description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an improvement in a method and device for the diagnosis and treatment of speech disorders and more particularly to the dynamic measurement of the functioning of the velum in the control of nasality during speech.
2. Description of the Related Technology
A. Velar Control and Oronasal Valving in Speech.
During speech or singing, it is necessary to open and close the passageway connecting the oral pharynx with the nasal pharynx, depending on the specific speech sounds to be produced. This is accomplished by lowering and raising, respectively, the soft palate, or velum. Raising the velum puts it in contact with the posterior pharyngeal wall, to close the opening to the posterior nasal airflow passageway.
This oronasal (or velopharyngeal, as it is usually referred to in medical literature) passageway must be opened when producing nasal consonants, such as /m/ or /n/ in English, and is generally closed when producing consonants that require a pressure buildup in the oral cavity, such as /p/, /b/ or /s/. During vowels, and also the vowel-like sonorant consonants (such as /l/ or /r/ in English), the oronasal passageway must be closed or almost closed for a clear sound to be produced, though in some languages an appreciable oronasal opening during a vowel can have phonemic significance and thus be required for proper pronunciation. The first vowels in the words “francais” and “manger” in French are examples of such nasalized vowels. In addition, vowels adjoining a nasal consonant are most often produced with some degree of nasality during at least part of the vowel, especially if the vowel is between two nasal consonants (such as the vowel in “man” in English).
There are many disorders that result in inappropriate oronasal valving, usually in the form of a failure to sufficiently close the oronasal passageway during non-nasal consonants or non-nasalized vowels. Such disorders include cleft palate and repairs of a cleft palate, hearing loss sufficient to make the nasality of a vowel not perceptible to the speaker, and many neurological and developmental disorders. The effect on speech production of insufficient oronasal closure is usually separated into two effects, namely, the nasal escape of pressurized oral air, termed ‘nasal emission’, that limits oral pressure buildup in those speech sounds requiring an appreciable oral pressure buildup (as /p/, /b/, /s/ or /z/), and, secondly, the incomplete velar closure during vowels and sonorant consonants that is often referred to as ‘nasalization’. (See R. J. Baken and R. F. Orlikoff, Clinical Measurement of Speech and Voice, second edition, 453 et seq. (Singular, Thomson Learning, 2000)). The terminology used here is that suggested by Baken and Orlikoff, supra, who also prefer to reserve the term ‘nasality’ for the resulting perceived quality of the voice.
Since the action of the velum is not easily observed and the acoustic effects of improper velar action are sometimes difficult to monitor auditorally, there is a need in the field of speech pathology for convenient and reliable systems to monitor velar action during speech, both to give the clinician a measure of such action and to provide a means of feedback for the person trying to improve velar control.
B. Previous Methods for Measuring Velar Function
The various methods for monitoring velar function according to the present art can generally be also divided into two categories, according to the aspect of nasality being measured: (a) those methods that measure velar control during consonants requiring an oral pressure buildup, and (b) those methods that measure velar control during vowels and sonorants. In this application, for brevity we hereafter use the term ‘vowel’ to refer to both vowels and sonorants (vowel-like consonants).
The field of the invention relates to a commonly used method for measuring the nasalization of vowels by recording the sound energies (either radiated acoustic pressure or radiated acoustic volume velocity, or airflow) separately emitted from the nose and mouth, usually in conjunction with the placing of a sound barrier held against the upper lip to improve the separation of the nasal and oral sounds, with microphones placed above and below the barrier, respectively. In U.S. Pat. Nos. 3,752,929 and 6,974,424, the nasal and oral energies are recorded in the form of the respective radiated acoustic pressures, while in U.S. Pat. No. 6,850,882, the nasal and oral sounds are recorded in the form of the respective volume velocities, using a two-chamber pneumotachograph mask having a separating membrane contacting the upper lip. The respective nasal and oral signals are suitably filtered and a ratio taken of the nasal to oral energies. This ratio is commonly referred to as vowel ‘nasalance’, and can be presented as either the Nasalance Ratio (nasal energy divided by oral energy) or Percent Nasalance (nasal energy divided by the sum of nasal and oral energies). The term ‘nasalance’ can be used to refer to either of these measures, or to any third measure mathematically derived by comparing oral and nasal acoustic energies.
Though nasalance is valuable as an objective measure of the degree of a lack of velar closure, in all methods for measuring vowel nasalance, there is a marked dependence of the value obtained on the vowel being spoken, even with the same degree of closure for each vowel. (Lewis K E, Watterson T and Quint T, “The effect of vowels on nasalance scores”, Cleft Palate-Craniofacial Journal, 37: 584-589 (2000); Gildersleeve-Neumann, and Dalston, “Nasalance scores in noncleft individuals: why not zero?” Cleft Palate-Craniofacial Journal, 38: 106-111 (2001)) This variation is presumed to be caused by the fact that for vowels having a constriction in the vocal tract anterior to the velum, there is a higher acoustic energy in the oral pharynx and thus a higher energy emitted nasally for the same degree of velar opening. Thus for a given velar opening, the vowel /i/ as in “bead” has a higher value of nasalance than the vowel /a/ as in “bob”. For example, Baken and Orlikoff, supra, in their summary of the literature, report that the nasalance recorded for normal-speaking children according to the present art can vary from approximately 7% in a non-nasalized /a/ vowel to 17% in a non-nasalized /i/ vowel (with both vowels measured in a /p/ phonetic context that minimizes nasalization of the vowel). This range is consistent with the measurement in FIG. 5 below for an adult subject. This variation of 10% according to the vowel being spoken occurs even if there is no velar opening, since with no velopharyngeal opening there is still a small amount of nasally emitted energy that is caused by vibrations of the velar tissue, and this energy is apparently greater for the /i/ vowel.
Errors of 7% or 17% are quite significant in that the total range for the nasalance of vowels is much less than 100%. This range is theoretically from zero to only about 40%. Consequently, the nasalization of a specific vowel can be expected to raise its nasalance score by no more than about 30%, depending on the degree of nasalization (velar opening). The limitation on the total range for vowels can be better understood by considering that if the velum is fully lowered during a typical vowel, resulting in an unnaturally large degree of nasalization, the Percent Nasalance should be close to 50%, say between 40% and 60%, since there is roughly equal energy emitted from the oral and nasal passageways. (This assumes no abnormal constriction of the nasal passages, as may be evidenced with the swollen mucous membranes accompanying nasal congestion.) Values much above 50% would be expected only during nasal consonants, when the oral passageway is occluded. Thus, when a device for measuring nasalance is constructed according to the present art, the nasalance for a totally non-nasalized /i/vowel could be similar to that recorded for a moderately nasalized /a/ vowel.
In addition to the variation with the vowel spoken, nasalance values obtained using devices constructed according to the current art are affected by acoustic energy from one channel crossing over into the other channel because of an incomplete acoustic separation of the channels. Thus the lowest values of nasalance obtained tend to be about 5% to 7%, instead of near zero, as otherwise expected, and the values of nasalance recorded in properly articulated nasal consonants tend to vary from approximately 90% to 95%, instead of being closer to the theoretically expected 100%.
The variation of vowel nasalance according to the vowel spoken can be reduced somewhat by suitably filtering the oral and nasal signals or by using airflows instead of pressures as the variables to be measured, and the effect of acoustic crossover can be decreased by improving the acoustic separation means, however, none of these methods have shown the ability to eliminate or make negligible these distortion effects. In their comprehensive review of attempts to use nasalance as a measure of velar closure and nasality, Baken and Orlikoff, supra, p. 466, conclude that “It also remains unclear how nasalance is affected by the physical characteristics of the oral and nasal cavities . . . and by the phonetic demands of the spoken utterance.” These authors review a number of attempts to devise testing procedures that circumvent, or at least take into account, the variability of the nasalance measure, by limiting testing to a fixed phonetic sequence, as a particular sentence, passage or nonsense syllable sequence.
SUMMARY OF THE INVENTION
It is a purpose of embodiments of the present invention to provide effective methods of and apparatus for significantly reducing the variation of recorded nasalance with the vowel being spoken, as well as for compensating for the acoustic energy crossing from one channel to the other because of incomplete acoustic separation of the channels. Nasalance measurements obtained according to embodiments of the invention better represent the degree of nasalization for all vowels, and could be effectively used with an arbitrary phonetic sequence in speech testing and training.
Methods for Identifying Vowels Spoken
In some embodiments of the methods and apparatus encompassed by the present invention, use is made of a computer program for the identification of the vowel being spoken. There are many such programs available, usually based on some partitioning of a multidimensional representation the frequency spectrum of the acoustic signal. One representative example has been presented by Zahorian and Nossair (A Partitioned Neural Network Approach for Vowel Classification Using Smoothed Time/Frequency Features, IEEE Transactions on Speech and Audio Processing, Vol. 7, No. 4, pp. 414-425, (1999)).
A method is described for correcting and improving the functioning of certain devices for the diagnosis and treatment of speech that dynamically measure the functioning of the velum in the control of nasality during speech. In said devices the respective oral and nasal components of the radiated acoustic energy during voiced speech sounds are physically separated and selectively compared to produce a measure of the nasalization that results from an incomplete velar closure between the oral and nasal cavities. This measure is generally termed nasalance. Previous systems for measuring nasalance do not accurately reflect the degree of velar closure in that the measure they provide can vary significantly with the vowel being spoken with the same degree of velar opening. The correction method described herein uses an estimate of the vowel frequency spectrum to greatly reduce the variation of nasalance with the vowel being spoken, so as to result in a corrected value of nasalance that reflects with greater accuracy the degree of velar opening. Correction is also described for reducing the effect on nasalance values of energy from the oral and nasal channels crossing over into the other channel because of imperfect acoustic separation.
It is an object of this invention to improve the utility of vowel nasalance measurement systems by correcting the nasalance reading for differences related to the articulation of the vowel being spoken.
It is a further object of this invention to correct a nasalance reading for the energy in one of the oral or nasal channels crossing over into the other channel because of incomplete acoustic separation of the channels.
In one embodiment of this invention, an estimate of the vowel being spoken is made is by measuring the frequency spectrum of the vowel being spoken, with the estimated vowel used to determine the proper correction of the nasalance reading.
In another embodiment of this invention, the patterns for various representative vowels are obtained from the user by having the user speak the vowels. In a preferred embodiment, the vowels are spoken in close conjunction with so-called pressure consonants, such as /b/ or /p/ in English that act to close the velopharyngeal pathway, so that the vowels recorded are non-nasalized or minimally nasalized.
In yet another embodiment of this invention, correction of the nasalance reading for incomplete acoustic separation of the respective nasal and oral channels is accomplished by subtracting from the energy recorded for each channel a percentage of the energy recorded for the other channel, before the calculation of nasalance is performed.
In yet another embodiment of this invention, correction of the nasalance reading for the vowel being spoken is accomplished by subtracting from the energy recorded for the nasal channel a proportion of the energy recorded for the oral channel, before the calculation of nasalance is performed, with the said proportion varying according to the vowel being spoken.
These, together with other objects, advantages, features and variants which will be subsequently apparent, reside in the details of the implementation of this method as more fully hereinafter described in the claims, with reference being had to the accompanying drawings forming a part thereof, wherein like numerals refer to like elements throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of a system for measuring nasalance that employs a correction for the vowel spoken.
FIG. 2 is another diagrammatic representation of an alternative system for measuring nasalance that employs a correction for the vowel spoken.
FIG. 3 is a diagrammatic representation of the system in FIG. 2 with provision added for correcting the nasalance values for acoustic crossover caused by inadequate acoustic separation between the nasal and oral channels.
FIG. 4 is a diagrammatic representation of the system in FIG. 2 with provision added for individualizing the parameters of the vowel identification determination.
FIG. 5 shows nasalance measurements that illustrate the manner in which the method of FIG. 3 would correct nasalance values.
FIG. 6 is a block diagram of a computer platform for executing computer program code implementing processes and steps according to various embodiments of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention is described in a preferred embodiment in the following description with reference to the Figures, in which like numbers represent the same or similar elements. While this invention is described in terms of one or more preferred embodiments, it will be appreciated by those skilled in the art that variations may be accomplished in view of these teachings without deviating from the spirit or scope of the present invention. For example, the present invention may be implemented using any combination of computer programming software, firmware or hardware. As a preparatory step, the computer programming code (whether software or firmware) will typically be stored in one or more machine readable storage devices such as fixed (hard) drives, diskettes, optical disks, magnetic tape, semiconductor memories such as ROMs, PROMs, etc. The apparatus including the computer programming code may be used by either executing the code directly from the storage device, by copying the code from the storage device into another storage device such as a hard disk, RAM, etc. or by transmitting the code on a network for remote execution. Methods according to the invention may be practiced by combining one or more machine readable storage devices containing the code according to the present invention with appropriate standard computer hardware to execute the code contained therein. An apparatus for practicing the invention may be one or more computers and storage systems containing or having network access to computer program(s) coded in accordance with the invention, and the method steps of the invention may be accomplished by routines, subroutines, or subparts of a computer program product.
FIG. 1 illustrates an embodiment of the method for improving the measurement of voice nasalization described in this invention. In this figure, microphones 1 and 2 that record the oral and nasal acoustic energies, respectively, are separated acoustically by a separation means 3 , which can be a partition resting against the upper lip or a mask that includes such a partition. The signals from these microphones, 11 and 12 , are led to a computer program or other computation device 4 that computes numerical values of the nasal and oral voice energies, 21 and 22 respectively, in a manner known to those of skilled in the art as set forth in the publications mentioned earlier and cited at the end of this disclosure. From the energy measures 21 and 22 , a calculation of nasalance 10 is made by computer program or other computation device 5 , implemented and constructed according to, for example, the aforementioned publications and otherwise employing methods and techniques known by those skilled in the art. The oral microphone signal 12 and optionally the nasal microphone signal 11 , or optionally the signal from a third microphone (not shown) that is placed so as to pick up both oral and nasal energy, are also entered into a computer program or other computation device 6 known to those skilled in the art that provides an estimate 13 of the vowel being spoken, which could be implemented in the manner described by Zahorian and Nassair (supra). The estimate 13 is provided to a computer program or other computation device 7 that computes a corrected value 14 for the nasalance from the original value 10 . This corrected value 14 is input to a display device 8 .
FIG. 2 illustrates another embodiment of the method for improving the measurement of voice nasalization described in this invention. In this embodiment, using the output 13 of the vowel identification program 6 , correction is made by a computer program or other computation device 7 to the measured nasal and oral acoustic energies 21 and 22 , to produce corrected estimates of the nasal and oral energies, 31 and 32 respectively, before the nasalance estimate 16 is computed from these energies by the program 5 .
FIG. 3 illustrates yet another embodiment of this invention in which there has been added a module 9 for the correcting for acoustic crossover between the nasal and oral channels caused by the imperfect acoustic separation of the channels. Modules 9 , as may other functional systems and subsystems included in and/or implemented by various embodiments, may be implemented by software, hardware, firmware and/or any combination thereof. Module 9 may function to implement or cause a subtraction from the measured energy in each channel of a fixed percentage of the measured energy in the other channel. This program has as output estimates of the nasal energy 41 and oral energy 42 which are substantially corrected for the crossover of acoustic energy between the nasal and oral channels caused by imperfect acoustic separation, but are not corrected for the variations caused by the vowel being spoken. Correction for the vowel being spoken, if it is to be included in this embodiment, is performed by program 7 , which has as input the energy estimates 41 and 42 .
FIG. 4 illustrates another embodiment of the invention in which the parameters for the identification of a specific user's vowels are individualized for that user. In this embodiment, spectral parameters 15 that are used in the identification of the vowel by the program 6 are also output from the program 6 . With the user speaking a predetermined vowel, these parameters are used by a program 8 to determine a set of individualized parameters 17 to be used in later testing by the vowel identification program 6 to output the correct identification of the vowel being spoken.
FIG. 5 illustrates the manner in which the method of FIG. 3 would correct nasalance values. The syllable sequence /papapa mamama pipipi mimimi/ was spoken by an adult male speaker with normal speech, and nasalance recorded using a mask-type separator for the oral and nasal energies. The system used for these nasalance measurements was the NAS system presently marketed by Glottal Enterprises (Nasalance System NAS-1 User Manual, supra). The vowels /a/ and /i/ were chosen because the /a/ vowel (as in “bob” or “bomb”) and the /i/ vowel (as in “bee” or “bead”) produce the least and the most, respectively, vowel-related nasal acoustic energy (Baken and Orlikoff, supra, Lewis and Watterson, supra, and Gildersleeve-Neumann and Dalston, supra)
The /p/ and /m/ consonant contexts for the vowels were chosen because for a speaker having normal articulation patterns, vowels between two /p/ consonants are produced with little or no nasalization, since the velopharyngeal passageway must be sealed to produce the oral pressure for the /p/ consonants, while between two /m/ consonants, the vowel is always produced nasalized because of coarticulation.
Shown in the FIG. 5 is the variation of nasalance for the middle syllable of each sequence of three syllables. Following standard phonetic notation, the nasalized vowels (spoken between the /m/ consonants) are labeled with a tilde (˜) over the vowel syllable, while the non-nasalized vowels (between the /p/ consonants) have no tilde.
At left in each of the two panels of FIG. 5 is the nasalance as measured with no correction for acoustic crossover, that is, as measured by the unmodified commercial system constructed according to the present art. The average value of nasalance, measured in the central 50% of each vowel, for the vowels are approximately 6.5% for the non-nasalized /a/ and 13.1 percent for the non-nasalized /i/. The values for the nasalized variants of each vowel were 22.2% and 41.8%. These values agree with values reported in the literature for these vowels, including in the references cited in the present disclosure.
Note that if nasalance were to represent the degree of the velopharyngeal opening, the nasalance values for the non-nasalized vowels should be uniformly low, say below 3 or 4 percent.
To test the method for correcting for acoustic energy crossover, according to one embodiment, the analysis software was modified so as to subtract 4% of the nasal energy from the measured oral energy and 4% of the oral energy from the measured nasal energy. The value of 4% was selected to be slightly less than the values of 5% to 7% that might be predicted as optimum from the nasalance values cited in the literature (Baken and Orlikoff, supra, and Gildersleeve-Neumann and Dalston, supra). The resulting corrected values of nasalance are shown at right in each of the two panels of FIG. 5 .
With a correction made for acoustic crossover between the oral and nasal channels, nasalance values were reduced to 2.4% for the non-nasalized /a/ vowel, and approximately 10.9% for non-nasalized /i/ vowel, an improvement, in both cases, in having the nasalance reflect the degree of velar closure. The differential in the nasalance values between nasalized and non-nasalized vowels of the same type was increased after correction, which is also an improvement. It can be noted that in both these measures, using a correction of slightly larger than 4%, say 5% or 6%, would yield further improvement.
Thus, for the vowel /a/, the corrected nasalance values reflect well the fact that there was no velar opening. However, further correction of the nasalance values for the /i/ vowels, to make them more similar to those for the /a/ vowels, would require the use of the additional correction for the vowel being spoken that is described in the application. In a possible implementation of this vowel-based correction, a percentage of the oral energy, dependent on the vowel, would be subtracted from the nasal energy, so as to reflect the degree to which additional nasal energy is forced by the vocal tract constriction anterior to the velum presented by the /i/. For example, if this percentage was chosen as 10% for the vowel /i/, a calculation of the resulting correction shows that the average corrected nasalance for the non-nasalized /i/ vowel would be reduced to 2.2%, clearly identifying it to be non-nasalized. The value for the nasalized vowel would go to 37.3% from 41.0%, with a differential of 35.1% between the nasal and non-nasal /i/ vowels. Correction could also be made by multiplying the computed nasalance value by a correction factor related to the vowel determination.
FIG. 6 is a block diagram of a computer platform for executing computer program code implementing processes and steps according to various embodiments of the invention. Object processing and database searching may be performed by computer system 600 in which central processing unit (CPU) 601 is coupled to system bus 602 . CPU 601 may be any general purpose CPU. The present invention is not restricted by the architecture of CPU 601 (or other components of exemplary system 600 ) as long as CPU 601 (and other components of system 600 ) supports the inventive operations as described herein. CPU 601 may execute the various logical instructions according to embodiments of the present invention. For example, CPU 601 may execute machine-level instructions according to the exemplary operational flows described above in conjunction with FIGS. 1 and 2 .
Computer system 600 also preferably includes random access memory (RAM) 603 , which may be SRAM, DRAM, SDRAM, or the like. Computer system 600 preferably includes read-only memory (ROM) 604 which may be PROM, EPROM, EEPROM, or the like. RAM 603 and ROM 604 hold/store user and system data and programs, such as a machine-readable and/or executable program of instructions for object extraction and/or video indexing according to embodiments of the present invention.
Computer system 600 also preferably includes input/output (I/O) adapter 605 , communications adapter 611 , user interface adapter 608 , and display adapter 609 . I/O adapter 605 , user interface adapter 608 , and/or communications adapter 611 may, in certain embodiments, enable a user to interact with computer system 600 in order to input information.
I/O adapter 605 preferably connects to storage device(s) 606 , such as one or more of hard drive, compact disc (CD) drive, floppy disk drive, tape drive, etc. to computer system 600 . The storage devices may be utilized when RAM 603 is insufficient for the memory requirements associated with storing data for operations of the system (e.g., storage of videos and related information). Although RAM 603 , ROM 604 and/or storage device(s) 606 may include media suitable for storing a program of instructions for video process, object extraction and/or video indexing according to embodiments of the present invention, those having removable media may also be used to load the program and/or bulk data such as large video files.
Communications adapter 611 is preferably adapted to couple computer system 600 to network 612 , which may enable information to be input to and/or output from system 600 via such network 612 (e.g., the Internet or other wide-area network, a local-area network, a public or private switched telephony network, a wireless network, any combination of the foregoing). For instance, users identifying or otherwise supplying a video for processing may remotely input access information or video files to system 600 via network 612 from a remote computer. User interface adapter 608 couples user input devices, such as keyboard 613 , pointing device 607 , and the dual microphone with acoustic separator required for nasalance measurement 614 , and output devices, such as speaker(s) 615 , to computer system 600 . Display adapter 609 is driven by CPU 601 to control the display on display device 610 to, for example, display information regarding a video being processed and providing for interaction of a local user or system operator during object extraction and/or video indexing operations.
It shall be appreciated that the present invention is not limited to the architecture of system 600 . For example, any suitable processor-based device may be utilized, including without limitation personal computers, laptop computers, computer workstations, and multi-processor servers. Moreover, embodiments of the present invention may be implemented on application specific integrated circuits (ASICs) or very large scale integrated (VLSI) circuits. In fact, persons of ordinary skill in the art may utilize any number of suitable structures capable of executing logical operations according to the embodiments of the present invention.
The illustrated embodiments are shown by way of example. The spirit and scope of the invention is not restricted by the preferred embodiments shown. Thus, it is to be understood that the invention is capable of use in various combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein.
It should also be noted and understood that all publications, patents and patent applications mentioned in this specification are indicative of the level of skill in the art to which the invention pertains. All publications, patents and patent applications are herein incorporated by reference to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety.
PUBLICATIONS CITED
U.S. Patent Documents
3,752,929
August 1973
Fletcher
6,850,882
February 2005
Rothenberg
6,974,424
December 2005
Fletcher
Non-Patent Publications
Baken, R. J. and Orlikoff, R. F., Clinical Measurement of Speech and Voice, second edition, Chapter 11, Velopharyngeal Function, pp. 453-510 (Singular, Thomson Learning, 2000)
Lewis, K E, Watterson, T and Quint, T, “The effect of vowels on nasalance scores”, Cleft Palate-Craniofacial Journal, 37: 584-589 (2000)).
Gildersleeve-Neumann, E. E. and Dalston, R. M . . . “Nasalance scores in noncleft individuals: why not zero?” Cleft Palate-Craniofacial Journal, 38 (2), pp. 106-111, 2001.
Nasalance System Model NAS-1 User Manual. Glottal Enterprises, April, 2009
Zahorian, S. A. and Nossair, Z. B., “A Partitioned Neural Network Approach for Vowel Classification Using Smoothed Time/Frequency Features,” IEEE Transactions on Speech and Audio Processing, Vol. 7, No. 4, pp. 414-425, July, 1999.
|
A method is described for correcting and improving the functioning of certain devices for the diagnosis and treatment of speech that dynamically measure the functioning of the velum in the control of nasality during speech. The correction method uses an estimate of the vowel frequency spectrum to greatly reduce the variation of nasalance with the vowel being spoken, so as to result in a corrected value of nasalance that reflects with greater accuracy the degree of velar opening. Correction is also described for reducing the effect on nasalance values of energy from the oral and nasal channels crossing over into the other channel because of imperfect acoustic separation.
| 6
|
FIELD OF THE INVENTION
[0001] This invention relates to the field of electronic article surveillance (EAS) systems, and in particular, an improved EAS coil.
BACKGROUND
[0002] Electronic article surveillance (EAS) systems are used for inventory control and to prevent theft and similar unauthorized removal of articles from a controlled area. Electronic article surveillance systems allow the identification of a marker or tag within a given detection region. EAS systems have many uses, but most often they are used as security systems for preventing shoplifting in stores or removal of property in office buildings. EAS systems come in many different forms and make use of a number of different technologies. The EAS systems typically utilize interrogation zones that must be traversed to remove articles from the controlled area. An electronic article surveillance system detectable label is attached to an article that is to be protected. When an unauthorized article removal is attempted, the EAS system detects the label as the article traverses the interrogation zone. The electronic article surveillance responds to the detected label with an alarm condition and a preselected action is taken. When an article is properly purchased or otherwise authorized for removal from the protected area, the EAS marker is either removed or deactivated. If the EAS marker is not removed or deactivated, the electromagnetic field causes a response from the EAS marker in the interrogation zone. A typical EAS system includes a transmitting and receiving antenna electronic detection unit, markers and/or tags, and a detacher or deactivator.
[0003] Transmitting and receiving antennas, often referred to as a transmitter/receiver pair, are usually mounted in floors, walls, ceilings or free standing pylons. These are necessarily fixed mounting positions. The articles, on the other hand, may be carried through the field of the interrogating signal in any orientation, and accordingly, so may the tags or markers.
[0004] An antenna acting as a receiver detects the EAS marker's response indicating an active marker is in the interrogation zone. An associated controller provides an indication of this condition such that appropriate action can be taken to prevent unauthorized removal of the item from the protected area.
[0005] The markers and/or tags have special characteristics and are specifically designed to be affixed to or embedded in merchandise or other objects sought to be protected. Electronic article surveillance (EAS) systems have employed either reusable EAS tags or disposable EAS tags to monitor articles. The reusable labels normally placed on the goods at the commercial establishment by a clerk and are removed from the goods by the clerk with a special tool before the customer exits the store. The label is then reused by having the clerk place the label on another article. The disposable tags are generally attached to the packaging by adhesive or are disposed inside the packaging. These tags remain with the articles and must be deactivated before they are removed from the store by the customer. Deactivation devices use coils which are energized to generate a magnetic field of sufficient magnitude to render the EAS tag inactive.
[0006] Efforts regarding such systems have led to continuing developments to improve their versatility, practicality and efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a top view of an exemplary EAS coil.
[0008] FIG. 2 is a cross-sectional view taken along lines 2 - 2 of FIG. 1 .
[0009] FIG. 3 a is a perspective view of an exemplary EAS system.
[0010] FIG. 3 b is an exploded perspective view of a portion of the EAS system shown in FIG. 3 a.
[0011] FIG. 3 c is an exploded cross-sectional view of a portion of the EAS system shown in FIG. 3 a.
[0012] FIG. 3 d is a perspective view of an exemplary EAS coil in the EAS system shown in FIG. 3 a.
[0013] FIG. 4 is a schematic block diagram of an exemplary EAS system.
DETAILED DESCRIPTION
[0014] Reference will now be made to exemplary embodiments of the invention which are illustrated in the accompanying drawings. This invention, however, may be embodied in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these representative embodiments are described in detail so that this disclosure will be thorough and complete, and will fully convey the scope, structure, operation, functionality, and potential of applicability of the invention to those skilled in the art. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0015] An exemplary EAS coil or antenna 110 configuration illustrated in FIGS. 1 and 2 is at least one conductor or wire 114 , 118 arranged in a loop or coil and encased in an insulation strip 122 . Exemplary wires are large gauge conductive coil wire co-molded with or molded into insulation material. Arrangement of the wires may be in the form of a pair of planar loops forming a Helmholtz coil wherein magnetic field lines will be approximately parallel in their center.
[0016] Exemplary insulator materials for the strip are elastomers, thermoplastic, natural rubber, polyisoprene, halobutyl rubbers, synthetic rubbers such as BIIR, BR, CIIR, CR, CSM, ECO, EP, EPDM, FKM, FVQM, HNBR, IR, IIR, MVQ, NBR, PU, SBR, SEBS, SI, XNBR or other rubber or rubber type materials and compounds that are flexible and can be molded or formed to have a low profile.
[0017] At least one mounting side of the insulation strip 110 may have an adhesive layer 126 attached or disposed thereon. An exemplary adhesive layer is comprised of a mixture in a liquid or semi-liquid state that adheres or bonds items together. Adhesives may come from either natural or synthetic sources. An exemplary adhesive layer may be an adhesive tape, such as pressure sensitive tape, water sensitive tape, heat sensitive tape. Adhesive tape may be one of many varieties of backing materials coated with an adhesive. Many types of adhesives may be used. The adhesive tape may have a covering adhesive protective film that is removed to adhere the strip to a desired surface on a product or device. Other adhesives may be utilized.
[0018] Pressure sensitive tape, PSA tape, self stick tape or sticky tape consists of a pressure sensitive adhesive coated onto a backing material such as paper, plastic film, cloth, or metal foil. It is sticky (tacky) without any heat or solvent for activation and adheres with light pressure. These tapes usually require a release agent on their backing or a release liner to cover the adhesive.
[0019] Water sensitive tape, water activated tape, gummed paper tape or gummed tape is starch, or sometimes animal glue based, adhesive on a paper backing which becomes sticky when moistened.
[0020] Heat activated tape is usually tack-free until it is activated by a heat source.
[0021] In an exemplary embodiment, the adhesive layer may be applied to the mounting surface of the coil by spraying, painting, coating or another manner so that the adhesive layer is integral with the insulation layer. A removable coating layer may be then applied to the mounting surface of the adhesive layer and removed just prior to installation of the coil on a surface.
[0022] The ends of the wires may have terminals or contacts 130 , 134 to connect to a EAS controller or EAS transmitter/receiver 138 to wirelessly pair with an EAS tag 198 .
[0023] The EAS antenna may be referred to as an EAS tape that may be packaged in the form of a roll of tape or shaped into a reticular, square, circular, rectangular, oval or any shape desired by an integrator. The benefit of the “tape” like nature is that the coil may be applied practically anywhere in or on an existing end user device making it easy to integrate or retrofit an EAS coil into an existing platform.
[0024] Exemplary EAS coils 160 , 164 illustrated in FIGS. 3 a - 3 d may be inserted into inlay tracks 166 . The inlay tracks may reside in frames or housings 168 around scanning windows 170 , 174 of a scanning device 180 . The conductors 176 may be capped once inserted into a track with a sealing cap 202 . The term “scan” or “scanning” refers to reading or extracting data from an information bearing indicia (or symbol). Scanning devices (also referred to as scanners, laser scanners, image readers, indicia readers, etc.) read data represented by printed or displayed information bearing indicia (IBI), (also referred to as symbols, symbology, bar codes, etc.) For instance one type of a symbol is an array of rectangular bars and spaces that are arranged in a specific way to represent elements of data in machine readable form. Indicia reading devices typically transmit light onto a symbol and receive light scattered and/or reflected back from a bar code symbol or indicia. The received light is interpreted by a processor which performs signal and/or image processing to extract the data represented by the symbol. Optical indicia reading devices typically utilize visible or infrared light. Laser indicia reading devices typically utilize transmitted laser light.
[0025] In an exemplary EAS system, coils 160 , 164 are arranged to be perpendicular Helmholtz coils which may be described as a perpendicular figure eight configuration.
[0026] An exemplary scanning system 180 is a bi-optic laser scanner with both vertical 184 and horizontal 190 scan sections. An exemplary system is configured to have a deep slot 166 or channel that surrounds the window surfaces 170 , 174 (scan areas) of the unit in which EAS coils are disposed. These slots may be molded into the plastic housing or formed in a metal platter 200 . These channels may be left empty when the EAS solution is not present and a plastic insert put in its place.
[0027] In an exemplary embodiment the transmitter phases are interlaced to provide alternating transmissions from the two EAC coils for maximizing the system performance for all orientations of markers in an interrogation zone.
[0028] In an exemplary embodiment, the transmitter drives the EAS coils at two frequencies.
[0029] When manufacturing or upgrading an EAS detection unit an exemplary EAS coil 176 is dimensioned such that it has to be “snapped” into an empty channel 166 and an insulating cap 202 “snapped” in front. Coil 176 , channel 166 and cap 202 are dimensioned such that they mate with one another in a tight fitting arrangement.
[0030] In an exemplary embodiment, the EAS coil may be a rigid coil. This coil may be formed from highly conductive metal material that may be bent and shaped with any gauge as desired. Multiple coil solutions may be found by increasing the depth of the channels\slots and inserting a sandwiched pair of rigid EAS coils.
[0031] An exemplary transmitter-antenna circuit 310 is shown in FIG. 4 . Inductors L 1 and L 2 represent the inductance of two transmitter coils 312 and 314 . Resistors R 1 and R 2 , represent the respective series resistances of the transmitter coils 312 and 314 . Capacitors C 1 and C 2 are used to tune the resonant frequency to the operating system frequency. V s1 and Rs1 represent the output voltage and internal source resistance for one antenna driver. V s2 and R s2 represent the output voltage and internal source resistance for a second antenna drivers. The compensation loop or coil 16 needed for in-phase tuning is represented by inductor L C , resistor R C , and capacitor C C . The coupling between the transmitter coils 312 and 314 is represented by K 12 . The coupling between the compensation coil 316 and each of the transmitter coils 312 and 314 is represented by K 1 and K w .
[0032] The detection for all these tags depends on their orientation relative to the detection loops. For a pair of planar loops forming a Helmholtz coil, magnetic field lines will be approximately parallel in their center. Orienting the tag so that no magnetic flux from the coils crosses them will prevent detection, as the tag won't be coupled to the coils. This shortcoming, documented in the first EAS patents, can be solved by using multiple coils or by placing them in another arrangement such as a figure-of-eight. Sensitivity will still be orientation-dependent but detection will be possible at all orientations.
[0033] In view of the wide variety of exemplary embodiments to which the principles of the present invention can be applied, it should be understood that the illustrated exemplary embodiments are exemplary only, and should not be taken as limiting the scope of the present invention. For example, the steps of the flow diagrams may be taken in sequences other than those described, and more, fewer or other elements may be used in the block diagrams. Also, unless applicants have expressly disavowed any subject matter within this application, no particular exemplary embodiment or subject matter is considered to be disavowed herein.
|
An electronic article surveillance (EAS) system includes: a plurality of conductors arranged into an EAS coil and disposed within a flexible, insulation strip; an adhesive layer for attaching to a mounting side of the insulation strip to a device; and, a transmitter/receiver connected to the plurality of conductors for pairing the EAS coil with an EAS tag.
| 7
|
BACKGROUND OF THE INVENTION
This invention relates to a gooseneck, which is also referred to as a tubing guide, and more particularly to a tubing guide for directing coiled tubing into a coiled tubing injector apparatus. Reeled or coiled tubing has been run into completed wells for many years for performing certain downhole operations. Those operations include, but are not limited to, washing out sand bridges, circulating treating fluids, setting downhole tools, cleaning the internal walls of well pots, conducting producing fluids or lift gas, and a number of other similar remedial or production operations. The tubing utilized for such operations is generally inserted into the wellhead through a lubricator assembly or stuffing box. Typically, there is a pressure differential on the well so that the well is a closed chamber producing oil or gas or a mixture thereof from the pressurized well. The tubing that is inserted into the well is normally inserted through a lubricator mechanism which seals the well for pressure retention in the well.
The tubing is flexible and can bend around a radius of curvature and is normally supplied on a drum or reel. The tubing is spooled off of the reel and inserted into a coiled tubing injector assembly. The coiled tubing injector assembly essentially comprises a curvilinear gooseneck, or tubing guide and a coiled tubing injector apparatus positioned therebelow.
The curvilinear tubing guide forms an upper portion of the injector assembly while the coiled tubing injector apparatus forms a lower portion thereof. Most coiled tubing injector apparatus utilize a pair of opposed inlet drive chains arranged in a common plane. Such drive chains are made up of links, rollers and gripper blocks. The drive chains are generally driven by sprockets powered by a motor which is a reversible hydraulic motor. The opposed drive chains grip the coiled tubing between them. The drive chains are backed up by linear beams, also referred to as pressure beams, so that a number of pairs of opposed gripping blocks are in gripping engagement with the tubing at any given moment. Coiled tubing injector apparatus are shown in U.S. Pat. No. 5,094,340 to Avakov, which is incorporated herein by reference for all purposes, and U.S. Pat. No. 4,655,291 to Cox, which is likewise incorporated herein for all purposes.
A typical tubing guide has a curvilinear first frame portion with a set of rollers thereon which support and guide the tubing as it is moved through the injector. Spaced from the first frame portion is a second frame portion also having a set of rollers thereon which are on the opposite side of the tubing from the first set of rollers and which also act to guide the tubing. The tubing guide is pivotable for easy alignment with the tubing reel. The radius of curvature of the typical tubing guide is constant and is typically smaller than the residual or natural radius of curvature of the coiled tubing in its free state after it has been spooled off the reel. The rollers therefore force the tubing to bend to match the curvature of the tubing guide and to straighten the tubing so that it is substantially vertical when it exits the tubing guide and enters the coiled tubing injector apparatus therebelow. The bending and stresses experienced by the tubing each time it is deformed or bent and injected into the well decrease the life of the coiled tubing.
SUMMARY OF THE INVENTION
The tubing guide of the present invention is an improvement over prior art tubing guides in that it directs coiled tubing into a substantially vertical, or injection position with reduced bending and reduced stresses thereby increasing the life of the coiled tubing. The tubing guide of the present invention also simplifies stubbing of the coiled tubing into the coiled tubing injector apparatus by utilizing the natural curvature of the tubing and allows for reduced overall injector assembly size and weight.
The tubing guide of the present invention generally comprises a base and a primary carrier extending upward from the base. The primary carrier is comprised of a curvilinear primary carrier arm with a plurality of rollers attached thereto.
In a preferred embodiment, the primary carrier has a plurality of arcuately shaped portions, and preferably three arcuately shaped portions including an upper approach, or entry portion defined by a first radius, a center or load portion defined by a second radius, and an exit portion defined by a third radius. The second radius of curvature is generally greater in magnitude than the first and third radius which are, in a preferred embodiment, of equal magnitude. The radius of curvature of each portion is defined or circumscribed by the center of the rollers attached to the primary carrier arm.
The tubing guide of the present invention also includes an offset contact point positioned above the base. The offset contact point is defined on one of the rollers, designated as an offset roller, attached to the primary carrier arm. The offset roller is offset from a center line of the coiled tubing injector apparatus positioned therebelow, and is thus positioned so that the coiled tubing passing thereover is likewise laterally offset from the center line of the coiled injector apparatus. The center line of the coiled tubing injector apparatus is co-linear with a center line of the wellbore therebelow. The offset roller is positioned so that the natural, or residual curvature of the tubing will cause the tubing to traverse the lateral distance between the offset roller and the center line of the coiled tubing injector apparatus as the tubing passes through a vertical distance between the offset roller and an engagement point defined on the coiled tubing injector apparatus. The engagement point is the point at which the outer diameter of the tubing is engaged by the coiled tubing injector apparatus, and will normally be the point at which the linear beams, or pressure beams in the coiled tubing injector apparatus become substantially vertical.
Thus, a line tangent to the coiled tubing at the location where it passes over the offset roller lies at an angle to the center line of the coiled tubing injector apparatus and the wellbore therebelow. The natural curvature of the tubing is such that the tubing is substantially vertical when it reaches the engagement point. Thus, a line tangent to the tubing at the engagement point will be substantially parallel to the center line of the coiled tubing apparatus and the wellbore therebelow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side elevational schematic of a prior art tubing injector.
FIG. 2 is a vertical cross section of the tubing guide apparatus of the prior art tubing injector.
FIG. 3 shows a prior art cross section taken along lines 3--3 in FIG. 2.
FIG. 4 is a side elevational schematic of the tubing guide of the present invention.
FIG. 5 shows a view taken through line 5--5 on FIG. 4.
FIG. 5A shows a view taken through line 5A--5A on FIG. 11.
FIG. 6 shows a view taken through line 6--6 on FIG. 4.
FIG. 7 shows a view taken through line 7--7 on FIG. 4.
FIG. 8 shows a view taken through line 8--8 on FIG. 4.
FIG. 9 shows a view taken through line 9--9 on FIG. 4.
FIG. 10 shows a view taken from line 10--10 on FIG. 4 and shows an upper end of a lifting beam.
FIG. 11 shows a schematic of the base of the tubing guide of the present invention with a schematic of the upper end of the structure which houses the coiled tubing injector apparatus therebelow.
FIG. 12 shows a partial section view of the attachment of the upper base portion to the lower base portion.
FIG. 13 shows a view looking down at the upper base portion.
FIG. 14 shows a partial section view taken from line 14--14 of FIG. 13.
FIG. 15 shows a view taken from line 15--15 of FIG. 11 and shows the stiffeners of the lower base portion.
FIG. 16 shows a view taken through line 16--16 of FIG. 11.
FIG. 17 is a schematic of the tubing guide of the present invention showing the radius of curvature of the arcuately shaped portions of the tubing guide.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and more particularly to FIGS. 1-3, a prior art coiled tubing injector assembly is shown and generally designated by the numeral 10. The assembly 10 is positioned over a wellhead 12 which is provided with a stuffing box or lubricator 14. Tubing 16 is provided to assembly 10 on a large drum or reel 18, and typically is several thousand feet in length. Tubing 16 has a longitudinal central axis 15 and an outer diameter, or surface, 17. The tubing is in a relaxed, but coiled, stated when supplied from drum or reel 18. The tubing has a natural, or residual radius of curvature when it is in its relaxed state after being spooled from the reel.
The well is typically pressure isolated. That is, entry of tubing 16 into the well must be through stuffing box 14 which enables the tubing, which is at atmospheric pressure, to be placed in the well which may operate at higher pressures. Entry into the well requires that the tubing be substantially straight. To this end, the assembly 10 incorporates a coiled tubing injector apparatus 22 which is constructed with drive chains which carry blocks adapted for gripping tubing 16. The details of drive chains and blocks 24 are known in the art. See for example, U.S. Pat. No. 5,094,340 entitled "GRIPPER BLOCKS FOR REELED TUBING INJECTORS," the details of which have been incorporated herein by reference.
A tubing guide 26 is attached to the upper end of coiled tubing injector apparatus 22. Typically, tubing guide 26 is pivotable about a vertical axis with respect to the injector 22 positioned therebelow. Tubing guide 26 includes a curvilinear first or bottom frame 28 having a plurality of first or bottom rollers 30 rotatably disposed thereon. Bottom frame 28 includes a plurality of lightening holes 32 therein.
Spaced from bottom frame 28 is a second or top frame 34 which has a plurality of second or top rollers 36 rotatably disposed thereon. Top rollers 36 generally face at least some of bottom rollers 30. In the embodiment illustrated, the length of curvilinear top frame 34 is less than that of curvilinear bottom frame 28. The distal end of top frame 34 is attached to bottom frame 28 by a bracket 38.
Referring now to FIG. 3, bottom rollers 30 have a circumferential groove 40 therein, and top rollers 36 have a similar circumferential groove 42 therein. Facing rollers 30 and 36 are spaced such that tubing 16 is generally received in grooves 40 and 42 to guide and straighten the tubing as it enters injector coiled tubing 22 of assembly 10. The tubing guide thus bends and straightens the tubing 16 into the vertical, or injection position.
Bottom rollers 30 are supported on first shafts 44, and similarly, top rollers 36 are supported on second shafts 46. Shafts 44 are disposed through a plurality of aligned pairs of holes 48 in bottom frame 28. Shafts 46 are disposed through holes 50 in top frame 34. Rollers 30 and 36 are supported on shafts 44 and 46, respectively, by bearings (not shown).
The prior art tubing guide, while serving its intended purpose, still has inherent difficulties. The tubing guide shown in FIG. 1 will bend and straighten the tubing so that it is vertical as it exits the tubing guide. The bending and the combination of stresses due to the pressures and loads experienced by the tubing due to straightening which occurs each time the tubing is injected, used, and/or withdrawn from the well shortens the life of the tubing.
Referring now to FIG. 4, a tubing guide of the present invention is shown and generally designated by the numeral 100. The tubing guide includes a base 105, a primary tubing carrier 110 and a secondary tubing carrier, or back guide 115 extending upwardly therefrom. A lifting beam 120 also extends upward from the base 105. A carrier linkage 125 may be included to connect the primary tubing carrier 110 to secondary carrier 115. A tubing approach guide 130 is attached to the carrier and extends upwardly therefrom.
Primary tubing carrier 110 is comprised of a primary carrier arm 132 having a plurality of rollers 134 rotatably disposed thereon. Upper approach guide 130 also has a roller 134 attached thereto. As better shown in FIG. 5, rollers 134 have a center or longitudinal central axis 133, an outer diameter 135 and a circumferential groove 137. Primary carrier 110 is attached to base 105 with pins 136. Secondary carrier 115 is attached to base 105 with a pin 138 while the lifting beam 120 is attached with pins 140. Pins 136, 138 and 140 may be held in place with cotter pins or by any other means known in the art. The attachment to the base is better shown in FIGS. 11 and 13.
Rollers 134 are supported on shafts 142 and 144 by bearings 146 and sleeves 148. The rollers are supported with shafts 142 at all locations along the primary carrier except at the two locations wherein carrier linkage 125 is attached. Shafts 144, which may be longer than shafts 142, but are otherwise identical thereto, are used at such locations. As shown in FIG. 9 the carrier linkage is comprised of a pair of opposed plates 150. A removable pin 152 is used to connect the carrier linkage to the secondary carrier arm. When the removable pin is not in place, the secondary carrier arm may be rotated about connecting pin 138.
The primary carrier arm, as better shown in FIG. 5, consists of outer plates 154 which are connected to a face plate 156. The plates may be connected by welding or other means known in the art. Secondary carrier, or back guide 115 may generally be comprised of outer plates 158 and back-up plates 160 and 162, which span between and are connected to outer plates 158 by welding or other means. Secondary carrier 115 further comprises a roller carrier 164 disposed between opposed outer plates 158, and an exit roller 163. Exit roller 163 may be identical to rollers 134 and supported on a shaft as described with respect to rollers 134. Roller carrier 164 includes a center roller 166 and outer rollers 170. Center roller 166 and outer rollers 170 have centers, or longitudinal central axis, 163 and 167 respectively, circumferential grooves 168 and 172 respectively and outer diameters 169 and 171 respectively.
As shown in FIGS. 6 and 7 roller carrier 164 includes outer roller carrier plates 174, and is attached to outer plates 158 with a threaded shaft 176. Center roller 166 is supported on shaft 176 by a sleeve 178 and bearings 180. Outer rollers 170 are supported on shafts 182 by bearings 184 and sleeves 185. Shafts 182 extend through plates 174 and can be affixed thereto by any means known in the art such as, but not limited to, a roll pin 186 which extends through plates 174 and shafts 182. A pair of U-shaped stiffeners 188 may be attached between outer plates 164 to provide additional strength. As described herein, the roller carrier 164 will pivot about shaft 176. A pair of thrust bearings 177 are interposed between outer plate 158 of the secondary carrier and plates 174 of the roller carrier so that there will be clearance between secondary carrier outer plates 158 and roller carrier outer plates 174 along the length of the roller carrier.
Lifting beam 120 comprises a pair of lifting beam outer plates 190 with a lifting plate 192 disposed therebetween. Lifting plate 192 includes an opening 194. A lifting beam linkage 196 may be used to connect the lifting beam with the secondary carrier. The attachment of the primary carrier, the secondary carrier and the lifting beam to the base is better seen in FIGS. 11 and 13.
Base 105 is comprised of an upper base portion 198 and a lower base portion 200. Referring now to FIG. 11, upper base portion 198 is rotatably connected to lower base portion 200 utilizing a plurality of bearings 201 which are attached to the upper and lower base portions with threaded fasteners 202 and 204, respectively. As seen in FIG. 13, the embodiment shown is adapted to utilize sixteen bearings. The bearings allow the upper base portion to rotate on the lower base portion. Thus, as viewed in FIG. 4, the base could be rotated 180° and locked in place, so that the tubing guide can be utilized in two different positions. The upper base portion may include a locking arm 206 which has a downwardly extending lug 208 having a pair of openings 210 defined therein. The lower base portion will have a mating lug extending upwardly therefrom (not shown) positioned so that bolts or pins can be inserted into openings 210 and into corresponding openings in the lug extending upwardly from the lower base portion so as to lock the arm in position.
The upper base portion comprises an upper base plate 212 having an elongated opening 214 defined therethrough for allowing coiled tubing to pass therethrough. The upper base portion further includes a pair of legs 216 and opposed attachment lugs 218 extending upwardly therefrom. As shown in FIGS. 13 and 14, primary carrier 110 is attached to legs 216 at four locations with pins 136. Secondary carrier 115 is attached with pins 138 and lifting beam 120 is attached to lugs 218 with pins 140.
The lower base portion is comprised of lower base plate 220 having stiffeners 222 extending downwardly therefrom. As schematically shown in FIG. 11, pins at each corner of the lower base portion will extend downwardly into and be attached to a structure 224 which will house the coiled tubing injector apparatus therebelow which, in combination with the tubing guide, makes up a coiled tubing injector assembly. A center line, or longitudinal central axis, 226 of the coiled tubing injector apparatus and the wellbore below is also seen in FIG. 11. Coiled tubing injector apparatus are well known in the art and the use of the tubing guide of the present invention is not limited in any way to any particular coiled tubing injector apparatus.
Referring now to FIG. 17, a schematic showing the curvature of the tubing guide of the present invention is shown along with a schematic of a coiled tubing injector apparatus therebelow. As seen in FIG. 17, the tubing guide of the present apparatus has a multiple radius curvature. The primary carrier 110 may thus be comprised of three portions including an arcuately shaped upper approach portion 250, an arcuately shaped center, or load portion 252 and an arcuately shaped lower or exit portion 254. The arcuate shape of the upper approach portion is defined by a first radius of curvature 256. The arcuate shape of the center portion is defined by a second radius of curvature 258 while the arcuate shape of the lower or exit portion is defined by a third radius of curvature 260. Referring back to FIG. 4, each radius is defined, or circumscribed by centers 133 of rollers 134, such that the arcuate shapes of each portion of carrier 110 are defined by the centers 133 of rollers 134. FIG. 4 shows the approximate locations of each portion on the embodiment described herein.
The magnitude of the first and third radii will typically be smaller than the magnitude of the second radius and will generally be of equal magnitude. The shape of the primary carrier is such that as tubing 16 passes over the primary carrier and is directed into the coiled tubing injector apparatus therebelow minimal bending and stresses are placed on the tubing. Rather than forcing the tubing straight, the tubing guide of the present invention allows the residual, or natural curvature of the tubing to direct the tubing into the proper injection position.
Each of the three radii which define the separate arcuate portions of the primary carrier will be smaller than the natural radius of curvature of the tubing after it is spooled from the reel. The tubing will pass through the approach guide 130 and will pass between the secondary carrier and primary carrier. Specifically, the tubing will pass between the rollers 166 and 170 on the roller carrier and rollers 134 on the center portion of the primary carrier. Because the first and third radii are smaller than the second radius, the tubing will have minimal to no contact with the upper approach and exit portions of primary carrier 110. As the tubing passes between the roller carrier and the primary carrier, the tubing will be placed under some bending as it attempts to conform to the radius of the carrier in that area. However, the bending and the stresses will be minimal since the roller carrier pivots.
An offset contact point 271 is defined on the lower or exit portion of the tubing guide. Offset contact point 271 is defined on one of the rollers 134, designated as offset roller 270. The center of offset roller 270 may be designated by the numeral 269. Center 269 of roller 270 is offset a distance 227 from center line 226 of the coiled tubing injector apparatus therebelow. The offset 227 is such that as tubing 16 is directed downward, the natural curvature of the tubing will cause the tubing to traverse the lateral distance, or offset 227 between the offset roller and the center line of the coiled tubing injector as it passes through the vertical distance or height 229 from the center 269 of the offset roller to an engagement point 272 on the coiled tubing injector. The natural curvature of the tubing thus directs the tubing to its proper injection position.
Referring again to the schematic shown in FIG. 17, engagement point 272 is located at the top of the operating length of the linear or pressure beam of the coiled tubing injector apparatus. The operating length of the pressure beam is the portion of the beam along which the coiled tubing injector apparatus engages the tubing passing therethrough. Thus, the engagement point is located where the linear beam becomes substantially vertical, which is the point at which the coiled tubing injector apparatus will first engage outer diameter 17 of tubing 16.
As set forth previously, the invention described herein is not limited by the use of any particular coiled tubing injector apparatus. The offset 227 is such that the natural curvature of the tubing will cause the tubing to be substantially vertical when it reaches engagement point 272. Because of inconsistencies in the tubing and differing tubing sizes, the tubing may contact backup plates 160 and 162 and exit roller 163 as it passes through the tubing guide. However, the contact will simply direct the tubing and will apply very little bending or stress thereto. The offset 227 can be determined utilizing the equation:
offset=R-R cos(arc sin H/R)
where "R" is the natural radius of curvature of the tubing and "H" is the vertical distance 229 between the center of the offset roller and the engagement point.
For example, it has been determined that tubing having diameters from 1.25 to 2.325 have a natural, or residual radius of curvature of approximately 240 inches when they are spooled from a reel 18. Utilizing an approximate radius of 240 inches for the radius of curvature of the tubing, the position of the offset roller can be determined.
Referring again to the schematic shown in FIG. 17, the arc designated by the numeral 280 depicts a center line or longitudinal central axis of coiled tubing having a radius of curvature of 240 inches in its free state. The center line, or longitudinal central axis of tubing passing through an upper approach guide and being directed by the tubing guide of the present invention is, as set forth previously, designated by the numeral 15. Center line 15 will tend to follow, or approximate the natural curvature depicted by radius 280 after the tubing exits the roller carrier and passes over center portion 258 of the primary carrier. Thus the lines 15 and 280 are shown to be co-linear at that point.
As shown in FIG. 17, the tubing becomes substantially vertical at engagement point 272. An arc utilizing the radius of 240 inches can be used to identify and locate center 269 of offset roller 270 on the primary carrier. In the example shown, a 15° arc 267 is utilized. Obviously, the arc can vary from 15°. It simply must be great enough to identify a point on the primary carrier above the base. The arc is drawn from a line 266 that is perpendicular to center line 226 at engagement point 272. Thus, line 266 is the horizontal radius drawn through the engagement point. "H" which is the height, or length of a vertical line from center 269 down to line 266, can be analytically determined. In the example provided, the height is approximately 62.12 inches. Utilizing 62.12 as "H" in the equation set forth above, the offset 227 is determined to be approximately 8.18 inches. Having determined the offset, radius 260 of exit portion 254 may then be circumscribed through an arc so that at center 269 of roller 270, center line 280 of tubing in its free state and radius of curvature 260 are tangent. As shown in FIG. 17, if radius 260 is extended, it will intersect radius 266 at its point of origin 273. Radius of curvature 258 can be circumscribed through an arc to define the center, or load portion starting from the point where the exit portion ends. An arc may then be circumscribed utilizing radius 256 to define the upper portion.
As set forth above, radius of curvature 258 is greater than radii 260 or 256. In one embodiment, radius 260 may be equal to a radius of 72 inches circumscribed through an arc of 30°. The 72-inch radius defines the arcuate shape of the exit portion in the example provided herein, and is circumscribed, as set forth earlier, by the centers of the rollers on the primary carrier. The center portion may be defined by a 120-inch radius circumscribed through an arc of 30° and the upper or approach portion is defined by an arc of 72 inches circumscribed through an arc of 60°.
In operation, the tubing will pass through the approach guide and will be directed between the secondary carrier and the primary carrier. As it passes between the roller carrier and the primary carrier, the tubing will be forced slightly to conform to the radius 258 of center or load portion 252 of the primary carrier. Once the tubing passes through center portion 252 it will attempt to return to its natural radius of curvature. Thus, when the tubing is unrestricted, the position of center line 15 of the tubing will be approximately tangent to center 269 of roller 270, as it passes thereby.
Practically, center line 15 of tubing 16 will not be tangent to center line 280 at center 269 of roller 270, since outer diameter 17 of tubing 16 will contact the circumferential groove of offset roller 270 of contact point 271, thus preventing center line 15 from becoming tangent to center line 280 at that point. However, because the radius of curvature of exit portion 254 is less than the natural radius of curvature of the tubing, the tubing will be unrestricted once it passes roller 270 and will continue to return to its natural radius, as depicted by center line 280. Thus, as tubing 16 travels through the vertical distance or height 229, it will traverse the lateral offset 227, and will be in the proper, or substantially vertical injection position when it reaches engagement point 272. The amount of contact with offset roller 270 at contact point 271 will vary because of variations in tubing size, inconsistencies in tubing, manufacturing tolerances and other factors. Further, as will be recognized by those in the art, the actual point of contact will be different for different tubing diameters. However, by determining the approximate natural radius of curvature of tubing 16, and by using the center line of the tubing to locate the center of the offset roller, it can be insured that the position of the tubing as it passes the offset contact point is such that the natural radius of curvature of the tubing will direct the tubing toward the proper injection position. In addition to contact with the offset roller 270, the tubing may slightly contact backup plate 162 or exit roller 163. However, the contact will be minimal, and will act to guide and direct the tubing, rather than to apply high bending or stresses. The life of the tubing can therefore be extended beyond what would be possible with prior art tubing guides.
The center line 15 of the tubing as it passes over offset roller 270 will be at an angle 261 to the vertical, and thus will be at an angle to the center line 226 of the coiled tubing injector apparatus and the well therebelow. The natural curvature of the tubing is such that as the tubing passes through the vertical distance to the engagement point, it will traverse the offset, and will become substantially vertical by the time it reaches engagement point 272. Center line 15 of the tubing will be substantially vertical when it reaches engagement point 272. Likewise, a line 268 tangent to the tubing at engagement point 272 is substantially vertical and thus substantially parallel to center line 226 of the coiled tubing injector apparatus. The tubing can therefore be easily stubbed, since it is substantially vertical and in the proper injection position when it reaches the engagement point.
Clearly, the example set forth herein is simply intended as an example and is not in any way intended to limit the invention described and claimed herein. The equations set forth herein will allow the determination of the offset which is required between the engagement point, which is a defined point, and the center of an offset roller located on the tubing guide. The magnitude of the multiple radii which circumscribe the portions of the primary carrier are not limited to the examples set forth herein.
It has been shown that the improved tubing guide of this invention fulfills all objects set forth hereinabove and provides distinct advantages over the known prior art. It is understood that the foregoing description of the invention and illustrative drawings which accompany the same are presented by way of explanation only and that changes may be had by those skilled in the art without departing from the true spirit of this invention.
|
An apparatus for guiding and directing tubing into a coiled tubing injector apparatus is disclosed. The tubing guide will direct the tubing into the coiled tubing injector apparatus for insertion or removal into the wellbore therebelow. The natural, or residual radius of the tubing is utilized to direct the tubing into the coiled tubing injector apparatus, so that minimal bending is applied to the tubing.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Patent Application No. 2006-0002066, filed on Jan. 8, 2006 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a washing machine and a washing control method thereof, and, more particularly, to a washing machine and a washing control method thereof, which can regulate the amount of detergent and wash water supplied during preliminary washing, achieving an improvement in wash performance.
[0004] 2. Description of the Related Art
[0005] In general, a washing machine, more particularly, a drum-type washing machine, is an appliance to wash laundry contained in a cylindrical rotary drum by repeatedly raising and dropping the laundry as the drum rotates. Although the drum-type washing machine has a long wash time, it tends to reduce damage to the laundry and reduce the amount of water used when compared to a conventional pulsator-type washing machine. Therefore, the demand for such a drum-type washing machine is increasing. Currently, a washing machine employs a variety of ways to improve a wash performance. One example of the variety of ways is to add a preliminary washing cycle to a basic washing process, such that the preliminary washing cycle is selectively performed if necessary.
[0006] The preliminary washing cycle agitates the laundry before a main washing cycle in order to remove dust or dirt clinging to the laundry, which improves the efficacy of the main washing cycle. The preliminary washing cycle is followed by a spin-drying operation after it is performed for a predetermined time. The amount of detergent used in the preliminary washing cycle corresponds to 30% to 50% of the main washing cycle, however, the preliminary washing cycle uses the same amount of wash water as the main washing cycle. A motor agitation time of the preliminary washing cycle is set to 12% to 34% of the main washing cycle.
[0007] In association with a conventional washing machine having both the preliminary and main washing cycles, if the preliminary washing cycle as stated above is selected, wash water for use in the preliminary washing cycle is supplied into a rotary drum by way of a preliminary washing detergent chamber that is defined in a detergent supply device. Then, the preliminary washing cycle is performed to wash the laundry in the drum using a force of gravity that results in the laundry falling as the drum rotates in accordance with a motor agitation, while allowing a detergent to be mixed well with the wash water. After completion of the preliminary washing cycle, a spin-drying operation is performed at approximately 400 to 600 rpm. After that, wash water is again supplied into the drum, to progress to the generally known main washing cycle.
[0008] The conventionally performed preliminary washing cycle as stated above has been provided to improve a wash performance by approximately 3% to 5%. However, such an improvement in wash performance is a negligible level when considering the amount of detergent and wash water used, and a motor agitation time required to perform the preliminary washing cycle. Therefore, there exists a need to improve the preliminary washing cycle to reduce the amount of detergent and wash water used.
SUMMARY OF THE INVENTION
[0009] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention.
[0010] The invention has been made in order to solve the above problems. It is an aspect of the invention to provide a washing machine and a washing control method thereof, wherein a preliminary washing cycle, which is an optional function of the washing machine, can be performed with a high efficiency while achieving a reduction in the amount of detergent and wash water that is used therefor.
[0011] It is another aspect of the invention to provide a washing machine and a washing control method thereof, wherein the amount of detergent and wash water that is used for a preliminary washing cycle can be regulated, whereby a reduction in the amount of detergent and wash water can be accomplished while achieving an improvement in wash performance.
[0012] It is yet another aspect of the invention to provide a washing machine and a washing control method thereof, which can reduce the amount of detergent used in a preliminary washing cycle without a reduction in wash performance.
[0013] Consistent with one aspect, an exemplary embodiment of the invention provides a method for controlling a washing machine, including: determining whether or not a preliminary washing cycle is selected; supplying a lesser amount of wash water than a desired amount of wash water that is determined based on an amount of laundry if the preliminary washing cycle is selected and performing the preliminary washing cycle; supplying a certain amount of wash water additionally after completing the preliminary washing cycle based on a difference between a desired amount of wash water and the lesser amount of wash water supplied during the preliminary washing cycle; and performing a main washing cycle.
[0014] The amount of wash water, supplied during the preliminary washing cycle, may be approximately 70% of the desired amount of wash water.
[0015] The main washing cycle may be performed as the wash water is additionally supplied to top up the desired amount without draining the used wash water after the preliminary washing cycle.
[0016] The certain amount of wash water, additionally supplied during the main washing cycle, may be obtained by subtracting the amount of wash water supplied during the preliminary washing cycle from the desired amount of wash water.
[0017] Consistent with another aspect, an exemplary embodiment of the invention provides a washing machine having a motor and a water supply device, including: a signal input unit to select a preliminary washing cycle; and a controller to control the water supply device if the preliminary washing cycle is selected, so as to reduce the amount of wash water, to be supplied during the preliminary washing cycle, below a desired amount of wash water that is determined based on the amount of laundry.
[0018] The controller may control the water supply device during the preliminary washing cycle in such a manner that a lesser amount of wash water than the desired amount of wash water, which is determined based on the amount of laundry, is supplied to perform the preliminary washing cycle, and a certain amount of wash water is supplied additionally after completing the preliminary washing cycle without draining the used wash water.
[0019] The controller may set the amount of wash water, to be supplied during the preliminary washing cycle, to approximately 70% of the desired amount of wash water.
[0020] Additionally, the controller may advance the main washing cycle after supplying the certain amount of wash water.
[0021] The controller may set the certain amount of wash water, to be supplied additionally during the main washing cycle, to approximately 30% of the desired amount of wash water.
[0022] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] These and/or other aspects and advantages of the exemplary embodiments of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings, of which:
[0024] FIG. 1 is a sectional view showing the configuration of a washing machine consistent with the invention;
[0025] FIG. 2 is a control block diagram showing a washing control mechanism of the washing machine consistent with an exemplary embodiment of the invention; and
[0026] FIG. 3 is a flow chart showing the sequential operation of a method for improving the effectiveness of preliminary washing in association with the washing machine consistent with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Reference will now be made in detail to an exemplary embodiment of the invention, an example of which is illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. The embodiment is described below to explain the invention by referring to the figures.
[0028] FIG. 1 is a sectional view showing the configuration of a washing machine consistent with the invention.
[0029] As shown in FIG. 1 , the washing machine consistent with the invention includes a drum-shaped water tub 11 received in a body 10 to contain wash water therein, and a rotary drum 12 rotatably received in the water tub 11 .
[0030] The water tub 11 is generally tilted relative to a washing machine mounting plane by a predetermined inclination α so that a front wall 11 a thereof, formed with a laundry entrance opening 11 b, is positioned higher than a rear wall 11 c thereof. In the same manner as the water tub 11 , the rotary drum 12 , received in the water tub 11 , is tilted so that a front wall 12 a thereof, formed with a laundry entrance opening 12 b, is positioned higher than a rear wall 12 c thereof.
[0031] Specifically, the rotary drum 12 is mounted so that a rotating center axis “A” thereof is tilted relative to the washing machine mounting plane by the predetermined inclination α to thereby allow the front wall 12 a, formed with the opening 12 b, to face up and to the front. In this case, a rotary shaft 13 , which is coupled to the center of the rear wall 12 c of the rotary drum 12 , is penetrated through and supported by the center of the rear wall 11 c of the water tub 11 . Accordingly, the rotary drum 12 is rotatable in the water tub 11 about the rotary shaft 13 .
[0032] A plurality of holes 12 d are perforated through a circumferential wall of the rotary drum 12 , and a plurality of lifters 14 are arranged along an inner wall surface of the rotary drum 12 to raise and drop laundry contained in the drum 12 as the rotary drum 12 rotates. A motor 15 is mounted at an outer surface of the rear wall 11 c of the water tub 11 to rotate the rotary shaft 13 connected to the rotary drum 12 . Accordingly, when the motor 15 is driven, the washing, rinsing and spin-drying operations of the washing machine can be performed. Also, a heater 16 is mounted in a bottom region of the water tub 11 to heat wash water supplied into the water tub 11 .
[0033] The motor 15 includes a stator 15 a fixed to the rear wall 11 c of the water tub 11 , a rotor 15 b rotatably disposed around the stator 15 a, and a rotary plate 15 c to connect the rotor 15 b to the rotary shaft 13 .
[0034] The body 10 is formed, at a front wall thereof, with an opening 17 b to correspond to the opening 12 b of the rotary drum 12 and the opening 11 b of the water tub 11 , so as to put laundry into the rotary drum 12 or to take the laundry out of the rotary tub 12 . A door 17 is mounted at the opening 17 b to open or close the opening 17 b.
[0035] A detergent supply device 18 and a water supply device 20 are mounted above the water tub 11 , and a drainage device 19 is mounted underneath the water tub 11 to drain wash water used from the water tub 11 . The drainage device 19 includes a drainage pipe 19 a, a drainage valve 19 b, and a drainage pump 19 c.
[0036] The detergent supply device 18 is internally sectionalized into a plurality of chambers, and is positioned close to the front wall of the body 10 to facilitate the input of a detergent and rinse agent into the respective chambers. The plurality of sectionalized chambers include a preliminary washing detergent chamber to store a detergent for use in a preliminary washing cycle, a main washing detergent chamber to store a detergent for use in a main washing cycle, and a rinse agent chamber to store a rinse agent for use in a rinsing cycle. This arrangement is disclosed in Korean Patent Application No. 2003-0011317 filed by the applicant of the invention. Admittedly, any other known techniques may be employed to construct the above described arrangement.
[0037] The water supply device 20 includes cold water and hot water supply pipes 21 and 22 to supply cold water and hot water, respectively, and water supply valves 23 and 24 mounted to the cold water and hot water supply pipes 21 and 22 to control the supply of cold water and hot water, respectively.
[0038] The cold water and hot water supply pipes 21 and 22 are connected to the detergent supply device 18 , such that water, supplied from an exterior water source, can be supplied into the detergent supply device 18 . A separate water supply pipe 25 is mounted between the detergent supply device 18 and the water tub 11 to supply the water, having passed through the detergent supply device 18 , into the water tub 11 . The water supply pipe 25 is provided at an outlet thereof with a water supply nozzle 26 . With this arrangement, the water is adapted to pass through the detergent supply device 18 prior to being supplied into the water tub 11 , whereby the detergents inside the detergent supply device 18 can be supplied into the water tub 11 after being dissolved in the water.
[0039] FIG. 2 is a control block diagram showing a washing control mechanism of the washing machine consistent with an exemplary embodiment of the invention. As shown in FIG. 2 , the washing control mechanism includes a signal input unit 100 , a temperature sensor 110 , a water level sensor 120 , a controller 130 , a drive unit 140 , and a speed sensor 150 .
[0040] The signal input unit 100 is used to input a variety of operational information, including a wash program, a temperature of wash water, revolutions per minute for a spin-drying cycle, and an additional rinsing cycle, which are selected based on the material of laundry, to the controller 130 . The signal input unit 100 is provided with a key for selecting the preliminary washing cycle, in which the amount of water supplied is regulated, before the main washing cycle in order to achieve an improvement in wash performance.
[0041] The temperature sensor 110 is used to sense the temperature of wash water supplied into the water tub 11 . The water level sensor 120 is used to sense the level of wash water supplied into the water tub 11 .
[0042] The controller 130 is a micro-computer to control the washing machine in accordance with the operational information inputted from the signal input unit 100 . If the preliminary washing cycle is selected, the controller 130 controls the operation of the water supply device 20 to reduce the amount of wash water used, in such a manner that 70% of the overall wash water is supplied during the preliminary washing cycle and the remaining wash water of 30% is supplied during the main washing cycle in a two-stage water supply control manner.
[0043] As the wash water is supplied based on the selection of the preliminary washing cycle, the controller 130 controls the supply of detergent in accordance with a three-stage detergent supply method. In a first stage, 30% of a predetermined amount of detergent is supplied for the preliminary washing cycle, and 100% of the predetermined amount of detergent is supplied for the main washing cycle. In a second stage, 30% of the predetermined amount of detergent is supplied for the preliminary washing cycle, and 80% of the predetermined amount of detergent is supplied for the main washing cycle. In a third stage, 50% of the predetermined amount of detergent is supplied for the preliminary washing cycle, and 60% of the predetermined amount of detergent is supplied for the main washing cycle. This detergent supply method is proved to reduce the amount of detergent used by 15% as compared to an amount of detergent conventionally used, or to achieve an improvement in wash performance with the amount of detergent conventionally used.
[0044] After completing the preliminary washing cycle, the controller 130 controls the operation of both the drainage device 19 and the water supply device 20 , such that the remaining wash water is 30% of the desired amount, except for the wash water used during the preliminary washing cycle, is supplied, along with the main washing detergent, in order to top up the wash water to 100% of the desired amount, while continuously maintaining the preliminary washing state without draining or dehydrating the wash water.
[0045] The drive unit 140 is adapted to drive the motor 15 , wash heater 16 , drainage valve 19 b, drainage pump 19 c, and water supply valves 23 and 24 based on drive control signals from the controller 130 .
[0046] Now, the operational sequence and effects of a washing control method associated with the washing machine having the above-described configuration will be described.
[0047] FIG. 3 is a flow chart showing the operational sequence of a method for improving the effectiveness of preliminary washing in association with the washing machine consistent with the invention. The washing control method of the invention proposes to regulate the amount of detergent and wash water used during both the preliminary washing cycle and the main washing cycle, in order to improve the efficiency of the preliminary washing cycle. For this, the preliminary washing cycle may be set to a default, or a separate optional key may be provided to selectively induce the preliminary washing cycle only when it is pushed by a user.
[0048] If laundry is put into the rotary drum 12 , and a variety of operational information, including a wash course, a temperature of wash water, revolutions per minute for a spin-drying cycle, and addition of a rinsing operation, is manually selected based on the material of laundry, the selected operational information is inputted to the controller 130 via the signal input unit 100 .
[0049] Accordingly, to advance washing and rinsing cycles based on the operational information inputted from the signal input unit 100 , the controller 130 first determines whether or not the preliminary washing cycle is selected (S 200 ).
[0050] If the preliminary washing cycle is selected, the controller 130 switches on the water supply valves 23 and 24 , such that wash water is supplied into the detergent supply device 18 through the water supply pipes 21 and 22 . After passing through the detergent supply device 18 , the wash water is supplied into the water tub 11 through the water supply pipe 25 until the wash water reaches a preliminary washing water level (S 210 ). Here, the preliminary washing water level is 70% of the overall wash water that is determined in accordance with the amount of laundry.
[0051] As the wash water for preliminary washing is supplied, a detergent, which is stored in the preliminary washing detergent chamber of the detergent supply device 18 , is supplied by 30% to 50% of the amount of detergent used for the main washing cycle in the same manner as a conventional detergent supply method. The reason why the preliminary washing detergent is supplied along with 70% of the overall wash water is to achieve a high density rough wash as compared to a conventionally performed preliminary washing cycle that supplies 100% of the overall wash water.
[0052] After the wash water is supplied into the water tub 11 to the preliminary washing water level, the controller 130 drives the motor 15 based on a predetermined rpm and operation rate (on/off rate), to rotate the rotary drum 12 . As the rotary drum 12 rotates, the preliminary washing cycle is performed to wash laundry contained in the drum 12 using a force of gravity that results when the laundry falls when the drum rotates and while, allowing the preliminary washing detergent to be mixed well with the wash water (S 220 ).
[0053] During the preliminary washing cycle, the controller 130 determines whether or not a predetermined preliminary washing time T has passed by timing an operation time of the preliminary washing cycle (S 230 ). If the predetermined preliminary washing time T has passed, the controller 130 stops operations of all units including the drainage device 19 , such that the preliminary washing state is continuously maintained without draining the wash water used.
[0054] Generally, after being used, the wash water looks dirty and has a low bubble generation performance. Therefore, the used wash water is considered to have a poor wash performance. However, in accordance with an article entitled “The Principle of Detergent and Wash”, published in the Journal of the Japanese Textile Consumption Science in November 1965, it has been proved, as a result of qualitative and quantitative analyses of the wash water used once, that the wash water contains 90% of detergent active components and has a good wash ability, and therefore, is reusable for subsequent washing cycles. Accordingly, when the detergent used for the preliminary washing cycle is used again in the main washing cycle, it achieves 100% effectiveness of the desired washing ability if the new detergent is replenished by only 10% of the wash water.
[0055] Accordingly, the controller 130 supplies the remaining wash water of 30% required for main washing, along with a detergent, after completing the preliminary washing cycle (S 240 ).
[0056] As the wash water for main washing is supplied, a detergent, which is stored in the main washing detergent chamber of the detergent supply device 18 , is supplied in the same manner as a conventional detergent supply method, or optionally, in an amount of detergent that is 60% to 80% less than the amount of detergent used for main washing cycle. When the same amount of detergent as the conventional detergent supply method is used, for example, the amount of detergent for the preliminary washing cycle is reduced by 30% to 50% and the amount of detergent used in the main washing cycle detergent is unchanged, the reduction in the amount of detergent only for the preliminary washing cycle has the effect of improving the wash performance from 3% to 10%. Here, an improvement in wash performance by 10% can be achieved by a European model using a water temperature of 40□.
[0057] In the invention, for example, the first amount of detergent of the conventional method is reduced by 15% when the amount of detergent for the preliminary washing cycle is reduced by 30% to 50% and the amount of detergent for the main washing cycle is reduced by 60% to 80% in a second amount of detergent. The washing effect of the second amount of detergent is the same as the conventional method. Thus, the results using the reduced second amount of detergent for the preliminary washing cycle and the main washing cycle are comparable to the conventional method using the first amount of detergent.
[0058] If the remaining wash water is 30% and supplied into the water tub 11 during the main washing cycle to top up the wash water to 100% of the desired amount, the controller 130 drives the motor 15 based on a predetermined rpm and operation rate (on/off rate) to rotate the rotary drum 12 . As the rotary drum 12 rotates, the main washing cycle is performed to wash laundry contained in the drum 12 using a force of gravity that results when the laundry falls as the drum rotates, while allowing the main washing detergent to be mixed well with the wash water (S 250 ).
[0059] After that, the remaining general cycles of the washing machine are successively performed (S 260 ), and then, the operation of the washing machine is finished.
[0060] As apparent from the above description, the invention provides a washing machine and a washing control method thereof having the following effects.
[0061] Firstly, according to the invention, it is possible to achieve not only an improvement in the efficiency of a preliminary washing cycle that is an optional function of the washing machine, but also a reduction in the amount of detergent and wash water for use in the preliminary washing cycle.
