated in the absence of the other wavefront and the frequency of the interference is dependant on the dimensions of the sound chamber exits.
In the preferred embodiment, the discontinuities of the passageways of both frequency bands are so sized that the interference occurs in a frequency range in which both high frequency and mid frequency drivers are capable of full acoustic output. The solution to the interference is found in time alignment of the mid frequency and high frequency wavefronts and the overlap in the frequency domain of the two frequency bands of sound. The result of this is that a transducer operating at a frequency where destructive interference will occur when the driver operates in the absence of the other frequency band does not encounter any interference when both drivers are operated simultaneously. This is so because the exits of both the mid frequency and high frequency sound chambers and thus the entire entrance of the waveguide is acoustically energized in the frequency range of concern.
An object of the present invention is to provide a method to create at least two wavefronts of at least two frequency ranges within a loudspeaker enclosure which will merge within the loudspeaker enclosure to form a single wavefront with virtual zero interference that includes all the acoustical energy of both wavefronts and both frequency ranges.
It is a further object of the present invention to provide a method to allow at least two wavefronts of a common frequency range and at least two wavefronts of a another common frequency range to produce a common wavefront within the same loudspeaker enclosure.
It is a further object of the present invention to provide a method to create one or more wavefronts within one or more loudspeaker enclosures that will merge with the wavefront(s) of the same frequency range in an adjacent similar loudspeaker enclosure with virtually zero interference.
It is a further object of the present invention to provide the optimal transformation of the shape of a sound wave between the exit of a mid range compression driver and the entrance of the associated waveguide by means of particular sound chambers.
It is a further object of the present invention to provide a method to eliminate interference between two wavefronts of different frequency ranges at the point of summation at the exit of particular sound chambers and the entrance of the associated waveguides by the application of particular geometric shapes, time delay and particular filtering of the sound signal in the electronic domain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a frontal view of several loudspeaker enclosures showing high and mid frequency exits and waveguide of the present invention;
FIG. 1B shows a first alternative arrangement of the loudspeaker enclosures shown in FIG. 1A;
FIG. 1C shows a second alternative arrangement of enclosures for loudspeakers as shown in FIG. 1A;
FIG. 1D shows a further alternate arrangement of loudspeaker enclosures similar to that shown in FIG. 1A;
FIG. 2 is an exploded view showing drivers, sound chambers and waveguide of the invention;
FIG. 3 is a cross sectional view showing a placement of an inner sound chamber within an outer sound chamber;
FIG. 4 is a cross sectional view similar to FIG. 3 but taken 90° with respect thereto;
FIG. 5A is a cross sectional view taken along line 5 A— 5 A of FIG. 3 showing a concentric relationship of the mid frequency sound chamber relative to the high frequency sound chamber at the entrances thereof,
FIG. 5B is a cross sectional view taken along line 5 B— 5 B of FIG. 3 at the approximate mid section of the high frequency sound chamber;
FIG. 5C is a cross sectional view taken along line 5 C— 5 C of FIG. 3 taken adjacent the exit end of the high frequency sound chamber;
FIG. 6A is a view similar to FIG. 3 illustrating the relationship of mid and high frequency wavefronts in accordance with the invention;
FIG. 6B is a view similar to FIG. 6A illustrating interference solutions with respect to the mid and high frequency wavefronts of the invention;
FIG. 7 is a loudspeaker enclosure array according to the invention; and
FIG. 8 is another loudspeaker enclosure array according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention as shown FIGS. 1 A, B, C, and D includes enclosures 1 that are trapezoidal in the vertical cross section, having front walls 2 , top walls 3 , bottom walls 4 , rear walls 5 and side walls 6 . When placed in use the top and bottom surfaces of the enclosures may be placed as shown in FIG. 1C as nearly to being co-planar 7 as practicable or may be placed as shown in FIGS. 1B and D so that the front or rear edge of the enclosures are touching one another 8 and the opposite edge is spaced 9 a predetermined distance from the adjacent enclosure. In this manner, it is possible to create arrays of enclosures with a wide variety of curvatures.
In the present invention a plurality of high frequency sound chamber exits 10 are arrayed contiguously at the entrance to a waveguide 11 permitting the formation of a nearly continuous ribbon of high frequency acoustical energy which does not suffer from acoustical interference between the individual elements in the array. Further a plurality of mid frequency sound chamber exits or output orifices 10 a are arrayed in two contiguous parallel rows spaced equidistant from the high frequency exits or output orifices 10 . The result is a single common wavefront that spans both the mid frequency and high frequency ranges and emanates from a plurality of enclosures which will be described in greater detail hereinafter.
FIG. 2 shows an exploded view of the principal parts of the invention in its present embodiment. This figure shows a single set of acoustical transducers or driver units 52 and their associated mid and high frequency sound chambers and waveguide. In the preferred embodiment there are two sets of acoustical transducers and their associated sound chambers and waveguides in each enclosure, such as shown in FIGS. 7 and 8.
Each drive unit includes a high frequency compression driver 12 , a mid frequency magnet assembly 13 , a mid frequency thin metallic diaphragm assembly 14 , a mid frequency phase plug assembly 15 , an inner body 35 of a high frequency inner sound chamber 16 which is mounted between outer shell halves 17 of the high frequency inner sound chamber, and mid frequency outer sound chamber shell halves 18 . Such typical high frequency compression drivers have a lower frequency operating limit between 500 Hz and 1200 Hz and an upper frequency limit of approximately 20,000 Hz. In the preferred embodiment the high frequency compression driver is a JBL Model 2451.
In the preferred embodiment the inner body 35 of the high frequency sound chamber 16 is shaped as an elliptical cone that has two approximately planar facets 62 cut from each side shaped so that the two facets extend from the mid point along the side of the cone and meet at the center of the large end of the ellipse forming a sharp edge 65 that extends to the full width of the large end of the ellipse. The outer shell 17 is so shaped that its inner surface and the outer surface of the inner body form a circular input orifice 66 and a rectangular output orifice 68 connected by a passageway of approximately constant width. The possible pathways that may be traversed by the sound wave are so sized by the geometry of the inner body and outer shell that the wavefront that emerges from the rectangular output orifice is nearly planar with a small curvature in the frontal plane. Such an arrangement is shown in U.S. Pat. No. 5,900,593 to Adamson, the contents of which are incorporated herein by reference.
FIG. 3 shows a cross section, side view and FIG. 4 shows a cross section, plan view of a single set of acoustical transducers and their associated sound chambers and waveguide. The mid frequency magnet 19 is constructed with an opening at its center 20 to allow the passage of high frequency sound waves through the mid frequency magnet and into entrance 21 of the high frequency sound chamber 16 . The mid frequency phase plug body 22 and the phase plug ring 23 are so constructed to guide the mid frequency sound wave generated by the mid frequency diaphragm 24 into the entrance or input orifice 25 of the mid frequency sound chamber 28 without acoustical interference caused by reflecting sound waves. The outer surface 26 of the high frequency sound chamber 16 is shaped to provide a smooth passageway for the transmission of the mid frequency sound waves in the mid frequency sound chamber 28 defined between shell halves 18 . The outside of the high frequency sound chamber is further modified to cause the mid frequency sound wave to be modified from an annular shape at entrance or input orifice 25 to a dual rectangular shape at exit or output orifice 10 a . Both the high and mid frequency sound waves are further controlled by the waveguide 11 which is placed at the exit of the sound chambers. It should be noted that a center of the input orifice 25 and a center of the output orifice 10 a of the mid frequency sound chamber are aligned along a primary axis A—A of the sound chamber.
FIGS. 5A-5C are sections of the inner and outer sound chambers which show changing shape of the mid and high frequency chambers which dictates the shape of the mid frequency wavefront. FIG. 5A shows the mid frequency sound chamber 28 is generally annular in configuration at the entrance 25 so that a wavefront is generally annular at the entrance. The annular wavefront is divided into two separate passageways 33 by wedge shaped protrusions 36 on the outside surface 26 of the inner or high frequency sound chamber 16 . This feature 36 can be observed in FIG. 5 A. The configuration of the mid frequency sound chamber 28 changes along its length and in FIG. 5D parallel channels or passageways 33 ′ are created so that the mid frequency wavefront is further changed. This is accomplished by increasing the width of the wedge shaped protrusion 36 . FIG. 5C shows the final transformation of the mid frequency sound chambers at the exit end 10 of the high frequency sound chamber 16 which functions to form the wavefront into two parallel rectangular wavefronts in passageways 33 ″ spaced equidistant from a high frequency wavefront exiting from the exit end of the high frequency sound chamber.
FIG. 6A shows a cross section of the high and mid frequency drivers and the inner and outer sound chambers 16 and 28 , respectively. The outer shell 17 of the inner high frequency sound chamber 16 is extended at 42 to guide the sound wave 43 at the desired angle A and to further provide acoustic loading to the high frequency compression driver. The outer shell is further modified to provide a smooth outer concave curve surface 44 which, combined with the inner surface 49 of the outer mid frequency sound chamber, provides a smooth passageway at 46 for the propagation of the mid frequency sound wave.
As shown in FIG. 6B, the correct summation of the mid frequency and the high frequency wavefronts requires that both wavefronts arrive at the point of summation at the entrance to the waveguide 11 at the same time. Since the sound generating diaphragm of the high frequency and mid frequency drivers are separated by a distance D, it is necessary to introduce a time delay into the signal path of the high frequency driver equal to D divided by the speed of sound in air. This method is common in prior art for systems of all types. In this manner, both wavefronts arrive at the same time and do not create destructive interference in the entrance of the waveguide.
When any sound wave exits any aperture where the aperture is smaller than the wavelength, diffraction, which can be described as a sudden change in the direction of the wavefront, will occur. When a sound wave of a frequency equal to two times the distance M exits from the two spaced points of exit of the two parallel mid frequency channels 33 ″ of the outer sound chamber 28 as shown in FIG. 5C, the sound originating at either exit diffracts at the sudden discontinuity 50 and moves in the direction S or S′ toward the other exit. Because the wavelength is two times the distance M, the sound arrives at the other exit 180 degrees out of phase with the sound exiting therefrom. This results in a sharp reduction in acoustic output at that frequency. This first cancellation frequency shows as a sharp notch in the frequency response of the device when operated in the absence of the high frequency driver. At higher frequencies, the phenomenon is not as apparent, but results in a degradation of the performance of the mid frequency device as measured in the frequency domain.
The mid frequency solution to this problem is found in limiting the physical dimension M and therefore the frequency derived therefrom to that which can also be produced by the high frequency driver. When the high frequency exit 10 is energized with the same frequency sound wave, in phase with the sound at the mid frequency exits 10 a , no diffraction can occur because the entire waveguide is energized.