[0062] Secondly, according to the invention, the amount of detergent and wash water used for the preliminary washing cycle can be regulated. This has the effect of achieving an improvement in wash performance by approximately 10% when the same amount of detergent as a conventional detergent supply method is used, and also reducing the amount of detergent to be used by 15% while achieving the same wash effect as the conventional method. As a result, the amount of wash water to be used can be reduced by up to 50%.
[0063] Although an embodiment of the invention has been shown and described, it would be appreciated by those skilled in the art that the described embodiment is merely exemplary so as to realize a washing machine and a washing control method consistent with the invention, and therefore, various changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
|
A washing machine and washing control method thereof. The washing control method not only improves the effectiveness of a preliminary washing cycle that is an optional function of the washing machine, but also reduces the amount of detergent and wash water that is used for the preliminary washing cycle. For this, the washing control method includes determining whether or not a preliminary washing cycle is selected, supplying a lesser amount of wash water than a desired amount of wash water that is determined based on the amount of laundry if the preliminary washing cycle is selected, and performing the preliminary washing cycle, and supplying a certain amount of wash water additionally after completing the preliminary washing cycle, and performing a main washing cycle.
| 3
|
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention relates to air brake systems for motor vehicles and more particularly to providing an air compressor system in which a vehicle body computer is programmed to learn normal operating ranges for air brake systems, including particularly the compressor cut-in and cut-out pressures.
[0003] 2. Description of the Problem
[0004] Air compressors on trucks can supply pressurized air to air brake systems for the truck, to any trailers pulled by the truck and to other vehicle systems such as air suspension systems. The operation of the air compressor system is critical to truck operation for engaging the brakes for stopping. For this reason the periodic verification of operation of the compressor and air brake system is important for insuring safe operation of the vehicle and has been made the subject of government regulations.
[0005] The air compressor on a truck is typically under the control of a governor which triggers compressor operation in response to falling system pressure. The point where compressor operation engages is called the cut-in pressure. The governor further responds to pressure in the system reaching an upper limit at which point it causes the air compressor to discontinue supplying pressurized air. This point is called the cut-out pressure.
[0006] Air compressor system performance varies by manufacturer, by age of the system and by its state of repair. Systems differ in the number of compressed air tanks and in the capacity of those tanks. Some vehicles are equipped with air suspensions which make independent demands on compressed air. Leakage rates vary from system to system and still other factors may effect operation. When new or in good repair an air compressor system should operate at close to its optimal levels. With age and deterioration of the system, the system may come to fall short of these optimal operating values. Inspection regimens should detect failure of a system to operate close to original specification.
[0007] Inspection regimens must be established to comply with government regulations. These regimens check variables such as compressor governor cut-out, governor cut-in and monitor gauge pressure against a clock to determine charge build time. A representative procedure requires a driver or operator to:
[0008] “Check Air Compressor Governor Cut-in and Cut-out Pressures. Pumping by the air compressor should start at about 100 psi and stop at about 125 psi. (Check manufacturer's specifications.) Run the engine at a fast idle. The air governor should cut-out the air compressor at about the manufacturer's specified pressure. The air pressure shown by your gauge(s) will stop rising. With the engine idling, step on and off the brake to reduce the air tank pressure. The compressor should cut-in at about the manufacturer's specified cut-in pressure. The pressure should begin to rise.”
[0009] “Check Rate of Air Pressure Buildup. When the engine is at operating rpm, the pressure should build from 85 to 100 psi within 45 seconds in dual air systems. (If the vehicle has larger than minimum air tanks, the buildup time can be longer and still be safe. Check the manufacturer's specifications.) In single air systems (pre-1975), typical requirements are pressure buildup from 50 to 90 psi within three minutes with the engine at an idle speed of 600-900 rpm.”
[0010] Making these determinations manually and daily is obviously time consuming. In addition, the pressure gauges used in making the tests are frequently imprecise and difficult to read.
[0011] It would be desirable to equip vehicles to determine normal compressor system operating variables notwithstanding differences in air pressurization systems from vehicle to vehicle. Operators should not be tempted to provide, or guess at, manufacturer's specifications in implementing an inspection regimen. The possibilities for operator error should be reduced. A system which automatically compensates for the effects of extraneous systems of compressed air availability would be further advantageous.
SUMMARY OF THE INVENTION
[0012] According to the invention there is provided an algorithm executable on a body computer, such as an electrical system controller or similar device for a vehicle controller area network, for determining normal operating ranges of a compressed air system installed on a motor vehicle, including governor cut-in and cut-out pressures. The algorithm utilizes air pressure readings from an air pressure sensor located in communication with the compressed air system. The time period between major air pressure deflection points is taken to correspond to compressor cut-out and cut-in. Periods between major deflection points are timed to determine rates of pressure increase. Periods of exogenous air pressure demand are detected and excluded from pressure rise time calculations by determination of the location of minor pressure deflection points. An information processor connected to receive the air pressure signal and utilizing the clock signal is programmed to execute the algorithm.
[0013] Additional effects, features and advantages will be apparent in the written description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0015] FIG. 1 is a side view of a possible truck/tandem trailer combination illustrating installation of an air brake system with which the invention may be used.
[0016] FIG. 2 is a block diagram of a controller area network for a motor vehicle such as shown in FIG. 1 .
[0017] FIG. 3 is a detailed block diagram of interacting components of the controller area network and the air brake system.
[0018] FIG. 4 is a block diagram of an electrical system controller for a controller area network which may be programmed to implement the invention.
[0019] FIG. 5 is a graphical representation of air pressure in a compressed air system used to support operation of air brakes and an air suspension system.
[0020] FIG. 6 is a flow chart illustrating operation of the determination algorithm for a compressed air system.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring now to the figures and in particular to FIG. 1 , a tandem trailer/tractor combination 10 equipped with air brake system 24 is illustrated as possible environments to which the invention can be applied. Tandem trailer/tractor combination 10 includes a tractor 26 and two trailers, 28 and 29 , respectively. Tractor 26 and trailers 28 , 29 are supported on wheels 12 , 14 , 26 , 32 and 33 , the rotation of which may be slowed or stopped using air pressure actuated brakes 36 . Air brake system 24 may be considered as including an air pressurization and storage subsystem including a compressor 16 , storage tanks 18 and air lines 20 , 40 and 38 . The details of air brake system 24 are otherwise conventional.
[0022] FIG. 2 illustrates a conventional vehicle electrical control system 40 having a controller area network (CAN) bus 42 as its backbone. CAN bus 42 conforms to the SAE J1939 protocol and provides for data transmission between a plurality of controllers connected to the bus including, an electrical system controller (ESC)/body computer 44 , an engine control module 45 , a stability and height controller 46 , a transmission controller 48 , a gauge controller 50 , an auxiliary gauge controller 52 and an anti-lock brake system (ABS) controller 54 . These controllers are generally attached to one or more devices the status of which may be transmitted over CAN bus 42 by its associated controller for the use of other controllers. For example, engine controller 45 is generally connected to a plurality of engine sensors 58 including, among other sensors, a crankshaft position sensor from which an engine tachometer indication may be developed. Transmission controller 48 controls a transmission 60 the output of which is measured by a drive shaft tachometer 62 . This signal may be used to generate a measurement of vehicle speed. A stability and height controller 46 controls the inflation of a plurality of air springs forming part of the vehicle suspension and represents an exogenous user of compressed air which complicates measurements of the performance of an air pressurization system. Gauge controller 50 and auxiliary gauge controllers 52 are often used to collect and format telemetry from vehicle sensors. Here various pressure sensors 70 , including an air brake system pressure sensor are shown as monitored by pressure data transmitters 68 connected to the auxiliary gauge controller 52 . Under some circumstances air pressure may be reported directly to the engine control module 45 or to body computer 44 . ABS controller 54 provides control over brake valves 72 responsive to signals received from body computer 44 and a plurality of wheel speed sensors 74 directly connected to the ABS controller. Body computer 44 , which operates as a coordinator between other controllers and is programmable is typically connected to a brake pedal switch 56 and accordingly determines the brake pedal's position. The various connections between sensors and controllers are somewhat flexible. Drive shaft tachometer 62 may be connected to report its output directly to engine control module 45 .
[0023] FIG. 3 is a schematic illustration of a set of controllers for an air brake system 80 involved in implementing a preferred embodiment of the invention. A vehicle engine 74 is mechanically linked to drive a compressor 70 which supplies air by a check valve 19 to compressed air storage tanks 18 . The representation is simplified by not referencing independently such components of a conventional air system such as an air dryer, and not distinguishing between dry tanks and wet tanks. As is conventional, the system is designed to maintain air pressure in a range of 100 to 125 psi. Air pressure is maintained by using a compressor 70 under the control of a governor 72 , which is responsive to air pressure communicated on a line to one of compressed air tanks 18 , usually a wet tank. Air pressure signals developed by air pressure sensor 71 are passed to body computer 44 , typically over CAN bus 42 . Air pressure sensor 71 is typically in communication with one of the dry tanks. Where two dry tanks are used either one may be selected, which then becomes the base for all measurements. Body computer 44 receives an engine tachometer signal from engine control module 45 , which is derived from an engine crankshaft position sensor 58 A. Brake pedal position sensor 56 functions as described above. Vehicle speed 84 is supplied from a transmission controller (not shown) or the engine control module 45 , which generate the signal from the drive shaft tachometer. ABS controller 54 and body computer 44 may exchange data relating to air brake system operation 80 . The possibility of other air using systems is represented by a general block 82 . Air compression systems come in a number of varying types. It is not necessary that the type of system be known in order to use the present invention, which is capable of learning normal values for the system's operation variables.
[0024] Body computer 44 may be realized as a programmable, general purpose computer having a CAN interface 98 for transmitting and receiving information over the CAN bus 42 . Body computer 44 includes a microprocessor or CPU 90 communicating with CAN interface 98 and memory 94 over an internal bus 97 . A program 96 for determining governor cut-in and cut-out pressures and performance is stored in memory 94 . The array 95 of values determined is also stored in memory 94 . CPU 90 utilizes clock signals from a clock 92 and communicates with external sensors 102 over a local interface 100 .
[0025] FIG. 5 graphically illustrates typical operational pressure variation for an air brake system. The principal line represents air pressure as periodically sampled. P_min and P_max are variables used by program 96 to determine cut_in and cut_out pressures. Two complete recovery or change cycles (A to B and C to D) and one complete cycle of exhaustion (B to C) are represented. P_max is reset to the current pressure reading on each of occurrence of locking on a cut-in pressure (points A and C). It then tracks the current measured pressure upwardly, ignoring occasional temporary reversals until it locks on a maximum pressure reading (B and D, i.e. cut-out pressure), which it holds until the next minimum. P_min is held at the last detected cut-in pressure (A and C) until a cut-out is detected, whereupon it is reset to the cut-out pressure, which it tracks downwardly until a major turning or deflection point is detected. Points A, B, C and D may be characterized as major deflection points. Points E, F, G and H are minor deflection points resulting from changes in the demand for air, and not cut-in or cut-out of the compressor. Time to rise excludes period following negative turning minor deflection points (E and G) until pressure recovers to the level where a negative turning minor deflection point occurred.
[0026] Referring now to FIG. 6 a flow chart illustrates program 96 which is executed on electrical system controller 44 for determining and updating governor cut-in and governor cut-out points for a vehicle air pressurization system of unknown operating characteristics. Program initialization includes definition of a list of variables (Init), which includes initial estimates of governor cut-in and cut-out pressures. The “Init” variables are set once on initial execution of program 96 on body computer 44 . The program thereafter use values for the variables developed by the program. Other variables are initialized every time the program is called as indicated at Step 600 . Governor cut-in and cut-out are reflected in variable stacks [Gov_In(n, . . . , n− 4 ); Gov_Out(n, . . . , n− 4 )]. Governor cut-in and cut-out are determined from an average of the current measurement (n) and the four most recent measurements (n− 1 , n− 2 , n− 3 and n− 4 ). Cut-in should occur at about 100 psi and so all five variables in the stack used for estimating cut-in are initially set to 100. Cut-out should occur at about 125 psi and the five variables for estimating cut-out are initially set to 125. Two variables, P_max and P_min, are provided which will indicate the end and start points, respectively, of a period of increasing pressure, allowing a determination of the rise slope to be made. Both variables are initially given values far higher than should ever appear, that is 150 and will, upon a successful test, be inserted at the top of the stacks Gov_In, Gov_Out. PointCount indicates the current sample count, and is initially 0. Two variable stacks P( 1 , 2 ){n . . . n− 4 }= 100 provide first in/first out temporary storage of current pressure measurements. Rising, SpikeFlag, SpikeTime and LastL are flags. GovErr is an error factor. LeakStartTime and StartTime are set to the current system clock.
[0027] Step 602 indicates entry to a rise detection phase of the program, where it is assumed that the compressor is cut-out and the system is losing air pressure due to leakage. Pressure readings P( 1 ) and P( 2 ) for the current period n are taken as indicated at step 604 and the measurements compared to find the lower of the two to which the variable Press is set equal. At step 608 it is determined if the variable Press has been set equal to the reading P( 1 ). If YES, flags T and L are set to 1 and 2, respectively (step 610 ), in NO, flags T and L are set to 2 and 1, respectively (step 612 ). Following step 610 or 612 a comparison is executed to determine if one of variables P(T){n} (i.e. P( 1 ){n} or P( 2 ){n} where n is the current period) is less than or equal to P_min. Initially the result of the comparison is almost always “YES” since P_min is 150 and any pressure measurement should be less than 125. Along the YES branch from the comparison P_min is reset to equal Press (step 616 ), the counter RiseCount is set equal to 0 and P_max is set equal to P(T){n}. Later instances of execution of steps 616 and 618 will be triggered by falling or steady pressure since P_min will be determined by readings from the prior periods. The program executes a return to step 602 and another set of samples P 1 , P 2 is read.
[0028] Consider now the NO branch from the comparison test of step 614 . Another comparison step 620 is executed to compare P(T){n} to P_max to determine if P(T){n} is greater than P_max. P_max will always be one of P(T){n− 1 , n− 2 , n− 3 , or n− 4 } so P(T){n} (see steps 618 , 624 ), which is a current sample, is being compared with an earlier sample in its stack. If the comparison fails execution follows the NO branch to comparison step 622 where it is determined if the counter variable RiseCount has reached its limit value. Because RiseCount has not yet been incremented, and was initially set to 0, the NO branch from step 622 is followed back to step 602 for depression of the stack and the collection of another set of samples. Where P(T){n} is greater than P_max, indicating an increase in the current pressure measurement over any previous recent pressure measurements, execution proceeds along the YES branch from step 620 to step 624 , where P_max is reset to P(T){n}. Next, at step 626 the variable RiseCount is incremented and at step 628 it is determined if RiseCount is equal to 1, which will occur only on the first occasion of detection of a possible series of increasing pressure readings. This is the occasion of setting of two variables BackTrack and BackTime to the values P(L){n− 1 } and Clock- 1 , respectively (step 630 ). Following step 630 execution returns to step 602 through decision step 622 . Only following a “No” determination at step 628 can RiseCount time out, indicating the occurrence of three increases in the maximum pressure reading with a change in the minimum pressure reading. This is taken as an indication of rising pressure.
[0029] The pressure rise detected portion of the algorithm requires initialization of several variables and counters as indicated in steps 632 , 636 , and 640 . The variables include “StartTime” which is initialized at the value “Clock- 3 ”; “Rising”, which is set to 1; and three variables, “PointCount”, “RPM_total” and “Speed_total”, all of which are set to 0. The variables allow adjustments to the measurement of pressure rise time to compensate for engine and vehicle speed. Leakage continues to be monitored (step 634 ) and data is recorded (step 638 ). These operations support other operations. Governor cut-in pressure is recalculated each time rise detection is initiated and is made equal to the five most recently calculated cut-in pressures as represented by taking the average of P_min, GovIn{n− 1 }, GovIn{n− 2 }, GovIn{n− 3 }, and GovIn{n− 4 } at step 642 . The variable P_max is confirmed to be P(T){n} at step 644 and new data is read, resetting P(T){n}, at step 646 .
[0030] Before the new pressure readings are used for comparison tests the old P_max, carried over from the rise detection phase of the algorithm, is compared to cut-out pressure, less an error factor (GovOut*GovErr), at step 648 . Ordinarily, it would be expected that the P_max value has been reset to a value in the P(T) stack at step 624 , and should be less than this value and accordingly processing advances along the NO branch to step 650 , where it is determined if the counter “SpikeDrops”, which is initially 0, has counted out. If NO, step 652 is executed to determine if pressure has continued to rise and a current pressure measurement P(T){n} is compared to P_max to determine if it is at least equal to the pressure reading from the previous measurements. Normally, on the occasion of the first local instance of execution of the step, the value for P(T){n} can be expected to exceed that for P_max. If it does, the YES branch from step 652 leads to execution of a another comparison test, step 654 , is executed to determine the value of a flag “SpikeFlag”, which indicates occurrence of a drop in the current pressure measurement since the most recent detection of rising pressure, i.e. since the last instance of compressor cut-in. The expected value is 0, whereupon process execution skips to step 658 , where P_max is reset to the current pressure measurement. If the spike flag is set, step 656 precedes execution of step 658 and the variable “SpikeStart” is set to the current clock for accumulation of rise time.
[0031] Following step 658 , a determination is made if the “SpikeLoop” flag has been set, indicating that an immediately previous occurrence of a current pressure reading falling below the prior period's pressure reading, as detected at step 652 . If not, execution proceeds along the branch from step 660 leading to steps 662 , 664 , 666 and 668 . These steps reflect the resetting or incrementation of several variables, including, respectively, resetting “SpikeStart” equal to the current clock; resetting “Speed_Total” to the sum of the previous Speed_Total and current speed measurement; resetting “RPM_Total” to equal to the sum of the old RPM_Total and the current measured RPM; and finally incrementing the counter “PointCount”, which will reflect the number of times Speed_Total and RPM_Total are incremented to allow calculation of an average for the two variables. Following step 668 processing returns to step 646 and a new set of variables are read.
[0032] Returning to step 652 , the case where the current pressure measurement P(T){n} falls, or has remained, below a prior measurement during the current rise detected phase of the algorithm is considered. Following the NO branch from step 652 it may be seen that steps 670 , 672 and 674 are executed, which in turn set “SpikeFlag” to 1, “SpikeLoop” to 1 and increment the counter “SpikeDrops”. SpikeDrops is the most significant of these since its accumulation to a value equal to 8 aborts the rise detect portion of the algorithm, as detected at step 650 . The YES branch from step 660 is followed only after a prior pass through steps 670 , 672 followed by an indication that pressure is again rising. Steps 676 , 678 and 680 provide for resetting “SpikeTime” to the old value for SpikeTime plus the current Clock less the time for “SpikeStart”. In other words, the elapsed time corresponding to a period when pressure is dropping or is rising, but has not yet recovered to the point where the interruption occurred is accumulated in “SpikeTime”. SpikeStart is then set to the current clock and the SpikeLoop flag is reset to 0. Processing returns to step 646 for the collection of new data.
[0033] As stated above, accumulation of a “SpikeDrops” count equal to 8 results in the process being aborted. No updates to governor cut_out occur under these circumstances as the process is advanced to a series of exit steps which reflect resetting variables for the next iteration of the leak monitoring and rise detection steps including steps 602 through 630 . These steps include resetting the flag termed “Rising” to 0 (step 682 ), writing data to a file (step 684 ), resetting P_min to the current pressure measurement P(T){n} (step 686 ) and resetting the SpikeFlag to 0 (step 688 ) before the algorithm is exited.
[0034] Returning to step 648 , the steps of the algorithm occurring once P_max has reached a value close to the governor cut-out pressure less an error factor are considered. Following the YES branch from step 648 , timing of rise time must discontinue and accordingly a variable “EndTime” is set equal to the current clock reading (step 690 ), anticipating that the compressor has been cut out. Next, at steps 692 and 694 the variables RPM_total and Speed_total are reset and the counter PointCount incremented, tracking steps 664 through 668 . RPM's and speed are tracked for the use of other processes. Risetime will vary as a function of engine RPM's. At this point in the process declining pressure is taken as confirmation of compressor cut-out. The current pressure measurement is compared to P_max at step 698 . If the current measurement at least equals P_max, indicating the cut-out has not occurred, P_max is reset to the current pressure measurement, the variable EndTime is reset to the current clock (steps 700 , 702 ) and another set of pressure measurements is taken (step 704 ). Otherwise, the NO branch from step 698 results in execution of a comparison (step 708 ) between the current measurement and the pressure measurement for the immediately preceding period. If the current measurement reflects an increase in pressure, processing returns to step 704 for yet another round of data measurements. If the current measurement indicates that pressure is steady or falling since the last measurement, the variable FallCount is incremented and at step 710 it is determined if FallCount has reached a value high enough to trigger an exit from the loop. If not, processing loops back through step 704 for still more pressure measurements. If YES, processing advances to steps providing from redetermination of the expected Governor cut-out pressure level.
[0035] The invention provides for determining both the expected governor cut-out pressure level and the expected rise time from cut-in to cut-out, ignoring intervening demands for air pressure and recovery. Expected rise time may require consideration of operating conditions. First, at step 712 , the average of engine RPM measurements made during the rise detected portion of the algorithm is made. Step 712 provides for determining the average “RPM_avg” from the accumulated RPM measurements divided by the number of samples “PointCount”. Next, at step 714 , a new, current governor cut-out pressure level is determined by averaging the final value for P_max with the prior four determinations of the governor cut-out pressure level. The oldest value is discarded. Rise time determinations take account of interruptions in pressure increase by determining first if any such interruption occurred. Step 716 checks the flag SpikeFlag. If the flag has not been set RiseTime is simply the EndTime of the rise detect portion of the algorithm less its StartTime (step 718 ). Otherwise RiseTime is adjusted to exclude what is termed “SpikeTime” which accumulated over periods when declining pressure measurements, and recovery from the period, occurred (step 720 ). The time rate of change of pressure over time may now be calculated by subtracting final maximum pressure from the initial minimum pressure and dividing the result by RiseTime (step 722 ) from either step 718 or 720 . The final step preceding the reset steps, step 724 , provides storage of the calculated slope as “System_Data_Change”.
[0036] The invention provides an automatic system allowing vehicles to determine normal compressor system operating variables notwithstanding differences in air pressurization systems from vehicle to vehicle. There is no need for vehicle drivers or operators to provide, or guess at, manufacturer's specifications in implementing an inspection regimen. The possibilities for operator error are reduced. A system automatically compensates for some extraneous demands on compressed air availability.
[0037] While the invention is shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit and scope of the invention.
|
Vehicles equipped with air brake systems and onboard vehicle management computers may be programmed to determine normal operating variables for the air compressor system used for maintaining air brake system pressure. The algorithm used determines normal compressor cut-in and cut-out pressures and actual rise times from cut-in to cut-out by compensating for periods of exogenous air pressure demand.
| 5
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to a robot remote manipulation system and a robot remote manipulation device, and specifically relates to such systems and devices that remotely manipulate bipedal walking robots via communication networks.
[0003] 2. Description of the Related Art
[0004] A variety of robot remote manipulation systems have been developed recently. As one prior art robot remote manipulation system, Tmsuk 04 (Robocon magazine No. 18, pp. 20-23, published by Ohm-sha in 2001) is known in which a robot can be remotely manipulated using a PHS line. In the Tmsuk 04 technology, an operator operates a master arm to control the motion of a robot as a slave. Another prior art manipulation system uses a joy stick. By moving the joy stick forward, backward, rightward or leftward, the moving direction, the length of a step and the walking speed of a robot can be controlled.
[0005] There is known one other prior bipedal walking robot remote manipulation system in which commands are inputted or a moving destination and route are inputted.
[0006] Such conventional bipedal walking robot remote manipulation systems, however, have comparatively large sizes. Further, while manipulating a robot in the conventional systems, it is not easy to be aware of forces applied to the legs of the robot and therefore it is not easy to control the robot.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is one object of the present invention to provide a robot remote manipulation system and manipulation device, by which an operator can with ease remotely manipulate a bipedal walking robot and can be aware of forces applied to the legs of the bipedal walking robot.
[0008] Another and more specific object of the present invention is to provide a robot remote manipulation system including a bipedal walking robot and a remote manipulation device for remotely manipulating the bipedal walking robot, the robot being connected to the remote manipulation device via a communication network and controlled by controlling data from the remote manipulation device,
[0009] the remote manipulation device comprising:
[0010] a pair of bilateral mechanical rotating elements each providing a quantity of motion for one of bilateral legs of the bipedal walking robot; and
[0011] a controlling data transmitter for transmitting controlling data corresponding to the quantities of motion to the bipedal walking robot; and
[0012] the bipedal walking robot comprising:
[0013] a controlling data receiver for receiving the controlling data transmitted from the remote manipulation device; and
[0014] a leg motion controller for processing the received controlling data and causing the bilateral legs to move forward or backward.
[0015] Another object of the invention is to provide a remote manipulation device for remotely manipulating a bipedal walking robot connected to the remote manipulation device via a communication network, comprising:
[0016] a pair of bilateral mechanical rotating elements each providing a quantity of motion for one of bilateral legs of the bipedal walking robot; and
[0017] a controlling data transmitter for transmitting controlling data corresponding to the quantities of motion to the bipedal walking robot.
[0018] A further object of the invention is to provide a remote manipulating method in a robot remote manipulation system including a bipedal walking robot and a remote manipulation device for remotely manipulating the bipedal walking robot, the robot being connected to the remote manipulation device via a communication network and controlled by controlling data from the remote manipulation device, the method comprising the steps of:
[0019] operating a pair of bilateral mechanical rotating elements in the remote manipulation device, and providing a quantity of motion for each of bilateral legs of the bipedal walking robot; and
[0020] transmitting controlling data corresponding to the quantities of motion to the bipedal walking robot;
[0021] in the bipedal walking robot, receiving the controlling data transmitted from the remote manipulation device; and
[0022] processing the received controlling data and causing the bilateral legs to move forward or backward.
[0023] Features and advantages of the present invention are set forth in the description that follows, and in part will become apparent from the description and the accompanying drawings, or may be learned by practice of the invention according to the teachings provided in the description. Objects as well as other features and advantages of the present invention will be realized and attained by an apparatus particularly pointed out in the specification in such full, clear, concise, and exact terms as to enable a person having ordinary skill in the art to practice the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1 shows a block diagram of a robot remote manipulation system according to the present invention;
[0025] [0025]FIG. 2 is an exterior appearance view of the remote manipulation device shown in FIG. 1;
[0026] [0026]FIG. 3 illustrates a controlling technique of a bipedal walking robot using the remote manipulation device shown in FIG. 1;
[0027] [0027]FIG. 4 shows schematic views of a treadmill mechanism used in the remote manipulation device shown in FIG. 1;
[0028] [0028]FIG. 5 illustrates a force applied to the bipedal walking robot on a slope;
[0029] [0029]FIG. 6 is a schematic diagram of a circuit for feeding the force back to the treadmill; and
[0030] [0030]FIG. 7 shows another example of feeding the force back to the treadmill;
[0031] [0031]FIG. 8 shows a relationship between the quantity of motion of the treadmill and the step length of the bipedal walking robot;
[0032] [0032]FIG. 9 is a flowchart for illustrating a remote manipulation process of the robot using the remote manipulation system shown in FIG. 1;
[0033] [0033]FIG. 10 is a flowchart for illustrating a control process of the treadmill resistance using information obtained by an inclination sensor provided in the robot; and
[0034] [0034]FIG. 11 shows schematic views of remote manipulation devices having rollers according to another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] In the following, embodiments of the present invention are described with reference to the accompanying drawings.
[0036] [0036]FIG. 1 shows a block diagram of a bipedal walking robot remote manipulation system according to a first embodiment of the present invention.
[0037] The remote manipulation system shown in FIG. 1 includes a bipedal walking robot 20 (referred to as merely “robot” hereinafter) and a portable type remote manipulation device 10 capable of remotely manipulating the robot 20 via a communication network 100 .
[0038] The remote manipulation device 10 includes a CPU 19 for controlling all the elements, a treadmill 11 having bilateral rotational belt mechanisms, a servo controller 12 for controlling outputs of motors for driving the rotational belts based on instructions from the CPU 19 , and a D/A 13 for D/A converting an input to the servo controller.
[0039] The remote manipulation device 10 further includes an encoder 14 for detecting rotational angles, speeds and directions of the motors, a counter 15 for counting the number of pulses from the encoder 14 , a display 16 for displaying audiovisual information sent from a CCD camera mounted on the robot, an operation part 17 such as a ten-key pad, and a radio communication part 18 for communicating with a base station (not shown) via the communication network 100 .
[0040] The robot 20 includes an inclination sensor 21 for sensing an inclination angle of the robot, a CPU 22 for calculating the status of the robot legs based on the inclination angle sensed by the inclination sensor 21 , and a radio communication part 23 . The radio communication part 23 data-processes the status of the robot legs calculated by the CPU 22 , and transmits the processed data (referred to as “force sense data” hereinafter) to a base station (not shown) via the communication network 100 .
[0041] [0041]FIG. 2 is an exterior appearance view of the remote manipulation device 10 shown in FIG. 1.
[0042] The remote manipulation device 10 in FIG. 2 shows the display 16 , the treadmill 11 and the operation part 17 . As shown in FIG. 2, the treadmill 11 has a pair of bilateral rotational belts. According to the present invention, as shown in FIG. 3, the bilateral rotational belts can be rotated and moved by the index finger and the middle finger of an operator's dominant hand (right hand, for example), and the right and left treadmills can receive their respective quantities of motion. The quantities of motion are used for manipulating the robot leg movements.
[0043] The treadmill can be configured as shown in FIG. 4, for example.
[0044] The treadmill 11 shown in FIG. 4 includes a rotational belt 31 , a motor 32 for controlling resistance to the movement of the rotational belt 31 , rollers 33 driven by the motor 32 to apply a resistance force to the rotational belt 31 wound around thereon, encoders 14 measuring the quantity of motion of the rotational belt 31 of the treadmill, and switches 35 sensing when the operator's finger touches the rotational belt 31 .
[0045] In this treadmill 11 , the belt can be rotated only when the switch 35 is ON. The encoders 14 (incremental encoders, for example) output pulses corresponding to the rotational angles of the rollers 33 . By counting the pulses outputted from the encoders, the quantity of motion of the treadmill 11 can be determined. Instead of the incremental encoder, an absolute encoder can be used, of course. In the case of the absolute encoder, outputted absolute rotational angle is deemed to represent the treadmill motion quantity.
[0046] In this embodiment, when the robot walks up or down on a slope, the resistance to the movement of the rotational belt 31 of the treadmill 11 is controlled and made heavy or light, respectively. In more detail, the inclination sensor 21 mounted on the robot 20 measures the status of the robot 20 . When it is determined that the robot is going up a slope based on the data measured by the inclination sensor 21 , the belt movement of the treadmill 11 is made heavy. When it is determined that the robot is going down a slope based on the data measured by the inclination sensor 21 , the belt movement of the treadmill 11 is made light. This resistance control is explained below.
[0047] [0047]FIG. 5 illustrates a force applied to the bipedal walking robot 20 walking on a slope In FIG. 5, when the robot 20 is going to walk up the slope having an inclination angle θ, a force Mgsin θ is applied to the robot in the down-slope direction, where M represents the mass of the robot and g represents the acceleration of gravity. In this case, a force C 0 Mgsin θ generated by the motor 32 is applied to the treadmill 11 (C 0 is a constant), and therefore the force applied to the robot 20 is indirectly fed back to the operator's fingers on the treadmill 11 .
[0048] When the upslope is steeper (θ becomes larger), the motor 32 provides a feed-back force to the treadmill 11 and makes it difficult to move the belt 31 of the treadmill 11 . On the other hand, when the slope is downward (θ becomes negative) the motor 32 provides a feed-back force to the treadmill 11 and makes it easy to move the belt 31 of the treadmill 11 . These feed-back forces are generated only when the operator's finger touches the belt 31 of the treadmill 11 (only when the switch 35 mounted on the treadmill 11 is ON).
[0049] In this embodiment an electric circuit as shown in FIG. 6 is used for generating the above force C 0 Mgsin θ against the treadmill 11 .
[0050] [0050]FIG. 6 is a schematic diagram of an electric circuit for feeding the above force back to the treadmill 11 . The circuit includes a motor 32 generating a torque T, a battery having a voltage V, a switch 35 and a variable resistance Ra 40 . The variable resistance Ra can be varied depending on force sense data transmitted from the robot, and therefore a voltage applied to the motor 32 can be varied according thereto. As a result, the torque T can be controlled so that the motor 32 generates a force C 0 Mgsin θ corresponding to the slope inclination θ, and therefore the resistance of the belt 31 of the treadmill 11 reflects the status of the robot walking on the slope having the inclination angle θ.
[0051] The resistance Ra in the above electric circuit can be obtained in the following equation (1) .
Ra = K T ( V - K · ω ) ( 1 )
[0052] This Ra can be represented as in the following equation (2), where the quantity of motion for the slope θ is Δl
Ra = K C 0 · M · g · sin θ ( V - C 1 · Δ l ) ( 2 )
[0053] Where K is a counter-electromotive force constant of the motor; Al is the quantity of motion of the treadmill; and C 0 , C 1 , are constants.
[0054] [0054]FIG. 7 shows another example of feeding the force back to the treadmill 11 .
[0055] As shown in FIG. 7, this example uses a bar-like module 45 , which is pressed against the treadmill 11 by a force F to control the resistance of the belt 31 of the treadmill 11 Where the friction coefficient between the belt 31 and the module 45 is represented by μ, the force F generates a friction force μF on the belt 31 . Accordingly, by varying F so that μF becomes equal to C 0 Mgsin θ, the treadmill 11 can receive a backward force of C 0 Mgsin θ.
[0056] The manner for feeding a force back to the treadmill is not limited to the above explained methods and can be fed back in a variety of ways within the scope of the present invention.
[0057] Next, referring to FIG. 8, the relationship between finger motion quantity on the treadmill 11 and robot leg movement is explained. If a quantity of motion of the left treadmill (operated by an index finger) is represented by Δl l and a quantity of motion of the right treadmill (operated by a middle finger) is represented by Δl r , movements of left and right leg steps are represented by ΔL L and ΔL R , respectively, then the relation as Δl l :Δl r =ΔL L :ΔL R holds The distance between two legs of the robot is represented by D.
[0058] Where the minimum turning radius of the robot 20 is represented by R, the curvature ρ having this radius R is obtained by the following equation (3):
ρ = 1 R = Δ L R - Δ L L 2 Δ L R + Δ L L D ( 3 )
[0059] Where the quantity of motion of the left treadmill is smaller, the robot turns to the left. When the quantities of motion of the left and right treadmills are equal, the robot walks straight. On the other hand, by moving the treadmill backward the robot can walk backward. Therefore, it is possible to manipulate the bipedal walking robot freely, such as walking forward, walking backward and turning.
[0060] Referring to a flowchart shown in FIG. 9, a process for manipulating the robot legs using the remote manipulation system in FIG. 1 is explained.
[0061] In FIG. 9, the robot 20 and the remote manipulation device 10 communicate with each other via a communication network to exchange information.
[0062] When an operator's finger moves on the treadmill 11 of the remote manipulation device 20 (S 1 ), the encoder 14 measures the number of pulses outputted by the treadmill 11 . The number of pulses corresponds to an angular amount of movement of the rotated belt. The measured result is transmitted to the CPU 19 . The CPU 19 calculates a quantity of motion of the treadmill 11 , based on the measured results sent by the encoder 14 (S 2 ). The quantity of motion of the treadmill 11 is converted to step length data of the robot 20 (S 3 ), and the converted step length data are transmitted to the radio communication part 18 . The radio communication part 19 performs a coding process, a modulation process, and a frequency conversion process and other processes on the step length data, and transmits the processed data to a base station (not shown) via the communication network 100 (S 4 ).
[0063] The step length data transmitted by the remote manipulation device 10 in the above mentioned manner is received at the radio communication part 23 of the robot 20 via the communication network 100 . After receiving the step length data transmitted by the remote manipulation device 10 , the radio communication part 23 of the robot 20 performs a frequency conversion process, a demodulation process, a decoding process and other processes on the step length data, and outputs the processed step length data to a mechanism for controlling the legs of the robot. Then the legs of the robot 20 are controlled based on the processed step length data (S 5 ).
[0064] In the above explained embodiment, an operator of the remote manipulation device 10 can remotely manipulate the robot 20 while monitoring an image on the display 16 , which is sent from a CCD camera (not shown) mounted on the robot 20 . However, if the operator can directly see the robot 20 at a near distance, he/she does not have to monitor the display 16 for manipulating the robot 20 .
[0065] In the above embodiment, the conversion calculation from the treadmill motion quantity to the robot step length is carried out by the CPU 19 in the remote manipulation device 10 . The present invention is not limited to such embodiment. For example, the remote manipulation device 10 may perform the transmission of the treadmill motion quantity only, and CPU 22 in the robot 20 can then perform calculations relating to conversion from the treadmill motion quantity to the robot step length.
[0066] Next, referring to the flowchart shown in FIG. 10, a process for controlling the treadmill resistance based on information obtained by the inclination sensor 21 mounted in the robot 20 is explained.
[0067] The inclination sensor 21 mounted in the robot 20 senses an inclination angle of the robot 20 (S 11 ), and sends the inclination information indicating the status of the robot legs to the CPU 22 . After receiving the inclination information, the CPU 22 calculates the mechanical status of the robot (whether the robot is on an up slope or a down slope) based on the inclination information (S 12 ), and calculates forces applied to the legs of the robot (S 13 )
[0068] The calculated results are sent from the CPU 22 to the radio communication part 23 . The radio communication part 23 performs a coding process, a modulation process, a frequency conversion process and other processes on the calculated results, and transmits the converted results as force sense data to a base station (not shown) via the communication network 100 (S 14 ).
[0069] As explained above, the force sense data transmitted by the robot 20 is received at the radio communication part 18 of the remote manipulation device 10 . The radio communication part 18 performs a frequency conversion process, a demodulation process, and a decoding process on the force sense data, and outputs the processed data to the motor 32 of the treadmill 11 of the CPU 19 (S 15 ). The motor 32 of the treadmill 11 outputs a certain force based on instruction from the CPU 19 . Accordingly, the belt 31 of the treadmill 11 rotates with resistance corresponding to the force applied to the robot legs, and therefore the operator can manipulate the steps of the robot 20 while being aware of the walking condition of the robot 20
[0070] In the above embodiment, the calculation of the force applied to the robot legs is carried out by the CPU 22 in the robot 20 . The present invention is not limited to such embodiment. For example, the robot 20 may perform the transmission of the output of the inclination sensor only, and the CPU 19 in the remote manipulation device 10 can then calculate the force applied to the legs of the robot 20 on a slope based on the output from the inclination sensor.
[0071] Referring to FIG. 11, a second embodiment of the present invention is explained. According to the second embodiment, a remote manipulation device 10 includes a pair of bilateral rollers 50 as shown in FIG. 11, instead of the treadmill 11 . Using the rollers, the bipedal walking robot can be remotely manipulated. The rollers shown in the left device in FIG. 11 are spaced apart from each other and can be operated with thumbs of both hands. The rollers shown in the right device in FIG. 11 are close together and can be operated with one or two fingers on one hand.
[0072] The remote manipulation device may have other types of mechanisms such as a pair of gear mechanisms used in portable audio equipment.
[0073] The above explained remote manipulation device 10 may be any kind of mobile terminal connectable to a communication network such as mobile radio terminals (e.g. mobile phones) connectable to a mobile communication network, notebook computers, and POAs. The communication network can be any kind of network such as a public network, a radio LAN, and an IP network, as long as the mobile terminals have a radio communications interface that can be used to connect to the utilized communication network.
[0074] According to the embodiments of the present invention, the operator of the remote manipulation device can remotely manipulate robot steps by moving his fingers in a manner of simulating human walking while being aware of mechanical conditions such as forces applied to the robot, which awareness cannot be obtained through a display. And the remote manipulation device can be miniaturized.
[0075] Further, real time manipulation can be attained because the system utilizes a mobile communication network. The walking area of a manipulated robot is not limited, because the robot can utilize a mobile communication network and its roaming services.
[0076] The present application is based on Japanese Priority Patent Application No 2002-241075 filed on Aug. 21, 2002 with the Japanese Patent Office, the entire contents of which are hereby incorporated by reference.
|
A robot remote manipulation system is provided, including a bipedal walking robot and a remote manipulation device for remotely manipulating the bipedal walking robot. The robot is connected to the remote manipulation device via a communication network and controlled by controlling data from the remote manipulation device. In the system, the remote manipulation device comprises a pair of bilateral mechanical rotating elements providing a quantity of motion for each bilateral leg of the bipedal walking robot; and a controlling data transmitter for transmitting controlling data corresponding to the quantities of motion to the bipedal walking robot. The bipedal walking robot comprises a controlling data receiver for receiving the controlling data transmitted from the remote manipulation device; and a leg motion controller for processing the received controlling data and causing the bilateral legs to move forward or backward.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not applicable
BACKGROUND OF THE INVENTION
[0003] The invention relates to a method for the operation of a wind turbine generator system with a rotor blade angle control and a torque control.
[0004] Siegfried Heyer, in Windkraftanlagen, Systemauslegung, Netzintegration und Regelung, Teubner Verlag, 4th edition, page 321, the entire contents of which are incorporated herein by reference, describes how to restrict the speed of the turbine, while in a full-load operation, to a nominal value by varying a blade setting angle. Likewise, a regulation is effected for the generator torque which regulates the system power into optimum values and leads the system to safe and component-relieving operating conditions.
[0005] The power (P) to be outputted by the wind turbine generator system is proportional to the torque (M) and speed (Ω). The interconnection is:
[0000]
P=M·Ω.
[0006] In a full-load operation, the power will rise during strong wind and gusts. This phenomenon, which is referred to as “excess production” is quite acceptable for free-standing systems, but cannot be tolerated in an interaction between multiple wind turbine generator systems, e.g. in a wind farm because there is a risk of the electric mains getting overloaded.
[0007] It is the object of the invention to perform the operation of the wind turbine generator system, while in a full-load operation, such as to restrict the power to be outputted to a maximum value by simple means.
BRIEF SUMMARY OF THE INVENTION
[0008] In the inventive method, in a full-load operation, a preset torque is lowered starting from a predetermined speed (n Absenkung ). Lowering is done in such a way that a predetermined value for a provided power is not exceeded. In a full-load operation, it is common to adjust the speed of the turbine via the blade setting angle. This allows for a certain control within the full-load range already. However, the preset torque is reduced from a predetermined speed onwards to prevent the transgression of the maximum power value to be outputted even if the speed increases. In case that the preset torque is reduced according to the above indicated interconnection between the torque and power a reduced power will arise when the speed increases. This makes it possible to limit the power even if the speed rises.
[0009] To achieve a high power yield it has proved to be particularly beneficial in the inventive method not to choose the rated speed as a predetermined speed for lowering the preset torque but a value instead which is slightly larger than the rated speed. Because of this value for the predetermined speed from which onwards the reduction of the preset torque is performed such full-load operation is distinguished into two sections: there is exclusively a regulation of the angle of blade attack in the first of these sections whereas both a torque control and control of the angle of blade attack takes place in the second section.
[0010] For the predetermined speed from which onwards there is a reduction of the preset value, it is preferable to choose a value which is larger by 0.5% to 5% than is the rated speed.
[0011] However, the rotor blade angle control will expediently regulate the attack of the blade angle already while starting from the rated speed. Thus, the result is that a regulation for speeds between the rated speed and the predetermined speed is done by the angle of blade attack only and, from the predetermined speed onwards, is done by both the control for the angle of blade attack and the preset torque.
[0012] In the inventive method, a first preset torque, which matches with the torque for the continuous-operation power, is determined for the maximum value of the power provided. Preferably, a second preset torque, which matches with the actual torque, is also determined for the maximum value of the power provided, wherein the smaller value of the first and second preset torques is applied to the torque control. The interconnection between the preset torque and the speed preferably is inversely proportional here, i.e. the preset torque is proportional to the reciprocal value of the speed. Based on the speed values present during the operation control of the wind turbine generator system, the hyperbolic course of the torque over the speed is largely approximated through a straight line.
[0013] In the inventive method, the torque control predetermines the reduction of the preset torque. At the same time, the control for the rotor blade angle controls the speed into the predetermined speed value. The value for the preset torque that is determined by the torque control corresponds to a predetermined maximum value of power.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0014] The inventive method will be described in more detail below with reference to two figures. In the drawings:
[0015] FIG. 1 shows the course of power over the speed, and
[0016] FIG. 2 shows the course of the preset moment over the speed.
[0017] FIG. 3 shows a block diagram of the inventive wind turbine generator system.
DETAILED DESCRIPTION OF THE INVENTION
[0018] While this invention may be embodied in many different forms, there are described in detail herein a specific preferred embodiment of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiment illustrated
[0019] For a general explanation, the characteristic-curve field shown in FIG. 1 for the regular behaviour of the wind turbine generator system will be explained first. The characteristic-curve field has a first section 10 in which the effective power P rises linearly with the speed. It is followed by a second section 12 in which the power does not depend linearly on the speed. Different curve runs are possible here. In the second section 12 of the characteristic curve, it is preferred to regulate power in conformity with the power P Aero as inputted from the wind. The mathematical interconnection between the speed and power ensues from the following formula:
[0000]
P
Aero
=
[
2
·
π
·
r
rot
·
n
gen
u
¨
getr
·
1
60
·
1
λ
(
n
ro
t
)
]
3
·
π
·
r
rot
2
·
ρ
luft
2
·
c
p
(
n
ro
t
)
[0000] where r rot is for the radius of the rotor blade, n gen is for the generator speed, ü getr is for the speed ratio of the transmission. λ(n rot ) signifies the high-speed number of the rotor dependent on the speed of the rotor, ρ luft denotes the density of the air while cp(n rot ) describes a power value coefficient for the rotor blade dependent on the speed of the rotor.
[0020] Starting from a speed n 2 , the wind turbine generator system is led to the full-load range from the partial-load range. To this end, the speed is increased to the rated speed. At this time, the increase in power is made in a linear proportion to the speed along section 14 .
[0021] When the rated speed is reached another characteristic-curve section 16 will follow in full-load operation up to a reduction in speed. Power will increase in a linear proportion to the speed in the characteristic-curve section 16 . In the characteristic-curve section 18 which follows, power over the speed remains constant. In the characteristic-curve section 20 which then follows, power will decrease again in order to finally be cancelled completely from a certain speed onwards.
[0022] The speed from which onwards power is constant independently of an increase in speed is 1.01 times the rated speed in the example shown; hence, it is by 1% higher than the rated speed. Because of this speed which is increased over the rated speed, the power provided is by 1% higher than the power which results for the rated speed.
[0023] The initially discussed interconnection between the power, torque, and speed makes it evident that if the speed increases it is necessary to lower the torque to achieve a constant power. This procedure is illustrated in FIG. 2 . FIG. 2 shows the torque curve of the torque presetting made for the main converter. The main converter predetermines the generator torque, e.g. in double fed asynchronous generators.
[0024] In a stationary case, the generator torque matches the moment as inputted by the rotor. FIG. 2 also allows to clearly appreciate how the moment initially is kept constant in a full-load operation at a maximum torque over the rated speed and will drop into a section 22 after a speed n Absenkung . Hence, the preset torque as plotted over the speed, in a full-load operation, has a section of a constant torque presetting 24 and a section with a decreasing torque presetting 22 . The transition between the two curves takes place at a speed n Absenkung .
[0025] FIG. 3 shows a block diagram of the wind turbine generator system 40 including the rotor blade angle control 50 and the torque control 60 .
[0026] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
[0027] Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below.
[0028] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
|
A method for the operation of a wind turbine generator plant with a rotor blade angle control and a torque control, wherein in a full-load operation, starting from a predetermined speed (n Absenkung ), a preset torque is lowered by the torque control in such a way that a predetermined value for a provided power (P) is not exceeded.
| 5
|
BACKGROUND OF THE INVENTION
[0001] The present invention relates to N -(aroyl)glycine hydroxamic acid derivatives and related compounds that are selective inhibitors of phosphodiesterase (PDE) type IV or of the production of tumor necrosis factor (TNF) and as such are useful in the treatment of asthma, arthritis, bronchitis, chronic obstructive airways disease, psoriasis, allergic rhinitis, dermatitis and other inflammatory diseases as well as AIDS, sepsis, septic shock, cachexia, and other diseases involving the production of TNF. The compounds of this invention may have combined PDE type IV and TNF inhibitory activity. The present invention also relates to the use of such compounds in the treatment of the above diseases in mammals, particularly humans, and to pharmaceutical compositions useful therefor.
[0002] Since the recognition that cyclic AMP is an intracellular second messenger (E. W. Sutherland, and T. W. Rail, Pharmacol. Ref., 1960, 12, 265), inhibition of the phosphodiesterases has been a target for modulation and, accordingly, therapeutic intervention in a range of disease processes. More recently, distinct classes of PDE have been recognized (J. A. Beavo and D. H. Reifsnyder, TIPS, 1990, 11, 150), and their selective inhibition has led to improved drug therapy (C. D. Nicholson, R. A. Challiss and M. Shahid, TIPS, 1991, 12, 19). More particularly, it has been recognized that inhibition of PDE type IV can lead to inhibition of inflammatory mediator release (M. W. Verghese et al., J. Mol. Cell Cardiol., 1989, 12, (Suppl. II), S 61) and airway smooth muscle relaxation (T. J. Torphy in Directions for New Anti-Asthma Drugs, eds S. R. O'Donnell and C. G. A. Persson, 1988, 37, Birkhauser-Verlag). Thus, compounds that inhibit PDE type IV, but which have poor activity against other PDE types, inhibit the release of inflammatory mediators and relax airway smooth muscle without causing cardiovascular effects or antiplatelet effects.
[0003] TNF is recognized to be involved in many infectious and auto-immune diseases, including cachexia (W. Friers, FEBS Letters, 1991, 285, 199). Furthermore, it has been shown that TNF is the prime mediator of the inflammatory response seen in sepsis and septic shock (C. E. Spooner et al., Clinical Immunology and Immunopatholoty, 1992,62, S 11).
SUMMARY OF THE INVENTION
[0004] The invention relates to compounds of formula
[0005] or a pharmaceutically acceptable salt thereof,
[0006] wherein R 1 is selected from the group consisting of methyl, ethyl, difluoromethyl and trifluoromethyl;
[0007] R 2 is (C 1 -C 6 )alkyl, (C 3 -C 7 )alkoxy(C 2 -C 4 )alkyl, phenoxy(C 2 -C 8 )alkyl, (C 3 -C 7 )cycloalkyl, (C 8 -C 9 )polycycloalkyl, phenyl(C 1 -C 8 )alkyl or indanyl wherein the alkyl portion of said R 2 groups is optionally substituted with one or more fluorine atoms and the aromatic portion of said R 2 groups is optionally substituted with one or more substituents independently selected from the group consisting of (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy and halogen;
[0008] AA is (AA-1) or (AA-2) wherein:
[0009] (AA-1) is
[0010] wherein R 3 and R 4 are independently selected from the group consisting of hydrogen, trifluoromethyl, (C 1 -C 6 )alkyl, —(CH 2 ) n CO 2 H, —(CH 2 ) n CONH 2 , —(CH 2 ) n phenyl, —(CH 2 ) x OH, and —(CH 2 ) x NH 2 , wherein x ranges from 1 to 5, n ranges from 0 to 5, R 5 is hydrogen, OH or (C 1 -C 6 )alkyl, and m ranges from 0 to 5; and,
[0011] (AA-2) is
[0012] wherein p ranges from 1 to 4; and,
[0013] Y is NHOH or OH.
[0014] The term “alkyl”, as used herein, unless otherwise indicated, includes saturated monovalent hydrocarbon radicals having straight or branched moieties.
[0015] The term “alkoxy”, as used herein, includes O-alkyl groups wherein “alkyl” is defined above.
[0016] The term “cycloalkyl”, as used herein, includes saturated monovalent cyclo hydrocarbon radicals including cyclobutyl, cyclopentyl and cycloheptyl.
[0017] The term “polycycloalkyl”, as used herein, includes saturated monovalent polycyclo radicals comprising ring assemblies that are fused, bicyclo or tricyclo. Such ring assemblies include bicycloheptyl, bicyclobutyl, tricyclooctanyl and perhydropentalenyl.
[0018] The term “aryl”, as used herein, unless otherwise indicated, includes an organic radical derived from an aromatic hydrocarbon by removal of one hydrogen, such as phenyl or naphthyl, optionally substituted by 1 to 3 substituents selected from the group consisting of fluoro, chloro, trifluoromethyl, (C 1 -C 6 )alkoxy, (C 6 -C 10 )aryloxy, trifluoromethoxy, difluoromethoxy and (C 1 -C 6 )alkyl.
[0019] The term “treatment” as used herein, unless otherwise indicated, includes (i) methods to cure, relieve or lessen the undesirable effects of, or the undesirable symptoms associated with, conditions and diseases that respond to the inhibition of PDE type IV or the inhibition of the production of TNF, where such conditions and diseases are actively occurring in a mammal, including a human, and (ii) methods to prevent such conditions and diseases from occurring in a mammal, and (iii) methods to slow the onset of such conditions and diseases in a mammal. The terms “treat” and “treating” as used herein are defined in accord with the above definition.
[0020] The term “therapeutically effective amount” as used herein, unless otherwise indicated, means an amount effective to inhibit PDE type IV or inhibit the production of TNF, or an amount effective in the treatment, as defined above, of a condition or disease that responds to the inhibition of PDE type IV or the inhibition of the production of TNF.
[0021] The compounds of formula I include certain compounds having chiral centers which therefore exist in different enantiomeric forms. This invention relates to all optical isomers and stereoisomers of the compounds of formula I and mixtures thereof.
[0022] Preferred compounds of formula I include those in which R 1 is methyl.
[0023] Other preferred compounds of formula I include those in which R 2 is cyclopentyl.
[0024] Other preferred compounds of formula I include those in which AA is the moiety (i) and R 3 is hydrogen, methyl, trifluoromethyl or —CH 2 OH.
[0025] Other preferred compounds of formula I include those in which AA is the moiety (AA-1) and R 4 is hydrogen.
[0026] Other preferred compounds of formula I include those in which AA is the moiety (AA-1) and R 5 is hydrogen.
[0027] Other preferred compounds of formula I include those in which AA is the moiety (AA-1) and m is 0.
[0028] Other preferred compounds of formula I include those in which Y is —NHOH.
[0029] Specific preferred compounds of formula I include the following:
[0030] α-monofluoromethyl-α- N -[(3cyclopentyloxy-4-methoxy)benzoyl]glycine hydroxamic acid;
[0031] α-difluoromethyl-α- N -[(3-cyclopentyloxy-4-methoxy)benzoyl]glycine hydroxamic acid;
[0032] α-ethyl-α- N -[(3-cyclopentyloxy-4-methoxy)benzoyl]glycine hydroxamic acid;
[0033] α-propyl-α- N -[(3-cyclopentyloxy-4-methoxy)benzoyl]glycine hydroxamic acid;
[0034] α- N -[(3-cyclopentyloxy-4-methoxy)benzoyl]-D-cystine hydroxamic acid;
[0035] α-trifluoromethyl-α- N -[(3-cyclopentyloxy-4-methoxy)benzoyl]glycine hydroxamic acid;
[0036] α- N -[(3-cyclopentyloxy-4-methoxy)benzoyl]-D-serine hydroxamic acid;
[0037] α- N -[(3-cyclopentyloxy-4-methoxy)benzoyl]glycine hydroxamic acid; and,
[0038] α- N -[(3-cyclopentyloxy-4-methoxy)benzoyl]-D-alanine hydroxamic acid.
[0039] The present invention further relates to a pharmaceutical composition for the inhibition of PDE type IV or the inhibition of the production of TNF in a mammal, including a human, comprising a therapeutically effective amount of a compound according to formula I or a pharmaceutically acceptable salt thereof, and a pharmaceutically acceptable carrier.
[0040] The present invention further relates to a pharmaceutical composition for the treatment of a condition or disease selected from the group consisting of asthma, arthritis, bronchitis, chronic obstructive airways disease, psoriasis, allergic rhinitis, dermatitis, AIDS, septic shock and other conditions or diseases that respond to the inhibition of PDE type IV or the inhibition of the production of TNF in a mammal, including a human, comprising a therapeutically effective amount of a compound according to formula I or a pharmaceutically acceptable salt thereof, together with a pharmaceutically acceptable carrier.
[0041] The present invention further relates to a method of inhibiting PDE type IV or inhibiting the production of TNF in a mammal, comprising administering to a mammal in need of such treatment a therapeutically effective amount of a compound according to formula I or a pharmaceutically acceptable salt thereof.
[0042] The present invention further relates to a method of treating a condition or disease selected from the group consisting of asthma, arthritis, bronchitis, chronic obstructive airways disease, psoriasis, allergic rhinitis, dermatitis, AIDS, septic shock and other conditions or diseases that respond to the inhibition of PDE type IV or the inhibition of TNF in a mammal, including a human, comprising administering to a mammal in need of such treatment a therapeutically effective amount of a compound according to formula I or a pharmaceutically acceptable salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0043] The following reaction Scheme 1 illustrates the preparation of the compounds of the present invention. Unless otherwise indicated, R 1 , R 2 , R 3 , R 4 , R 5 , AA, n, m, p, and Y, as used in Scheme 1 and the following discussion, are as defined above. In Scheme 1 and the Preparations and Examples that follow, all synthesis reactions and other procedures are done at room temperature (20-25° C.) unless otherwise indicated.
[0044] In reaction 1 of Scheme 1, a carboxylic acid of formula V is coupled to O-benzylhydroxylamine to obtain a compound of formula VI using a coupling method well known to those skilled in the art of peptide chemistry. The carboxylic acid of formula V is available from various commercial sources or can be prepared according to synthetic methods known to those skilled in the art. The preferred coupling method is to combine the compound of formula V with O-benzylhydroxylamine hydrochloride, 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride and a base, such as triethylamine, in an inert solvent, such as methylene chloride, at a temperature of 0° C. to 30° C. (20-25° C. preferred) for a period of 2 hours to 48 hours (16 hours preferred).
[0045] In reaction 2 of Scheme 1, the compound of formula VI is treated with an acid, such as hydrochloric acid or trifluoroacetic acid, to remove the t-butyloxycarbonyl group to give a salt of formula VII, wherein X of HX is chloride or trifluoroacetate, and m, R 3 , R 4 and R 5 are as defined above.
[0046] In reaction 3 of Scheme 1, the salt of formula VII is coupled to a benzoic acid derivative of formula VIII to prepare the compound of formula IX using a coupling method well known to those skilled in the art of peptide chemistry. The benzoic acid derivative of formula VIII can be prepared according to synthetic methods known to those skilled in the art. For instance, 3-cyclopentyloxy-4-methoxybenzoic acid can be prepared according to the method described in M. N. Palfreyman et al., J. Med. Chem., vol. 37, page 1696 (1994), which is herein incorporated by reference. The preferred coupling method is to combine the compound of formula VIII with the salt of formula VII, 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride and a base, such as triethylamine, in an inert solvent, such as methylene chloride, at a temperature of 0° C. to 30° C. (20-25° C. preferred) for a period of 2 hours to 48 hours (16 hours preferred).
[0047] In reaction 4 of Scheme 1, the compound of formula IX is hydrogenated over Pd(OH) 2 in a solvent such as methanol or ethanol for a period of 4 to 48 hours (16 hours preferred) to obtain the compound of formula X.
[0048] While Scheme 1 illustrates the preparation of compounds of formula I wherein AA is (AA-1), the preparation of compounds of formula I wherein M is (AA-2) follows essentially the same route. In particular, in the first step, the compound of formula V is replaced with a compound of the same formula except the AA portion is (AA-2) rather than (AA-1). Such compounds are commercially available or can be made by synthetic techniques known to those skilled in the art. Then, reactions 1-4 are performed as described above.
[0049] To prepare compounds of formula I wherein Y is OH rather NHOH, the process begins at the third reaction of Scheme 1 where the compound of formula VII is replaced with a compound of formula XI: HX.NHR 5 CR 3 R 4 (CH 2 ) m CO 2 CH 2 Ph. Compounds of formula XI are commercially available or can be made by synthetic techniques known to those skilled in the art. The compound of formula XI is coupled with the compound of formula VIII as described above for reaction 3 of Scheme 1. Then, reaction 4 of Scheme 1 is followed as described above to prepare the compound of formula I wherein Y is OH.
[0050] Pharmaceutically acceptable acid addition salts of the compounds of this invention include, but are not limited to, those formed with acetic, lactic, succinic, maleic, tartaric, citric, gluconic, ascorbic, benzoic, cinnamic, fumaric, sulfuric, phosphoric, hydrochloric, hydrobromic, toluenesulfonic, mandelic, di-p-toluoyl-L-tartaric and related acids. The acid addition salts of the compounds of formula I are prepared in a conventional manner by treating a solution or suspension of the free base of formula I with about one chemical equivalent of a pharmaceutically acceptable acid. Conventional concentration or crystallization techniques are employed in isolating the salts. Pharmaceutically acceptable cationic salts of the compounds of formula I wherein Y is hydroxyl include, but are not limited to, those of sodium, potassium, calcium, magnesium, ammonium, N , N ′-dibenzylethylenediamine, N -methylglucamine (meglumine), ethanolamine and diethanolamine.
[0051] The ability of the compounds of formula I and their pharmaceutically acceptable salts to inhibit PDE type IV or inhibit the production of TNF and, consequently, demonstrate their effectiveness for treating diseases that respond to the inhibition of PDE IV or the inhibition of the production of TNF is shown by the following in vitro assay tests.
BIOLOGICAL ASSAY
Human Eosinophil PDE
[0052] Human peripheral blood is collected in ethylenediaminetetraacetic acid, diluted 1:2 in piperazine- N , N ′-bis-2-ethanesulfonic acid (PIPES) buffer and then layered over percoll solution. Gradients are formed by centrifugation for 30 minutes at 2000 rpm at 4° C. The remainder of the isolation procedure, which is based on the procedure of Kita et al., J. Immunol., 152, 5457 (1994), is carried out at 4° C. The neutrophil/eosinophil layer is collected from the percoll gradient and the red blood cells are lysed. Remaining cells are washed in PIPES (1% FCS), incubated with anti-CD16 microbeads (MACS) for 1 hour, and passed over a magnetic column to remove the neutrophils. Eosinophils are collected in the eluate and analyzed for viability by trypan blue and purity by diff-quick stain. Eosinophil purity is routinely greater than 99% using this method.
[0053] Purified eosinophils are resuspended in 750 μL of PDE lysis buffer (20 mM triethylamine, 1 mM ethylenediaminetetraacetic acid, 100 μg/ml bacitracin, 2 mM benzamidine, 50 μM leupeptin, 50 μM PMSF, 100 μg/ml soybean trypsin inhibitor) and quick frozen in liquid nitrogen. Cells are thawed slowly and sonicated. Membranes are vortexed (disruption is confirmed by Trypan blue staining of fragments). Disrupted cells are centrifuged at 45 k rpm for 30 minutes at 4° C. to isolate membranes. Cytosol is decanted, and membrane resuspended to 200 μg/ml for use as PDE source in the hydrolysis assay yielding a window from 3000 to 5000 counts.
[0054] Compounds are dissolved in dimethyl sulfoxide at 10-2M, then diluted 1:25 in water to 4×10 −4 M. This suspension is serially diluted 1:10 in 4% dimethyl sulfoxide, for a final dimethyl sulfoxide concentration in the assay of 1%.
PHOSPHODIESTERASE INHIBITION ASSAY
[0055] To 12×75 mm glass tubes add:
[0056] 25 μl PDE assay buffer (200 mM Tris/40 mM MgC12)
[0057] 24 μl 4 nM/ml cAMP stock
[0058] 25 μl test compound
[0059] 25 μl PDE source (membrane)
[0060] Background control=membrane boiled 10″
[0061] Positive control—25 μl unboiled membrane
[0062] Incubate 25 minutes in 37° C. water bath.
[0063] Reaction is stopped by boiling samples 5 minutes. Samples are applied to Affigel column (1 ml bed volume) previously equilibrated with 0.25 M acetic acid followed by 0.1 mM N-[2-hydroxyethyl]piperazine- N ″-2-ethanesulfonic acid (HEPES)/0.1 mM NaCl wash buffer (pH 8.5). cAMP is washed off column with HEPES/NaCl, 5″-AMP is eluted in 4 ml volumes with 0.25 M acetic acid. 1 ml of eluate is counted in 3 ml scintillation fluid for 1 minute ([3H].
[0064] Substrate conversion=(cpm positive control×4)/total activity. Conversion rate must be between 3 and 15% for experiment to be valid.
[0065] % Inhibition—1-(eluted cpm—background cpm/control cpm—bkgd cpm)×100.
[0066] IC 50 values are generated by linear regression of inhibition titer curve (linear portion); and are expressed in μM.
TNF
[0067] The ability of the compounds of formula I and the pharmaceutically acceptable salts thereof to inhibit the production of TNF and, consequently, demonstrate their effectiveness for treating diseases involving the production of TNF is shown by the following in vitro assay:
[0068] Peripheral blood (100 mls) from human volunteers is collected in ethylenediaminetetraacetic acid (EDTA). Mononuclear cells are isolated by Ficol/Hypaque and washed three times in incomplete Hanks' balanced salt solution (HBSS). Cells are resuspended in a final concentration of 1×10 6 cells per ml in prewarmed RPMI (containing 5% FCS, glutamine, pen/step and nystatin). Monocytes are plated as 1×10 6 cells in 1.0 ml in 24-well plates. The cells are incubated at 37° C. (5% carbon dioxide) and allowed to adhere to the plates for 2 hours, after which time non-adherent cells are removed by gently washing. Test compounds (10 μl) are then added to the cells at 3-4 concentrations each and incubated for 1 hour. Lipopolysaccharide (LPS) (10 μl) is added to appropriate wells. Plates are incubated overnight (18 hrs) at 37° C. At the end of the incubation period TNF was analyzed by a sandwich ELISA (R&D Quantikine Kit). IC 50 determinations are made for each compound based on linear regression analysis.
[0069] For administration to humans in the curative or prophylactic treatment of inflammatory diseases, oral dosages of the compounds of formula I and the pharmaceutically acceptable salts thereof (hereinafter also referred to as the active compounds of the present invention) are generally in the range of from 0.1-400 mg daily for an average adult patient (70 kg). Thus for a typical adult patient, individual tablets or capsules contain from 0.1 to 60 mg of active compound, in a suitable pharmaceutically acceptable vehicle or carrier. Dosages for intravenous administration are typically within the range of 0.1 to 40 mg per single dose as required. For intranasal or inhaler administration, the dosage is generally formulated as a 0.1 to 1% (w/v) solution. In practice the physician will determine the actual dosage which will be most suitable for an individual patient and it will vary with the age, weight and response of the particular patient. The above dosages are exemplary of the average case but there can, of course, be individual instances where higher or lower dosage ranges are merited, and all such dosages are within the scope of this invention.
[0070] For administration to humans for the inhibition of TNF, a variety of conventional routes can be used including oral, parenteral and topical administration routes. In general, the active compound will be administered orally or parenterally at dosages between about 0.1 and 25 mg/kg body weight of the subject to be treated per day, preferably from about 0.3 to 5 mg/kg. The compound of formula I can also be administered topically in an ointment or cream in concentrations of about 0.5% to about 1%, generally applied 2 or 3 times per day to the affected area. However, some variation in dosage will necessarily occur depending on the condition of the subject being treated. The person responsible for administration will, in any event, determine the appropriate dose for the individual subject.
[0071] For human use, the active compounds of the present invention can be administered alone, but will generally be administered in an admixture with a pharmaceutical diluent or carrier selected with regard to the intended route of administration and standard pharmaceutical practice. For example, they may be administered orally in the form of tablets containing such excipients as starch or lactose, or in capsules or ovales either alone or in admixture with excipients, or in the form of elixirs or suspensions containing flavoring or coloring agents. They may be injected parenterally; for example, intravenously, intramuscularly or subcutaneously. For parenteral administration, they are best used in the form of a sterile aqueous solution which may contain other substances; for example, enough salts or glucose to make the solution isotonic.
[0072] The present invention is illustrated by the following preparations and examples, but it is not limited to the details thereof. In the following preparations and examples, the term “t-BOC” represents a t-butoxycarbonyl group, and the symbol “Bn” represents a benzyl group.
PREPARATION 1
O-Benzyl-α-N-t-BOC-Glycine Hydroxamate
[0073] To a mixture of 3.0 g (0.017 mol) of α-N-(t-butoxycarbonyl)glycine, 2.7 g (0.017 mol) of O-benzylhydroxylamine hydrochloride, and 60 ml of CH 2 Cl 2 was added 3.6 ml (2.6 g, 0.026 mol) of triethylamine followed by 5.0 g (0.026 mol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide. The suspension was stirred for 16 h at room temperature under N 2 . The clear mixture was evaporated and the semi-solid residue was dissolved in 300 ml of EtOAc, washed with aqueous 1N HCl solution (2×200 ml), saturated aqueous NaHCO 3 solution (2×200 ml), and dried over MgSO 4 . Removal of the drying agent by filtration and evaporation of the solvent afforded 4.3 g (90%) of the title compound as a clear oil. R f 0.2 (2:3 EtOAc-hexane).
[0074] [0074] 1 H-NMR (CDCl 3 ): δ 1.37 (9H, s), 2.62 (2H, br s), 4.82 (2H, s), 5.10 (1H, br s), 7.23-7.35 (5H, m), 8.89 (1H, br s).
PREPARATION 2
O-Benzyl-α-N-[(3-Cyclopentyloxy-4-Methoxy)Benzoyl]Glycine Hydroxamate
[0075] A mixture of 4.3 g of the compound of Preparation 1 and 20 ml of a 4M HCl solution in dioxane was stirred for 4 hr at room temperature protected from atmospheric moisture with a CaCl 2 tube. At this time TLC analysis showed complete consumption of starting materials and the solvent was evaporated to give 3.2 g of O-benzyl-glycine hydroxamate hydrochloride as a gummy solid.
[0076] To a mixture of 1.35 g (6.35 mmol) of the solid above, 1.50 g (6.35 mmol) of 3-cyclopentyloxy-4-methoxybenzoic acid, and 60 ml of CH 2 Cl 2 was added 1.33 ml (966 mg, 9.53 mmol) of triethylamine followed by 1.83 g (9.63 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide. After stirring for 16 hr at room temperature, the mixture was evaporated and the residue was dissolved in 150 ml of EtOAc, washed with aqueous 1N HCl solution (2×75 ml), saturated aqueous NaHCO 3 solution (2×75 ml), and dried over MgSO 4 . The drying agent was removed by filtration, the filtrate was evaporated, and the residue was purified by flash chromatography (75 g of silica gel) using a 4:1 EtOAc-hexane eluant to give 773 mg (30%) of the title compound as a foam; R f 0.35 (EtOAc).
[0077] [0077] 1 H-NMR (DMSO-d 6 ): δ 1.44-2.00 (9H, m), 3.75 (5H, br s), 4.70-4.82 (1H, m), 4.74 (2H, s), 6.95 (1H, d, J=8), 7.22-7.46 (7H, m), 8.54 (1H, m).
PREPARATIONS 3-16
[0078] The following compounds, having a structure of formula 11, were prepared in accord with the procedure of Preparation 1 except using as starting materials an α- N -t-BOC-AA-OH amino acid, wherein AA is as defined in Table 1, in place of α- N -t-BOC-glycine.
TABLE 1 II α-N-t-BOC-AA-NHOBn Preparation Melting Point No. AA (° C.) Data 3 103-105 1 H-NMR(CDCl 3 ): δ1.43(9H, s), 2.91(3H, s), 3.91(2H, br s), 3.92 (2H, s), 7.36-7.43(5H, m) 4 101-103 1 H-NMR(CDCl 3 ): δ1.31(3H, d, J=8), 1.40(3H, s), 3.90-4.03(1H, m), 4.80-4.92(1H, br s), 4.89 (2H, s), 7.25-7.36(5H, s), 8.78-8.96(1H, br s) 5 102-104 1 H-NMR(CDCl 3 ): δ1.29(3H, d, J=8), 1.38(9H, s), 3.88-4.01(1H, m), 4.78-4.92(1H, br s), 4.85 (2H, s), 7.20-7.36(5H, s), 8.75-9.00(1H, br s) 6 107-109 1 H-NMR(CDCl 3 ): δ1.44(9H, s), 2.21-2.65(2H, m), 2.41(2H, q, J=7), 4.76-5.07(3H, m), 7.33-7.44(5H, m), 8.27(1H, br s) 7 134-136 1 H-NMR(CDCl 3 ): δ1.36(9H, s), 1.42(6H, s), 4.66(1H, br s), 4.86 (2H, s), 7.26-7.37(5H, m), 9.30 (br s) 8 — 1 H-NMR(CDCl 3 ): δ1.37(9H, s), 4.60-4.76(1H, m), 4.85(2H, s), 5.56-5.64(1H, br s), 5.26-5.7.35 (5H, m), 8.97(1H, br s) 9 oil 1 H-NMR(CDCl 3 ): δ0.86(6H, d, J=7), 1.37(9H, s), 1.50-1.67(3H, m), 3.80-3.90(1H, m), 4.70-4.81 (1H, m), 4.85(2H, s), 7.25-7.36 (5H, m), 8.70(1H, br s) 10 oil 1 H-NMR(CDCl 3 ): δ0.80(6H, d, J=7), 1.31(9H, s), 1.44-1.60(3H, m), 3.76-3.88(1H, m), 4.68-4.80 (1H, m), 4.79(2H, s), 7.20-7.30 (5H, m), 8.77(1H, br s) 11 127-129 1 H-NMR(CDCl 3 ): δ0.93(6H, d, J=7), 1.43(9H, s), 1.99-2.12(1H, m), 3.62-3.72(1H, m), 4.91(2H, s), 4.98-5.10, 7.30-7.42(5H, m), 8.80(1H, s) 12 128-130 1 H-NMR(CDCl 3 ): δ0.93(6H, d, J=7), 1.44(9H, s), 1.99-2.13(1H, m), 3.60-3.73(1H, m), 4.92(2H, s), 4.98-5.10(1H, m), 7.30-7.43 (5H, m), 8.77(1H, br s) 13 90-92 1 H-NMR(CDCl 3 ): δ1.40(9H, s), 2.86-3.00(1H, br s), 3.52-3.64 (1H, m), 3.92-4.10(2H, m), 3.89 (2H, s), 5.44-5.56(1H, m), 7.26-7.38(5H, m), 9.20(1H, br s) 14 84-86 1 H-NMR(CDCl 3 ): δ1.40(9H, s), 3.05-3.15(1H, br s), 3.50-3.63 (1H, m), 3.92-4.03(2H, m), 3.89 (2H, s), 5.46-5.56(1H, m), 7.28-7.40(5H, m), 9.33(1H, br s) 15 186-87 Anal. Calculated formula C 17 H 24 N 2 O 4 : C, 63.96; H, 7.80; N, 8.87. Found: C, 63.96; H, 7.80; N, 8.87 16 187-188 Anal. Calculated formula C 17 H 24 N 2 O 4 : C, 63.96; H, 7.80; N, 8.87. Found: C, 63.91; H, 7.76; N, 8.94
PREPARATION 17
O-Benzyl-(3-Cyclopentyloxy-4-Methoxy)Benzoylhydroxamate
[0079] Following the procedure of Preparation 1 except substituting 3-cyclopentyloxy-4-methoxybenzoic acid for α- N -t-BOC-glycine, the title compound was prepared as fluffy white crystals after recrystallization from hexane/CH 2 Cl 2 , m.p. 120.5-121° C.
[0080] Anal. Calculated formula C 20 H 23 NO 4 : C, 70.36; H, 6.79; N, 4.10. Found: C, 70.31; H, 6.97; N, 4.43.
PREPARATION 18
t-Butyl-α-N-Benzyloxy-α-N-[(3Cyclopentyloxy-4-Methoxy)Benzoyl]Glycinate
[0081] To a dry 25 ml 3-necked flash under N 2 was placed 77.8 mg (1.62 mmol) of 50% NaH in mineral oil which was subsequently washed with hexane. The bare hydride was suspended in 1 ml of tetrahydrofuran (hereinafter “THF”) and treated dropwise with a solution of 504 mg (1.48 mmol) of the compound of Preparation 17 in 4 ml of THF. After the H 2 evolution had ceased and the mixture became clear, 261 μl (315 mg, 1.62 mmol) of t-butyl acetate was added. An additional 447 μl of t-butyl acetate was added 2 hours later. After stirring for 16 hours at room temperature, the mixture was diluted with 50 ml of ether, washed with H 2 O (1×30 ml), 1N NaOH solution (3×30 ml), dried (MgSO 4 ), and evaporated to 846 mg of an oil.
[0082] Purification of the oil by flash chromatography (70 g of silica gel) using 20% EtOAc-hexane as eluant gave 476 mg of an oil which spontaneously crystallized. Trituration in hexane gave 392 mg a white solid, m.p. 87-89° C., which was recrystallized from hexane to yield 302 mg of the title compound as white needles, m.p. 88-90° C.
[0083] Anal. Calculated formula C 26 H 33 NO 8 : C, 68.55; H, 7.30; N, 3.07. Found: C, 68.84; H, 7.57; N, 3.02.
PREPARATION 19
O-Benzyl-α-N-Benzyloxy-α-N-[(3-Cyclopentyloxy-4-Methoxy)Benzoyl]Glycine Hydroxamate
[0084] A mixture of 1.64 g (4.11 mmol) of the compound of Preparation 18 and 20 ml of trifluoroacetic acid was stirred at room temperature for 45 min using a CaCl 2 drying tube. The mixture was evaporated and the residue was dissolved in 100 ml of ether, washed with H 2 O (3×76 ml), brine (1×75 ml), dried (MgSO 4 ), and evaporated to give 1.42 g of α- N -benzyloxy-α- N -[3-cyclopentyloxy-4methoxy)benzoyl]glycine,
[0085] [0085] 1 H-NMR (CDCl 3 ): δ 1.52-1.97 (8H, m), 3.88 (3H, s), 4.50 (2H, s), 4.68-4.75 (1H, m), 4.78 (2H, s), 6.84 (1H, d, J=8), 7.12-7.42 (7H, m), 9.02 (1H, br s).
[0086] The title compound was prepared as a foam in analogy to the procedure of Preparation 1 substituting the above acid for α- N -(t-butoxycarbonyl)glycine.
[0087] [0087] 1 H-NMR (CDCl 3 ): δ 1.48-1.95 (8H, m), 3.88 (3H, s), 4.38 (2H, s), 4.58-4.68 (1H, m), 4.69 (2H, s), 4.93 (2H, s), 5.83 (1H, d, J=8), 7.07-7.16 (2H, m), 7.23-7.42 (10H, m), 9.27 (1H, s).
PREPARATIONS 20-33
[0088] The following compounds, having the structure of formula III, were prepared in accord with the procedure of Preparation 2 except using as starting material the compounds from the indicated Preparations in place of the compound of Preparation 1.
TABLE 2 III Starting Material - Compound Of Melting Preparation Preparation Point No. AA No. (° C.) Data 20 3 oil 1 H-NMR(CDCl 3 ): δ1.50-1.95(8H, m), 3.07 (3H, s), 3.85(3H, s), 3.95(2H, s), 4.68-4.78 (1H, m), 4.91(2H, s), 6.79(1H, d, J=8), 6.84-7.40(7H, m), 9.44(1H, br s) 21 4 161-163 Anal. Calculated formula C 23 H 28 N 2 O 5 : C, 66.97; H, 6.84; N, 6.79. Found: 66.77; H, 7.02; N, 6.87 22 5 163-165 1 H-NMR(DMSO-d 5 ): δ1.31(3H, d, J=7), 1.50-1.96(8H, m), 3.82(3H, s), 4.35(1H, br t), 4.81 (2H, s), 4.82-4.90(1H, m), 7.21(1H, d, J=8), 7.32-7.56(7H, m), 8.39 (1H, d, J=7) 23 6 148-149 Anal. Calculated formula C 23 H 28 N 2 O 5 : C, 66.97; H, 6.84; N, 6.79. Found: 66.58; H, 7.12; N, 6.74 24 7 135-137 Anal. Calculated formula C 24 H 30 N 2 O 5 : C, 67.58; H, 7.09; N, 6.57. Found: C, 67.31; H, 6.68; N, 6.80 25 8 Oil 1 H-NMR(CDCl 3 ); δ1.46-1.96(8H, m), 3.85 (3H, s), 4.68-4.76(1H, m), 4.87(2H, s), 4.35-4.45(1H, m), 6.80(1H, d, J=8), 7.10(1H, d, J=8), 7.18-7.38(6H, m), 9.89(1H, s) 26 9 140-142 Anal. Calculated formula C 26 H 34 N 2 O 5 : C, 68.70; H, 7.54; N, 6.16. Found: C, 68.36; H, 7.69; N, 6.37 27 10 142-144 Anal. Calculated formula C 26 H 34 N 2 O 5 : C, 68.70; H, 7.54; N, 6.16. Found: C, 68.46; H, 7.72; N, 6.31 28 11 173-176 Anal. Calculated formula C 25 H 32 N 2 O 5 : C, 68.16; H, 7.32; N, 6.36. Found: C, 67.88; H, 7.30; N, 6.48 29 12 173-176 Anal. Calculated formula C 25 H 32 N 2 O 5 : C, 68.16; H, 7.32; N, 6.36. Found: C, 67.88; H, 7.33; N, 6.50 30 13 122-124 Anal. Calculated formula C 23 H 28 N 2 O 6 .1/4H 2 O: C, 63.74; H, 6.60; N, 6.47. Found: 63.37; H, 7.02; N, 6.83 31 14 144-148 Anal. Calculated formula C 23 H 28 N 2 O 6 .1/4H 2 O: C, 63.74; H, 6.60; N, 6.47. Found: 63.73; H, 6.56; N, 6.52 32 15 foam 1 H-NMR(DMSO-d 6 ): δ1.41-2.16(12H, m), 3.40-3.63(2H, m), 3.75 (3H, s), 4.05-4.28(1H, m), 4.37-4.63(1H, m), 4.75(2H, s), 6.80-7.38 (8H, m), 8.25(1H, s) 33 16 foam 1 H-NMR(DMSO-d 6 ): δ1.42-2.10(12H, m), 3.36-3.58(2H, m), 3.71 (3H, s), 4.03-4.25(1H, m), 4.35-4.58(1H, m), 4.70(2H, s), 6.76-7.35 (8H, m), 8.20(1H, s)
PREPARATION 34
N-[(3-Cyclopentyl-4-Methoxy)Benzoyl]Glycine Benzyl Ester
[0089] [0089]
[0090] To a mixture of 0.500 g (2.12 mmol) of 3-cyclopentyl-4methoxybenzoic acid and 0.470 g (2.33 mmol) of glycine benzyl ester hydrochloride in 20 ml of CH 2 Cl 2 was added 0.410 g (2.12 mmol) of 1-(3dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride followed by 0.236 g (2.33 mmol) of triethylamine. The mixture was stirred for 16 hours at room temperature.
[0091] The solvent was evaporated and the residue was diluted with water (150 ml) and extracted with ether (2×150 ml). The combined ether extracts were washed with aqueous 1N HCl (1×150 ml), saturated aqueous NaHCO 3 , dried (MgSO 4 ), and evaporated to 940 mg of a white solid. Purification by flash chromatography (55 g of silica gel) using a 3:7 EtOAc:hexane eluant afforded 518 mg of the title compound, mp 108-109° C.
[0092] [0092] 1 H NMR (CDCl 3 ): δ 1.40-1.95 (8H, m), 3.85 (3H, s), 4.24 (2H, d, J=5), 4.70-4.80 (1H, m), 5.20 (2H, s), 6.50 (1H, br s), 6.83 (1H, d, J=8), 7.10-7.40 (7H, m).
EXAMPLE 1
α-N-[(3-Cyclopentyloxy-4-Methoxy)Benzoyl]Glycine Hydroxamic Acid
[0093] A mixture of 770 mg of the compound of Preparation 2, 70 mg of Pd(OH) 2 , and 50 ml of methanol was hydrogenated at 40 psi on a Parr Shaker apparatus for 16 hours. The catalyst was removed by filtration and the filtrate was evaporated to a solid which was triturated in ether to afford 510 mg of the title compound, m.p. 160-161° C.
[0094] Anal. Calculated formula C 15 H 20 N 2 O: C, 57.54; H, 6.55; N, 8.95. Found, C, 57.48; H, 6.51; N, 8.74.
EXAMPLES 2-16
[0095] The compounds of Examples 2-16, having the structure of formula IV, were prepared in accord with the procedure described in Example 1 except using as starting material the compounds of Preparations 19-33 rather than the compound of Preparation 2.
TABLE 3 IV Starting Material - Compound Of Example Preparation Melting Point No. AA No. (° C.) Data 2 19 80-105(dec.) Anal. Calculated formula C 15 H 20 N 2 O 6 : C, 55.55; H, 6.22; N, 8.64. Found: C, 55.40; H, 6.61; N, 8.44 3 20 132-142 (dec.) Anal. Calculated formula C 16 H 22 N 2 O 5 : C, 59.62; H, 6.88; N, 8.69. Found: C, 59.77; H, 7.10; N, 8.49 4 21 117-130 (dec.) Anal. Calculated formula C 16 H 22 N 2 O 5 : C, 59.62; H, 6.88; N, 8.69. Found: C, 59.82; H, 6.99; N, 8.74 5 22 152-154 Anal. Calculated formula C 16 H 22 N 2 O 5 .1/4H 2 O: C, 58.78; H, 6.94; N, 8.57. Found: C, 58.72; H, 7.03; N, 8.56 6 23 153-156 Anal. Calculated formula C 16 H 22 N 2 O 5 : C, 59.62; H, 6.88; N, 8.69. Found: C, 59.37; H, 6.59; N, 8.83 7 24 104-107 Anal. Calculated formula C 17 H 24 N 2 O 5 .1/2H 2 O: C, 59.06; H, 7.24; N, 8.11. Found: C, 59.14; H, 7.59; N, 7.83 8 25 155-147 LSI-MS(m/e); 377(M + ), 344, 276, 219 9 26 150-153 Anal. Calculated formula C 19 H 28 N 2 O 5 : C, 62.62; H, 7.74; N, 7.69. Found: C, 62.95; H, 8.14; N, 7.71 10 27 151-154 1 H-NMR(DMSO-d 6 ): δ0.89(3H, d, J=7), 0.94 (3H, d, J=7), 1.43-2.03 (11H, m), 3.80(3H, s), 4.55(1H, br t), 4.82-4.98 (1H, m), 7.01(1H, d, J=8), 7.48(1H, s), 7.55 (1H, d, J=8), 8.22 and 8.32(1H total, two d, J=9), 8.85(0.5H, s), 10.72(0.5H, s) 11 28 166-167 Anal. Calculated formula C 18 H 26 N 2 O 5 .1/2H 2 O: C, 60.10; H, 7.51; N, 7.80. Found: C, 60.21; H, 7.70; N, 7.87 12 29 183-186 Anal. Calculated formula C 18 H 26 N 2 O 5 .1/4H 2 O: C, 60.86; H, 7.47; N, 7.89. Found: C, 60.64; H, 7.70; N, 7.76 13 30 149-152 Anal. Calculated formula C 16 H 22 N 2 O 6 .3/4H 2 O: C, 54.56; H, 6.68; N, 7.96. Found: C, 54.17; H, 6.81; N, 8.15 14 31 143-147 Anal. Calculated formula C 16 H 22 N 2 O 6 .1/4H 2 O: C, 55.99; H, 6.56; N, 8.17. Found: C, 55.67; H, 6.96; N, 7.87 15 32 116-120 (dec.) Anal. Calculated formula C 18 H 24 N 2 O 5 .1/2H 2 O: C, 60.49; H, 7.00; N, 7.84. Found: C, 60.75; H, 7.20; N, 7.81 16 33 117-121 1 H-NMR(DMSO-d 6 ): δ1.51-2.22(10, m), 3.50 (1H, br t), 3.62(1H, br t), 3.80(3H, s), 4.33(1H, br t), 4.78-4.86(1H, m), 6.90(1H, br s), 7.00(1H, d, J=8), 7.12(1H, s), 7.15(1H, d, J=8), 11.2 (1H, s)
EXAMPLE 17
N-[(3-Cyclopentyl-4-Methoxy)Benzoyl]Glycine
[0096] [0096]
[0097] The compound of Example 17 was prepared in accord with the procedure described in Example 1 except using as starting material the compound of Preparation 34 rather than the compound of Preparation 2; m.p. 156-158° C.
[0098] Anal. Calculated formula C 15 H 19 NO 5 .1/4H 2 O: C, 60.04; H, 6.55; N, 4.70. Found: C, 60.07; H, 6.59; N, 4.56.
|
Compounds' of formula (I) and pharmaceutically acceptable salts thereof, wherein R 1 , R 2 , AA and Y are as defined herein, inhibit phosphodiesterase type IV or inhibit the production of tumor necrosis factor, and therefore are useful in the treatment of certain conditions and diseases including asthma, arthritis, and sepsis.
| 2
|
[0001] This application is a divisional of U.S. application Ser. No. 10/536,473, filed May 25, 2005.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a ball bearing having an inner race and an outer race. Moreover, the present invention relates to a vacuum pump, preferably a turbomolecular vacuum pump equipped with a ball bearing of this type.
[0003] Ball bearings of the type stated serve the purpose of holding and guiding rotatable machinery components, generally shafts. The outer race—in the instance of inverted bearings also the inner race—is supported by a fixed component (bearing disk, housing or alike). Generally bearings of this type are oil- or grease-lubricated bearings. The present invention may also be applied to grease-free bearings. Equally the present invention is independent of whether the bearings are implemented with or without a cage.
[0004] It is the task of the present invention to implement a ball bearing of the aforementioned kind such that in the event of a failure of the bearing and guidance of the rotating component damage to, respectively within the machine is avoided.
SUMMARY OF THE INVENTION
[0005] This task is solved by the present invention through the characterising features and measures of the patent claims.
[0006] In that the gap between surfaces which oppose each other is relatively small, these surfaces assume in the instance of uncontrolled movements of the rotating unit the function of emergency bearing surfaces. The rotating unit is guided in a single emergency rundown to standstill without the occurrence of a rotor crash. The friction produced during an emergency rundown is so great that the installed drive power will no longer suffice. The converter of the drive unit switches to failure so that standstill is attained rapidly.
[0007] Still further advantages of the present invention will be appreciated to those of ordinary skill in the art upon reading and understanding the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention.
[0009] FIGS. 1 to 4 depict cross sections of ball bearings with differently designed emergency bearing surfaces and
[0010] FIG. 5 depicts a molecular drag vacuum pump equipped with emergency bearing surfaces in accordance with any one of FIGS. 1-4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] The bearings 1 depicted in the drawing FIGS. 1 to 4 exhibit each an inner bearing race 2 , an outer bearing race 3 , balls 4 and a cage 5 . The axis of the bearing 1 is in each case designated as 6 . In the axial direction (in the drawing FIGS. 1 to 4 at the top in each instance) the inner chamber 7 of the ball bearing 1 is substantially sealed by a bearing cover 8 and specifically employing a snap ring 10 which is clamped within an inner groove 11 in the outer bearing race 3 . Commonly bearing covers of this type are provided to both sides of the balls 4 .
[0012] In order to form the emergency bearing surfaces 14 , 15 in accordance with the present invention one or both bearing races 2 , 3 are equipped with ring-shaped projections which—when arranged on the side opposing the bearing cover 8 simultaneously provide the function of a second bearing cover 8 . In the solution in accordance with FIG. 1 the outer bearing race 3 is provided on its side opposing the bearing cover 8 with a projection 16 extending in the direction of the inner race 2 . The inner surface of said outer bearing race 3 forms with reference to the axis 6 the cylindrical emergency bearing surface 14 . The section of the outer surface of the inner race 2 opposing said surface 14 is the second emergency bearing surface 15 .
[0013] In the solution in accordance with FIG. 2 , the inner race 2 is equipped with a projection 17 extending radially towards the outside. The outer surface of the inner race 2 and a part of the inner surface of outer race 3 also form cylindrical emergency bearing surfaces 14 , 15 .
[0014] In the solutions in accordance with FIGS. 3 and 4 the inner bearing race 2 and the outer bearing race 3 are equipped with projections 18 , 19 respectively 21 , 22 . The emergency bearing surfaces 14 , 15 opposing each other exhibit a stepped cross-section ( FIG. 3 ) respectively form with the axis 6 the angle α. In this manner emergency bearing surfaces are created which not only become effective in the instance of a failure of the radial guidance of the rotating system by the bearings but also in the instance of an axial failure.
[0015] The size of the gap 24 between the emergency bearing surfaces 14 , 15 should be as small as possible. However, the size of said the gap must not fall below the permissible bearing tolerances. The fact that the bearing tolerances are frequently different in the radial and the axial direction needs to be taken into account when selecting the gap size.
[0016] FIG. 5 depicts as an example for a molecular drag vacuum pump a turbomolecular pump 25 the stator of which is designated as 26 and the rotor of which is designated as 27 . Said pump is designed by way of a compound pump and is equipped with a turbomolecular pumping stage 28 equipped with blades and a molecular pumping stage 29 equipped with a thread. The rotor 27 is partly of a bell-shaped design. Within, respectively slightly below the space 31 encompassed by the bell, the rotor is supported rotatably through the shaft 34 in the bearings 35 and 36 . Moreover, there is accommodated within the space 31 the electric drive motor, its stator pack which is designated as 37 and the rotor pack which is designated as 38 . The bearings 35 , 36 and the rotor stator 37 are supported by a sleeve-like carrier 39 .
[0017] For the purpose of supplying the bearings 35 and 36 with a lubricant, a vessel 41 filled with oil 40 is affixed underneath the turbomolecular pump 25 . The drive shaft 34 , the lower end of which is immersed in the oil exhibits an inner coaxial bore 42 which owing to the conically expanding bottom section 43 effects pumping of the lubricating oil towards the top. Through cross bores 44 the oil first arrives at the upper bearing 35 and there flows, due to the effect of gravity, through the bottom bearing 36 back into the oil vessel.
[0018] Through the forevacuum port 45 and the line 46 the turbomolecular pump 25 is connected to the forevacuum pumping facility 47 . Since there exists between the motor/bearing chamber 31 and the forevacuum port 45 a connection, there also prevails in space 31 the necessary forevacuum pressure needed to operate the turbomolecular pump. In order to prevent corrosive gases being pumped by the turbomolecular pump from entering into the bearing chamber 31 , a purge gas facility is provided which initially comprises the gas admission pipe 48 opening out into the bearing chamber. For the purpose of admitting the purge gas in a controlled manner said gas inlet pipe 48 exhibits a valve 50 . The purge gas (N 2 for example) entering into the motor/bearing chamber 31 flows through the motor as well as the upper bearing 35 and passes outside the bearing carrier 39 to the discharge port 45 . Thus the entry of corrosive gases, which are being pumped by the turbomolecular pump 25 , into the motor/bearing chamber 31 is prevented.
[0019] Within the scope of the present invention one bearing or both bearings 35 , 36 has/have been designed (not depicted in detail) as depicted in one of the FIGS. 1 to 4 . An advantage of this measure is that in the instance of a failing bearing, the active pumping surfaces (blades of the rotor/stator thread) are not damaged. The gap 24 between the emergency bearing surfaces 14 , 15 defines in the instance of a failed bearing the maximum deflection of the rotor 27 from its nominal position. Correspondingly narrow also the distances between the active pumping surfaces can be selected. The smaller these distances, the better the properties of the pump. Moreover, the fact, that between the bearing races 2 , 3 at least for bearing 35 there exists a narrow relatively long gap 24 , offers the advantage of a considerable reduction in the rate of the purge gas flowing through the bearing. Finally, the projections at the bearing races 2 , 3 permit larger contact surfaces which effect an improvement in the dissipation of heat from the bearing.
[0020] The gap 24 needs to be selected corresponding to the bearing tolerances. In the instance of pumps of the described kind, the gap width is expediently less than 0.1 preferably less than 0.05 mm. The size of the emergency bearing surfaces is defined through the axial extension of the gap. Said extension should not drop below 1.5 mm, in the case of oblique or stepped emergency bearing surfaces correspondingly larger.
[0021] It is of importance that in the instance of a failed bearing the friction produced by the emergency bearing surfaces 14 , 15 is high so that the drive for the rotating system can switch to failure. The friction characteristic of the emergency bearing surfaces 14 , 15 depends on the material (expediently hardened rolling bearing steel). By coating one or both emergency bearing surfaces (with MOS 2 , Teflon, for example) it is not only possible to increase the amount of friction but also reduce the tendency of seizing for the given pair of materials.
[0022] The invention has been described with reference to the preferred embodiments. Modifications and alterations may occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be constructed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
[0023] Having thus described the preferred embodiments, the invention is now claimed to be:
|
A ball bearing ( 1 ) has an inner race ( 2 ) and an outer race ( 3 ). In order to prevent the rotating parts from being damaged when the bearing assembly fails, the bearing has emergency bearing surfaces ( 14, 15 ) which are concentric to the rotational axis ( 6 ) and of which one is a part of the rotating bearing race and the other is a part of the fixed bearing race. During normal operation, the emergency bearing surfaces ( 14, 15 ) are situated opposite one another with a relatively narrow gap ( 24 ) therebetween. But, in the event of failure, the surfaces ( 14, 15 ) engage and function as emergency bearing surfaces.
| 5
|
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The invention relates to an inflatable packing device including a sophisticated elastomeric inflatable bladder, either alone or in combination with a sophisticated cover.
(2) Definition of Terms
As used herein and in the claims, the phrase "inflation initiation" refers to the location or point on the exterior of the device where first flexing of the contour of the device resulting from effective inflation is expected to occur. Inflation initiation can occur at a plurality of locations or points, depending upon choice of design.
As used herein and in the claims, the phrase "inflation element" means: the sub-assembly generally composed of the bladder, ribs, cover, upper securing means and lower collars or securing means.
As used herein and in the claims, the phrase "point of contact" means: the initial and subsequently latest expected location of interface between the exterior of the device and the wall of the well during effective inflation.
As used herein and in the claims, the phrase "effective inflation" means: the quantum of expansion of the bladder during the setting of the packing device from the run-in position of the apparatus to from between no more than about 70% to no more than about 85%, by volume, of the interior of the bladder when fully set in the well bore.
As used herein and in the claims, the phrase "departure angle" means: the angle between a straight line parallel to the longitudinal axis of the well and along the inside diameter wall of the well passing through a point of contact and a straight line drawn tangent to the exterior surface of the device for an interval of length extending from the point of contact to a distance of about one run-in diameter, this line too passing through the same point of contact. The longitudinal axis of the borehole and the two lines defining the departure angle must all be coplanar.
As used herein and in the claims, the phrase "expansion profiles" means: the transitional forms taken by the flexible portion of the inflation element during effective inflation.
As used herein, the phrase "uniform inflation profiles" means: the circumstance when the "expansion profiles" taken by the inflation element closely approximate straight line profiles from the point of contact to the end of the collar.
As used herein, the phrase "expansion ratio" means: the ratio of the diameter of the fully set inflation element, divided by the run-in diameter of the inflation element.
(3) Description of the Prior Art
Inflatable packers, bridge plugs, and the like, have long been utilized in subterranean wells. Such inflatable tools normally comprise an inflatable elastomeric bladder element concentrically disposed around a central body portion, such as a tube or mandrel. A sheath of reinforcing slats or ribs is typically provided exteriorally around the bladder with an elastomeric packing cover concentrically disposed around at least a portion of the sheath. Generally, a medial portion of the sheath will be exposed and without a cover for providing anchoring engagement of the packer to the wall of the well. Pressured fluid is communicated from the top of the well or interior of the well bore by means of a down hole pump to the interior of the body and thence through radial passages provided for such purpose or otherwise around the exterior of the body to the interior of the bladder during inflation.
Normally, an upper securing means engages the upper end of the inflatable elastomeric bladder and the reinforcing sheath (if included in the design), sealably securing the upper end of the bladder relative to the body, while a lower collar or securing means engages the lower end of the bladder and reinforcing sheath, securing the lower end of the bladder for slidable and sealable movement relative to the exterior of the body, in response to inflation forces. The elastomeric cover may be secured to the exterior of the sheath or placed around the exterior of the bladder, in known fashion.
With inflatable packers of this type, it has been observed that the portion of the bladder adjacent the exposed sheath section of the packer prematurely inflates prior to the other portions of the bladder which are reinforced against expansion by the reinforcing sheath and/or the elastomeric packing cover element. When the inflation element expands, one end of the bladder moves toward the other end of the device, and the bladder area adjacent the exposed sheath inflates until it meets the wall of the well bore, which may be cased or uncased. If the well bore is uncased, the well bore will have an earthen wall, and if the well bore is cased, the wall of the well bore will be the internal diameter surface of the casing.
It has been noted in a number of prior art designs that when service conditions encompass moderate expansion ratios, a propensity for the bladder to pinch around the exterior of the body arises, creating either a seal or a convoluted fold in the bladder that sometimes prevents the effective communication of further fluid throughout the bladder and preventing contiguous inflation propagation. The pinching seal and/or fold(s) can become entrenched in the bladder whereupon they obstruct further passage of fluid employed for inflating the bladder and therein keep fluid from reaching the farthest portions of bladder to be inflated. When this occurs in service, it always results in a soft set condition and in the imminent loss of seal between the cover and wellbore. This problem is discussed in detail in Eslinger, et al. "Design and Testing of a High-Performance Inflatable Packer," SPE 37483, Society of Petroleum Engineers (1997). Tools designed to control inflation shape problems are discussed in the Eslinger paper are described in detail in U.S. Pat. No. 5,605,195 issued Feb. 25, 1997, and entitled "Inflation Shape Control System For Inflatable Packers," and in U.S. Pat. No. 5,507,341 issued Apr. 16, 1996, and entitled "Inflatable Packer With Bladder Shape Control."
Folds in the bladder can be expected to occur in prior art devices like that shown in FIG. 18 when the expansion ratio is greater than 2:1. Designs of this sort inherently experience large departure angles and unfavorable expansion profiles when the expansion ratio is about 2:1 or more. By utilization of the design of the present invention, the departure angle is preferably controlled at no more than about 15° and the inflation element experiences a uniform inflation profile and therefore, no folds or pinches will occur even if the expansion ratio is 3:1, or even higher. Elimination of the propensity to form folds and pinches in the present invention can be attributed to exceptionally low departure angles throughout inflation and the propagation of uniform inflation profiles throughout effective inflation.
The formation of folds creates unusually high triaxial stresses and strains in the vicinity of the fold. Correspondingly, these triaxial stresses and strains create a condition that causes localized failure of the bladder by means of cracking and/or tearing. Failure occurs because the physical properties of the elastomeric material composing the bladder are not adequate to survive the localized triaxial stresses and strains.
Except for the devices described in my patents U.S. Pat. No. 5,469,919, U.S. Pat. No. 5,564,504 and U.S. Pat. No. 5,813,459, all other prior art devices having an element construction similar to that shown in FIG. 18 experience large departure angles and unfavorable expansion profiles when the expansion ratio is greater that 2.00:1, i.e., departure angles greater than 25° at a 2:1 expansion ratio and expansion profiles similar to that shown in FIG. 18. An expansion profile would be deemed unfavorable if the slope of the exterior surface at any point on the inflation element exceeds 15° relative to the longitudinal axis of the wellbore. The term "unfavorable expansion profile" is only applicable to the "effective inflation" portion of the inflation cycle. The propensity to form pinching seals and folds is directly related to undesirable combinations of expansion ratio, departure angles and expansion profiles of the device. In prior art devices, pinching seals and folds are experienced upon the combination of departure angles greater than about 15° and an expansion ratio greater than about 2.35:1.
With regard to covers, at expansion ratios of 2:1 and more, the departure angle in prior art devices other than those for the preferred embodiments in my aforementioned patents will be greater than 20° and the combination of a departure angle greater than 20° and an expansion ratio greater than about 2:1 has been observed to result in cracking and tearing in covers. Once a tear or tears occur, non-uniform rib spacing results. Non-uniform load distribution within the cover also occurs and general discontinuity of the cover results. These conditions, in turn, can result in extrusion of the bladder between ribs resulting in subsequent failure of the bladder and service failure of the device.
In my U.S. Pat. Nos. 5,469,919, and 5,564,504, and 5,813,459 entitled "Programmed Shaped Inflatable Packer Device," issued Sep. 29, 1998, I disclose methods to abate the formation of pinching seals and folds during inflation of prior art devices by using a design which includes a series of shaped-controlling means on an elastomeric packing cover along the length of the bladder in the form of high and low modulus modules of varying lengths and thicknesses. While this design is an advancement in the art, the design of the modules leaves comparatively sharp angled transitional chamfers and significant size Differences between the high and low modules. These chamfers and different diameters are of such magnitude that they are easily detected by the naked eye. The short transitional chamfers give rise to localized stresses and strains in expanded covers. These localized stresses and strains can cause cracking and/or tearing in the covers which can ultimately result in device failure.
In another prior art device which was subjected to service conditions having expansion ratios of 2.35:1 and 3:1, the minimum achievable departure angles were about 15° and 23°, respectively. This device used a plateau cover interval concept in accordance with my patents U.S. Pat. No. 5,469,919, U.S. Pat. No. 5,564,504 and U.S. Pat. No. 5,813,459 and has been made commercially available by High Pressure Integrity, Inc. under the product name "Z-44". While this product was an advancement and improvement over other prior art devices, the variations of constant thickness cover intervals with abrupt and relatively short transitions from one thickness to another caused comparatively high localized stress and strain concentrators in the cover which occasionally resulted in cracking and tearing of the cover. Z-44 and similar devices always exhibited rib kinking and experienced occasional rib cutting of the bladder. Additionally, inflation profiles exhibited plateau intervals (intervals of constant diameter along the length of the device) rather than relatively straight sloped profiles in the interval between the last point of contact with the casing (POC) and the end of the collar. Additionally, the plateau cover interval concept abated the formation of pinches and folds in bladders at moderate expansion ratios, but did not eliminate their occurrence at expansion ratios greater than 2.35:1.
The ability to successfully deflate and retrieve an inflatable device is a common service requirement. A pinch or fold might still have formed in a bladder during inflation even though the inflation element effected a satisfactory seal against the wall of the well. During deflation, a fold can pinch and seal around the body, obstructing the transmission of fluid out of the lower portions of the bladder and thereby prevent complete deflation of the bladder. Once a fold is formed, it is permanently entrenched in the bladder and results in multiple layers of bladder beneath the ribs. These layers in turn result in a deflated diameter which is greater than the initial run-in diameter of the inflation element. Retrieval of the device to the earth's surface is thus compromised since the device might not be able to pass through restrictions in the well bore as it is moved upwardly therein.
I have now discovered that the problems described above can be further abated by providing an inflatable packing device having a combination of an excellent uniform expansion profile during effective inflation and minimal departure angles throughout the inflation cycle.
The invention permits orchestration of varying sophisticated contours and configurations in the bladder or in a combination of the bladder and the cover to provide a uniform expansion profile in an expected, i.e., pre-determinable, manner which can be achieved with only minimal or nominal experimentation which will be within the ordinary skills of those knowledgeable in the design and use of inflatable elastomeric devices for use in subterranean wells, and by adhering to the teachings herein.
SUMMARY OF THE INVENTION
An inflatable packing device such as a bridge plug, packer, cement retainer, etc., is provided for use in a subterranean well bore. The well bore has a wall which may either be open hole or casing, and the use of the term "wall" or "well bore wall" contemplates either open hole or cased hole. The packing device is carriable into the well bore on a "conveyance mechanism," such as coiled tubing, production or workover tubing, conventional threaded pipe, wireline, electric line, or the like. The device is inflated in known ways by pressured fluid communicated to the device from a source of fluid to cause the packing device to seal against the wall upon inflation.
The packing device includes a housing, preferably having an elongated mandrel extending between each of the ends of the housing. Means are provided on the housing for effective engagement of the housing relative to the conveyance mechanism. Such engagement may either be direct, such as by threads, or may be indirect, by provision of a setting tool which is connected to the conveyance mechanism at one end thereof and to the packing device at the other end thereof. A sophisticated, programmed inflatable elastomeric bladder is included along the housing and concentrically disposed around the mandrel. An elastomeric cover, which also may be so programmed, is positioned exteriorally of the bladder for sealing against the wall of the well bore. The bladder or a combination of the bladder and the cover is programmed to permit the cover to have a continuously smooth outer surface area extending from a point of contact during effective inflation at a departure angle of no more than about 20° at expansion ratios up to 3:1, whereby a uniform expansion profile permits the cover to displace well fluids between the wall of the well bore and the exterior of the cover during effective inflation. In such manner, rib kinking and pinching or folding of the bladder around the mandrel is abated during such inflation. The resulting uniform continuous smooth outer surface on the cover is provided by means of orchestrated variation in the original thickness of the bladder component or by a combined orchestration of the bladder and the cover during manufacture.
The design of the packing device may provide for a single cover extending from approximate one end of the housing to the other approximate other end thereof. The packing device may also be provided in a design in which plural cover sections are provided along the length of the housing with a series of circumferentially extending expandable metallic slats being exposed directly to the well bore between such cover sections for anchoring the packing device during setting. The invention also contemplates a packing device having a design wherein there are plural points of initial contact with the continuously smooth contour configuration of the cover extending toward each end of the housing.
The configuration of the invention eliminates any sharp changes in the cover thickness, such as "stepped" variances which are so dramatic that they are readily identifiable, both visually and by feel. All thicknesses in the sophisticated bladder and in the cover, if it is programmed for orchestrated results with such bladder, are intentionally graduated over comparatively long intervals, resulting in the elimination of stress and strain concentrations in the bladder and the cover related to changes in thickness and the assurance of continuous, contiguous/homogeneous sealing contact of the cover means to the well wall. Such contours reduce the propensity to initiate tears in the cover and/or the bladder, as opposed to some prior art devices which merely attempt to arrest the propagation of a tear in the cover and/or bladder via abrupt changes in cover thickness.
The ability of the device of the present invention to prevent tearing in the bladder or cover is a direct result of the combination of very low departure angles and the reduction of stress and strain concentrations in the bladder or cover. These features are achieved by providing continuous interengagement of variations in the thickness of the bladder or the bladder and the cover without sharp or abrupt angular changes between such contours during effective inflation of the device by adhering to the low departure angle concept of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical partial cross-sectional schematic illustration of a prior art inflatable packing device being set in a subterranean well with a resultant departure angle well in excess of the maximum angle of the present invention, resulting in sharp angular transitions in the cover along the line of taper defined by the departure angle.
FIG. 2 is a longitudinal cross section of a preferred embodiment bladder having programmed variations in wall thickness.
FIGS. 2A and 2B better depict wall thickness features of the bladder in FIG. 2.
FIGS. 3A and 3B together constitute a cross-sectional view of an apparatus of the present invention incorporating the sophisticated bladder of FIG. 2 in an inflation element having a sophisticated cover.
FIGS. 4-20 constitute a sequence of computer enhanced photographic views illustrating the approximate anticipated inflation cycle which can be expected to occur with the use of the present invention at a 2.35:1 expansion ratio and simulates actual down hole setting within a casing conduit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, with first reference to FIG. 1, there is shown a prior art apparatus PAA of the inflatable variety partially set within a well W along the interior wall A of a casing conduit C extending to the top of the well (not shown). A 1 is a straight line drawn parallel to the longitudinal axis of the wellbore and the inside diameter of the wall W. The apparatus PAA is run in the well W on a conveyance mechanism, such as conduit CT, in conventional fashion.
As schematically illustrated in FIG. 1, the view is taken subsequent to inflation initiation. As shown, each departure angle F is about 40° as determined by measuring the angle between interior wall A and the exterior surface of the device at the point of contact, PC. A line E is drawn from the point of contact PC and tangent to the line of PAA. Departure angle F is defined as the angle between lines A and E.
FIGS. 4-20 are illustrative of the expected inflation cycle which may be achieved when practicing the present invention and are necessary to illustrate the application and significance of the various terms defined in the "Definition of Terms." These FIGS. correspond to FIGS. 1-17 in my co-pending application Ser. No. 09/290,373, filed Apr. 12, 1999, and entitled "Inflatable Packing Device Including Cover Means for Effecting a Uniform Expansion Profile" and are views of a device incorporating a sophisticated cover, as opposed to a sophisticated bladder or a combination of a sophisticated bladder and case. Nevertheless, these Figs. serve to illustrate the application of the defined terms as well as the inflation profiles which are expected to occur in a device in which the sophisticated bladder of the present invention is to be substituted for a sophisticated cover.
As shown in FIGS. 4-20, an apparatus 10 is shown disposed within a plexi-glass or other clear conduit section, representing casing C, within a well W. In FIG. 4, the apparatus 10 is viewed in the run-in position just prior to initiation of inflation of the apparatus 10. FIGS. 7-20 are illustrative of basic invention performance at a 2.35:1 expansion ratio. The casing C has an interior wall A.
FIG. 5 represents the apparatus 10 at inflation initiation which is visually observant by the outwardly flexing of the circumferentially extending set of metallic ribs or sheath 22 which is exposed in this representative design for anchoring engagement along the interior wall A of the casing C. In FIG. 5, the point of inflation initiation is indicated by B with a straight line A 1 drawn parallel to the interior wall A being drawn from the inflation initiation point B in one direction of rolling inflation.
As apparent in FIG. 6, a substantially straight line of taper E is also drawn in the same direction from inflation initiation B resulting in a departure angle of F of about 21/2°. In photographic FIG. 6, inflation of the apparatus is continued and the open or exposed ribs or sheath 22 continue to flex outwardly towards the interior wall A of the casing C.
In photographic FIG. 7, the initial point of contact PC has been made with the interior wall A of the casing C and the departure angle F remains at about 8°.
In FIG. 8, the inflation of the bladder has continued to the extent that the point of contact PC now is first defined on the cover 24 as opposed to the metallic slats 22, but the departure angle F continues at approximately 7.7° or less. Fluid between the exterior of the cover 24 and the interior wall A of the casing C would be swept away from the rolling expansion of the cover means as the bladder is inflated.
FIG. 11 represents a continuation of the inflation cycle from FIG. 10. In FIG. 12, the rolling effect of the inflation cycle continues and the departure angle F is expected to still remain within the acceptable range of no more than about 15° at its 2.35:1 expansion ratio, and preferably 7.0°.
In the design of the device 10 shown in photographic FIGS. 4-20, upper and lower sections of the cover 24 are shown in sequential inflation views with one of the cover sections being moved to contact with interior surface A somewhat earlier than that of the other cover section. This sequence is contemplated in the invention at hand.
Photographic FIGS. views 8-12 show a continuation of effective inflation with a moving point of contact PC and a continuation of a satisfactory departure angle F of about 5-8°, or less.
FIG. 13 illustrates satisfactory inflation contemplated within the invention through effective inflation EI at one end of the device, while inflation will continue at the opposite end. FIG. 13 illustrates the basic inflation element profile at the termination of effective inflation.
While the apparatus 10 may be designed such that the bladder is inflated to cause the cover means 24 to continue inflation at a departure angle of no more than about 20°, at this point and because effective inflation has been terminated, it is no longer critical for continued inflation to be within an angle of departure of about 20°.
FIG. 20 illustrates photographically the apparatus 10 in the complete, set position in the well W.
Photographic FIGS. 14-20 illustrate expected continued inflation of a device which would incorporate the present invention subsequent to effective inflation upon and through the upper most section (or left side of view) of cover C-1.
The invention contemplates a device in which the incorporation of a sophisticated contoured bladder or a combination of sophisticated contoured bladder and cover, results in a very low departure angle and uniform expansion profile for the cover throughout effective inflation.
Although the text of this specification discusses the method of maintaining a constant bladder OD and varying bladder ID to achieve wall thickness variations, the inventor can invision maintaining a constant bladder ID and varying the OD so as to achieve wall thickness variations. Correspondingly, the inventor can invision combinations of these two methods to achieve the purposes previously described in this text.
The bladder may be manufactured utilizing a number of known procedures. Those skilled in the art of designing and utilizing inflatable packing devices for subterranean wells will be familiar with elastomers which can be utilized as a bladder contemplated by the invention at hand. The exterior profile occurring in the device during inflation is the result of gradual, fine, reductions and contouring of either the exterior or interior of the bladder surface, which may be accomplished by conventional machining techniques to reduce the initial diameter of such bladder means either upon the outer diameter or the inner diameter, or, in some instances, both, to orchestrate a fine shaping of the inflation profiles taken during effective inflation without apparent, dramatic diameter "steps" resulting in the exterior diametral profile.
In the sequence of photographs of expansion in FIGS. 5-20, the smooth, continuous, rolling nature of the uniform expansion profile is apparent. The absence of rib kinking is both obvious and unique for an inflation element having an exposed rib anchor section. Additionally, any well fluids between the exterior of the flexing parts of the device except the extreme ends adjacent the collars and the point of contact PC will be swept away from the point of contact, continuously, as the cover means expands as a result of the uniform inflation of the bladder. This eliminates the possibility of soft set failure of the device.
Now with reference to FIGS. 2, 2A and 2B, there is shown a preferred configuration of the apparatus 10 of the present invention. The sophisticated bladder 100 of the present invention is shown as being 64.00 inches in total length. The bladder 100 has a constant and continuous outer diameter (OD) of 1.69 inches. The bladder wall thickness varies in deliberate fashion as one travels down the longitudinal axis of the bladder. In traversing from left to right, the first 9.75" of bladder length has a constant wall thickness of 0.280". This interval of bladder length is identified as interval 101. Interval 101, of course, corresponds with an interval of constant inside diameter (ID). Point 108 demarks the termination of interval 101 and the beginning of an 11.25" interval, 102, where bladder wall thickness varies in linear proportional fashion with the length of the interval, i.e., at the beginning of the 11.25" long interval the wall thickness is 0.280", at the end of the interval the wall thickness is 0.315" and the wall thickness between the two ends of the interval varies in linear proportion with spacial location along the length of the interval. The ID of the bladder at points interval 102 vary in linear proportion to spacial location along the length of the interval. Point 106 demarks the termination of tapered interval 102 and the beginning of interval 103 which is 10.38" long and has a constant wall thickness of 0.315". Interval 103 corresponds with an interval of bladder length having a constant ID. Point 110 demarks the termination of interval 103 and the beginning of a 3.00" long interval, 104, where the wall thickness tapers in linear fashion from an initial thickness of 0.315" to a final thickness of 0.240". The ID of the bladder at points in interval 104 vary in linear proportion to spacial location along the length of the interval. Point 111 demarks the termination of interval 104 and the beginning of an 8.00" long interval, 105, which has a constant wall thickness of 0.240". Interval 105 has a constant ID. Point 112 demarks the termination of interval 105 and the beginning of a 6.00" long interval, 106, where the wall thickness tapers in linear fashion from an initial thickness of 0.240" to a final thickness of 0.315". The ID of interval 106 varies in linear proportion to spacial location along the length of interval 106. Point 113 demarks the termination of interval 106 and the beginning of a 15.63" long interval, 107, which has a constant wall thickness of 0.315". Interval 107 has a constant ID along its entire length.
Bladder 100 is a single unit continuum having a constant OD and intervals having variable wall thicknesses. The length and thicknesses of the intervals are selected to act in concert with mating components of the inflation element, i.e., ribs and cover(s), to achieve desired enhanced inflation characteristics.
Although the preferred embodiment illustrates bladder thicknesses varying in linear taper fashion, thickness programming is not limited to this fashion. Variations can vary in curvilinear and other sophisticated manners.
Now, with reference to FIGS. 3A and 3B, the apparatus 10 of the present invention is shown with incorporation of the bladder 100 illustrated in FIG. 2. The apparatus 10 includes a housing 11 which is formed of an upper coupling 11A and an upper collar 11B. The coupling 11A is threaded at threads 11C to a tubular component (not shown), of known construction. Similar couplings and collars are illustrated at the opposing end of the apparatus 10. The apparatus 10 also includes a cover 12 which may be of a sophisticated variety as illustrated in FIGS. 3A and 3B or can be more conventional like the cover shown in FIGS. 4-20, where the upper and lower cover segments have a constant nominal thickness of 0.070 inches and an outer diameter of 2.008 inches. Cover 12 is contoured such that it has a 4.14" long by 2.097" OD (0.109" thick) interval, and an adjacent 9.36" long interval with linearly varying cover thickness. Cover 12A has a 4.14 long by 2.097" OD (0.109" thick) interval, a 10.86" long linearly varying interval where the thickness linearly tapers from 0.109" on one end to 0.068" on the other end and a 9.00" long interval having a constant thickness of 0.068". As shown in FIG. 3B, the apparatus 10 also includes a series of radially extending metallic slats 13, also of conventional nature, which are housed between the interior of the cover 12 and the bladder 100. As illustrated, the slats 13 are uncovered for a portion of the length, 14, of the apparatus 10, such that, upon radial expansion, they may anchoringly engage against the inner wall of the well on the casing, in the event that the well is cased, or along the open bore wall of an uncased hole. Cover section 12A extends from the exposed rib section 14 to the lower collar 11D.
It will be appreciated that the angle of departure shown in FIGS. 4-20 will typically be less than 8°. This, of course, is well within the range of anticipated departure angles of the present invention, i.e., no more than about 15° at a 2.35:1 expansion ratio.
To enhance the programmed effect on prior art inflation elements and their inflation characteristics to abate rib kinking and pinching and the like, as described earlier, a programmed bladder may be incorporated with a cover having the shape-controlling means as described in my U.S. Pat. No. 5,813,459. The programming of the bladder would be uniquely matched with the features of the mating covers used in the subject inflation element.
It will be appreciated that the present invention provides a contoured bladder as a continuous tubular member with a finite length composed of contiguous intervals having varying magnitudes of length and diameter. By varying the combinations of interval diameters and lengths in the bladder, as well as varying the juxtaposition of the intervals, desired transitional shapes of the bladder and the inflation element during inflation will be produced.
It will also be appreciated that each interval does not need to be a constant diameter, as the diameter of an interval can vary in a smooth gradual manner to provide, for instance, a sloped profile or a curved profile as opposed to a plateau-type profile. But it is important to note that the present invention avoids profiles that are "stepped," or dramatically varied between one another, as in prior art components and the use of sophisticated profiles can be used to achieve optimal transitional shapes for a wide variety of cover/anchor designs.
It will also be appreciated that the orchestration of the variable diameters and lengths and the spacial location and interaction of the juxtaposed intervals will allow the user to program these parameters to achieve specific desired characteristics and are not just limited to minimizing departure angle. Moreover, deliberate combinations of bladder profile features and combinations of such features in bladders as well as in covers can be used to achieve other desired transitional shapes during the inflation cycle.
It will also be appreciated that incorporation of the present invention in a bladder for such a packer device results in elimination of rib kinking, rib cutting of the bladder and abrupt changes in the cover thickness and no sealing pinches or convoluted folds occurring during inflation. Moreover, soft sets are eliminated because there is no trapped fluid between the cover and the casing. Improved reliability and service performance for the bladder are achieved as a result of reduced triaxial stresses and strains.
In actuality, excellent uniform expansion profiles do not project perfect straight lines from their contact points through the components of the device, such as end collars, but instead exhibit near straight lines like those in FIGS. 7-20. Those who are experienced in design and testing of inflatable devices would equate the profile lines in FIGS. 7-20 with straight lines.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
|
An inflatable packing device for use in a subterranean well provides a sophisticated bladder, either alone or in combination with a sophisticated cover, which results in a uniform expansion profile and exceptionally low angles of expansion propagation during inflation of the bladder to set the device, whereby well fluids between the wall of the well bore and the exterior of the cover of the device are swept away from the area of subsequent sealing of the cover. The propensity for rib kinking and rib cutting, pinching, folding, cracking and tearing of the bladder during inflation are eliminated. Correspondingly, reduced stresses and strains in cover segments combined with near ideal inflation profiles result in enhanced expansion propagation of the inflation element and improved service performance and reliability of the downhole device.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to objects and devices used to help retain shopping carts within the confined area of a parking lot.
2. Description of the Related Art
One common device used to retain shopping carts within the boundaries of a parking lot is a barrier. Barriers such as walls made from concrete blocks or metal posts are placed around the perimeter of the parking lot. The barrier is constructed in such a manner as to prevent the removal of the shopping cart. Although the barrier device is effective at preventing the removal of shopping carts at pedestrian entrances, it does not address the problem of the removal of a shopping cart via the motor vehicle entrance.
That short fall led to the development of devices to be attached to the shopping cart. Such developments included electronic tracking devices, beepers and automatic wheel locking units. Those devices would activate when the shopping cart was removed from the specified boundaries of the parking lot. One example is the shopping cart equipped with a retractable fifth wheel. When the shopping cart senses that it is being lifted, such as being lifted over a perimeter retention wall, a fifth wheel is automatically lowered from its retracted position. The lowered fifth wheel lifts and locks the shopping cart in such a manner that further movement of the shopping cart is inhibited.
However, the advantages of the prior art devices did not outweigh their disadvantages. The disadvantages of the attachment devices included: a. the expense of supplying one device per cart, b. the cost of maintaining, repairing and replacing the devices, and c. the ease of device circumvention.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide, a shopping cart retention entrance which overcomes the herein-mentioned disadvantages of the heretofore-known devices of this general type, and provides a cost effective vehicle entrance which makes it difficult to remove a shopping cart from a designated parking lot.
With the foregoing and other objects in view there is provided, in accordance with the invention, a combination of a barrier for retaining shopping carts around a parking lot, and a vehicle entrance comprising a roadway having a surface; and a plurality of geometric objects protruding upward from the surface for entrapping a wheel of a shopping cart when the wheel of the shopping cart is pushed over the geometric objects.
In accordance with another feature of the invention, the goemetric objects have a given height greater than the radius of the wheel of the shopping cart, and a given distance between the geometric objects is greater than the diameter of the wheel of the shopping cart.
In accordance with an added feature of the invention, the geometric objects are block like in shape.
In accordance with another feature of the invention, the geometric objects are tube like in shape.
In accordance with an additional feature of the invention, the geometric objects are shaped in sinusoidal wave like forms.
In accordance with a concomitant feature of the invention, the geometric objects are v-shaped like blocks.
A second embodiment of the invention provides a combination of a barrier for retaining shopping carts around a parking lot, and a vehicle entrance comprising a roadway; a housing being formed over the roadway; a plurality of sprinklers disposed in the housing; and at least one motion sensor located in the housing for controlling the sprinklers, the at least one motion sensor activating the sprinklers when the at least one motion sensor detects motion in the housing for deterring the removal of a shopping cart from the vehicle entrance.
A third embodiment of the invention provides a combination of a barrier for retaining shopping carts around a parking lot, and a vehicle entrance comprising a roadway; a water trap in the roadway, the water trap having sides and a pool of water for inhibiting movement of a shopping cart through the vehicle entrance; and a ramp on each side of the water trap over which a vehicle is lowered into the water trap.
A fourth embodiment of the invention provides a combination of a barrier for retaining shopping carts around a parking lot having an exit road, and a vehicle entrance comprising a housing; a ramp unit being articulatingly connected to the housing, the ramp unit having a roadway to be traversed by a motor vehicle; and a movable, controlled counter weight being connected to the roadway for moving the roadway about its axis and causing the roadway to lower to the exit road.
Other characteristic features of the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a shopping cart retention entrance, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of the specific embodiment when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagramatic, top-plan view of a typical parking lot arrangement according to the invention;
FIG. 2 is a perspective view of a shopping cart and retention posts;
FIG. 3 is a perspective view of a vehicle entrance formed with a water trap;
FIG. 4a is a top-plan view of the vehicle entrance formed with a roadway having protruding geometric shapes;
FIG. 4b is a sectional view taken along the line IV--IV shown in FIG. 4a and shows a block surface of the roadway entrance;
FIG. 4c is a sectional view taken along the line IV--IV shown in FIG. 4a and shows a sinusoidal surface of the roadway entrance;
FIG. 4d is a sectional view taken along the line IV--IV shown in FIG. 4a and shows a tube surface of the roadway entrance;
FIG. 4e is a top-plan view of the vehicle entrance formed with the roadway having protruding v-shaped objects;
FIG. 4f is an enlarged perspective view of the v-shaped objects;
FIG. 5a is a front-elevation view of the vehicle entrance having a water tunnel;
FIG. 5b is a side-elevation view of the water tunnel;
FIG. 6a is a side-elevation view of the vehicle entrance having a ramp unit in a raised position;
FIG. 6b is a side-elevation view of the vehicle entrance having the ramp unit in a partially lowered position; and
FIG. 6c is a side-elevation view of the vehicle entrance having the ramp unit in a fully lowered position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is shown a typical parking lot 1 surrounded by a barrier 4. The barrier can be a cement wall, a ring of metal posts or other suitable materials for forming the barrier 4. The parking lot 1 has multiple vehicle entrances 2 and a pedestrian entrance 3. The vehicle entrances 2 are not obstructed and a shopping cart 5 could be easily removed from the parking lot 1. The pedestrian entrance 3 is obstructed by the post barrier 4 such that the removal of the shopping cart is difficult.
FIG. 2 shows how the post barrier 4 is formed such that the removal of the shopping cart 5 at the pedestrian entrance 3 is inhibited. The shopping cart has wheels 27 which will be discussed below.
FIG. 3 shows one of multiple embodiments of the invention of the instant applicant constructed to allow the passage of a motor vehicle through the vehicle entrance 2, with minimal obstruction to movement of the vehicle, but at the same time obstructing the movement of the shopping cart 5 at the vehicle entrance 2. FIG. 3 shows the vehicle entrance having a water trap 6. The water trap 6 has ramps 7 on both sides to lower the roadway 9. The water trap 6 contains a pool of water 8. A person removing the shopping cart 5 from the parking lot 1 would have to traverse the pool of water 8 to remove the cart 5. The pool of water 8 provides a deterrent to the removal of the shopping cart 5 but at the same time minimally interferes with the motor vehicle traversing the vehicle entrance 2.
FIG. 4a shows a vehicle entrance 2 formed of a roadway 9 having a surface 26. The surface 26 of the roadway 9 is constructed in such a way that the wheels of the motor vehicle can easily pass over the roadway 9 but that the wheel 27 of the shopping cart 5, shown in FIGS. 2 and 4b, would get stuck in the surface 26 of the roadway 9 making the removal of the shopping cart 5 a tedious task. The surface 26 can be formed of various geometric shapes or objects as shown in FIGS. 4b-4f. FIG. 4b shows the surface 26 of the roadway 9 constructed with a block surface 10. The block surface 10 is formed of blocks 11 spaced apart a distance D and having a height H to allow vehicle traffic but to interfere with the movement of the wheels 27 of the shopping cart 5. In an alternative, FIG. 4c shows the roadway 9 formed with a sinusoidal surface 12. The sinusoidal surface 12 is configured with wave forms 28 spaced apart a distance D' and having a height H' to allow vehicle traffic but to interfere with the movement of the wheels 27 of the shopping cart 5. In another alternative, FIG. 4d shows the surface 26 of the roadway 9 formed with a tube or pipe surface 13. The tube surface 13 is constructed with metal tubes 25 spaced apart a distance D" and having a height H" to allow vehicle traffic but to interfere with the movement of the wheels 27 of the shopping cart 5. FIGS. 4e and 4f show another alternative to the surface 26 of the roadway 9.
The surface 26 of the roadway 9 can be formed in a v-shaped configuration 14. The v-shaped configuration 14 is constructed with v-shaped blocks 29 laid across the roadway 9. The v-shaped blocks are spaced apart a distance D'" and having a height H'" to allow vehicle traffic but to interfere with the movement of the wheels 27 of the shopping cart 5. It is clear that many shapes can be substituted for the v-shaped configuration 14 as long as they inhibit the movement of the wheels of the shopping cart but minimally inhibit the movement of the vehicle. The heights H, H', H" and H'" are greater than a radius of the shopping cart wheel 27. The distances D, D', D" and D'" between the geometric objects are greater than a diameter of the shopping cart wheel 27.
FIGS. 5a and 5b show the vehicle entrance 2 being enclosed by a water tunnel 15. The water tunnel 15 is composed of a housing 16 containing multiple shower heads or sprinklers 17 and multiple motion sensors/controllers 18. As a moving body such as the vehicle enters the housing 16 of the water tunnel 15, the motion sensors/controllers 18 detect the movement and activate the shower heads 17 causing a stream of water 30 to be ejected within the confines of the housing 16. The stream of water 30 does not interfere with the movement of the vehicle but does provide a deterrent to an individual thinking of removing a shopping cart from the parking lot 1. In an alternative embodiment, the housing 16 could contain an automatic car wash.
FIG. 6a shows the vehicle entrance 2 having a ramp unit 19. The ramp unit 19 extends a height HT above an exit road 23 such that the removal of the shopping cart requires overcoming the height HT at a raised ramp end 24. The ramp unit 19 has a housing 20. Articulatingly connected to the housing 20 is a roadway 21. When an automobile drives onto the roadway 21, the weight of the automobile lowers the roadway 21, as shown in FIGS. 6b and 6c, such that roadway 19 is flush with the exit road 23. The ramp unit 19 is calibrated as requiring a weight greater than that of a person and the loaded shopping cart in order to lower the ramp unit 19. The ramp unit 19 has a movable, sensor controlled, counter weight unit 22 which opposes the weight of the vehicle. When the weight of the automobile is no longer sensed by the counter weight unit 22, the counter weight unit 22 moves and acts upon the roadway 21 such that it automatically raises the roadway 21 to its raised position as shown by the height HT.
|
In combination with a barrier for retaining shopping carts around a parking lot, a vehicle entrance includes a roadway having a surface and a plurality of geometric objects protruding upward from the surface for entrapping a wheel of a shopping cart when the wheel of the shopping cart is pushed over the geometric objects. Another embodiment includes a water trap in the roadway. All of the embodiments of the invention help retain shopping carts within a confined area such as a parking lot.
| 4
|
BACKGROUND OF THE INVENTION
The invention relates to a process for the production of high-tenacity technical-grade yarns, particularly of polyamide and polyester, having a low reference elongation, by spin-drawing, in which the filaments extruded from a spinneret are cooled in a cooling zone by being exposed to a stream of air, are passed over a preparation device, and then passed directly over several sets of rolls to be drawn, in at least one draw field, between at least two of the sets of rolls. The filaments are subjected to a temperature of at least 160° C. in at least one set of rolls and, finally, are passed over a set of let down rolls prior to being wound up at a speed of at least 2,200 meters/min.
In order to use the yarns for straps, belts and layer webs for textile fabrics, the heat shrinkage of the yarns should be low and, at the same time, the lowest possible reference elongation should be sought.
Feed yarns made from polyamide or polyester will undergo a change in textural condition during the various process stages. In the article, "Spinning Process and Crystal Structure of Perlon," Angewandte Chemie, Vol. 74, 1962, No. 13, p. 566, it is noted that a yarn drawn directly during the spinning operation passes through crystallization stages that are different from those of a yarn made on a drawing machine from staple stock.
Furthermore, at higher production speeds, a uniform temperature transfer to the yarn becomes more difficult. Higher speeds also translate into shorter contact times between the yarn and the heating systems, so that the heating of the yarn to predetermined temperatures becomes more of a problem. However, it is the temperature and structural properties which largely determine the attainable qualitites of textile yarn.
The technical and economical value of the spin-draw process, however, can be rated as positive only if, at the same time, the textile yarn qualities are not impaired and even improved.
From German published patent application No. 1,435,467, a process for spin-drawing of polyester (PES) at speeds of 1000 to 4000 m/min. is known. The process disclosed therein utilizes a temperature treatment of the filaments at predetermined residence times prior to the drawing operation. However, no process parameters for drawing and thermal stabilizing, such as temperature control and yarn tensions, are disclosed. In applying the teachings of this reference, low reference elongation values were generally obtained in combination with high tenacities and low elongation or low shrinkage values.
U.S. Pat. No. 3,452,131 and German published patent application No. 1,912,299 disclose processes for the spin-drawing of polyamide filaments in which additional draw means are employed. In the case of a steam jet, there is a danger of simultaneous wetting or moistening because of the low yarn temperature, a fact which is well known, and which has a substantial influence on the glass transition point. At high speeds, i.e., short residence times, this expedient may lead to complications in the drawing process. The use of a stationary draw pin is known from conventional methods, but is recommended only for moderate speeds. At high speed production, the friction is too strong causing the increase in temperature of the pin to be uncontrollable. Both of these references fail to make any recommendations as to how low reference elongations might be attained.
If, in spin-drawing, the cooled filaments are drawn at high speeds on stationary draw means, and if, for the purpose of increasing productivity, more than one strand of filaments is processed at one station, there is danger of non-uniform draw action, particularly among the yarns at different stations.
U.S. Pat. No. 3,790,995 discloses a process for spin-drawing of polyester at speeds of at least 1800 m/min, in which the feed and draw rolls are provided with a surface roughness to allow slippage of the continuous filaments over a number of wraps on the rolls. Such filament slipping leads to a high degree of friction at high production speeds, and the frictional heat generated causes an uncontrollable increase in temperature of the rolls. No teaching can be derived from the given parameters of this reference as to how to achieve a low reference elongation.
U.S. Pat. No. 4,003,974 discloses a process for spin-drawing of polyester, in which the filaments are thermally stabilized or "set" at 225°-250° C., and are allowed to relax at a tension of 0.09-0.15 g/den, with a speed given, by way of example, as 1.829 m/min. It does not teach an operation at higher speeds. The given temperatures could not be further increased because temperatures in the range of the polymer melting point cause the filaments to stick to the rolls. An increase in the residence time of the filaments on heated rolls has limits for mechanical reasons. Relaxation tensions of the given range generally cause a shrinkage of the filament to an extent which necessarily is offset by a high and undesired reference elongation. As relaxation tensions of less than or equal to 0.2 g/dtex are applied to the heated, thermally set filaments, either between the heated draw rolls, or between the heated relaxation roll and the windup unit operating at different speeds, a severe yarn shrinkage occurs which, while yielding a lower heat shrinkage value, also results in a high reference elongation value. In the process disclosed, the heated, thermally fixed yarn is passed over the unheated relaxation or let down roll onto the windup or, if the last named roll was used for the thermal setting operation, directly onto the windup. The yarn is not allowed to cool off sufficiently fast and, therefore, has a tendency to shrink while under low tension. The result is an increase in the reference elongation. This becomes more critical with higher production speeds, and, thus, lower residence times of the yarn.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a process for spin-drawing of high tenacity, technical-grade yarns which, notwithstanding high production speeds, produces yarns of high industrial quality having a low break elongation and low reference elongation, or a low heat shrinkage and low reference elongation.
The object of the present invention is achieved through the following steps:
(a) The set of rolls positioned in advance of the minimum of one draw zone is heated to a constant temperature between T G -20° C. and T G +65° C., with T G being the temperature of the glass transition point, and the filaments are drawn without the use of additional stationary draw means;
(b) The sets of rolls following the minimum of one draw zone have a temperature in excess of 110° C., and the tension of the yarn after leaving these roll systems is not less than 0.2 g/dtex;
(c) The residence time of the yarn in the let down roll system is selected to be at least 0.2 sec.;
(d) The windup speed of the yarn does not decrease by more than 2.5% from the peripheral speed of the let down roll system; and
(e) The temperature of the system of let down rolls is adjusted to a value of less than or equal to 110° C.
The yarn packages thus produced can be used directly on a thread machine without requiring any additional process steps. Plying and twisting of the yarn will produce cord for further processing in textile manufacture.
By combining the two operational steps of spinning and drawing, the coupled spin-drawing process saves a separate operation, and, by employing high windup speeds, it becomes extremely economical.
The drawn feed yarns meet high quality requirements because of their predictable technical performance in the manufacture of woven and other textiles.
Feed yarn used in the manufacture of tire cord requires, in addition to other properties, first and foremost, a high degree of tenacity, low break elongation and low reference elongation. These conditions are also met by the product of the present invention.
The characteristic features of the invention define for each process step a specific treatment of the yarn, as determined by yarn temperatures, yarn residence times and yarn tensions, so that a combination of the inventive features will yield the desired yarn characteristics. The heating of the filament yarn on the rotating rolls is sufficient to permit a precise adjustment of the temperature necessary for the drawing operation and the thermal treatment. The upper limit of temperatures of greater than or equal to 160° C. employed in the thermal setting step of the yarn is defined by the instant the yarn adheres to the rolls, i.e., when the temperature range of the polymer melting point has been reached. Hence, the maximum possible temperature is higher for polyester than it is for polyamide-6. In conventional processes, the yarn then may pass into a low tension zone of less than or equal to 0.2 g/dtex thereby causing a considerable shrinkage of the yarn, depending on the yarn temperature. Such relaxation of the yarn is in part desired because the tendency of the finished yarn to shrink in hot air is thereby lessened, i.e., a yarn is obtained having a low dry heat shrinkage value. In conventional processes, relaxation tensions of less than or equal to 0.15 g/den are employed to obtain dry heat shrinkage values (at 160° C.) of less than or equal to 4%. This, however, is accompanied by a strong increase in reference elongation, which is undesirable for technical-grade material. Consequently, it is necessary to limit the relaxation tension to greater than or equal to 0.2 g/dtex to obtain a low reference elongation, along with low dry heat shrinkage.
To eliminate relaxation to a large extent, tensions of greater than or equal to 1.0 g/dtex are employed, so that yarns having a low break elongation and low reference elongation are obtained. If the let-down roll is heated for the thermal stabilization step of the yarn, the heated yarn, upon leaving the let-down roll, directly enters a region of low tension, which is usually adjusted at less than 0.2 g/dtex prior to the windup operation and a stable build-up of the yarn package. However, since the yarn temperature is much higher than 110° C., the reference elongation will be strongly increased, as in Example 6 herein.
Even if the let-down roll is not heated, the yarn heated on the roll effecting the thermal stabilization transfers considerable quantities of heat to the let down roll. At medium speeds of less than 2,200 m/min and thermal setting temperatures of 190°-250° C., conventional let down rolls will heat up to temperatures of 55°-85° C. Increasing the speed may cause the roll temperature to rise up to 115° C. The yarn leaving the roll then has a relatively high temperature and experiences a strong and undesirable shrinkage. If, however, the let rolls are cooled, the yarn temperature will decrease accordingly and the tendency of the yarn to shrink is curtailed to a large extent.
While the heating of the yarn by contact with rolls at high production speeds if difficult, the cooling carried out under the conditions according to the present invention has produced a positive effect. The preferred let down roll system consists of at least one driven roll and may include additional rolls, not driven and freely mounted, and a stretch or zone of free space between the rotating aggregates. The flow of air, especially in the zone of free space, produces a special cooling effect if the total residence time is at least 0.2 sec.
The speed ratio between the let-down roll and the windup device directly determines the shrinkage of the yarn and, in combination with the associated yarn tension, also the shrinkage tendency of the yarn on the bobbin. For these reasons, the speed ratio must not exceed the specified limit. Under conventional conditions, the ratio is in excess of 2.5% with a usual windup tension of less than 0.2 g/dtex. However, only with yarn cooled as proposed by the present invention can low ratios be realized. Such yarns then have a lower shrinkage propensity and, hence, a lower value of the reference elongation.
The process of the invention may be carried further to best advantage through the following steps:
(1) the filaments extruded from the spinneret are passed through a heat zone before they enter the cooling zone;
(2) for the preparation of the filaments, an oil having less than 5% by weight of water, particularly a water-deficient oil, is applied to the filaments in the absence of heat;
(3) the let down roll system is unheated and is provided with cooling means enabling a surface temperature of less than or equal to 25° C.;
(4) in the proximity of the set of let down rolls, a cooling zone is provided having a temperature of less than or equal to 25° C. to enable a heat exchange with the yarn;
(5) the residence time of the yarn in the cooling zone is adjusted to be at least 0.4 sec;
(6) the set of let-down rolls is positioned in a closed environment, the temperature of which is maintained by forced cooling at or below 45° C.;
(7) the tension of the withdrawn yarn is not less than 0.5 g/dtex;
(8) the set of rolls positioned downstream of the drawing zone has a temperature of at least 160° C. and the yarn tension of the withdrawn yarn is not less than 1.0 g/dtex; and
(9) the yarn is passed through a whirling unit prior to being wound up in order to improve the closing off of the yarn end.
The process of the present invention will be described in further detail with reference to a preferred embodiment illustrated in FIGS. 1-3 and several process examples. The characteristics of all examples are summarized in the table at the end of the description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration of an apparatus for use with a preferred embodiment of the process according to the present invention.
FIG. 2 is a graph showing the relation between reference elongation (ordinate) and heat shrinkage (abscissa).
FIG. 3 is a graph showing the relation between reference elongation (ordinate) and break elongation (abscissa).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a spinneret 1 has a multiplicity of orifices or holes in a spinning block 2. Filaments 3, which subsequently form continuous filament strands or yarn are extruded from the spinneret 1 and are passed through a heater 4 enclosing a heating zone 4a. The filaments 3 then pass through a blow duct 5, enclosing a cooling zone 5a, in which the filaments are cooled by an air current blowing in the direction of the arrows 6.
Below the blow duct 5, a preparation system 7 is arranged by which a finish or preparation is applied to the filaments. Following is a first set of rolls 8 ("first duo"), which may be designated a feed roll system and which is heated to a temperature of T G -20° C. to T G +65° C., based on the glass transition point. The continuous filaments 3 are passed over this roll system 8.
The first roll system 8 is followed by a second roll system 9 ("second duo"), which may be termed a draw roll system, and over which the filaments 3 also are passed. Located between the two roll systems 8 and 9 is a draw zone "V." The roll system 9 consists of rolls which have a temperature of more than 110° C. and the strands of filaments 3 leaving this roll system have a yarn tension of at least 0.2 g/dtex. In the case where only a single roll system 9 is provided, subsequent to the draw zone, as shown in FIG. 1, this roll system is additionally and simultaneously adapted to fulfill the condition that the respective rolls have a temperature of at least 160° C.
Following the roll system 9 is a let-down roll system 10 ("third duo") which, like the roll systems 8 and 9, is in the form of a "duo," i.e., it consists of two rolls 10a and 10b. In the region of the roll system 10, a cooling zone 11 is formed which is located inside a roll box or casing 12 enclosing the rolls 10a and 10b. The arrangement of the rolls 10a and 10b is such that the residence time of the strands of filaments 3 in the let-down roll system 10 and the cooling zone 11, respectively, is at least 0.2 sec. The temperature of the let-down roll system 10 is no greater than 110° C.
Finally, a windup unit 13 is provided for the takeup of the yarn 3. The peripheral speed of the windup 13, at the point of first contact with the yarn, decreases by no more than 2.5% from the peripheral speed of the let-down roll system 10.
The present invention can be better understood with reference to the following examples. Characteristic values used in the following examples are based on the following measuring procedures: Tenacity and break elongation were measured on conventional tensile testing equipment. The reference elongation was determined from the load/extension diagram of the yarn. The reference elongation is defined as the elongation of the yarn at a force of 4.85 g/dtex.
EXAMPLE 1
Polyamide-6 having a relative viscosity n rel of 3.3 was melted at 293° C. and was passed at a rate of 247 g/min through two spinneret plates each having 140 holes, each hole having a diameter of 0.4 mm.
The extruded filaments were passed through a 600 mm long heater having a wall temperature of 300° C., and were subsequently passed through a 1100 mm long blow duct in which they were cooled by a transversely directed air current blowing at a speed of 0.8 m/sec.
Thereafter, a 99% preparation was applied to the filaments by means of cold rolls, so that the oil film on the finished feed yarn was 1.1%.
The continuous filaments were then drawn between two sets of rolls (duos) at a temperature of 90° C. and a draw ratio of 1:5.1, were thermally stabilized on the second duo at a temperature of 195° C., were passed over the unheated let-down roll system at a temperature of 45° C. and a speed of 2,805 m/min, and then through a cooling zone having an ambient temperature of 40° C., and were finally wound up at a speed of 2,740 m/min.
Disregarding the permissible amount of shrinkage between duo 2 and duo 3, the thermal setting tension was 2.1 g/dtex, the windup tension was 150 g, and the denier of the wound up yarn was 940/140 dtex. The residence time of the yarn in the let-down or relaxation roll system was 0.72 sec.
No disturbances occurred in the drawing operation. The yarn characteristics are reported in Table 1. A high tenacity was obtained as well as a low break elongation and a low reference elongation.
EXAMPLE 2
Polyamide-6 filaments were extruded and spin-drawn under the same conditions as in Example 1, except that the temperature of the let-down roll system was adjusted to 60° C. and the cooling zone temperature was 32° C. The values reported in Table 1 show a further improvement in the reference elongation. The tenacity was somewhat lower and the break elongation was slightly higher than in Example 1.
EXAMPLE 3
Polyamide-6 filaments were extruded and spin-drawn under the same conditions as in Example 2, except that two pairs of rolls operating at the same speed were used as the let-down roll system. The pair of rolls, first engaged by the filaments, had a temperature of 60° C., the second pair of rolls had a temperature of 34° C., and the cooling zone had a temperature of 23° C. The residence time of the yarn in this system was 2.7 sec. There were no difficulties during the drawing operation. The yarn showed a low break elongation and a low reference elongation coupled with a high tenacity.
EXAMPLE 4
(Comparison Example)
Polyamide-6 filaments were extruded and prepared under the same conditions as in Example 1. The filaments were drawn between two sets of rolls (duos) at a temperature of 90° C. and a draw ratio of 1:5.1. They were allowed to thermally set on the second duo at a temperature of 195° C., were passed over unheated let down rolls operating at a speed of 2,805 m/min, and finally were wound up at a speed of 2,675 m/min.
The temperature of the let-down rolls adjusted itself after a short initial period of a few seconds to a surface temperature of 112° C. The residence time of the yarn on these rolls was 0.15 sec. Disregarding the permissible amount of shrinkage occurring between duo 2 and duo 3, the setting tension was 2.1 g/dtex. The windup tension was 150 g. The finished yarn thus produced exhibited a strong shrinkage propensity during the windup which had an adverse effect on the buildup of the yarn package. The yarn showed a low tenacity and a higher break elongation than in Example 1. The reference elongation was substantially higher than in the previous examples.
EXAMPLE 5
Polyamide-6 having a relative viscosity n rel of 2.8 was melted at 284° C. and was extruded at a rate of 247 g/min through a spinneret plate with 140 holes, each hole having a diameter of 0.4 mm. The extruded filaments were passed through a 1700 mm long blow duct in which they were cooled by a transversely directed current of air blowing at a speed of 0.6 m/sec. Thereafter, a 99% preparation was applied to the filaments by cold rolls, so that the oil film on the finished yarn was 0.8%.
The filaments were then drawn between two sets of rolls (duos) at a temperature of 90° C. and a draw ratio of 1:5.1. On the second duo, the continuous filament strands were allowed to thermally set, were passed over the unheated let-down roll system operating at a speed of 2,805 m/min, and were finally wound up at a speed of 2,790 m/min. The let-down rolls were water cooled and maintained at a temperature of 23° C. The cooling zone had an ambient temperature of 20° C. The residence time in the let-down roll system was 1.6 sec. At a relaxation tension of 0.22 g/dtex between duo 2 and duo 3 and a windup tension of 150 g, a denier of 940/140 dtex was obtained.
The yarn thus produced had a dry heat shrinkage of 3.5% and a reference elongation of 8.5%. The break elongation was about 19.8%.
EXAMPLE 6
(Comparison Example)
Polyamide-6 filaments were extruded and spin-drawn under the same conditions as in Example 5, except that the let-down roll was adjusted to a temperature of 195° C., the yarn residence time was 0.15 sec., and the windup speed was 2,635 m/min.
While the yarn thus obtained showed a dry heat shrinkage of 3.7%, which is comparable to the result of Example 5, it had a substantially higher reference elongation of 12%. The break elongation of 24% was clearly higher.
EXAMPLE 7
Polyester having a relative viscosity n intr of 0.68 was melted at 305° C. and was extruded at a rate of 307 g/min from two spinneret plates, each having 192 holes, each hole having a diameter of 0.4 mm. The extruded filaments were passed through a 1700 mm long blow duct in which they were cooled by a transversely directed stream of air flowing at a speed of 0.6 m/sec. Thereafter, a 99% preparation was applied to the filaments by cold rolls, so that the oil film of the finished yarn was 0.7%.
The filaments were then drawn between two sets of rolls (duos) at a temperature of 115° C. and a draw ratio of 1:6.1. On the second duo, the filaments were allowed to thermally set at a temperature of 220° C., were then passed over the unheated let-down roll system at a temperature of 45° C. and a speed of 3,050 m/min, and through the cooling zone at a temperature of 38° C., and were finally wound up at a speed of 2,990 m/min.
With a permissible amount of shrinkage between duo 2 and the let-down roll system, with a relaxation tension of 0.2 g/dtex and a windup tension of 170 g, a yarn of 1100/192 dtex denier was obtained. The residence time of the yarn in the let-down roll system was 0.22 sec. No disturbances occurred during the drawing operation. The dry heat shrinkage was 3.5%, the reference elongation was 7.6%, and the break elongation was about 13.5%.
In a subsequent run, the permissible amount of shrinkage between duo 2 and the let-down roll system was varied, all other conditions remaining equal. The setting tension increased to 1.2 g/dtex.
By this modification of the process, it is possible to obtain yarns having the desired reference elongation, up to about 5%, and a low break elongation, as is shown in FIG. 2, in which the abscissa represents the dry heat shrinkage and the ordinate represents the reference elongation, each in percentage. It will be noted, however, that, with low reference elongations, the dry heat shrinkage increases. In FIG. 3, the abscissa shows the break elongation and the ordinate shows the reference elongation, each in percentage. The graphs illustrate Example 7, i.e., they are representative of polyester.
EXAMPLE 8
(Comparison Example)
Polyester filaments were extruded and spin-drawn under the same conditions as in Example 7, except that the unheated let-down roll system, after an initial period of a few seconds, heated itself up to a temperature of 115° C.
With about the same dry heat shrinkage value as in Example 7, a substantially higher reference elongation of 9.9% was obtained. The tenacity value was clearly lower.