In FIG. 6A the high frequency sound waves 43 exiting the inner sound chamber encounter interference from the open cavity 46 represented by the outer sound chamber exit. This interference results in uneven amplitude and overall reduced acoustical output in the lower end of the operating spectrum of the high frequency driver.
The solution at this problem is found in extending the high frequency sound chamber 16 to provide acceptable high frequency response to at least the upper frequency of operation of the mid frequency driver and energizing the two outer sound chamber exits 10 a with the same frequency sound wave, in phase with the sound at the high frequency exits 10 . The upper frequency limit of the mid frequency driver in the preferred embodiment is more than 1.5 octaves above the first occurrence of mid frequency acoustic cancellation. Since the high frequency driver can operate from below the cancellation frequency and the mid frequency driver can operate well above the high frequency interference, the entire range of problem frequencies is corrected.
In the preferred embodiment the high frequency driver is capable of operating to a low frequency limit of 1,000 Hz. The mid frequency dimension M is 5″ which is half the wavelength at 1,350 Hz. By setting the operating band of the high frequency driver from 1,200 Hz to 20,000 Hz the high frequency driver energizes the entrance to the waveguide in the frequency range where the mid frequency wavefront exhibits diffraction. Thus the mid frequency problem is solved.
In the preferred embodiment the mid frequency driver is capable of full output to an upper frequency limit of 3,000 Hz. The high frequency sound chamber extension is approximately 4″ wide and provides good high frequency performance to a lower limit of 3,000 Hz. However, the mid frequency sound chamber exits prove to interfere with high frequency performance below 3,000 Hz. By extending the operating bandwidth of the mid frequency driver to an upper limit of 3,000 Hz, the mid frequency exits are energized in the frequency range where the high frequency performance exhibits reflections and uneven performance. When such energization of said exits takes place the interference is eliminated.
The relationship between the high frequency sound chamber and the mid frequency sound chamber is clearly a symbiotic relationship. Each waveform requires the other in order to exit cleanly from the sound chambers and to enter into the throat of the waveguide.
FIG. 7 shows a side view cross section of two speaker enclosures 1 , each enclosure containing two driver units 52 placed in an ideal curved array. The curvature of the high frequency wavefront as described in U.S. Pat. No. 5,900,593, to Adamson, is proportional to the high frequency exits as controlled through the geometry of the inner high frequency sound chamber 16 . Provided that the distance “H” between centers of the mid frequency exits 10 a is less than one wavelength of the frequency propagated, the mid frequency exits will be mutually coupled. The resultant curvature of the mid frequency wavefront 43 will be proportional to the curvature of the array.
FIG. 8 shows a side view cross section of two speaker enclosures 1 , each enclosure containing two driver units 52 placed in an ideal flat array according to U.S. Pat. No. 5,163,167 to Heil, the contents of which are also incorporated herein by reference. The planar shape of the high frequency exits will result in cylindrical wavefronts 56 as described in Heil shaped through the geometry of the inner high frequency sound chamber 16 . Provided that the distance between centers of the mid frequency exit H is less than one wavelength of the frequency propagated, the mid frequency exits will be mutually coupled. The resultant mid frequency wavefront will similarly cylindrical.
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A loudspeaker system of improved clarity, coherence and uniformity of energy distribution containing mid frequency sound chambers with an annular input and approximately rectangular output for use in multi-way co-axial horn loaded line array systems. The sound chambers propagate the annular mid frequency sound wave co-axially with a high frequency sound wave, gradually changing the cross section of the mid frequency wavefront resulting in co-linear acoustic mid and high frequency wavefronts from multiple devices which range from the shape of a flat ribbon to that of a curved ribbon. The sound chambers may be arrayed contiguously and placed at the entrance of a suitable waveguide to form a wide band width acoustic line source of extended length and controlled beamwidth.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a self-adjusting clutch assembly, in particular for commercial vehicles or tractors, as well as to a method for operating a clutch assembly.
2. Description of Related Art
Clutch assemblies having a multi-plate clutch are already known.
These known clutch assemblies which are used in the case of commercial vehicles or tractors, have a driving clutch as well as a clutch for additional implements. These clutches are operable separately through a clutch pedal or through a hand lever.
These known clutch assemblies are suitable for use in vehicles where a separate clutch is to be provided for driving and a separate clutch is to be provided for the implements.
These known clutches all have the drawback that when the clutch discs wear out the operating point of the clutch is shifted so that the release force required to operate the clutches varies accordingly.
SUMMARY OF THE INVENTION
The object of the invention is therefore to provide a clutch assembly for a multi-plate clutch as well as a method for operating a multi-plate clutch which can be produced cost-effectively in a structurally simple manner and which has an improved release characteristic, more particularly a more constant release characteristic with a high operating accuracy over the entire service life.
Thus according to the invention it is proposed to design a clutch assembly, more particularly a clutch assembly for a motor vehicle, such as a commercial vehicle or a tractor, with at least a self-adjusting clutch device with at least one clutch disc and at least two contact pressure plates.
The clutch assembly preferably has a clutch disc which can be coupled, more particularly with keyed engagement, to two contact pressure plates.
It is also preferable if the clutch assembly has a number of clutch discs, such as for example two clutch discs which can each be coupled, more particularly with keyed engagement, to one or more contact pressure plates.
The invention is particularly advantageous because the operating force of the clutch assembly can be kept within a predetermined tolerance band as a result of the self-adjusting device of the clutch assembly or of the clutches. The width of this tolerance band is preferably aimed at zero.
According to a particularly preferred embodiment of the invention a device is provided which keeps the installation position of a plate spring substantially unchanged throughout the entire wear on the lining and thus keeps the release force of the clutches, more particularly of two clutches, unchanged and guaranteed throughout the service life. The plate spring thereby preferably loads pressure plates which act on the linings or the discs.
This device which keeps the installation position of the plate springs substantially constant preferably has at least one cast ring and at least two sheet metal tapered rings wherein one of these sheet metal tapered rings is connected rotationally secured to a pressure plate, more particularly to the pressure plate on the transmission side. This device also preferably has two circumferentially mounted compression springs which in the event of wear at least partially or under predetermined conditions turns one of the tapered rings relative to the other tapered ring until the wear in the axial direction is compensated. This device is preferably coupled to a driving clutch or to a clutch on the transmission side.
In a particularly preferred embodiment during activation of the clutch through an operating mechanism, for example through a lever, the cast ring is displaced in the axial direction, with a stepped bolt or friction device causing a pressure plate to lift off from the friction lining or disc. More particularly the friction force applied to the stepped bolt is greater than the operating axial compression spring force—according to the geometry of the taper.
It is preferable if, in the event of wear on the clutch disc on the engine side or on the transmission side, as a result of force applied by a plate spring a contact pressure plate, more particularly a pressure plate on the engine side, draws the stepped bolt through the bolt head of this stepped bolt out from the friction device and thus release a gap at a shoulder or ledge of the stepped bolt.
Then preferably when operating a clutch, more particularly a clutch on the transmission side, through a lever the cast ring is moved up to the shoulder or to the ledge of the stepped bolt so that the tapered rings can be turned relative to each other under the action of a compression spring force acting on at least one of these tapered rings, preferably on both tapered rings, so that the wear in the axial direction is compensated and the plate spring swings back again in its original installation position. The level of the release force of the clutch device thus corresponds again to the level in the new state or in the substantially unworn state.
Thus according to the invention an assembly of several clutches is provided wherein the release characteristic of at least two of these clutches is constant or unchanged over the entire service life of the clutches or at least an element of these clutches. An element of this kind over the service life of which the release characteristic of the clutch or the release characteristics of the clutches is constant is in particular at least a disc or at least a clutch lining of the clutch assembly.
The element over the service life of which the release characteristic of the clutch or clutches is constant is preferably an element which has the fundamental property of influencing the release characteristic of the clutch assembly.
It is proposed for example that an element, such as for example a friction lining or a disc is provided which when changed or shifted in position would or does basically influence the release characteristic of the clutch or one of the clutches. Despite the presence of such an element the release characteristic is preferably kept substantially constant. This is achieved for example in that the influence which the thickness of the friction lining or the thickness of the discs has on the release characteristic is substantially compensated by a self-adjusting device.
According to the invention it is thus proposed that a clutch assembly having at least one clutch disc and at least two contact pressure plates is provided with an adjustment device for compensating at least in part changing or changed operating conditions of the clutch device.
By operating conditions of the clutch assembly are meant here in particular the characteristic values of the clutch assembly or characteristic values which characterise the operating process of the clutch assembly. By way of example the operating time for releasing the clutch or the operating force or the time path of the operating force or the like can be considered as an operating condition.
It is also preferable if predetermined operating conditions or predetermined operating characteristic values are set whereby when these are changed or at the start of a change the adjustment device triggers, more particularly independently or automatically, measures for compensating this change. According to the invention it is preferable if the adjustment device controls or regulates predetermined positions or relative positions of structural elements.
This problem is further solved by a clutch assembly having at least one clutch disc and at least two pressure plates.
Thus according to the invention it is proposed to provide a clutch assembly with at least one spring device, more particularly a plate spring device, wherein the position of the plate spring device can be controlled or regulated by a control or regulating device. The plate spring device thereby preferably acts on the contact pressure plate. The plate spring device thereby preferably acts on the contact pressure plates so that the pressure plates when the operating device for operating the clutch is not activated are pressed against the friction linings or the discs of the clutch assembly so that the clutches are substantially in a closed state.
It is however also preferred if when the operating device of the clutch assembly is not activated the spring device or the plate spring device holds one or more of the pressure plates in an opened state so that the relevant clutch is substantially opened.
Two contact pressure plates are thereby preferably provided to form when the clutch is closed a positive, more particularly a keyed, connection with the clutch discs or friction linings. The plate spring device thereby preferably tensions the contact pressure plates between the clutch discs.
It is thereby preferred if a predetermined operating characteristic is maintained within a predetermined interval with a predetermined interval length by the regulating device or control device. More particularly it is preferred if the operating characteristic is maintained within an interval so that a maximum permissible upper deviation and a maximum permissible lower deviation is defined for each operating point. It is also preferable if the maximum upper deviation and the maximum lower deviation agree with each other and is substantially the same for all operating points of the operating characteristic.
It is preferred if the interval length of the interval aims at being zero so that the operating characteristic is actually maintained substantially constant.
According to a particularly preferred further development of the invention the clutch assembly is provided with at least one adjustment device by which at least one clutch characteristic value can be regulated in dependence on the wear on the clutch, more particularly the wear on the clutch discs or linings.
An adjustment device is preferably provided by which in dependence on at least one operating characteristic value, such as for example the spring force existing in a predetermined state of the plate spring device, at least a further characteristic value of the plate spring device can be adjusted so that the spring force of the plate spring device is regulated substantially to a predetermined value under predetermined conditions.