TABLE 1__________________________________________________________________________Example No. 1 2 3 4 5 6 7 8Invention/Comparison Invention Invention Invention Comparison Invention Comparison Invention Comparison__________________________________________________________________________Polymer PA-6 PA-6 PA-6 PA-6 PA-6 PA-6 PES PESDenier (dtex) 940/140 -- -- -- 940/140 -- 1100/192 --Speed (m/min)1st down rolls 10 2,805 2,805 2,805 2,805 2,805 2,805 3,050 3,050windup unit 13 2,740 2,740 2,740 2,675 2,790 2,635 2,990 2,925Draw ratio 1: 5.1 5.1 5.1 5.1 5.1 5.1 6.1 6.1Admissible shrinkage % 0 0 0 0 6 6 5 5Temp. roll system 8 °C. 90 90 90 90 90 90 115 115roll system 9 °C. 195 195 195 195 195 195 220 220let-down roll 10 °C. 45 60 60/34 112 23 195 45 115roll box °C. 40 32 23 23 20 20 38 38Setting tension g/dtex 2.1 2.1 2.1 2.1 0.22 0.22 0.2 0.2Windup tension g 150 150 150 150 150 150 170 170Residence time of the yarn 0.72 0.72 2.7 0.15 1.6 0.15 0.22 0.22in the let down system sec.Yarn characteristics:reference elongation % 8.3 8.0 7.0 10.0 8.5 12 7.6 9.9break elongation % 18.4 19.0 17.8 22 19.8 24 13.5 16tenacity g/dtex 9.0 8.5 9.1 8.3 7.8 7.2 7.7 6.9Dry heat shrinkage % 7.9 7.8 8.2 8.0 3.5 3.7 3.5 3.6__________________________________________________________________________
|
An improved process for the spin-drawing of high-tenacity, technical-grade yarns is disclosed. The process produces yarns of high industrial quality having a low break elongation and low reference elongation, or a low heat shrinkage and low reference elongation. The process is especially suitable for yarns of polyamide and polyester.
| 3
|
This application is a division of Ser. No. 09/623,341 filed on Dec. 14, 2000.
BACKGROUND OF THE INVENTION
The inventions disclosed herein concern improvements in wheeled luggage and associated devices. Conventionally, wheeled luggage includes one or more wheels integral with the frame of the luggage. A retractable or foldable handle is provided to allow the luggage to be pushed or pulled along the ground. This alleviates the need for the user to carry and thus support the entire weight of the luggage.
In order to provide further stability and support to the luggage, a retractable panel has been provided which includes an extra wheel or two. The retractable panel is automatically deployed by pulling up on the handle. The extra wheels can be casters in order to increase the maneuverability of the luggage. Examples of such items are disclosed in U.S. Pat. Nos. 5,519,919 and 5,568,848.
One major disadvantage of the devices disclosed in the above two mentioned patents is that the retractable panel including the extra wheel or wheels is automatically deployed upon pulling up of the handle. Thus, even when the extra stability and support of the extra wheel(s) is not needed, the retractable panel is deployed. There is no way to use the luggage with the handle in an extended state while at the same time not deploying the retractable panel.
What is needed, therefore, are improvements in wheeled luggage which overcome the above noted disadvantages of the prior art as well as other improvements in the detent systems for the handle, the caster disposed on the retractable panel and pushbutton mechanisms.
SUMMARY OF THE INVENTION
The luggage article of the invention satisfies the above-mentioned needs as well as others. The luggage article includes a storage compartment and first rolling means projecting from the storage compartment. A wheeled panel mechanism is provided which includes a pivotably mounted panel, the panel having second rolling means. Operatively associated with the wheeled panel mechanism is a handle which is movable between a retracted position and an extended position. The luggage article finally includes means for selective deployment or nondeployment of the second rolling means when the handle is moved from the retracted position to the extended position. In this way, the user has a choice to use or not use the second rolling means even when the handle is in an extended position.
An improved detent means and improved caster system for the second rolling means are also disclosed. A wheeled panel mechanism itself for use not only with luggage but also other articles, such as carts, dollies and baby carriages is also provided. An improved pushbutton device is also disclosed.
BRIEF DESCRIPTION OF THE DRAWING
A full understanding of the invention can be gained from the following detailed description of the invention when read in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a luggage article, partially cutaway, showing the wheeled panel mechanism of the invention with the handle in a retracted position and the wheeled panel mechanism in a nondeployed position.
FIG. 2 is a perspective view of a luggage article, partially cutaway, showing the handle in an extended position and the wheeled panel mechanism in a nondeployed position.
FIG. 3 is a perspective view of a luggage article, partially cutaway, showing the handle in an extended position and the wheeled panel mechanism in a deployed position.
FIG. 4 is a partially exploded perspective view showing the wheeled panel mechanism.
FIG. 5 is an exploded perspective view of the handle means.
FIG. 6 is a perspective view, partially cutaway, of the handle means in the extended position.
FIG. 7 is a view similar to FIG. 6 only showing when the pushbutton is pushed and the detent is moved.
FIG. 8 is a view similar to FIG. 7 only showing the handle being pushed down towards the retracted position.
FIGS. 8A and 8B are cross-sectional views of another embodiment of the pushbutton.
FIG. 9 is a perspective view of the wheeled panel mechanism by itself in its deployed state.
FIG. 10 is a view similar to FIG. 9 only showing the wheeled panel mechanism being partially closed.
FIG. 11 is a view similar to FIGS. 9 and 10 only showing the wheeled panel mechanism being fully closed.
FIG. 12 is a cross-sectional view taken along line 12 — 12 of FIG. 1 .
FIG. 13 is a cross-sectional view taken along line 13 — 13 of FIG. 2 .
FIG. 14 is a cross-sectional view similar to FIGS. 12 and 13.
FIG. 15 is a cross-sectional view taken along line 15 — 15 of FIG. 3 .
FIG. 16 is a side elevational view, partially in section, showing the caster of the invention in a storage position.
FIG. 17 is a side elevational view, partially in section, of a caster of the invention bearing on a surface.
FIG. 18 is a side elevational view, partially in section, of the caster with its wheel lifted off of the ground.
DETAILED DESCRIPTION
Referring more particular to FIGS. 1-3, the basic concept of one of the inventions disclosed herein will be discussed. A luggage article 20 is shown. The luggage article 20 includes, in this embodiment, a unitary frame or gusset 22 made of plastic. A fabric covering (not shown) can be used to create the storage compartment 24 for the luggage article 20 . It will be appreciated that the invention herein can also be used with so-called “hard-sided” luggage, in addition to the soft-sided (or gussetted) luggage shown. Broadly, the luggage article 20 includes handle means 26 which includes a pair of spaced apart male tubing members 28 and 30 which are joined together at the top by a gripping portion 32 . The male tubing members 28 and 30 engage into female tubes 40 and 42 . It will be appreciated that the male tubing members 28 and 30 and the gripping portion 32 can be moved from a retracted position, as shown in FIG. 1 to an extended portion as shown in FIGS. 2 and 3.
FIG. 2 shows the luggage article 20 with the handle means 26 in an extended position. In this position, the luggage article 20 can be rolled along a surface by means of first rolling means shown here as a pair of spaced apart wheels 44 and 46 . The design and positioning of these wheels are well known to those skilled in the art.
Referring to FIG. 3, the luggage article 20 is also shown with the handle means 26 extended. A wheeled panel mechanism 50 , which will be discussed in much greater detail below, is provided which includes second rolling means, in this case unique and novel casters 52 and 54 , mounted by means of a caster support bar 55 to a pivotably mounted panel 56 of the wheeled panel mechanism 50 (see FIG. 3 ). The wheeled panel mechanism 50 provides greater support for the luggage article 20 and allows the luggage article 20 to be more easily pushed by the user.
In accordance with the invention, the luggage article 20 includes means for selective deployment or nondeployment of the second rolling means 52 , 54 of the luggage article when the handle means 26 is moved from the retracted position (FIG. 1) to the extended position (FIGS. 2 and 3 ). The advantage of the luggage article 20 of the invention is that, in contrast to prior art luggage articles, the user has a choice of whether or not to deploy the wheeled panel mechanism 50 when the handle means 26 is extended. Thus, for example, when the user only needs to use the first rolling means 44 , 46 , such as when the load is light or when it is desired to move the luggage article 20 in close quarters, the wheeled panel mechanism 50 does not have to be deployed when the handle means 26 is extended. Conversely, when the wheeled panel mechanism 50 is really needed, such as when the load is heavy or when it is desired to stack other items on the luggage article 20 , the wheeled panel mechanism 50 can be deployed to create a luggage cart.
Referring now more particularly to FIGS. 4-15, one embodiment of the invention for accomplishing the broad concept of the invention will be discussed. It will be appreciated, however, that the invention can encompass other means, not shown, for allowing the selective deployment or nondeployment of the second rolling means (casters 52 and 54 ) which are mounted to the pivotably mounted panel 56 .
Referring now specifically to FIG. 4, with reference generally to FIGS. 1-3, the wheeled panel mechanism 50 is preferably a modular component which can be attached separately to an existing luggage article. A framing member 60 is attached to the female tubing members 40 and 42 . The wheeled panel mechanism 50 is then attached to the framing member 60 and secured thereto by fastening means, such as rivets 63 , 64 , 65 and 66 . The construction and operation of the wheeled panel mechanism 50 will be discussed in detail below.
Referring now to FIGS. 5-7, the handle means 26 will be explained in greater detail. The handle means 26 includes the male tubing members 28 , 30 which are slidingly engaged in the female tubing members 40 , 42 . The female tubing members 40 , 42 include openings 40 a , 42 a and longitudinal slots 40 b , 42 b . The purpose of the longitudinal slots 40 b , 42 b will be explained below. The free end of each of the male tubing members 28 and 30 encloses the detent housing 70 , 71 which contains the detent 72 , 73 of the invention. The detent 72 , 73 includes a channel 74 , 75 and a rounded opening 76 , 77 . Cable 78 , 79 has one end 78 a , 79 a connected to the detent 72 , 73 as shown in FIG. 5 . The other end 78 b , 79 b of the cable 78 , 79 is connected to a tab 80 , 81 movably mounted to a lower portion 84 of the gripping portion 32 . The tab 80 , 81 has an engagement opening 80 a , 81 a including a sloped pilot surface 80 b , 81 b . A pushbutton 90 is provided that is movably mounted into an opening 92 in upper portion 93 of the gripping portion 32 . The pushbutton 90 has a first projection 94 with a sloped pilot surface 94 a and a second projection 95 with a sloped pilot surface 95 a . The pushbutton 90 is biased upwardly by means of spring 96 . Each of the tabs 80 , 81 includes a toothed projection portion 98 , 99 that is meshingly engaged with a round gear 100 rotatably mounted to the lower portion 84 of the gripping portion 32 .
The detent 72 , 73 has the general shape shown in FIG. 5 and includes a top flat section 102 , 103 ; a sloped section 104 , 105 ; a vertical section 106 , 107 ; a bottom flat section 108 , 109 ; a lockdown device engagement section 110 , 111 ; an intermediate horizontal section 112 , 113 and an outside vertical section 114 , 115 . A portion 120 , 121 of the detent 72 , 73 extends beyond the outer surface 122 , 123 of the male tubing members 28 , 30 .
Also provided in the female tubing members 40 , 42 are lockdown devices 130 , 131 . These lockdown devices 130 , 131 include projections 132 , 133 having a detent mechanism engagement portion 134 , 135 including a sloped pilot surface 136 , 137 which act as detent engaging portions. The lockdown device 130 , 131 includes a spring 138 , 139 . The projection 132 , 133 also includes a slider mechanism engagement portion 132 a , 133 a . The operation of the lockdown device 130 , 131 will be discussed below in further detail with respect to FIGS. 12-15.
Referring now particularly to FIGS. 6-8, the operation of the detent 72 , 73 vis-a-vis the handle 26 will be explained. In FIG. 6, the handle 26 is shown in its extended position (see FIGS. 2 and 3 ). In this position, the extension portion 120 , 121 of the detent 72 , 73 extends into the openings 40 a , 42 a in the female tubing 40 , 42 . In this position, it will be appreciated that the male tubing 28 , 30 is locked into the female tubing 40 , 42 . If it is desired to move the handle 26 to a retracted position (FIG. 1 ), the pushbutton 90 is depressed, thus rotating the detent 72 , 73 out of the openings 40 a , 42 as can be seen in FIG. 7 .
It will be appreciated that when the pushbutton 90 is depressed, the pilot surface 94 a , 95 a of the first and second projections 94 and 95 engage against the sloped pilot surfaces 80 b , 81 b of the tabs 80 , 81 thus causing the tabs 80 , 81 to move towards each other by means of toothed projection portions 98 , 99 meshingly engaging with the round gear 100 (see FIG. 5 ). This will pull the cables 78 , 79 (moving the cables in the direction of the arrow shown in FIG. 7) and thus pivot the detent 72 , 73 out of the opening 40 a , 42 a as shown in FIG. 7 . This will allow the male tubing 28 , 30 to be pushed downwardly into the female tubing 40 , 42 . Once the detent 72 , 73 clears the opening 40 a , 42 a , the pushbutton 90 can be released, and the detent 72 , 73 will contact the inner surface 40 c , 42 c of the female tubing 40 , 42 as shown in FIG. 8 . Due to the design and configuration of the detent 72 , 73 , the male tubing 28 , 30 can slide downwardly in the female tubing 40 , 42 .
FIGS. 8A and 8B show an alternate embodiment of the pushbutton mechanism. In this embodiment, a pair of camming means 140 , 141 are provided to which the cables 78 ′ and 79 ′ are attached. The pushbutton 142 includes two projections 144 , 145 which engage against the camming means 140 , 141 when pushed down, causing the camming means 140 , 141 to rotate about pivot point 146 , 147 . This in turn will draw the cable 78 ′, 79 ′ inward and thus rotate the detent, as in the embodiment shown in FIGS. 5-8. The pushbutton 142 is biased in the non-engaged position by spring 148 .
The above detent design is a unique invention in and of itself and can be used with any retractable handle for a luggage article, whether having a wheeled panel mechanism or not. In fact, the detent design can be used for any item having an extendable handle, such as a dolly or a baby carriage. However, the detent design is especially advantageous when used in connection with the unique wheeled panel mechanism 50 of the invention, as will be explained in further detail below.
The wheeled panel mechanism 50 of the invention is shown apart from the luggage article in FIG. 9 . As was explained above, the mechanism 50 is a modular component which can be attached separately to an existing luggage article or to any other carrying article such as a dolly, cart or baby carriage. The mechanism 50 is connected to a framing member 60 that is itself attached to the female tubing members 40 , 42 as was seen in FIG. 4 .
Referring now to FIG. 9, the wheeled panel mechanism 50 includes a body portion 150 , a pivotably mounted panel 56 (shown in phantom for the sake of clarity) including casters 52 , 54 mounted to caster bar 55 and linkage means 152 connecting the body portion 150 to the pivotably mounted panel 56 . The linkage means 152 consists of a first link 156 and a second link 158 . The first link 156 is pivotably mounted to the panel 56 and the second link 158 whereas the second link 158 is pivotably mounted to the body portion 150 and the first link 156 . A first spring 160 is disposed at the joining point of the panel 56 and the first link 156 and a second spring 162 is disposed at the joining point of the body portion 150 and the second link 158 . The springs will aid in the deployment of the panel 56 as will be explained below. In addition, a roller 166 is provided at the joining point of first link 156 and second link 158 .
The wheeled panel mechanism 50 further includes a slider mechanism 170 . The slider mechanism 170 includes a pair of arms 172 , 174 that extend away from a central roller 176 . The ends of the arms 172 , 174 include extension portions 177 and 178 , respectively which extended through the slots 40 b and 42 b in female tubing members 40 and 42 (not shown in FIG. 9 ).
The body portion 150 includes a pair of spaced apart rollers 180 and 182 , with central roller 166 being disposed intermediate thereof. A belt 184 has one end 184 a attached to the pivotably mounted panel 56 and a second end 184 b attached to the body portion 150 . Taking it from end 184 a , the belt 184 is threaded through an opening 156 a in first link 156 , over roller 166 and threaded back through an opening 158 a in second link 158 . From there, the belt 184 is threaded under roller 182 , under central roller 176 , over roller 180 and then over central roller 176 of the slider mechanism 170 . The belt end 184 b is then attached to the body portion.
FIGS. 10 and 11 show how the movement of the slider mechanism pivots the panel 56 so that the wheeled mechanism 50 can be placed in a nondeployed state. As can be seen in FIG. 10, once the slider mechanism 170 is moved downwardly by the detent housing 70 , 71 pushing down on the extensions 177 , 178 which extend into the female tubing 40 , 42 (as will be explained in detail with respect to FIGS. 12 - 15 ), the belt 184 is pulled by central roller thus pulling the belt 184 and drawing the first link 156 inward, causing the first link 156 and second link 158 to fold up on each other. Continuing to move the slider mechanism 170 downward will fold up flat the first and second links 156 and 158 so that they will be disposed in the body portion 150 with panel 56 overlying them, as shown in FIG. 11 .
Now that the handle 26 and the wheeled panel mechanism 50 have been explained, the cooperation therebetween in order to achieve one of the objects of the invention will now be explained with reference to the cross-sectional views shown in FIGS. 12-15 below. In these cross-sectional views the belt 184 and other parts are not shown in order to increase the clarity of the drawings.
FIG. 12 is a cross-sectional view taken along line 12 — 12 of FIG. 1, which shows the handle 26 in its retracted position and the wheeled panel mechanism 50 in its nondeployed position. As can be seen in FIG. 12, the extension 177 , 178 of the arm 172 , 174 of the slider mechanism 170 extends into the hollow female tubing member 40 , 42 through slots 40 b and 42 b and also engages against, and is locked down to the lockdown device 130 , 131 by means of the extension 177 , 178 engaging against the slider mechanism engagement portion 132 a , 133 a of the projection 132 , 133 . The slider mechanism 170 is biased against springs 138 , 139 of the lockdown device 130 , 131 .
If it is desired to extend the handle means 26 without deploying the wheeled panel mechanism 50 (FIG. 2) the male tubing 28 , 30 is merely slid upwardly in the female tubing 40 , 42 as is shown in FIG. 13 . It will be appreciated that the slider mechanism 170 remains locked down to the lockdown device 130 , 131 thus preventing the deployment of the wheeled panel mechanism 50 .
If it is desired to extend the handle means 26 and deploy the wheeled panel mechanism 50 (FIG. 3 ), the pushbutton 90 is pushed, and the detent 72 , 73 is rotated as is shown in FIG. 14 . This action will cause the detent 72 , 73 to engage against the sloped pilot surface or detent engaging portions 136 , 137 of the projection 132 , 133 and rotate the projections 132 , 133 away from the extension 177 , 178 , thus unlocking the slider mechanism 170 from the lockdown device 130 , 131 and causing it to move upwardly as shown by arrows on FIG. 14 . The combination of the springs 138 , 139 along with the springs 160 , 162 on the linkage means 152 will cause the wheeled panel mechanism to automatically deploy when the slider mechanism 170 is unlocked from the lockdown devices 130 , 131 and thus moves upwardly as is shown in FIG. 15 .
When it is desired to retract the handle 26 , the male tubing 28 , 30 is pushed downwardly which causes the detent housing 70 , 71 to engage against the extension 177 , 178 of the slider mechanism, thus moving the entire sliding mechanism downwardly until the extension is again locked down onto lockdown device (FIG. 12 ).
Referring to FIGS. 16-18, the novel and unique caster of the invention will be discussed. Referring particularly to FIG. 16, a caster 200 is shown associated with a retractable portion 202 , such as a retractable panel similar to pivotably mounted panel 56 of the wheeled panel mechanism 50 shown in FIG. 3, for example. The retractable portion 202 is shown partially in section in FIGS. 16-18 in order to illustrate the invention. The caster 200 is shown retracted into a cavity 204 of an item 205 , such as wheeled panel mechanism 50 , for storage purposes. One of the advantages of the design of the caster 200 , which will be explained in detail below, is that the caster 200 , when retracted and stored, fits better into the cavity 204 .
The caster 200 consists of a wheel 210 , a wheel frame 212 and a swivel 214 . The swivel 214 includes a rod 216 including a cross pin 217 extending therefrom into guiding means 218 formed in the retractable portion 202 . The wheel frame 212 connects the swivel 214 to the wheel 210 and is pivotably mounted to the swivel 214 by a pair of connectors 220 , 222 . Wheel 210 includes an axle 223 having each of its ends axially rotatably mounted to the wheel frame 212 , as can be seen in FIG. 17 . Retractable portion 202 also includes biasing means, in this embodiment a spring 224 , having one end secured to the wall 226 of the retractable portion 202 and having another end bearing against the top surface of rod 216 . The spring 224 biases the caster into a storage position wherein the cross pin 217 engages into the V-shaped guiding means 218 , and so that a gap 228 is formed between the swivel 214 and the bottom surface 202 a of the retractable portion 202 .
Referring now to FIG. 17, when the retractable portion 202 is moved from the storage position shown in FIG. 16 and the wheel 210 bears against a surface 230 , the entire caster 200 is pushed upwardly against the bias of the spring 224 , shown by arrow A. This, in turn, allows the cross pin 217 to move out of the V-shaped guiding means 218 . Now, the swivel 214 is able to freely rotate about its vertical axis 240 a full 360°. This is advantageous when the caster 200 bears on surface 230 in that the caster 200 can aid movement of the item on which it is disposed (such as a luggage article) in any desired direction. It will also be appreciated that the cross pin 217 prevents the caster 200 from becoming disengaged from the retractable portion 202 .
It will be appreciated that it is desired, once the retractable portion 202 is retracted for storage as shown in FIG. 16, that the caster 200 assume a predetermined position for efficient, space-saving storage. Referring to FIG. 18, once the caster 200 is lifted off of the surface 230 , the spring 224 will bias the caster 200 downwardly, as shown by arrow B, thus forcing the rod 216 and cross pin 217 downwardly. This will cause the cross pin 217 to engage against the V-shaped guiding means 218 , which will force the cross pin 217 and thus the entire caster 200 to rotate on its vertical axis 240 to the predetermined position as dictated by the construction and arrangement of the guiding means 218 and which is desired based on the design of the item and/or retractable portion to which the caster is mounted. Of course, if the caster is already in its predetermined position when the wheel 210 is lifted off of the ground, there will be no rotation of the caster 200 . In this way, whenever the wheel 210 is lifted off of the ground, the caster 200 will assume a predetermined position having a particular desired orientation for efficient storage of the caster 200 .
It will be appreciated that although the caster 200 is shown on a retractable portion 202 , the invention is not so limited and the caster design disclosed can be used on any item, having a retractable portion or not, where it is desired to use a caster having free range of motion while its wheel is on a surface, but which is desired to assume a predetermined position having a particular desired orientation when its wheel is lifted off of the surface.
Referring back to FIG. 16, it will be seen that the wheel frame 212 of the caster 200 is designed to pivot about a pivot point P in order to further efficiently store the caster 200 into the cavity 204 , as shown by arrow C.
While specific embodiments of the invention have been disclosed, it will be appreciated by those skilled in the art that various modifications and alterations to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed 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.
|
A luggage article including first rollers and selectively deployable or nondeployable second rollers. The luggage article includes a handle that is movable between a retracted position and an extended position. The user can selectively deploy or not deploy the second rollers even when the handle is in the extended position. An improved detent device and also an improved caster system are also disclosed. Also, a wheeled panel mechanism by itself for use not only with luggage but also other articles such as carts, dollies and baby carriages, is disclosed.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention contained herein relates to conductivity cells of the flow-through type having inner and outer electrodes for measuring the conductivity of fluids passing therebetween.
2. Description of the Prior Art and Objectives of the Invention
Various electrolytic conductivity cells have been conceived in the past such as set forth in U.S. Pat. No. 3,916,300 and instruments termed SOLU-BRIDGE® made by Beckman Instruments, Inc. These devices are useful in determining the conductivity of fluids such as water and are generally designed for a specific conductivity range. With manufacturers becoming increasing aware of problems associated with impure water, more and more attention is being paid to purity and as a result conductivity is being measured more often and in various stages of manufacturing processes and in raw materials. Since fluids such as water vary greatly in their conductivity, it is not uncommon for a manufacturer to maintain an inventory of conductivity cells, each for a different range of conductivity measurement.
With this background known of conventional conductivity measuring devices, the present invention was conceived and one of its objectives is to provide a conductivity cell which has an adjustable inner electrode to provide a wide range of conductivity measurements.
It is another objective of the present invention to provide a conductivity cell which is relatively simple in construction and economical to manufacturer.
It is still another objective of the present invention to provide a conductivity cell which can be simply adjusted and calibrated by a technician with little training.
Various other objectives and advantages of the present invention will become apparent to those skilled in the art as a more detailed explanation of the invention is presented below.
SUMMARY OF THE INVENTION
The aforesaid and other objectives are met by forming a conductivity cell with a housing of durable plastic such as polyvinyl chloride (PVC), polyproplyene, or other generally stable, inert plastics. Included within the housing is a cylindrical, hollow titanium alloy outer electrode and an inner, solid titanium alloy electrode which is threadably mounted with the housing. By turning a control knob positioned on the exterior portion of the inner electrode, the inner electrode can be adjustably extended into or withdrawn from the center of the hollow outer electrode thereby providing more or less surface area within the outer electrode for conductivity. A meter is connected to the inner and outer electrodes and to a temperature sensor positioned in the passageway between the electrodes for conductivity determinations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the conductivity cell of the present invention with a conductivity meter attached thereto; and
FIG. 2 is an end view along lines 2--2 expanded and shown in elevational fashion.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred form of the invention is shown in FIG. 1 and includes a housing formed from PVC and having an outer electrode formed from a titanium alloy. The inner electrode is also formed from a titanium alloy and is adjustably threaded into the housing. A knob on the exterior end of the inner electrode allows the user to adjust the conductivity measurement range by rotatably extending or withdrawing the inner electrode. A circuit in the housing allows the flow of fluid into the passageway between the inner and outer electrodes. A meter is slidably attached to the exterior end of inner electrode and is joined to the outer electrode and to a temperature sensor which provides a temperature compensation for the meter.
DETAILED DESCRIPTION OF THE DRAWINGS
Turning now to the drawings, conductivity cell 10 as shown in FIG. 1 includes an outer housing 11 which may be formed from suitable plastic such as PVC or polyproplyene. Conduit 12 has an inlet 13 whereby a hose, a fitting or otherwise can be mounted to allow fluids to enter conduit 12 and to flow through outlet 14 and into passageway 15 between inner electrode 16 and outer electrode 17. As shown on the exterior portion of inner electrode 16, are a series of threads 18 which provide adjustment as knob 19 is rotated. Seal 21 is positioned to prevent fluid leakage along the unexposed portion of inner electrode 16.
Meter 20 depicted in FIG. 1 is of the conventional wheatstone bridge type having a gauge on its face with graduations for relative conductivity measurements. As is understood, conductivity of water is generally expressed in micromhos-per-centimeter whereby a mho is defined as a reciprocal of an ohm. In water and other such fluids, the higher the resistance, the lower its reciprocal, conductivity. With increasing demands for higher and higher purity water, 10 to 20 megohm water is not uncommon and this means water with a total dissolved solids content on the order of 0.01 to 0.02 parts per million.
By using standarized solutions, conductivity cell 10 can be adjusted and calibrated to display a conductivity range of 100-200 mmho (micro mho) water or can be further adjusted to demonstrate 10-20 mmho water on its guage. Additional ranges can be calibrated by making the proper adjustment in the relative position of inner electrode 16 and outer electrode 17 and with the use of a properly calibrated fluid. As would be understood once conductivity cell 10 is calibrated then water of an unknown conductivity is tested and its conductivity is determined.
As further shown in FIG. 1, connector slide 22 is attached to the exterior portion of inner electrode 16 and is joined to meter 20 through connector line 23. Connector line 24 provides an electrical signal between outer electrode 17 and meter 20 whereas connector lines 25 and 26 join temperature sensing means 27 to meter 20, which as previous mentioned contains conventional wheatstone bridge circuitry having temperature compensation. Temperature sensing means 27 may consist of a thermoprobe, thermistor, thermometer or a thermal junction. It has been found that by placing the temperature sensing means in contact with the actual fluid to be tested, an accurate and reliable temperature compensation for the conductivity reading is assured and the temperature sensing is both fast and efficient.
FIG. 2 shows an end view of conductivity cell 10 shown along line 2--2 of FIG. 1 but as a full end elevational view demonstrating bearing 28 which is rigidly affixed to housing 11.
The illustrations and examples presented herein are for demonstrative purposes and are not intended to limit the scope of the appended claims.
|
A conductivity cell is presented having a solid inner electrode and a hollow electrode whereby the inner electrode is adjustably mounted. The adjustable feature allows the cell to be accurately calibrated for various fluids having a wide range of conductivities.
| 6
|
BACKGROUND OF THE INVENTION
The present invention relates to a de-clutch mechanism for coupling a rotatable driven load member to a secondary drive and decoupling the power drive when the primary drive is inactive, and for disconnecting the secondary drive and automatically connecting the power drive when the primary drive is actuated. The primary drive is typically a power drive while the secondary drive is ordinarily a manual handwheel drive.
While a de-clutch mechanism of the type here involved may have other uses, the mechanism is particularly suited for use in valve operators. Valve operators are power driven operating mechanisms used for opening and closing large valves. In such cases, the rotatable member which is to be driven by either the primary or secondary drive, is an internally threaded drive sleeve or nut which, when driven rotationally, moves an externally threaded valve stem in one axial direction or the other, thereby to move the valve toward its open or closed position. The drive sleeve or nut is typically driven by a worm gear driven by a power driven worm shaft.
If, for adjustment or maintenance purposes, or in the event of a power failure, or for any other reason, it is desired to rotate the drive sleeve manually, as by a handwheel, while the power is off, a de-clutch mechanism must be provided for shifting the drive from power drive to manual drive, and for returning the drive automatically from manual to power drive means when the power is available.
SUMMARY OF THE INVENTION
While many manual clutching systems have been developed, the principal object of the present invention is to provide reliable de-clutch mechanism which will allow the drive to shift into manual handwheel position and disconnect from power drive while under heavy external loads. This feature is lacking in other systems because of frictional lock. When the power comes on, the new de-clutch mechanism is effective to disconnect automatically the handwheel drive and to connect the power drive.
The foregoing object is achieved by a mechanism which requires the attendant to rotate manually a shaft to shift the clutch mechanism into handwheel drive and out of power drive. When, however, the power comes on, the de-clutch mechanism automatically disconnects the handwheel drive and shifts to power drive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view, largely in section, of a portion of a valve operating mechanism which includes a de-clutch mechanism according to the present invention.
FIG. 2 is a view, in section, looking down along the line 2--2 of FIG. 1.
FIG. 3 is a view, in section, looking up along the line 3--3 of FIG. 1.
FIG. 4 is an enlarged fragmentary view, in section, looking down along the line 4--4 of FIG. 1.
FIG. 5 is an enlarged fragmentary view of the right hand portion of the mechanism shown in FIG. 1, but showing the latch 41 in latched position rather than in unlatched position. FIG. 5a is a further enlargement of the hooked end of the latch member showing how it engages the upper cam of the clutch ring.
FIG. 6 is an elevational view looking along the line 6--6 of FIG. 5.
FIG. 7 is an exploded perspective view showing the clutch sleeve 35, the lug ring 60 (positioned below the clutch sleeve), and the camming ring 90 (positioned above the clutch sleeve.
FIG. 8 is an enlarged view looking down along the line 8--8 of FIG. 1.
FIG. 9 is a fragmentary view of a modified form of valve operating mechanism in which the handwheel shaft is disposed at right angles to the axis of the valve stem.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a power driven worm shaft 19 is driven by a motor or other form of power not shown. The worm 21 is in engagement with and drives rotationally a worm gear 22 which is spaced by spacer 222 from the drive sleeve 23. Worm gear 22 has a pair of upstanding lugs 122 adapted to engage a pair of lugs 125 which extend downwardly from a motor clutch ring 25. The motor clutch ring 25 is adapted, through a pair of detent rollers 27, to drive a cup-shaped drive ring 28 which is positioned within the motor clutch ring. The lower portion of the drive ring 28 is connected through splines 228, and aligned as by alignment key 328 to the drive sleeve 23. The drive sleeve 23 is internally threaded and is in threaded engagement with the externally threaded valve stem 20.
It will be seen from the foregoing description that when the worm shaft 19 is driven rotationally, as by a power drive, the drive sleeve 23 is driven rotationally in a corresponding manner. The drive train may be traced from the worm shaft 19 through the worm 21, worm gear 22, upstanding lugs 122, depending lugs 125, the motor clutch ring 25, the detent rollers 27, the drive ring 28, the key 328, and the drive sleeve 23. Rotation of drive sleeve 23 causes the valve stem 20 to move axially in either the upward or downward direction according to the direction of rotation of drive sleeve 23.
During motor or power drive, just described, the handwheel 70 is disconnected from the drive.
As seen in FIG. 1, the upper portion 123 of the drive sleeve 23 drives, through a key 223, a ring member 90 which is pinned, as by pin 91, to a bevel gear 92 which is in mesh with and drives a bevel pinion 95 mounted on a shaft 96. Shaft 96 may extend to and operate either a limit switch mechanism of known type or a counter mechanism, neither of which is shown, not being an essential part of the present invention.
Ring member 90 also functions as a cam ring for a purpose to be described later.
Referring now to FIGS. 1 and 5, in the event of power failure, or if for any other reason an attendent wants to operate the valve mechanism manually with the power off, the attendent manually, as by a crank or a lever not shown, rotates a pinion de-clutch shaft 40 through about 180°, in a clockwise direction as viewed in FIGS. 1 and 5. Secured to shaft 40 is the pinion 44 having a fixed number of teeth, which are engaged within the circumferential grooves 135 of a clutch sleeve 35. The configuration of clutch sleeve 35 is shown in perspective in FIG. 7.
As seen in FIG. 7, extending upwardly from the main body of clutch sleeve 35 are a pair of opposed arms 36 spaced 180° apart. Arms 36 have wider base and narrower upper end portions 37, forming between the upper end and base portions the inclined surfaces 38 which functions as cam surfaces, as will be described.
Extending downwardly from the main body of clutch sleeve 35 are a pair of opposed legs 39 spaced 180° apart. (In the actual physical embodiment, the pair of depending legs 39 are located in vertical planes which are spaced 90° from the planes of the pair of upwardly extending arms 36. However, for convenience of illustration in FIG. 1, which is a sectional view, depending legs 39 have been shown to be located in the same vertical planes as the upwardly extending arms 36. To be consistent, this same relationship has been shown in the perspective view in FIG. 7).
Positioned below clutch sleeve 35 is a lug ring 60 which is supported on the annular floor of the cup-shaped drive ring 28. The wall of lug ring 60 is provided with a pair of opposed slots 61 which are located to receive the downwardly extending legs 39 of clutch sleeve 35. Extending radially outwardly from the wall of lug ring 60 are a pair of opposed lugs 62 spaced 180° apart. These lugs 62 are located in the upper half of the lug-ring wall. In the lower part of the lug-ring wall, in the outer surface thereof, are a pair of recesses 63. These recesses 63 are adapted to receive the detent rollers 27. In FIG. 7, one of the recesses 63 has been shown. The recess 63 which is visible in FIG. 7 is actually located closer to the left slot 61 than is illustrated in the drawing. Actually, the recess 63 is only 11° removed from the slot. In its true position, the recess 63 would not have been visible in FIG. 7.
Positioned above the clutch sleeve 35 is the ring member 90 on which bevel gear 92 is pinned. Ring member 90 also functions as a cam ring, as will now be described. Ring 90 has a pair of opposed slots 93 in its annular wall 94. The interior surface of wall 94 is provided with a keyway 97 for the key 223 which connects the ring member 90 to the drive sleeve 23, as seen in FIG. 1.
Referring now to FIGS. 1, 5, 6 and 7, when the hand operated de-clutch shaft 40 is turned clockwise, as viewed in FIGS. 1 and 5, the pinion 44 lifts the clutch sleeve 35 from its lowered position shown in FIG. 1 to its raised position shown in FIG. 5. When the sleeve 35 is so raised, the upstanding arms 36 are moved downwardly through the slots 93 in the ring member 90. When this is done, the inclined cam surfaces 38 of the upstanding arms 36 engage the lower left edge of the respective slot 93 in the wall 94 of the ring member 90. The ring member 90, being keyed to drive sleeve 23, is locked against rotation in respect to drive sleeve 23. Thus, when the clutch sleeve 35 is raised, the inclined cam surfaces 38 cam the sleeve 35 angularly counterclockwise, as viewed in FIG. 7. When the clutch sleeve 35 so moves (the presently preferred magnitude of the angular movement is 11°), the depending legs 39 cause the lug ring 60 to move angularly in a corresponding manner. As viewed in FIG. 4, this shifts the recess 63 from the solid-line position to the position shown in phantom. As seen in FIG. 4, in this shifted position, recess 63 is in radial alignment with slot 128 in the drive ring 28. The pair of slots 128 are the slots which carry the pair of detent rollers 27. When the lug ring 60 is thus moved angularly in the counterclockwise direction (as viewed in FIG. 2), the radially projecting lugs 62 of the lug ring 60 compress the compression spring 65.
Referring again to FIGS. 1, 5, 6 and 7, when the clutch sleeve 35 is raised by the pinion 44, the uppermost ends 37 of the pair of upstanding arms 36 are lifted above the upper surface 98 of the annular wall 94 of the ring member 90, as seen in FIG. 6. In this raised position, the portions 37 of the arms 36 are adapted to be engaged by the depending lugs 73 of the handwheel 70. These depending lugs 73 are seen in FIG. 1.
It will be seen, after the attendent has set the de-clutch shaft 40 in handwheel position, that when the handwheel 70 is rotated manually, the lugs 73 engage the upstanding portions 37 of the clutch sleeve 35 and cause the sleeve 35 to be driven rotationally. The lower sides 137 of upstanding lugs 37 of sleeve 35 drive rotationally ring member 90 (through sides of slots 93) as seen in FIG. 6.
The ring member 90 drives, in a corresponding manner, drive sleeve 23 by means of key 223 as seen in FIGS. 1 and 9. Drive ring 28 is locked on drive sleeve 23 by means of splines 228 and key 328 and is rotated along the drive sleeve 23 as seen in FIG. 1. Thus, ring 28 must be decoupled from the motor drive when the handwheel 70 is rotated, to avoid trying to drive the motor drive manually.
When the drive ring 28 is driven rotationally by key and splines as previously described, the pair of detent rollers 27, one of which is seen in FIG. 4, move into the recesses 63 since, as previously described, the recesses 63 were shifted into radial alignment with the slots 128 in the drive ring 28 by the action of the cam surfaces 38 when the clutch sleeve 35 was raised. When the drive ring 28 is moved rotationally, the detent rollers 27 are cammed from the solid line position shown in FIG. 4 into the phantom position shown in FIG. 4 by the inclined walls of the recesses 225 in the motor clutch ring 25 which is now stationary. As viewed in FIG. 4, the lower inclined wall of the recess 225 is effective, when drive ring 28 is moved counterclockwise, to cam roller 27 into the slot 128 of the drive ring 28 and into the recess 63 of the lug ring 60. As a result, the drive ring 28 moves angularly, relative to the motor clutch ring 25.
Since ring member 90 is connected by key 223 to drive sleeve 23, it will be seen that the handwheel 70 is now effective to drive the drive sleeve 23 rotationally. As a result, the stem 20 may be moved axially in its upward or downward direction according to the direction of rotation of handwheel 70.
Referring now to FIGS. 1, 5, 6 and 8, when the de-clutch pinion shaft 40 is manually rotated clockwise to lift the clutch sleeve 35 to its upper position, in which the ends 37 of the arms 36 are in position to be engaged by the depending lugs 73 of the handwheel 70, a hook latch 41 which is pinned, as by pin 43, to portion 144 of pinion 44, is lowered from the position illustrated in FIG. 1 to the position illustrated in FIG. 5. A torsion spring 45 on pin 43, seen in FIG. 8, urges the latch 41 in a clockwise direction as viewed in FIGS. 1 and 5. Another torsion spring 47 on the de-clutch pinion shaft 40 urges shaft 40 to move in a counterclockwise direction. As a result, when the attendent stops turning the de-clutch shaft 40 in the clockwise direction to lift the clutch sleeve, the pinion shaft 40 returns counterclockwise, under the torque influence of spring 47, sufficiently to cause the hooked end 141 of the latch member 41 to be pulled upwardly into engagement with the undersurface of the lip of the motor clutch ring 25. This has the effect of locking the clutch sleeve 35 in a fixed raised position in which the portion 37 projects above the upper edge 98 of the wall 94 of the ring member 90, as is illustrated in FIG. 6.
The undersurface of the lip of motor clutch ring 25, which is engaged by the hook 141 of latch 41, is designed as a pair of cams, an upper cam 324 and a lower cam 325, as seen enlarged in FIG. 5(a). Each of these cams extends for approximately 270°, so that their end portions are overlapping. The function of these cams is to cam the hook 141 off the lip of ring 25 when the ring 25 is rotated.
Assume that, with the mechanism in handwheel drive, the power comes on. The worm shaft 19 is then driven rotationally to drive the worm gear 22. When this occurs, the motor clutch ring 25, as has already been described, is driven rotationally. Referring now to FIG. 3, assume that when the motor power went off the worm gear 22 and motor clutch ring 25 were in such rotational (angular) position that the hook 141 of latch 41 is in the relative position L1 shown in phantom at the bottom of FIG. 3. In this position, the hook 141 is pulled up against the surface of the lower cam 325. When the clutch ring 25 is driven rotationally, clockwise as viewed in FIG. 3, the surface of lower cam 325 against which hook 141 is bearing, gradually decreases, and after a rotation of about 130° the cam surface is so small that the hook 141 is pulled, by the action of spring 47, to the surface of the upper cam 324. Thereafter, as rotation continues, the hook 141 is gradually cammed off the upper cam 324 by the front wall 326 of the lower cam 325. In this example, a total rotation of the order of 310° is required to push the hook 141 off the lip of the clutch ring 25. This assumed that the hook 141 is in the relative position L1 when the motor power comes on. It is to be understood that it is the cam which moves; the hook 141 remains angularly stationary.
If, when the motor power comes on, the hook 141 is in the relative position L2, shown in phantom at the top of FIG. 3, the hook 141 is already bearing against the upper cam 324, and in such case, only about 130° of rotation of the clutch ring 25 is required to cam the hook 141 off the lip of the ring 25.
It will be understood that the positions L1 and L2 illustrated in phantom in FIG. 3, are but two of the many positions which the hook 141 could be in when the power comes on, and that the number of degrees of rotation of the clutch ring 25 necessary to release the hook latch 41, after the power comes on, ranges from 15° -20° (approximately) to 360° (approximately).
If while the attendant is manually rotating handwheel 70, the power should come on and the worm shaft 19 be driven rotationally, the motor clutch ring 25 will be driven rotationally through the engagement of worm gear lugs 122 and the motor clutch ring lugs 125. When that happens, the eccentric surface 326 of motor clutch ring 25, cams latch hook 141 off the under surface of the lip of motor clutch ring 25, as just described above. The heavy torsion spring 47 is able to rotate the pinion de-clutch shaft 40 in the counterclockwise direction, as viewed in FIGS. 1 and 5. This pulls the clutch sleeve 35 immediately and rapidly down from its raised position, thereby moving the upper end portion 37 of arms 36 from the path of the lugs 73 of the handwheel 70. In this manner, handwheel 70 is automatically disconnected from the drive when the power comes on. When this happens, the recesses 225 of the motor clutch ring 25 come into radially alignment with the slots 128, the detent rollers 27 will move out of the recess 63 and into the recess 225. This happens because the rollers are being cammed in a radially outward direction by the inclined wall of the recess 63 of the lug ring 60 which has been angularly moved by the compress spring 65 as viewed in FIGS. 2 and 4. Thereafter, the drive ring 28 will be driven by the motor clutch ring 25.
It will be seen that, by the present invention, there is provided, in combination, a rotational load member (23), a primary rotational drive (19, 21, 22), clutch means (25, 27, 28, 60) normally connecting the primary drive to the load member, a secondary rotational drive (70), manually operable de-clutch means (35, 90, 60) coupled to said clutch means and normally disconnecting the secondary drive (70) from the load member (23), said manually operable de-clutch means (35) adapted to be shifted from normal to shifted position to connect the secondary drive (70) to the drive sleeve 23 and to disconnect the motor drive, the de-clutch, means being adapted to automatically disconnect the secondary drive and connect the primary drive in response to activation of the primary drive.
It will be further seen that the manually operable de-clutch means includes latch means (40, 41) for latching the de-clutch means (35) in its shifted position.
It will be further seen that, in the illustrated embodiment, the latch means includes spring bias means (45) tending to maintain the latch means in latched position, that cam means (324, 325) are provided for unlatching the latch means when the motor power comes on, and that the de-clutch means (35) includes spring bias means (47) tending to return the de-clutch means to normal position when the latch means is unlatched.
FIG. 9 illustrates that the de-clutch mechanism of the present invention may be applied to a valve operating mechanism in which the handwheel drive shaft is at right angles to the stem as well as to the form of valve operating mechanism shown in FIG. 1 in which the handwheel is rotatable about an axis which coincides with the axis of the drive sleeve 23 and valve stem 20. In FIG. 9 the handwheel shaft 100 has secured thereto a bevel gear 101 which drives a bevel gear 102 which is part of the handwheel adapter 172 having depending lugs 173 which are adapted to be engaged by the lugs 37 of the sleeve 35 when the sleeve is lifted to its raised position.
|
A de-clutch mechanism is actuated, when the power is off, by manual actuation of a de-clutch lever shaft. When thus actuated, the de-clutch mechanism couples a rotatable driven sleeve to a handwheel drive and decouples the sleeve from the power drive. When the power is activated, the de-clutch mechanism automatically disconnects the handwheel drive. A typical application of the de-clutch mechanism is in valve operators.
| 5
|
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates generally to replaceable runners for snowmobile skis, and method of making same more particularly to the mounting of such runners on the ski.
2. Related Art
FIG. 1 is a cross sectional end view of a conventional snow ski outfitted with a typical wear bar or runner that is used to enhance the traction of the snow ski, particularly on icy terrain. The conventional runner includes an elongated runner body fabricated of cast steel rod that extends between opposite ends. A pair of threaded studs are welded to the top surface of the runner body and extend through associated openings in the ski. Nuts are threaded onto the exposed upper ends of the threaded studs and are tightened to draw the upper surface of the runner body tightly against the underside of the ski to secure the runner rigidly, but removably, in place. A slot is cut in a lower surface of the runner body and a carbide wear strip is brazed therein. The carbide wear strip presents an exposed lower running surface for engaging a terrain and enhancing the traction and thus steerability of the skis, particularly on icy or packed snow conditions. While such runners are effective at enhancing the steerability of the skis, they are rather bulky and take time to replace, particularly if the threads of the mounting studs become corroded, making removal of the nut difficult. Moreover, the runners are prone to loosening due to constant vibration and stress placed on the mounting system causing the nuts to unthread over time.
It is an object of the present invention to improve upon runner systems for snowmobile skis and to simplify the construction and mounting of such runner systems.
SUMMARY OF THE INVENTION AND ADVANTAGES
A runner constructed according to one aspect in the invention is mountable on a ski of an ice-going vehicle and comprises an elongate runner body fabricated of a first material having longitudinally opposite ends, an upper surface and a lower surface. At least two mounting members extend from the upper surface of the runner body. A wear strip, fabricated of a second material relatively harder than that of the first material, projects from the lower surface of the runner body and presents an exposed ice-engaging runner body surface. According to the invention, the runner body and the at least two mounting members are fabricated of a single piece of flat metal plate of the first material.
The invention has the advantage of providing a runner in which the runner body and mounting members are fabricated of the same material and further which have a flat plate construction, thereby minimizing the weight of the overall runner and simplifying the construction of the runner. Unlike the prior art runners in which the mounting members are separately fabricated from the runner body and then joined by a separate brazing or welding operation in the typical form of a threaded cylindrical stud, the present invention has the advantage of incorporating the manufacture of the mounting members in with the manufacture of the runner body, thereby simplifying the construction and manufacture of the runner.
According to a further aspect of the invention, an improved mounting system is provided for readily mounting and unmounting the runner to and from a snow ski. In particular, the mounting members are formed with a wedge-engaging surface which is preferably arranged transverse to the longitudinal direction of the mounting members. The wedging surfaces are operative to interact with a wedge connection that acts between the wedging surface and the snow ski to forceably draw the mounting members through associated openings in the ski, bringing an upper surface of the runner body tightly against an underside of the snow ski. This wedging approach to mounting the runner body is to be used in place of the traditional threaded stud and nut-type mounting system of conventional runners and is less prone to loosening when subjected to stress and vibration during use. In addition, the wedge-type mounting system provides a convenient quick-release feature to the runner, enabling a user to quickly and conveniently mount and dismount the runner which is advantageous, particularly in competitive snowmobile racing conditions where time is crucial.
According to another aspect in the invention, a snowmobile ski assembly is provided having a longitudinally extending ski with an upper and lower surface and at least two longitudinally spaced runner openings extending between the surfaces. A runner is provided having a runner body extending longitudinally between opposite ends and having an upper surface and a lower surface. At least two mounting members extend from the upper surface of the runner body and are spaced longitudinally from one another at a distance to enable the mounting members to be extended through the runner openings from the lower surface of the ski. A hard wear strip which may comprise carbide, projects from a lower surface of the runner and provides an ice-engaging running surface to enhance traction. According to the invention, the mounting members comprise flat portions which are simple to make and weigh less than the traditional threaded stud mounting members of prior art runners. The flat portion mounting members further are readily adaptable to the wedge lock mounting system described above and thus shares the same advantages.
According to a further aspect of the invention, a method of fabricating a runner of the type described is provided and includes the stamping of the runner body from a thin flat plate of metal with mounting features which facilitate quick coupling and decoupling to and from the underside of a snowmobile ski. In one configuration, the mounting features are formed by concurrently stamping transverse wedge openings in the runner body. In another configuration, the mounting features are formed by concurrently stamping mounting members which are integral with the upper surface of the runner body. The method contemplates the concurrent stamping of wedging surfaces that comprise wedge holes or notches extending through the mounting members.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein:
FIG. 1 is a front end cross-sectional view representative of a prior art snowmobile ski and runner assembly;
FIG. 2 is a front end cross-sectional view of a snowmobile ski and runner assembly constructed according to a first embodiment of the present invention;
FIG. 3 is a side elevation view of a runner constructed according to a first embodiment to the invention and mounted in the assembly illustrated in FIG. 2 ;
FIG. 4 is an enlarged rear cross-sectional view taken along the section line 4 — 4 of FIG. 3 ;
FIG. 5 is a side cross-sectional view taken generally along the section line 5 — 5 of FIG. 2 ;
FIGS. 6–7 are greatly enlarged fragmentary cross-sectional end views, similar to FIG. 2 , but illustrating the steps involved in installing the runner in position on the ski;
FIG. 8 is fragmentary cross-sectional end view, similar to FIGS. 6 and 7 , illustrating a final installation step;
FIG. 9 is a greatly enlarged top cross-sectional view, taken along the line 9 — 9 of FIG. 8 ;
FIG. 10 is a front end cross-sectional view of a snow ski and runner constructed according to a second embodiment of the invention;
FIG. 11 is a front end cross-sectional view of a snow ski and runner assembly constructed according to a third embodiment of the invention;
FIG. 12 is a cross-sectional side view taken generally along section line 12 — 12 of FIG. 11 ;
FIGS. 13–14 are fragmentary sectional side views of a snow ski and runner assembly, constructed according to a fourth embodiment of the invention, illustrating sequential steps of installation;
FIGS. 15–19 are enlarged front cross-sectional end views taken through carbide receiving slot of the runner body illustrated in FIG. 3 , illustrating successive steps in the manufacture of a runner according to the invention;
FIG. 20 is a front end cross-sectional view of a snowmobile ski and runner assembly constructed according to a fifth embodiment of the invention;
FIG. 21 is a front end cross-sectional view of a snow ski and runner assembly constructed according to a sixth embodiment of the present invention;
FIG. 22 is a greatly enlarged sectional side view, taken along the line 22 — 22 of FIG. 21 ;
FIG. 23 is a bottom view, taken along the line 23 — 23 of FIG. 24 illustrating the initial stamping or die cutting of the blank utilized to form the runner body illustrated in FIGS. 21 and 22 ;
FIG. 24 is a sectional end view, taken along the section line 24 — 24 of FIG. 23 illustrating the footprint in a planar position;
FIG. 25 is an end elevational view illustrating a subsequent step of the manufacture with the wings in the folded position illustrated in phantom lines;
FIG. 26 is an end elevational view illustrating the folded runner body in an inverted position in which time the carbide wear bar is brazed into a socket formed in a base of the runner body;
FIG. 27 is an end elevational view after the brazing of the wear bar has been completed;
FIG. 28 is a side sectional view, taken along the section line 28 — 28 of FIG. 27 ; and
FIG. 29 is a bottom view, taken along the line 29 — 29 of FIG. 27 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A traction increasing wear bar or runner constructed according to a first presently preferred embodiment of the invention, as indicated generally at 10 in FIGS. 3 and 4 , shown mounted on a snowmobile ski 12 in FIGS. 2 and 5 – 9 . The ski 12 includes a ski runner 11 , which may be fabricated from plastic material, having a vertically depressed, centrally disposed, elongate keel 13 provided with opposed side walls 15 .
The runner 10 includes a runner body 14 which is fabricated as a single piece, stamped, die cut or otherwise totally concurrently cut from a flat sheet or plate of metal stock of a first material, such as steel or aluminum-based metals. The runner body 14 extends longitudinally between opposite ends 16 , 18 and has an upper surface 20 , a lower surface 22 and opposed lateral side surfaces 23 extending therebetween. The runner 10 includes mounting features associated with the runner body 14 which are concurrently stamped and operate to mount the runner 10 to the ski 12 in a manner to be described in greater detail below. According to the first embodiment, the mounting features are in the preferred form of at least a pair of mounting members 24 projecting from and integral with the upper surface 20 of the runner body 14 . ( FIG. 3 ). The mounting members 24 are preferably fabricated of the same sheet stock material as that used to form the runner body 14 and are preferably concurrently stamped or die cut at one time and as one piece with the runner body such that the mounting features are incorporated into the one piece construction of the runner body 14 . The mounting members 24 thus have a flat plate construction and extend transverse to the longitudinal axis of the runner body 14 . The mounting members 24 are spaced longitudinally from one another by a distance corresponding to an associated set of longitudinally spaced ski runner openings 26 , formed in the ski 12 , as illustrated best in FIG. 5 . The ski runner openings 26 may have a slot-shaped configuration corresponding generally to the cross-sectional size and shape of the mounting members 24 or, as illustrated in FIGS. 2 and 5 – 9 , with particular emphases on FIGS. 5 and 9 , the runner openings 26 may have a generally cylindrical shape with the width of the mounting members 24 being sized to engage or be spaced slightly from the walls of the runner openings 26 as shown in FIGS. 5 and 9 such that the walls of the runner openings provide both for and aft and side to side support to the mounting members despite being circular in cross-section rather than rectangular. As such, the flat plate mounting member feature can be readily adapted as a retrofit to existing snowmobile skis 12 fitted with cylindrical runner openings 26 that previously would have been used to receive cylindrical threaded mounting studs of prior art runners, such as that shown representatively in FIG. 1 described in the background. The mounting members 24 are preferably free of screw thread features.
A wear strip 28 is joined to the lower surface 22 of the runner body 14 . The wear strip 28 is fabricated of a second material, such as a carbide material, which is relatively harder and thus more wear resistant than that of the first material of the runner body 14 . For example, the wear strip 28 can be fabricated of a hard carbide material, whereas the runner body 14 can be fabricated of an aluminum-based material of lesser hardness. The runner body 14 is preferably formed with a wear strip notch 30 that is recessed in the lower surface and which is spaced from the ends 16 , 18 but extends fully across the entire width of the runner body 14 so as to be open to the opposing side surfaces 23 of the runner body. The wear strip 28 preferably has a width or thickness corresponding to that of the runner body 14 and a length corresponding to that of the notch 30 . The height of the wear strip 28 exceeds the depth of the notch 30 such that the wear strip 28 projects downwardly from the lower surface 22 of the runner body 14 to present an exposed ice-engaging runner surface for engaging the terrain on which the ski 12 runs, such as on ice or snow-packed conditions. As illustrated in FIGS. 2 , 8 and 10 the runner body 14 , mounting members 24 , and wear strip 28 lie in the same vertical plane P. As illustrated in FIG. 9 , the transverse thickness T of the runner body 14 and mounting members 24 is uniform and substantially equal throughout.
With reference to FIGS. 15–19 , a process is provided for joining the wear strip 28 to the runner body 14 . As mentioned, the invention contemplates using an aluminum-based material for the runner body which presents challenges since aluminum is prone to forming a very tough, stable oxide on its surface which is resistant to forming a metallurgical bond with another material at the interface as the oxide serves as a barrier to the intermixing of metals. The invention provides one technique for addressing and overcoming the challenges of joining the wear strip 28 to an aluminum runner body 14 , which could equally be used when materials other than aluminum are used for the runner body, such as steel. As shown in FIGS. 15–18 , the method involves inverting the runner 10 such that the lower surface 22 of the runner body 14 is facing upwardly. When so positioned, a flux agent 34 is introduced to the notch 30 ( FIG. 16 ). The flux agent 34 is one chosen to interact favorable during joining to break up any oxides or other impurities or impediments to promote the formation of a metallic bond at the interface of the materials to be joined. In the preferred method, a strip 36 of brazing material is laid in the notch 30 overtop the fluxing agent 34 , as illustrated in FIG. 17 . The wear strip 28 is then placed in the notch 30 atop of the strip of braze material 36 , as shown in FIG. 18 , and the pre-joined assembly of components is supported by relatively positioning the components and a guide 38 so that the guide 38 is at least partially around the components to hold them in position during joining. The guide 38 is shown in FIG. 19 and preferably comprises a block of electrically non-conductive material, such as a ceramic material. The guide 38 is formed with a downwardly opening recess 40 that compliments the shape of the assembled components such that the walls of the recess engage and support the wear strip 28 in alignment with the runner body 14 during joining. Brazing is carried out preferably by induction heating. As shown schematically in FIG. 19 , the assembled wear strip 28 , runner body 14 and guide 38 are placed in the presence of an induction heating field 42 which passes through the guide 38 and reacts at the interface to heat the runner body 14 , flux agent 34 , braze material 36 and wear strip 28 but without heating the guide 38 . On heating, the flux agent 34 reacts with the runner body 14 to break up any oxides on its surface simultaneously or near simultaneously with the melting of the brazed material 36 which then interacts with the surfaces of the runner body 14 and wear strip 28 to form, upon cooling, a metallic braze joint therebetween. When brazing of the strip 28 to the runner body 14 is completed, the entire assembly may be deposited into a quenching liquid such as oil to thru harden the runner body 14 to increased hardness (if the runner body 14 is steel) which is still less than the hardness of the carbide wear strip 28 . The quenching liquid preferably has a quenching rate of reducing the temperature of the product 600° F. per minute. Other quenching mediums include molten salt baths, polymers, etc.
Turning back to FIGS. 2 through 9 , the means for mounting the runner 10 on the ski 12 according to the invention will now be described in connection with the first embodiment. As illustrated in FIGS. 3 and 5 , the mounting members 24 are formed with wedge-engaging surfaces 44 , in the preferred form of mounting holes, provided adjacent the free ends of the mounting members 24 . To mount the runner 10 on the ski 12 , the free ends of the mounting members 24 are extended into the ski runner openings 26 from the lower surface 68 of the ski 12 . The ski 12 is preferably formed to include a pair of laterally spaced mounting blocks 46 mounted atop the ski 12 and defining an opening communicating with the runner openings 26 in position to receive the upper free ends of the mounting members 24 as they are extended through the ski runner openings 26 . The lateral spacing between the adjacent mounting blocks is sufficient to accommodate the introduction of the mounting members 24 and can be either a snug or loose fit with respect to the lateral thickness or width of the mounting members, but is preferably slightly greater in spacing than the thickness of the mounting members 24 . As shown best in FIG. 6 , the mounting blocks 46 are formed with a cross-bore 48 for receiving a fastener 50 as described below. The fastener or coupling bolt 50 has a reduced diameter threaded end 52 with a conical shaped terminal end 54 . The threaded end section 52 transitions to an enlarged diameter unthreaded shank section 56 via an intermediate frustoconical shaped camming surface or ramp 58 . A bolt head 60 is secured to the free end of the shank 56 . The cross-bore 48 of the mounting blocks 46 has a shape complimenting that of the fastener 50 and includes a threaded section 62 and an adjoining frustoconical camming surface 64 provided on one half of the mounting blocks 46 , and an enlarged shank bore 66 provided on the other of the mounting blocks. If the mounting blocks 46 are formed of yieldable plastic material, the threaded sections 62 may comprises an internally threaded metal fastener, such as a T-nut.
The mounting hole 44 of the mounting members 24 is positioned along the mounting members 24 , such that when a user inserts the mounting members 24 the runner body 14 by hand into the runner openings 26 and extends the runner body 14 to the point where its upper surface 20 closely approaches a lower surface 68 of the ski 12 , there is a slight misalignment between the holes 44 and the mounting members 24 and the cross-bore 48 in the mounting blocks, such that the axis of the mounting holes 44 is slightly below the axis of the cross-bore 48 . According to the invention, there is a wedging action which occurs between the fastener 50 , the cross-bore 48 and the mounting holes 44 which acts to bring the axis of the holes into alignment and to urge the runner body 14 further upwardly into tight, stable engagement with the underside 68 of the ski to hold the runner firmly in place during operation. As the upper surface 20 engages the underside of the ski runner keel 13 , any undulations on the underside of the plastic material in the ski runner keel may slightly yield and compress under the force of the wedging action to facilitate the final upward positioning of the runner body 12 , with a preload, in tight clamping relation with the ski keel 13 . As illustrated in FIG. 7 , the threaded section 62 of the fasteners 50 are guided through the shank bores 66 , mounting holes 44 and camming surface 64 into the threaded section 62 , whereupon turning the fasteners 50 to tighten it brings the camming surface 58 of the fasteners 50 into engagement with the upper edge of the mounting holes 44 of the runner body 14 . Further advancement of the fasteners 50 causes the mounting members 24 , and thus the runner body 14 , to cam upwardly across the camming surface 64 , whereupon the upper surface 20 of the runner body 14 is urged more and more into tight engagement with the lower surface 68 of the ski, until such point as the fastener 50 is advanced to where the unthreaded shank section 56 enters the mounting hole 44 , as illustrated in FIGS. 2 , 5 and 8 . In this manner, the runner 10 is firmly locked to the ski 12 , but yet is readily removable for replacement by simply unthreading the fastener 50 and inserting a pry tool, such as a screwdriver (not shown) in one of both notches 70 and to apply a downward prying force to withdraw the mounting members 24 from the runner openings 26 .
Alternate Embodiment
FIG. 10 illustrates an alternative embodiment of the invention wherein the same reference numerals are used to represent the same or like features, but are offset by 100 . The runner 110 is constructed identically to that of the runner 10 of the first embodiment. The mounting blocks 146 differ in that the cross-bores 148 are simply a straight bore of uniform diameter corresponding closely to that of the diameter of the mounting holes 144 of the runner 110 . A simple fastener 150 with a bolt head 160 and threaded end section 152 is passed through the cross-bore 148 and mounting hole 144 without any wedging action and is secured by a nut 72 .
Third Alternate Embodiment
FIGS. 11 and 12 illustrate a snowmobile ski and runner assembly constructed according to a third embodiment of the invention, wherein the same reference numerals are used to indicate the same or like features as that of the first embodiment, but are offset by 200 . In this embodiment, the runner body 214 lacks the projecting mounting members 24 employed in the first embodiment, and instead provides at least two and preferably at least three mounting holes 244 formed in the runner body 214 at locations between the ends 216 , 218 and between the upper and lower surfaces 220 , 222 . The wear strip 228 is formed and joined to the underside of runner body 214 in the same manner as that described in connection with the first embodiment. The ski 212 has its runner opening 226 ( FIG. 11 ) provided in the keel 213 in the form of an elongated vertical channel or slot 74 which is opened to the lower surface 268 of the ski 212 , but is closed at least in part to the upper surface thereof such that the runner 210 does not extend above the upper surface of the ski 212 . The keel 213 is formed with a plurality of cross-bores 76 which intersect the slot 74 in alignment with the mounting holes 244 of the runner body 214 . A fastener 78 is introduced into each cross-bore 76 and extends through the mounting holes 244 and is secured by an associated nut 80 for securing the runner 210 to the ski 212 . The invention contemplates that the cross-bore 76 can be configured to correspond to that of the cross-bore 48 of the first embodiment and the fastener 78 configured to correspond to that of the fastener 50 to provide wedging engagement of the runner 210 within the slot 74 of the ski 212 wherein an upper surface of the runner 210 would be urged under the camming action firmly against the upper base wall of the slot 74 . Depending on the thickness of the walls of the keel 213 , the squeezing force exerted by the relative turning of the bolt 78 and the nut 80 , the keel walls 215 can be compressed against opposite sides of the runner body 214 .
Fourth Alternate Embodiment
FIGS. 13 and 14 illustrate yet a fourth embodiment of the invention, wherein the same reference numerals are used to indicate the same or like features, but are offset by 300 . The runner 310 has a runner body 314 and mounting members 324 projecting from an upper surface 320 of the runner body 314 . The wedge-engaging surface 334 is in the form of a camming notch 82 formed in at least one and preferably all of the mounting members 324 , as illustrated best in FIG. 13 . The camming notches 82 are preferably formed at the base of the mounting members 324 and taper inwardly to a point deepest at the base. The ski 312 is formed with runner openings 326 associated with the mounting members 324 . The runner openings 326 are oversized in relation to the width of the mounting members 24 one edge of each runner opening 326 is formed with a camming surface 84 . The mounting members 324 are initially introduced through the runner openings 326 with the camming notch 82 spaced longitudinally from the camming surfaces 84 , as illustrated in FIG. 13 . The runner body 314 is then forceably slid longitudinally relative to the ski 312 by application of a force F applied to the runner 310 such as by a sharp blow from a hammer, to forceably urge the camming notches 82 into camming engagement with the camming surfaces 84 of the openings to drive the runner 310 further upwardly, bringing the upper surface 320 of the runner body 314 tightly against the lower surface 368 of the ski 312 .
As shown in FIG. 13 , at least one of the mounting members 324 is formed with a retaining hole 86 which is initially misaligned with a corresponding retaining hole 88 formed in the ski. However, when the runner 310 is forced to the tightly wedged installed position of FIG. 14 , the holes 86 , 88 align, enabling a pin 90 to be installed therein to retain the runner 310 in position on the ski 312 against inadvertent loosening. To remove the runner 310 , the user simply pulls the pin 90 and then strikes the runner 310 with a hammer in the opposite direction to drive the camming notches 82 out of engagement with the camming surface 84 as in FIG. 13 , allowing the runner 310 to be disassembled from the ski 312 and replaced.
Fifth Alternate Embodiment
FIG. 20 illustrates a further embodiment of the invention which, essentially is like the embodiment of FIGS. 11 and 12 , except that instead of just a single runner 214 , there is provided a plurality of such laterally spaced longitudinally extending runners 214 , with two being shown. The keel 213 of the ski is formed with a corresponding plurality of laterally spaced apart, longitudinally extending grooves, channels or slots 74 in which the runners 214 are received. The fasteners 78 extend through the aligned openings 244 in the runners 214 and pass transversely through the slots 74 for securing the runners 214 releasably on the ski. The runners 214 are preferably identically constructed and thus interchangeable. The runners 214 are preferably discrete, separate structures that, when mounted, are spaced laterally from one another. If desired, the runner 214 may be of different lengths and/or may be longitudinally staggered.
Sixth Alternate Embodiment
FIGS. 21–22 and 27 – 29 illustrate yet a sixth embodiment of the invention wherein the same reference numerals are used to indicate the same or like features but are offset by 400 . The ski 412 and the keel 413 differ from the ski 12 and keel 13 in that the ski 412 and the keel are more flexible throughout their lengths to more closely follow any undulations in the underlying terrain being traversed. The ski 412 may be much thinner than the ski 12 and the keel 413 is much narrower than the keel 13 and does not include a downwardly opening slot therein or vertically extending therethrough.
As illustrated in FIG. 22 , the runner 410 , rather than including a one piece runner body 14 , includes a plurality of longitudinally spaced apart, discrete, separate runner body segments, generally designated 99 . Each runner body segment 99 includes a runner body 414 which is fabricated as a single piece that is stamped or die cut in its entirety from a flat sheet or plate of metal stock, such as aluminum or steel. The stock material is of uniform thickness T ( FIG. 24 ) in the range of 3/16″ thick. The runner body 414 has a U-shape when longitudinally viewed, ( FIGS. 21 and 27 ) and includes an elongate central base 91 having laterally outer edges 91 A integrally coupled to the laterally inner edges 93 A of laterally spaced apart upstanding wings, legs or plates 93 . The plates 93 have aligned transverse mounting aperture 444 therethrough for pivotally receiving a pivotal coupling pin 478 when the holes 444 are aligned with a cross bore 476 in the keel 413 . The holes 444 and the cross bore 476 or each segment 93 are aligned with the holes 444 when the runner body segments 99 are mounted on the underside of the ski 412 as illustrated in FIG. 22 .
The legs 93 , as laterally viewed in FIGS. 22 and 28 , have a trapezoidal or truncated triangle shape. Each wing or leg 93 includes a laterally inner edge 93 A integrally coupled to one of the laterally outer edge portions 91 A of the base 91 and a laterally outer edge 95 disposed parallel to the laterally inner edges 93 A.
Each upwardly disposed wing, plate or leg 93 includes downwardly converging longitudinally spaced, forward and rearward sides or end edges 93 C and 93 D, respectively, which provide a clearance or spacing, generally designated by the arrow 94 between the adjacent segments 99 . This spacing allows each runner body 414 , when the ski 412 and keel 413 vertically flex or undulate along their lengths, to conform to the underlying terrain, and swing, in a to-and-fro path about the axis of one of the pins 478 , represented by the directions of the arrows 95 and 96 .
A hardened carbide strip 428 is disposed in a slot 430 which is stamped cut or machined in the underside of the base 91 . The strip 428 is then brazed or otherwise suitably coupled to the underside of the base 91 of each runner body segment 414 .
The lengths L and L 1 of the laterally inner and outer parallel edges 91 A and 95 , respectively, may typically be in the range of 2–2½″ and 3–3½″, respectively. The slot 430 has a width typically in the range of 3/16 to ½ inch and a depth of approximately ½ of the thickness T of runner body 414 .
As illustrated in FIG. 28 , the wings and/or walls 93 include longitudinally spaced forward and rear edges 93 C and 93 D, respectively, which longitudinally diverge outwardly away from the base 91 in a direction toward the outer edge 95 . As illustrated in FIG. 28 , when the wings 93 are folded upwardly, to the positions illustrated in FIGS. 27 and 28 , longitudinally opposite ends 95 and 96 of the carbide wear bar 428 , also upwardly diverge and are disposed flush with the longitudinally spaced end edges or surfaces 93 C and 93 D, respectively.
FIGS. 23–27 illustrate successive steps in the manufacture of the runner 410 which includes a plurality of longitudinally aligned, longitudinally spaced runner bodies 414 . Each runner body 414 is stamped or die cut from a flat sheet of metal in the shape illustrated in FIG. 23 that is sometimes referred to as a “footprint” and may be generally classified as having an “hour glass” or “bow tie” shape. The runner body 414 includes the central base section 91 having laterally opposite edges 91 A and 91 B integrally coupled at the fold lines F and F 1 , respectively, to the laterally inner edges 93 A of the pair of laterally outwardly extending legs 93 . The stamped out footprint illustrated in FIG. 23 includes the wings 93 each in the form or shape of a trapezoid or truncated triangle having a laterally inner edge 93 A of a predetermined length L and a laterally outer terminal parallel edge 95 which has a length L 1 which is substantially greater than the length of the laterally inner wing edge 93 A. As illustrated in FIG. 24 , when the hour glass shape is cut, a notch 430 is concurrently stamped into the underside of the central base section 91 . During the stamping operation, a mounting hole 444 is concurrently cut into each of the wings 93 . The wings 93 are then folded or rolled upwardly and inwardly, in the opposite direction represented by the arrows X and Y to the final positions illustrated in chain lines in FIG. 24 and in solid lines in FIG. 25 . The runner 410 is then inverted to the position illustrated in FIG. 26 and a flux agent 434 and brazing material 436 are deposited into the slot 430 and the hardened wear strip 428 is deposited therein. The assembly is placed into an induction heater where brazing occurs as was previously described with regard to FIGS. 2–9 so that the runner body is now in its finished position as illustrated in FIG. 27 . The heated and brazed construction may be deposited into a quenching bath to harden the runner body 444 .
When the footprint of the runner body 414 is die cut as illustrated in FIG. 23 , the holes 444 are concurrently cut and the slot 24 in the carbide wear strip is concurrently punched to form a slight elongate ridge R open the top surface of the base 91 . If desired, the ridge R can be removed via machining. Alternatively, the slot 24 may be machined into the undersurface to eliminate the formation of ridge R.
It is to be understood that the drawings and descriptive matter are in all cases to be interpreted as merely illustrative of the principles of the invention, rather than as limiting the same in any way, since it is contemplated that various changes may be made in various elements to achieve like results without departing from the spirit of the invention or the scope of the appended claims.
|
A runner for a snowmobile ski is fabricated from flat metal plate stock and incorporates mounting features for securing the runner to the ski and a wear strip of a relatively harder material provided on and projecting from a lower surface of the runner body. A quick release mounting system is provided for attaching the runner to the ski, including quick installation and release wedge mounting systems. The thin runner blade and wear strip are of the same thickness and are joined by a brazed joint. The invention contemplates a method of fabricating the runner and a method of mounting the runner.
| 8
|
TECHNICAL FIELD OF THE INVENTION
[0001] The invention relates to a system for arranging elements in an orderly fashion into a container, a tray or similar.
BACKGROUND OF THE INVENTION
[0002] Currently, there is a multitude of elements, goods and products that must be subjected to different processes in different locations and need to be conveyed for this purpose by means of conveyor belts. In the logistics sector, they are used quite often. Likewise, in the food, pharmaceutical, chemical or cosmetic industries, there are products that must undergo pasteurisation and/or sterilisation processes before their marketing and consumption. These products may have very different features.
[0003] Usually to process the products, they have to be conveyed between different locations by means of conveyor belts, also referred to as endless belts. Whilst they are in operation, some of these conveyor belts may modify their speed. By contrast, to our knowledge, they do not allow changes in their constitution. They are limited to the essential function of conveying elements continuously.
[0004] Nevertheless, sometimes, the processes associated with the elements conveyed on a conveyor belt require to be placed in an orderly fashion for their ulterior treatment (packaging, cooking, sterilisation, conditioning, packing, etc.). Known conveyor belts, do not have enough functionalities to carry out this kind of additional tasks and use to leave them piled up.
[0005] Generally, it involves products conditioned in different packagings, such as rigid, semi-rigid and flexible packagings. They may also vary in shape, i.e., cylindrical, square, truncated conical packagings and are subjected to processes.
[0006] If the packagings are rigid and metallic, they can be handled with a movable magnetic plate, by magnetizing their upper portion and depositing them somewhere else.
[0007] With rigid non-metallic packagings, a drive system that moves the packagings from the conveyor belt to another place can be used. It is also possible to pick non-metallic packages by their upper portion using a suction system provided with a suction plate (by air). Another option is to employ systems with mechanical or electro-mechanical clamps.
[0008] By contrast, when the packagings are flexible their handling becomes more difficult. These packagings, composed by different sheets of polymer welded at their seams, with different finishes, shapes, etc. have a high variety of mechanical properties, and in addition, they vary according to the product packaged inside. Flexible packagings are used more and more often because of their advantageous characteristics (appealing, lower distribution costs, easy to handle when they are empty, easy to open, require shorter heat processing, portable, microwaveable, etc.).
[0009] The truncated conical packagings also present difficulties for being positioned in an orderly fashion given their shape, since when they are grouped they lose their verticality.
[0010] Regarding the container, tray or similar, they are positioned stacked so they can be easily moved, but they have to be separated in order to deposit the products inside them. The method that is currently used is to separate the tray, (method commonly known as unstacking), from the remaining trays, move that tray to another location where the products are deposited inside it and placing the tray back with the rest of the stacked trays, (method commonly known as stacking).
BRIEF DESCRIPTION OF THE INVENTION
[0011] In view of the limitations observed, a system to place elements in an orderly fashion would be desirable. It would also be advantageous for it to be capable of interacting with the containers where the elements are going to be deposited (for instance, trays or platforms) in order to increase speed and accuracy.
[0012] The present invention proposes a system for placing elements in an orderly fashion that includes a conveyor belt, variable in length, for conveying and depositing elements; a separating device to select an active container and separate al least the active container from other stacked containers, thus creating a gap that enables the insertion of the conveyor belt. The separator and the conveyor belt are coordinated such that, the conveyor belt may vary in length by either projecting or retracting itself as the elements pass from the conveyor belt to the active container For this purpose, the speed at which the belt projects/retracts, the speed of the elements on the belt can be adjusted according to the element and container type and/or the desired spacing between elements.
[0013] Optionally, it may include a mobile module associated with the conveyor belt, the mobile module being capable of moving sideways the conveyor belt in order to place an additional row of elements into the active container.
[0014] Optionally, the mobile module associated with the conveyor belt may move vertically the conveyor belt up to where a new active container is located.
[0015] Optionally, the separator is capable of selecting and separating a new active container when the conveyor belt is in its retracted or projected position.
[0016] Optionally, the separator is provided with arms to handle at least two containers simultaneously.
[0017] Optionally, the length variation of the conveyor belt is a function of the linear speed of the belt of the conveyor belt. In this way, it is possible to prevent the elements from piling up in the container or being poorly distributed.
[0018] Optionally, the length variation of the conveyor belt is a function of the container size. For example, that way it is possible to use the entire usable area of the container to deposit elements.