Thus according to the invention it is proposed for example that the position of the plate spring device under predetermined conditions is displaced in dependence on the spring force of the plate spring device so that the spring force of the plate spring device again assumes its original value. It should be noted that predetermined conditions hereby preferably exist. By way of example a predetermined position is set of the pressure plates (e.g. extreme position) or a predetermined position of the operating lever of the operating device of the clutches (e.g. extreme position).
According to a particularly preferred embodiment of the invention the adjusting device or the self-adjusting device for adjusting the clutch device or the clutches is designed to be path-controlled.
According to a particularly preferred embodiment of the invention the clutch device has at least one operating device, such as for example an operating lever, for operating the clutch. It is preferable if separate operating devices are provided for the different clutches, i.e. more particularly for different spots at which the force flow can be selectively interrupted or closed. It is also preferable if a single operating device, such as for example a single operating lever or the like is provided for operating several clutches.
According to a particularly preferred embodiment of the invention during the course of the self-adjusting process of the clutch assembly, or clutch devices, a force equilibrium is set, more particularly increasing. It is also preferred if with a path-controlled adjustment device during the self-adjusting process a force equilibrium is increasingly set. By way of example the position of a plate spring device is hereby regulated or controlled whereby the force applied by the plate spring device interacts with other forces so that a force equilibrium is set.
A particularly preferred clutch assembly according to the invention has n clutch discs and/or m clutches and/or p pressure plates wherein n, mεN and pεN≧2.
A clutch assembly according to the invention preferably has two clutches which in a particularly preferred embodiment are both self-adjustable.
It is particularly preferred if the clutches, more particularly the two clutches, are self-adjusting by an identical adjustment device. It is thereby particularly preferred if the self-adjusting process is substantially in part identical substantially independently of the identity of the worn clutch discs.
By way of example in the event of wear on any one clutch disc or any one friction lining a plate spring device adopts a position which it would likewise adopt if wear of a similar amount were to appear on any other clutch disc or any other friction lining or if the sum of the wear on several clutch devices would correspond to this wear. In the adjusting process the original position or installation position of this plate spring device for example is produced again so that independently of where the wear has occurred, during the adjustment process a substantially identical first position of the plate spring device is changed each time into a likewise substantially identical second position of the plate spring device.
According to a particularly preferred embodiment of the invention the clutch assembly or the clutches has/have n clutch discs and p pressure plates wherein an adjustment device is related to the p pressure plates. By this is meant that the adjustment device takes into account the potential wear occurring on each friction face of a clutch disc which forms a friction-locking connection at least at times with one of the p pressure plates so that the relevant clutch is closed.
According to a particularly preferred embodiment of the invention the adjustment or self-adjustment of the clutch assembly is carried out under predetermined conditions. By way of example the adjustment or self-adjustment is always carried out when the clutch is released.
It is also preferred if the self-adjustment is undertaken during engagement of the clutch.
According to a particularly preferred embodiment of the invention a device is provided for preventing uncontrolled adjustment of the adjustment device. A device of this kind has for example a pin, such as a bolt or a stepped bolt. A device of this kind for preventing an uncontrolled adjustment of the adjustment device is preferably designed as a friction device and/or as a clamping device. It is thereby ensured by a friction and/or clamping device of this kind that an adjustment is only possible under predetermined conditions, such as for example in the presence of predetermined force conditions.
These predetermined forces can be determined for example by geometric conditions, such as in particular the geometric conditions of the clutch discs, thus e.g. the question of the presence or absence of wear.
According to a particularly preferred embodiment of the invention adjustment is carried out (automatically) so that with the clutch closed the pressure plates apply each time substantially a constant force on the clutch discs throughout the service life.
A motor vehicle with clutches according to the invention preferably has at least one driving clutch and/or at least one clutch for assemblies.
According to a particularly preferred embodiment of the invention the adjustment device has at least a first and a second device wherein the first device releases an area in the event of wear on at least one of the clutch discs. By way of example a lash or play is produced in the event of wear. This area or this play is eliminated or compensated again by the second device for removing the wear-conditioned influence on predetermined operating characteristic values of the clutch or clutch adjustment process under predetermined conditions, thus in particular at predetermined time points or under predetermined conditions. By way of example an element, such as a stepped bolt, is mounted with friction engagement in a contact pressure plate. The friction engagement existing between this bolt or this element and the pressure plate can thereby be overcome under predetermined conditions whereby a relative displacement of the element opposite the pressure plate is produced in particular by a first (part) device. This relative displacement preferably corresponds to the wear which has appeared on at least one of the clutch discs.
As a result of this relative displacement of the bolt opposite the pressure plate the bolt also changes its position relative to a further element, such as for example a further plate aligned parallel with the pressure plate.
In order to compensate the wear-conditioned influences on the clutch process the relative displacement which the bolt has undergone relative to the additional plate, such as intermediate plate, is then compensated under predetermined conditions by a second device. The relative position of the further plate (intermediate plate) opposite the aforementioned pressure plate is hereby preferably changed.
The relative displacement between the further plate (intermediate plate) and the pressure plate thus preferably also corresponds to the wear which has appeared.
If now for example the distance has changed between at least one of two friction linings and at least one of two clutch discs, since at least one of these clutch discs has worn, then for example the path change between these clutch discs is compensated through a change in the spacing between an intermediate disc and a pressure plate whereby the interspace between the friction linings is filled out more particularly by a series connection of the pressure plate, the intermediate plate and a spring device, such as plate spring device, and where applicable further substantially rigid elements.
According to a particularly preferred embodiment of the invention the clutch assembly according to the invention has at least one sensor device for detecting a relative movement between different pressure plates. This sensor device detects more particularly a changed relative position of the pressure plate under predetermined conditions, By way of example this sensor device detects a changed maximum spacing between the pressure plates. This maximum spacing is for example determined by the spacing of two friction linings or discs. The spacing changes as a result of the wear on these friction linings.
According to a preferred embodiment of the invention this sensor device has at least one bolt. It is also preferred if the sensor device or adjustment device is coupled to at least one operating element for operating at least one of the clutches so that the adjustment or detection of a relative movement is automatically undertaken during operation of this operating element.
According to a particularly preferred embodiment of the invention the sensor device is coupled to at least one component part which is moved during an operating process of one of the clutches in dependence on the operating movement.
A component part of this kind is for example an intermediate lever.
According to a particularly preferred embodiment of the invention the adjustment device and/or the sensor device has at least one clamping or friction device. A clamping or friction force is preferably applied by a friction or clamping device of this kind. This clamping or friction action is provided in particular to connect elements which are or are to be coupled together under first conditions and which are to be mounted movable relative to each other under second predetermined conditions.
By way of example a clamping or friction connection of this kind is provided between a bolt, more particularly a stepped bolt, and one of the pressure plates.
It is preferable if a predetermined clamping or friction force can be applied by the friction or clamping device and which is produced for example by a fitting with oversize, such as a close tolerance or transition fit, or by means of a spring device or the like.
By way of example the friction or clamping device has a clamping screw which, screwed in axially or circumferentially, applies in the radial direction a clamping force on a bolt device. A screw of this kind is screwed into the pressure plate for example and contains in its inner space a bolt device or stepped bolt device. It is also preferred if a clamping screw of this kind is formed as a type of clamping sleeve.
It is preferred if a substantially adjustable clamping force or friction force can be applied by the clamping screw or sleeve or friction or clamping device.
By way of example a substantially constant clamping force can be applied throughout the service life by the clamping or friction device or the clamping screw or sleeve whereby this clamping force is exerted preferably on a bolt device, such as a stepped bolt device and thus holds this stepped bolt device always fixed opposite the pressure plate when the relative force between the pressure plate and stepped bolt is less than a relative force, which is predetermined in terms of direction and size, between the stepped bolt and this pressure plate.
According to a particularly preferred embodiment of the invention the clamping screw and/or the clamping sleeve is a component part which is slit substantially lengthwise at least in part or is slit with a longitudinal component. This component part is slit in screw fashion for example. A slit of this kind makes it possible for example for the walls of the clamping screw or clamping sleeve to move radially inwards when biased by radial force and thus to apply a clamping force.
It is preferable if the clamping force is overcome under predetermined conditions when wear appears on at least one of the clutch devices. By way of example the clamping force is overcome immediately if wear has occurred, so that a relative displacement takes place between the bolt and pressure plate. It is also preferred if the bolt device slides relative to the pressure plate at another point in time.
According to a particularly preferred embodiment of the invention the bolt embraced by the friction or clamping device is a stepped bolt which has different diameter ranges so that an axial stop is formed.
According to a preferred embodiment of the invention a second stop can be additionally provided to restrict movement in a second axial direction, and is mounted more particularly on the stepped bolt, for example in the form of a bolt head.
According to a particularly preferred embodiment of the invention the bolt device which is embraced by the friction or clamping device is arranged so that it runs substantially axially movable through a first pressure plate and an intermediate plate which is mounted between a first and second pressure plate.
It is preferable if the aforementioned stops or ledges serve as a stop for this first pressure plate and this intermediate plate.
According to a particularly preferred embodiment of the invention the bolt device is secured against slipping out. More particularly the bolt device is secured against slipping out from the contact pressure plates or the intermediate plate.
According to a particularly preferred embodiment of the invention an intermediate device, such as for example an intermediate plate, is mounted spatially between the first and second pressure plate, with the intermediate plate being held through a friction device at a certain distance from the second pressure plate, and this distance being variable in the event of wear. A plate spring device ensures for example force is applied on the pressure plates in the direction of the relevant clutch disc or friction lining, whereby the plate spring device is mounted between the first pressure plate and the intermediate plate.
According to a particularly preferred embodiment of the invention the intermediate plate, as also preferably the pressure plate, is mounted axially movable wherein it is particularly preferred if under predetermined conditions the movement of the intermediate plate is blocked or prevented in at least one orientation.
By way of example the movement is blocked in a first orientation if the second pressure plate adjoins the one disc or a friction lining.
According to a particularly preferred embodiment of the invention the adjustment device has an overrunning type device or an overrun which adjusts the clutch assembly under predetermined conditions,. More particularly this adjustment takes place for example at least at times in the event of wear on the friction linings. The overrunning device is mounted for example between the intermediate plate and the second pressure plate. It is preferable if this overrunning-type arrangement in the event of movement in a first direction increases the distance between the intermediate plate and the second pressure plate, whilst the movement is blocked in the counter direction.
Under predetermined conditions, more particularly at least at times, the overrun can be moved in its overrunning direction so that the distance between the intermediate plate and the second pressure plate increases.
In a corresponding way an adjustment device can also be mounted for example between the plate spring device and one of the pressure plates or between the pressure plates.
A corresponding device which is likewise designed for example as a type of overrun, for increasing the distance, which is arranged between the force introduction points of the spring device or plate spring device, is also preferred.
According to a particularly preferred embodiment of the invention the adjustment device has at least two elements which contact one another and which in the event of a predetermined movement or with a predetermined introduction of force or force direction execute a movement relative to each other which leads to a change in the spacing, more particularly to an increase in the spacing in a predetermined direction.