[0019] Optionally, the length variation of the conveyor belt is a function of the element variety. It is possible to adapt it to different types of items having diverse shapes and volumes.
BRIEF DESCRIPTION OF THE FIGURES
[0020] FIG. 1A : Is a longitudinal sectional view of the conveyor belt.
[0021] FIG. 1B : Is a perspective view of the conveyor belt.
[0022] FIG. 2A : Is a perspective view of the mobile module associated with the conveyor belt.
[0023] FIG. 2B : Is a side view of the mobile module.
[0024] FIG. 2C : Is a top view of the mobile module.
[0025] FIG. 3A : Is a perspective view the tray separator, on site.
[0026] FIG. 3B : Is a side view of the tray separator.
[0027] FIG. 3C : Is a top view of the tray separator.
DETAILED DESCRIPTION OF THE INVENTION
[0028] With reference to the previous figures, a non-limiting exemplary embodiment is set forth for clarity purposes.
[0029] In FIG. 1A , a sectional view of the conveyor belt 1 is shown, in which some of its elements can be observed. In particular, a guide 11 that is projected longitudinally varying the length of the endless belt 12 . The mechanism that enables the extension is mainly formed by a first motor 14 , which activates the guide 11 and a second motor 16 , which activates a motor roller 15 for driving the endless belt 12 so as to make it extensible and retractable. An idler pulley 13 keeps the endless belt stretched. FIG. 1B depicts a perspective view of the same conveyor belt 1 depositing elements into a tray 10 . The elements, flexible packagings in this case, are deposited directly into a stackable tray without having to group the packagings previously or picking them up. This way, it is possible to do without additional systems such as mechanical clamps or suction systems, which are slower and more complex.
[0030] FIG. 2A shows a perspective view of a mobile module 2 where the conveyor belt 1 is to be mounted so it can move vertically and sideways. In FIGS. 2B and 2C a side and a top view of said mobile module can be observed, wherein the motion is signalled with arrows. A lifting support 22 is responsible of the vertical motion; insofar a pair of side moving guides 21 transmits a lateral movement.
[0031] FIG. 3A illustrates the separator 3 that enables creating between the trays 10 or containers a space for the insertion of the conveyor belt 1 by means of arms 31 , which select a tray, hold it whilst they separate the tray from the other trays stacked above. In FIGS. 3B and 3C a side and a top view can be observed, wherein the motion of the arms is signalled with arrows.
[0032] Below, the operation relating to a manufacturing plant that works with flexible packagings is described. It should be understood that the present embodiment might be employed in numerous domains where it is necessary to convey elements, goods, products, etc., in an orderly fashion, with a conveyor belt and deposit them in stackable containers or trays.
[0033] To insert the product into the packaging it is not necessary to unstack the trays and move them to another place. The tray 10 separator 3 operates on site separating the trays from one another and enabling to insert directly the conveyor belt 1 .
[0034] On one hand, the flexible packagings coming from filling machines, which approach forming a row with a given separation and at a given speed, are collected by the conveyor belt 1 , which is extensible and retractable in a longitudinal direction, that places the packagings preferably with no separation between them, inside an active tray 1 , in parallel rows, which complete the tray area.
[0035] The insertion is carried out through one of the sides of the tray; the conveyor belt 1 is located above the tray on one end and extends until reaching the opposite side of the tray, where it will start leaving the first row of packagings. At the same time, the packagings advance on the endless belt at a given speed and with a given separation, so when the first packaging reaches the end, it falls by gravity into the active tray 10 , the belt 1 retracts so there is enough distance such that the following packaging falls contiguous to the previous one and they stay together. This process is repeated until completing the row. Once the row has been completed, the belt 1 moves horizontally to position itself in the second row position and simultaneously it extends again in order to reach the level at which the first packaging of that row is to be left, as described above, on the opposite side. When it initiates the extension, the linear extension velocity is greater that the linear velocity of the belt conveying the packagings and prevents the packagings from falling in the wrong location. The row insertion process is repeated until completing all the rows of a tray.
[0036] Moreover, the trays 10 are provided empty and stacked vertically in groups of a given number. This stack of trays is located in a static position. The trays separator 3 runs on site and preferably consists of four arms 31 that operate in two sets of two synchronized parallel arms and each one is capable of moving horizontally.
[0037] These two sets of arms 31 , which operate independently from each other, are located at both sides of the stack of trays with a vertical travel running from the lowest tray to the uppermost tray of the stacked trays. The support of the lifter 32 is also capable of moving horizontally, which enables the arms insertion into the tray 1 at both sides and to support in this way the tray so it can be lifted. When the lifting movement is carried out with a set of two arms 31 , the tray in which the claws have been inserted is lifted as well as, the trays stacked above, thus creating a gap or separation distance between the lifted trays and those that remain below. Given that there is another set of arms 31 , which has exactly the same functionality, it is possible to create another gap between the trays.
[0038] Below there is an example with a stack of ten trays, for a better understanding thereof:
[0039] The trays are numbered from bottom to top, from the 1 st to the 10 th . A set of arms lifts the 2 nd tray and leaves a gap between the 2 nd and the 1 st , if the other set of arms lifts the 3 rd tray, it will leave a gap between the 3 rd and the 2 nd tray. Two gaps have been created, between the 1 st and the 2 nd tray, and between the 2 nd and the 3 rd tray. If the first set of arms comes down and leaves the 2 nd tray next to the 1 st , these arms will then be free and come up until the 4 th tray, and lift it thus creating a gap between the 4 th and the 3 rd tray. In this position, there are two gaps between the 2 nd and the 3 rd and between the 3 rd and the 4 th tray. If this sequence is repeated two contiguous gaps will be created from the 1 st tray to the 10 th tray. Each set of arms may lift from below the lowest tray to above the uppermost tray, from the 1 st to the 10 th in the previous example and creates gaps between the trays. To change the stack of trays, the sets of arms move below or above the first and the last tray and there is an obstacle-free area around the stack of trays so it can be replaced whenever the process that is being carried out with it finishes.
[0040] As it can be appreciated, the belt 1 mounted on the mobile module 2 and the trays separator 3 operate interacting in a synchronised manner. The separator 3 creates the gaps between the trays 10 , which are stacked and empty, while, the belt 1 deposits the packagings into the trays in an orderly fashion.
[0041] Interaction between the devices:
[0042] A set of arms 31 of the tray separator 3 , separates one tray 10 from the remaining trays thus creating a gap and the other set of arms 31 creates another contiguous upper gap between the trays. The belt 1 modifies its structure in a longitudinal direction so as to deposit the packagings in rows on an empty tray 10 in the first gap, to this end it extends above the active tray 10 and retracts gradually to deposit the packagings on it. It is also capable of moving horizontally thanks to the mobile module 2 , so once a row has been deposited on the tray 10 , it moves on to the next parallel row, repeating this process until completing all the rows in the tray 10 . At that moment, the first and second set of arms 31 come down in a synchronised manner thus eliminating the first gap by joining the trays together and liberating this set of arms. Simultaneously, the belt 1 , which is capable of moving vertically thanks to the mobile module 2 , moves to the level where the gap is, which previously was the second gap, and initiates its cycle of depositing packagings on this empty tray and the set of arms, which was previously the first one, creates another gap above the tray on which the packagings are now being deposited. These cycles are repeated until completing all the trays 10 of a stack.
[0043] In conclusion, the proposed system offers, among others, these advantages:
It does not require grouping the elements previously for their insertion since they are deposited directly on the area of interest (which may be a tray) as they come thus avoiding eventual deformations. It is not affected by the packaging shape, the material in which the packaging is made, the weight or temperature thereof, etc. since they are conveyed on an endless belt, which inserts them directly into the tray without the intervention of any additional device and/or apparatus. It has a very high rate of packaging insertion since they are inserted directly into the tray in a continuous manner and is not necessary to pick them up, or move them, thus involving a minimum work cycle. It is a modular and flexible system given that it is possible to place one or more devices in parallel, making the system flexible with respect to its production over time. It does not require unstacking the trays and lining them up, one by one, in order to deposit packagings on them. The gaps are created in the stack itself, with the resulting space optimisation. By creating the gap in the stack itself, the cycle times are significantly reduced, thus allowing a much higher production rate.
[0050] It should be understood that is possible to use various alternatives, modifications and equivalents. Therefore, the present invention shall not be considered as limiting the scope of the invention, which is defined by the appended claims.
REFERENCE NUMERALS
[0051] 1 Conveyor belt.
[0052] 10 Tray.
[0053] 11 Guide.
[0054] 12 Endless belt.
[0055] 13 Idler pulley.
[0056] 14 First motor.
[0057] 15 Motor roller.
[0058] 16 Second motor.
[0059] 2 Mobile module.
[0060] 21 Side moving guide.
[0061] 22 Lifting support.
[0062] 3 Separator.
[0063] 31 Arm.
[0064] 32 Lifting support.
|
System for placing elements in an orderly fashion, which comprises a conveyor belt ( 1 ) variable in length that projects or retracts itself to convey and deposit elements; a separator ( 3 ) for selecting an active container and separating at least the active container from a plurality of stacked containers, thus creating a gap that enables the insertion of the conveyor belt ( 1 ). The separator ( 3 ) and the conveyor belt ( 1 ) are coordinated such that, the conveyor belt ( 1 ) is designed to vary in length by either projecting or retracting itself as the elements pass from the conveyor belt ( 1 ) to the active container
| 1
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a washing machine and a control method of the same. More specifically, the present invention relates to a washing machine and a washing method capable of reducing amount of water used and washing time.
[0003] 2. Description of the Conventional Art
[0004] In general, a washing machine is a device which removes debris of fabric and handles laundry. The washing machine removes debris of fabric in various ways. The washing machine, after removing debris of laundry, performs a step for removing moisture in the laundry. At this time, washing water contained in an inner tub is discharged to the outside. When washing water of the washing machine is discharged to the outside, the washing machine measures the degree of unbalance of the inner tub. If it is found that unbalance of the inner tub exists, the washing machine provides a small amount of washing water to the inner tub. Due to the washing water provided, fabric is made to flow inside the inner tub. At this time, the washing machine again measures the degree of unbalance of the inner tub. The procedure above is repeated until the unbalance of the inner tub is removed. Once unbalance of the inner tub is removed, a driving apparatus removes moisture of fabric by accelerating the inner tub.
[0005] However, a washing machine according to the related art repeats the above procedure, leading to excessive consumption of washing water and energy.
SUMMARY OF THE INVENTION
[0006] An object of the present invention is to provide a washing machine capable of reducing amount of water used and energy.
[0007] A washing method according to the present invention comprises a washing step that at least one of an inner tub and a pulsator is rotated for washing fabrics; a distribution step that the inner tub containing the washing water is rotated in one direction and fabrics is distributed to a side wall of the inner tub and the washing water is discharged to outside; and a dehydration step that the inner tub is rotated by the dehydration rotation speed for dehydrating fabrics after the distribution step is ended.
[0008] In the present invention, the washing step comprises a first washing step that the inner tub is rotated in one direction with a first rotation speed so as to form a circulation water flow which is risen between the inner tub and an outer tub by the centrifugal force and then is fed back to the inner tub, and a second washing step that at least one of the inner tub and the pulsator is rotated in both directions alternately with a second rotation speed different from the first rotation speed.
[0009] In the present invention, the distribution step includes that washing water is discharged by turning on a discharge pump, and the first washing step includes that washing water is not discharged by turning off the discharge pump.
[0010] In the present invention, the first washing and the second washing are repeated multiple times.
[0011] In the present invention, the distribution step is performed for a predetermined time and the dehydration step is performed after the predetermined time.
[0012] In the present invention, the distribution step is completed, unbalance detection step for detecting unbalance of fabrics is performed.
[0013] In the present invention, if fabric is found unbalanced in the unbalance detection step, the distribution step is performed again.
[0014] In the present invention, if fabric is found not unbalanced in the unbalance detection step, the dehydration step is performed.
[0015] In the present invention, further including the balancing step where washing water contained in an inner tub is rotated by rotating at least one of the inner tub and the pulsator.
[0016] In the present invention, the balancing step is performed between the washing step and the distribution step.
[0017] In the present invention, when the distribution step is completed, unbalance detection step for detecting unbalance of fabric is performed.
[0018] In the present invention, if fabric is found unbalanced in the unbalance detection step, the distribution step is performed again.
[0019] In the present invention, if fabric is found not unbalanced in the unbalance detection step, the dehydration step is performed.
[0020] A washing machine according to the present invention comprises an inner tub; a pulsator disposed inside the inner tub; a discharge apparatus for discharging washing water of the inner tub outside; a driving apparatus for driving the inner tub and the pulsator; and a controller for controlling the discharge apparatus to discharge washing water and controlling the driving apparatus to rotate the inner tub in one direction.
[0021] In a washing machine according to the present invention, if a washing step is ended, a distribution step that the inner tub containing the washing water is rotated in one direction and fabrics is distributed to a side wall of the inner tub and the washing water is discharged to outside is performed. Because a fabric is evenly distributed in the distribution step, a dehydration step can be performed without carrying out a separate procedure for avoiding unbalance. Therefore, energy such as washing time and power used during the operation of the washing machine and amount of water used can be saved. Also, since a washing machine according to the present invention rotates the inner tub not only during the distribution step but also during the hydration step afterwards, operation of a clutch used to selectively rotate the pulsator and the inner tub at the time of entering to the dehydration step from the distribution step is not required. Therefore, noise due to the operation of a clutch can be reduced and operation time of the washing machine can be reduced.
BRIEF DESCRIPTION OF THE DRAWING
[0022] 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.
[0023] In the drawings:
[0024] FIG. 1 is a perspective view of one embodiment of a washing machine according to the present invention;
[0025] FIG. 2 illustrates a cross sectional view of FIG. 1 as seen along II-II line;
[0026] FIG. 3 illustrates a block diagram of a control flow of a washing machine of FIG. 1 ;
[0027] FIG. 4 illustrates a flow diagram of a washing method of a washing machine according to a first embodiment of the present invention;
[0028] FIG. 5 illustrates a flow diagram of a washing method of a washing machine according to a second embodiment of the present invention; and
[0029] FIG. 6 illustrates a flow diagram of a washing method of a washing machine according to a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] FIG. 1 is a perspective view of one embodiment of a washing machine according to the present invention and FIG. 2 illustrates a cross sectional view of FIG. 1 as seen along II-II line.
[0031] With reference to FIGS. 1 and 2 , a washing machine 100 according to the present invention comprises a cabinet 110 ; a outer tub 125 disposed inside the cabinet 110 and storing washing water; an inner tub 122 disposed inside the outer tub 125 and receiving laundry; a driving apparatus 170 rotating the inner tub 122 in both directions alternately or in one direction by delivering driving force to the inner tub 122 ; a discharge apparatus 150 discharging washing water of the outer tub to the outside; and a washing water provision apparatus 120 disposed in one side of the cabinet 110 and providing washing water from the outside to the outer tub 125 and the inner tub 122 .
[0032] A pulsator 140 is disposed in the bottom surface of the inner tub 122 . The pulsator 140 can be formed as a single body with the inner tub 122 ; and at the same time, the pulsator 140 can be formed separately and combined as such therewith. An operation method varied according to the structure of the inner tub 122 and the pulsator 140 will be described in detail later.
[0033] The cabinet 110 comprises a cabinet main body 111 having an opening; a base (not shown) disposed in a lower side of the cabinet main body 111 and fastened to the cabinet main body 111 ; a cover (not shown) fastened to the opening; and a control panel 126 formed on one side of the cover and fastened to the cabinet main body 111 . A door 123 capable of rotational movement together with the cover is installed at the cover to open and close the opening. Meanwhile, the control panel 126 incorporates an input unit 116 which receives input signals from a user.
[0034] The driving apparatus 170 comprises a motor including a rotor and a stator and generating rotational force; a rotation axis delivering rotational force of the motor; and a clutch delivering rotational force of the motor selectively to at least one of the inner tub and the pulsator 140 .
[0035] FIG. 3 illustrates a block diagram of a control flow of a washing machine 100 of FIG. 1 .
[0036] With reference to FIG. 3 , a washing machine 100 according to the present invention further comprises an input unit 116 disposed on the control panerl and receiving input signals entered by the user; and a controller 190 controlling the operation of the washing machine 100 according to the input signals entered to the input unit 116 .
[0037] The input signal is formed in various ways and determines a washing step or a method for handling laundry. For example, the washing step can include a blue jean step, a bedclothes step, and a wool step. Also, the treatment method of fabric can include a washing method, a dehydration method, and a rinsing method.
[0038] When the user enters the input signal, the washing machine 100 performs a washing step. In the washing step, the controller 190 makes washing water flow into the inner tub 122 by operating the washing water provision apparatus 120 .
[0039] When the washing water provision apparatus 120 begins to operate, washing water is provided to the inner tub 122 from the outside.
[0040] FIG. 4 illustrates a flow diagram of a washing method of a washing machine according to a first embodiment of the present invention.
[0041] With reference to FIG. 4 , when provision of the washing water is completed, the controller 190 performs a washing step, removing dirt of fabric while controlling the operation of the driving apparatus 170 .
[0042] According to a control method of the driving apparatus 170 , the washing step can be classified as described below. The washing step can include a first washing step S 120 forming a circulating water flow fed back to the inner tub after washing water has risen in between the inner tub 122 and the outer tub 125 due to centrifugal force developed as the inner tub 122 is rotated in one direction with a first rotation speed; and a second washing step S 130 rotating at least one of the inner tub 122 and the pulsator 140 in both directions alternately with a seond rotation speed different from the first rotation speed.
[0043] In the first washing step S 120 , the driving apparatus 170 rotates the inner tub 122 in one direction with the first rotation speed. By centrifugal force generated by accelerated rotation of the inner tub 122 in one direction, a part of fabric put inside the inner tub 122 can be distributed being adhered closely to the inner wall of the inner tub 122 together with washing water. At this time, washing water can make an inclination with a predetermined angle with respect to the inner wall of the inner tub 122 . In other words, the washing water can be so formed that width from the inner wall of the inner tub 122 is thicker in a lower part than that in an upper part.
[0044] Also, the washing water flows out to the outer tub 125 through a plurality of holes formed in the inner tub 122 . If the inner tub 122 continues to rotate, washing water moves from a space between the inner tub 122 and the outer tub 125 to the upper side. Washing water which has moved to the upper side of the outer tub 125 runs into the tub cover disposed in the upper side of the outer tub 125 and then drops into the inside of the inner tub 122 . Washing water dropping into the inside of the inner tub 122 runs into laundry; fabric is washed being forced from dropping washing water. At this time, the first rotation speed can be set to exceed a second rotation speed described later S 120 .
[0045] Meanwhile, in the second washing step S 130 , the driving apparatus 170 can rotate at least one of the pulsator 140 and the inner tub 122 in both directions alternately with a second rotation speed different from the first rotation speed.
[0046] At this time, when the pulsator 140 and the inner tub 122 are combined together being formed separately, the controller 190 , by controlling the operation of the clutch (not shown), can rotate selectively at least one of the pulsator 140 and the inner tub 122 in a predetermined direction. The driving apparatus 170 can rotate the pulsator 140 and the inner tub 122 in different directions from each other. At least one of the pulsator 140 and the inner tub 122 can be rotated in clockwise direction and then in counter clockwise direction after a predetermined time. Also, the driving apparatus 170 can rotate the other one from the pulsator 140 and the inner tub 122 in counter clockwise direction and then again in clockwise direction after a predetermined time. In case the pulsator 140 rotates, washing water inside the inner tub 122 can form a water flow due to the pulsator 140 . Due to the water flow, washing water flows and produces friction against laundry; and fabric can be washed owing to the friction.
[0047] Meanwhile, in case the pulsator 140 and the inner tub 122 are formed as a single body, the controller 190 , while rotating the inner tub 122 with the second rotation speed, can control the driving apparatus 170 to rotate in both directions alternately. When the inner tub 122 rotates, the pulsator 140 can rotate in the same direction as the inner tub 122 . During the rotation of the inner tub 122 , washing water does not move to the upper side of the outer tub 125 . When the inner tub 122 repeats rotation in both directions, washing water can form a water flow inside the inner tub 122 . Washing water inside the outer tub 125 rotates according to the rotation direction of the inner tub 122 . Fabric can be washed as washing water and fabric are rotated in the same direction as that of the inner tub 122 , S 130 .
[0048] At the time, the first washing step S 120 and the second washing S 130 are performed alternately, performing order thereof being allowed to be changed.
[0049] Meanwhile, after a predetermined time, the controller 190 measures a number N of performance of the first washing step S 120 and the second washing step S 130 . S 140
[0050] When the number N is less than a predetermined number n, the controller 190 adds one to the number N of performance of the washing steps S 141 .
[0051] Then, the controller 190 repeats performing the first washing step S 120 and the second washing step S 130 sequentially.
[0052] If the number N of performance of the washing steps is determined to be more than the predetermined number n, the controller 190 terminates the steps. In other words, the controller 190 terminates the washing step.
[0053] When the washing step is terminated, the controller 190 performs a distribution step S 150 . In the distribution step S 150 , the controller 190 rotates the inner tub 122 in one direction by controlling the driving apparatus 170 while washing water is contained in the inner tub 122 . Fabric inside the inner tub 122 can be distributed across a side wall of the inner tub 122 by centrifugal force developed by rotation of the inner tub 122 in one direction. Also, the controller 190 operates a discharge pump of a discharge apparatus 150 to discharge washing water of the inner tub 122 to the outside. At this time, the controller 190 can operate the discharge pump not only after the inner tub 122 has been rotated in one direction for a predetermined time but also while the inner tub 122 is being rotated in one direction.
[0054] As fabrics distributed across a side wall of the inner tub 122 and washing water is discharged to the outside by the operation of the discharge apparatus 150 , unbalance of the inner tub 122 can be minimized. Also, moisture of fabric can be removed quickly. Moreover, since washing water is not provided to compensate unbalance of the inner tub 122 , amount of water used can be reduced S 150
[0055] When the distribution step S 150 is terminated, the controller 190 , by accelerated rotation of the inner tub 122 with a dehydrationspeed, performs dehydration step to remove moisture of fabric S 160 .
[0056] At this time, since the inner tub 122 has been made to rotate in the distribution step S 150 before the dehydration step S 160 , accelerated rotation of the inner tub 122 can be possible without a operation of the clutch in the dehydration step S 160 . Therefore, noise due to the operation of the clutch, operation time, and energy can be reduced.
[0057] Since additional washing water is not provided to accommodate unbalance of the inner tub 122 before entering into the dehydration step S 160 , not only amount of water used can be reduced but also amount of washing water to be drained during the dehydration step S 160 is reduced; therefore, an advantageous effect can be obtained that dehydrationtime can be reduced.
[0058] FIG. 5 illustrates a flow diagram of a washing method of a washing machine according to a second embodiment of the present invention.
[0059] With reference to FIG. 5 , a washing method of a washing machine according to a second embodiment of the present invention is described.
[0060] First, after washing water is supplied, the controller 190 performs washing which removes dirt of fabric while controlling the operation of the driving apparatus 170 .
[0061] The washing includes a first washing S 220 which rotates the inner tub 122 in one direction and a second washing S 230 which rotates at least one of the inner tub 122 and the pulsator 140 in both directions alternately. Since detailed description thereof is the same as in the first embodiment, description associated therewith is not provided further.
[0062] Meanwhile, after a predetermined time is passed, the controller 190 measures a number N of performance of the first washing step S 220 and the second washing step S 230 . S 240 .
[0063] When the number N is less than a predetermined number n, the controller 190 adds one to the number N of performance of the washing step S 241 .
[0064] Then, the controller 190 repeats performing the first washing step S 220 and the second washing step S 230 sequentially.
[0065] If the number N of performance of the washing step is determined to be more than the predetermined number n, the controller 190 terminates the steps. In other words, the controller 190 terminates the washing step.
[0066] After the washing is completed, the controller 190 performs a balancing step S 250 to form a rotating water flow of washing water. At this time, washing water is rotated by rotating at least one of the inner tub 122 and the pulsator 140 selectively. In the balancing step S 250 , employed is rotation speed slower than that in the washing or distribution step S 260 described later.
[0067] After performance of the balancing step S 250 for a predetermined time, distribution step S 260 is performed. Both the distribution step S 260 and the balancing step S 250 aim to remove unbalance by distributing laundry; the two steps are different by rotation speed, washing water flow, and discharge state.
[0068] In other words, the distribution step S 260 makes fabric adhere closely to a side wall of the inner tub 122 by centrifugal force developed by roation of the inner tub 122 with higher speed than in the balancing step S 250 . At this time, the controller rotates the inner tub 122 while washing water is contained in the inner tub 122 . And since a discharge pump of the discharge apparatus 150 is turned on in the distribution step, washing water of the inner tub 122 is discharged to the outer tub 125 through the holes of the discharge apparatus 150 , helping fabric adhere to the inner wall of the inner tub 122 . As fabric is distributed across a side wall of the inner tub 122 and washing water is discharged to the outside by the operation of the discharge apparatus 150 , unbalance of the inner tub 122 can be minimized. Also, moisture of fabric can be removed quickly. Moreover, since washing water is not provided to compensate unbalance of the inner tub 122 , amount of water used can be reduced.
[0069] When the distribution step S 260 is completed, the controller 190 determines the degree of unbalance of the inner tub 122 , S 270 .
[0070] If it is found that unbalance of the inner tub exists, the controller 190 performs the distribution step S 260 again. At this time, even if unbalance is detected, the controller 190 does not provide additional water supply.
[0071] If it is determined that unbalance of the inner tub 122 does not exist, the controller 190 performs dehydration step S 280 which removes moisture of fabric by accelerated rotation of the inner tub 122 with a dehydrationspeed.
[0072] At this time, because the inner tub 122 is rotated in the distribution step S 260 before the dehydration step S 280 , accelerated rotation of the inner tub 122 can be possible without the operation of the clutch in the dehydration step S 280 . Therefore, noise due to the operation of the clutch, operation time, and energy can be reduced.
[0073] Since additional washing water is not provided to accommodate unbalance of the inner tub 122 before entering into the dehydration step S 160 , not only amount of water used can be reduced but also amount of washing water to be drained during the dehydration step S 160 is reduced; therefore, an advantageous effect can be obtained that dehydrationtime can be reduced.
[0074] A washing method of a washing machine according to a second embodiment of the present invention can minimize unbalance of the inner tub 122 by repeating the distribution step S 260 according to the existence of unbalance of the inner tub 122 , thereby improving the user satisfaction owing to the improvement of quietness at the time of spin drying.
[0075] FIG. 6 illustrates a flow diagram of a washing method of a washing machine according to a third embodiment of the present invention.
[0076] With reference to FIG. 6 , a washing method of a washing machine according to a third embodiment of the present invention is described.
[0077] First, after washing water is supplied, the controller 190 performs washing which removes dirt of fabric while controlling the operation of the driving apparatus 170 .
[0078] The washing includes a first washing step S 320 which rotates the inner tub 122 in one direction and a second washing step S 330 which rotates at least one of the inner tub 122 and the pulsator 140 in both directions alternately. Since detailed description thereof is the same as in the first embodiment, description associated therewith is not provided further.
[0079] Meanwhile, after a predetermined time is passed, the controller 190 measures a number N of performance of the first washing step S 320 and the second washing step S 330 . S 340 .
[0080] When the number N is less than a predetermined number n, the controller 190 adds one to the number N of performance of the washing steps S 341 .
[0081] Then, the controller 190 repeats performing the first washing step S 320 and the second washing step S 330 sequentially.
[0082] If the number N of performance of the washing step is determined to be more than the predetermined number n, the controller 190 terminates the steps. In other words, the controller 190 terminates the washing step.
[0083] After the washing is completed, the controller 190 performs balancing step S 350 to form a rotating water flow of washing water. Since the balancing step S 350 is the same as in the second embodiment, description associated therewith is not provided further.
[0084] After performance of the balancing step S 350 for a predetermined time, distribution step S 360 is performed.
[0085] The distribution step S 360 makes fabric adhere closely to a side wall of the inner tub 122 by centrifugal force developed by rotation of the inner tub 122 with higher speed than in the balancing step S 350 . Also, since a discharge pump of the discharge apparatus 150 is turned on in the distribution step, washing water of the inner tub 122 is discharged to the outer tub 125 through the holes of the discharge apparatus 150 , helping fabric adhere to the inner wall of the inner tub 122 . As fabric is distributed across a side wall of the inner tub 122 and washing water is discharged to the outside by the operation of the discharge apparatus 150 , unbalance of the inner tub 122 can be minimized. Also, moisture of fabric can be removed quickly. Moreover, since washing water is not provided to compensate unbalance of the inner tub 122 , amount of water used can be reduced.
[0086] When the distribution step S 360 is completed, the controller 190 performs dehydration step S 370 which removes moisture of fabric by accelerated rotation of the inner tub 122 with a dehydration step speed.
[0087] A washing method of a washing machine according to a third embodiment of the present invention, when the distribution step S 360 is completed, does not determine the existence of unbalance and not readily enter into the dehydration step S 370 ; therefore, operation time of a washing machine can be reduced.
[0088] It will be apparent to those skilled in the art that other specific embodiments of the invention can be made without departing from the spirit or modifying fundamental characteristics of the invention. Thus, it should be understood that the embodiments described above are provided as examples in all aspects and do not limit modifications and variations of the invention. The scope of the invention is specified by the appended claims rather than the detailed description given above. It should be interpreted that the spirit and the scope of the claims and all the modifications or variations derived from their equivalents belong to the scope of the invention.
|
In a washing machine according to the present invention, if a washing step is ended, a distribution step that the inner tub containing the washing water is rotated in one direction and fabrics is distributed to a side wall of the inner tub and the washing water is discharged to outside is performed. Because a fabric is evenly distributed in the distribution step, a dehydration step can be performed without carrying out a separate procedure for avoiding unbalance. Therefore, energy such as washing time and power used during the operation of the washing machine and amount of water used can be saved. Also, since a washing machine according to the present invention rotates the inner tub not only during the distribution step but also during the hydration step afterwards, operation of a clutch used to selectively rotate the pulsator and the inner tub at the time of entering to the dehydration step from the distribution step is not required. Therefore, noise due to the operation of a clutch can be reduced and operation time of the washing machine can be reduced.
| 3
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to foreign European patent application No. EP 14000580.2, filed on Feb. 19, 2014, the disclosure of which is incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention refers to a foldable urinary catheter for draining the human bladder defining an internal flow path for the urine, with a catheter tube for insertion into the urethra, the catheter tube comprising at least one hinge which is conceived to bring the catheter in a foldable, compact storage condition and an unfolded, straight ready-for-use condition.
[0003] Furthermore, the present invention also refers to a foldable urinary catheter kit comprising a foldable urinary catheter and a catheter package.
BACKGROUND
[0004] Such urinary catheters are commonly used for intermittent catheterization by persons suffering from urinary incontinence or by disabled individuals like paraplegics or quadriplegics, who are able to do so without any assistance of a healthcare professional. Urinary catheters for intermittent self-catheterization are usually disposable. Therefore, users often carry multiple urinary catheters with them when they are away from home for an extended period of time. Especially male catheters may be 40 cm long or even longer so that they require a considerable amount of space when transported. Therefore, attempts have been made to develop less space consuming catheters and catheter assemblies which allow the catheters and assemblies to be handled and stored more discreetly, for instance in the pocket of a user's clothing or handbag.
[0005] US 2003/0004496 A1 shows a urinary catheter comprising at least two catheter sections which are adapted to be arranged in a first mutual configuration in which the sections together constitute a catheter having a length longer than the length of each individual section and which also can be arranged in a second mutual configuration in which the length is less than the length of the catheter in the assembled configuration. The two catheter sections can be connected via a hinge and folded together in a “Swiss knife” embodiment. In this case, the outer diameter of the second section is larger than the outer diameter of the first section of the catheter. Furthermore, it is shown that the first and the second catheter sections are connected telescopically. Also in this embodiment, the outer diameter of the second catheter section is larger than the outer diameter of the first catheter section. It is also shown that the two catheter sections can be connected via a soft and flexible plastic hose which allows the catheter to be bent in this region. If the catheter is stored in the bent condition for a longer period of time, the catheter may stay in the bent condition and is difficult to insert into the urethra.
SUMMARY OF THE INVENTION
[0006] It is therefore the object of the present invention to provide a foldable urinary catheter and a foldable urinary catheter kit which overcome, at least partially, the disadvantages of the devices known so far, and which provide a long insertable length of the catheter which can be easily inserted in the urethra without obstacles.
[0007] For this purpose, the at least one hinge is provided in an insertable length of the catheter tube and comprises means for stabilizing the ready-for-use condition.
[0008] In this context, the term “insertable length” means the length of the catheter tube which is intended and adapted for insertion in the urethra. The insertable length of the catheter tube extends on both sides of the hinge that is before and after the hinge, so that also the hinge is inserted into the urethra when using the catheter.
[0009] The foldable urinary catheter is very small in the folded, compact storage condition and can therefore easily be stored or packed in a handbag or a clothing pocket for transportation. In the unfolded, straight ready-for-use condition, the catheter has a sufficiently long insertable length so that it can also be used by male users and can be inserted into the urethra without causing inconvenience.
[0010] Furthermore, it can be provided that the outer diameter of the catheter tube is sufficiently constant over the insertable length of the catheter tube. Therefore, the outer diameter of the part of the catheter tube which is inserted into the urethra does not have any difficult obstacles for insertion and has a smooth outer surface. The outer diameter of the catheter tube may therefore have different sizes along the insertable length. However, the changes in size are only small so that they do not hinder the introduction of the catheter tube in the urethra.
[0011] It can further also be provided that the at least one hinge is arranged in the catheter tube in such a way that the internal flow path is uninterrupted in the folded, compact storage condition. Therefore, the foldable urinary catheter is liquid-tight over the complete length also when in the folded, compact storage condition.
[0012] In a further embodiment, it can be provided that the at least one hinge forms a support structure in the catheter tube, the support structure is made of a shape memory alloy or a highly elastomeric material or a memory polymer and resumes its initial unfolded, straight condition after being brought in the folded, compact storage condition. Thus, it can be guaranteed that the urinary catheter has a straight condition in use which allows easy insertion of the urinary catheter into the urethra.
[0013] A simple and cost effective manufacturing of the foldable urinary catheter can be achieved when the support structure comprises at least one strip of a shape memory alloy or a highly elastomeric material or memory polymer extending in the longitudinal direction of the catheter tube in the region of the at least one hinge.
[0014] In another embodiment it can be provided that the at least one hinge comprises a rotary joint which allows to bring adjacent parts of the catheter tube which are separated by the at least one hinge into a position where they lie side by side. This is another easy solution for providing a liquid tight connection between the catheter tube parts in both conditions.
[0015] In still another embodiment it can be provided that the at least one hinge interrupts the internal flow path in the catheter tube in the folded, compact storage condition. Due to this solution, the bending radius between the two catheter tube parts in the folded, compact storage condition can be further reduced so that a very compact storage condition is achieved.
[0016] It can further be provided that the at least one hinge is composed of at least two components, each associated to one of the parts of the catheter tube which are connected via the hinge and wherein one of the components comprises a protrusion which engages the other one of the components in the unfolded, straight ready-for-use condition. This also includes that at least one of the hinge components is unitary with the respective catheter tube part. Due to the engagement of the protrusion of the one components in the respective other component, the unfolded, straight ready-for-use condition can easily be achieved and is maintained during insertion and use.
[0017] It can further be provided that the at least one hinge comprises a connection means which keeps the parts of the catheter tube together in the folded, compact storage condition. Thus, even when folded, the parts of the catheter tube are held together and can easily be assembled to bring them in the unfolded, straight, ready-for-use condition.
[0018] Preferably, the connection means is integrated in the two components of the hinge. In this way, a safe connection between the two catheter tube parts is realized.
[0019] In a simple embodiment which is easy to manufacture the connection means is preferably a flexible strip connecting the two components.
[0020] However, it is also possible that the connection means is integrated in the catheter tube. When the connection means is integrated in the catheter tube, it is possible to obtain a larger inner diameter of the urinary catheter.
[0021] In still another embodiment, the foldable urinary catheter further comprises a straightening aid which is slidably arranged on the catheter tube. The straightening aid is especially advantageous for users with reduced dexterity and helps them in bringing the folded urinary catheter in the unfolded, straight ready-for-use condition.
[0022] The straightening aid can be easy and cost effective in production when it comprises a short, tube like piece which is arranged on the outer diameter of the catheter tube.
[0023] The above mentioned object is also solved by a foldable urinary catheter kit with a foldable urinary catheter as described above and a catheter package which tightly surrounds the folded catheter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] In the following, the invention is described in more detail with the aid of drawings.
[0025] FIG. 1 a shows a foldable urinary catheter in an unfolded, straight ready-for-use condition,
[0026] FIG. 1 b shows the foldable urinary catheter from FIG. 1 a in a folded, compact storage condition,
[0027] FIG. 2 a shows another embodiment of a hinge of the foldable urinary catheter of FIGS. 1 a and 1 b in a folded condition,
[0028] FIG. 2 b shows the hinge of FIG. 2 a in the straight condition,
[0029] FIG. 3 a shows a further embodiment for a hinge of the foldable urinary catheter of FIGS. 1 a and 1 b in a folded condition,
[0030] FIG. 3 b shows the hinge of FIG. 3 a in an intermediate position,
[0031] FIG. 3 c shows the hinge of FIGS. 3 a and 3 b in the straight condition,
[0032] FIG. 3 d shows a section through the hinge of FIG. 3 c,
[0033] FIG. 4 a shows a further embodiment of a hinge for the foldable urinary catheter of FIGS. 1 a and 1 b in a folded condition,
[0034] FIG. 4 b shows the hinge of FIG. 4 a in a straight condition,
[0035] FIG. 5 a shows a further embodiment for a hinge for the foldable urinary catheter of FIGS. 1 a and 1 b in a folded condition,
[0036] FIG. 5 b shows the hinge of FIG. 5 a in the straight condition,
[0037] FIG. 5 c shows a perspective view of the hinge of FIGS. 5 a and 5 b in an intermediate position,
[0038] FIG. 6 a shows a further embodiment of a hinge for the foldable catheter of FIGS. 1 a and 1 b in a folded condition,
[0039] FIG. 6 b shows the hinge of FIG. 6 a in the straight condition,
[0040] FIG. 7 a shows a further embodiment of a hinge for the foldable urinary catheter of FIGS. 1 a and 1 b in a folded condition,
[0041] FIG. 7 b shows the hinge of FIG. 7 a in the straight condition,
[0042] FIG. 8 a shows a further embodiment of a foldable urinary catheter in a folded condition,
[0043] FIG. 8 b shows the urinary catheter of FIG. 8 a in a straight condition,
[0044] FIG. 9 a shows still a further embodiment of a foldable urinary catheter in a folded condition,
[0045] FIG. 9 b shows the urinary catheter of FIG. 9 a in a straight condition,
[0046] FIG. 10 a shows a foldable urinary catheter with a straightening aid,
[0047] FIG. 10 b shows the foldable urinary catheter of FIG. 9 a with the straightening aid in the straight condition,
[0048] FIG. 11 a shows a foldable urinary catheter comprising three hinges in a folded condition,
[0049] FIG. 11 b shows the urinary catheter of FIG. 11 a in a package.
DETAILED DESCRIPTION
[0050] FIG. 1 a shows a foldable urinary catheter 1 . The urinary catheter 1 comprises a catheter tube 2 with a catheter tip 3 at its first end and a funnel 4 at its other end. However, the funnel is not necessary and the catheter can have a different second end without a funnel.
[0051] In FIG. 1 a , the urinary catheter 1 is shown in an enlarged view. The catheter tube 2 may have a longer length as depicted in FIG. 1 a with the interrupted lines. The first end of the urinary catheter 1 with the catheter tip 3 is inserted into the urethra. When the catheter tip 3 reaches the human bladder, urine from the bladder can flow through at least one eyelet 5 disposed at or near the catheter tip 3 into the catheter tube 2 and is then discharged through the funnel 4 . This fluid connection defines an internal flow path 6 of the urinary catheter 1 .
[0052] The urinary catheter 1 further comprises a hinge 7 which is arranged in an insertable length of the catheter tube 2 . The term “insertable length” means the part of the catheter tube 2 which is intended and adapted for insertion into the urethra. As can be clearly seen from FIG. 1 a , the outer diameter D of the catheter tube 2 is constant at least along the insertable length of the catheter tube 2 . In FIG. 1 a , the urinary catheter 1 is shown in an unfolded, straight ready-for-use condition. The urinary catheter 1 can be folded at the hinge 7 and be brought in a folded, compact storage condition. This condition is shown in FIG. 1 b . In the folded, compact storage condition, the hinge 7 is opened and the two parts of the catheter tube 2 which are connected via the hinge 7 are arranged side by side. In the embodiment shown in FIG. 1 b , the internal flow path 6 is interrupted in the folded, compact storage condition. The hinge 7 comprises two components 8 , 9 . The first component 8 is connected with the part of the catheter tube 2 which carries the catheter tip 3 . The second component 9 of the hinge 7 is connected with the second part of the catheter tube 2 which carries the funnel 4 . The two component 8 , 9 are connected via a connection means 10 . In the embodiment shown in FIG. 1 b , the connection means 10 is a strip, which is integrated in the two components 8 , 9 . The first component 8 of the hinge 7 carries a protrusion 11 which engages with the second component 9 of the hinge 7 in the unfolded straight ready-for-use condition and ensures that the catheter tube 2 with the hinge 7 remains in the unfolded straight condition when the urinary catheter 1 is inserted in the urethra.
[0053] FIGS. 2 a and 2 b show a further embodiment of the hinge 7 . 1 in the catheter tube 2 . In this embodiment, identical parts as in FIGS. 1 a and 1 b are named with the same reference numbers. FIGS. 2 a and 2 b show only parts of the catheter tube 2 with the hinge 7 . 1 . In FIG. 2 a , the catheter tube 2 and the hinge 7 . 1 are shown in the folded, compact storage condition. The hinge 7 . 1 comprises a piece of flexible tube 12 which is reinforced with strips 13 . The strips 13 are made of a shape memory alloy. In FIGS. 2 a and 2 b it is shown that the hinge 7 . 1 is reinforced with four strips which are evenly distributed around the diameter of the catheter tube 2 . However, it is also possible that the hinge comprises fewer strips, for example only one, or more strips. The strips 13 extend in the longitudinal direction L of the catheter tube 2 .
[0054] In FIG. 2 b , the catheter tube 2 and the hinge 7 . 1 of FIG. 2 a are shown in the unfolded, straight ready-for-use condition. As already described above, the strips 13 are made from a shape memory alloy, for example Nitinol. The straight condition as shown in FIG. 2 b is the initial condition of the strips 13 . When the strips 13 made of the shape memory alloy are brought in folded, compact storage condition as shown in FIG. 2 a , the strips 13 remember the initial condition and will spring back in this initial condition when possible. The strips 13 thus guarantee that the catheter tube 2 remains straight, at least along its insertable length, when inserted in the urethra. In the embodiment shown in FIGS. 2 a and 2 b , the hinge 7 . 1 is so conceived that the internal flow path 6 is uninterrupted in the folded, compact storage condition as well as in the unfolded, straight ready-for-use condition.
[0055] Another embodiment, where the internal flow path 6 of the urinary catheter 1 is uninterrupted in the folded, compact storage condition as well as in the straight, unfolded ready-for-use condition is shown in FIGS. 3 a to 3 d . Also in this embodiment, identical parts already shown in the earlier embodiments are named with the same reference number.
[0056] FIG. 3 a shows the catheter tube 2 and with a hinge 7 . 2 in the folded, compact storage condition. The hinge 7 . 2 is designed so that the internal flow path 6 in the urinary catheter 1 remains uninterrupted in the folded and in the unfolded condition. The hinge 7 . 2 comprises three components 14 , 15 , 16 . The two components 14 , 16 are substantially identical and are made of a tube-like piece. Components 14 and 16 each comprise an extension 17 , 18 which has an outer diameter that essentially corresponds to the inner diameter of the catheter tube 2 . The extensions 17 , 18 are inserted in the pieces of the catheter tube 2 which are separated by the hinge 7 . 2 . The second ends of the components 14 and 16 have a larger outer diameter which is substantially identical to the outer diameter D of the insertable length of the catheter tube 2 . This second end of the components 14 , 16 is slanted at an angle of approximately 45° with the longitudinal axis L of the catheter tube 2 . The two components 14 , 16 are connected via the third component 15 . The third component 15 is also slanted at both ends so that it comprises an angle of approximately 45° with the longitudinal direction L of the catheter tube 2 .
[0057] FIG. 3 d shows a cross section of the catheter tube 2 with the hinge 7 . 2 in the unfolded, straight ready-for-use condition. In FIG. 3 d , the bottom side of component 15 is longer than the upper side of component 15 and component 15 comprises annular protrusions at both slanted ends which engage with annular grooves in the outer components 14 , 16 .
[0058] It is now explained with the aid of FIGS. 3 a to 3 c how the urinary catheter 1 can be unfolded. FIG. 3 a shows the catheter tube 2 and the hinge 7 . 2 in the folded, compact storage condition. The two parts of the catheter tube 2 which are separated by the hinge 7 . 2 lie side by side. For unfolding the catheter, one of the parts of the catheter tube is rotated so that component 16 is rotated in respect to component 15 and the respective part of the catheter tube 2 extends in the longitudinal direction of component 15 . The two parts of the catheter tube 2 separated by the hinge 7 . 2 now form an angle of 90°. The other part of the catheter tube 2 is then also rotated around 90°, so that the complete insertable length of the catheter tube 2 extends in the longitudinal direction L and the catheter 1 is in the unfolded, straight ready-for-use condition. The three components 14 , 15 , 16 of the hinge 7 . 2 ensure that the catheter 1 remains in the straight condition when unfolded. The catheter 1 can thus be easily inserted into the urethra.
[0059] As shown in FIG. 3 d , the inner diameter of the catheter tube 2 and therewith the diameter of the internal flow path 6 in the urinary catheter 1 is reduced in the region of the hinge 7 . 2 . In the catheter shown in FIGS. 2 a and 2 b on the contrary, the hinge 7 . 1 does not lead to a reduction of the internal diameter of the catheter tube 2 .
[0060] FIGS. 4 a and 4 b show a further embodiment of a hinge 7 . 3 of the foldable urinary catheter 1 . FIGS. 4 a and 4 b also show only parts of the catheter tube 2 with the hinge 7 . 3 . Same components as in the previously described embodiments are named with the same reference numbers. FIG. 4 a shows the catheter tube 2 and the hinge 7 . 3 in the folded condition. The hinge 7 . 3 comprises two components 19 , 20 . The first component 19 is attached to the first part of the catheter tube 2 , the second component 20 is attached to the second part of the catheter tube 2 . Both components 19 , 20 comprise an extension 21 , 22 . The extensions 21 , 22 have an outer diameter which is smaller than the outer diameter of the insertable length of the catheter tube 2 and which can be inserted in the internal flow path 6 of the urinary catheter 1 . The remaining outer diameter of the hinge 7 . 3 , that is the remaining outer diameter of the two components 19 , 20 , is substantially identical to the outer diameter of the catheter tube 2 along the insertable length so that the insertable length of the catheter tube 2 in which the hinge 7 . 3 is arranged, has a constant outer diameter.
[0061] The first component 19 of the hinge 7 . 3 further comprises a protrusion 23 . The outer diameter of the protrusion 23 is substantially identical to the inner diameter of the second component 20 . The two components 19 , 20 are connected via a connecting means 24 . For bringing the catheter from the folded, compact storage condition as shown in FIG. 4 a in the unfolded straight ready-for-use condition as shown in FIG. 4 b , one of the catheter parts is folded outwards as shown with arrow 25 in FIG. 4 a . The protrusion 23 of the first component 19 of the hinge 7 . 3 then engages with the second component 20 of the hinge 7 . 3 . For this purpose, the protrusion 23 preferably has a slanted edge which simplifies the insertion of the protrusion 23 in the second component 20 . The two parts of the hinge 7 . 3 then snap together and keep the urinary catheter 1 and the catheter tube 2 in the unfolded, straight condition during use of the catheter. As shown in FIG. 4 b , the connection means 24 which keeps the two components of the hinge 7 . 3 together is a strip which is integrated in the two components 19 , 20 of the hinge 7 . 3 .
[0062] In FIGS. 5 a to 5 c , an alternative for the connection means is shown. The hinge 7 . 4 as shown in FIGS. 5 a to 5 c is substantially identical to the hinge as shown in the embodiment described in connection with FIGS. 4 a and 4 b . However, in this embodiment, the connection means is a strip 26 which is unitary with the protrusion 28 on the second component 30 of the hinge 7 . 4 . At the free end of strip 26 , a stop 31 is provided. The first component 29 of the hinge 7 . 4 comprises a channel 32 , through which the strip 26 extends. The free end of the strip 26 with the stop 31 projects out of the channel 32 . When the urinary catheter 1 is in the folded, compact storage condition as shown in FIG. 5 a , the stop 31 abuts at the end of the channel 32 and keeps the two parts of the catheter tube 2 together. Then, one end of the catheter is turned around 180° as shown in FIG. 5 a with arrow 33 . FIG. 5 c shows an intermediate position when bringing the catheter in the unfolded, straight ready-for-use condition. The two parts of the catheter tube are pushed together, so that protrusion 28 of the second component 30 of the hinge 7 . 4 approaches the first component 29 of the hinge 7 . 4 . The strip 26 is pushed through the channel 32 . FIG. 5 b shows the catheter in the unfolded straight condition wherein the two components 29 , 30 of the hinge 7 . 4 engage. The protrusion 28 is completely inserted in the first component 28 and thus keeps the catheter in the unfolded, straight condition, also when inserting the catheter in the urethra.
[0063] FIGS. 6 a and 6 b show a still further embodiment of the hinge 7 . 5 in the catheter tube 2 . Identical parts of the catheter and the hinge are named with the same reference numbers as used in the preceding embodiments. In the following, only the differences are described. The hinge 7 . 5 comprises a first, short tube-like component 34 made of a rigid material which is inserted in one part of the catheter tube 2 . The outer diameter of component 34 is substantially identical to the inner diameter of the catheter tube 2 . The second component of the hinge 7 . 5 is the other part of the catheter tube 2 . The connection means 38 , which keeps the two parts of the catheter tube together in the folded condition is integrated in the catheter tube 2 .
[0064] FIG. 6 a shows the catheter tube 2 and the hinge 7 . 5 in the folded condition. The two parts of the catheter tube lie side by side. The component 34 is inserted in one part of the catheter tube 2 so that it protrudes over the end of this part of the catheter tube 2 .
[0065] FIG. 6 b shows the catheter tube of the hinge 7 . 5 in the unfolded, straight ready-for-use condition. The protruding part of the component 34 is inserted in the second part of the catheter tube 2 so that the catheter tube 2 is stabilized in the region of the hinge 7 . 5 and remains in the straight condition when inserting the catheter 1 in the urethra.
[0066] FIGS. 7 a and 7 b show another embodiment for a hinge 7 . 6 for a foldable urinary catheter 1 . As in the description of the preceding embodiments, identical parts of the catheter and the hinge are named with the same reference numbers. At the hinge 7 . 6 , the catheter tube 2 is divided in two parts. However, the two parts may not be completely separated but can still be held together at a connection means 39 . This can, for example, be achieved by a partial cut through the catheter tube 2 which does not completely separate the wall of the catheter tube 2 . The uncut wall then forms the connection means 39 . In each of the two parts of the catheter tube 2 , a respective end 40 , 41 of a plug 44 is inserted. The two ends 40 , 41 of the plug 44 are connected with each other via a further connection means 42 . In FIG. 7 a , the hinge 7 . 6 and the two parts of the catheter tube 2 are shown in the folded condition. In this folded, compact storage condition, the two parts of the catheter tube 2 lie side by side but are connected with each other via the connection means 39 of the catheter tube 2 and the connection means 42 of the plug 44 . However, the connection means of the two ends of the catheter tube 2 are not necessary and can be disposed of. The two ends of the plug 40 , 41 comprise protruding ribs 43 which engage with the inner wall of the catheter tube 2 . Thus, the plug 44 is secured in the two parts of the catheter tube 2 . The protrusions 43 can be barbed to ensure a secure hold of the plug 44 in the catheter tube 2 .
[0067] FIG. 7 b shows the hinge 7 . 6 in the unfolded, straight ready-for-use condition. The two parts of the catheter tube 2 abut on each other, so that the internal flow path 6 of the catheter tube 2 is continuous and not interrupted. The two ends 40 , 41 of the plug 44 which are connected via the connecting means 42 substantially have a tube like form and also form a passageway for the liquid which is dispensed through the urinary catheter. In the region of the hinge 7 . 6 , there is a cut out in between the two end regions 40 , 41 of the plug 44 and only the connection means 42 remains. Thus, the catheter tube 2 and the plug 44 can easily be brought in the folded, compact storage condition.
[0068] Still another embodiment of a hinge 7 . 7 for urinary catheter 1 is shown in FIGS. 8 a and 8 b . In FIGS. 8 a and 8 b , the complete urinary catheter 1 is shown. The urinary catheter 1 comprises a catheter tube 2 , a catheter tip 3 with at least one eyelet 5 at one end of the catheter tube 2 and a funnel 4 at the other end of the catheter tube 2 . The hinge 7 . 7 is provided in the insertable length of the catheter tube 2 . At the hinge 7 . 7 , the catheter tube 2 is separated in two parts, however, the catheter tube is not completely cut through but sticks together at a connection means 45 . Connection means 45 is a part of the wall of the catheter tube 2 which has not been cut through in the region of the hinge 7 . 7 . In the catheter tube 2 , a telescopic extension tube 46 is inserted. The extension tube 46 is inserted in the end of the catheter tube 2 which lies opposite to the catheter tip 3 . The outer diameter of the extension tube 46 is slightly smaller than the inner diameter of the catheter tube 2 so that the telescopic extension tube 46 is slidably arranged in the catheter tube 2 . At the outer end of the extension tube 46 , the funnel 4 is attached. The inner end of the extension tube 46 is connected with a hollow plug 47 , for example with a string or a tether 48 or by means of a skived tube acting as telescopic extension tube 46 and hollow plug 47 and tether 48 . The position of the plug can also act as an eyelet door(s) confining the fluid flow of fluid in a packaged state.
[0069] FIG. 8 a shows the urinary catheter 1 in the folded, compact storage condition. The catheter tube 2 is split open at the hinge 7 . 7 so that the two parts of the catheter tube 2 lie one beside the other. The extension tube 46 is completely inserted in the catheter tube 2 and the hollow plug 47 is arranged in the catheter tube 2 near the catheter tip 3 . The string 48 is folded in the region of the hinge 7 . 7 .
[0070] FIG. 8 b shows the urinary catheter 1 in the unfolded, straight ready-for-use condition. The two parts of the catheter tube 2 are now aligned so that the internal flow path 6 is continuous and uninterrupted. The extension tube 46 has been pulled outward, whereby the hollow plug 47 has been pulled in the region of the hinge 7 . 7 and engages and reinforces the hinge 7 . 7 . Thus, the urinary catheter 1 is secured in the unfolded, straight ready-for-use condition. The inner end of the extension tube 46 forms a fluid tight seal 49 with the catheter tube 2 . Thus, the extension tube 46 can be used to deliver or direct urine directly to a toilet or another disposal device.
[0071] FIGS. 9 a and 9 b show another embodiment of a urinary catheter 1 with a hinge 7 . 8 . As in the preceding embodiments, the same or identical parts of the catheter and the hinge have the same reference numbers. FIG. 9 a shows the urinary catheter 1 in the folded, compact storage condition. The urinary catheter 1 comprises a catheter tube 2 with a catheter tip 3 at one end and a funnel 4 at the opposite end. The catheter tip 3 is provided with at least one eyelet 5 . In the insertable length of the catheter tube 2 , the hinge 7 . 8 is provided. As in the embodiment shown in FIGS. 8 a and 8 b , a telescopic extension tube 46 is inserted in the catheter tube 2 . The extension tube 46 is inserted in the end of the catheter tube 2 which lies opposite to the catheter tip 3 . The outer diameter of the extension tube 46 is slightly smaller than the inner diameter of the catheter tube 2 so that the telescopic extension tube 46 is slidably arranged in the catheter tube 2 . At the outer end of the extension tube 46 , the funnel 4 is attached. At the other end of the extension tube 46 , the inner end, a hollow plug 47 is arranged in the folded, compact storage condition as shown in FIG. 9 a . The hollow plug 47 is not connected to the extension tube 46 . The extension tube protrudes over the end of the catheter tube along a distance Z.
[0072] FIG. 9 b shows the urinary catheter 1 of FIG. 9 a in the unfolded, straight ready-for-use condition. For bringing the urinary catheter 1 in the unfolded, straight ready-for-use condition, the telescopic extension tube 46 is pushed inwardly in the catheter tube 2 so that the hollow plug 47 is pushed in the bent region or hinge region 7 . 8 of the catheter tube along the distance Z. The hollow plug 47 then straightens the urinary catheter 1 and remains in the hinge region 7 . 1 to fix the unfolded, straight, ready-for-use condition. The hollow plug 47 can be provided with a slanted front edge to facilitate the unfolding of the catheter 1 . After the plug 47 is pushed in the hinge region and the unfolded condition of the catheter 1 is achieved, the telescopic extension tube 46 is retracted by the user and can be used as an extension. The distance Z of the extension tube 46 is at least as large as the length X of the hinge region as shown in FIGS. 9 a and 9 b . The hollow plug recovers the shaft tube bent region X to regain optimum fluid patency and the intended geometry of the intermittent catheter design.
[0073] FIGS. 10 a and 10 b show a foldable urinary catheter 1 . The urinary catheter 1 comprises a straightening aid 35 which is slidably arranged on the catheter tube 2 and helps a user in bringing the urinary catheter 1 from the folded, compact storage condition in the unfolded, straight ready-for-use condition. The straightening aid 35 has essentially a tube-like shape with an internal passageway and an outer surface. The diameter of the internal passageway is slightly larger than the outer diameter of the catheter tube 2 . Thus, the straightening aid 35 is slidable along the outer surface of the catheter tube 2 . The outer surface of the straightening aid 35 may have a concave shape so that it can be easily gripped with two fingers. Furthermore, the outer surface of the straightening aid 35 may comprise protrusions or grooves to provide a certain roughness which allows a firm grip on the straightening aid 35 . When bringing the urinary catheter 1 from the folded condition into the unfolded condition, the user simply slides the straightening aid 35 along the longitudinal direction L of the catheter tube 2 . The straightening aid 35 then brings the parts of the catheter tube 2 which are separated by the hinges 7 in the same direction, so that the hinges 7 engage in the straight condition.
[0074] The urinary catheter 1 may also comprise an insertion aid 36 which allows an easy insertion of the catheter into the urethra of a user. Furthermore, the insertion aid 36 can also act as the straightening aid by itself. In FIGS. 10 a and 10 b , the hinges 7 are schematically shown. Hinges as described in the embodiments shown in FIGS. 2 to 9 may be arranged in the urinary catheter 1 as shown in FIGS. 10 a and 10 b . As shown in FIG. 10 b , a urinary catheter 1 may comprise more than one hinge, for example, two or three hinges.
[0075] FIG. 11 a shows the urinary catheter 1 of FIGS. 10 a and 10 b in the folded condition. The urinary catheter 1 comprises three hinges so that the catheter tube 2 is divided in four parts. In the folded condition as shown in FIG. 11 a , the parts of the catheter tube 2 which are separated by the hinges 7 , lie side by side. The insertion aid 36 and the straightening aid 35 are arranged near the catheter tip 3 . Catheter tip 3 and funnel 4 also lie side by side.
[0076] FIG. 11 b shows a catheter kit comprising the urinary catheter 1 of FIG. 11 a and a package 37 . The urinary catheter 1 is placed in the catheter package 37 in the folded condition so that it is very compact. The package 37 tightly encloses the folded urinary catheter so that the complete kit is very compact and can be easily stored or transported, for example in a clothing pocket or in a handbag.
[0077] Preferably, the urinary catheter is shown in all figures is a hydrophilic coated urinary catheter. The hydrophilic coating of the catheter extends along the complete insertable length of the catheter tube 2 , including the part where the hinge 7 is arranged.
[0078] In order to provide the desired catheter flexibility, the catheters shown may have a tapered distal section. This can, for example, be achieved by a slight decrease of the inner and outer diameter of the catheter tube. A decrease of both, the inner and the outer diameter of the catheter tube is more efficient in increasing flexibility (decreasing second moment of area) than reducing the inner or outer diameter individually.
LIST OF REFERENCE NUMBERS
[0000]
1 : Urinary catheter
2 : Catheter tube
3 : Catheter tip
4 : Funnel
5 : Eyelet
6 : Internal flow path
7 ; 7 . 1 ; 7 . 2 ; 7 . 3 ; 7 . 4 ; 7 . 5 ; 7 . 6 ; 7 . 7 ; 7 . 8 ; Hinge
8 : First hinge component
9 : Second hinge component
10 : Connection means
11 : Protrusion
12 : Flexible tube
13 : Strip
14 : First hinge component
15 : Third hinge component
16 : Second hinge component
17 : First extension
18 : Second extension
19 : First hinge component
20 : Second hinge component
21 : First extension
22 : Second extension
23 : Protrusion
24 : Connection means
25 : Arrow
26 : Strip
28 : Protrusion
29 : First hinge component
30 : Second hinge component
31 : Stop
32 : Channel
33 : Arrow
34 : Hinge component
35 : Straightening aid
36 : Insertion aid
37 : Package
38 : Connection means
39 : Connection means
40 : First end plug
41 : Second end plug
42 : Connection means
43 : Protrusions
44 : Plug
45 : Connection means
46 : Telescopic extension tube
47 : Hollow plug
48 : String
49 : Seal
D: Outer diameter catheter tube
L: Longitudinal direction catheter tube
|
A foldable urinary catheter is provided for draining the human bladder defining an internal flow path for the urine, with a catheter tube for insertion into the urethra, the catheter tube comprising at least one hinge which is conceived to bring the catheter in a folded, compact storage condition and an unfolded, straight ready-for-use condition as well as to a foldable urinary catheter kit. A foldable urinary catheter and a foldable urinary catheter kit are provided which are very small and compact in a transport or storage condition and which provide a long insertable length of the catheter tube. Therefore, the at least one hinge in the catheter tube is provided in the insertable length of the catheter tube and is configured for stabilizing the ready-for-use condition. The kit comprises the foldable urinary catheter and a catheter package which tightly surrounds the folded catheter.
| 0
|
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority of Provisional application serial No. 60/209,447, filed on Jun. 5, 2000.
FIELD OF THE INVENTION
This invention relates to polymer blends of PVDF thermoplastics with FKM fluoroelastomers.
BACKGROUND OF THE INVENTION
Rubber/plastic blends are known in the prior art. Prominent examples include the blends of nitrile/butadiene copolymer rubber (NBR) with polyvinylchloride (PVC), and blends of styrene/butadiene copolymer rubber (SBR) with so-called “high-styrene resins” (which are styrene/butadiene copolymers with typically 20% or less butadiene). In some cases, the plastic phase of a rubber/plastic blend may co-crosslink with the rubber phase, as in blends of SBR with high-styrene resins. Blends in which the plastic phase does not crosslink or graft with the elastomer phase are also useful, as in the case of NBR/PVC blends.
Rubber/plastic blends of FKM with “THV” polymers from Dyneon are also known in the prior art. THV polymers are copolymers of tetrafluoroethylene (TFE), hexafluoropropene (HFP), and vinylidene fluoride (VDF), with VDF content well below 50% by weight. Such blends have been used in fuel-containment applications, such as fuel lines and fuel filler neck hoses.
FKM/PVDF and FKM/THV blends in which the FKM is present as crosslinked particles are also known in the prior art. This is believed to be the foundation of the “Fluoroprene” product line from Freudenberg NOK. See, for example, the paper by Craig Chmielewski, “Fluoroprene: Freudenberg NOK's new Fluorinated TPV,” presented at the Performance Elastomers & TPEs 2001 seminar in Cleveland, Ohio May 14-15, 2001. Note that in such dynamically cured blends, the FKM phase is crosslinked and does not flow per se, which is quite different than the case of the present invention.
SUMMARY OF THE INVENTION
The invention is a moldable, extrudable, crosslinkable composition of matter involving at least two flowable, non-crosslinked polymer phases, wherein Phase 1 is composed primarily of an FKM fluoroelastomer and Phase 2 is composed primarily of a PVDF thermoplastic copolymer, plus crosslinking agents for the FKM fluoroelastomer. The invention also applies to the partially crosslinked articles that are derived from thermally crosslinking the above compositions. The FKM fluoroelastomer of Phase 1 is a copolymer of vinylidene fluoride, hexafluoropropene, and optionally also tetrafluoroethylene and/or various perfluorovinylethers, and/or various cure site monomers, which we shall refer to generically as “FKM.” Component 2 is a PVDF homopolymer or a copolymer of vinylidene fluoride with one or more co-monomers, including specifically hexafluoropropene (PVDF/HFP copolymers), tetrafluoroethylene (PVDF/TFE copolymers), and chlorotrifluoroethylene (PVDF/CTFE copolymers). The crosslinking agents used for the FKM may or may not also react with the PVDF.
The blends of this invention are shaped by molding, extrusion, or other methods of processing to final shape, usually but not necessarily below 140 degrees C. After shaping, the blends are thermally cured, usually but not necessarily at a temperature above 140 degrees C. In most cases, but not necessarily, the blends of this invention must be under pressure during curing to avoid blisters. The maximum practical cure temperature for the blends of this invention is often limited by the tendency of the cured parts to blister when the mold is opened (due to the sudden pressure decrease).
The FKM component of the blends of this invention can be crosslinked by any method known in the prior art, such as for example diamines or diamine-releasing chemicals, bisphenol cure systems, or peroxide cure systems. Cure systems that release minimal amounts of volatile compounds are preferred over cure systems that release a lot of volatile compounds, because volatile compounds lead to blistering.
Weight % fluorine in FKM is a critical variable that impacts especially resistance to swelling by hydrocarbons and permeation by fuels. Insofar as the FKM-rich Phase 1 forms the major part of the blends of this invention, it is vital to choose a high-fluorine content FKM if one wishes to obtain a high permeation resistance. Because of the importance of permeation resistance, a particular bisphenol-crosslinkable high fluorine-content FKM (Dai-El G-621, which contains 71.5% fluorine, approximately) has been used in most of the experiments performed in developing the present invention. The process of this invention is equally applicable to blends of PVDF and/or PVDF copolymers with other commercially significant grades of FKM, containing 65-73% combined fluorine, such as dipolymers of vinylidene fluoride with hexafluoropropene (e.g., Viton A from DuPont), low-temperature grades of FKM containing perfluorovinylether monomer residues, and/or various peroxide crosslinkable FKMs containing labile bromine or iodine, or vinyl groups.
The compositions of this invention may also contain additional components, such as fillers, fibers, pigments, and processing aides. A particularly useful group of examples of this invention comprise electrically conductive moldable, extrudable, crosslinkable compositions of matter in which an effective level of conductive carbon black and/or combinations of carbon black with larger particle size conductive fillers (such as graphite, silicon carbide, metal powders, or metal-coated mineral fillers) is mixed with the FKM/PVDF blend. Admixing of conductive carbon black into such a conductive blend may occur either simultaneously with formation of the blend, or the conductive carbon black may be pre-incorporated into the PVDF prior to mixing the PVDF with the FKM.
This invention features a moldable, extrudable, thermally crosslinkable composition of matter blend comprising about 50-99% by weight fluoropolymers, in which about 50-95% of the polymer content of the blend is an FKM fluoroelastomer and about 5-50% of the polymer content of the blend is one or more thermoplastic PVDF polymers or copolymers containing at least about 70% by weight vinylidene fluoride monomer units, and the crosslinked articles derived from processing and curing the subject composition of matter.
The composition may comprise one or more PVDF/HFP copolymers at a total level between 10-45% by weight of the polymer content of the blend. The composition may comprise a PVDF/CTFE copolymer at a level between 10-45% by weight of the polymer content of the blend. The composition may comprise a PVDF/HFP copolymer at a level between 10-44.5% by weight of the polymer content of the blend and a minor portion of a PVDF/CTFE copolymer at a level between 0.5-5% of the polymer content of the blend. The composition may comprise a PVDF/HFP copolymer at a level between 10-44.5% by weight of the polymer content of the blend and a minor portion of a THV copolymer with a melting temperature below 150° C., at a level between 0.5-5% of the polymer content of the blend.
The composition may further comprise one or more platy fillers selected from the group of such fillers consisting of mica, talc, clay, and delaminated graphite, to accomplish a low-permeability composition. The platy filler may be composed at least in part of mica, talc, or clay which has been treated with an aminosilane.
The composition may comprise a PVDF/HFP copolymer at a level between 10-45% by weight of the polymer content of the blend, optionally a fluoroplastic processing aid at a level up to 5% by weight of the polymer, with the balance of the polymeric portion of the composition consisting of a high-fluorine FKM polymer, containing at least 71% by weight fluorine.
The composition may further comprise at least two conductive fillers of different size and shape, to accomplish electrical resistivity below 10 6 ohm-cm. The conductive fillers may comprise 2-4% by volume of a platy conductive filler selected from the group consisting of graphite powder, metal-coated mica, and metal flakes, plus 5-8% by volume of an electrically conductive carbon black which has at most 120 m 2 /gram BET surface area. The composition may further comprise a platy filler selected from the group consisting of mica, talc, clay, and delaminated graphite. The platy filler may be composed at least in part of mica, talc, or clay that has been treated with an aminosilane. The composition may further comprise one or more types of oligomeric poly-CTFE as a processing aid.
The FKM may be a peroxide-crosslinkable elastomer, and the composition may further comprise a free radical generating initiator and optionally a coagent. The FKM may be a peroxide-crosslinkable low-temperature FKM elastomer. The FKM may be a labile iodine-containing peroxide-crosslinkable FKM elastomer. The FKM may be a high-fluorine material with greater than 72% combined fluorine by weight. The composition may further comprise about 0.2-4 parts of a zinc salt of one or several fatty acids. The composition may comprise a PVDF/HFP copolymer at a level between 10-44.5% by weight of the polymer content of the blend, a conductive carbon black, and a minor portion of a THV copolymer with a melting temperature below 150° C., at a level between 0.5-5% of the polymer content of the blend.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plot of measured permeation constants for the six compounds of table 4 as a function of time; and
FIG. 2 is a re-plot of data from FIG. 1 for the five compounds that are based on 71% fluorine FKMs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Copolymers of vinylidene fluoride (VDF) with hexafluoropropene (HFP) in which 70% or more of the polymer weight is derived from vinylidene fluoride are well known in the prior art. These polymers retain significant crystallinity due to PVDF domains, unlike FKM elastomers, which have lower levels of vinylidene fluoride units. Such PVDF/HFP thermoplastic copolymers are available from Ausimont, Solvay, and Elf Atochem for example. Such copolymers contain the same two monomers that make up the major portion of FKM, and also contain the same type of cure site that is present in bisphenol-curable FKM elastomers, though at a lower concentration than is found in typical FKM polymers. PVDF/HFP copolymers with HFP content between 10-15% by weight, in conjunction with bisphenol-cured FKM elastomers and the cure systems for the FKM, have been found to be particularly desirable embodiments of the present invention.
PVDF/HFP copolymers are believed to covulcanize to some extent with FKM via the bisphenol cure system, whereas PVDF/TFE and PVDF/CTFE copolymers are not believed to covulcanize via the bisphenol cure mechanism. Thus, PVDF/CTFE copolymers remain fluid at the end of a bisphenol cure cycle, whereas PVDF/HFP become somewhat grafted to the FKM phase. The practical result is that FKM/PVDF blends containing primarily PVDF/CTFE polymers are prone to blistering after vulcanization by the bisphenol cure system, whereas FKM/PVDF blends containing primarily PVDF/HFP polymers do not blister until a higher cure temperature is applied. (Blistering in the bisphenol cure system is caused mainly by steam, which is a byproduct of the vulcanization chemistry. Use of a purely MgO/Mg(OH) 2 activation system in a bisphenol-cured FKM decreases the tendency to blister somewhat. Uncured molten polymer creates a weak point where a steam bubble can nucleate.)
Note that neither PVDF homopolymer nor any of the known PVDF copolymers crosslink via peroxide/coagent crosslinking. Peroxide-crosslinkable FKM is also more expensive than bisphenol-crosslinkable FKM of comparable properties, so blends of this invention involving peroxide-crosslinkable FKM are more expensive than blends based on comparable bisphenol-cure grades of FKM. Blends of PVDF with peroxide-crosslinkable FKM are still useful, however, in that certain key properties, such as very good low temperature properties for example, are only available with peroxide-cure grades of FKM.
Blends of bisphenol-cured FKM with high levels (more than 5% of the total polymer) of PVDF/CTFE must be cured at rather low temperatures to avoid blistering. Since this necessarily entails longer cure times, PVDF/CTFE copolymers are not usually preferred as the sole basis for FKM/PVDF blends in which a bisphenol cure is used to crosslink the FKM. This may be due to the inertness of PVDF/CTFE copolymers towards the bisphenol cure system, or it could be that PVDF/CTFE polymers provide better conditions for bubble nucleation. It has been found however, that low addition levels of either PVDF/CTFE copolymers or low-melting THV copolymers are desirable as additives to FKM/(PVDF/HFP) blends which are crosslinked via the bisphenol cure mechanism.. Addition of either THV 220 (from Dyneon, LLC) or Solef 31508 or Solef 32008 (PVDF/CTFE copolymers) to blends of FKM/(PVDF/HFP) lowers ML (the minimum torque observed in an oscillating disk rheometer curve) substantially, and improves processability.
It has also been observed that Solef 31508 or Solef 32008 (PVDF/CTFE copolymers) strongly inhibit the bisphenol cure system for FKM, so that blends of this invention of FKM with PVDF/CTFE copolymers must use either a diamine cure system or peroxide-crosslinkable FKMs. (The reason such blends are appealing is that Solef 31508 and Solef 32008 have excellent low-temperature flexibility compared to PVDF/HFP or THV polymers of comparable crystallinity.)
Additional highly desirable versions of the novel blends of the present invention are electrically conductive compounds in which a conductive carbon black is first dispersed into the PVDF. Subsequently the PVDF/carbon black mixture is admixed with FKM and additional compounding ingredients. It has been found that certain blends prepared this way have higher electrical conductivity and a smoother texture indicating superior mixing of the polymer phases compared to compositionally identical blends in which the carbon black is added to the FKM/plastic mixture as the mixture is being formed. In order for this methodology to work, the conductive carbon blacks employed must be capable of withstanding the high shear forces generated during compounding of the PVDF/carbon black masterbatch. It has been found that high surface area carbon blacks such as the various grades of Ketchenblack from Akzo, or Cabot's Black Pearls 2000 are significantly mechanically degraded during mixing of a PVDF/carbon black masterbatch. Also, these same high surface area carbon blacks have been found to substantially slow down the bisphenol cure of FKM/PVDF blends compared to lower surface area carbon blacks. Therefore, high structure, relatively low surface area (less than 100 meter 2 per gram BET nitrogen surface area) conductive carbon blacks such as Ensaco 250 (from MMM Carbon Company) have been found to work much better in the electrically conductive versions of the invention than high surface area conductive carbon blacks (which are mechanically degraded during mixing to a greater extent than low surface area blacks).
Additional highly desirable versions of the novel blends of the present invention are those which use oligomeric poly(chlorotrifluoroethylene) (“poly-CTFE” herein, CAS number 9002-83-9) as a processing aid. Compared to other processing aids that are highly fluid at typical molding/extruding temperatures (100-130° C.), oligomeric poly-CTFE produces compositions with lower permeability.
TABLE 1
Polymers used in Examples
Polymer name used
Trade name and description
in application
of key polymer properties
FKM #1
Dai-El G-621, 71% fluorine FKM, 50 Mooney
viscosity, bisphenol/phosphonium cure
incorporated, with medium bispenol level;
designed for molded goods.
FKM #2
Fluorel E-15128, 71% fluorine FKM, 30 Mooney,
bisphenol/phosphonium cure incorporated, with
relatively low bisphenol level; designed for hoses.
FKM #3
Fluorel FT 2320, 70% fluorine FKM, 20 Mooney,
bisphenol/phosphonium cure incorporated, with
medium bisphenol level; designed for molded
goods.
FKM #4
Fluorel FC 2152, 66% fluorine FKM, 50 Mooney,
bisphenol/phosphonium cure incorporated, with
relatively low bisphenol level; designed for
diaphragms.
FKM #5
Fluorel FC 2260, 66% fluorine FKM, 60 Mooney,
peroxide crosslinkable, with labile bromine
cure sites.
FKM #6
Dai-El G-999, 73% fluorine FKM, 35 Mooney at
100° C., peroxide crosslinkable, with
labile iodine cure sites.
FKM #7
Dai-El LT-302, 30 Mooney, 65% fluorine low-
temperature FKM, 30 Mooney, peroxide cross-
linkable, with labile iodine cure sites.
FKM #8
Viton GFLT-502, 70% fluorine FKM, 50 Mooney,
peroxide crosslinkable, with both labile
bromine & iodine cure sites.