According to a particularly preferred embodiment of the invention one of these two elements is biased by an energy accumulator device, such as a spring. This spring force is counteracted under first predetermined conditions or circumstances by a counter force so that a relative displacement of the two elements of the adjustment device is substantially avoided. Under second predetermined conditions or circumstances, the counter force decreases at least so that the two elements of the adjustment device move relative to each other under the action of the spring force or a part of the spring force.
The two aforementioned elements of the adjustment device are for example the already mentioned tapered rings. By way of example these tapered rings change their axial spacing as a result of their facing inclines during rotation. It is preferable if detents are provided on the slopes of these tapered rings to engage in each other so that a reduction in the spacing of the rings is substantially prevented by the detent formation.
It should be noted that other spacers or fixing devices can also be provided in place of or as an addition to the detents.
The surface contour, particularly on the slope side, of the tapered rings is preferably formed with a linear rise. It is also preferred if this surface contour is curved or follows an exponential function. Other functional or non-functional surface contours are also preferred.
According to a particularly preferred embodiment of the invention the change in the axial spacing of the tapered rings in the event of their rotation corresponds to the play which is to be compensated. More particularly it is preferred if the tapered rings have a linear surface rise wherein a is the pitch angle of this linear rise and tan a corresponds to the play which is to be compensated.
It is also preferable if the surface contour on the slope side of the tapered rings which preferably rotate relative to each other is different and follows for example different functions.
According to the invention it is preferred if each of the pressure plates when the clutch is closed contacts precisely a clutch disc or precisely a friction lining. It is also preferred if a pressure plate contacts different friction linings when the clutch is closed. By way of example when the clutch is closed a pressure plate contacts two different friction linings simultaneously. It is also preferable if a pressure plate for closing a first clutch contacts a first pressure plate and for closing a second clutch contacts a second pressure plate. It is further preferred if the pressure plate or pressure plates is or are formed with variable thickness.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained in further detail with reference to the non-restricting embodiments illustrated by way of example in the drawings in which:
FIG. 1 shows an example of an embodiment of the invention in a partial sectional view taken along a first section plane in which the clutch is in a first shift position and the clutch discs are in a first state;
FIG. 2 shows the example of an embodiment according to FIG. 1 in a second sectional plane;
FIG. 3 shows the example of an embodiment according to FIG. 1 in a second clutch position;
FIG. 4 shows the embodiment according to FIG. 3 in a second sectional plane;
FIG. 5 shows the example of an embodiment according to FIG. 1 in a second state of the clutch discs;
FIG. 6 shows the embodiment according to FIG. 5 in a second sectional plane;
FIG. 7 shows the example of an embodiment according to FIG. 1 in a third state of the clutch discs;
FIG. 8 shows the example of an embodiment according to FIG. 7 in a second sectional plane;
FIG. 9 shows the adjusting device for the clutch used in the example of an embodiment according to the invention in a partial sectional view in a first position;
FIG. 10 shows the illustration according to FIG. 9 in a second position;
FIG. 11 shows a side view of an example of a clutch device according to the invention in which the operating levers are visible;
FIG. 12 shows a sectional view of FIG. 11 along the line 11 — 11
FIG. 13 shows a plan view of a pressure plate according to the invention on the transmission side with a friction device.
FIG. 14 shows a plan view of a pressure plate on the engine side with a through bore for a stepped bolt, such as is embraced for example by a clutch device according to the invention
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows an example of an embodiment according to the invention in a diagrammatic partially sectional view wherein the clutch discs are located in a first, more particularly unworn, state. The clutch is thereby shifted in a first clutch position.
The figure shows two pressure plates 10 , 12 which with the clutch 14 , 16 closed adjoin the relevant linings 18 and 20 with friction engagement. The clutch devices 14 , 16 are each held in a substantially closed clutch position—more particularly by the plate spring device 22 .
The contact pressure plates 10 , 12 are thereby substantially tensioned between the linings 18 , 20 through the action of the plate spring device 22 . Thus the two clutch devices 14 , 16 are basically held in a closed position more particularly by a single plate spring device 22 .
In the embodiment according to FIG. 1 the plate spring device 22 is supported with one side on the contact pressure plate 10 on the engine side, and with the other side on an intermediate device or intermediate plate 24 . This intermediate plate 24 is substantially in fixed connection with the operating lever 26 . This connection is produced in the example according to FIG. 1 by screwing the intermediate plate 24 onto an intermediate lever 28 which in turn is connected by the articulated joint 30 to the operating lever 26 .
The operating lever 26 is in the illustration shown in FIG. 1 a lever through which the clutch device 16 can be opened.
By way of example in order to open this clutch device 16 several operating levers 26 are provided, e.g. arranged star-shaped relative to each other. By way of example three operating levers 26 are arranged star-fashion to control the clutch device 16 .
Preferably, but not shown in FIG. 1, at least one operating lever is likewise provided for releasing the clutch device 14 on the engine side. By way of example three operating levers are likewise provided for controlling or releasing the clutch device 14 . These operating levers for operating the clutch device 14 are likewise arranged star-fashion relative to each other for example. It is preferable if one operating lever for controlling the clutch device 14 is arranged each time between two operating levers 26 for controlling the clutch device 16 .
The operating lever 26 which is attached to the intermediate lever 28 by the articulated joint 30 is attached to the housing at a second articulated point 32 .
The intermediate plate 24 is pressed against the pressure plate 12 substantially under the action of the plate spring device 22 so that the pressure plates 10 , 12 are tensioned against each other.
The intermediate plate 24 thereby preferably lies not directly against the pressure plate 12 but against the first tapered ring 34 . This first tapered ring 34 thereby adjoins in the direction of the pressure plate 12 a second tapered ring 36 which in turn is supported against the pressure plate 12 .
The first tapered ring 34 and the second tapered ring 36 are biased by the spring device 38 . The spring device 38 which is formed for example as a compression spring or traction spring or as a rotary spring device, biases the first tapered ring 34 so that when there is no or no sufficient counter force the tapered rings 34 , 36 are moved or turned relative to each other so that the distance between the end of the tapered ring 34 facing the intermediate plate 24 and the end of the second tapered ring 36 facing the pressure plate 12 is increased. Consequently when there is no or no sufficient counter force to the pretensioning force of the spring device 38 the distance between the intermediate plate 24 and pressure plate 12 would increase. This change in the spacing or change in the length is preferably controlled so that it always adapts to the sum of the wear-conditioned erosions on the linings 18 , 20 .
It is hereby possible by way of example according to the invention to keep the plate spring device 22 substantially in a position which is independent of the wear. This in turn means that the spring or pretensioning force of the plate spring device 22 is substantially independent of the wear-conditioned erosion on the linings 18 , 20 .
This in turn makes it possible for the operating force which is to be applied to the operating lever or the operating torque which is to be applied to the operating lever, to be substantially independent of the wear on the linings 18 , 20 .
FIG. 2 shows the embodiment according to the invention of FIG. 1 in a diagrammatic partially sectional view in a second sectional plane.
This view likewise shows the first pressure plate 10 , the second pressure 12 and the intermediate plate 24 .
FIG. 2 further shows a holding/release device or a friction device or a distance-varying device 50 for varying the maximum permissible spacing between the pressure plates 10 and 12 .
This friction device 50 has in the example of the embodiment according to the invention shown in FIG. 2 a bolt which is designed more particularly as a stepped bolt 52 and which extends substantially in or through the pressure plates 10 , 12 and the intermediate plate 24 .
The stepped bolt 52 is thereby preferably mounted substantially freely movable, more particularly freely movable in the axial direction, in the pressure plate 10 and intermediate plate 24 . The stepped bolt is preferably housed in the pressure plate 12 by a friction or clamping device 50 which produces at least at times a substantially fixed connection between the stepped bolt 52 and the pressure plate 12 .
The substantially fixed connection between the stepped bolt 52 and the pressure plate 12 is thereby preferably designed so that a clamping screw 54 or the like is screwed into the pressure plate 12 and exerts a normal force on the more particularly sleeve-shaped surface of the stepped bolt 52 so that an axial movement between the stepped bolt and the pressure plate 12 is prevented at least then when the force acting in the axial direction between the pressure plate 12 and the stepped bolt 52 is less than a predetermined force, more particularly one dependent on the clamping force.
It is preferable for example if this clamping force is preset or adapted to the pretensioning force of a spring device, more particularly the plate spring device 22 , so that in the event of movement of the stepped bolt 52 , and more particularly an axial movement of the bolt device 52 caused by the spring force of the plate spring device 22 , the pressure plate 12 is also moved along, insofar as substantially only inertia forces, more particularly inertia forces of the stepped bolt 52 and of the pressure plate 12 counteract the spring force of the plate spring device 22 , so that no relative movement takes place between the bolt 52 and the pressure plate 12 .
If however the bolt is in a substantially axially fixed position—at least in relation to one orientation—which can be brought about for example by stopping against a stop, more particularly by a bolt head 56 stopping against the pressure plate 10 , then the clamping or holding force is not sufficient to prevent a relative movement between the stepped bolt 52 and pressure plate 12 , if the pressure plate 12 or an object substantially fixedly coupled thereto is not fixed in a similar way to the bolt 52 , so that the relative movement is substantially not or not only achieved by a positive, force or friction locking between the stepped bolt 52 and pressure plate 12 .
More particularly if the pressure plate 12 is movable substantially freely, with an axial fixing of the bolt device 52 the intermediate plate 24 is pressed through the plate spring device 22 in a direction away from the bolt head so that this biases the pressure plate 12 through the tapered rings 34 , 36 . The relative force between this pressure plate 12 and the (held) stepped bolt 52 is thereby greater than the set friction force acting in the axial direction. In this way a relative displacement is possible between the stepped bolt 52 and the pressure plate 12 which will be explained in further detail with reference to the following drawings.
It should be pointed out that instead of the clamping screw 54 it is also possible to use corresponding devices such as for example spring-loaded friction devices or the like.
FIG. 3 shows the example of the embodiment according to the invention shown in FIG. 1 in a released clutch position for the clutch assembly or driving clutch device 16 .
Shifting into a released position of the clutch device 16 can be carried out in particular by moving the operating lever 26 in the direction of the arrow 70 or by turning the operating lever 26 about the axis or articulation point 32 . One axis of the articulation point 32 is thereby mounted for example in the housing 72 .