PVDF #1
Hylar FXH PVDF/HFP copolymer with 5-6% HFP,
melting temperature 155-160° C., Melt
Flow Index 1-4 (10 kilo load)
PVDF #2
Solef 31508 PVDF/CTFE copolymer with about
15% CTFE, melting temperature
150-169° C., Melt Flow Index 15-25
PVDF #3
Solef 21508 PVDF/HFP copolymer with about
15% HFP, melting temperature 130-135° C.,
Melt Flow Index 4-8
PVDF #4
Kynar 740A PVDF homopolymer, melting
temperature 165-170° C., Melt Flow index 15-25
Notes for Table 1:
Mooney viscosities cited above are based on the large rotor, value after 1 minute preheat plus 10 minutes run time. Run temperature is 121° C., unless otherwise specified.
Melting temperature data are per ASTM D4318.
Melt Flow Index data on PVDF polymers measured with 5-kilogram load at 232° C., unless a different load is specified.
Dai-El is a trademark of Daikin America, Hylar is a trademark of Ausimont, Fluorel is a trademark of Dyneon, Viton is a trademark of DuPont, Solef is a trademark of Solvay, and Kynar is a trademark of Elf Atochem.
EXAMPLES
Table 2 shows several typical embodiments of the present invention. In Example 1 (lab book #RF3-7-2), PVDF #1 is Banbury-mixed with a conductive grade carbon black and high-fluorine bisphenol-curable FKM #1 in a first stage mix, followed by addition of calcium hydroxide and magnesium oxide in a second-stage mix. In the absence of any processing aides, this composition is quite viscous, as shown by the high ML (40.2 inch-pounds). Although this compound was difficult to process, it had useful mechanical properties.
Examples 2-5 demonstrate that various polymeric, fluorine-containing processing aides can dramatically lower ML compared to Example 1.
Example 2 (lab book #RF3-8-2) shows that 2.04 phr (parts per hundred polymer) of oligomeric poly-CTFE (Halocarbon 200 oil from Halocarbon Products Corporation) lowers ML dramatically, increases the scorch delay, and speeds up the crosslinking reactions. This particular processing aid also has a positive effect on permeation rate compared to various hydrocarbon plasticizers tested.
Example 3 (lab book #RF3-8-4) shows that 2.04 phr (parts per hundred polymer) of THV-220 also reduces ML dramatically, without slowing the cure or speeding up the scorching process.
Example 4 (lab book #RF3-8-5) shows that 2.0 phr (parts per hundred polymer) of THV-220 plus 2.0 phr of poly-CTFE oligomer also reduces ML dramatically, with very little effect on cure rate. There is however no evidence of synergism between THV 220 and poly-CTFE oligomer.
Example 5 (lab book #RF3-6-4) demonstrates that a combination of poly-CTFE and zinc stearate produces a very unusual and highly desirable cure profile in which a long scorch delay is combined with a fast cure. This is especially important for the FKM/PVDF blends of the present invention because such blends must be mixed, extruded, and/or molded at higher temperatures than are conventional for non-plastic-containing FKM, and so better scorch safety is highly desirable.
Examples 6-12 of Table 2 show the effects of various conventional processing aids on the same basic FKM/PVDF formula used in Examples 1-5. Example 6 shows that only 0.68 phr of zinc stearate dramatically reduces ML, while extending scorch delay (compared to Example 1). A variety of other conventional processing aids and combinations thereof were also evaluated, with little advantage seen over zinc stearate (Examples 7-12).
Examples 7-9 show that both PEG 400 (polyethylene glycol of average molecular weight 400 daltons) and TP-95 (di(butoxy-ethoxy-ethyl)adipate) cause an acceleration of cure rate, which can be opposed effectively by zinc stearate. Separate experiments indicate that these polyether materials also cause an unacceptable rate of curing during storage. PEG 400 is thought to be the primary cause of the high ML of Example 9, having caused a substantial degree of crosslinking during mixing, though Halocarbon 200 oil could also be synergistic in this regard. (Example 9 is replicated; see Table 3, Example 20.)
Examples 10-12 of Table 2 show the effects of three particular processing aides that are often used in oil-resistant elastomers, each used in conjunction with 0.68 phr of zinc stearate. Example 10, using 1.36 phr of Vanfre AP-2 (from R. T. Vanderbilt Company) has the same sort of extreme scorch delay and relatively fast cure as Example 5. Example 11, using 1.36 phr of Struktol WB-222 (from Struktol Company of America), cures faster and with less scorch delay compared to Example 10. Example 12, using 1.36 phr of TOTM (trioctyltrimellitate), has greater elongation to break compared to Example 10 (or any other compound presented in Table 2).
Table 3 shows a variety of formulations of the present invention which are intended to be electrically conductive to an extent which is adequate for electrostatic dissipation (ESD). Several alternative methods to measure electrical conductivity are known; we used the surface microprobe from Prostat, Inc. (PRS-801, consistent with ESD Association standard 11.11). The microprobe was used to measure conductivity at least 5 times on different portions of the sample. The raw data were analyzed by calculating the mean and standard deviation of the raw data; this information is included in the tables where it was measured. Second, an estimate of the maximum resistance which can reliably be guaranteed for the particular sample is calculated as (mean resistance+3(standard deviation of resistance)). For ESD applications, it is conventional to require a maximum resistance of 10 8 ohm-cm. Several of the compounds of Table 3 meet this target maximum resistance level.
Examples 13-16 of Table 3 show a series of compounds with increasing levels of THV-220. All these compounds had adequate electrical conductivity. There is some evidence that THV-220 enhanced conductivity, compared to other similar formulae without THV; there appears to be an optimum THV-220 level around 3 phr based on these experiments.
Example 17 shows that TP-95 (di(butoxy-ethoxy-ethyl)adipate) is a potent cure accelerator. It is believed that the multiple ether linkages of TP-95 serve to solvate calcium ions, therefore increasing the reaction rate of Ca(OH) 2 with the FKM, which is a vital step in the sequence of reactions leading to FKM vulcanization. The increased ML of Example 17 versus Example 13 clearly shows that the curing process has occurred to some extent during mixing.
Comparing Example 18 and/or Example 19 to Example 20 shows the effect of adding a high-surface area conductive carbon black (Ensaco 350) to a formulation containing 8.15 phr of Ensaco 250. This substitution increased conductivity, but no more than simply increasing the level Ensaco 250 (compare Example 18 to Example 22; even in the presence of 20 phr of talc, conductivity of Example 22 was nearly equal to that of Example 18). In the particular case of Example 18, the Ensaco 350 was added as the very last ingredient, under conditions where the PVDF plastic phase did not fully melt during processing; this is believed to have caused an increase of ML. In the particular case of Example 19, the Ensaco 350 was added into the first stage mix, under conditions where the PVDF plastic phase did fully melt during processing; this leads to a lower ML.
Comparing Example 19 to Example 23, it is clear that the high surface area conductive carbon black, Ensaco 350, strongly inhibits the bisphenol cure. This could in principle be due to sulfur content of Ensaco 350, but this should not be true based on the manufacturer's data. Therefore, the bisphenol cure inhibition of Ensaco 350 and other high surface area carbon blacks is thought to be due to adsorption of one or more ingredients (such as bisphenol or phosphonium accelerator) onto the carbon black surface.
Example 19 is very similar to Example 18 without the Halocarbon 200 oil, but in this case both the Ensaco blacks (250 & 350) were incorporated into a masterbatch of rubber and plastic in a high-temperature blending step prior to incorporation of the Ca(OH) 2 and MgO. It is surprising that this small change of recipe, together with the change of mix method caused such a large change in cure rate. (Example 19 did not crosslink to a normal extent in 12 minutes, and was still in the early stages of curing when the experiment was terminated.) It is also possible that the Halocarbon 200 oil had a profound effect on the cure rate, and in this case the observed difference in the ML could be more due to a degree of scorching in Example 18 as opposed to the Ensaco 350 per se.
Example 20 apparently scorched during mixing. This compound includes both Halocarbon 200 and PEG 400, and is a replicate of Example 9.
All the examples up to and including Example 21 were prepared by first mixing a masterbatch of FKM, conductive carbon black, and PVDF at a temperature above the softening point of the FKM. This masterbatch was subsequently admixed with the remaining compounding ingredients, including Ca(OH) 2 and MgO, in a final stage mixing operation. These intermediate masterbatches are not explicitly shown for Examples 1-20 in the tables, but Example 23 of Table 3 is the specific intermediate masterbatch used in preparing Example 21.
Example 22 was prepared differently than Example 21, though it is compositionally identical. In preparing Example 22, all the conductive carbon black for the entire batch was first mixed with the PVDF plastic, as shown in masterbatch Example 24. Then, this plastic/carbon black MB was mixed with the FKM and some additional compounding ingredients in a second masterbatch (compositionally identical to Example 23). Comparing Examples 21 and 22 shows the effect of pre-dispersing the conductive carbon black into the PVDF plastic prior to making the hot blend of PVDF and FKM (Example 23). The largest effect of the modified mix procedure is on the conductivity, which is higher by a factor of more than one million for the version (Example 22) prepared by first pre-dispersing the carbon black into the PVDF before forming the blend.
Examples 21 and 22 contain aminosilane-grafted talc as reinforcing and permeation-limiting filler. It has been found that ordinary talc inhibits the cure of high-fluorine FKMs like FKM #1 and FKM #2 used in most of the experiments cited in the tables of this application, whereas aminosilane-grafted talc does not inhibit the cure. This cure inhibiting effect is not seen for lower fluorine FKMs such as FKM #3.
Table 4 shows recipes, physical properties, and permeability to fuel for a set of compositions of this invention compared to a prior art compound, WG-7-29-33 (Example 25), which is also an elastomer/plastic blend based on FKM #2 blended with THV-500. Example 25 is considered a state-of-the-art elastomer compound for resistance to fuel permeation. The particular permeability numbers reported in Table 4 were developed for replicate samples of each compound, and represent averaged data for a long-term experiment from 592-665 hours.
The permeation measurements reported in Table 4 were performed by the gravimetric method described in SAE Technical Paper 2000-01-1096, using Thwing-Albert permeation cups at room temperature (21±1° C.). The permeant used in these experiments was CM15, ASTM Reference Fuel C+15% methanol (one of several industry standards). The measured permeation constants for the six compounds of Table 4 are shown in FIG. 1 as a function of experimental time. The one compound that has much higher permeation than the other five is Example 27 (RF3-15-4), which is based on 70% fluorine FKM #3, whereas all the other compounds are based on 72% fluorine FKMs. FIG. 1 shows why the reported data in Table 2 was selected as an average of data from 592-665 hours; the calculated permeation constants showed a lot of variation in the early data, but became stable after an extended permeation time.
FIG. 2 replots the data for the five compounds of Table 4 that are based on 71% fluorine FKMs. Removing Example 27 (which has much higher permeation rate than the other samples) gives a better comparison of the remaining compounds, which are logically comparable based on the fact that all five of the compounds shown in FIG. 2 are based on 72% fluorine FKMs.
FIG. 2 demonstrates graphically that various compounds of the present invention outperform a state-of-the-art FKM/THV blend. The two lowest-permeability compounds out of the series are Examples 28 and 30, neither of which contains any added non-fluorocarbon processing aids. Comparing these compounds with Example 25, the FKM #2/THV-500 sample (which also does not include any added process aids), Example 28 produced 5 times lower permeation, and Example 30 produced permeation which is lower by a factor of 2 compared to the FKM/THV-500 control.
Comparing Examples 28 and 30, it is clear that adding more PVDF/CTFE copolymer (FKM #2) to the basic composition of Example 28 increased permeability significantly. This seems to imply that the permeability of the FKM/PVDF blends is better than PVDF #2, a pure PVDF/CTFE copolymer. This is rather surprising.
Comparing Examples 26 and 29, which are identical except for using THV-220 in Example 26 and PVDF #2 in Example 29, it appears that even at such a low level (1 phr), a processing additive can significantly affect permeability. It further appears that PVDF/CTFE copolymer is preferable to THV-220 copolymer in terms of permeability of the final compound.
It is instructive to notice that Example 29 had lower permeability than the FKM/PVDF control, even though this compound had a significant amount of non-fluorocarbon additives (which are known to increase permeability). It is believed that in this instance the lower intrinsic permeability of the polymer system, combined with the effect of aminosilanized talc (a platy filler), produced equivalent permeability to the FKM/THV control.
Table 5 presents data on a variety of FKM/PVDF blends of this invention which are designed to show that the invention is also applicable to a range of FKM polymers, and not just to high-fluorine FKMs. Note in particular that good properties have been attained for a variety of compositions in which the FKM cure system is not believed to form crosslinks with the PVDF at all.
TABLE 2
FKM/PVDF Blends
This series reviews data from several different experiments.
Lab book number, recipe in parts per 100 polymer (phr)
lab book #:
RF3-7-2
RF3-8-2
RF3-8-4
RF3-8-5
RF3-6-4
RF3-6-2
INGREDIENT
#1
#2
#3
#4
#5
#6
PVDF #1 (PVDF/HFP copolymer)
32.07
32.07
32.07
32.07
32.07
32.07
FKM #1
67.93
67.93
67.93
67.93
67.93
67.93
THV-220 (Dyneon)
—
—
2.04
2.00
—
—
TOTM
—
—
—
—
—
—
Halocarbon 200 oil
—
2.04
—
2.00
2.00
—
Carbowax PEG 400
—
—
—
—
—
—
TP-95 (di(butoxy-ethoxy-ethyl)adipate)
—
—
—
—
—
—
Zinc stearate
—
—
—
—
0.68
0.68
Vanfre AP-2
—
—
—
—
—
—
Struktol WB 222
—
—
—
—
—
—
EXP-835-73-1 (HiMod 360 mica, aminosilanized)
—
—
—
—
—
—
Ensaco 250 Black Beads
8.15
8.15
8.15
8.15
8.15
8.15
Calcium hydroxide-HP
6.11
6.11
6.11
6.11
6.11
6.11
StarMag CX-150 (MgO)
3.40
3.40
3.40
3.40
3.40
3.40
Total:
117.65
119.69
119.69
121.66
120.33
118.33
Calculated Specific Gravity:
1.862
1.903
1.903
1.903
1.894
1.893
Lab book number, recipe in parts per 100 polymer (phr)
lab book #:
RF3-7-3
RF3-7-5
RF3-7-4
RF3-6-6
RF3-6-8
RF3-6-11
INGREDIENT
#7
#8
#9
#10
#11
#12
PVDF #1 (PVDF/HFP copolymer)
32.07
32.07
32.07
32.07
32.07
32.07
FKM #1
67.93
67.93
67.93
67.93
67.93
67.93
THV-220 (Dyneon)
—
—
—
—
—
—
TOTM
—
—
—
—
—
1.36
Halocarbon 200 oil
—
—
1.36
—
—
—
Carbowax PEG 400
0.68
—
0.68
—
—
—
TP-95 (di(butoxy-ethoxy-ethyl)adipate)
—
1.36
—
—
—
—
Zinc stearate
1.36
0.68
—
0.68
0.68
0.68
Vanfre AP-2
—
—
—
1.36
—
—
Struktol WB 222
—
—
—
—
1.36
—
EXP-835-73-1 (HiMod 360 mica, aminosilanized)
—
—
—
—
—
—
Ensaco 250 Black Beads
8.15
8.15
8.15
8.15
8.15
8.15
Calcium hydroxide-HP
6.11
6.11
6.11
6.11
6.11
6.11
StarMag CX-150 (MgO)
3.40
3.40
3.40
3.40
3.40
3.40
Total:
119.69
119.69
119.69
119.69
119.69
119.69
Calculated Specific Gravity:
1.838
1.837
1.854
1.873
1.872
1.874
Rheological & Cure Properties
RF3-7-2
RF3-8-2
RF3-8-4
RF3-8-5
RF3-6-4
RF3-6-2
ML
40.20
11.90
12.40
12.30
10.00
12.10
MH
68.80
59.20
61.80
59.00
62.80
61.50
ts2
2.60
3.15
3.13
3.30
6.20
3.18
t′50
4.87
4.87
4.95
4.97
8.20
5.13
t′90
7.38
6.07
6.22
6.30
9.38
6.42
ODR initial torque
—
—
—
—
—
—
Cure system figure of merit (ts2/(t′90-ts2)
0.54
1.08
1.01
1.10
1.95
0.98
Rheological & Cure Properties
RF3-7-3
RF3-7-5
RF3-7-4
RF3-6-6
RF3-6-8
RF3-6-11
ML
11.90
12.40
47.20
11.50
10.60
10.30
MH
66.10
65.40
70.40
70.00
70.30
65.90
ts2
4.12
3.23
2.25
5.88
4.32
4.53
t′50
6.20
4.77
3.35
7.75
5.95
6.20
t′90
7.55
6.15
6.58
8.97
7.02
7.17
ODR initial torque
—
—
—
—
—
—
Cure system figure of merit (ts2/(t′90-ts2)
1.20
1.11
0.52
1.90
1.60
1.72
RF3-7-2
RF3-8-2
RF3-8-4
RF3-8-5
RF3-6-4
RF3-6-2
Physical Properties
#1
#2
#3
#4
#5
#6
Shore A Durometer
85
93
93
92
—
93
Tensile Strength, pounds/square inch (psi)
2,217
2,148
2,147
1,738
—
2,110
Elongation at break (%)
228
292
277
188
—
286
Stress at 100% Strain (psi)
1,324
1,401
1,412
1,409
—
1,388
Max Electrical Resistance, ohm-cm. (mean +
no data
7.6E + 13
2.0E + 10
2.1E + 10
no data
3.7E + 13
3 sigma)
Average electrical resistance, ohm-cm.
no data
1.9E + 13
6.1E + 09
4.1E + 09
no data
5.3E + 12
standard deviation electrical resistance, ohm-cm
no data
1.9E + 13
4.5E + 09
5.7E + 09
no data
1.1E + 13
RF3-7-2
RF3-8-2
RF3-8-4
RF3-8-5
RF3-6-4
RF3-6-2
Physical Properties
#7
#8
#9
#10
#11
#12
Shore A Durometer
93
90
—
—
93
91
Tensile Strength, pounds/square inch (psi)
2,068
2,233
—
—
1,580
2,152
Elongation at break (%)
310
296
—
—
212
358
Stress at 100% Strain (psi)
1,325
1,406
—
—
1,150
1,255
Max Electrical Resistance, ohm-cm. (mean +
9.9E + 13
2.5E + 13
no data
no data
no data
no data
3 sigma)
Average electrical resistance, ohm-cm.
5.7E + 13
1.5E + 13
no data
no data
no data
no data
standard deviation electrical resistance, ohm-cm
1.4E + 13
3.2E + 12
no data
no data
no data
no data
TABLE 3
FKM/PVDF Blends
This series reviews data from several different experiments.
Lab book number, recipe in parts per 100 polymer (phr)
lab book #:
RF3-8-8
RF3-8-9
RF3-8-10
RF3-8-11
RF3-8-12
RF3-13-7
INGREDIENT
#13
#14
#15
#16
#17
#18
PVDF #1 (PVDF/HFP copolymer)
31.00
31.00
31.00
31.00
31.00
32.07
FKM #1
68.00
68.00
68.00
68.00
68.00
67.93
THV-220(Dyneon)
1.00
2.00
3.00
4.00
1.00
1.35
Ensaco 250 Black Beads
12.00
12.00
12.00
12.00
12.00
8.15
Ensaco 350 Black Beads
—
—
—
—
—
2.60
Calcium hydroxide-HP
6.10
6.10
6.10
6.10
6.10
6.10
StarMag CX-150 (MgO)
3.40
3.40
3.40
3.40
3.40
3.40
Total:
121.50
122.50
123.50
124.50
123.00
122.95
Calculated Specific Gravity:
1.900
1.901
1.901
1.902
1.880
1.901
Lab book number, recipe in parts per 100 polymer (phr)
lab book #:
RF3-13-9
RF3-8-3
RF3-15-7
RF3-15-10
RF3-15-1
RF3-15-8
INGREDIENT
#19
#20
#21
#22
#23
#24
PVDF #1 (PVDF/HFP copolymer)
31.00
32.07
31.00
31.00
31.00
31.00
FKM #1
68.00
67.93
68.00
68.00
68.00
—
THV-220(Dyneon)
1.00
—
1.00
1.00
1.00
1.00
Ensaco 250 Black Beads
8.00
8.15
11.00
11.00
11.00
11.00
Ensaco 350 Black Beads
2.60
—
—
—
—
—
Calcium hydroxide-HP
6.10
6.11
6.10
6.10
6.10
—
StarMag CX-150 (MgO)
3.40
3.39
3.40
3.40
3.40
—
Total:
120.10
119.69
142.70
142.70
120.50
43.00
Calculated Specific Gravity:
1.901
1.892
1.894
1.876
1.900
1.872
Rheological & Cure Properties
RF3-8-8
RF3-8-9
RF3-8-10
RF3-8-11
RF3-8-12
RF3-13-7
ML
14.90
14.30
14.40
14.00
21.20
17.50
MH
54.00
53.60
53.30
53.10
59.10
62.60
ts2
3.20
3.30
3.33
3.80
2.12
2.48
t′50
5.28
5.43
5.52
6.23
3.68
4.50
t′90
6.82
6.88
7.07
7.93
5.35
6.90
ODR initial torque
—
—
—
—
—
58.40
Cure system figure of merit [ts2/(t″90-ts2)]
0.88
0.92
0.89
0.92
0.66
0.56
Rheological & Cure Properties
RF3-13-9
RF3-8-3
RF3-15-7
RF3-15-10
RF3-15-1
RF3-15-8
ML
13.50
47.80
14.5
13.6
11.50
10.60
MH
23.00
71.50
50.9
50.6
70.00
70.30
ts2
6.63
2.23
3.52
4.13
5.88
4.32
t′50
9.52
3.63
6.78
8.57
7.75
5.95
t′90
11.52
6.70
11.62
13.38
8.97
7.02
ODR initial torque
63.50
—
58.8
59.4
—
—
Cure system figure of merit [ts2/(t″90-ts2)]
1.36
0.50
0.54
0.99
1.90
1.60
Physical Properties
RF3-8-8
RF3-8-9
RF3-8-10
RF3-8-11
RF3-8-12
RF3-13-7
Example #:
#13
#14
#15
#16
#17
#18
Shore A Durometer
94
95
94
92
92
92
Tensile Strength, pounds/square inch (psi)
1,768
1,758
1,672
1,728
1,943
2,061
Elongation at break (%)
274
281
286
254
283
187
Stress at 100% Strain (psi)
1,497
1,477
1,412
1,450
1,489
1,568
Surface res., Maximum ohm-cm. (mean + 3 sigma)
1.5E + 04
2.9E + 05
9.0E + 03
8.8E + 03
1.4E + 08
4.4E + 07
Average surface res., ohm-cm.
4.6E + 03
5.7E + 04
3.6E + 03
2.5E + 03
3.0E + 07
5.6E + 06
standard deviation resistance, ohm-cm
3.3E + 03
7.6E + 04
1.8E + 03
2.1E + 03
3.5E + 07
1.3E + 07
Physical Properties
RF3-13-9
RF3-8-3
RF3-15-7
RF3-15-10
RF3-15-1
RF3-15-8
Example #:
#19
#20
#21
#22
#23
#24
Shore A Durometer
—
93
96
96
—
93
Tensile Strength, pounds/square inch (psi)
—
2,147
1733
1669
—
1,580
Elongation at break (%)
—
277
142
155
—
212
Stress at 100% Strain (psi)
—
1,412
1700
1618
—
1,150
Surface res., Maximum ohm-cm. (mean + 3 sigma)
no data
6.7E + 13
1.9E + 14
2.3E + 08
no data
no data
Average surface res., ohm-cm.
no data
4.9E + 13
#######
1.09E +
no data
no data
0.7
standard deviation resistance, ohm-cm
no data
6.2E + 12
#######
7.35E +
no data
no data
0.7
TABLE 4
FKM/PVDF Blends
This series reviews data from several different experiments for which permeability was measured.
Lab book number, recipe in parts per 100 polymer (phr)
lab book #
WG-7-29-33
RF3-15-10
RF3-15-4
RF3-16-2
RF3-15-13
RF3-16-3
INGREDIENT
#25
#26
#27
#28
#29
#30
PVDF #1 (PVDF/HFP copolymer)
—
31.00
31.00
31.00
31.00
31.00
FKM #1
—
68.00
—
68.00
68.00
68.00
THV-220 (Dyneon)
—
1.00
1.00
—
—
—
FKM #3
—
—
68.00
—
—
—
N-990 carbon black
20.00
—
—
—
—
—
PVDF #2 (PVDF/CTFE copolymer)
—
—
—
1.00
1.00
5.00
Carbowax PEG 400
—
—
—
—
—
—
Dyneon THV-500
30.00
—
—
—
—
—
FKM #2
70.00
—
—
—
—
—
TP-95 (di(butoxy-ethoxy-ethyl)adipate)
—
1.50
1.50
—
1.50
—
Zinc stearate
—
0.70
0.70
—
0.70
—
Vanfre AP-2
—
—
—
—
—
—
Struktol WB 222
—
—
—
—
—
—
Polar Minerals 9603 (talc, aminosilanized)
—
20.00
—
10.00
20.00
10.00
Ensaco 250 Black Beads
7.50
11.00
11.00
11.00
11.00
11.00
Ensaco 350 Black Beads
Calcium hydroxide-USP
5.00
6.10
6.10
6.10
6.10
6.10
StarMag CX-150 (MgO)
—
3.40
3.40
3.40
3.40
3.40
Total:
132.50
142.70
122.70
130.50
142.70
134.50
Calculated Specific Gravity:
1.917
1.873
1.933
1.918
1.959
1.912
Rheological & Cure Properties
WG-7-29-3
RF3-15-10
RF3-15-4
RF3-16-2
RF3-15-13
RF3-16-3
ML
11.70
13.60
11.00
13.50
13.40
13.30
MH
32.10
50.60
63.80
51.70
55.60
46.90
ts2
3.58
4.13
3.93
3.75
4.25
6.93
t′50
5.48
8.57
8.58
7.48
8.85
16.18
t′90
7.83
13.38
12.12
11.28
14.72
21.52
ODR initial torque
41.50
59.40
65.80
—
60.90
—
Cure system figure of merit [ts2/(t′90-ts2)]
0.84
0.45
0.48
0.50
0.41
0.47
WG-7-29-33
RF3-15-10
RF3-15-4
RF3-16-2
RF3-15-13
RF3-16-3
Physical Properties
#25
#26
#27
#28
#29
#30
Shore A Durometer
92
96
96
93
96
95
Tensile Strength, pounds/square inch (psi)
1,856
1,669
1,733
1,770
1,712
2,019
Elongation at break (%)
283
155
142
191
173
144
Stress at 100% Strain (psi)
1,381
1,618
1,700
1,686
1,666
1,958
Permeability to CM15 fuel blend 21C
2.84E − 05
4.43E − 05
2.34E − 04
5.85E − 06
2.35E − 05
1.38E − 05
Surface res., Maximum ohm-cm. (mean + 3 sig
1.8E + 08
no data
2.5E + 08
no data
no data
no data
Average surface res., ohm-cm.
3.6E + 07
2.0E + 07
6.1E + 07
no data
no data
no data
standard deviation resistance, ohm-cm
4.9E + 07
2.9E + 07
6.4E + 07
no data
no data
no data
Permeability relative to FKM/THV blend
100%
156%
823%
21%
83%
49%
TABLE 5
FKM/PVDF Blends
This series reviews data from several different experiments.
Lab book number, recipe in parts per 100 polymer (phr)
lab book #:
RF3-31-25
RF3-31-26
RF3-31-27
RF3-31-28
RF3-31-29
RF3-31-30
INGREDIENT
#31
#32
#33
#34
#35
#36
FC-2260
68.00
FC-2152
68.00
Dai-EI G999
68.00
Dai-EI LT302
68.00
68.00
GFLT-502
68.0
Hylar FXH (XPH-487)
32.0
32.00
32.00
32.00
32.0
Solef 31508 PDVF/CTFE copolymer
32.00
N-990
25.00
25.00
2500
25.00
25.00
25.00
Total
125.00
125.00
125.00
125.00
125.00
125.00
Following ingredients added on mill
MASTER Batch
125.00
125.00
125.00
125.00
125.00
125.00
Varox DCP-40KE HP
1.00
1.00
1.00
TAIC-DLC-A (72%)
3.50
3.00
3.00
3.00
3.50
Varox DBPH-50
3.50
3.50
Flourocal H-20
6.00
StarMag CX-150
3.00
Total:
132.00
134.00
129.00
129.00
129.00
132.00
Calculated Specific Gravity:
Rheological & Cure Properties
RF3-31-25
RF-31-26
RF3-31-27
RF3-31-28
RF3-31-29
RF3-31-30
ML
17.90
17.90
4.50
11.40
11.30
17.20
MH
54.30
45.20
69.80
70.90
63.50
57.70
ts2
1.43
1.93
1.55
1.78
1.80
1.48
t′50
2.17
3.03
2.60
3.00
2.97
2.22
t′90
4.28
4.18
3.82
4.50
4.40
4.17
ODR initial torque
50.10
49.60
34.10
48.30
39.10
47.50
Cure system figure of merit [ts2/(t′90-ts2)]
0.50
0.85
0.68
0.65
0.69
0.55
Physical Properties
RF3-31-25
RF3-31-26
RF3-31-27
RF3-31-28
RF3-31-29
RF3-31-30
TEAR C-DIE
290
316
380
306
231
245
Shore A Durometer
92
91
94
92
87
89
Tensile Strength, pounds/square inch (psi)
2,214
1,585
1,867
1,751
1,577
2,088
Elongation at break (%)
251
373
139
222
313
210
Stress at 100% Strain (psi)
1,402
1,148
1,818
1,321
909
1,568
|
A moldable, extrudable, thermally crosslinkable composition of matter containing 50-99% by weight fluoropolymers, in which 50-95% of the polymer content of the blend is an FKM fluoroelastomer and 5-50% of the polymer content of the blend is one or more thermoplastic PVDF polymers or copolymers containing at least 70% by weight vinylidene fluoride monomer units, and the crosslinked articles derived from processing and curing the subject composition of matter.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the papermaking arts. More specifically, the present invention relates to through-air-drying (TAD) fabrics used in the manufacture of bulk tissue and towel, and of nonwoven articles and fabrics.
2. Description of the Prior Art
Soft, absorbent disposable paper products, such as facial tissue, bath tissue and paper toweling, are a pervasive feature of contemporary life in modern industrialized societies. While there are numerous methods for manufacturing such products, in general terms, their manufacture begins with the formation of a cellulosic fibrous web in the forming section of a paper machine. The cellulosic fibrous web is formed by depositing a fibrous slurry, that is, an aqueous dispersion of cellulose fibers, onto a moving forming fabric in the forming section. A large amount of water is drained from the slurry through the forming fabric, leaving the cellulosic fibrous web on the surface of the forming fabric.
The cellulosic fibrous web is then transferred to a through-air-drying (TAD) fabric or belt by means of an air flow, brought about by vacuum or suction, which deflects the web and forces it to conform, at least in part, to the topography of the TAD fabric or belt. Downstream from the transfer point, the web, carried on the TAD fabric or belt, passes through a through-air dryer, where a flow of heated air, directed against the web and through the TAD fabric or belt, dries the web to a desired degree. Finally, downstream from the through-air dryer, the web may be adhered to the surface of a Yankee dryer and imprinted thereon by the surface of the TAD fabric or belt, for further and complete drying. The fully dried web is then removed from the surface of the Yankee dryer with a doctor blade, which foreshortens or crepes the web and increases its bulk. The foreshortened web is then wound onto rolls for subsequent processing, including packaging into a form suitable for shipment to and purchase by consumers.
As noted above, there are many methods for manufacturing bulk tissue products, and the foregoing description should be understood to be an outline of the general steps shared by some of the methods. For example, the use of a Yankee dryer is not always required, as, in a given situation, foreshortening may not be desired, or other means, such as “wet creping”, may have already been taken to foreshorten the web.
It should be appreciated that TAD fabrics may take the form of endless loops on the paper machine and function in the manner of conveyors. It should further be appreciated that paper manufacture is a continuous process which proceeds at considerable speeds. That is to say, the fibrous slurry is continuously deposited onto the forming fabric in the forming section, while a newly manufactured paper sheet is continuously wound onto rolls after it is dried.
Those skilled in the art will appreciate that fabrics are created by weaving, and have a weave pattern which repeats in both the warp or machine direction (MD) and the weft or cross-machine direction (CD). Woven fabrics take many different forms. For example, they may be woven endless, or flat woven and subsequently rendered into endless form with a seam. It will also be appreciated that the resulting fabric must be uniform in appearance; that is, there are no abrupt changes in the weave pattern to result in undesirable characteristics in the formed paper sheet. In addition, any pattern marking imparted to the formed tissue will impact the characteristics of the paper.
Contemporary papermaking fabrics are produced in a wide variety of styles designed to meet the requirements of the paper machines on which they are installed for the paper grades being manufactured. Generally, they comprise a base fabric woven from monofilament and may be single-layered or multi-layered. The yarns are typically extruded from any one of several synthetic polymeric resins, such as polyamide and polyester resins, used for this purpose by those of ordinary skill in the paper machine clothing arts.
The present application is concerned, at least in part, with the TAD fabrics or belts used on the through-air dryer of a bulk tissue machine although it may have other applications beyond this. However, the present application is primarily concerned with a TAD fabric.
Such fabric may also have application in the forming section of a bulk tissue or towel machine to form cellulosic fibrous webs having discrete regions of relatively low basis weight in a continuous background of relatively high basis weight. Fabrics of this kind may also be used to manufacture nonwoven articles and fabrics, which have discrete regions in which the density of fibers is less than that in adjacent regions whereby the topography of the nonwoven article is changed, by processes such as hydroentanglement.
The properties of absorbency, strength, softness, and aesthetic appearance are important for many products when used for their intended purpose, particularly when the fibrous cellulosic products are facial or toilet tissue, paper towels, sanitary napkins or diapers.
Bulk, tensile, absorbency, and softness are particularly important characteristics when producing sheets of tissue, napkin, and towel paper. To produce a paper product having these characteristics, a fabric will often be constructed so that the top surface exhibits topographical variations. These topographical variations are often measured as plane differences between strands in the surface of the fabric. For example, a plane difference is typically measured as the difference in height between a raised weft or warp yarn strand or as the difference in height between MD knuckles and CD knuckles in the plane of the fabric's surface. Often, the fabric surface will exhibit pockets in which case plane differences may be measured as a pocket depth.
A close study of the designs discussed above showed that both warp and weft yarns are primarily responsible for the creation of the depth of the pocket, thus limiting caliper generation. An ideal TAD fabric should provide for both MD and CD contact, thus facilitating sheet transfer to the Yankee dryer, enhancing the TAD fabric operation in the manufacturing process and enhancing creping at the end of the process.
U.S. Pat. No. 6,649,026 relates to a PMC fabric with a web pattern which recurs regularly over the surface and has indentations that are formed by the thread overlays, the latter having been surface ground. The thread overlays cover three consecutive warp or weft threads crosswise thereto. The fabric according to the '026 patent, however, provides for boxed shaped patterns, which fail to provide enhanced MD and CD support.
U.S. Pat. No. 6,592,714 relates to a woven TAD fabric. The relative pocket depths of the fabric which are open towards the contact surface of the paper are 20% or more. The pattern disclosed herein is also boxed shaped and therefore fails to provide enhanced MD and CD support.
U.S. Pat. No. 6,708,732 relates to a web forming fabric which includes first and second substantially linear arrays of systematically distributed areas of high drainage on one side thereof. These linear arrays are oriented at an acute angle to the machine direction and at an acute angle to each other. The boundaries of each of the systematically distributed areas are defined by two pairs of adjacent sides; the adjacent sides of one pair being angled segments of one transversely extending yarn and the adjacent sides of the other pair being angled segments of a second transversely extending yarn contiguous to the one transversely extending yarn. The opposite side of the fabric has long machine direction floats over adjacent transverse yarns and the machine direction floats of adjacent machine direction yarns partially overlap each other in the machine direction. However, in this case only MD yarns produce high drainage areas, and thus, is limited to support in MD only.
U.S. Pat. No. 5,832,962 relates to a papermaking fabric containing a number of relatively long warp knuckles at locations where one of the warp threads crosses over at least four of the shute threads. The long warp knuckles are positioned in a shed pattern to form a first axis of bulky ridges that are defined by long warp knuckles positioned next to each other on adjacent warp threads, the first axis being disposed at a first angle with respect to the cross-direction of the drying fabric that is substantially between 68 and 90 degrees; and a second axis formed by each of the long warp knuckles with other, overlapping long warp knuckles on nearby, but not immediately adjacent, warp threads, the second axis forming a second angle with respect to the cross-direction of the drying fabric of less than about 28 degrees. The '962 patent, however, teaches a top surface plane with long knuckles only in warp direction and a diagonal trough pattern. The fabric is also limited to MD support.
U.S. Pat. No. 3,974,025 relates to an absorbent paper sheet exhibiting a diamond-shaped pattern in its surface after creping. The paper sheets are produced by impressing a dot-dash knuckle pattern, wherein the long axis of the dash impressions is aligned parallel to the machine direction of papermaking, using the back side of a monofilament, polymeric fiber, semi-twill fabric of selected coarseness, the knuckle imprint area of which constitutes between about 20 and about 50 percent of the total fabric surface area, as measured in the plane of the knuckles on an uncompacted paper web at selected fiber consistencies induced by thermal predrying prior to final drying and creping. This patent uses a dot-dash pattern which is a non continuous and broken MD & CD pattern and mainly focuses on pockets. An ideal TAD fabric should provide for both MD and CD contact, facilitating sheet transfer to the Yankee dryer, enhancing the TAD operation in the manufacturing process and enhancing creping at the end of the process.
The present invention provides an improved TAD fabric which exhibits favorable characteristics for the formation of tissue paper and related products.
SUMMARY OF THE INVENTION
The present invention is primarily directed towards a through-air-drying (TAD) fabric, although it may also tend to be used in the forming, press and dryer sections of a paper machine.
The present invention is preferably a TAD fabric comprising a plurality of warp yarns interwoven with a plurality of weft yarns to produce a paperside surface pattern characterized by long knuckles in both warp and weft directions.
It is therefore an object of the present invention to provide for a fabric that has improved MD and CD contact area, thus facilitating sheet transfer to the Yankee dryer.
It is another object of the present invention to provide for enhanced creping.
It is also an object of the present invention to provide suitable pockets for enhanced sheet appearance in order to improve sheet properties such as bulk and absorbency.
It is also an object of the present invention to provide suitable pockets for enhanced sheet appearance and sheet properties such as bulk and absorbency.
Other embodiments of the present invention can include fabrics implementing different weave patterns and yarn combinations than that illustrated and discussed with or without one or more layers of a surface coating.
The present invention will now be described in more complete detail with frequent reference being made to the drawing figures, which are identified below.
BRIEF DESCRIPTION OF THE DRAWINGS
To the accomplishment of the foregoing and related ends, certain illustrative aspects of the invention are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles of the invention may be employed and the present invention is intended to include all such aspects and their equivalents. Other advantages and novel features of the invention may become apparent from the following description of the invention when considered in conjunction with the drawings. The following description is given by way of example, but is not intended to limit the invention solely to the specific embodiments described and may best be understood in conjunction with the accompanying drawings, in which:
FIG. 1 shows a paper side view and a surface depth view highlighting the MD and CD knuckles on the paper side surface of a preferred embodiment of the present invention; and
FIG. 2 shows a paper side view and a surface depth view highlighting the L-shaped knuckle pattern on the paper side surface of a preferred embodiment of the present invention.
DETAILED DESCRIPTION
It is noted that in this disclosure and particularly in the claims and/or paragraphs, terms such as “comprises,” “comprised,” “comprising,” and the like can have the meaning attributed to it in U.S. patent law; that is, they can mean “includes,” “included,” “including,” “including, but not limited to” and the like, and allow for elements not explicitly recited. Terms such as “consisting essentially of” and “consists essentially of” have the meaning ascribed to them in U.S. patent law; that is, they allow for elements not explicitly recited, but exclude elements that are found in the prior art or that affect a basic or novel characteristic of the invention. These and other embodiments are disclosed or are apparent from and encompassed by, the following description.
The present invention relates to industrial fabrics for use on a papermaking machine. Industrial fabrics, as referred to herein, include an impression fabric, a tissue forming fabric, a texturing or impression fabric for the production of nonwovens and TAD fabrics for use on a papermaking machine. According to an embodiment of the present invention, the invention is a TAD fabric and the method of making it. The fabric comprising of a plurality of warp and weft yarns interwoven to form the base fabric structure. The fabric can be formed using any weave pattern suitable for the purpose and can be formed from a wide selection of monofilament yarns known in the art of paper machine clothing, as will be discussed. The fabric, in general, forms long knuckles in the warp direction, wherein warp yarns float over two or more weft yarns to form MD knuckles. Selected portions of either or both warp and weft knuckles are flattened via sanding, calendering, machining or by other means, whereby the fabric contact with the sheet is increased and thus facilitating sheet transfer to the Yankee dryer, enhanced creping in the end of the process, and better defining the pocket area with the advantages attendant thereto.
Turning now, more particularly, to the figures, FIG. 1 is a plan view of one side of fabric 10 , which is preferably its forming side or paper side. The paper side is so-called because it is the side which faces the newly formed paper web when the fabric 10 is a fabric running on a paper machine. The fabric 10 is woven from a plurality of warp yarns 12 and weft yarns 14 .
Warp yarns 12 and weft yarns 14 are in the machine direction (“MD”) and cross-machine direction (“CD”) of the fabric 10 respectively, which may be flat-woven and joined into endless form with a seam. Warp yarns 12 weave with weft yarns 14 in a weave pattern, wherein each warp yarn 12 passes over and under two or more successive weft yarns 14 . It will be observed that each weft yarn 14 makes a float over one or more consecutive warp yarns 12 on the side of the fabric 10 shown in FIGS. 1 and 2 .
According to the embodiment of the present invention, there are two long warp knuckles 16 , 22 , each residing in a different plane of the fabric 10 . First long warp knuckle 16 floats over four weft yarns 14 . One weft yarn 14 passes under the long warp knuckle 16 in an over-under-over configuration for support to the long warp knuckle 16 . First long warp knuckle 16 is in a higher plane to facilitate sheet transfer to the Yankee dryer. The two first long warp knuckles 16 , which are separated by two warp yarns 12 , define the MD boundaries of the pocket 20 . Two weft knuckles 18 , 24 , separated by two weft yarns 14 , define the CD boundaries of the pocket 20 . Second long warp knuckle 22 floats over three weft yarns 14 . Second warp knuckle 22 is in a lower plane and is arranged diagonally across the pocket 20 , as shown in FIG. 1 . The second long warp knuckle 22 provides fiber support at the base of the pocket 20 . FIGS. 1 and 2 show progressive sanding of the knuckles 16 and 18 . While sanding was utilized for this illustration, other means, as aforementioned also may be used to obtain the desired result. In this regard, the MD yarns 16 were initially sanded to a length of 1.3 mm.
According to the present invention when the fabric 10 is sanded to a first long warp knuckle length of 1.7 mm, the first long warp knuckle 16 and first weft knuckle 18 begin to create an L-shaped pattern 28 with separate MD and CD knuckles that are non-continuous, as shown in FIG. 1 . When the fabric 10 is further sanded to a first long warp knuckle length of 1.9 mm, the first long warp knuckle 16 and first weft knuckle 18 or portions thereof are now co-planar creating a continuous L-shaped knuckle pattern 26 , as shown in FIG. 2 with increased contact area with the sheet and the attendant advantages as aforenoted. Note, the illustrated lengths or contact areas obtained after the stepwise sanding are used merely as an example since other dimensions may also be suitable for the purpose.
Pocket sizes can be characterized by an MD/CD dimension and/or by a pocket depth. The pockets are formed/bounded by weft yarns and warp yarns which are raised from the base plane of the fabric. The raised weft yarns and warp yarns are produced by knuckles in the weave pattern. The fabric base inside each pocket can be a plain weave pattern or any other suitable pattern. In addition, a pocket may include one or more raised or semi-raised warp yarns or weft yarns inside. The raised or semi-raised warp yarns or weft yarns may lie in the base of the pocket and may bisect the pocket area in parallel, perpendicular, or diagonal manner.
Warp yarns 12 and weft yarns 14 are preferably monofilament yarns of any of the synthetic polymeric resins used in the production of such yarns for paper machine clothing. Polyester and polyamide are but two examples for such materials. Other examples of such materials are yarns of polyphenylene sulfide (PPS), which is commercially available under the name RYTON®, and yarns of a modified heat-, hydrolysis, and contaminant-resistant polyester of the variety disclosed in commonly assigned U.S. Pat. No. 5,169,499 incorporated herein by reference and used in dryer fabrics sold by Albany International Corp. under the trademark THERMONETICS®. Any combination of polymers for any of the yarns can be used as identified by one of ordinary skill in the art. The yarns may have a circular cross-section with one or more different diameters or any other shape suitable for the purpose.
Note, the fabric according to the present invention may be formed using any weave pattern that produces an L-shaped knuckle pattern. The present invention is intended to cover other fabric patterns having different sizes and shapes of pockets. Accordingly, the present invention should not be construed as being limited to the embodiment disclosed above.
Modifications to the above would be obvious to those of ordinary skill in the art, but would not bring the invention so modified beyond the scope of the appended claims.
Although illustrative embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope and spirit of the invention as defined by the appended claims.
|
A through-air-drying (TAD) fabric for producing tissue paper and related products on a papermaking machine comprising a plurality of warp yarns interwoven with a plurality of weft yarns to produce warp and weft knuckles on a paper-side surface of the fabric, preferably to form an L-shaped knuckle pattern.
| 3
|
[0001] This application is a continuation of U.S. patent application Ser. No. 10/378,176, filed Mar. 3, 2003, now abandoned.
FIELD OF THE INVENTION
[0002] This invention relates to the field of winding cores, in particular, winding cores for use with paper, paper board, or other sheet material.
BACKGROUND OF THE INVENTION
[0003] Sheet material, such paper, fabric, plastic sheeting and the like is typically wound onto paper cores. For example, in the direct mail industry, paper mills wind their stock forms onto paper board cores for shipment to a direct mail printing facility. The forms come in various sizes; generally 25,000 forms or pages per roll. The press department then punches pin feeds into the paper. The press department then prints anything that may be consistent on the form such as letter head or form numbers for any given customer. During this process the form is unwound from the shipped roll and then wound onto another paperboard core. The core that came with the paper is customarily discarded when there is still some paper left on it . . . any where from 1″ to 3″ thickness of paper and then the core and paper is customarily discarded.
[0004] After the press punches pin feeds, prints letter head and rewinds the sheet forms, the roll is transferred to the laser printing department where the roll is unwound and rewound onto yet another core during the personalization process. (Names, addresses, phone numbers, letter information, etc.)
[0005] A direct mail facility that produces between 30 or 40 million names/addresses per month goes through between approximately 2,500 to 3,500 cores that are thrown into bins for recycling. Furthermore, there are more than 2,000 rolls with cores on the production floor waiting to go through the process at any given time.
[0006] Currently, winding cores are made of paper board and paper products. Their reuse is limited to several times, recycling and/or refurbishing the core so that it can be again used for winding material thereon. Double-sided tape is wrapped around the core in a “candy cane style” to adhere the sheet material to the core. Once the paper is completely wound onto the core, wooden plugs are pounded into the ends of the core to prevent it from collapsing from the weight of the load that was would upon it if the rolled material stays on the core for a considerable amount of time.
[0007] There is not found in the prior art a reusable core that will eliminate the need to throw away these rolls and will also the need to wrap double sided tape around the core to attached the sheet material to the core for winding.
SUMMARY OF THE INVENTION
[0008] It is an aspect of the invention to provide a reusable core that is suitable for having paper or other sheet material wound thereon A multi-sectioned core is provided that is easily assembled. Interlocking sections that provide a pivot are held together by a sliding pin inserted therein. By removing one pin between adjacent interlocking sections, the core collapse thereby permitting easy removal. The sheet material is held onto the core by means of a strip of double sided tape until the core is wound several times to keep the sheet material firmly in place.
[0009] This aspect of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an isometric view of the preferred embodiment of the reusable collapsible core in accordance with the invention.
[0011] FIG. 2 is an isometric view of the core with one pin removed showing how the core is able to be collapsed.
[0012] FIG. 3 is isometric bottom view of one section of the core.
[0013] FIG. 4 is an end view of one section of the core.
[0014] FIG. 5 is a top view of the core.
[0015] FIG. 6 is a cross-sectional view of the core along line BB as shown in FIG. 5 .
[0016] FIG. 7 is a cross-sectional view of the core along line AA as shown in FIG. 5 .
[0017] FIG. 8 is a detailed view of the pin locking assembly.
[0018] FIG. 9 is an isometric view of another embodiment of the invention.
[0019] FIG. 10 is an end view of the embodiment shown in FIG. 9 .
[0020] FIG. 11 is a view of the invention without the key section in place.
[0021] FIG. 12 is the two halves of the interlocking sections of the core separated and apart from the key section.
[0022] FIG. 13 is an isometric view of the extractor mechanism.
[0023] FIG. 14 is a detailed top view of the embodiment shown in FIG. 9 .
[0024] FIG. 15 is a detailed view of the spring used in an alternative embodiment for sheet material attachment.
[0025] FIG. 16 is an end view of the preferred embodiment of the invention.
[0026] FIG. 17 is a detailed view of the sliding pin used to activate the material attachment slat.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The invention is a reusable collapsible core that is useful for winding paper forms or other sheet material thereon. The core is preferably made of plastic but metal or hard rubber could also be used. The life span will be measured in years with little or no maintenance required.
[0028] As shown in FIG. 1 , invention 10 is assembled from at least substantial identical segments 11 to form a cylinder. Each segment can be manufactured from the same material or different materials. As noted above, plastic is the preferred material which is either injection molded or extruded. The hinge joint assembly 16 is designed to fit loosely in order to allow for expansion and contraction of the cylinder outside diameter for the purpose of both allowing for the maximum cylinder circumference while winding rolled sheet materials and to allow for collapsing the invention for removal so that it can be used again. Locking pin assemblies 14 lock each segment 11 to another segment 11 immediately adjacent to it as shown. Once one of pin assemblies 14 is removed, the segments 11 are easily collapsed so that invention 10 can be removed from waste sheet material that is wound thereon as shown in FIG. 2 .
[0029] The interior of invention 10 is provided with a plurality of detents 43 as shown in FIG. 2 which permit increase the structural integrity of the core without adding additional mass or cost of material. As shown, segment 11 is provided with interlocking joint assemblies 16 which mesh with opposing joint assemblies 16 of an immediately adjacent segment 11 .
[0030] When joined together, the segments 11 form a cylindrical tube. As shown in FIG. 4 each segment 11 has an arc of a circle having an outer radius R 1 and an inner radius R 2 . Radius R 2 is selected to fit onto the printing mandrel that is being used. The difference between R 1 and R 2 is selected based on the strength that the core must provide in to prevent it from collapsing until one of pin assemblies 16 is removed from opening 17 so that invention 10 may be easily withdrawn from the remaining sheet material wrapped around the core. Then, the sheet material, usually paper, is discarded and invention 10 may be used again.
[0031] Referring to FIG. 5 , a top of invention 10 is shown with one complete segment 11 and the segment 11 immediately adjacent to it, attached with pin assemblies 16 (shown in detail in FIG. 8 ).
[0032] As shown in FIG. 6 , the cross-sectional view taken along line BB noted in FIG. 5 , shows the plurality of detents 43 which to make each segment 11 egg-crate shaped in appearance as viewed from the inside. Each pin assembly 16 is inserted through openings 17 in the respective segment 11 to hold each segment 11 in place while sheet material (not shown) is wound onto surface 19 . FIG. 7 shows a similar cross-sectional view taken along a different section line AA in FIG. 5 .
[0033] Referring to FIG. 8 , a detail view of pin assembly 16 is provided. Pin 23 is fed into openings 17 of interlocking segments 11 and then held firmly in place via a snap ring 25 which fits into circumferential channel 29 . Snap ring 25 is easily removed using snap ring pliers (not shown) which are well known in the art. A quick release pin 23 would not use snap rings 25 but merely could be fitted with a structure well known in the art which easily allows pin 23 to be pulled out such as a handle or a loop, an end having a right angled section, etc. in order to collapse the core 10 .
[0034] Referring to FIG. 9 , an alternative embodiment of invention 10 is shown. In this embodiment, invention 10 is made up of three sections. The two larger pieces 12 , 14 of the cylinder are formed to loosely lock into each other thus providing hinge 16 which runs the entire length of the cylinder. The key section 18 runs the entire length of the cylinder and is designed to slide out of the cylinder in order to allow the remaining pieces to collapse. The key section could also be made as the larger sections and held together using the locking pins and quick release pin as noted above.
[0035] FIG. 10 shows an end view of the cylinder. Male interlocking section 12 is provided with a locking bead 26 that fits into groove 28 of the female interlocking section 14 . Bead 26 and groove 28 run the entire length of the interlocking sections to ensure that the two sections are locked together. As noted above, bead 26 and groove 28 are designed to have space 34 (see FIG. 11 ) between them so that it is easy to collapse these two sections toward one another when it is desired to removed the invention from material that has been wound thereon.
[0036] Key section 18 slides into male and female interlocking sections and is held in position by keyways 32 with engages slots 30 to form the complete cylinder. The inner surface of the key section 18 and interlocking sections 12 , 14 are provided with a liner 24 which is preferably a rubberized material. Liner 24 helps hold invention 10 firmly onto a mandrel (not shown) when sheet material is to be wound onto or off of the core. Two lever arms 22 are fitted immediately adjacent to each end of the cylinder preferably on interlocking section 14 as shown. However, lever arms 22 could also be attached to interlocking section 12 or even key section 18 if it is made sufficiently large to accommodate this mechanism. Each lever arm 22 is spring actuated (see FIG. 15 ) via spring 50 and is connected to a sheet material attachment slat 38 (see FIG. 14 ) which is used to attach the sheet material, usually paper, that is to be wound on the cylinder core.
[0037] As shown in FIG. 11 , once lever arms 22 are pulled away from interlocking section, the end of the paper or other material that is to be wound thereon is fed under attachment slat 38 and the lever arms 22 are released so that material is held fast and ready for winding. An indent for slat 38 (shown in FIG. 16 ) is provided so that slat 38 is flush and so that material can be more easily wound thereon.
[0038] FIG. 12 is the two halves of the interlocking sections 12 , 14 of the core separated and apart from the key section 18 . Optionally, slots 42 are provided on provided on one or both of sections 12 , 14 , either completely as shown or partially so that sufficient room is provided to permit lever arms 22 and attachment slat 38 to run the entire length of the cylinder core. The slots 42 decrease the surface area that is in contact with wound material and thus facilitate removal of the key section. Also, slots 42 also decrease the amount of plastic material that must be used to form invention 10 .
[0039] As shown, hand hold 20 is provided so that core can be pulled from any remaining sheet material that is wound on the core. If removal is difficult, then extractor 44 (shown in FIG. 13 ) is inserted into the core and hooks 46 engage recesses 40 so that the core can be pulled free from any material wound thereon by handle 48 .
[0040] Referring now to FIGS. 16 and 17 , another embodiment of invention 10 is shown This embodiment differs only in embodiment shown in FIG. 9 in that the method for attaching the material that is to be wound on the core. In this embodiment, slat 38 is held on the core by the attachment mechanism shown in FIG. 17 . Slot 56 in sleeve 51 is threaded into immediately adjacent to one end of the core. Another substantially identical sleeve 51 is threaded into the other end. Into each sleeve 51 , locking pin 52 is inserted. Spring loaded ball bearing 54 is used to releasably hold locking pin 52 into sleeve 51 via slot 56 . D-shaped pull 53 is bent at approximately 90 degrees relative to the longitudinal axis of pin 52 and is used to attach to slat 38 using techniques well known in the art. In this manner, slat 38 can be extended as shown in FIG. 16 so that the material that is to be wound on the core can be inserted under slat 38 and then slat 38 can be slid back into place to hold material until a sufficient number of windings is wound thereon.
[0041] The illustrated embodiments of the invention are intended to be illustrative only, recognizing that persons having ordinary skill in the art may construct different forms of the invention that fully fall within the scope of the subject matter disclosed herein. Other features and advantages of the invention will be apparent from the descriptions hereof
|
A reusable core that is suitable for having paper or other sheet material wound thereon. A multi-sectioned core is provided that is easily assembled. Interlocking segments that provide a pivot are held together by a sliding pin inserted therein. The pin is preferable held into position by use of a snap ring or other similar fastening arrangement. By removing one pin between adjacent interlocking sections, the core collapses inwardly thereby permitting easy removal of the core from any remaining sheet material that must be discarded. The sheet material is held onto the core by means of a strip of double sided tape until the core is wound several times to keep the sheet material firmly in place.
| 1
|
This application is a continuation of application Ser. No. 776,791, filed Sept. 16, 1985, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to semiconductor devices and, in particular, III-V semiconductor devices.
2. Art Background
Devices, e.g., light emitting diodes (LEDs) and lasers based on III-V semiconductor materials, generally are fabricated on a bulk semiconductor substrate such as a bulk indium phosphide substrate. A typical fabrication step involves the epitaxial deposition of a III-V semiconductor material on the heated substrate through the thermally induced reaction in a gas mixture at the substrate surface. A variety of deposition mixtures has been employed. One class of mixtures suitable for the deposition of III-V semiconductor materials containing phosphorus are those including phosphine as the source of this phosphorus. Thus, for example, for the deposition of indium phosphide, the initial gas mixture includes phosphine as a source of phosphorus and indium chloride as a source of indium.
The morphological quality of the deposited layer significantly affects device quality. A common defect in the growth of III-V based semiconductor materials by hydride epitaxy is the formation of hillocks, i.e., crystallographic defects including a portion of grown material that extends at least 0.5 μm above all other grown material within an area of 100 μm 2 . (See G. H. Olsen, GaInAsP Alloy Semiconductors, edited by T. P. Pearsall, John Wiley & Sons, page 11 (1982) for a description of hydride epitaxy, i.e., an epitaxial process where the source of the Group V element is phosphine, and the walls of the reactor in the reaction region of the apparatus are heated by an external source such as a furnace). Hillocks, however, substantially degrade or catastrophically limit device properties such as current confinement, light output, electrical contact performance, and reliability. Additionally, hillocks often preclude device fabrication steps, such as contact mask pattern delineation, which depend on a planar morphology. In an attempt to limit morphological defects such as hillocks, growth on substrate surfaces that are slightly misoriented, e.g., 1 to 6 degrees misoriented from a crystallographic plane such as the (100) plane, has been attempted. Despite this precaution, substantial hillock formation still occurs. Additionally, for many structures whose fabrication depends on the use of precise crystallographic orientation, even the slight improvement attained by misorientation is precluded. For example, in the fabrication of V-groove lasers, the production of the groove depends on the in-plane crystallographic orientation of the substrate. If a misoriented substrate is utilized, an unacceptable etch structure such as a dovetail, rather than a V-groove, is obtained. Thus, hillock formation remains a significant source of degradation in device yield and efficacy.
SUMMARY OF THE INVENTION
Hillock formation in hydride transport of indium phosphide is avoided by ensuring that the phosphine utilized in the deposition procedure is essentially completely decomposed before it reaches the deposition substrate. Phosphine decomposition is achievable by a variety of expedients. For example, phosphine is typically decomposed heterogeneously at a heated surface such as a catalytic, heated surface.
The use of phosphine decomposition is also advantageous in the hydride transport chemical vapor deposition of III-V semiconductor materials such as III-V ternaries and quaternaries having a phosphorus component.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1 and 2 are illustrative of apparatuses suitable for practicing embodiments of the invention.
DETAILED DESCRIPTION
The inventive procedure for growing III-V semiconductor materials for production of devices such as LEDs, lasers, and photodetectors is based on a hydride deposition gas system. Hydride systems, in general, are well known and are extensively described in reviews such as Olsen supra. Basically, the Group V material(s), such as phosphorus and/or arsenic, are provided in the form of their corresponding hydride, i.e., phosphine and/or arsine. These materials are generally brought into the gas mixture using a carrier gas flow, e.g., a reactive carrier such as hydrogen or an inert carrier such as helium. (For the growth of materials containing indium, some hydrogen is generally required in the carrier. However, for materials having essentially no indium, a carrier gas having only inert constituents is acceptable.) The Group III material is brought to the reaction mixture by any of numerous conventional expedients. For example, commonly hydrogen chloride is diluted in hydrogen and passed over liquid indium. Once the reaction mixture is formed, it is passed over the deposition substrate. The deposition substrate is maintained at a temperature suitable for inducing reaction of the gas mixture to produce the desired epitaxial layer. For phosphorus-containing binaries (e.g., indium phosphide), ternaries, and quaternaries, generally temperatures in the range 600 to 750 degrees C. are adequate. The precise temperature to yield an adequate epitaxial layer for a given stoichiometry of the deposited material is determined by utilizing a controlled sample.
The reactor geometry is also not critical. Suitable geometries have been described in reviews such as Olsen supra. One advantageous geometry is shown in FIG. 1 and includes a quartz growth chamber 15 having at least one source of Group III material, 17, and a source of phosphine, 16. Additionally, it is possible to introduce other Group V materials through their respective hydrides, e.g., arsine from source 18. The deposition gases are exhausted from the reactor by conventional expedients such as an effluent conduit, 20. Other conventional growth procedures, such as rotation of the substrate, growth at pressures below atmospheric pressure, and use of a multibarrel reactor, although not essential, are compatible with the inventive technique.
As discussed, it is essential that the phosphine, before it reaches the deposition substrate, has substantially decomposed into entities such as P 2 , P 4 , and hydrogen moieties, i.e., H and H 2 . (Substantial decomposition, in the context of this invention, means at least 93 mole percent of the phosphorus reacting at the deposition substrate is in a form other than phosphine.)
Generally, phosphine undergoes only heterogeneous decomposition, i.e., requires a surface to induce decomposition. Since phosphine decomposes relatively slowly at typical reactor temperatures, i.e., temperatures in the range 600 to 900 degrees C. in the presence of only the reactor walls, it is not sufficient to rely on thermal decomposition of the introduced phosphine. Thus, modification to promote decomposition is required. For example, it is possible to substantially lengthen the transit distance (assuming a given deposition temperature), to lengthen the time available for contact with walls, and thus to increase the percentage of introduced phosphine undergoing decomposition. Alternatively, it is possible to utilize a catalyst or a heated high surface area material to augment the decomposition rate and utilize a substantially shorter transit region.
Suitable materials for inducing decomposition of phosphine through catalysis, through the presence of large surface area, and/or through both, are Group VI (of the Mendelyeevian Periodic Table) metals such as tungsten and molybdenum, as well as tantalum. Typically, surface areas in the range 10 to 500 cm 2 for phosphine flow rates in the range 1 to 10,000 sccm yield suitable decomposition rates when the surface inducing decomposition is heated to a temperature in the range 400 to 900 degrees C. Surface areas less than 5 cm 2 generally lead to inadequate decomposition at temperatures and flow rates typically employed in III-V CVD. Surface areas larger than 500 cm 2 , although not precluded, typically are inconvenient because such large surface areas require either (1) large reactor volumes or (2) the use of powders that are difficult to localize in a flowing gas system. The rate of decomposition depends on temperatures, surface area, catalytic activity, and flow rate. The conditions given are those generally adequate to yield the desired level of decomposition. For any specific conditions, a controlled sample is performed to ensure the accomplishment of a decomposition rate sufficient to eliminate the hillocks.
The phosphine need not be decomposed in the reaction chamber itself but can be decomposed in a region outside the chamber and then introduced into the chamber. Conditions should be maintained, however, so that extensive condensation of less volatile decomposition products, e.g., P 4 , does not occur. Avoidance of excessive condensation is generally possible by maintaining the environment of the decomposition products at more than 400 degrees C.
Once the deposition of the III-V based semiconductor material(s) is effected, the rest of the device is completed. Extensive review articles on completing a wide variety of devices are available. For example, fabrication steps for V-groove lasers are described in Journal of Applied Physics, Vol. 56, No. 3, D. P. Wilt et al, page 710 (1984), and fabrication sequences for LEDs are described in Bell System Technical Journal, Vol. 62, No. 1, H. Temkin et al, page 1 (1983).
The following examples are illustrative of the invention.
EXAMPLE 1
Indium phosphide substrates were cut so that their major surface was in the (100) plane. These substrates were chemically polished by subjecting them to bromine dissolved in methanol. After polishing, the substrates were cleaved into sections measuring 0.8 in.×1.25 in. These sections were then stored under dry nitrogen until use.
Immediately before epitaxial growth, the sections were cleaned by sequential immersion for 3 minutes in boiling trichloroethane, 3 minutes in boiling acetone, 3 minutes in boiling methanol, and 3 minutes in a room temperature 5:1:1 mixture of sulfuric acid, hydrogen peroxide, and water. The substrates were then rinsed in deionized water, rinsed in methanol, and spun dry under flowing dry nitrogen. The substrates were placed on a quartz sample holder, 19 (FIG. 1), in a reactor having a quartz chamber, 21. The chamber was evacuated to 10 Torr and then backfilled with hydrogen to a pressure of approximately 780 Torr. The reactor contained a tungsten catalyst, 80, in the form of a loosely wound coil made from 11.52 grams of 0.45 mm in diameter tungsten wire. The reactor was initially maintained with a furnace (not shown) at a temperature of 820 degrees C. in the source region, 14, shown by a dashed line, and 680 degrees C. in the growth region, 15. At these temperatures, a continuous flow of hydrogen at 500 sccm was maintained by introducing equal hydrogen flows through each of the input tubes 10, 11, 12, and 13.
To initiate growth, the flow of pure hydrogen was discontinued, a counterflow of hydrogen through tube 21 was established at 1600 sccm, and this flow was mixed with a 50 sccm hydrogen flow containing 5 percent phosphine using a mass flow controller (indicated in the Figures by MFC). After 5 minutes, the sample was translated to the preheat position (not shown) and maintained in this position for 10 minutes. An 1150 sccm flow of hydrogen was then introduced over molten indium in boats 17. A 75 sccm flow of 5 percent phosphine in hydrogen was mixed with a 750 sccm dilution flow of hydrogen. This combination was directed through tube 10. An 8 sccm flow of hydrogen containing 500 parts per million of hydrogen sulfide was combined in line 11 with a 1600 sccm flow of hydrogen. Additionally, a flow of 8 sccm of hydrogen containing 1.5 percent hydrogen chloride was introduced into line 11. These flows were allowed to stabilize for approximately 2 minutes. The sample was then translated into growth position 15 to initiate an etch removal of approximately 0.5 μm of indium phosphide. After 3 minutes, the hydrogen dilution of the 5 percent phosphine-in-hydrogen flow was terminated. The 5 percent hydrogen chloride-in-hydrogen flow was increased to 375 sccm and flowed over the liquid indium in boats 17. As a result, the growth of n-type indium phosphide was induced. After 23 minutes, the hydrogen sulfide content in its hydrogen flow was removed, and 1 gram of zinc was inserted into position, 25, where it was subjected to a temperature of approximately 375 degrees C. In this manner, growth of p-type indium phosphide was begun. After 13 minutes, the hydrogen sulfide flow was reintroduced into the hydrogen under the previously discussed conditions, the zinc was withdrawn to its initial position, and growth of the resulting n-type indium phosphide layer was continued for 19 minutes. This sequence of conditions produced a structure having an underlying n-type indium phosphide layer of 2.0 μm in thickness, an intermediary p-type indium phosphide layer of 1 μm in thickness, and a top n-type indium phosphide layer of 1 μm in thickness. V-groove lasers were then produced in this structure, as described in D. P. Wilt et al supra. These lasers had a threshold of 19 mA and delivered 10 mW/facet at 87 mA drive.
EXAMPLE 2
The procedure of Example 1 was followed, except before growth, the substrate was hand-polished. This polishing was accomplished by mounting the substrate on a vacuum chuck and rubbing the surface for 10 seconds with a cotton twill cloth that had been wetted by a 1 percent by volume bromine in methanol solution. The substrate was then rinsed with methanol and spun dry under dry nitrogen. After loading the substrate, the growth proceeded as described in Example 1 except the etch step was omitted. The resulting lasers had operating properties that were essentially the same as the lasers described in Example 1.
EXAMPLE 3
Indium phosphide substrates with their major surface in the (100) plane were cut into sections approximately 0.5 in. square and hand-polished by the procedure described in Example 2. The sections were then loaded onto the sample holder 26 of the reactor shown schematically in FIG. 2. The chamber was evacuated to a pressure of approximately 1 Torr and refilled with hydrogen to a pressure of approximately 2 psi above the pressure of the ambient. A 700 sccm flow of hydrogen was introduced through tube 30 using a mass flow controller, a 180 sccm flow of hydrogen was introduced through tube 27, a 300 sccm flow of hydrogen was begun over catalyst 28, a 275 sccm flow of phosphine was introduced into the hydrogen flow over the catalyst, and an additional 300 sccm flow of hydrogen was introduced through tube 31. All the zones of the furnace (not shown) were maintained at 700 degrees C. (The catalyst was formed by cutting 10 in. lengths from 19.3 grams of 0.25 mm in diameter tantalum wire.)
The sample was inserted into growth position 35 for 5 minutes to allow it to adjust to the growth temperature. During this adjustment period, it was verified by the UV absorption technique (190 nm) described by M. Halmann, Journal of the Chemical Society, 164, page 2853 (1963), that the phosphine ovr the catalyst had been completely pyrolyzed (greater than 93 mole percent).
After 5 minutes of stabilization, a 4 sccm flow of 5 percent by volume hydrogen chloride in hydrogen was established through tube 30 around indium present in boat 32 and maintained for 5 minutes to etch the sample. After 5 minutes, the 5 percent hydrogen chloride-in-hydrogen flow over the indium was begun at 160 sccm to initiate indium phosphide growth. This growth was continued for 60 minutes. The resulting indium phosphide layer was free of hillocks, as observed by Normarski contrast optical microscopy.
|
Hillock formation in the vapor phase epitaxial hydride deposition of indium phosphide is avoided. This effect is accomplished by ensuring that the phosphine utilized in the deposition gas flow is essentially completely decomposed before reaching the deposition area. Additionally, by utilizing the phosphine decomposition procedure, advantageous results are also achieved in the epitaxial hydride deposition of phosphorus-containing semiconductor materials.
| 8
|
FIELD OF THE INVENTION
[0001] The subject invention relates generally to systems and methods for applying electronics to a tire for the purpose of monitoring tire condition parameters and, more specifically, to a system and method for electrically connecting such electronics to a tire-mounted antenna so as to facilitate communication between the electronics and a remote reader/transmitter by means of the antenna.
BACKGROUND OF THE INVENTION
[0002] It is common to employ annular apparatus, including an antenna, for electronically transmitting tire or wheel identification or other data at radio frequency. The apparatus includes a radio-frequency tag, or transponder, comprising an integrated circuit chip having data capacity at least sufficient to retain identification information for the tire or wheel. Other data, such as the inflation pressure of the tire or the temperature of the tire or wheel at the transponder location, can be transmitted by the transponder along with the identification data.
[0003] The annular antenna is tire-mounted and transmits, at radio frequencies, data from the transponder to a reader mounted on the wheel assembly. The antenna and transponder may be incorporated into a tire during “pre-cure” manufacture of the tire. The integrity of the connection between the tire and antenna is greatly enhanced by a pre-cure assembly procedure. In practice, however, it is very difficult to do this. Both radial ply and bias ply tires undergo a substantial diametric enlargement during the course of manufacture. Bias ply tires are expanded diametrically when inserted into a curing press, which typically has a bladder that forces the green tire into the toroidal shape of the mold enclosing it. Radial ply tires undergo diametric expansion during the tire building or shaping process and a further diametric expansion during the course of curing. An annular antenna and the electronic tag associated therewith built into the tire in a pre-cure process, therefore, must endure significant strain that can result in component failure. The electronic tag and the connection between the tag and the antenna, in particular, is vulnerable to damage from the forces imposed from pre-cure assembly to tire.
[0004] To avoid damaging the electronic tag or the connection between the tag and the annular antenna during the curing procedure, an alternative known approach is to assemble the tag and antenna into a separate annular apparatus for post-cure attachment to the tire. The annular apparatus may be attached to the tire after the tire is cured by adhesive or other known techniques. While such an approach avoids damaging the tag electronics during tire manufacture, adhesive attachment of the antenna and tag to a tire in a post-cure procedure has certain drawbacks. First, the procedure adds labor, and hence cost, to the manufacturing process. Secondly, the security of the attachment between the annular apparatus and the tire is dependent upon the efficacy of the adhesive system employed. Development of a suitable adhesive that is inexpensive, convenient to use, and durable enough to function throughout the life cycle of a tire has proven problematic.
[0005] Accordingly, there remains a need for a system and method of applying tag electronics to a tire that is convenient, cost effective, and reliable. Such a procedure should further ensure the functional safety of the electronics and result in a positive electrical connection between the antenna and tag electronics. Finally, such a procedure ideally would incorporate the advantages, but avoid the shortcomings, of both the pre-cure and post-cure assembly alternatives discussed above.
SUMMARY OF THE INVENTION
[0006] A method for post-cure application of electronics to a tire is disclosed that achieves the objectives of positively securing an antenna apparatus to a tire while protecting the electronics from the damaging forces attendant tire manufacture. The method comprises the steps: forming an antenna wire into a predetermined shape having first and second free ends; interposing a base plate between the free antenna ends, the base member having conductive regions surrounding grommet openings; positioning the free antenna ends into electrical contact with respective base plate conductive portions; affixing a removable plug to the base member to hold the antenna free ends in contact with the base member conductive portions; curing the antenna wire into a tire during a tire manufacturing procedure; removing the plug from the base member in a post-cure operation; affixing a tag carrier to the base member; and establishing electrical contact between the tag carrier and the antenna free ends. Pursuant to one aspect of the invention, the method may include the step of forming the antenna wire into an annular configuration. Pursuant to another aspect, the method may comprise the steps of extending the antenna ends through respective conductive grommets in the base plate, affixing the removable plug to the base plate by means of inserting plug prongs into the base member grommets, and maintaining the antenna ends in place by means of the plug prongs.
[0007] A further aspect of the invention provides that the removable plug and tag carrier interchangeably mate to the base plate. The plug member is incorporated within the antenna assembly during its attachment to a tire during tire manufacture. Thereafter, the plug member is conveniently replaced in a post-cure operation by the tag carrier. The tag carrier electronics are thereby protected from damage during tire manufacture. The tag carrier and plug member are inexpensive to manufacture, readily incorporated into the antenna assembly, and conveniently interchangeable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention will be described by way of example and with reference to the accompanying drawings in which:
[0009] FIG. 1 is a top plan view of the base plate with antenna ends in contact therewith;
[0010] FIG. 2 is a top plan view of the plug member and antenna assembly prior to attachment to a tire;
[0011] FIG. 3 is a side elevational view of the plug member;
[0012] FIG. 4 is a top plan view of the tag carrier and antenna assembly;
[0013] FIG. 5 is a side elevational view of the tag carrier;
[0014] FIG. 6 is an exploded side elevational view of the tag carrier and antenna assembly;
[0015] FIG. 7 is a longitudinal section view through the tag carrier of FIG. 5 , taken along the line 5 - 5 ;
[0016] FIG. 8 is a perspective view shown partially in section for illustration of a tire having the annular antenna assembly affixed thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Referring initially to FIG. 8 , a preferred embodiment 10 of the subject invention is shown deployed within a tire 12 . The tire 12 is formed from conventional materials such as rubber or rubber composites by conventional means and may comprise a radial ply or bias ply configuration. A typical tire 12 is configured having a tread 14 , a shoulder 16 , an annular sidewall 18 , and a terminal bead 20 . An inner liner 22 is formed and defines a tire cavity 24 . The tire 12 is intended for mounted location upon an annular rim 26 having a peripheral rim flange 28 and an outer rim flange surface 30 . Rim 26 is conventionally configured and composed of a suitably strong metal such as steel.
[0018] An annular antenna 32 is provided and, in the preferred embodiment, embodies a sinusoidal configuration. Antenna 32 may be alternatively configured into alternative patterns or comprise a straight wire(s) if desired and may be filament wire, or cord or stranded wire. Acceptable materials for the wire include steel, aluminum, copper or other electrically conducting wire. As mentioned previously, the wire diameter is not generally considered critical for operation as an antenna and multiple strands of fine wire is preferred. The curvilinear form of antenna 32 provides flexibility and minimizes the risk of breakage during manufacture and use of the tire.
[0019] With continued reference to FIG. 1 , a tag carrier 34 of the general type described above is provided and may include means for sensing tire parameters such as pressure and temperature. Included as part of the apparatus 10 is a carrier strip of material 36 formed into the annular configuration shown. Carrier strip 36 is formed of electrically insulating, preferably semi-rigid elastomeric material common to industry such as rubber or plastic. The strip 36 is formed to substantially encapsulate the antenna wire(s) 32 and at least a portion of the tag carrier 34 . In the post manufacturing state shown in FIG. 1 , therefore, the apparatus 10 comprises antenna 32 , tag carrier 34 , and carrier strip 36 , in a unitary, generally circular, assembly. The diameter of the apparatus assembly 10 is a function of the size of the tire 12 . The preferred location of the antenna assembly 10 on the tire is on the tire just above the rim flange 30 . Such a location minimizes stress forces on the assembly from operation of the tire and minimizes interference to RF communication between the tag and an external reader (not shown) that might otherwise be caused by the metal rim. Other mounting locations of the antenna assembly 10 on the tire, however, may be employed if desired for specific tire applications.