The intermediate lever 28 is preferably attached to the operating lever 26 at the bearing point 30 . If—as in the example shown here—the bearing point 30 and the point at which the external force is introduced into the lever 26 are mounted on the same side of the bearing point 32 then the type of force (compression force or tensile force) introduced from outside into the operating lever 26 corresponds substantially to the type of force introduced from the operating lever 26 into the bearing point 30 . This means in particular that in the example shown in FIG. 3, where the bearing point 30 and the point of force introduction are mounted substantially on the same side of the bearing point 32 , when force is applied to the left or in the direction of the arrow 70 the bearing point 30 or the intermediate lever 28 is pressed to the left. According to the invention it is however also preferred if the bearing point 32 is arranged between the point of force introduction into the operating lever 26 and the bearing point 30 . In such a case for example in order to produce a movement of the intermediate lever 28 to the left, a force directed to the right, thus a force directed opposite the arrow 70 would be introduced into the operating lever 26 —for example at the upper end.
As a result of the operation of the operating lever 26 the intermediate lever 28 is forced to the left. The intermediate lever 28 runs with—an at least slight—play 74 through the pressure plate 12 and is connected rotationally secured—preferably at its end—to the intermediate plate 24 . By way of example the intermediate lever 28 is screwed to the intermediate plate 24 . Consequently a movement of the intermediate plate 24 in substantially the same direction or to the left corresponds with a lever movement of the lever 26 in this embodiment of the invention.
It should be noted that according to an embodiment of the invention (not shown) a spring assembly can be provided for example inside the assembly made up of the lever 26 , intermediate lever 28 and intermediate plate 24 . By way of example a spring assembly of this kind is arranged—for example switched in series—in the transitional area between the intermediate plate 24 and the intermediate lever 28 . Then a movement of the intermediate plate 24 would not automatically correspond with a movement of the lever 26 for example.
An assembly having the tapered rings 34 and 36 is preferably mounted between the intermediate plate 24 and the pressure plate 12 . The tapered rings 34 , 36 are biased by the spring device 38 in the direction of an increasing distance between the intermediate plate 24 and the pressure plate 12 . An uncontrolled adjustment through an unrestricted displacement of the tapered rings 34 , 36 in the direction of an increasing distance between the intermediate plate 24 and the pressure plate 12 is avoided according to the invention.
This is achieved for example in that the force exerted by the spring device 38 on the tapered rings 34 and 36 is varied—substantially controlled. It is hereby proposed for example that the force counteracting the spring force of the spring device 38 and which likewise acts for example on the tapered rings 34 , 36 is less than the spring force of the spring device 38 when a displacement of the displacement device or assembly of tapered rings is required or desired.
In situations where a displacement of the tapered rings is desired or necessary, the counter force to the force of the spring device 38 is preferably set or is such that this is less than the spring force of the spring device 38 so that the tapered rings are displaced opposite one another through the action of a resulting force and thus increase the distance between the pressure plate 12 and intermediate plate 24 or so long until a force equilibrium prevails at the tapered rings 34 , 36 or until the force directed against the spring device 38 is greater than the force of the spring device 38 .
It is hereby particularly preferred that the tapered rings 34 , 36 are self-holding. It is hereby particularly preferred that the arrangement of tapered rings 34 , 36 is designed as a freewheel. It is also preferred that at least one of these tapered ramps has a detent locking mechanism. It is also preferred that the ramps have a type of cogged surface wherein the spline is designed so that movement of the ramps relative to each other in a first direction is substantially possible and movement of the ramps in a second orientation opposite the first is substantially prevented.
The plate spring device 22 furthermore biases the intermediate plate 24 . This plate spring device 22 , as shown in FIG. 3, is preferably mounted between the first pressure plate 10 and the intermediate plate 24 . So long as the pressure plate is not moved through the operating lever (not shown in FIG. 3) for opening the clutch device 14 , 16 into a substantially opened clutch position, the pressure plate 10 is pressed substantially against the lining 10 by the plate spring device 22 .
In a corresponding way the pressure plate 12 is pressed against the lining 20 by the plate spring device 22 which acts on the intermediate plate 24 , through the coupling between the intermediate device 24 and the pressure plate 12 , which will be described in more detail, provided a force is not introduced into the intermediate plate 24 or pressure plate 12 through the operating lever 26 as a result of which the pressure plate 12 is lifted off from the lining 20 , as shown in FIG. 3 .
By way of example the spring force of the spring device 22 is thereby dependent on the spring path or on the elongation. A change in the spring path would consequently condition a change in the force in the spring device 22 . A clutch device 14 , 16 without any adjustment device according to the invention, as shown for example in the drawings, could have the effect for example that as the wear on the linings increases the pressure plates 10 and 12 are pressed under the action of the spring device 22 against the linings 18 , 20 whose spacing has increased though the wear, so that the force in the spring device 22 changes. The force in the plate spring device 22 which is therefore changed could have the effect for example that also the operating force which is to be applied onto the operating lever 26 would change.
It should be pointed out that the linings 18 , 10 are preferably resilient.
FIG. 4 shows the example of the embodiment of FIG. 3 in a second plane showing in particular one example of the position of the stepped bolt device 52 in a released position.
As already explained, the intermediate plate 24 for disengaging is displaceable to the left through the operating lever 26 or the intermediate lever 28 . More particularly when there is no wear appearing on the discs 18 , 20 the stepped bolt 52 substantially follows the movement of the intermediate plate 24 since the intermediate plate 24 is coupled—particularly through the step or through the shoulder 76 —with the stepped bolt 52 —at least in the absence of wear on the discs 18 , 20 as well as a movement of the intermediate plate to the left, or adjoins the stepped bolt 52 .
The stepped bolt 52 is hereby moved to the left. The stepped bolt is thereby pressed in particular through the first pressure plate 10 or the bolt head 56 of the stepped bolt 52 increasingly away from the pressure plate 10 , more particularly to the left.
The second pressure plate 12 is in turn fixedly connected to the stepped bolt 52 at least under predetermined conditions—more particularly at least at times and/or at least in part. More particularly the second pressure plate 12 is connected to the stepped bolt 52 through the clamping or friction device 50 under predetermined conditions. More particularly this friction device 50 has a friction or clamping screw 54 .
This clamping screw 54 is thereby formed for example as a hollow element. More particularly the clamping screw 54 is formed as a type of sleeve which supports a thread 78 on its outer sleeve face. This thread 78 can be screwed into a thread 80 which is mounted inside the pressure plate 12 . More particularly a radially directed clamping force is exerted on the stepped bolt 52 through this coupling or through screwing the threads 78 , 80 together.
This clamping force is preferably predetermined. It is also particularly preferred if this clamping force is adjustable. According to the invention it is preferably proposed that this clamping force is substantially constant or can be set constant for a predetermined time, more particularly throughout the service life. It is also preferred if the clamping screw 54 is slit at least in part in the longitudinal direction. By an at least partial slit in the longitudinal direction of the clamping screw 54 is meant here in particular that the clamping screw 54 has a slit in its wall along the path of which at least the axial position is also changed. A non-continuous slit is also understood by this for example.
According to the invention other clamping devices or friction devices 50 , such as for example a clamping or friction assembly 50 are preferred which have wedges or wedge rings or the like which run towards each other. By way of example a device or element is preferred which allows an at least also radially inwardly aligned force. By way of example an element is preferred, such as a friction lining or the like for example, which acts under spring force on the stepped bolt 52 . The aforementioned wedge rings or wedges can have for example an area in which they are screwed against each other. By way of example the area of one wedge has a through bore whilst an area of the second wedge or wedge ring has an at least radially outwardly aligned oblong hole so that the wedges or wedge rings are able to ‘wander’ radially relative to each other when they are connected to a connecting element, such as for example a screw.
The distance between the intermediate plate 24 and the pressure plate 10 is determined in particular by the first tapered ring 34 , the second tapered ring 36 as well as the spring device 38 . More particularly this spacing is substantially not changed or is held constant by the first tapered ring 34 , the second tapered ring 36 and the spring device 38 or is held constant through the interaction of the tapered rings 34 , 36 as well as the spring device 38 if substantially no wear has appeared on the discs 18 , 20 which would need compensating.
Particularly as the intermediate plate 24 strikes against the shoulder 76 the tapered rings 34 and 36 are not displaced relative to each other as a result of the spring force of the spring device 38 since a corresponding play area does not exist.
The bolt device 52 is pressed by the pressure plate 10 which is substantially fixed in its position. The pressure plate 10 adjoins the disc 18 for example. It is also preferable if the pressure plate 10 or the clutch disc 18 is likewise released when the clutch device 16 is released. As can be seen by comparing FIGS. 3 and 4 the distance 77 between the pressure plate 12 and the disc 20 corresponds substantially to the distance 98 between the end face 100 of the bolt head 56 facing the pressure plate 10 , and the end face 102 facing the bolt head 56 , of the pressure plate 10 which serves in particular as a stop for the bolt head 56 .
FIG. 5 shows the device according to the invention in a second state. Here the driving disc or the disc 20 is at least partly worn.
As can be seen from FIG. 5, the operating lever is substantially unstressed so that the pressure plates 10 , 12 also substantially adjoin the discs 18 , 20 .
This contact despite the presence of wear is due in particular to the fact that the plate spring device 22 presses the pressure plates 10 , 12 apart from each other. For this purpose it presses with its one end directly against the pressure plate 10 whilst it presses at its other end against the intermediate plate 24 which through an arrangement which comprises in particular the spring device 38 as well as the tapered rings 34 , 36 , and/or the friction device 50 , exerts pressure on the pressure plate 12 which is thus pressed against the disc 20 . The plate spring device 22 has hereby relaxed increasingly so that in particular the spring force has changed or reduced.
Particularly as a result of this changed plate spring device or its changed position the danger arises that the release force which is required to disengage into a released position is also changed.
This is avoided through a device according to the invention, more particularly through an adjustment device according to the invention.
FIG. 6 shows a device according to the invention in the state of FIG. 5 in a second plane.
It can be seen from FIG. 6 or by comparing FIGS. 2 and 6 that the intermediate plate 24 or the contact pressure plate 12 has moved by the distance 104 relative to the shoulder 76 of the stepped bolt 52 . This distance 104 corresponds substantially to the wear which has appeared on the discs 18 , 20 , more particularly here on the driving disc or the disc 20 .
This distance is due in particular to the fact that the disc 20 which represents for example a type of “stop” has moved to the right so that the pressure plate 12 can move further to the right. The spring device 22 however as already mentioned presses the pressure plates 10 , 12 apart so that the position of the pressure plate 10 is substantially unchanged, namely adjoining the disc 18 .
Since here the bolt head 56 of the stepped bolt stops against the pressure plate 10 , the plate spring device 22 tensions the pressure plate 10 opposite the pressure plate 12 and the pressure plates 10 , 12 each (ought to) adjoin the discs 18 , 20 , the clamping force of the clamping device 50 is here overcome at least at some times so that the pressure plate 12 can move, more particularly together with the intermediate plate 24 , along the bolt to the right until the pressure plate 12 stops against the disc 20 . More particularly the spring force of the plate spring 22 is (thereby) then also greater than the clamping force which the clamping device applies or which the clamping screw 54 exerts on the stepped bolt 52 when the plate spring 22 has relaxed in part as a result of the wear.
It is thereby preferable if the plate spring 22 is selected and pre-set so that with a predetermined amount of wear and more particularly with the maximum possible amount of wear on one and/or both discs 18 , 20 the plate spring 22 is greater than the clamping force or friction force which is applied by the clamping or friction device 50 . It is also preferred if under predetermined conditions with a predetermined amount of wear or with the maximum amount of wear the plate spring force of the—in particular partially relaxed—plate spring 22 is greater than the friction force by a predetermined amount. It is further preferred if the ratio of the plate spring force and the friction force or clamping force of the friction device 50 under the aforementioned circumstances is greater by a predetermined amount than one.
It should be pointed out that the displacement between the pressure plate 12 and the stepped bolt 52 occurs more particularly when the stepped bolt 52 is fixed in its position—at least in relation to one orientation—more particularly by the bolt head 56 stopping against the pressure plate 10 . So long as this type of fixing does not exist the unit comprising the intermediate plate 24 and pressure plate 12 as well as the stepped bolt 52 is displaced as a whole since in particular the relative force between the stepped bolt 52 and the pressure plate 12 in the axial direction is substantially zero.
During the next release process the operating lever 26 illustrated in FIG. 5 is operated anew so that a force is exerted on the intermediate plate 24 through the intermediate lever 28 in the manner substantially explained already above. As a result of this force the intermediate plate 24 which is mounted movable on the stepped bolt 52 is displaced to the left and is thereby removed from the second pressure plate 12 at least so long until the intermediate plate 24 stops against the shoulder 76 .
This removal makes it possible for the tapered rings 34 , 36 to be displaced under the action of the spring device 38 until these tapered rings 34 , 36 again fill out axially the area released by the displacement of the intermediate plate 24 on the shoulder 76 of the stepped bolt 52 .
It is particularly preferred if the component of the force of the spring device 38 which acts in the direction of the holding force of the clamping device 50 is less than the holding force of the clamping device 50 . It is hereby possible in particular that as a result of the spring device 38 as well as the tapered rings 34 , 36 these rings are only displaced relative to each other until they fill out the aforementioned released area. Then it is basically preferred that no further displacement of the pressure plate 12 takes place in the axial direction.
FIGS. 7 and 8 show illustrations corresponding to FIGS. 5 and 6 wherein wear has occurred on the two discs 18 and 20 .
FIG. 9 shows the adjustment device in a diagrammatic partial sectional view . An assembly comprising the spring device 38 , a first tapered ring 34 as well as a second tapered ring 36 is provided between the intermediate ring 24 and the pressure plate 12 or the tapered rings 34 , 36 are enclosed by the relevant plates 24 , 12 . The tapered ramps each have a pitch which is shown diagrammatically by the pitch triangle 110 . The spring device 38 loads the tapered ring 34 so that it is pressed in the direction of the rising pitch of the ring 36 so that in the event that there is not sufficient counter force opposing this spring force of the spring device 38 , the spacing 112 would increase. As shown for example by the enlarged cut-out section 116 for the area 114 —in order to prevent a reduction in the spacing 112 , holding devices or detent locking devices are provided more particularly acting on one side and arranged in particular along the ramps.
FIG. 10 shows the object illustrated in FIG. 9 in a second state in which wear has appeared on the discs 18 and/or 20 .
Particularly as a result of the enlarged spacing of the intermediate ring 24 from the pressure plate 12 or through the enlargement of this spacing the spring device 38 presses the tapered ring 34 “high” on the incline 110 so that the spacing 112 is enlarged and the device comprising the tapered rings 34 , 36 as well as the spring device 38 fills out the interspace between the intermediate plate 24 and the pressure plate 12 . It is also preferred if one or both of the tapered rings 34 , 36 is coupled to the relevant adjoining plate 24 or 12 so that the spring device 38 displaces a one-piece element 34 , 24 opposite a one-piece element 36 , 12 whilst increasing the spacing 112 . It is also preferable if a one-piece coupling of this kind exists only between one of the rings 34 , 36 and the relevant adjoining plate 24 , 12 .
It should be pointed out that preferably a device (not shown) prevents the rings from escaping in order to avoid an enlargement of the spacing 112 .
FIG. 11 shows as an example a plan view of a device as shown by way of example and in partial section in FIGS. 1 to 8 .
The illustration according to FIG. 11 shows one example of the arrangement of the operating levers 26 , 130 wherein the operating levers 26 are provided for coupling or engaging and releasing the clutch device 16 whilst the operating levers 130 are provided for coupling the clutch device 14 .
FIG. 12 shows a sectional view along the line 11 — 11 in FIG. 11 . This arrangement shows by way of example the arrangement of the operating lever 26 for operating the clutch device 16 compared with the arrangement of the operating lever 130 for coupling the clutch device 14 .
FIG. 13 shows an example of the pressure plate 12 according to the invention on the transmission side. In particular the arrangement of the at least one friction device 50 is shown.
FIG. 14 shows an example of the design of the pressure plate 10 on the engine side having through bores 140 for holding the stepped bolts 152 .
According to the invention it is thus proposed that the at least one clutch device of a motor vehicle such as for example a tractor or commercial vehicle adjusts automatically and/or independently so that in particular the operating force of the clutch device is moved within a tolerance band substantially throughout the service life, with the width of this tolerance band preferably being moved towards zero.
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The invention relates to a clutch assembly which is designed to be self-adjusting. The invention relates to a multi-plate clutch assembly as well as to a method for operating a multi-plate clutch which can be produced cost-effectively in a structurally simple manner and which has an improved release characteristic. In particular the clutch has a more constant release characteristic with a high operating accuracy over the entire service life.
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BACKGROUND
1. Field of the Invention
The present invention relates to a device for measuring current which traverses a light-emitting structure, such as a light-emitting diode.
Current measurement at a high potential often constitutes a problem and at present requires expensive and complicated equipment. Equipment is required that is capable of operating at a high potential and of sending measurement values to ground potential. For example in case of high-voltage, direct current transmission, measuring devices having such capabilities are very expensive. At such currents, the operating instruments have to be provided with an insulation that corresponds to the potential of the conductor where the current is measured. This results in constructional problems, for example in current transformers for high voltage levels.
2. Prior Art
It is previously known to use two photo-sensitive elements which are sensitive to different light frequency bands, to radiation detection (U.S. Pat. No. 3,244,894) in which optical fiber bundles are used so that the photosensitive elements are located at some distance away from the location of the measurement.
SUMMARY OF THE INVENTION
Our invention is a modification of the above-mentioned technique and provides a solution to the above-mentioned problems and other problems associated therewith. The emitted light signal is adapted to be supplied to two photo-detectors via at least one optical fiber, with the photo-detectors having different sensitivity spectra with respect to the wavelength of the incident light. At least one of the photo-detectors is connected to an optical filter, and the measuring device includes one additional light-emitting structure (reference structure), the output signal of which is modulated by a frequency other than the first-mentioned light-emitting structure, or which is time-multiplexed by the other frequency. In this way, a device is obtained that provides relatively reliable measurement values at ground potential without using expensive equipment for insulation at the high measurement potential.
In a preferred embodiment at least one of the photodiode detectors is connected to an optical filter.
In another embodiment at least one of the photodetectors is arranged in optical contact with a photoluminescent material. In a further embodiment the emitted light signal is supplied to an integrated wavelength-demultiplexed structure, for example designed so that light signals traverse two pn junctions made in a material having different band gaps. (See Appl. Phys. Lett. 34, 401, 1979.)
The output signals obtained from the photo-detectors are suitably supplied to a quotient forming circuit to obtain a signal which is compensated for intensity variations arising because of temperature variations in the light-emitting structure or because of other error sources.
In a first preferred embodiment the photo-diode detector consists of at least one semiconductor containing silicon or any other high current semiconductor, to which there is connected at least one optical fiber arranged to take up the luminescent radiation that is emitted upon recombination between electrons and holes in the volume of the crystal and which radiation constitutes a measure of current passing through the semiconductor. When measuring currents at a high voltage level, current transformers are used to the greatest possible extent to insulate the measurement system from the high potential of the quantity to be measured. By the embodiment proposed, an optical method is provided which in a simple manner solves the problem of electrically insulating the measurement system from the quantity to be measured.
In a preferred embodiment, the light-emitting structure consists of a light-emitting diode (LED), traversed by current, for example connected to a current transformer, possibly connected in anti-parallel relationship with another diode, whereby the light signal received and transmitted by the optical fiber is a measure of the current. Thus, this embodiment provides a number of possibilities of utilizing electroluminescence for optical measurement of current. The quantity that is measured is the intensity of the light emitted from an LED when it is traversed by an electric current. The light intensity is therefore a reliable measure of the current passing through the LED, and this device can be connected to a current transformer. In this way a current may be measured at a high potential without the current transformer having to be provided with insulation corresponding to the potential of the conductor in which the current is measured. Current transformers can therefore be insulated in the same way independently of the voltage level, which results in considerably cheaper constructions for high voltage levels.
A problem in connection with measurement of the light intensity from the LED is that the light intensity emitted for a certain current is dependent on the temperature of the semiconductor crystal of the diode, but this can be solved in accordance with the embodiments described below.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is exemplified in greater detail in the accompanying drawings, wherein:
FIG. 1 shows a semiconductor for high currents to which optical fibers are connected;
FIG. 2 shows the shape of the semiconductor crystal in a device according to FIG. 1;
FIG. 3 shows emission spectra from two LEDs;
FIGS. 4a and 4b show the measured intensity from two photo-detectors;
FIG. 5 shows a diagram for determining temperature;
FIG. 6 shows a block diagram for an embodiment according to the invention;
FIG. 7 shows a spectrum for an LED;
FIG. 8 shows a system for performing division;
FIG. 9 shows a system for current measurement;
FIG. 10 shows an alternative embodiment of the current measurement system of FIG. 9;
FIG. 11 shows a system for comparative measurement of current; and
FIG. 12 shows an antiparallel connection of two-photo-diodes.
DETAILED DESCRIPTION
The principles of measurement described below are based on spectral division of the light that is emitted from a solid material when traversed by an electric current. A suitable component for this may be a pn junction of GaAs, GaP, GaAlAs, GaAsP or Si, or Schottky diodes of, for example, CdS, CdSe, ZnSe. In the following description and in the claims, the term "light" refers to electromagnetic radiation within the wavelength range 0.1 to 10 μm.
FIG. 1 shows an embodiment of the light-emitting element, in which semiconducting crystal plate 1 is attached between two round metal plates 2 which are electrically connected to current carrying conductor 3. Optical fibers 4 are in optical contact with semiconductor crystal 1 and receive the light which is emitted when the current from conductor 3 passes through crystal plate 1.