[0020] From FIG. 8 , it will be apparent that an optimal manner for attaching annular assembly 10 to a tire is during the tire manufacturing process. In curing the tire, the assembly 10 will adhere directly to the liner 22 and a reliable mechanical connection results. However, for the reasons previously discussed, the tire manufacturing operation can impart significant stress to the tag 70 , and/or its leads 72 , 74 , resulting in a failure of the electronics. The subject invention avoids the possibility of such a failure by replacing the tag 70 with a temporary assembly during the manufacturing process.
[0021] Referring to FIG. 1 , the invention utilizes a base plate 38 having a main body 40 of generally rectangular configuration formed of electrically conductive material such as copper or steel. The base plate body 40 includes a pair of spaced apart circular grommets 42 , 44 extending therethrough. The plate 38 is disposed between free ends 46 , 48 of the antenna wire 32 in a first stage of the assembly process. Free antenna ends 46 , 48 are routed from an underside of the plate 38 up and through respective grommets 42 , 44 as shown. The grommets 42 , 44 conduct electrical signals between the antenna and a tag electronics package by means of antenna ends 46 , 48 .
[0022] With regard to FIGS. 1,2 and 3 , in a second stage of the assembly process, the antenna ends 46 , 48 , are held in place by means of a plug member 50 coupled to the base plate 38 . The plug member 50 includes a rectangular body 52 dimensioned to substantially cover base plate 38 . Protruding from the body 52 are spaced apart prongs or protrusions 54 , 56 , each prong having an enlarged diametric dimension at the equator 58 . Prongs 54 , 56 are dimensioned and spaced for press insertion into apertures 42 , 44 of base plate 38 , whereby the plug member 50 may be detachably coupled to the base plate 38 . Frictional retention force between prongs 54 , 56 and apertures 42 , 44 may be varied and adjusted by adjusting the diametric dimension and configuration of prongs 54 , 56 as will be understood by those in the art. Plug member 50 may be detached from the base plate 38 by pulling the prongs 54 , 56 out of respective apertures 42 , 44 . Press insertion of prongs 54 , 56 into apertures 42 , 44 pinches the antenna ends 46 , 48 against sides of the apertures 42 , 44 and prevents withdrawal of the wires during the shaping and curing process.
[0023] The annular assembly, with plug member 50 , shown in FIG. 2 is thereafter shaped to conform to a tire and positioned against the tire liner as explained above and illustrated in FIG. 8 . The tire is cured and the annular antenna assembly is thereby cured into the tire. The plug member 50 throughout the procedure maintains the fixed relationship between the antenna wire ends 42 , 44 and the base plate 38 .
[0024] The tag carrier is illustrated in detail by FIGS. 5, 6 , and 7 . As shown, carrier 60 comprises a carrier body 62 formed of any suitable material such as plastic. The body 62 has inwardly and upwardly tapering sides 61 that lead to an upper cylindrical socket 63 . Depending from the body 62 are spaced apart prongs or protrusions 64 , 66 . Prongs 64 , 66 are formed to have an enlarged equatorial diameter 68 . Seated and secured within the socket 63 is an electronic tag 70 . The invention is not intended to be tag specific and any suitable electronic tag available in the industry may be employed. Typical tag packages have sensor means for measuring the temperature and pressure within a tire cavity. Such tags may further have stored therein an identification code for identifying the tire associated therewith. Tags of the subject general type may be powered by a local source such as a battery. More useful, however, are tags that are powered by an external RF energy source transmitted to the tag by means of an antenna. Such configurations do not require battery replacement and are therefore considered preferable. Typically, tags communicate by RF signal through an antenna to an external reader on a vehicle. Connection between the tag and the antenna is by means of conductor leads 72 , 74 . As best seen from FIG. 7 , the leads 72 , 74 are extended through the carrier body 62 to terminal ends 76 located at an outside surface of each carrier prong 64 , 66 , proximate to the equatorial plane 68 . The leads 72 , 74 are stabilized by the carrier body 62 so that the terminal ends 76 are fixed in their intended orientation outboard of prongs 64 , 66 substantially at the equatorial plane 68 .
[0025] In a post-cure operation, the plug member 50 is removed from attachment with the base plate 38 by extraction of prongs 54 , 58 from apertures 42 , 44 . The antenna ends 46 , 48 will remain within grommets 42 , 44 . In a next step, the tag carrier of FIG. 5 is inserted into mating engagement with the base plate 38 by the press insertion of carrier prongs 64 , 66 into the grommet apertures 42 , 44 . The prongs 64 , 66 replace the prongs 54 , 56 of the plug member 50 and are of like configuration, having an enlarged equatorial diameter 68 . The prongs 64 , 66 pressure the antenna leads 42 , 44 against sides of apertures 42 , 44 and ensure that positive electrical contact is established and maintained between the antenna ends 42 , 44 and the base plate 38 . See FIG. 6 .
[0026] With reference to FIGS. 6 and 7 , it will further be noted that insertion of prongs 64 , 66 into grommet apertures 42 , 44 also establishes and maintains electrical contact between the terminal ends 76 of tag leads 72 , 74 and the base plate 38 . Preferably prongs 64 , 66 and 54 , 58 are formed of resilient plastics material. As they are press inserted into the base plate grommets, the prongs will be compressed and exert radially directed outward force against the ends of the antenna. The terminal ends 76 of the tag 70 are disposed at the oversized equatorial plane of each prong such that when the prongs 64 , 66 are fully inserted into their respective grommet, the ends 76 of each lead will be pressured against sidewalls defining each grommet. Positive electrical continuity is thereby established between the tag 70 and the base plate 38 through leads 72 , 74 . The antenna is likewise electrically in contact with the base plate 38 as the same carrier prongs 64 , 66 serve to pressure antenna ends 46 , 48 against the grommet sidewalls. Resultantly, there is established and maintained an electrical continuity between tag 70 and the antenna 32 .
[0027] From the foregoing, it will be appreciated that the subject invention accomplishes the needs outlined above. First, the subject method allows the annular antenna and carrier strip to be incorporated within the tire during the tire building operation, resulting in a mechanical connection of high integrity. The tag 70 , however, is spared from exposure to stresses associated with the tire building operation by the substitution of plug member 60 . The plug member 60 is conveniently inserted into the annular antenna apparatus and serves to maintain the antenna ends at their designated locations within base plate grommets. In a post-cure operation, the plug member may be conveniently removed and replaced with the tag carrier. Replacement effectively establishes electrical continuity between the tag electronics and the annular antenna wire without the need for extensive labor or parts. The tag electronics are thereby incorporated into the annular antenna assembly at a final stage.
[0028] Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims.
|
A system and method for post-cure application of electronics to a tire includes: a first stage assembly in which an ends of an annular antenna wire are positioned within conductive grommets in a base member; a second stage in which a plug is affixed to the base member to hold the antenna ends in place during shaping and curing of the antenna wire into a tire; and a third stage in which the plug is replaced by a tag carrier, the carrier including means for establishing and maintaining electrical contact between the antenna ends and the tag.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of International application PCT/RU2013/000941 filed on Oct. 23, 2013 which claims priority benefits to Russian patent application RU 2012145198 filed on Oct. 24, 2012. Each of these applications is incorporated herein by reference for all purposes.
TECHNICAL FIELD
The present invention relates to the field of veterinary and human medicine. In particular, the invention relates to a composition suitable for parenteral administration, based on hydrolyzate obtained from natural bioresources, a method for producing said composition, a method of treating and/or preventing a pathological condition in a mammal in need thereof, using the above composition and various uses of said composition for treating and/or preventing purposes and other applications. More particularly the invention relates to a composition having immunomodulatory properties being based on a hydrolyzate obtained from bioresources, which composition is used for parenteral administration to a mammal in need thereof.
The present disclosure provides a composition for parenteral administration, based on a hydrolyzate obtained from bioresources. The composition comprises a wide variety of essential amino acids, melanoidins acting as antioxidants, regulatory peptides, saturated and unsaturated fatty acids, vitamins and micronutrient elements in a natural balanced ratio, having a number of useful properties and utilised in veterinary and medicine for the treatment and/or prophylaxis various diseases and conditions. In particular, it was surprisingly found that the composition for parenteral administration comprising 1-10% aqueous solution of the hydrolyzate obtained from the above-identified biological material for parenteral administration, has significant advantages as compared to compositions known in the state of the art. Moreover, a number of effects of the composition observable upon parenteral administration either do not appear upon oral intake of a pure hydrolyzate or appear after an extended period of time. On the other hand, said composition has also a number of advantages relative to known parenteral forms. Furthermore, it was found that parenteral intake of the composition disclosed herein is safe and does not provoke allergic reactions and other adverse effects.
BACKGROUND OF THE INVENTION
Various preparations and biologically active additives representing protein hydrolyzates obtained from source material of animal origin, in particular, sea products such as Mytilidae mussels and fish, meat of mammals and the like are known from the prior art. Said protein hydrolyzates usually represent bioadditives intended for oral administration, either individually or in combination with other preparations, as well as a food additive.
DE 4309339 discloses biologically active pharmaceutical product of natural origin, which comprises acid hydrolyzate of molluscs belonging to genus Mytilus , comprising amino acids, melanoidins and trace elements of edible mussel ( Mytilus edulis ) and Mediterranean mussel ( Mytilus galloprovincialis ). In addition, the invention relates to various usages of the product. In particular, said product is used as a prophylactic, therapeutic radiopharmaceutical agent for humans and animals, has antipyretic properties and stimulates haemopoiesis, especially during radio- and chemotherapy.
Also known in the state of the art is the product MIGI-K (MIGI-K LP (M - ®), a liquid for oral administration, which represents a solution obtained by hydrolysis of Mediterranean mussels and used as a biologically active food supplement (see http://www.migiklp.ru).
Known in the art is a biologically active additive MIDEL (M ) having general tonic effect, close in properties to MIGI-K obtainable from White Sea mussels meat. Therapeutic and remedial administration of MIDEL combined with conventional treatment methods or as an individual preparation is recommended in immune deficiency conditions of various etiologies.
One of the disadvantages of oral hydrolyzates obtained from Mytilidae mussels meat is a relatively low rate of the development of desired effect upon daily administration.
Immunomodulatory compositions obtained from source material of animal origin other than mussels are also known in the state of the art.
RU 2221456 discloses a universal biologically active substance (BAS), which is a protein hydrolyzate obtained by a method comprising acid hydrolysis followed by neutralization of fish meat and protein containing by-products of animal or fish origin; filtering to provide a hydrolyzate and a residue; and subsequently drying the hydrolyzate. The claimed BAS is disclosed to be used as a food additive for animals, as a base for veterinary preparation, oral alimentation, perfume and beauty products, dairy products, confectionaries, etc.
Additionally, various preparations and compositions based on hydrolyzates derived from fish meat are known from EP 1653981, US 2009111747, US 2011124570.
RU 2402320 discloses a preparation comprising various amino acids, salts and micronutrient elements in a form of aqueous solution, as well as a method for preventing and correcting pathological conditions in animals, consisting in injectable administration of said preparation to an animal organism for prophylactic purposes 2 times a week over a month in a dose of 1.5-2.0 ml per 10 kg body weight, for treatment purposes in a dose of 3.0-5.0 ml per 10 kg body weight 2 times per 24 hours over 3-5 days in case of intoxication with synthetic and/or food poisoning in a 10-fold therapeutical dose. In particular, subcutaneous or intramuscular administration of said preparation provides more efficient prophylaxis and treatment of diseases of various etiologies. However, the production of said synthetic preparation is a tedious and energy-demanding process which comprises developing optimal qualitative and quantitative compositions of aqueous solutions of amino acids, vitamins, micro- and macroelements and glucose, in order to normalize metabolic processes in an animal organism, and preparation techniques thereof.
Various injectable preparations, such as, for example, evinton, are also known in the state of the art. Due to a combination of three homeopathic ingredients, evinton stimulates phagocytic activity and promotes barrier function of lymph nodes, skin, and mucous membranes as well as of other organs and tissues. Evinton is an immunomodulator used for treating diseases of bacterial and viral etiology such as canine distemper, panleukopenia, parvoviral enteritis, viral hepatitis, rhinotracheitis, etc. Evinton is administered daily, a mode of treatment lasting from a few days (for viral enteritis) up to 2-3 weeks (for viral hepatitis).
All the above-identified compositions have relatively low therapeutic and preventive efficiency. Beneficial effect upon oral administration of the preparations obtained from aquatic bioresources usually develops after a long period of time, provided that they are used in continuous manner. Oral preparations are used as biologically active food supplements, where the amount of preparation consumed over the entire course varies significantly and can be from tens of millilitres to a few litres. Moreover, the known injectable preparations do not possess broad spectrum of effects, probably due to their not sufficiently balanced composition, as in the case of, e.g., synthetically produced compositions, or, depending on their natural origin, as in the case of fish hydrolyzates, failing to comprise a full set of ingredients necessary and sufficient for achieving rapid preventive or therapeutic effect in human and animals.
Therefore, the present disclosure provides a composition having various therapeutic and preventive properties allowing one to achieve the desired positive effect within relatively short period of time regardless of a patient's ability and/or willingness to take food, ability and possibility of swallowing the composition and/or difficulties associated with its gastrointestinal uptake. Such composition may turn out to be particularly useful in veterinary medicine, where in many cases an animal suffering from a pathological condition or being in need of prophylactic agents for a certain disease, refuses to take food comprising oral preparation due to unpleasant taste and/or odour of the latter. The present composition solves this problem as well.
It was surprisingly found that properties of the composition disclosed herein include immunomodulatory activity, phagocytic activity, hepatoprotective activity, adaptogenic activity, antiherpetic activity, detoxifying activity, antiviral activity, and antibacterial activity, burn treating and wound healing properties. Moreover, said therapeutic effect can be achieved after the first few applications of the composition. In some cases therapeutic improvement is observable since the very first application of the present parenteral composition.
The present disclosure further provides a method for preparing the above-identified composition. Said method is simple in technique and its implementation does not require special manufacturing facilities and high professional skills, thereby contributing to its higher economic efficiency.
The composition for the parenteral administration is used in treating and/or preventing a pathological condition in a mammal in need thereof. That is to say, in other aspect the present disclosure provides a method of treating and/or preventing a pathological condition of various etiology in a subject in need thereof, the method comprising administering the above-identified composition. Said method includes an optimal dosage schedule for administering the composition, providing beneficial preventive and/or therapeutic effect while exhibiting no adverse effects irrespective of a subject's individual parametres; in particular not a single case of individual intolerance to the composition was observed in a mammal throughout clinical trial period.
Thus, the present disclosure provides an composition for parenteral administration, the composition comprising a hydrolyzate obtained from biological material of animal origin, methods for preparing said composition, the methods of treating and/or preventing a pathological condition in a mammal in need thereof using the composition described herein, and various other uses of said composition for medical and veterinary purposes.
SUMMARY
In a first aspect, the present disclosure provides a composition for parenteral administration to a mammal, comprising
1 to 10% wt of a hydrolyzate obtained from bioresources; and water.
The term “bioresources>> refers to any material of animal or plant origin used as a source for hydrolyzate. For example, animals and/or plants of marine or terrestrial origin can be used as a bioresource.
In one embodiment, the bioresources are selected from a group comprising bivalve molluscs, crustaceans, annelids and leeches. The bioresources are used for the production of the hydrolyzate with a balanced chemical constitution, including but not limited to a wide variety of amino acids such as essential amino acids, saturated and unsaturated fatty acids, melanoidins, carbohydrates, micro- and macroelements, the hydrolizate being a basis for producing a composition which provides a desired therapeutic and preventive effect upon its parenteral administration to a mammal in need of such a treatment or prophylaxis.
The composition can comprise hydrolyzate, which is obtained from one or more species of source material. In particular, composition can comprise hydrolyzate obtained from bivalve molluscs, and/or crustaceans, and/or annelids, and/or leeches.
In one embodiment, the bivalve molluscs include floaters ( Anodonta ), Unio freshwater mussels, oysters (Ostreidae), true mussels (Mytilidae), tridacna ( Tridacna ), pearl-oysters ( Pinctada ), scallops (Pectinidae), shipworms (Teredinidae), geoduck ( Panopea abrupta ), ocean quahog ( Arctica Islandica ) and other harvested species of molluscs.
In one embodiment, crustaceans include krill, shrimps, crabs, langoustes, langoustines, crayfishes, lobsters and other harvested species. Preferably crustaceans include krill ( Meganyctiphanes norvegica ) and/or American lobster ( Homarus americanus ).
In another embodiment, the bioresource is a Red sea urchin ( Strongylocentrotus franciscanus ).
A composition having a number of prophylactic and therapeutic properties can be obtained from any of the above-identified bioresources. Furthermore, bivalve molluscs and crustaceans are common commercial primary products and therefore are commercially available bioresources for the production of the present composition. The qualitative and quiantitive contents of the hydrolyzate obtained from marine animal species can slightly vary depending on location and environmental conditions where the species are grown; however, major properties generally remain similar. Preferably, annelids and leeches are grown in invariable manufacturing environment, providing strictly constant formulation of the composition derived from these species. Alternatively, a composition according to the present invention can also be obtained from hydrolizate derived from marine bioresorces harvested from their natural environment.
The term “hydrolyzate obtained from bioresources”, as used herein, refers to liquid solution obtained by hydrolysis of bioresources. According to one embodiment the hydrolizate has a dry matter content in a range from 1 to 20% by weight, preferably from 1 to 15% by weight, more preferably form 1 to 10% by weight, and most preferably form 1 to 5% by weight.
In one embodiment of the present invention, the hydrolyzate content in the composition is from 2 to 8% wt, preferably from 3 to 7% wt, more preferably from 4 to 6% wt, most preferably approximately 5% wt. In a further embodiment, the hydrolyzate content may vary from 1 to 4% wt, 1 to 3% wt, 1 to 2% wt, 6 to 9% wt, 7 to 9% wt and 8 to 9% wt. According to one embodiment the rest of the composition is water or isotonic solution suitable for injection into animal or human body. More specifically water may represent sterile water for injection.
In general, the hydrolyzate mass ratio does not preferably exceed 10% wt of the composition; otherwise the composition might not be suitable for some types of parenteral administration, in particular, for injectable administration, due to, for example, high salt concentration. On the other hand, the hydrolyzate weight ratio is usually kept not less than 1% wt in order to provide sufficient amount of components in the composition for desired effect in treating and/or preventing various conditions in a subject in need thereof.
In one embodiment, the hydrolizate can represent any product obtained from the above-identified bioresources suitable for oral consumption as a healthy food additive or feedstuff. More specifically, the hydrolyzate represents an orally consumed product extracted from bivalve molluscs, and/or crustaceans, and/or annelids, and/or leeches.
In one embodiment, the hydrolizate represents a commercially available nutrition product, food supplement or feedstuff produced from sea mussels, which is suitable for oral administration.
The term “a mammal/subject in need (of treatment or prophylaxis)” refers to any animal including Mammalia , or to a human, in need of treatment and/or prophylaxis of a pathological condition, disease, disorder, etc, or any other health condition, including healthy subjects, in need of health improvement.
In one embodiment, the mammal is an animal or human. Preferably the animal is a livestock animal selected from the group comprising cow, buffalo, yak, deer, pig, goat, sheep, rabbit, horse, donkey, camel, lama, sable, fox, mink, ferret and etc., or the animal can be a pet animal, such as dog, cat, rat, hamster, guinea pig, etc. In a further embodiment, the animal can be a wild animal living in wild nature conditions.
In one embodiment, “parenteral administration” comprises any ways of administration, except introduction of the present composition to a mammal in need thereof through gastrointestinal tract.
In one embodiment, the composition is an injectable composition. Said injectable administration can be performed intravenously (i.v.), intracutaneously, subcutaneously (s.c), intramuscularly (i.m.) or intraosseously. Surprisingly, it has been found that parenteral administration of the above composition significantly increases therapeutic, preventive and health improvement effects as compared to oral intake of undiluted (pure) hydrolyzate. Moreover, it considerably facilitates the development of such effects. Furthermore, parenteral administration of said composition allows achieving some effects which were not identified upon either oral administration of undiluted hydrolyzate derived from Mytilidae mussels' meat, or upon administration of the injectable forms, known in the prior art. It should also be noted that the composition had no adverse effects and does not cause allergic reactions upon regular parenteral administration according to clinical trials on animal models.
In a further embodiment, the composition can be formulated for topical administration that is applied to body surfaces such as the skin or mucous membranes to treat ailments via a large range of classes including but not limited to creams, foams, gels, lotions and ointments. In some embodiments, a topical formulation according to the invention can be epicutaneous, for application directly to the skin. In some embodiment, a topical formulation of the invention can be applied to the surface of tissues other than the skin, such as eye drops applied to the conjuctiva, or ear drops placed in the ear, or medications applied to the surface of a tooth. A topical effect achieved when using a topical formulation naccording to the present invention, in the pharmacodynamic sense, may refer to a local, rather than systemic, target for a medication. However, some other topically administered formulations according to the present invention may have systemic effects.
In particular, the composition can be formulated as an ointment, paste, liniment, cream, lotion, and other dosage forms, or other dosage forms suitable for topical application. The composition may be employed in skin application formulations, including, but not limited to cutaneous prolonged-action therapeutic system or transdermal patches. In particular, the disclosed composition can be applied to the thin skin body area of a mammal in need thereof. Furthermore, composition for external use may be used in treating open wounds, burns, frostbites, bruises, dislocations, fractures and other cutaneous and subcutaneous lesions.
In a further embodiment, the composition is characterized by amine nitrogen weight ratio of at least 0.01% wt. Preferably, the amine nitrogen weight ratio is 0.01 to 0.5% wt. More preferably, the amine nitrogen weight ratio is from 0.05 to 0.5% wt, most preferably from 0.02 to 0.1% wt. The amine nitrogen weight ratio characterizes the extent of the hydrolysis of the bioresources, and further represents a parameter indicating the completeness of the hydrolysis. The amine nitrogen weight ratio serves as an indirect measure of the presence of essential components in the final composition for parenteral administration.
In another embodiment, the composition provided herein has a pH value of 4 to 7, preferably 5 to 7, most preferably 5.5 to 6.5. A pH value within the said range indicates both sufficient neutralization of the hydrolyzate and suitability to use said composition for the treatment and/or prophylaxis of a mammal in need thereof.
In another embodiment, the composition provided herein has a dry matter content of 0.5 to 5% wt, preferably of 1 to 3% wt, most preferably of 1.2 to 1.8% wt based on the total weight of the composition.
In a further embodiment, the composition comprises a wide variety of amino acids depending on the type of bioresources used for producing thereof. In particular, the composition comprises amino acids, selected from a group comprising taurine, aspartic acid, threonine, serine, glutamic acid, sarcosine, glycine, alanine, valine, cystine, methionine, cystathionine, isoleucine, leucine, tyrosine, phenylalanine, β-alanine, γ-aminoisobutyric acid, γ-aminobutyric acid, ornithine, lysine, histidine, carnosine, arginine, oxyproline and proline. The composition may also comprise other amino acids.
In a further embodiment, the composition comprises at least one or more of human essential amino acids, selected from a group comprising valine, isoleucine, leucine, lysine, methionine, threonine, tryptophane, phenylalanine, arginine and histidine.
In one embodiment, composition comprises the following amino acids having the below specified mass ratios with respect to total amino acid content in said composition:
taurine 1 to 10% aspartic acid 1 to 30% glutamic acid, 1 to 30% glycine 1 to 20% alanine 1 to 10% leucine 1 to 15% phenylalanine 1 to 15% lysine 1 to 10% arginine 1 to 20% proline 1 to 50% serine 1 to 10% histidine 1 to 10% threonine 0.5 to 10% valine 0.1 to 10% methionine 0.1 to 10% isoleucine 1 to 10%
In one embodiment, the same composition may optionally have a dry matter weight ratio, pH value, amine nitrogen weight ratio and qualitative and quantitive amino acid content as indicated above.
In one embodiment, the composition disclosed herein is characterized by
amine nitrogen weight ratio of 0.01 to 0.5% wt, and/or pH value of 4 to 7, and/or dry matter weight ratio of 0.5 to 2% wt
The composition disclosed herein comprises, along with amino acids, saturated and unsaturated fatty acids, selected from a group comprising acids with a long hydrocarbon chain having 12 to 25 carbon atoms. In particular, the composition preferably comprises one or more fatty acids, selected from a group comprising tridecyl acid C13:0, myristinic acid C14:0, tetradecenic acid C14:1, pentadecanoic acid C15:0, palmitic acid C16:0, palmitoleic acid C16:1, hexadecadienoic acid C16:2, hexadecapentanoic acid C16:5, heptadecanoic acid C17:0, heptadecenoic acid C17:1, heptadienoic acid C17:2, stearic acid C18:0, oleic acid C18:1, linolic acid C18:2, linolenoic acid C18:3, octadecatetraenoic acid C18:4, eicosenoic acid C20:1, eicosadienoic acid C20:2, eicosatrienoic acid C20:3, arachidonic acid C20:4, eicosapentaenoic acid C20:5, heptacosapentaenoic acid C21:5, docosanoic acid C20:0, docosadienoic acid C22:1, docosenoic acid C22:2, docosatetraenoic acid C22:4, docosahexaenic acid C22:6, tricosatetraenoic acid C23:4, tricosapentaenoic acid C23:5, tetracosenoic acid C24:1.
In other embodiment, the composition comprises micronutrient elements such as potassium, calcium, magnesium, iron, zink, copper, cadmium, manganese, nickel, chrome, selenium, iodine.
The composition may additionally comprise biologically active additives, which are known in the state of the art; agents and preparations for preventing and treating pathological conditions, diseases and disorders in humans and animals, known in the field of veterinary and medicine; macro- and micronutrient elements, amino acids, melanoidins, carbohydrates, peptides and vitamins. Preferably, said composition is supplemented with appropriate salts to produce physiological solution, suitable for parenteral administration. In one embodiment of the invention, said composition is admixed with glucose prior to administration.
In a second aspect, the present disclosure provides a method for producing a composition for parenteral administration to a mammal in need of prophylaxis and/or treatment. In particular, herein disclosed to method for producing composition for parenteral administration to a mammal, including:
(a) an enzymatic hydrolysis and/or acid hydrolysis of bioresources selected from a group comprising bivalve molluscs, crustaceans, annelids and leeches, to provide a first solution;
(b) filtering the first solution to provide a second solution;
(c) mixing the second solution with water to provide a composition comprising from 1 to 10% wt of the second solution.
In one embodiment, step (a) includes enzymatic and acid hydrolysis. Any enzymes of animal, plant or microbial origin can be used. In particular, said enzymes include without limitation protomegaterin, protakrin, protosubtilin, trypsin, pepsin and other interchangeable enzymes. The amount of enzyme, pH value, temperature and other conditions are selected empirically, depending on the type of enzyme and source material subjected to enzymatic hydrolysis. pH value during enzymatic hydrolysis is maintained between 1 and 12, more preferably between 1 and 10, most preferably between 1 and 9. Temperature during enzymatic hydrolysis is maintained between 20 and 80° C., more preferably between 30 and 70° C., most preferably between 30 and 60° C. An enzyme is added to a source material as a dry powder, while stirring. Said step does not require additional fresh water supply, and can be carried out at the sites of harvesting of said source material. Enzymatic hydrolysis is carried out over 10 min to 5 hours, preferably over 20 min to 3 hours, most preferably over 30 min to 1 hour.
Where said biological material is a bivalve mollusc, enzymatic hydrolysis may be needed for loosening of the mollusc adductor muscle, thereby permitting separation of molluscs' soft tissues and shells, and for primary hydrolysis of the molluscs' soft tissues. Once the acid hydrolysis is finished, the molluscs' shells are separated from soft tissues by filters such as vacuum filter or press filter, and/or vibration screen. Separation of soft tissue is followed by acid hydrolysis or further enzymatic hydrolysis with one or more enzymes.
Alternatively, valves and shells of bivalve molluscs can be detached physically by hand and/or by methods employing no enzymatic means, for instance, by hot vapour. Bivalve molluscs can also be crushed and acidolysed without the use of enzymes.
Source materials other than bivalve molluscs such as crustaceans, in particular krill, as well as leeches and annelids, may also be subjected to enzymatic hydrolysis.
In one embodiment, acid hydrolysis of the source material is either following enzymatic hydrolysis or performed instead of it. Acid hydrolysis is performed using an acid selected from a group comprising common acids such as sulphuric and/or hydrochloric acid, as well as other interchangeable mineral acids and organic acids. Acid hydrolysis takes approximately 10 to 30 hours, more preferably 12 to 27 hours, most preferably 14 to 24 hours. Duration of the hydrolysis depends on the amount and type of the source material, as well as on its degree of processing prior to acid hydrolysis. Generally, enzymatic hydrolysis promotes the reduction of subsequent acid hydrolysis duration by approximately 3-7 hours.
In one embodiment, the amount of acid employed in the acid hydrolysis is between 5 to 20% wt, preferably 5 to 15% wt, more preferably 5 to 10% wt with respect to the amount of source material being processed. Said amount of acid is generally sufficient for the hydrolysis process to be entirely completed. However, the amount of acid may be selected empirically, depending on the type of biological resource and the extent of hydrolytic conversion.
In one embodiment, the temperature for acid hydrolysis is adjusted in the range of between 80 to 120° C., preferably between 90 to 110° C., most preferably between 95 to 105° C. In particular, acid hydrolysis is carried out while the solution is boiling.
According to one embodiment, acid hydrolysis is carried out in a glazed or glass reactor equipped with a thermometer or thermocouple for temperature control, and with a stirring device.
Alternatively, feed source material may not be subjected to acid hydrolysis where it is unnecessary. In particular, completeness of the hydrolysis can be achieved by the enzymatic hydrolysis only. Whether the acid hydrolysis has been carried out, the next step is a step of neutralization of the first solution, including adding a neutralizing agent to the first solution in an amount, sufficient for adjusting pH value of the solution from 4 to 7, preferably 5 to 7, most preferably 5.5 to 6.5. Agents that produce water and neutral salt, for example, bases such as NaOH and/or KOH in solid form, or a solution thereof, as well as basic salts and solutions thereof, are used as neutralizing agents. In particular, sodium or potassium carbonates and/or hydrocarbonates can be employed as a salt. Preferably neutralizing agent is a solid sodium hydroxide.
According to one embodiment, filtration of the obtained first solution is further performed to give the second solution.
In one embodiment, a step of filtration of the first solution is preceded by its stroring at the temperature of 1 to 25° C., preferably of 4 to 15° C., most preferably of 4 to 6° C. for at least 10 days, preferably from 10 to 20 days, most preferably from 10 to 30 days. This step provides a more complete sedimentation of the insoluble components of the first solution and their separation during the next step, thereby increasing stability of the final composition for parenteral administration.
After storing, the residue is separated to provide the second solution. The step of filtering the first solution to provide the second solution is performed by using mechanical filters, preferably vacuum filters. Said step may be subdivided into several steps and may include hot filtering the first solution after completed enzymatic and/or acid hydrolysis, as well as one or more repetitive steps of filtering the cooled first solution to provide the second solution. Preferably, the step of filtering is carried out after the step of storing the first solution under above specified conditions.
The next step comprises admixing the second solution with water to give a composition comprising from 1 to 10% wt of the second solution, preferably 2 to 8% wt, or 3 to 7% wt, more preferably 4 to 6%, most preferably approximately 5% wt. In a further embodiment, weight content of the second solution may be from 1 to 4% wt, 1 to 3% wt, 1 to 2% wt, 6 to 9% wt, 7 to 9% wt and 8 to 9% wt. Said water is a distilled water, or sterile water for injection. The second solution weight content in the composition corresponds to the amount required for the production of a final composition which is suitable for parenteral administration, in particular, for intravenous administration. In one embodiment, the resulting composition is isotonic to the blood of a mammal in need of prophylaxis or treatment with said composition. The composition may be admixed with an ingredient selected from a group comprising vitamins, carbohydrates, additional amino acids, micro- and macroelements, glucose and the like, prior to its administration.
In other embodiment, after the addition of distilled water and/or water for injection, the composition is sterilized and loaded into storage containers. Ampoules, flacons, bottles, bags and the like can be used as storage containers for the composition. The production method is performed under aseptic conditions in compliance with all the requirements stipulated by the State Pharmacopoeia for particular parenteral forms. Containers with the final composition are stored at the temperature of 0 to 25° C., preferably of 4 to 6° C. A shelf life of the composition upon appropriate conditions may last for at least 2 years. Preferably, if all the above-identified conditions are observed, the composition remains stable and suitable for use for 5 years and more.
In a third aspect, the composition is used in treating and/or preventing a pathological condition in a mammal in need thereof, wherein the composition is administered parenterally to a subject in need thereof. Alternatively, in a third aspect the present invention relates to a use of the composition for treating and/or preventing a pathological condition in a mammal in need thereof.
In another embodiment, the present invention provides a method of treating and/or preventing a pathological condition in a mammal in need thereof, including parenteral administration of said composition to a mammal in need of such a treatment or prophylaxis.
In one embodiment, the present invention relates to a use of the composition for treating and/or preventing a pathological condition in a mammal in need thereof including parenteral administration of said composition to a mammal in need of such treatment or prophylaxis.
Said parenteral administration includes any mode of administration which does not involve introduction of said composition into a mammal body through organs of gastrointestinal tract. In particular, the parenteral administration may be an injectable administration, selected from a group comprising subcutaneous injectable administration, intracutaneous injectable administration, intramuscular injectable administration, intravenous injectable administration or intraosseously injectable administration. Said parenteral administration can also be an external application of the above-identified composition.
In one embodiment, the composition is administered in an amount of 0.05 ml/kg to 10 ml/kg of a body weight of said mammal for 1-5 times per 24 hours over 1 to 50 days. More preferably, composition is administered in an amount of 0.1 to 1 ml/kg over 1-15 days.
In another embodiment, the composition is administered once in an amount of 0.05 ml/kg to 10 ml/kg of a body weight of said mammal every 1-5 days in an amount of 0.05 to 10 ml/kg over 1 to 50 days. More preferably, the composition is administered in an amount of 0.1 to 1 ml/kg over 1-15 days.
In another embodiment, the composition is optionally applied once in 45-120 days over a year in an amount of 0.05 ml/kg of a body weight to 10 ml/kg of a body weight of said mammal. More preferably, composition is administered in an amount of 0.1 to 1 ml/kg once in 90 days.
Furthermore, a regime of administration of the composition can be adjusted according to the type of pathological condition and general well-being of a mammal in need thereof, or according to specific purpose of said composition.
In one embodiment, said pathological condition, which is treated and/or prevented, is a liver injury of various etiology, hepatosis, organism intoxication, skin disease, hair disease, dermatitis, skin integument discontinuities due to wounds or burns, obstructive pulmonary diseases, pneumonia, acute respiratory viral infection (ARVI), influenza virus, circovirus infection, acidosis, herpes, stress condition, postoperative weakness, inflammatory processes affecting intestinal mucous membranes, osteodystrophy, rickets-like conditions, arthrosis, osteochondrosis, atherosclerosis and other diseases.
In another embodiment, the composition is useful for fast and effective immunity improvement, normalization of metabolism, in particular calcium-phosphorus metabolism, body weight gain, where necessary, and loss of overweight, increasing liver protein synthetic ability; as a wound-healing and burns healing promoting agent; as an agent delaying benign and malignant tumor growth; as a hair growth stimulating agent; as an agent for inducing estrus in live-stock animals and improving reproductive function in animals.
In one embodiment, the composition is used in any intoxications, e.g., in particular, intoxications of exogenous and endogenous origin. Therefore, the composition is used as a detoxifying agent, wherein the composition is administered as a single dose in an amount of 0.1 to 10 ml/kg of a body weight of a mammal in need thereof. In most cases a mammal in need thereof gets rid of intoxication symptoms upon administration of a dose between 0.1 to 0.5 ml/kg. In case of poisoning symptoms recurrence, the composition is administered 1 to 5 times in similar doses.
According to one embodiment the present disclosure relates to a method of detoxifying a mammal in need thereof by administering via injection to said mammal a composition comprising about 1 to 10% wt of the hydrolyzate, obtained by enzymatic hydrolysis and/or acid hydrolysis from bioresources, said bioresources selected from a group comprising bivalve molluscs, crustaceans, annelids and leeches, and water.
In another embodiment, the composition is used for boosting the immune status of a mammal in need thereof. In other words, said composition is an immunomodulatory composition. In particular, the composition is used to cure weakness of the body resulting from various diseases, and also where a mammal is attenuated, e.g., due to previous treatment with antibiotics and/or immunosuppressive agents. For example, the composition is administered to a mammal in need of rehabilitation during postoperative or post-chemotherapy period, or during post-pregnancy period, feeding offspring and etc. During epidemic of infectious diseases such as influenza, acute respiratory virous infections and other diseases, the composition is administered as a prophylactic agent.
In another embodiment, the composition is used for the normalization of metabolism in a mammal in need thereof. In this case, normalization of the metabolism is indirectly assessed, in addition to key parameters estimation, by increased or reduced body weight in a mammal in need of such an increase or reduction, respectively; augmentation of hair or wool coat covering, improving mobility and overall activity of senior animals; and by other parameters.
In another embodiment, the composition is used for the normalization of calcium-phosphorus metabolism in a mammal in need thereof. In this case, normalization of calcium-phosphorus metabolism is assessed by calcium and phosphorus content in a mammal organism.
In another embodiment, the composition is used for estrus induction in an animal and for general improvement of the animal's reproductive function.
According to one embodiment the present disclosure relates to a method of improving reproductive function of a mammal in need thereof by administering via injection to said mammal a composition comprising about 1 to 10% wt of the hydrolyzate, obtained by enzymatic hydrolysis and/or acid hydrolysis from bioresources, said bioresources selected from a group comprising bivalve molluscs, crustaceans, annelids and leeches, and water.
In particular, it was found that intramuscular administration of 1 to 3 doses of the composition in an amount of 0.005 to 1 ml/kg, preferably 0.01 to 0.1 ml/kg, more preferably 0.01 to 0.05 ml/kg of animal body weight, to livestock animals during 24 hours prior to fertilization, allows the above effect to be achieved. In particular, achievement of the above effect was observed upon intramuscular administration of the composition to cows in an amount of 0.01 to 0.05 ml/kg twice over 24 hours.
In another embodiment, the composition is used for reducing stress in a mammal in need thereof. In particular, it was shown in experimental models on animals that the composition exhibits a number of adaptogenic/antistress properties. For example, the composition was shown to improve survival and to increase postnatal performance in pigs, and also gave positive results in the model of transport stress in horses.
According to another embodiment the present disclosure relates to a method of reducing stress in a mammal in need thereof.
In another embodiment, the composition is used as a wound healing agent in a mammal in need thereof, wherein said wounds may occur as a result of various physical injuries, in particular skin integument discontinuities, as well as various diseases such as dermatitis, psoriasis, herpes and other lesions of skin integument of various etiology.
According to another embodiment the present disclosure relates to a method of healing wounds in a mammal in need thereof.
In another embodiment, the composition is used as a growth-promoting agent in a mammal. In particular, growth-promoting effect of said composition was estimated by weight gain figures in livestock animals treated with the composition relative to the control group of animals, not treated with the composition or only treated with hydrolyzate administered orally.
In one embodiment the composition is used for treating oedema of various etiology.
In one embodiment the composition is used for treating and/or preventing a pathological condition selected from a group comprising atherosclerosis, hypertonic disease, coronary insufficiency, myocardial infarction in the acute phase and later in the recovery phase, kidney failure, hereditary and acquired metabolic disorders (dyslipidemia etc.), thrombosis and thrombophlebitis, endocrine age-related disorders, nonrespiratory pulmonary pathology (asthma), stroke, chronic heart disease, vegetative vascular dystonia, rheumatoid arthritis, urinary stone disease, haematuria of various origin, vasculitis, psoriasis, burns and ulcers, dermatitis, neurodermatitis, eczema, atopic dermatitis, ocular burns, type II diabetes, consequences of type I and II diabetes mellitus, lupus erythematosus, rheumatoid arthritis, autoimmune glomerulonephritis, myasthenia, osteochondrosis vertebralis, degenerative joint disease, osteoporosis, arthrosis, arthritis, hip dysplasia, gout, coxarthrosis, fractures, trauma and trauma consequences, muscular dystrophy, secondary immunodeficiency of various etiologies, immunodeficiency due to chemotherapy of cancer, gastroduodenitis, gastric andduodenal ulcer, colitis of different origin, intestinal andbiliary dyskinesia, pancreatitis, disbacteriosis, Crohn's disease.
It should be appreciated that the above-mentioned expression “a composition is used for < . . . >” has substantially the same meaning as “use of a composition for < . . . >”.
According to one embodiment the present disclosure relates to a method of treating and/or preventing an above-identified pathological condition.
These and other advantages of the present invention are illustrated in more detail by specific examples in the detailed description that is set forth herein below.
DETAILED DESCRIPTION
Production of the Composition for Parenteral Administration
EXAMPLE 1
100 kg of ocean quahog ( Arctica Islandica ) was placed into fermenter, and upon continuous mechanical stirring the apparatus was heated with hot water to 42° C. 1 kg of protosubtilin was added to the fermenter. pH was adjusted to neutral reaction according to pH-meter readouts. Enzymatic hydrolysis was carried out for 40 minutes upon continuous stirring, and then valves were separated by mechanical screening. The resulting solution was supplemented with concentrated hydrochloric acid and underwent acid hydrolysis over 16 hours in a glazed stirred-tank reactor at the temperature of 100-105° C. Upon completion of the hydrolysis process, the resulting solution was vacuum pumped into neutralizing tank, cooled by water circuit and neutralized with a dry alkali to pH value falling in the range of 4-6, while continuous cooling. The neutralized hydrolyzate was stored to settle for 15 days at the ambient temperature of 20° C. Further, vacuum filtration was performed to separate the resulting residue, thereby producing a hydrolyzate solution without solids. The resulting hydrolyzate solution weighting approximately 10 kg was supplemented, upon stirring, with the required amount of distilled water (<<water for injection>>), to provide a solution containing 5% wt of the hydrolyzate. Prior to filling containers with the end-use composition, the composition was subjected to thermal sterilization, followed, where appropriate, by filtration of the solution. Containers with the final composition were stored at the temperature of 4-6° C., out of direct sunlight. Results of chemical examination of the obtained composition are given below.
an amine nitrogen weight ratio is 0.08%
a dry matter weight ratio is 1.5% wt
a pH value is 5.7
Micronutrient elements (qualitative composition):
1. Potassium
2. Calcium
3. Magnesium
4. Iron
5. Zink
6. Copper
7. Cadmium
8. Manganese
9. Nickel
10. Chrome
11. Selenium
12. Iodine
Amino acid content
(including essential amino acids)
Fatty acids (lipids)
1. Taurine
1. Tridecyl acid C 13:0
2. Phosphoethanolamine
2. Myristinic acid C 14:0
3. Aspartic acid
3. Tetradecenic acid C 14:1
4. Threonine
4. Pentadecanoic acid C 15:0
5. Serine
5. Palmitic C 16:0
6. Glutamic acid
6. Palmitoleic C 16:1
7. Sarcosine
7. Hexadecadienoic C 16:2
8. Glycine
8. Hexadecapentanoic C 16:5
9. Alanine
9. Heptadecanoic C 17:0
10. Valine
10. Heptadecenoic C 17:1
11. Cystine
11. Heptadienoic C 17:2
12. Methionine
12. Stearic C 18:0
13. Cystathionine
13. Oleic C 18:1
14. Isoleucine
14. Linolic C 18:2
15. Leucine
15. Linolenoic C 18:3
16. Tyrosine
16. Octadecatetraenoic C 18:4
17. Phenylalanine
17. Eicosenoic C 20:1
18. β-alanine
18. Eicosadienoic C 20:2
19. γ-aminoisobutyric
19. Eicosatrienoic C 20:3
20. γ-aminobutyric
20. Arachidonic C 20:4
21. Ethanolamine
21. Eicosapentaenoic C 20:5
22. Ornithine
22. Heptacosapentaenoic C 21:5
23. Lysine
23. Docosanoic C C 20:0
24. Histidine
24. Docosadienoic C 22:1
25. Carnosine
25. Docosenoic C 22:2
26. Arginine
26. Docosatetraenoic C 22:4
27. Oxyproline
27. Docosahexaenic C 22:6
28. Proline
28. Tricosatetraenoic C 23:4
29. Tricosapentaenoic C 23:5
30. Tetracosenoic C 24:1
EXAMPLE 2
50 kg of krill ( Meganyctiphanes norvegica ) was placed into reactor upon continuous stirring and supplemented with concentrated hydrochloric acid. Acid hydrolysis was carried out for 24 hours in a glazed stirred-tank reactor at the temperature of 100-105° C. Upon completion of the hydrolysis process, the resulting solution was vacuum pumped into neutralizing tank, cooled by water circuit and neutralized with a dry alkali to pH value being in the range from 4 to 6, while continuous cooling. The neutralized hydrolyzate was stored to settle for 20 days at the ambient temperature of 20° C. Further, vacuum filtration was performed to separate the resulting residue, thereby producing a hydrolyzate solution without solids. The obtained hydrolyzate solution was supplemented with the required amount of distilled water (<<water for injection>>) while stirring, to provide a solution containing 5% wt of the hydrolyzate. Prior to filling containers with the end-use composition, the composition was subjected to thermal sterilization, followed, where appropriate, by filtration of the solution. Containers with the final composition were stored at the temperature of 4-6° C., out of direct sunlight. Chemical analysis of the obtained composition is given below.
an amine nitrogen weight ratio is 0.10% a dry matter weight ratio is 0.8% wt a pH value is 5.5
Amino acid Micro- content, Fatty acid nutrient No Amino acid % wt composition of lipids elements 1 taurine 0.020 Myristinic acid C14:0 Potassium 2 aspartic acid 0.042 palmitic acid Calcium C16:0 3 glutamic acid 0.045 palmitoleic acid C16:1 Magnesium 4 Glycine 0.030 heptadienoic acid C17:2 Iron 5 alanine 0.017 stearic acid C18:0 Zink 6 cystine 0.003 oleic acid C18:1 Copper 7 leucine 0.031 linolenoic acid C18:3 Chrome 8 tyrosine 0.0063 eicosenoic acid C20:1 Iodine 9 phenylalanine 0.041 arachidonic acid C20:4 10 gamma-amino- 0.002 eicosapentaenoic acid butyric acid C20:5 11 Ethanolamine 0.003 docosenoic acid C22:2 12 lysine 0.018 docosahexaenic acid C22:6 13 arginine 0.023 tricosatetraenoic acid C23:4 14 proline 0.114 tricosapentaenoic acid C23:5 15 serine 0.018 tetracosenoic acid C24:1 16 histidine 0.008 docosenoic acid C22:2 17 threonine 0.015 18 valine 0.012 19 methionine 0.006 20 isoleucine 0.014
Toxicity Studies of the Composition Based on Bivalve Molluscs
The objectives for the first stage of studies on the composition for parenteral administration, comprising 5% aqueous solution of the hydrolyzate produced in Example 1 (hereinafter referred to as composition A), included the following:
1. Toxicological and biological assays: definition of acute and subacute toxicity (including irritant and allergenic effects).
2. Estimation of embryotropic (embryotoxic and teratogenic) effects.
3. Possible subchronic toxicity testing in several animal species.
Materials and Methods
Experiments were carried out on 115 white rats and 55 white mice using existing pharmacological, toxicological, haematological, biochemical and immunological assays. Some techniques and schemes of toxicity studies of the preparation in laboratory animals and other animal models are provided throughout the disclosure of the experiments.
Experiments were carried out twice with statistical analysis of the results.
Determination of Acute and Subacute Toxicity (Including Irritant and Allergenic Effects)
Acute toxicity of composition A was measured by a single intramuscular administration of therapeutic dose 0.2 ml/animal, and of 2-fold increased and 4-fold increased doses, i.e. 0.4 and 0.8 ml/animal, that is 1600 and 3200 mg/kg. No apparent deviations in animal behavior were observed, rats took food and water willingly. According to toxicological classification, preparation having LD 50 higher than 1000 mg/kg belongs to low toxicity substances. For the composition being studied, this parameter exceeded the dose of 1000 mg/kg by several times.
To determine subchronic toxicity, the preparation in a dose of 0.2 ml/animal (or 800 mg/kg) was administered to rats continuously for 10 days. As well as in the acute experiments, no negative effects of the composition on animals were observed.
Irritation effects were estimated using epicutaneous application. Two groups of white rats with body weight 250-270 g were formed for estimation of possible irritative and allergenic effect of the composition. Each group consisted of 5 animals. For the first group, the composition for parenteral administration was applied for 20 days onto shaved areas on the backs (1.5×2 cm) and hips (1×0.5 cm), and onto conjunctiva of animals, while for the second group 0.9% sodium chloride solution was applied.
The following parameters were taken into account during the experiment: onset of conjunctival hyperaemia; cutaneous and palpebral edema, development of inflammation, skin reaction (erythema, rash) while using the preparations. Observations on experimental laboratory animals showed no allergenic and local irritant effects of the composition. No skin reaction manifesting as erythema or rash was observed on shaved areas on backs and hips.
Effects of the composition for parenteral administration and these of normal saline solution on eye mucosa and shaven back and hip areas of white rats are presented in Table 1.
TABLE 1
Parameters
1 st group
2 nd group
Skin hyperemia
absent
absent
Cutaneous edema
absent
absent
Eyelids condition
unchanged
unchanged
Conjunctivitis
absent
absent
Keratitis
absent
absent
Lacrimation
absent
absent
Pain reaction
absent
absent
The provided data show that the composition A does not have local irritant allergenic effect. Eye mucosa and eyelids of the white rats stayed in satisfactory condition, signs of inflammation, edema, skin hyperemia and lacrimation were absent and no pain reaction was observed after application of the solutions. Overall condition of the white rats was satisfactory; they were physically active and took food and water willingly.
Skin capillary permeability, considered as secondary endpoint for evaluation of the irritant effect, was measured by McClure-Aldrich test. The test consists in intracutaneous administration of 0.2 ml of physiological solution to experimental animals, into the area whereto the studied preparation was applied, and into symmetrical control area, on the 15 th day of experiment. Time of salt blister resorption in both areas was recorded. The studies showed that the preparations do not influence skin capillary permeability.
Definition of Embryotropic Effect of the Composition (Embryotoxic and Teratogenic)
Embryotoxic and teratogenic effects of the composition A were estimated according to guidelines published by A. G. Tretyakov (1988).
Possible embryotoxic effects of the preparation were tested on 15 pregnant female rats weighing 150-180 g, and 3 males of first and second generation. Males were introduced to females at estrus and proestrus at evening hours, one male for each 4 females. Detection of sperm in vaginal swabs the next morning was considered the first day of gestation. The studies began with administration of therapeutic dose of the composition—0.2 ml per capita. The composition was administered intramuscularly during the period from 1 st to 17 th day of gestation. Control animals were administered normal saline solution intramuscularly over the same period and in the same dosage.
Gestation course was surveyed by examination of vaginal swabs of the female rats on the days 4-5 after insemination and gestation course on gestation days 10 to 11 and by weighing the females on gestation days 1, 7, 14 and 20. On 20th day of gestation the females were decapitated; numbers of yellow bodies of pregnancy in ovaries and numbers of implantation sites was calculated.
To determine embryotoxic effects of the composition A, pre-implantation zygote death (difference between the number of yellow bodies of pregnancy in ovaries and number of implantation sites in uterus, to total number of yellow bodies), postimplantational fetal death (i.e., difference between the number of implantation sites and the number of alive fetuses in uterus, to the number of implantation sites) and total fetal mortality (difference between the number of yellow bodies of pregnancy and number of alive fetuses, as percents of the yellow bodies number in ovaries), were calculated.
No disorders during pregnancy were detected upon administration of composition A to pregnant rats in the dose of 0.2 ml per capita in said time points of embryogenesis and organogenesis (gestation days 1 to 17); animals took water and food willingly. Furthermore, no disorders were detected by examination of internal organs using Wilson's method and of skeletal system using Dawson's method.
Key parameters, i. e., preimplantation zygote death—equal to 1.90 in the test group and 2.3% in the control group, postimplantational fetal death—equal to 1.92 and 2.0%, respectively, total fetal mortality—equal to 3.3 and 3.46%, respectively, were close in value, indicative of no embryotoxic effects of the composition. Weight, size and number of fetuses and fetoplacental index in test and control groups were not statistically different and fell within physiological range. For example, mean number of fetuses per one female upon administration of the preparation was equal to 8.9±0.06 against 8.7±0.06 in the control group, weight equal to 2093.3±8.3 and 2010.2±5.1 mg and size equal to 2.7±0.9 and 2.7±0.1 cm, respectively.
Visual inspection and microscopic examination of internal organs by Wilson's method revealed no fetal malformations in rats which were administered the preparation (no external and internal abnormalities).
Microscopic examination of fetal skeletal bones by Dawson's method showed that the studied composition did not cause abnormalities in fetal skeletal system throughout the embryonic period.
The absence of fetal skeletal system abnormalities is confirmed by identical weights of test and control animals and fetoplacental indices (26.97 and 27.60, respectively).
It was established that composition A administered in a dose of 0.2 ml per capita daily throughout gestation (1 st to 17 th day) was neither embryotoxic nor teratogenic. The animals tolerated daily administration of the composition well, and the data resulting from the study of materials obtained from them, i.e., weight and size of fetuses, condition of the internal organs and the skeletal system, were identical (in specific series, weight and size of fetuses and particular bones sizes were even greater) relative to that of control animals, that was further confirmed by probability levels equal to or higher than 0.05 (P 0.05).
Therefore, composition A does not cause second-generation embryotoxic and teratogenic effects in laboratory animals.
Local Farm Scale Tests on Possible Subchronic Toxicity of the Composition in Various Animal Species.
Experiments were carried out on cows, calves, weaner piglets and dogs.
Composition A was administered intramuscularly for the duration of 10 days in the following dosages: to cows—10 ml/animal; to calves (live weight 30-33 kg)—5 ml/animal; to piglets (live weight 9.3 kg)—2 ml/animal; to dogs (live weight 35-40 kg)—5 ml/animal.
Overall clinical condition, appetite and possible adverse events in animal behavior were considered during daily monitoring of the animals. Certain haematological and immunobiochemical parameters were measured in blood samples taken at the beginning and at the end of experiment. In piglets and calves, initial and final live weight was measured.
Tests on Cows. It was established that daily administration of the above composition to cows in a dose of 10 ml/animal did not adversely affect external behavior of the animals, which took their feeding ration and water as usual. No negative impact on the animals' behavior was revealed. Neither were statistically significant differences in erythrocytes count, WBC count and haemoglobin content revealed by haematological analyses. Biochemical analyses showed a certain decrease in carotin and total protein content in blood serum; however these changes were not significant. Concentrations of calcium and phosphorus in blood serum were within normal ranges, no variations of indices obtained prior to and at the end of the experiment were recorded. Administration of the composition had a beneficial effect consisting in possibility of an earlier (by 7-10 days) fertilization in 6 out of 10 experimental cows.
Tests on Calves. The composition was administered to calves immediately after birth. No adverse events in their behavior were observed. Conversely, only 3 out of 10 calves got diarrhea, though this ratio averages between approximately 67-75%. Blood analysis revealed that haematological parameters were almost the same before and after administration of the composition. As regards biochemical parameters, a trend toward increasing total protein levels was observed, though the difference was statistically non-significant. At the same time, the experimental calves had a higher body weight at the age of one month (51.3+2.1 kg against 50.1+2.7 kg in control calves), and recorded incidence of bronchopneumonia was lower in these animals.
Tests on Piglets. Composition A was injected to piglets 10-13 days before weaning. No deviations in piglets' behavior were observed. Neither were differences between initial and final data regarding formed elements count, and Ca and P levels, detected in blood. However, a trend toward increasing total protein content was observed, to manifest later in a 3.7±0.2% higher live weight as compared to control animals.
Tests on Dogs. Tests were conducted on dogs of middle age group (5-7 years). It was found that intramuscular administration of composition A in the dose of 5 ml/animal over 10 days had no negative impact on dogs' behavioral reactions. The animals took food and water willingly. Furthermore, haematological parameters did not change throughout the experiment.
The above described studies on laboratory and livestock animals confirmed low toxicity of the composition A, in particular, lack of embryotropic effect.
EXAMPLE 3
Immunostimulative, Adaptogenic, Growth-promoting and Wound Healing Effects of Composition A
Materials and Methods
Tests were conducted on 84 white rats and 36 white mice using pharmacological, haematological, biochemical and immunologic assays known in the art. Upon studying beneficial effects of composition A on the organisms of laboratory animals, certain haematological and immunobiological indices of the test and control animals were considered. Haematological parameters were evaluated in blood specimens by methods known in the art: white blood cells count per 1 cubic millimeter using Gorjaev's chamber. The following immunobiological indices were counted: blood protein content, glucose, phagocytosis and a number of other parameters, characterizing condition of an organism. The total protein content in blood serum was measured by refractometric analysis. Refractive index of blood serum depends mainly on the amount of proteins.
Glucose concentration was measured using the ortho-toluidine method based on staining of glucose compound with ortho-toluidine in acetic acid solution, the intensity of said being proportional to the glucose concentration.
Immunoglobulin G content in blood serum was measured using Mancini's method (1965) in modification by L. S. Kolabskaya et al. (1975). This method consists in formation of precipitin ring as the result of interaction of the mixture of agar and immunoglobulin antiserum with antigen of the studied serum, introduced into wells of an agar plate. Precipitate area, as a squared ring diameter, is directly proportional to the antibodies concentration in agar. In this case, the concentration of the test antigen and the precipitate area are linearly dependent.
Study of phagocytic activity is based on in vitro evaluation of the peripheral neutrophils capacity (opsonophagocytosis assay, OPA) in tested animals to phagocytize (to engulf) microbial cells. White Staphylococcus Staph. albus is employed as a test culture for OPA.
The intensity of phagocytosis was measured on the basis of phagocytic activity (PA), phagocytic number (PN) and phagocytic index (PI).
Phagocytic activity (PA) is a percentage of phagocytizing neutrophils in total neutrophil count. Phagocytic index (PI) is a number of engulfed microbial cells (m.c.), per one neutrophil, in total neutrophil count. Phagocytic number (PN) is a number of microbal cells in one active (phagocytizing) neutrophil.
The tests were repeated twice and the results obtained were statistically analysed.
3.1 Immunostimulative Effect
Composition A was administered intramuscularly to experimental white rats (three groups, each consisting of 6 animals) over 5 days in a dose of 0.2 ml/animal. Blood phagocytic index (PI), phagocytic activity (PA) and phagocytic number (PN) and immunoglobulins A and G for immunological parameters (Tables 2, 3) were evaluated. Phagocytic activity provided by the composition was compared to that of the well-known immunomodulator evinton. Evinton is comprised of: Thuja D6, Vincetoxicum D4, Echinacea purpurea D4 and normal saline solution.
TABLE 2
Groups of
Phagocytic
animals
Phagocytic index
Phagocytic activity
number
Composition A
8.2 ± 1.42
50.0 ± 1.24
19.6 ± 1.47
Evinton
10.0 ± 1.34
60.0 ± 1.45
15.33 ± 1.29
Control
6.72 ± 1.87
33.33 ± 1.39
8.0 ± 1.64
TABLE 3
Groups of animals
Immunoglobulin A
Immunoglobulin G
Composition A
2.99 ± 0.59
8.06 ± 1.57
Evinton
2.9 ± 0.62
7.42 ± 1.32
Control
1.85 ± 0.37
6.85 ± 0.32
The obtained results indicate that the use of the composition promotes the increase in phagocytic activity of neutrophils relative to the control group; also, production of immunoglobulin G was somewhat higher relative to the effect of Evinton and to the control group of white rats.
Thus, composition A has a certain immunostimulatory effect on test animals organisms and increases cellular and humoral immunity indices.
3.2. Adaptogenic (Antistress) Properties
The test was conducted on 12 rats, 4 animals being in each of three groups. Stress in experimental white rats was induced using a shaking machine simulating transport (physical) stress. The box with animals was placed onto the shaker and held atop the operating machine for 30-40 min. The most informative parameters, characterizing the onset and development of stress response (stress mediators): glucose, total protein and leukocytes (WBC) levels, were measured in blood of the white rats.
Composition A was administered to the animals of the 1 st group intramuscularly 3 days previous to stress induction in a dose of 0.2 ml. 2.5% solution of neuroleptic agent aminazin in a dose of 0.5 mg per capita was administered to the animals of the 2 nd group. A normal saline solution was administered intramuscularly to the animals of the 3 rd (control) group. Rats' blood examination to estimate the above parameters was performed 1 h and 24 h after stress induction.
Laboratory data indicate that glucose and WBC levels increase and total protein content decreases under stress.
By way of example, glucose concentration in the group receiving composition A was 4.97±0.1 mmol/L against 6.46±0.45 mmol/L in the group receiving aminazin and 10.0±0.7 mmol/L in the control group as early as 1 h after stress induction. This variable increased to 5.42±0.2 mmol/L, 6.25±0.3 mmol/L and 8.33±0.4 mmol/L, respectively, 24 hours after stress induction. Values of laboratory blood tests 1 h and 24 h after stress induction are represented in Tables 4 and 5, respectively.
TABLE 4
Haematological parameters 1 hour after stress induction
Glucose
Total
Leukocytes
Group
mmol/L
protein, g/L
(WBC), 10 3 /uL
Composition A
4.97 ± 0.1
67.5 ± 1.2
5.6 ± 1.7
Aminazin
6.46 ± 0.45
66.0 ± 0.5
4.3 ± 0.4
Isotonic NaCl solution
10.0 ± 0.7
66.0 ± 0.9
5.8 ± 0.52
(Normal saline solution)
TABLE 5 Haematological parameters in white rats 24 hours after stress induction Glucose, Total Leukocytes Group mmol/L protein, g/L (WBC), 10 3 /uL Composition A 5.42 ± 0.2 72.7 ± 2.3 5.6 ± 0.1 Aminazin 6.25 ± 0.3 72.4 ± 1.6 6.1 ± 0.3 Normal NaCl solution 8.33 ± 0.4 66.2 ± 2.5 7.05 ± 0.2
3.3. Study of Growth-promoting Effect
The influence of composition A on growth and development of the laboratory animals was studied on 18 white mice weighing 19-23 g. 3 groups, each consisting of 6 animals, were formed. “Evinton>>, a complex homeopathic preparation for animals, was used as a comparative agent. All animals were weighed before and after the experiment. At the end of the experiment, specimens of blood were taken for clinical and immunobiochemical analysis. During the experiment, which lasted for 15 days, the animals did not show signs of anxiety, took food and drank water willingly. The highest mobility was observed in animals of the test group, which were administered a dose of 0.1 ml of composition A per capita subcutaneously. Animals of the comparison group were administered a dose of 0.1 ml of complex homeopathic preparation for animals “Evinton>> per capita subcutaneously. A normal saline solution was administered in a dose of 0.1 ml per capita subcutaneously to the control group. Course of administration of the preparations was 3 days.
The best values of weight gain relative to control animals were obtained upon using composition A. The data are represented in Table 6.
TABLE 6 Growth-promoting effect of the preparations Body weight Body Weight before weight by gain Weight gain Groups experiment the end of within 10 relative to of animals (g) experiment (g) days (g) controls (%) Composition A 25.75 ± 0.692 32.0 ± 0.75 6.25 ± 0.62 113.6 Evinton 24.75 ± 0.56 30.75 ± 0.56 6.0 ± 0.56 105.1 Control 21.5 ± 1.19 27.0 ± 1.4 5.5 ± 1.34 100.0
3.4. Study of the Composition's Wound Healing Activity
Wound healing goes through three main phases: inflammation, regeneration, and remodeling of the scar and epithelialization. Sluggish wound process with a slow growth of granulations and delayed epithelialization may occur at any phase of healing.
For estimation of the wound healing effect of composition A, tests were conducted on 6 rats, weighting 250 g, each group consisting of 4 animals. Back areas 2×2 cm were theretofore shaven, dehaired skin being cleaned of impurities; then, the skin was grasped with surgical forceps and a 1 cm long scalpel incision was made.
The progress of experimental wound healing was evaluated by the following parameters:
1. Visual observations
time point when granulations appear in the wound closure of the wound bed by granulation filling of the wound chamber with granulations quality of the granulations progress of epithelialization condition of tissues surrounding the wound.
2. Recording wound area changes. 3. Scab shedding was considered to be the time of completed wound healing.
During the experiment, composition A was administered to the test group intramuscularly in therapeutic dose of 0.2 ml per capita over 4 days. Control animals were administered normal saline solution intramuscularly in the same dosage over the same period.
Granulations appeared in the wounds on the 2 nd day in both groups, the wound bed closure and filling of the wound chamber with granulations in both the test and the control groups was observed on the 5th day from the beginning of the experiment. In the course of the experiment, wound area contraction by 0.3 cm was observed in the test group on the 4th day; no wound area contraction was observed during this period in the control group.
The duration of complete wound healing was 6 days in the test group and 8 days in the control group.
The above studies have revealed a number of pharmacological benefits of composition A such as immunostimulative, adaptogenic, growth-promoting and wound healing effects. Recommendations on use of composition A for increasing productivity and natural resistance of animal organism were developed on the basis of the undertaken studies and the results obtained.
Clinical data obtained in laboratory animal models provided the basis for the tests on livestock and domestic animals, the results of which are given below.
EXAMPLE 4
Influence of the Composition on Leucogram and Bone Metabolism in Blood of the Nursery Piglets
Tests were conducted for 2 weeks on piglets aged 45 and 65 days (n=15) kept in the conditions of a pigsty. There were 2 groups of animals: the test group of animals to which composition A was administered intramuscularly once per 24 hours in the dose of 2 ml per capita, every other day over 14 days, and the control group of animals not getting special treatment. Animals were recruited into groups according to an analogue method.
The results of studying the effects of the composition on electrolyte exchange and bone metabolism in piglets' blood are represented in Table 7.
TABLE 7
No
Control group
Test group
Π/
Before
After
Before
After
Π
Variable
Units
experiment
experiment
1.
calcium
mmol\L
2.32 ± 0.3
2.4 ± 0.5
2.52 ± 0.5
2.4 ± 0.6
2.
phospho-
mmol\L
1.83 ± 0.3
1.78 ± 0.5
1.76 ± 0.3
1.84 ± 0.27
rus
3.
alkaline
IU\L
87.8 ± 7.8
86.2 ± 5.5
60.9 ± 2.7
39.5 ± 1.2
phospha-
tase
The following conclusion can be derived from the research results: piglets of the control group exhibit imbalance of calcium:phosphorus ratio, as well as increased levels of alkaline phosphatase, that may indicate (regardless of age-related changes) inflammatory processes affecting intestinal mucosa, juvenile osteodystrophy, rickets-like conditions.
Improvement was recorded after two weeks of application of the composition in piglets of the test group relative to the control group: appetite back to normal, animals more active.
Biochemical variables dynamics was the following: alkaline phosphatase level decreased by 35.1%, calcium and phosphorus levels came close to physiological range in contrast to animals of the control group, not exhibiting changes of said biochemical parameters.
Therefore, use of composition A promotes normalization of calcium-phosphorus metabolism and thus it can be recommended for use in combined treatment of osteo-articular pathologies.
The results of studying the composition influence on weaner piglets' blood leucogram are shown in Table 8.
TABLE 8
Control group
Test group
Reference
Before
After
Before
After
Parameter
Units
Range
experiment
experiment
experiment
experiment
Leukocytes
thous/uL;
8.7-37.9
10.9 ± 1.2
15.1 ± 2.1
11.05 ± 1.6
16.1 ± 2.5
(WBC)
10 9 /Π
Juvenile
%
0-2
0.15 ± 0.02
0.17 ± 0.01
0.14 ± 0.02
0.17 ± 0.12
neutrophils
Band
%
2-4
1.9 ± 0.04
1.01 ± 0.011
1.85 ± 0.3
3.5 ± 0.7
neutrophils
Segmento
%
40-48
65.45 ± 12.1
59.21 ± 9.8
64.3 ± 14.4
55.2 ± 8.9
nuclear
neutrophils
Eosinophils
%
1-3
0.8 ± 0.01
0.9 ± 0.012
0.85 ± 0.03
1.6 ± 0.04
Basophils
%
0-1
0.7 ± 0.013
0.78 ± 0.01
0.73 ± 0.13
1.3 ± 0.3
Monocytes
%
2-6
3.5 ± 0.24
4.2 ± 0.9
3.6 ± 0.23
3.1 ± 0.07
Lymphocytes
%
40-50
27.5 ± 3.1
32.73 ± 3.6
28.53 ± 4.7
37.13 ± 4.9
These findings display the reduction of lymphocytes, basophils and eosinophils in piglets, whilst levels of segmented neutrophils are increasing; these alterations may be indicative of protective and adaptive response to stress in animal organisms. Improvement was recorded after two weeks of application of the composition in piglets of the test group in contrast to these of the control group: appetite back to normal, animals behave more actively. Haematological parameters were closer to physiological values in the test group relative to the control group. Therefore, composition A can be recommended for combined corrective treatment of postweaning stress in livestock.
EXAMPLE 5
Study of Detoxifying Properties of the Composition
17 dogs with acute piroplasmosis confirmed by presence of Babesia parasites in peripheral smears were followed up. Condition of all animals was regarded as severe: rectal temperature up to 41.0° C., mucous membranes pale and icteric, dark urine with blood, decreased appetite down to food refusal, gait disorders, general weakness; in some cases, fainting.
Piro-Stop (“ po-C TO ”) drug was employed as a specific therapy (twice, intramuscularly, at 24 hour intervals). Composition A was used in an amount 5-15 ml (depending on animal weight) intravenously (by stream infusion) once every 24 hours in addition to conventional therapy (Ringer-Lockes solution intravenously, 60 drops/min, 10-15 ml/kg 2 times per 24 hours, heart preparations). In most severe cases the preparation was administered 2 times per 24 hours intravenously during first 2-3 days, followed by single intramuscular administrations every 24 hours.
It was observed that the use of the above composition substantially increased the treatment efficacy relative to conventional therapy. For example, the overall condition of all patient animals improved significantly as early as 3-5 hours after the very first administration of the composition. The animals regained appetite quickly, body temperature and cardiac rate being decreased. In all dogs, haemoglobin values returned to normal by the end of the 2 nd week from the beginning of treatment.
Detoxification effect of the above composition is due to hepatoprotective properties, as confirmed by the results of liver function dynamic analysis in sick animals. Normalization of ALT, AST, albumin, GGT, globulin, total protein, prothrombin and alkaline phosphatase levels, and positive dynamics of total bilirubin and indirect bilirubin fraction and amylase levels were observed upon even a single intravenous administration of the composition.
Thus, the composition of the present disclosure has a strong detoxifying effect, in particular due to its hepatoprotective properties.
EXAMPLE 6
Influence of the Composition on Musculoskeletal System in Dogs
Composition A was used as a mono- and complex therapy in dogs with age-related changes of musculoskeletal system. The group consisted of 5 dogs with normal and excess weight. The core symptoms manifested in animals as apathy, absence of appetite, refusal to walk, lameness of varying severity and various pain syndromes. The examination of the animals' joint stiffness, pain reaction to spine palpation (thoracic and lumbar regions). Radiographs revealed various degrees of hip joint arthrosis and spine osteochondrosis.
Three Russian hunting sighthounds aged 13 years and weighting approximately 25 kg (normal) were administered a dose of 5 ml of the composition, comprising 5% aqueous solution of the hydrolyzate derived from bivalve molluscs meat, intramuscularly, every other day, for a total of 15 injections.
The above composition was prescribed to the Airedale terrier aged 12 years (female), suffering from overweight with spine tenderness, in a dose of 4 ml intramuscularly every other day in an amount of 10 injections. The above composition was prescribed to the English bulldog aged 10 years, suffering from obesity and lack of activity, as part of complex therapy: 4 ml intramuscularly every other day, for a total of 10 injections, 2 ml of bonharen intravenously once a week in the amount of 4 injections, 10 ml of Kynosil once a day over 2 months. Specimens of blood were collected from dogs for clinical and biochemical analyses before and after administration of the preparations. After the course of treatment, the animals' condition has changed drastically: in all dogs, appetite restored, physical activity increased, alkaline phosphatase levels fell from excess to normal, alanine transaminase (ALT) decreased, urea level increased while staying within normal range; taken together, all these indicate beneficial effects of composition A on the condition of musculoskeletal system and liver function.
EXAMPLE 7
Treating Pathological Conditions in Dogs
Provided hereafter are the results of using composition A in treating various pathologies in dogs.
1). English Bulldog Age: 1 year and 3 months Weight: 30 kg
Diagnosis: demodecosis, urine acid diathesis, streptoderma: areas affected are the entire head, cheeks, forehead, areas between and behind ears, all covered in purulent crust, moist eczema.
Treatment regime: common symptomatic treatment, and Composition A in the dose of 3 ml intramuscularly, once a day for 5 days.
Results in a week: dry, healing skin; edema and itching absent, no pus. Clean healing skin.
2). Dobermann Age: 2 years 6 months Weight: 23 kg
Diagnosis: Severe leanness despite good nutrition and no helminthes or parasites. Dandruff on skin, bilirubin in urine.
Treatment regime: Composition A in the dosage of 5 ml, i.m., once a day, for 5 days.
Results in a month: weight gain 2 kg, bilirubin is normal, hair clean and shiny.
3). American Bulldog Age: 5 years Weight: 60 kg
Diagnosis: Leptospirosis. Symptoms: otopyosis, bloody diarrhea, vomiting.
Treatment regime: Drip infusion and symptomatic treatment, as well as composition A in the dose of 5 ml i.m. once a day, for 5 days.
Results: vomiting and diarrhea stopped within 2 days, clinical blood and urine were back to normal within a week after initiation of treatment. No relapse was observed within 4 months.
4). Dalmatian dog Age: 1 year and 7 months Weight: 22 kg
Diagnosis: Trichophytia accompanied by allergic dermatitis. The entire back and sides affected.
Treatment regimen: symptomatic treatment.
Treatment for a month was ineffective.
Treatment regimen: 5 injections of composition A, each 3 ml, i.m., every second day.
Results after two weeks: all symptoms disappeared, clean hair.
5). Yorkshire terrier Age: 1.5 months Weight: 1 kg
Diagnosis: Combined revaccination was done one week before its due time; temperature of 41.6, bronchopneumonia, unilateral purulent discharge from the eyes and nose 4 days later.
Treatment regimen: symptomatic treatment and 1 ml of Composition A 5:0, i.m., once a day, for 5 days.
Results after two days: body temperature back to normal, purulent discharge and lung rales are absent.
6). Kurzhaar (German shorthaired pointer) Age: 12 years Weight: 17 kg
Diagnosis: Chronic leptospirosis. Body temperature of approximately 40 degrees over the period of two months, tenderness of liver and kidneys, cachexia, dandruff, skin odour, hardly walks, appetite absent. Conventional therapy is ineffective.
Treatment regimen for the first week: high doses of antibiotics; symptomatic treatment. Clinical blood count normalized, but all the symptoms continued.
Treatment regimen: Withdrawal of antibiotics, symptomatic treatment of liver and kidney; Composition A in the dose of 3 ml i.m. once a day for 5 days.
Results after two days: body temperature back to normal, state of the liver and kidneys improved within 3 weeks, dandruff disappeared, hair coat and appetite improved.
Relapse two months later: infectious arthritis—two injections of the composition, each 3 ml, i.m., once a day.
All symptoms were gone.
EXAMPLE 8
Canine Piroplsmosis: Comparative Study of the Present Composition with Oral Conventional Products
The present example demonstrates the effectiveness of the present composition administered parenterally to dogs suffering from piroplasmosis as compared to oral administration of conventional products
The study includes 45 dogs suffering from piroplasmosis. In addition to clinical signs, diagnostics included examination of peripheral blood smears for the presence of Babesia.
The dogs suffered from severe piroplasmosis symptoms including rectal temperature 39.7-41,0° C., dark bloody urine, reduced appetite, food refusal, pale mucous membranes, general weakness, in some cases fainting and gait failure disorders.
As a general therapy the dogs were administered PiroStop intramuscularly (by weight, twice during 24 hours) along with Ringer-Lockes solution (I.V., 60 drops per minute, 10-15 ml/kgB.I.D.), and cardiovascular supportive drugs.
Further the dogs were uniformly divided into 3 groups including
Group 1: animals receiving the above-identified general therapy,
Group 2: animals administered 10-30 ml (depending on body weight) of the composition comprising sea mussels undiluted hydrolizate 1-2 times per day orally, in addition to the general therapy,
Group 3: animals administered 5-15 ml (depending on animal's body weight) of the composition representing 5% aqueous solution of the hydrolizate via intravenous infusion, 1-2 times daily, in addition to the general therapy.
The selection of animals in each group was made with maximum possible uniformity taking a general condition, age, body weight, and breed of the dogs into account.
As a result of the therapy no statistically significant difference in animals' condition and duration of recovery was revealed between Groups 1 and 2. The number of deceased animals was 3 in Group 1, and 2 in Group 2, all of the animals surviving in Group 3.
In Group 3, dogs with severe symptoms were treated via intravenous administration two times a day over the first 2-3 days followed by daily intramuscular administration. The general condition of the affected animals was found to improve significantly in 3-5 hours after initial infusion of the composition. Animals having the disease of moderate and mild severity regained appetite. The dogs experienced rapid reduction of toxicity reactions. Haemoglobin parameters were back to normal in all of the dogs within about 3 weeks. The clear reduction of intoxication symptoms is observable immediately after its intravenous administration. Beneficial effect on main parameters of animals' liver function was shown over the course of the composition application. Normalization of ALAT, AAT, albumine, GGT, globulins, total protein, prothrombin and alkaline phosphatase levels was observed. Further, the improvement of total bilirubin and indirect bilirubin fraction as well as amylase was observed.