FIG. 2 shows the shape of the semiconductor crystal, which is designed as an integrated anti-parallel structure so that it may be used in connection with alternating current as well, that is, so that it may measure during both half-cycles of the AC current. For the current passing through the crystal to give rise to light emission, the current has to be carried by electrons as well as by holes, so that recombination may take place between these particles. This recombination takes place by giving off energy in the form of photons, either in such a way that an electron in the conduction band of the semiconductor is directly joined to a hole in its valence band, or in such a way that the recombination takes place via one or more energy levels in the band gap of the semiconductor. In order that injection of both electrons and holes may take place in an efficient manner, the semiconductor crystal has to be provided with one or more pn junctions. When measuring alternating current, these pn junctions are located in such a configuration that the semiconductor crystal carries current in both directions.
In the embodiment according to FIG. 2, semiconductor 1 of n type is shown which has been provided with p type regions 5 and 6, which may alternately inject holes in n type region 11, depending on the direction of the applied voltage. Ohmic metal contacts 8 and 9 are applied to the surfaces of the semiconductors where the current is injected. When the voltage is applied with a positive potential to contact 8, holes will be injected from p type region 6 into n type region 11, whereas electrons are injected from contact 9 into n type region 11 and further into p type region 6. These particles recombine and emit light which may be detected through opening 12 in metal contact 8. When the voltage is applied with a positive potential to contact 9, holes will be injected from p type region 5 into n type region 11, whereas electrons are injected from contact 8 into n type region 11 and further into p type region 5. In the same way as before, light will be emitted, which may be detected through opening 10 in metal contact 8. The structure, as it is shown in FIG. 2, is intended to be used for measuring alternating current. It must then be designed with two antiparallel-connected pn junctions 6, 11 and 5, 11, respectively. When measuring direct current, a structure consisting only of one pn junction is used, designed as the central portion 5, 11 with the fiber in FIG. 2. The structure in FIG. 2 may also be constructed inversely, so that a p type semiconductor is the starting-point, which is then provided with n regions in the same configuration as the p regions in FIG. 2. Diodes of this kind may be manufactured from silicon using known technology. This means that the conducting area may be made very large, which permits measurements of high currents.
All possible light-emitting structures will be designated "LED" in the following description. The emitted light from the LED is passed into the optical fiber, which is connected to one or more photo-detectors, which may be provided with optical filters. The current which is generated in the photo-detector may be described as follows.
It is assumed that the LED emits a spectrum of α(Hν), where hν is photon energy. The transmission spectrum of the optical filter is τ(hν). The photo-detector generates an electric current, which is a function of the photon energy of the incident light. The spectral response of the photo-detector is described by a function χ(hν). The current φ from the photo-detector for a certain emitted spectrum from the LED and a certain filter may then be expressed by the integral φ=∫α(hν)τ(hν)χ(hν) d(hν).
To facilitate the description in the following, χ(hν) will be omitted from all expressions. This may be justified by the fact that a photo-detector where χ(hν)=a constant is used, a so-called grey photo-detector, or that χ(hν) is incorporated in the function for the emitted spectrum α(hν).
FIG. 3 shows the characteristics of two LEDs having different emission spectra, namely e(hν, T, I) and f(hν, T, I). It is assumed that the diodes are series-connected so as to be traversed by the same current I, and that they are mounted in such a way as to have the same temperature T. If these spectra are separated at hν 0 with the aid of edge filters, the measured intensity of two grey detectors will be: ##EQU1##
The functions φ 1 and φ 2 are respectively illustrated in FIGS. 4a and 4b. Each measured value of the intensities φ 1 and φ 2 corresponds to a function I 1 (T) and I 2 (T), respectively, in the IT plane. With knowledge of the functions I 1 and I 2 , the temperature of the diodes may be determined by solving equations (1) and (2) according to FIG. 5, that is, where I 1 (T)=I 2 (T). A block diagram of one way of applying this is is shown in FIG. 6. LEDs 41 and 42 emit light into two optical fibers, which are joined into fiber 43. Fiber 43 is then branched and is connected to photo-detectors 46 and 47, each of which is provided with edge filter 44 and 45, respectively. The transmission spectra of the edge filters, which are mutually different, are clear from FIG. 7. After amplification of the electric signals from photo-detectors 46, 47 by amplifiers 46a, 47a the amplified signals are fed into computer 51, which determines the functions I 1 (T) and I 2 (T) and which also solves equations (1) and (2) for the condition I 1 (T)=I 2 (T). The temperature and current (TI) of LEDs 41 and 42 are thus obtained from computer 51. The internal values are calculated by calculating units 48 and 49 and the output signals I and T therefrom are put together in unit 50 within computer 51.
If the spectrum from an LED has different dependences on I and T for different values of hν, different parts of the spectrum may be filtered out and be processed in the same way as the spectra from two different LEDs. It is assumed that an LED has the spectrum g(hν, T, I) according to FIG. 7 and that the T and I dependence of g is different for hν<hν 0 and hν>hν 0 , respectively. By utilizing edge filters 44 and 45, respectively, two functions φ 1 and φ 2 may then be obtained according to the following: ##EQU2##
This can be detected by the aid of the photodetector. The system will have the same appearance as the previous FIG. 6 with the difference that only one LED is employed in this case.
The measured intensity φ in the equations (1)-(5) is a function of current and temperature. We will now consider the case where φ may be separated into a product of two functions and ε according to
φ(T, I)=ε(T)· (I) (6)
In the same way as described previously, two parts of a spectrum may then be separated out as indicated by equations (4)-(5) by means of two edge filters 44 and 45 (FIG. 7). Two functions φ 1 and φ 2 are then obtained, each one capable of being separated according to equation (6). Two cases may be considered:
(a) The integral of the spectrum has uniform temperature dependence so that
φ.sub.1 (T, I)=A·ε(T)· .sub.1 (I) (7)
φ.sub.2 (T, I)=B·ε(T)· .sub.2 (T) (8)
(b) The integral of the spectrum has uniform current dependence so that
φ.sub.1 (T, I)=A· (I)·ε.sub.1 (T) (9)
φ.sub.2 (T, I)=B· (I)·ε.sub.2 (T) (10)
If the integral of the spectrum has uniform temperature dependence, a measure of the current will be obtained by performing a division between equations (7) and (8): ##EQU3##
A system for obtaining this is shown in the block diagram of FIG. 8. LED 12 emits light into fiber 13, which is branched off so that the light hits photo-detectors 14 and 15, which are each provided with an edge filter 16 and 17. The electric signals then obtained are amplified by amplifiers 14a and 15a and the quotient therebetween is formed by divider circuit 18, the output signal of which is a non-linear measure of the current. That output signal is linearized in unit 19, which provides an output signal φ proportional to the current in the diode.
If the integral of the spectrum has uniform current dependence, a measure of the temperature of the diode will be obtained by performing a division between equations (9) and (10): ##EQU4##
The temperature of the diode 12 is thus obtained from the quotient φ 2 /φ 1 , whereas its current is obtained by measuring φ 1 or φ 2 and by compensating for the temperature dependence of these parameters when the temperature is known.
A system for measuring current by the above-mentioned method is shown in FIG. 9. LED 20 emits light into fiber 21, which is branched off so that the light hits photodetectors 22 and 23, which are each provided with edge filter 24 and 25, respectively. The electric signals then obtained are amplified by amplifiers 22a and 23a and the quotient therebetween is formed by divider circuit 26. With this information, temperature and current values may be calculated in computer 27.
In the foregoing, a number of spectra have been described, and these may be classified as follows, depending on the signal processing method:
A. Arbitrary spectra from one or two LEDs.
B. Separable spectra, the integral of which has uniform temperature dependence for different photon energies.
C. Separable spectra, the integral of which has uniform current dependence for different photon energies.
In case A, arbitrary light-emitting structures may be used, such as pn junctions of Si, GaAs, GaAlAs, GaP, GaAsP or Schottky diodes of ZnSe, CdS or CdSe.
Spectra of type B are obtained from (Zn,O) and (Cd,O) doped GaP diodes, or from GaAs diodes with recombination processes of band-band type and impurity type occurring at the same time.
Spectra of type C occur at pn junctions of float-zone drawn n type GaAs having electron concentrations in the region 10 16 cm-3, where the n region has been formed by indiffusion of Zn.
When bending the optical fiber, a change in the intensity of the transmitted light occurs, for which some form of compensation has to be carried out. Such compensation has to be carried out for spectrums of type A and type C. For spectra of type B, such compensation is not necessary, since in this case the current is measured as the quotient between two current-dependent quantities which are influenced in the same manner by changes in the bending of the fiber. A method for compensating for fiber bendings in case of A and C spectra is illustrated in FIG. 10.
LED 29 delivers a reference signal into fibers 30 and 31. The signal has a certain frequency which deviates from the frequency of the measuring signal of LED 33. The signal from LED 29 which is fed into fiber 30 is transmitted through fiber 32 and is reflected against the end thereof, which is coated with a partially reflecting layer, close to LED 33. After the reflection the reference signal together with the measuring signal from LED 33 pass through fiber 32 and impinge upon photo-detector 34 which is provided with filter 40. The electric signal from photo-detector 34 is divided into a measuring signal and a reference signal by the action of two electric filters 35 and 36. The reference signal passes through filter 35 and is input to divider circuit 37. The damping in the fiber optical system is dominated by fiber 32, since this has the greatest length of all fiber branches. The reference signal from diode 29 passes through fiber 32 twice and is therefore influenced quadratically by the damping factor thereof. Photo-detector 38, which is connected to LED 29 by a very short fiber 31,delivers an electric signal which is not influenced by the bending of fiber 32. Divider circuit 37 has input signal F 2 φ R from filter 35 as well as signal φ R from photo-detector 38. By root extraction at root extractor circuit 38a, signal F is obtained which is a measure of the damping of fiber 32. Signal F φ s is obtained from filter 36, which signal is divided by divider circuit 39 by the damping factor F, thus obtaining measuring signal φ s . The latter signal is freed from the effect of the fiber bending and may be processed in a manner previously described in dependence on the property of the spectrum of LED 33.
A system for measuring current by a comparative method is illustrated in FIG. 11. The system is built up around two LEDs 61 and 62 having identical properties. The temperature and the current for LED 62 may be controlled by means of regulating systems 63 and 64. Optical signals are detected in four detector systems D1-D4, two of them being provided with filters 65, 66 for dividing the spectrum into different wavelength intervals. From the above description it is clear how this enables determination of temperature as well as of current. The optical signal from LED 61 is amplitude-modulated by frequency f A , which is determined by the frequency of current I A which is to be measured. The optical signal from LED 62 is amplitude-modulated by frequency f B which is chosen so that the output signal from the photo-detector systems may be divided into contributions with frequency f A and frequency f B by electric filtering. The damping factor F is assumed to be caused by damping of the central part of the fiber system, which is marked in the Figure. By forming the quotient of signals according to FIG. 11, signals proportional to T A and T B may be supplied to regulating circuit 63, and signals proportional to φ A and φ B , i.e. light flux from LEDs 61 and 62, may be supplied to regulating system 64. The regulating systems operate in such a way that T A =T B and φ A =φ B . I B and T B are measured in the reference systems and are thus obtained independently of factor F.
The transformation from current into light in current transformer 129 may take place in several ways. To be able to measure the current through conductor 128 during the two half-cycles, two LEDs 21 may be connected in antiparallel as shown in FIG. 12. LEDs 21 may be mounted on the same case and their emitted light intensity may be detected with one or two fiber ends in the manner shown in FIG. 12. A further possibility is to integrate two antiparallelly-connected LEDs in the same semiconductor crystal, the light intensity of the LEDs thus being detected with the same fiber end. This may be carried out in principle in the same way as was shown in connection with the device according to FIG. 2.
The devices according to the above may be varied in many ways within the scope of the following claims.
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The invention relates to a device for measuring current which traverses a light-emitting structure, the current passage thus causing emission of light. It is characterized in that the emitted light signal is adapted to be supplied to two photo-detectors having different sensitivity spectra and/or with at least one photo-detector being provided with an optical filter. The output signals of the photo-detectors are adapted to be supplied to a quotient forming member and/or a calculating member for obtaining a signal which is compensated for temperature variations in the light-emitting structure and other sources of error.
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[0001] This is a divisional application of U.S. patent application Ser. No. 11/146,583, filed on Jun. 7, 2005, which is herein incorporated by reference in its entirety, and assigned to a common assignee.
FIELD OF THE INVENTION
[0002] The invention relates to the general field of magnetic disk recording with particular reference to formation of the write pole.
BACKGROUND OF THE INVENTION
[0003] For current cavity pole designs, RIE (Reactive Ion Etching) and Al 2 O 3 are used to create the pole mold, including a bevel angle. One process phenomenon is that the bevel angle in the yoke area is greater than in the pole area (due to etch area differences). This, however, causes the NH (Neck Height) to be much longer at the bottom of the pole than at its top. Also, the magnetic volume at the flare point is significantly reduced. All of which will impact the head's writing performance.
[0004] FIGS. 1 a - 1 d illustrate this problem. FIG. 1 a is a plan view of a mold which will be used to form the write pole. Line 15 indicated the plane of the ABS (air bearing surface in the completed device). Neck height is the distance from the ABS to the flare
[0005] FIG. 1 b is an isometric view of FIG. 1 a . Section cut 1 c - 1 c corresponds to line 15 in FIG. 1 a while layer 42 is a hard mask of tantalum that was used during RIE (reactive ion etching) to form the pole tip portion of mold area 61 . FIG. 1 d shows one of the sidewalls 16 in the tip area, illustrating how it slopes, at angle 17 (typically between about 7 and 12 degrees), at the flare point which results in the longer neck height B at the bottom of 61 relative to neck height A at the top.
[0006] This invention describes a new process to reduce the bevel angle in the yoke area while continuing to maintain the angle at the pole tip area, thereby resulting in a neck height that is the same at both levels. A routine search of the prior art was performed with the following references of interest being found:
[0007] U.S. Pat. No. 6,614,620 (Tagawa et al) describes using Al 2 O 3 to etch the pole. In U.S. Pat. No. 6,510,024, Otsuka et al. disclose Al 2 O 3 or other low etch rate material used to form the recording gap. U.S. Pat. No. 6,854,175 (Sasaki) shows that tantalum can be used in addition to alumina for the write gap layer while U.S. Pat. No. 6,504,675 (Shukh et al) discusses the slope angle of the pole sides.
[0008] U.S. Patent Application 2004/0175596 (Inomata et al) shows a tantalum protective layer on top of a stack including Al 2 O 3 . U.S. Patent Application 2002/0041465 (Sasaki) shows tantalum on alumina and RIE to form the pole. U.S. Pat. Nos. 4,672,493 (Schewe) and 4,656,546 (Mallory) disclose magnetic recording head pole designs.
SUMMARY OF THE INVENTION
[0009] It has been an object of at least one embodiment of the present invention to provide a method to form a cavity having inner walls of varying slope.
[0010] Another object of at least one embodiment of the present invention has been to provide a process to form a mold for use in the manufacture of a perpendicular magnetic pole write head.
[0011] These objects have been achieved by replacing the conventional alumina with tantalum in the yoke portion of the mold. When both the tantalum and the alumina areas are simultaneously subjected to reactive ion etching, sloping sidewalls are obtained in the alumina area (write pole portion) whereas the sidewalls are almost vertical in the tantalum (yoke) area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 a is a plan view of a magnetic write pole mold of the prior art.
[0013] FIG. 1 b is an isometric view of FIG. 1 a .
[0014] FIG. 1 c is an edge-on view of a sidewall in the pole tip area.
[0015] FIG. 1 d is a cross-section made at the future site of the ABS.
[0016] FIG. 2 shows formation of a layer having a beveled edge as part of a liftoff process.
[0017] FIGS. 3 a and 3 b illustrate embedding the beveled edge of FIG. 2 in a layer.
[0018] FIG. 4 shows a second layer over said embedded beveled edge layer.
[0019] FIG. 5 is a cross-section of the mask used to etch the mold.
[0020] FIG. 6 is a plan view of the cross-section seen in FIG. 5 .
[0021] FIG. 7 shows the structure of FIG. 5 at the completion of etching.
[0022] FIG. 8 a shows the appearance of FIG. 6 when the latter is formed according to the process of the present invention. In particular, the neck height is the same at the top and the bottom of the write pole.
[0023] FIG. 8 b is an isometric view of FIG. 8 a.
[0024] FIG. 8 c is a cross-sections taken at the site of the future ABS.
[0025] FIG. 8 d is a view of part of the sidewall of the pole tip trench.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Before cavity etching by RIE, tantalum is used in the yoke area instead of Al 2 O 3 , and also in the pole tip area. This is followed by the RIE process. Due to material etch property differences, the Al 2 O 3 sidewalls will have the designed bevel angle, and the Ta sidewall will remain almost vertical. This is for NH (neck height) at the bottom of the pole to equal NH at the top of pole.
[0027] Compared with the existing cavity process that uses only Al 2 O 3 for mold material, this invention uses two materials for RIE etching, Al 2 O 3 at the pole tip and Ta at the yoke. Therefore, different bevel angles can be created for different portions. NH at the bottom of the pole will be the same as at the top of the pole, and the magnetic volume will be larger in the flare point area. There are three additional processes in order to deposit Ta.
[0028] One is a bi-layer photo liftoff process used in conjunction with sputtered Ta, second is deposition of Al 2 O 3 , and the third is a polishing step to make the surface flat.
[0029] With the existing cavity pole process, NH at the bottom of the pole is longer than at the top. The present invention makes NH at the bottom the same as at the top of the pole, and the magnetic volume is also increased.
[0030] Now follows a detailed description of the process of the present invention. This description will also make clear the structure of the present invention.
[0031] Referring now to FIG. 2 the process of the invention begins with the formation of liftoff mask 13 a / 13 b on substrate 11 (of a material such as alumina). Both layers of the liftoff mask are photosensitive but layer 13 a is easily dissolved while layer 13 b is etch resistant. Tantalum layer 12 is then deposited to a thickness between about 2,000 and 3,000 Angstroms, using a process such as sputtering, chemical vapor deposition ( CVD), or ion beam deposition, which allows the deposited tantalum to extend beneath the overhang (of 13 b over 13 a ) so that the tantalum has a wedge shaped edge that slopes towards the substrate at an angle of about 45 degrees. Following liftoff of mask 13 a /b, tantalum layer 12 will remain in the area within which the yoke portion of the write head will later be formed.
[0032] Next, as seen in FIG. 3 a , layer of alumina 21 is deposited on all exposed surfaces, to a thickness between about 3,000 and 4,000 Angstroms, following which the structure is planarized until tantalum layer 12 is just exposed, giving the structure the appearance illustrated in FIG. 3 b . This is followed by the deposition of second tantalum layer 42 , to a thickness between about 500 and 1,000 Angstroms, as shown in FIG. 4 .
[0033] Referring next to FIG. 5 , photoresist layer 53 is deposited and patterned to form a mask that defines areas for the write pole and the yoke. The width of the write pole area is typically between about 0.15 and 0.25 microns while that of the yoke area (at its widest) is typically between about 10 and 15 microns. A key feature of the invention is that the flare point, where the narrow write pole first widens to become the yoke, is located directly over tantalum layer 12 's sloping edge 56 . This can be seen in FIG. 6 which is a plan view of the cross-section shown in FIG. 5 , showing the relative positions of write pole 61 and yoke 62 .
[0034] Now follows another key feature of the invention, namely the simultaneous etching, by means of a RIE process, of both the write pole and yoke areas. Our preferred RIE process has been source power of up to 1,200 W, chuck power of 40 W, at a pressure of 0.3 Pa for about 90 seconds. The chamber temperature was about 100% C and the etchants were Cl 2 at a flow rate of about 15 sccm, BCl 3 at a flow rate of about 80 sccm, and CF 4 at a flow rate of about 12 sccm. It should be noted that similar, related, RIE processes could also have been effectively used.
[0035] At the completion of RIE, cavity 61 / 62 is formed in the alumina and tantalum layers. Because of the different responses of the alumina and the tantalum layers to the RIE process, cavity portion 61 (for the write pole tip) is found to have sidewalls that slope at an angle of between about 7 and 12 degrees while cavity portion 62 has sidewalls that slope an angle of up to about 4 degrees.
[0036] This difference in the slopes of the sidewalls in the two regions can be seen in FIG. 7 , with layer 21 showing a significant slope while for layer 12 the slope is near vertical. FIG. 8 a is a plan view of the section seen in FIG. seen in FIG. 7 while FIG. 8 b is a partial isometric view similar to FIG. 1 b , showing pole tip portion 61 (with sloping sidewalls) and yoke portion 62 (with steep sidewalls).
[0037] FIG. 8 c is a cross-section taken at 8 c - 8 c in FIG. 8 b showing the afore-mentioned slope of the sidewalls at the site of the future ABS while FIG. 8 d views the sidewall from inside the pole tip section where it can be seen that, due to the low value of etch angle 87 , the neck height NH is essentially the same at the top as at the bottom.
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An improved mold, for use in the formation of a perpendicular magnetic write head, is described, together with a process for its manufacture. Conventional alumina is replaced by tantalum in the yoke portion of the mold. When both the tantalum and the alumina areas are simultaneously subjected to reactive ion etching, sloping sidewalls are obtained in the alumina area (write pole tip portion) whereas the sidewalls are almost vertical in the tantalum (yoke) area, resulting in a uniform neck height.
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