On the other hand, haemoglobin parameters and normalization of ALAT, AAT, albumin, GGT, globulins, total protein, prothrombin and alkaline phosphatise levels occurred significantly later (in 6-14 days) in animals of Groups 1 and 2 as compared to Group 3. The dogs in Group 2 and 3 was getting back to normal condition unevenly and there was a long-lasting lack of appetite. Physical condition recovery after the formal recovery took 1-2 months longer in animals of Group 1 and Group 2 as compared to the animals of Group 3.
EXMAPLE 9
Improvement of Reproductive Function in Cows
The present example illustrates the method of improving reproductive function in cows. More specifically the present example demonstrates the effectiveness of the present composition administered via injection to cows suffering form ovarian hypofunction as compared to oral administration of conventional products.
Low efficiency of insemination in cows is a problem of current concern in the farms of Northwest Russia. This can be explained by various reasons varying from housing and feeding conditions to semen material quality. The ratio of cows diagnosed with ovarian hypofunction in a number of farms is up to 70%.
A study was performed to estimate the influence of the present composition on insemination efficiency in cows suffering from ovarian hypofunction.
The cows were divided into 3 groups.
Group 1: a control group;
Group 2: animals receiving oral administration of a hydrolizate produced from sea mussels;
Group 3: animals receiving the composition representing 5% aqueous solution of the hydrolizate via intramuscular injections.
Each group included 20 cows uniformally selected on the basis of age, intensity of the identified ovarian hypofunction and time of last calving. Artificial insemination was conducted according to standard well-proven procedure in all groups for the first time immediately after oestrus confirmation and for the next time at 12 hours thereafter.
Group 1 did not receive any medication. The animals of Group 2 were given to drink the preparation twice including 20 ml immediately after oestrus confirmation (prior to the first insemination), and then immediately after the second insemination. The animals of Group 3 received a first intramuscular injection of 10 ml immediately after oestrus confirmation (prior to the first insemination), and the second intramuscular injection of 10 ml immediately after the second insemination.
As a result, Group 1 was found to comprise 12 calvers, Group 2 was found to comprise 12 calvers, and Group 3 was found to comprise 17 calvers.
The results of the present example demonstrate that the oral administration of the conventional hydrolizate has no substantial influence on animal condition and reproductive function. However use of the injectable composition according to the present invention results in a rapid detoxification and recovery of haematological parameters, and reduces lethality rates for canine piroplasmosis as well as improves reproductive function in cows having ovarian hypofunction.
The embodiments described hereinabove are further intended to explain best modes known of practicing it and to enable others skilled in the art to utilize the disclosure in such, or other, embodiments and with the various modifications required by the particular applications or uses. Accordingly, the description is not intended to limit it to the form disclosed herein. Also, it is intended that the appended claims be construed to include alternative embodiments.
|
The present invention relates to a field of veterinary and human medicine. In particular, the invention relates to a composition suitable for parenteral administration, based on hydrolyzate obtained from natural bioresources, a composition for use in treating and/or preventing a pathological condition in a mammal in need thereof, and various other uses thereof. More particularly the invention relates to a composition having immunomodulatory properties being based on a hydrolyzate obtained from bioresources, which composition is used for parenteral administration to a mammal in need thereof.
| 0
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The instant disclosure relates to an oxygen sensing device; in particular, to an oxygen sensing device with capability of storing energy and releasing energy utilized for removing pollutants, output electricity, storing electrical energy, and making specific chemicals.
[0003] 2. Description of Related Art
[0004] FIG. 1A shows a schematic diagram of a traditional fuel converting mechanism of a car. The traditional fuel converting mechanism in a car comprises an alternator 10 , an internal combustion engine 11 , a turbine 12 , an oxygen sensing device 13 and a catalytic converter 14 . The internal combustion engine 11 makes the combustion of air and fuel (e.g. hydrocarbons) and generates gas such as carbon dioxide, carbon monoxide, water, and nitrogen monoxide . . . etc. Then, the internal combustion engine 11 outputs the mentioned gas (CO 2 , CO, H 2 O, and NO . . . etc.) to the turbine 12 . The turbine 12 cooperates with the alternator 10 to generate electrical energy. The oxygen sensing device 13 senses the oxygen outputted from the turbine 12 and generates a control signal A/F for adjusting the ratio of the air and the fuel transmitted to the internal combustion engine 11 . The catalytic converter 14 converts the carbon monoxide (CO), hydrogencarbons (HCs) and nitrogen monoxide (NO) outputted from the turbine 12 to carbon dioxide (CO 2 ) and nitrogen (N 2 ) for complying with environmental standards.
[0005] FIG. 1B shows a schematic diagram of a traditional oxygen sensing device. The traditional oxygen sensing device 13 comprises an oxygen sensing unit 130 and a voltmeter 131 . The oxygen sensing unit 130 comprises a conductive catalyst layer 132 , a solid oxide electrolyte 133 and a conductive catalyst layer 134 . The solid oxide electrolyte 133 is disposed between the conductive catalyst layer 132 and the conductive catalyst layer 134 . The conductive catalyst layer 132 receives the gas from the turbine 12 . The oxygen concentration of the gas from the turbine 12 is unknown. The conductive catalyst layer 134 receives air from the atmosphere with oxygen concentration of 0.21 atm. A voltage difference would be occurred between the conductive catalyst layer 132 and the conductive catalyst layer 134 , and the voltage difference could be measured by the voltmeter 131 . When the oxygen concentration of the gas from the turbine 12 is less, the voltmeter 131 could sense a larger voltage difference. On the contrary, when the oxygen concentration of the gas from the turbine 12 is more, the voltmeter 131 could sense a smaller voltage difference. Accordingly, the oxygen sensing device 13 generates the control signal A/F to adjust the ratio (A/F) of the air and the fuel transmitted to the internal combustion engine 11 . Therefore, the combustion process in the internal combustion engine 11 could be adjusted.
[0006] However, the traditional oxygen sensing device 13 has only the aforementioned single-function, thus applications of the oxygen sensing device 13 may be limited thereto.
SUMMARY OF THE INVENTION
[0007] The object of the instant disclosure is to offer an oxygen sensing device with capability of storing energy and releasing energy for processing chemical reactions, such as catalytic reaction, oxygen sensing, power generation, electrolysis for storing energy and electrolysis for making synthesis gas.
[0008] In order to achieve the aforementioned objects, according to an embodiment of the instant disclosure, an oxygen sensing device is offered. The oxygen sensing device comprises an oxygen sensing unit, a gas storing unit and a control unit. The oxygen sensing unit comprises a first conductive catalyst layer, a second conductive catalyst layer and a solid oxide electrolyte. The solid oxide electrolyte is disposed between the first conductive catalyst layer and the second conductive catalyst layer. The control unit comprises a voltmeter, a power output circuit, a power source and a judgment circuit. The voltmeter senses a voltage generated between the first conductive catalyst layer and the second conductive catalyst layer when the oxygen sensing unit senses the oxygen concentration difference. The power output circuit outputs an electric power, wherein the oxygen sensing unit causes a reaction of the hydrocarbons stored in the gas storing unit and the oxygen for generating the electric power to the power output circuit. The judgment circuit controls conducting status of a power source, the voltmeter, or the power output circuit through at least a switch. The judgment circuit controls the gas storing unit to store the gas generated by the oxygen sensing unit or provide the gas to the gas sensing unit, wherein the electric power is provided to the first conductive catalyst layer of the oxygen sensing unit for processing a catalytic reaction to generate hydrocarbons. The oxygen sensing unit utilizes the electric power of power source of the control unit to generate hydrogen or carbon monoxide.
[0009] In summary, the oxygen sensing device according to an embodiment of the instant disclosure could process catalytic reaction, oxygen sensing, electrical energy generating, electrolysis for storing energy and making synthesis gas (carbon monoxide and hydrogen). Therefore, pollution exhaust could be decreased, pollution exhaust could be used for power generation, the surplus electricity could be used, or the industrial synthesis gas (carbon monoxide and hydrogen) could be made too.
[0010] In order to further the understanding regarding the instant disclosure, the following embodiments are provided along with illustrations to facilitate the disclosure of the instant disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A shows a schematic diagram of a traditional fuel converting mechanism of a car;
[0012] FIG. 1B shows a schematic diagram of a traditional oxygen sensing device;
[0013] FIG. 2 shows a schematic diagram of an oxygen sensing device according to an embodiment of the instant disclosure;
[0014] FIG. 3A shows a schematic diagram for an electrochemical catalytic reaction of an oxygen sensing unit according to an embodiment of the instant disclosure;
[0015] FIG. 3B shows a schematic diagram of the operation for an electrochemical catalytic reaction of an oxygen sensing device according to an embodiment of the instant disclosure;
[0016] FIG. 4 shows a schematic diagram of an oxygen sensing unit processing the oxygen sensing according to an embodiment of the instant disclosure;
[0017] FIG. 5A shows a schematic diagram of an oxygen sensing unit processing the reaction of hydrocarbons and oxygen according to an embodiment of the instant disclosure;
[0018] FIG. 5B shows a schematic diagram of a output circuit of an oxygen sensing device outputting electricity according to an embodiment of the instant disclosure;
[0019] FIG. 6 shows a schematic diagram of an oxygen sensing unit generating hydrogen and monoxide according to an embodiment of the instant disclosure;
[0020] FIG. 7A to FIG. 7D shows a cross-sectional diagram of an oxygen sensing unit according to an embodiment of the instant disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The aforementioned illustrations and following detailed descriptions are exemplary for the purpose of further explaining the scope of the instant disclosure. Other objectives and advantages related to the instant disclosure will be illustrated in the subsequent descriptions and appended drawings.
[0022] This embodiment offers an oxygen sensing device could process chemical reactions, such as catalytic reaction, oxygen sensing, electrical power generation, electrolysis for storing energy and electrolysis for making synthesis gas. The oxygen sensing device could be installed in a car or a power plant, and the oxygen sensing device can process one of the aforementioned reactions according to usage requirements.
[0023] FIG. 2 shows a schematic diagram of an oxygen sensing device according to an embodiment of the instant disclosure. The oxygen sensing device 2 comprises an oxygen sensing unit 21 , a gas storing unit 22 and a control unit 23 . The oxygen sensing unit 21 comprises a solid oxide electrolyte 212 , a conductive catalyst layer 211 and a conductive catalyst layer 213 . The control unit 23 comprises a power source 24 , a voltmeter 29 , a power output circuit 25 , a judgment circuit 26 and switches 27 , 28 . The power output circuit 25 comprises a switch 251 and a resistor R.
[0024] The solid oxide electrolyte 212 is disposed between the conductive catalyst layer 211 and the conductive catalyst layer 213 . The gas storing unit 22 is connected to the conductive catalyst layer 211 and the conductive catalyst layer 213 of the oxygen sensing unit 21 . The oxygen sensing unit 21 is electrically coupled the control unit 23 . The power source 24 , the voltmeter 29 and the power output circuit 25 of the control unit 23 are connected in parallel and electrically coupled to the conductive catalyst layer 211 and the conductive catalyst layer 213 . The switch 251 and the resistor R of the power output circuit 25 are connected serially. The switch 27 and the switch 28 are serially connected to the voltmeter 29 and the power source 24 respectively. The judgment circuit 26 is electrically coupled to the switches 251 , 27 , and 28 and the gas storing unit 22 .
[0025] The solid oxide electrolyte 212 of the oxygen sensing unit 21 may be metal oxides, such as ZrO 2 , CeO 2 . . . etc. The conductive catalyst layer 211 , 213 may comprise metal catalyst, oxide catalyst or metal oxide catalyst. The metal catalyst may be Platinum (Pt), Rhodium (Rh), or Palladium (Pd). Platinum (Pt) and Rhodium (Rh) are catalyst for converting the oxides of nitrogen (NO X ) to nitrogen (N 2 ) and oxygen (O 2 ). Palladium (Pd) is catalyst for converting the carbon monoxide (CO) to carbon dioxide (CO 2 ). The oxide catalyst may be Lanthanum-Strontium-Cobalt pervoskite, for example, the Lanthanum- Strontium -Manganese oxide (LaSrMnO) may catalyze reaction of oxygen ion (O 2− ) with oxides of nitrogen (NO X ), Methane (CH 4 ), or carbon monoxide (CO). The metal oxide catalyst may be Zirconia (ZrO 2 ) or Cerium oxide (CeO 2 ). The conductive catalyst layer 211 , 213 may be conductors or carriers with large surface area (e.g. Alumina, Zeolite) coated with aforementioned metal catalyst, oxide catalyst or metal oxide catalyst.
[0026] The gas storing unit 22 receives the exhausted gas (generated by the internal combustion engine) transmitted from the turbine. The gas storing unit 22 is controlled by the judgment circuit 26 for transmitting the gas stored in the gas storing unit 22 to the oxygen sensing unit 21 or storing the gas generated by the oxygen sensing unit 21 . The gas storing unit 22 may comprise at least a two-way valve (not shown in the figure) to make the gas flowing between the gas storing unit 22 and the oxygen sensing unit 21 . Those skilled in the art will readily observe the valve of the gas storing unit 22 , thus there is no need to go into details.
[0027] The power output circuit 25 comprises the switch 251 and the resistor R. The power output circuit 25 has output terminals a, b. Electrical equipment (not shown in the figure) could be connected to the output terminals a, b for obtaining electrical power. The switch 251 is controlled by the judgment circuit 26 . When the switch 251 is conductive, the power output circuit 25 and the electrical equipment could perform a conducting loop. The resistor R of the power output circuit 25 is an output resistance for adjusting the output power.
[0028] The judgment circuit 26 is for controlling the oxygen sensing device 2 to perform functions, and the judgment circuit 26 may be connected to exterior interface (not shown in the figure). A user may manipulate the interface to make commands (or controlling signals) to the judgment circuit 26 of the oxygen sensing device 2 , and the judgment circuit 26 could determine to execute corresponding functions according to the commands (or controlling signals). According to the executed function of the oxygen sensing device 2 , the judgment circuit 26 controls the conducting state of the switches 251 , 27 , and 28 . The judgment circuit 26 controls the power output circuit 25 , the voltmeter 29 , and the power source 24 through the switches 251 , 27 , and 28 . The judgment circuit 26 may also controls the gas storing unit 22 to store the gas generated by the oxygen sensing unit 21 , or makes the gas storing unit 22 provide gas to the oxygen sensing unit 21 . In practical applications, the judgment circuit 26 may be accomplished by a micro controller unit (MCU), however the instant disclosure is not restricted thereto.
[0029] Please refer to FIG. 3A and FIG. 3B , FIG. 3A shows a schematic diagram for an electrochemical catalytic reaction of an oxygen sensing unit according to an embodiment of the instant disclosure, FIG. 3B shows a schematic diagram of the operation for an electrochemical catalytic reaction of an oxygen sensing device according to an embodiment of the instant disclosure. When the oxygen sensing device 2 processes the electrochemical catalytic reaction, the conductive catalyst layer 211 of the oxygen sensing unit 21 may process catalytic reaction of oxides of nitrogen (NO X ) and carbon monoxide (CO) exhausted from the turbine (not shown in the figure) of the car. The gas exhausted from the turbine may be transmitted to the gas storing unit 22 , then the judgment circuit 26 of the control unit 23 makes the exhausted gas stored in the gas storing unit 22 be transmitted to the conductive catalyst layer 211 . For example, the judgment circuit 26 may open the valve between the conductive catalyst layer 211 and the gas storing unit 22 to make the exhausted gas be transmitted to the conductive catalyst layer 211 . When judgment circuit 26 conducts the switch 28 , the power source 24 could provide electrical power (electrons e − ) to the conductive catalyst layer 211 of the oxygen sensing unit 21 for processing the catalytic reaction to generate hydrocarbons, and the hydrocarbons may be stored to the gas storing unit 22 . For example, when the conductive catalyst layer 211 comprises Platinum (Pt), Rhodium (Rh) and Palladium (Pd), the oxides of nitrogen (NO X ) in the exhausted gas could make a reaction (1) through the catalyst of Platinum (Pt) and Rhodium (Rh), the reaction (1) is described in the following: 2NO X +2e − →O 2− +N 2 .
[0030] In the reaction (1), the oxides of nitrogen (NO X ) is converted to nitrogen (N 2 ). Additionally, the oxygen ions (O 2− ) can be transmitted to the conductive catalyst layer 213 through the solid oxide electrolyte 212 . And, the conductive catalyst layer 213 converts the oxygen ions (O 2− ) into oxygen (O 2 ) and transmits the excess electrons e − to the power source 24 . On the other hand, the catalyst of Palladium (Pd) makes a reaction (2) of carbon monoxide (CO) of the exhausted gas, the reaction (2) is described in the following: CO+O 2− →CO 2 +2e − .
[0031] The solid oxide electrolyte 212 conducts oxygen ions (O 2− ) needed in the reaction (2), and the electrons (e − ) generated in the reaction (2) may be transmitted to the power source 24 through the conductive catalyst layer 211 . It is worth mentioning that when the switch 28 is conductive, the switch 27 and the switch 251 are non-conductive.
[0032] Please refer to FIG. 2 and FIG. 4 , FIG. 4 shows a schematic diagram of an oxygen sensing unit processing the oxygen sensing according to an embodiment of the instant disclosure. The judgment circuit 26 of the control unit 23 conducts the switch 27 to make the voltmeter 29 for sensing the voltage difference between the conductive catalyst layer 211 and the conductive catalyst layer 213 . Meanwhile, the switch 28 and the switch 251 are non-conductive.
[0033] The conductive catalyst layer 211 of the oxygen sensing unit 21 receives the exhausted gas from the turbine, the exhausted gas may comprise carbon dioxide (CO 2 ), water (H 2 O), oxides of nitrogen (NO X ), hydrocarbons (HC), carbon monoxide (CO), and oxygen (O 2 ). The manner for sensing oxygen of the oxygen sensing device 2 is the same as to the manner for sensing oxygen of the traditional oxygen sensing device 1 (shown in FIG. 1B ). It is worth mentioning that the conductive catalyst layer 213 receive the air of atmosphere, the conductive catalyst layer 213 do not receive the gas stored in the gas storing unit 22 . The method of the conductive catalyst layer 211 receiving the exhausted gas generated by the internal combustion engine comprises, the gas storing unit 22 receiving the exhausted gas from the turbine, and the judgment circuit 26 controlling the gas storing unit 22 to transmit the exhausted gas to the conductive catalyst layer 211 .
[0034] Please refer to FIG. 5A and FIG. 5B , FIG. 5A shows a schematic diagram of an oxygen sensing unit processing the reaction of hydrocarbons and oxygen according to an embodiment of the instant disclosure, FIG. 5B shows a schematic diagram of a output circuit of an oxygen sensing device outputting electricity according to an embodiment of the instant disclosure. When the oxygen sensing device 2 is used for outputting electricity, hydrocarbons stored in the gas storing unit 22 can make electrochemical catalytic reaction by utilizing the oxygen sensing unit 21 for generating electric current. The electric current may be transmitted to exterior electrical equipment through the power output unit 25 . The conductive catalyst layer 211 of the oxygen sensing unit 21 receives hydrocarbons (HC) stored in the gas storing unit 22 and processes the reaction (3): HC+O 2− →CO 2 +H 2 O+2e − .
[0035] The reaction of hydrocarbons (HC) and oxygen ions (O 2 ) produces carbon dioxide (CO 2 ), water (H 2 O) and electrons (e − ). The oxygen ions (O 2− ) in the solid oxide electrolyte 212 may be replenished through conductive catalyst layer 213 decomposing oxygen of the air into oxygen ions (O 2− ), and the oxygen ions (O 2− ) may be transmitted from the solid oxide electrolyte 212 to the conductive catalyst layer 211 . When the judgment circuit 26 controls the switch 251 to accomplish a conducting loop, the electrons (e − ) generated in the reaction (3) may outcome electric current for power receiving of the electrical equipment connected to the output terminals a, b of the power output circuit 25 . Briefly, the oxygen sensing unit 21 makes the reaction of hydrocarbons (HC) stored in the gas storing unit 22 and oxygen ions for generating electricity to the power output circuit 25 .
[0036] Please refer to FIG. 2 and FIG. 6 , FIG. 6 shows a schematic diagram of an oxygen sensing unit generating hydrogen and carbon monoxide according to an embodiment of the instant disclosure. When the electrical power of the power source 24 is excess, the electrical power may be stored in the form of hydrogen (H 2 ) generated by the oxygen sensing unit 21 . On the other hand, carbon monoxide (CO) and hydrogen (H 2 ) may be generated from carbon dioxide (CO 2 ) and water (H 2 O) of the exhausted gas from the internal combustion engine by utilizing the oxygen sensing device 2 . The carbon monoxide (CO) and hydrogen (H 2 ) may be upstream material with industrial value, for example, carbon monoxide (CO) and hydrogen (H 2 ) may used to produce chemicals, such as methanol or methane. The judgment circuit 26 of the control unit 23 conducts the switch 28 , makes the switch 27 , 251 be non-conductive, and makes the exhausted gas stored in the gas storing unit 22 be transmitted to the conductive catalyst layer 211 of the oxygen sensing unit 21 . Because power source 24 supplies electrical power, the conductive catalyst layer 211 makes a reaction (4) of the water (H 2 O) in the exhausted gas and the electrons (e − ) from the power source 24 to produce hydrogen (H 2 ), the reaction (4) is described in the following: H 2 O+2e − →H 2 +O 2− .
[0037] Then, the solid oxide electrolyte 212 transmits the oxygen ions (O 2− ) to conductive catalyst layer 213 . The conductive catalyst layer 213 converts the oxygen ions (O 2− ) into oxygen (O 2 ) and transmits excess electrons (e − ) to the power source 24 . The reaction (4) converts the electricity of the power source 24 into the form of hydrogen (H 2 ) which is green energy replacing fossil fuels. On the other hand, when making carbon monoxide (CO) and hydrogen (H 2 ), the conductive catalyst layer 211 makes a reaction (5) of carbon dioxide (CO 2 ) and water (H 2 O), the reaction (5) is described in the following: CO 2 +H 2 O+4e − →CO+H 2 +2O 2− . Briefly, the oxygen sensing unit 21 may use the electricity of the power source 24 to generate hydrogen (H 2 ) for storing energy or generate carbon monoxide (CO).
[0038] FIG. 7A to FIG. 7D shows a cross-sectional diagram of an oxygen sensing unit according to an embodiment of the instant disclosure. The oxygen sensing unit 21 may be flat-shaped, such as the shape shown in FIG. 7A to FIG. 7 C. A thicker one of the solid oxide electrolyte 212 , the conductive catalyst layer 213 or the conductive catalyst layer 211 may utilized to structurally support the oxygen sensing unit 21 . The conductive catalyst layer 213 may surrounds the solid oxide electrolyte 212 and the conductive catalyst layer 211 for covering the solid oxide electrolyte 212 and the conductive catalyst layer 211 . The shape of the conductive catalyst layer 213 may be a cone, a tube, or the shape shown in FIG. 7D , as long as the solid oxide electrolyte 212 is between the conductive catalyst layer 211 and the conductive catalyst layer 213 . Briefly, the shapes of the conductive catalyst layer 211 and the conductive catalyst layer 213 are not restricted, as long as the solid oxide electrolyte 212 is between the conductive catalyst layer 211 and the conductive catalyst layer 213 . The solid oxide electrolyte 212 may transmits oxygen ions (O 2− ) between the conductive catalyst layer 211 and the conductive catalyst layer 213 . On the other hand, the solid oxide electrolyte 212 may not contact tightly the conductive catalyst layer 211 and the conductive catalyst layer 213 , and an air gap could be existed between the solid oxide electrolyte 212 and the conductive catalyst layer 211 (or conductive catalyst layer 213 ). The air gap may filled with air, thus the aforementioned reactions still could be processed.
[0039] In summary, according to the aforementioned embodiments, the oxygen sensing device may process electrochemical catalytic reactions, oxygen sensing, electrical power generation, electrolysis for storing energy and electrolysis for making carbon monoxide (CO). Therefore, the exhausted gas could be reduced and be used to generate electricity, or syngas (including hydrogen and carbon monoxide) could be made. The user may make the oxygen sensing unit to process required chemical reaction through controlling judgment circuit.
[0040] The descriptions illustrated supra set forth simply the preferred embodiments of the instant disclosure; however, the characteristics of the instant disclosure are by no means restricted thereto. All changes, alternations, or modifications conveniently considered by those skilled in the art are deemed to be encompassed within the scope of the instant disclosure delineated by the following claims.
|
An oxygen sensing device with capability of storing energy and releasing energy including an oxygen sensing unit, a gas storing unit, and a control unit. The oxygen sensing unit includes a solid oxide electrolyte disposed between two conductive catalyst layers. The control unit includes a power source, a voltmeter, and a power output circuit. The power source provides electrical power to these conductive catalyst layers of the oxygen sensing unit to process a catalytic reaction and generate hydrocarbons for being stored in the gas storing unit. The voltmeter senses a voltage generated by the oxygen sensing unit when the oxygen sensing unit senses oxygen. The oxygen sensing unit makes the hydrocarbons stored in the gas storing unit and oxygen process a chemical reaction for generating electrical power to the power output circuit. The oxygen sensing unit uses the power source to generate hydrogen or syngas.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from and claims the benefit of U.S. Provisional Application No. 60/677,963, filed May 5, 2005, entitled “Portfolio Execution and Reporting Facility”, which is hereby incorporated by reference.
BACKGROUND
Portfolio traders manage portfolios of stocks and/or other financial instruments and, when they trade, they often times make large dollar value trades in a number of different stocks or other instruments. Portfolio traders are typically fund managers or traders and brokers acting on behalf of a large institution, such as a mutual find or a money-management firm. Portfolio traders employ a variety of different trading strategies to manage their portfolios, and they use program trading to implement these strategies.
A program trade is a series of related purchases or sales of a group of securities where the related purchases and sales satisfy parameters for a minimum number of securities and a minimum market value. The specific parameters of a program trade are defined by market regulations, which currently define a program trade as the purchase or sale of a basket of at least fifteen securities with a total market value of at least one million dollars.
Several limitations exist in prior systems in which program trade orders are executed. For example, in some prior systems, where the portfolio trader executes his program trade orders on an exchange in the market place, the portfolio trader is required to execute the orders during the trading day. If the size of the trade print is large enough, executing this order during the trading day will likely have the negative effect of moving the market away from the position of the portfolio trader that executed the order. This is due to the fact that trades executed within the marketplace are reported immediately. Furthermore, program trade orders executed on an exchange during the trading day run the risk of being broken up due to interaction with the marketplace. Such market interaction poses a serious issue for a trader because a trader wants the program trade orders that make up the program trade to each cross cleanly at a single price. With market interaction, an individual program trade order that is part of the program trade gets separated into a matched portion that crosses and an unmatched portion which must be executed manually. The result is that the individual program trade order ends up getting traded, potentially, at multiple prices.
To remedy this problem, portfolio traders often execute such program trade orders off the exchange (e.g., at an institutional trading desk or within an alternative trading system such as a crossing network). While this method resolves the trader's problem by keeping large orders from interacting with the marketplace and from having execution of the order reported out immediately and potentially negatively moving the market, such order executions must still be reported. Marketplace rules require that executed trades be reported to an exchange or comparable public market center. Program trade orders that are executed off an exchange typically are reported either at the end of the day as aggregated program trade totals, with the details of the execution being reported over the next several days, or reported the next morning as individual trades.
Crossing systems have been developed where program trade orders may be executed on a public exchange, and execution of such orders is captured for market reporting. For example, the New York Stock Exchange (“NYSE”) offers a special trading session (i.e. Crossing Session II) where program trade orders may be received and executed on the NYSE at the end of the day, after the market has closed.
Accordingly, there is a need for a crossing system that allows traders to submit their program trade orders throughout the trading day at the trader's convenience for execution at a pre-specified time so that these orders do not interact with other orders on the exchange.
SUMMARY
According to an aspect of the present invention, a method for processing a program trade, includes providing a crossing market center and designating a portfolio crossing session start time outside of normal market trading hours and throughout the trading day until the designated portfolio crossing session start time, receiving and storing a plurality of program trade orders at the crossing market center, wherein each program trade order contains a basket identification number identifying the program trade that the program trade order is part of. It further includes, at the designated start time, initiating a portfolio crossing session and executing the received program trade orders, resulting in portfolio crosses. It further includes linking together the completed portfolio crosses having the same basket identification number.
DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims and accompanying drawings where:
FIG. 1 is a block diagram illustrating the trading environment in which an embodiment of the present invention operates;
FIG. 2 illustrates the process implemented by a portfolio cross order implementation program when the program receives a portfolio cross order; and
FIGS. 3A-3B illustrates a process implemented by an embodiment of the present invention in performing surveillance on the trades executed through the system.
DETAILED DESCRIPTION
Referring to FIG. 1 , a trading environment in which an embodiment of the system and method of the present invention operates is depicted. The examples discussed herein describe the use and application of the present invention in an equity security market center environment, but it should be understood that the present invention could be used in any type of financial instrument market center environment (e.g., securities, futures contracts, options, bonds, etc.). The trading environment of this embodiment includes a crossing market center 20 which interacts with a number of other market centers 24 (i.e. away market centers) and traders 26 . It should be understood that the crossing market center 20 referred to herein refers to a computing system having sufficient processing and memory capabilities and does not refer to a specific physical location. In fact, in certain embodiments, the computing system may be distributed over several physical locations. It should also be understood that any number of traders 26 or away market centers 24 can interact with the crossing market center 20 . The crossing market center 20 is the market center to which a portfolio trader 26 sends a specific program trade order. The crossing market center 20 includes an order matching engine 21 , which validates, matches and processes all orders on the market center 20 . In this embodiment, the order matching engine 21 includes a program trade order implementation program 22 , which functions to facilitate the execution of program trade orders sent to the crossing market center 20 . The program trade order implementation program 22 may also be utilized as stand alone code separate and apart from the order matching engine 21 . In this embodiment, the code for the order matching engine 21 and for the program trade order implementation program 22 are stored in the crossing market center's memory.
The crossing market center 20 may also include a program trade order parameters data structure 27 . The program trade order parameters data structure 27 stores pre-defined parameters and rules that are used by the order matching engine 21 in executing program trade orders (e.g., portfolio crossing session start time, program trade order definition parameters such as minimum number of symbols in a portfolio and minimum portfolio value parameters, etc.). The crossing market center 20 may also include an order and execution interface 28 which interacts with the traders 26 , the away market centers 24 and the order matching engine 21 in crossing a program trade order and, in this embodiment, the regular order execution process. The crossing market center 20 may also include a program trade order data structure 29 where program trade order information is stored, an order execution data structure 30 where executed order information is stored and a trade reporting data structure 31 where trade reporting information is stored (e.g., trade reporting rules and the tape data for trade reports).
Throughout the discussion herein, it should be understood that the details regarding the operating environment, data structures, and other technological elements surrounding the crossing market center 20 are by way of example and that the present invention may be implemented in various differing forms. For example, the data structures referred to herein may be implemented using any appropriate structure, data storage, or retrieval methodology (e.g., local or remote data storage in data bases, tables, internal arrays, etc.). Furthermore, a market center of the type described herein may support any type of suitable interface on any suitable computer system.
Incoming Program Trade Order
Referring to FIG. 2 , at step 100 , a new program trade order is received by the order matching engine 21 . The order matching engine 21 , recognizing the program trade order designation, stores the program trade order to the program trade order data structure 29 and queues this order for later execution, as indicated at step 102 . The program trade order has an order identification number and a basket identification number that are assigned by the trader 26 that sent the order. The order identification number acts as a reference and tracking identifier for that order, and the basket identification number is a reference which links all of the orders in the portfolio basket of crosses together. Since program trade orders are created so that they do not need to interact with the general market, price/time priority rules, from an order matching standpoint, are irrelevant. As every order is guaranteed to execute at its specified order price, the process simply stores the received program trade orders for each symbol in the order in which such order was received. The process can optionally store the orders according to symbol or basket identification number or can simply store all the received orders sequentially in a single file. As each order represents a self-contained cross, the sequence in which the orders are stored is irrelevant. The stored program trade orders, in this embodiment, are not displayed on the crossing market center's order book or to the general marketplace in any manner, which keeps the trader's trading intentions from the market.
The portfolio crossing time parameter (e.g. “Portfolio Crossing Time”) is a pre-set parameter which sets the time that the daily portfolio crossing session commences and resides in the program trade order parameters data structure 27 . As indicated at step 110 , at the point in the day when the portfolio crossing time parameter is reached, the process initiates a portfolio crossing session, as indicated at step 112 . Typically, the portfolio crossing session is set up to execute outside of normal market hours to keep the portfolio crossing orders from interacting with the market. However, it should be understood that the start time for the portfolio crossing session can be set for any time (e.g. set for prior to market opening rather than after the close of the market) and that the process can be set up to conduct more than one portfolio crossing session in a day if desired (e.g. one prior to the market opening and one after the close of the market). Also, it should be understood that, in this embodiment, submitted program trade orders stored on the program trade order data structure 29 may be modified and/or canceled prior to the commencement of the portfolio crossing session.
The portfolio crossing session commences by retrieving a program trade order stored in the program trade order data structure 29 , as indicated at step 114 . At step 116 , the process retrieves the Trade Reporting rule for the symbol in the program trade order record. At step 122 , the process executes the cross defined by the program trade order (i.e. price and size).
Reporting the Executed Program Trade Crosses
In this embodiment, as each program trade order is executed, each resulting cross is reported. It is contemplated that in other embodiments the crosses might not be reported. Reporting requirements for crosses are based on the symbol traded. When the process reports on an executed cross, it retrieves the reporting rules that apply for that symbol from the trade reporting data structure 31 and reports on the trade in accordance with those rules. For example, one market center or Trade Reporting authority, away market center 24a, may require crosses to be reported in aggregate and that crosses be reported immediately after the end of the portfolio crossing session; while another market center or Trade Reporting authority, away market center 24b, may require the crosses to be reported individually for each symbol and that they be reported the next morning. If the crosses are to be reported in the aggregate, the process computes the sum of all the shares and the total value of all the shares that were crossed during the portfolio crossing session, combining together all crosses for all traders for the market center symbols being aggregated.
Referring again to FIG. 2 , at step 126 , the process determines how the symbol executed in the cross is reported, specifically it determines whether the symbol crossed is reported to the tape in aggregate. If the symbol is not to be reported in the aggregate, the cross is reported individually to the tape, as indicated at step 128 , and the process proceeds to determine if there are any additional stored program trade orders that need to be executed, as indicated at step 136 . If the process determines that the symbol crossed needs to be reported in the aggregate, then, as indicated at step 130 , the process adds the volume of shares of the symbol crossed to the running total of aggregate shares that have been crossed in the trading session to that point for all symbols for a specific market center (i.e. parameter AggregateSharesCrossed stored on the trade reporting data structure 31 ). At step 132 , the process determines the total value of the aggregated shares by multiplying the volume of the cross by the price per share of the cross. Then, at step 134 , the process adds the computed trade value to the running total of aggregate value of the shares that have been crossed in the trading session to that point for all symbols for a specific market center (i.e. parameter AggregateValueCrossed stored on the trade reporting data structure 31 ). At step 136 , the process then determines if there are any other stored program trade orders that need to be executed. If yes, then the process returns to step 114 and retrieves the next program trade order and processes the order in the manner described above. If, at step 136 , it is determined that there are no further program trade orders that need to be executed, then the process reports the value of the aggregate shares crossed parameter and the aggregate volume crossed parameters to the tape, as indicated at step 138 . The portfolio crossing session is then complete, as indicated at step 140 .
Surveillance of Program Trade Crosses
Only orders that meet the definition of a program trade order are eligible to be treated and executed as a program trade order. In this regard, the process of the present invention checks the program trade orders executed to verify that the basket of crossed orders did in fact meet the definition of a program trade, which, in this embodiment, is a basket of crossed orders having a value of at least one million dollars and including at least fifteen securities' symbols. In this embodiment, the process validates a basket of crossed orders after execution. However, it is contemplated that in other embodiments a basket awaiting execution could be validated prior to execution.
Referring to FIGS. 3A-3B , after completion of the portfolio crossing session, order surveillance takes place. At step 142 , the process initiates the portfolio crossing surveillance reporting process. At step 144 , the process retrieves the parameters for a valid program trade order (i.e. the parameter which defines the minimum number of symbols that need to be included in the basket (“MinPortfolioSymbols”) and the parameter which defines the minimum dollar value for the basket (“MinPortfolioValue”). In this embodiment, these parameters are retrieved from the program trade order parameters data structure 27 .
At step 146 , the process retrieves all the program trade crosses executed during the portfolio crossing session and sorts these crosses by basket identification number. At step 148 , the process retrieves a program trade cross record. If the record retrieved is the first record, the basket-in-process parameter is set to the basket identification number of the retrieved record, as indicated at step 150 . At step 152 , the process determines whether the basket identification number for the record retrieved is the same as the basket-in-process parameter. If the two values are the same, then the process proceeds to step 154 , where the process adds to the parameter that counts the number of symbols in the portfolio basket (“PortfolioSymbolCount”). Then at step 156 , the process computes the value of the cross for the record being analyzed which is equal to the cross volume multiplied by the price per share. At step 158 , the process keeps a running total of the entire value of the portfolio crossed by adding the value computed for the individual cross at step 156 to the total value at that point. Referring back to step 152 , if the basket identification number being processed is not the same as the basket-in-process parameter, the process proceeds to step 162 where, in this embodiment, it prints out the basket identification number for the basket that was just analyzed. It also prints out the total number of symbols that were in the portfolio basket, and it prints out the total value of the crosses that were executed in the basket. At step 164 , the process checks to make sure the portfolio basket included the proper number of symbols for a program trade. The process does that by determining whether the number of symbols that crossed within the basket (“PortfolioSymbolCount”) is greater than or equal to the parameter that defines the minimum number of symbols that must be present in a portfolio basket (“MinPortfolioSymbols”). If the number of symbols crossed in the portfolio basket is less than the required minimum, the process, as indicated at step 166 , prints an error message which indicates that the basket did not contain the requisite number of symbols. If the basket did have at least the minimum number of symbols, the process continues to step 168 where it determines whether the basket of executed crosses satisfied the requisite dollar value as defined by the minimum basket value parameter. If the value of the basket of trades is greater than or equal to the minimum basket value parameter, then the criteria for the minimum basket value has been satisfied, and the process proceeds to step 172 . However, if the value of the basket of crosses executed is less than the minimum basket value parameter, the process, as indicated at step 170 , prints an error message which indicates that the basket did not meet the minimum value required for a program trade. At steps 172 and 174 , the process, re-sets the field for the total number of symbols in the basket to zero and re-sets the field for the total value of the basket of crosses to zero, respectively. At step 176 , the process then sets the basket-in-process parameter equal to the basket identification number for the basket now being analyzed and proceeds to step 154 .
At step 160 , the process determines if there are remaining program trade crosses to analyze. If yes, the process returns to step 148 and repeats the process described above for the next program trade cross record. If there are no further program trade crosses to analyze, then the portfolio crossing surveillance process is complete, as indicated at step 178 .
Examples of program trade orders received by a crossing market center 20 are provided below. It should be understood that the order prices discussed in the examples below are by way of example only to illustrate how the process of an embodiment of the invention handles program trade orders of the present invention. For ease of illustration in showing how different symbols have different Trade Reporting requirements, the orders in the examples below have been aggregated according to symbol. As previously described, however, the orders may be stored in any sequence required.
A. EXAMPLE INCOMING PROGRAM TRADE ORDERS
As steps 100 and 102 indicate, program trade orders sent to the crossing market center 20 throughout the day are captured and stored as a record in the program trade order data structure 29 .
Example A1
Program Trade Order
In this example, the crossing market center 20 receives the following program trade order from trader 26a:
Order 17: Cross 10,000 Symb01@20.04, Portfolio Cross, BasketID=A127
The record for this order stored in the program trade order data structure 29 , in this example, has the following format:
Time
Symbol
FirmID
received
OrderID
BasketID
Quantity
Price
Symb01
Trader26a
08:05:13
17
A127
10,000
20.04
Trader 26a has assigned order identification number 17 and basket identification number A127 to this order. The basket order identification number links this order to all of the other orders with a basket order identification number of A127. All of the orders linked together in “basket” A127 constitute the portfolio being traded.
Example A2
Program Trade Order for the Same Symbol, but Different Trader
In this second example, the crossing market center 20 receives the following program trade order from a different trader 26b:
Order 202: Cross 9,200 Symb01@20.05, Portfolio Cross, BasketID=B1743A
The queue of records for Symb01 now appear as follows:
Time
Symbol
FirmID
received
OrderID
BasketID
Quantity
Price
Symb01
Trader26a
08:05:13
17
A127
10,000
20.04
Symb01
Trader26b
08:40:35
202
B1743A
9,200
20.05
Example A3
Program Trade Order for the Same Symbol but Different Basket
Traders can submit multiple program trade orders for the same symbol if the symbol is a constituent of more than one basket. In this third example, the crossing market center 20 receives the following program trade order from the first trader 26a for symbol Symb01, but for a different basket:
Order 103: Cross 16,000 Symb01@20.10, Portfolio Cross, BasketID=F234
This program trade order is inserted into the queue for symbol Symb01. None of these orders for Symb01 will ever interact with each other. By definition, program trade orders do not interact with any other orders.
Time
Symbol
FirmID
received
OrderID
BasketID
Quantity
Price
Symb01
Trader26a
08:05:13
17
A127
10,000
20.04
Symb01
Trader26b
08:40:35
202
B1743A
9,200
20.05
Symb01
Trader26a
09:33:24
103
F234
16,000
20.10
Example A4
Program Trade Order for Different Symbol for an Open Basket
In this example, traders must submit cross orders for at least 15 different symbols for the same basket. In this fourth example, the crossing market center 20 receives the following program trade order from the first trader 26a for symbol Symb02 for an open basket, basket A127:
Order 268: Cross 20,000 Symb02@17.57, Portfolio Cross, BasketID=A127
The process inserts the order in the queue for symbol ‘Symb02’:
Time
Symbol
FirmID
received
OrderID
BasketID
Quantity
Price
Symb02
Trader26a
10:17:40
268
A127
20,000
17.57
B. EXAMPLE PORTFOLIO CROSSING SESSION
In this example, the late trading session ends on the crossing market center 20 , and the market closes. In this example, away market center 24a and away market center 24b have the following tape reporting requirements for program trade orders executed on the crossing market center:
Crosses in the symbols ‘Symb01’ and ‘Symb03’ must be reported to away market center 24a. Away market center 24a requires program trade crosses to be reported in aggregate form at the end of the portfolio crossing session; and Crosses in the symbol ‘Symb02’ must be reported to away market center 24b. Away market center 24b requires program trade crosses to be reported individually at the beginning of the next trading day following the close of the portfolio crossing session.
Referring to step 110 , in this example, shortly after market close, the time equals the time designated by the portfolio crossing time parameter. As indicated at step 112 , the portfolio crossing session is initiated.
Example B1
First Portfolio Cross in Symb01 Executes
The queue for symbol ‘Symb01’ looks like this when the portfolio crossing session commences:
Time
Symbol
FirmID
received
OrderID
BasketID
Quantity
Price
Symb01
Trader26a
08:05:13
17
A127
10,000
20.04
Symb01
Trader26b
08:40:35
202
B1743A
9,200
20.05
Symb01
Trader26a
09:33:24
103
F234
16,000
20.10
As indicated at steps 114 and 116 , the process retrieves the first program trade order and the Trade Reporting rules for the symbol designated therein (i.e. Order 17 and Symb01). At Step 122 , the process executes the order, crossing 10,000 shares of Symb01 at $20.04:
Trader 26a Crossed 10,000 Symb01 at $20.04
Then, at step 126 , the process determines whether crosses for Symb01 are reported in the aggregate or not. In this example, since Symb01 is reported to away market center 26a, the cross needs to be reported in the aggregate. At step 130 , the process adds the cross volume (i.e. 10,000 shares) to the computed variable AggregateSharesCrossed. In step 132 , the process computes the value of the cross (i.e. 10,000 shares×$20.04) as $200,400. At step 134 , the process then adds the value of the cross ($200,400) to the running total in variable AggregateValueCrossed. In this example, the current values of the aggregated statistics are the following:
AggregateSharesCrossed=10,000
AggregateValueCrossed=$200,400
At step 136 , the process determines that there are more program trade orders to execute and returns to step 114 to get the next order.
Example B2
Second Portfolio Cross in Symb01 Executes
At step 114 , the process retrieves the second portfolio cross order (i.e. Order 202) and retrieves the Trade Reporting rules for the symbol, which, in this example, happens to be the same as the previously processed order (i.e. Symb01). At step 122 , the process executes Order 202 crossing 9,200 shares at $20.05:
Trader 26b Crossed 9,200 Symb01 at $20.05
As with the first program trade order above, at step 126 , the process determines that crosses for Symb01 are reported in the aggregate. Therefore, at step 130 , the process adds the cross volume (i.e. 9,200 shares) to the computed variable AggregateSharesCrossed. At step 132 , it computes the value of the cross as $184,460. As above, the value of the cross is added to the running total for the total value of shares crossed in this symbol. The updated aggregate values for the number of shares crossed and their value for Symb01 at this point are as follows:
AggregateSharesCrossed=19,200 (10,000+9,200)
AggregateValueCrossed=$384,860 ($200,400+$184,460)
Once again, the process at step 136 determines that there are more program trade orders to execute and returns to step 114 to retrieve the next order.
Example B3
Third Portfolio Cross in Symb01 Executes
At step 114 , the process retrieves the third program trade order (i.e. Order 103). At step 116 , the process, in this example, retrieves the Trade Report rules for Symb01 again. Then at Step 122 , the process crosses 16,000 shares at $20.10:
Trader 26a Crossed 16,000 Symb01 at $20.10
The process again determines that crosses for Symb01 are reported in the aggregate so it adds the cross volume (i.e. 16,000 shares) to the running total for the total amount of shares crossed in the specified symbol. Then, at step 132 , as before, it computes the value of the cross as $321,600. In step 134 , it adds the computed value of the cross to the aggregated running total of the value of crossed shares in the specified symbol. The updated values of the aggregated statistics are the following:
AggregateSharesCrossed=35,200 (10,000+9,200+16,000)
AggregateValueCrossed=$706,460 ($200,400+$184,460+$321,600)
Since there are further program trade orders to execute, the process returns to step 114 to retrieve the next order.
Example B4
First Portfolio Cross in Symb02 Executes
The queue for symbol ‘Symb02’ looks like this at this point:
Time
Symbol
FirmID
received
OrderID
BasketID
Quantity
Price
Symb02
Trader26a
10:17:40
268
A127
20,000
17.57
At steps 114 and 116 , the process retrieves the next stored program trade order shown above and the Trade Reporting rules for the symbol designated therein (i.e. Order 268 and Symb02). The process then proceeds to step 122 where it executes the order and crosses 20,000 shares at $17.57:
Trader 26a Crossed 20,000 Symb02@17.57
Then at step 126 , as with Symb01, the process determines whether trades for Symb02 are reported in the aggregate or not. In this case, it determines they are not reported in the aggregate (Market Center 24b's rule). The process, therefore, proceeds to step 128 where it reports the cross individually to the Tape and no further processing is required. All the individual crosses that must be reported to Market Center 24b are sent to Market Center 24b the next morning per its requirements.
At step 136 , the process determines if there are additional program trade orders that require processing. In this example, there are. The process therefore returns to step 114 and retrieves the next stored order.
Example B5
First Portfolio Cross in Symb03 Executes
The queue for symbol ‘Symb03’ looks like this at this point:
Time
Symbol
FirmID
received
OrderID
BasketID
Quantity
Price
Symb03
Trader26a
10:17:53
269
A127
9,000
40.40
At steps 114 and 116 , the process retrieves the next stored program trade order shown above and the Trade Reporting rules for the symbol designated therein (i.e. Order 269 and Symb03). The process then proceeds to step 122 where it executes the order and crosses 9,000 shares at $40.40:
Trader 26a Crossed 9,000 Symb03@40.40
Then, proceeding to step 126 , the process determines that crosses in Symb03 need to be reported in the aggregate (Market Center 24a's rule). As such, during steps 130 - 134 , the process continues to increment the AggregateSharesCrossed and AggregateValueCrossed parameters that were started with Symb01, even though this trade is for a different symbol. In this example, the variables AggregateSharesCrossed and AggregateValueCrossed are aggregated values for all crosses in symbols for which Market Center 24a sets the reporting requirements.
Therefore, at step 130 , the process adds the cross volume (9,000 shares) to the computed variable AggregateSharesCrossed, and at step 132 , it computes the TradeValue by multiplying the cross volume (9,000 shares) by the cross price ($40.40) to derive the TradeValue of $363,600. At step 134 , it adds the TradeValue to the computed variable AggregateValueCrossed.
These are the updated values of the aggregate statistics in this example:
AggregateSharesCrossed=44,200 (10,000+9,200+16,000+9,000)
AggregateValueCrossed=$1,070,060 ($200,400+$184,460+$321,600+$363,600)
The process continues processing stored program trade orders in this manner until all the stored program trade orders are processed. Then, at that point, as indicated at steps 136 - 140 , the process reports the aggregated values to Tape and the portfolio crossing session is terminated. In this example, at the beginning of the next trading day, the crossing market center 20 reports the individual trades to Market Center 24b per its requirements.
C. EXAMPLE OF SURVEILLANCE OF PROGRAM TRADE ORDERS
Referring to FIGS. 3A-3B , after the end of the portfolio crossing session, the process implements the portfolio crossing surveillance reporting routine, as indicated at step 142 . As described earlier, in this embodiment of the invention, the process does not perform surveillance prior to trade execution. However, it should be understood that in other embodiments, the process may be configured to check if a portfolio of cross orders satisfies the criteria for a program trade prior to the execution of the basket.
At step 144 , the process retrieves the parameter that defines the minimum number of symbols that are required in a program trade (“MinPortfolioSymbols”) from the program trade order parameters data structure 27 . The MinPortfolioSymbols parameter, in accordance with market regulations, is set to 15 symbols in this example. At step 144 , the process also retrieves the parameter that defines the minimum value that is required for a program trade (“MinPortfolioValue”) from the program trade order parameters data structure 27 . The MinPortfolioValue parameter, in accordance with market regulations, is set to $1 million in this example. At step 146 , the process retrieves all crosses that were executed and sorts the crosses by basket identification number (“BasketID”). In this example, the first BasketID is BasketID=A127. These are the fifteen crosses that were executed for BasketID A127 during the portfolio crossing session:
Time received
OrderID
BasketID
Symbol
Quantity
Price
08:05:13
17
A127
Symb01
10,000
20.04
10:17:40
268
A127
Symb02
20,000
17.57
10:17:53
269
A127
Symb03
9,000
40.40
11:35:03
310
A127
Symb04
3,000
63.95
13:24:34
405
A127
Symb05
15,000
9.43
14:04:57
497
A127
Symb06
6,000
18.25
15:40:43
603
A127
Symb07
4,000
37.37
15:46:15
604
A127
Symb08
5,500
43.16
16:10:18
627
A127
Symb09
12,000
13.49
16:25:20
646
A127
Symb10
6,000
95.73
17:53:07
838
A127
Symb11
1,000
112.24
18:09:45
905
A127
Symb12
7,500
25.74
18:37:24
934
A127
Symb13
8,000
56.67
19:40:10
953
A127
Symb14
4,000
73.37
19:57:09
954
A127
Symb15
7,000
47.26
At step 148 , the process retrieves the first cross, OrderID=17 in this example. At step 150 , since this is the first record, the process sets the parameter for the basket-in-process to A127 (i.e. BasketInProcess=A127). Because of step 150 , the current BasketID is equal to the basket-in-process parameter. Therefore, the process moves on to step 154 where it adds one to the parameter that aggregates the number of symbols in the basket (i.e. PortfolioSymbolCount). At step 156 , the process computes the value of the order presently being analyzed by multiplying the volume of the cross (10,000 shares) by the cross price ($20.04) to derive a cross value of $200,400. At step 158 , the calculated cross value is added to the total value for the basket (i.e. TotalPortfolioValue).
After analyzing the first trade in BasketID A127, the current portfolio values are:
PortfolioSymbolCount=1
TotalPortfolioValue=$200,400
At step 160 , the process determines that there are additional crosses to be processed in this basket and returns to step 148 to retrieve the next cross (i.e. OrderID=268). Since the BasketID for this order is the same as the basket-in-process parameter, at step 154 , the process adds one to the PortfolioSymbolCount parameters. At step 156 , it computes the TradeValue parameter for this cross by multiplying the volume (20,000 shares) by the cross price ($17.57) to derive a value of $351,400. At step 158 , it adds the computed cross value for OrderID 268 to the aggregated TotalPortfolioValue parameter.
After analyzing the second trade in BasketID A127, the updated portfolio values are as follows:
PortfolioSymbolCount=2
TotalPortfolioValue=$551,800 ($200,400+$351,400)
The process continues in the manner described above for all of the remaining crosses in BasketID A127, the third through fifteenth crosses in this example. After processing all of Basket ID A127's crosses at Step 148 , the process retrieves the next cross, which it recognizes as belonging to a new BasketID (B1743A) and compares it to the BasketInProcess parameter, which is presently set to A127. Since the BasketID values are not the same, the process prints the final PortfolioSymbolCount and the final TotalPortfolioValue for Basket A127 at step 162 :
Portfolio A127
Symbol Count: 15
Portfolio Value: $3,864,270
At step 164 , the process determines whether the PortfolioSymbolCount parameter for BasketID A127 (i.e. 15 in this example) is greater than or equal to the MinPortfolioSymbols parameter (i.e. 15 in this example). As the parameters equal each other, the process proceeds to step 168 , where the process determines whether the TotalPortfolioValue for BasketID A127 (i.e. $3,864,270 in this example) is greater than or equal to the MinPortfolioValue parameter (i.e. $1,000,000 in this example). In this example, the TotalPortfolioValue for BasketID A127 is greater than the MinPortfolioValue required. Therefore, Basket ID A127 met the criteria for a valid program trade.
The process then proceeds to steps 172 and 174 where it zeroes out the PortfolioSymbolCount and the TotalPortfolioValue parameters. At step 176 , the process sets the basket-in-process parameter to the latest basket identification number that was retrieved (i.e. BasketInProcess=B1743A). The process then returns to step 154 where it begins the process of analyzing BasketID B1743A.
The process continues to analyze and report the value of all the baskets that had crosses executed in the portfolio crossing session. When the process determines there are no more crosses to analyze at step 160 , the portfolio crossing surveillance reporting is complete, as indicated at step 178 .
While the invention has been discussed in terms of certain embodiments, it should be appreciated that the invention is not so limited. The embodiments are explained herein by way of example, and there are numerous modifications, variations and other embodiments that may be employed that would still be within the scope of the present invention.
|
A program trade order process and related market center are disclosed which accumulate program trade orders throughout the trading day and execute the accumulated program trade orders at a designated time. The process disclosed provides trade reporting and order surveillance capabilities as well.
| 6
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is the National Phase application under 35 U.S.C. §371 of International Application No. PCT/CN2015/076743, filed Apr. 16, 2015, which claims the benefit of priority from Chinese application CN 201410751966.9, filed Dec. 9, 2014, and Chinese application CN 201410752500.0, filed Dec. 9, 2014, each of which is hereby incorporated by reference in its entirety for all purposes as if put forth in full below.
FIELD OF THE INVENTION
The present invention relates to the pharmaceutical technical field, especially relates to the use of atractylenolide compound or its derivatives in the manufacture of a medicament for inhibiting platelet aggregation and the medicament for inhibiting platelet aggregation.
BACKGROUND OF THE INVENTION
In modern medical science, it is deemed that the formation of thrombus has a certain relationship with the exorbitant platelet aggregation rate.
Thrombus originates from the local coagulation mechanism, which is covered by proliferative endotheliocyte after hyper-thrombosis of endarterium surface, while lipides and other active substances, which are released by the lysis of platelet and leukocyte, enter the mural thrombus of artery to form the atheromatous plaque gradually. Subsequent researchers find out that the disease originates from the injury in arterial tunica intima, then platelet activating factor (PAF) increases and platelets adhere and aggregate here, subsequently microthrombus is formed by fibrin deposition. Some active substances are released by the platelet after their aggregation, wherein the thromboxane A2 (TXA2) can offset the effect of platelet depolymerization and vasodilatation produced by the prostacycline (PGI2) that is synthesized by blood vessel wall and thus promotes further platelet aggregation and vasoconstriction, the platelet derived growth factor can stimulate the proliferation and contraction of smooth muscle cells and make them move towards tunica intima, 5-serotonin and fibroblast growth factor can stimulate fibroblast smooth muscle cells and endotheliocyte to produce epinephrine and ADP (adenosine diphosphate) and thus promote further platelet aggregation, Factor VIII causes the further adhesion of platelet, platelet factor 4 can make the blood vessels constrict, PAI (plasminogen activator inhibitor) inhibits the thrombolysis of thrombus. These substances aggravate the injury of endotheliocyte, which subsequently causes the following results that are all in favor of the formation of scleratheroma: LDL (low-density lipoprotein) enters tunica intima and even beneath it, monocytes aggregate in tunica intima and develop into foam cells, smooth muscle cells proliferate and move into tunica intima to phagocytose the lipids, and endothelial cells proliferate.
There are coagulation system and anticoagulation system in human blood. Under normal circumstances, these two systems keep a dynamic balance to ensure the normal flow of blood in blood vessels, which means thrombus wouldn't be formed. Under special circumstances, e.g. blood vessels have injury such as vascular sclerosis and hemadostenosis, cold weather, excessive sweating, hypotension, insufficient water drinking, etc., blood flows slowly and becomes concentrated and viscous, leading to hypercoagulation or impaired anticoagulation, and subsequently the abovementioned balance is disrupted which results in a “thrombophilic state”. Thromboembolic diseases may occur everywhere of blood vessels, wherein thrombus flows in blood vessels along with blood. If thrombus stays in cerebral artery vessels and hinders the normal blood flow of the cerebral artery, it is referred to as cerebral thrombus which thereby causes ischemic stroke attacks, and if it blocks coronary artery vessels of the heart, it causes myocardial infarction, as well as arterial thrombosis in lower extremity, deep venous thrombosis in lower extremity and pulmonary embolism, etc.
When it onsets, most thrombosis will cause severe symptoms, such as hemiplegia and aphasia for cerebral infarction, intense angina in precordial region for myocardial infarction, severe chest pain, dyspnoea, hemoptysis and other symptoms caused by pulmonary infarction, pain in legs or coldness and intermittent claudication, etc. in case of thrombosis in lower extremity. Extremely severe heart infarction, cerebral infarction and pulmonary infarction can even result in sudden death. Whereas thrombosis may have no obvious symptoms sometimes, taking the commonly observed deep venous thrombosis in lower extremity for example, patients suffering this disease just feel sour and swollen legs, and most of them often consider it as the result of fatigue or cold, and subsequently miss the optimal treatment timing. It is particularly unfortunate that many doctors often misdiagnose it as other diseases. When typical edema of lower extremity develops, the treatment of the disease will be difficult and sequela will be left. The formation of thrombus will often result in the aforesaid severe consequences, but up to now there hasn't been a drug with high efficacy without toxic-and-side effects for use in treating or preventing thrombosis.
Atractylenolide compounds, e.g. atractylenolide II, atractylenolide III, etc., derive from extracts of dried roots of compositae plant Atractylodes macrocephala Koidz. In researches of prior art, atractylenolide compounds have anti-inflammatory and antitumor effects together with properties of regulating gastrointestinal peristalsis and promoting the absorption of nutrients. Nonetheless, up to now, the effect of inhibiting platelet aggregation of atractylenolide compounds has not been reported yet.
SUMMARY OF THE INVENTION
In order to solve the technical problem of lacking effective and safe drugs used for the treatment and prevention of thrombus currently, the present invention provides a drug comprising atractylenolide compound or its derivatives having the effect of anti-platelet aggregation, wherein the drug has a simple composition and is composed by active ingredients of natural medicinal materials or extracts thereof. This drug has high efficacy without toxic-and-side effects, lower tendency of tolerance, convenient to take and generally applicable for preventing or treating symptoms like viscous blood and thrombus caused by exorbitant platelet aggregation rate.
In one aspect of the present invention, it provides a medicament for inhibiting platelet aggregation comprising atractylenolide compound or its derivatives, wherein said atractylenolide compound has the structural formula shown in following formula (I):
wherein R1 represents H or C1-C10 linear or branched alkyl, R2 represents H or C1-C10 linear or branched alkyl, and R3 represents H or hydroxyl.
Preferably, said atractylenolide compound has the structural formula shown in following formula (II):
The structural formula shown in formula (II) is the chemical structural formula of atractylenolide M. Preferably, said atractylenolide compound has the structural formula shown in following formula (III):
The structural formula shown in formula (M) is the chemical structural formula of atractylenolide I. Preferably, said derivatives of atractylenolide compound have the structural formula shown in following formula (IV):
The structural formula shown in formula (IV) is the chemical structural formula of atractylenolide II.
Said medicament is present in the dosage forms including tablet, granule, capsule, patch or injection.
Said C1-C10 alkyl is preferably C1-C8 alkyl, more preferably C1-C6 alkyl, such as methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, tert-butyl, n-pentyl, iso-pentyl, n-hexyl, iso-hexyl.
Wherein, said alkyl can be linear alkyl or branched alkyl, preferably linear alkyl.
The derivatives of atractylenolide compound in the present invention refer to a kind of substances having similar chemical structures to atractylenolide, which are obtained by the derivatization and modification of functional groups in the chemical structural formula of atractylenolide, such as ester bond, epoxy ring, carbon-carbon double bond, etc. For example, the modification of ester bond is achieved by ester hydrolysis of atractylenolide under acidic or alkaline condition. The hydrolysis of epoxy ring is occurred under acidic or alkaline condition.
The medicament for inhibiting platelet aggregation of the present invention also comprises pharmaceutically acceptable excipients.
Preferably, said excipients include one or more of the following: solvent, propellent, solubilizer, cosolvent, emulsifier, colorant, adhesive, disintegrant, filling agent, lubricant, wetting agent, osmotic pressure regulator, stabilizer, glidant, corrigent, preservative, suspending agent, coating material, fragrance, anti-adhesive, chelating agent, penetration enhancer, pH regulator, buffering agent, plasticizer, surfactant, foaming agent, defoaming agent, thickening agent, clathrate agent, humectant, absorbent, diluent, flocculant and deflocculant, filter aid agent, or releasing blocker.
In another aspect of the present invention, it provides the use of atractylenolide compound or its derivatives shown in formula (I) in the manufacture of a medicament for inhibiting platelet aggregation,
Wherein, R1 represents H or C1-C10 linear or branched alkyl, R2 represents H or C1-C10 linear or branched alkyl, and R3 represents H or hydroxyl.
Said medicament for inhibiting platelet aggregation includes the medicament that is used for treating or preventing viscous blood, cerebral infarction, myocardial infarction, pulmonary embolism, arterial thrombosis in lower extremity and deep venous thrombosis in lower extremity.
The medicament for inhibiting platelet aggregation of the present invention has a good efficacy while no toxic and side effect. As shown by the comparative experiment with current medicament for inhibiting platelet aggregation, acetylsalicylic acid, that the atractylenolide compound or its derivatives of the present invention have a significant effect of inhibiting platelet aggregation, and is suitable to prevent or treat diseases caused by exorbitant platelet aggregation and have a broad prospect in application.
BRIEF DESCRIPTION OF THE DRAWINGS
Below is a detailed description of the present invention in combination with drawings and specific examples.
FIG. 1 shows the experimental results of in vitro platelet aggregation inhibition by atractylenolide II in Example 1;
FIG. 2 shows the experimental results of in vitro platelet aggregation inhibition by atractylenolide Ill in Example 2;
FIG. 3 shows the oil immersion lens observation of the effect of atractylenolide II on platelet spreading in Example 3;
FIG. 4 shows the oil immersion lens observation of the effect of atractylenolide Ill on platelet spreading in Example 4;
FIG. 5 shows the testing results of Western blotting in Example 5;
FIG. 6 shows the testing results of Western blotting in Example 6;
FIG. 7 shows the result of comparative experiments comparing in vitro platelet aggregation inhibition by atractylenolide II and acetylsalicylic acid in Example 7;
FIG. 8 shows the result of comparative experiments comparing in vitro platelet aggregation inhibition by atractylenolide III and acetylsalicylic acid in Example 8.
DETAILED DESCRIPTION OF THE INVENTION
Taking atractylenolide II and atractylenolide III for example, the effect of atractylenolide compound or its derivatives of the present invention on inhibiting platelet aggregation is illustrated in details.
EXAMPLE 1
Effect of Atractylenolide II on Platelet Aggregation Inhibition in Platelet Aggregation Test
I. Materials and Preparation
Atractylenolide II, dissolved in DMSO.
II. Experimental Procedure
Platelet Aggregation Test
(1) Preparation of platelets: human blood plasma with high concentration of platelets is used to prepare platelets counting 3×10 8 /mL, which are placed in a water bath of 37° C.
(2) Concentration gradient of compound atractylenolide final concentrations of the compound in 300 uL platelets are respectively 0.1 μM, 0.5 μM, 1 μM, 5 μM, 10 μM.
The compound is incubated in platelets for 3 mins before the experiment, and resting and DMSO are included in the experiment as control groups. Thrombin is used as stimulant. The aggregation curve and aggregation rate are obtained by the platelet aggregation test instrument.
References:
Weng Z, Li D, Zhang L, et al. PTEN regulates collagen-induced platelet activation. Blood. 2010; 116(14): 2579-2581.
Liu J, Jackson C W, Gruppo R A, Jennings L K, Gartner T K. The beta3 suunit of the integrin alphallbbeta3 regulates alphaIIb-mediated outside-in signaling. Blood. 2005; 105(11):4345-4352.
(3) Experimental results (see FIG. 1 ):
It can be seen from the above experimental results that: atractylenolide II has an effect of inhibiting platelet aggregation and the high concentration of atractylenolide II has a more significant effect.
EXAMPLE 2
Effect of Atractylenolide III on Platelet Aggregation Inhibition in Platelet Aggregation Test
I. Materials and Preparation
Atractylenolide III, dissolved in DMSO.
II. Experimental Procedure
Platelet Aggregation Test
(1) Preparation of platelets: human blood plasma with high concentration of platelets is used to prepare platelets counting 3×10 8 /mL, which are placed in a water bath of 37° C.
(2) Concentration gradient of compound atractylenolide III; final concentrations of the compound in 300 uL platelets are respectively 0.1 μM, 0.5 μM, 1 μM, 5 μM, 10 μM.
The compound is incubated in platelets for 3 mins before the experiment, and resting and DMSO are included in the experiment as control groups. Thrombin is used as stimulant. The aggregation curve and aggregation rate are obtained by the platelet aggregation test instrument.
(3) Experimental results (see FIG. 2 ):
It can be seen from the above experimental results that: atractylenolide III has an effect of inhibiting platelet aggregation and the high concentration of atractylenolide III has a more significant effect.
EXAMPLE 3
Influence of Atractylenolide II in Platelet Spreading Test
Platelet Spreading Test
(1) Preparation of platelets: use the same method as abovementioned to prepare platelets counting 3×10 7 /mL.
(2) Concentration gradient of compound atractylenolide II: final concentrations of the compound in 100 uL platelets are respectively 1 μM, 5 μM, 10 μM. The compound is incubated in platelets for 3 mins. The platelets treated by the drug are spread on fibrin (40 μg/mL). After Staining by the fluorescent antibody phalloidin, the spreading of platelets are observed under the 100× oil immersion lens.
References:
Chen X, Zhang Y, Wang Y, et al. PDK1 regulates platelet activation and arterial thrombosis. Blood. 2013; 121(18): 3718-3726.
(3) Experimental results (see FIG. 3 ):
The experimental results show that atractylenolide II has an influence on platelet spreading.
EXAMPLE 4
Influence of Atractylenolide III in Platelet Spreading Test
Platelet Spreading Test
(1) Preparation of platelets: use the same method as abovementioned to prepare platelets counting 3×10 7 /mL.
(2) Concentration gradient of compound atractylenolide III; final concentrations of the compound in 100 uL platelets are respectively 1 μM, 5 μM, 10 μM. The compound is incubated in platelets for 3 mins. The platelets treated by the drug are spread on fibrin (40 μg/mL). After staining by the fluorescent antibody phalloidin, the spreading of platelets is observed under the 100× oil immersion lens.
(3) Experimental results (see FIG. 4 ):
The experimental results indicate that atractylenolide III has an influence on platelet spreading.
EXAMPLE 5
Western Blotting Test on Phosphorylation Levels of Related Molecules During the Inhibition of Platelet Aggregation by Atractylenolide II
After acquiring the aggregation curve in Example 1, platelet protein samples (2×SDS loading protein lysis buffer) are collected, and tested by Western blotting for phosphorylation levels of related molecules.
Experimental results (see FIG. 5 ) are as follows:
Testing the phosphorylation levels of related molecules in the signal pathway using Western blotting, when the PI3K/Akt signal pathway is activated, the Akt molecule is activated via phosphorylation, which leads to the activation of downstream enzymes, kinases, transcription factors (e.g. GSK3), etc. Subsequently, platelets are activated to aggregate, and the higher the phosphorylation level of the Akt molecule is, the higher degree the platelets aggregate. The experimental results show that: atractylenolide II affects the phosphorylation level of the Akt molecule, and the influence of concentration variation on phosphorylation level of the Akt molecule is consistent with that on the degree of platelet aggregation.
EXAMPLE 6
Western Blotting Test on Phosphorylation Levels of Related Molecules During the Inhibition of Platelet Aggregation by Atractylenolide III
After acquiring the aggregation curve in Example 2, platelet protein samples (2×SDS loading protein lysis buffer) are collected, and tested by Western blotting for phosphorylation levels of related molecules.
Experimental results (see FIG. 6 ) are as follows:
Testing the phosphorylation levels of related molecules in the signal pathway using Western blotting, when the PI3K/Akt signal pathway is activated, the Akt molecule is activated via phosphorylation, which leads to the activation of downstream enzymes, kinases, transcription factors (e.g. GSK3), etc. Subsequently, platelets are activated to aggregate, and the higher phosphorylation level of the Akt molecule is, the higher degree the platelets aggregate. The experimental results show that: atractylenolide III affects the phosphorylation level of the Akt molecule, and the influence of concentration variation on phosphorylation level of the Akt molecule is consistent with that on the degree of platelet aggregation.
EXAMPLE 7
Comparative Experiments Comparing in vitro Platelet Aggregation Inhibition by Atractylenolide II and Acetylsalicylic Acid
(1) Preparation of platelets: use the same method as abovementioned to prepare platelets counting 3×10 8 /mL.
(2) Acetylsalicylic acid is dissolved in anhydrous ethanol, and diluted into a concentration of 50 mmol/L, it is then stimulated with the thrombin stimulant to observe the platelet aggregation.
Experimental results (see FIG. 7 ) are as follows:
In the in vitro experiments with identical conditions, acetylsalicylic acid does not show the inhibitory effect yet at a high concentration of 150 μM under the stimulus of thrombin, but atractylenolide II has the effect of inhibiting platelet aggregation at a low concentration (10 μM) in the in vitro experiment.
EXAMPLE 8
Comparative Experiments Comparing in vitro Platelet Aggregation Inhibition by Atractylenolide III and Acetylsalicylic Acid
(1) Preparation of platelets: use the same method as abovementioned to prepare platelets counting 3×10 8 /mL.
(2) Acetylsalicylic acid is dissolved in anhydrous ethanol, and diluted into a concentration of 50 mmol/L, it is stimulated with the thrombin stimulant to observe the platelet aggregation.
Experimental results (see FIG. 8 ) are as follows:
In the in vitro experiments with identical conditions, acetylsalicylic acid does not show the inhibitory effect yet at a high concentration of 150 μM under the stimulus of thrombin, but atractylenolide III has the effect of inhibiting platelet aggregation at a low concentration (10 μM) in the in vitro experiment.
The aforementioned examples merely illustrate embodiments of the present invention, the description is comparatively concrete and detailed, but it cannot be consequently understood as a limit of the scope of the present invention. It should be pointed out that for persons skilled in the art, many changes and improvements can be made without departing from the conception of the present invention, all of which fall into the protection scope of the present invention. Therefore, for the protection scope of the present invention, the attached claims should prevail.
|
A medicament for inhibiting platelet aggregation, comprising atractylenolide compound or its derivatives, wherein the said atractylenolide compound has the following structural formula shown in formula (I), wherein R1 represents H or C1-C10 linear or branched alkyl, R2 represents H or C1-C10 linear or branched alkyl, and R3 represents H or hydroxyl. Use of atractylenolide compound shown in formula (I) or its derivatives in the manufacture of a medicament for inhibiting platelet aggregation. The medicament for inhibiting platelet aggregation of the present application has good efficacy without toxic-and-side effect, lower tendency of tolerance, convenient to take and applicable for preventing or treating diseases caused by high platelet aggregation rate.
| 0
|
FIELD OF THE INVENTION
This invention relates to traffic barricades. It relates particularly to molded plastic traffic barricades.
BACKGROUND OF THE INVENTION
Traffic barricades are commonly used to warn vehicle traffic and pedestrians of danger and block off restricted areas. Barricades made of molded plastic have been known for some time. Examples are found in the Stehle et al. U.S. Pat. Nos. 3,880,406 and 3,950,873, and the Glass U.S. Pat. Nos. 4,298,186 and 4,624,210. Barricades illustrated in these patents include two panel units hinged together so that they can be spread apart for use and collapsed for storage or transport. The individual panel units are one piece, integral, hollow plastic panels, formed by rotational or blow molding. The lower hollow sections may contain ballast.
These plastic traffic barricades were a great improvement over conventional steel and wood barricades. They are rugged, yet cause less damage to vehicles if inadvertently struck. Through the use of ballast in the units the center of gravity of the barricade is lower than either wood or metal barricades. The result is a barricade less susceptible to being blown over by wind. Other features typically incorporated in such barricades are bright colored reflective horizontal panels, flashing lights or signs, and a structural member near the bottom where a sand bag can be placed if additional ballast is required.
As previously pointed out, the barricades are collapsed for storage or transport. When transported they are normally handled in collapsed form. However, it is frequently necessary to move them about, on the job, so to speak, while in spread apart form. In either mode, the plastic barricade industry has long needed a simple and inexpensive carrying grip, handle, or device for them.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improvement in a plastic traffic barricade which permits it to easily be moved about, whether it is in an open position for use or folded flat for storage.
Another object is to provide an improvement embodied in a carrying handle for easy handling of the barricade.
In its preferred embodiment a plastic traffic barricade includes two hollow plastic panel units comprised of three horizontal panel members and two side leg members. The upper end of each leg member has a hinge element or elements formed unitarily therewith. In accord with the present invention, a hinge pin extends through each mated set of hinge elements. Between each mated pair of hinge elements, spaced above the uppermost panel members, a hollow plastic tube encircles the pin or pins. The tube length is such that it abuts, or comes into immediately adjacent relationship with, opposing hinge elements.
In one embodiment of the invention a single pin extends through and between the hinge elements atop each leg member. The pin takes the form of a long bolt, having a head at one end and a short threaded section at the other end. A nut threaded onto the threaded section holds the pin in place and, accordingly, the panel units in hinged relationship. The plastic tube encircling the pin has an internal diameter slightly larger than the external diameter of the pin whereby the tube rotates freely but does not rattle.
In another embodiment, employed principally where the barricade is relatively narrow and the leg members closer together, two completely threaded pins are used, one connecting the hinge elements of each opposed pair of leg members. In this form of the invention the inner, free ends of the pins are threaded into opposite ends of the plastic tube so that it is firmly seated on respective pins, i.e., the thread diameter of the pins is equal to or slightly greater than the internal diameter of the tube so that it threads onto each pin.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the present invention will be best understood by reference to the following drawings, in which:
FIG. 1 is a perspective view of one embodiment of the improved barricade;
FIG. 2 is an enlarged sectional view taken on line 2--2 of FIG. 1;
FIG. 3 is an enlarged sectional view taken on line 3--3 of FIG. 1; and
FIG. 4 is an enlarged sectional view similar to FIG. 2 showing another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 illustrates a plastic traffic barricade 10 incorporating features of one embodiment of the present invention. The barricade 10 is comprised of a pair of identical, integral, hollow plastic panels units 15 and 15'. (throughout the specification, all parts of panel unit 15' are numbered exactly as their counterparts in panel unit 15, with the added prime designation).
Each panel unit 15 and 15' is constructed with three horizontal panel members 21, 21', 22, 22', and 23, 23', two vertical leg members 31, 31' and 32, 32', extended foot portions 71, 71', and 72, 72', and hinge elements 41, 41' and 42, 42'. These components are all parts of the hollow, integral panel units, 15 and 15', molded as unitary structures by conventional blow molding techniques. Panel members 21, 21' and 22, 22' are sometimes referred to as "stripe bars".
The vertical leg members 31, 31' and 32, 32' are approximately thirty nine inches in length and two and one-half inches wide where they are not contiguous with the horizontal panel members or hinge members. The foot members 71, 71' and 72, 72' extend approximately one and one-half inches below the lower horizontal panel members. The foot members allow the barricade to be secured on uneven terrain.
The panel units 15 and 15' are normally filled with approximately five pounds of ballast material. The ballast material naturally fills the lower portions of panel units 15 and 15', including foot members, the lower panel members 23 and 23', and the lower portions of leg members. The ballast material 91, which preferably is comprised of sand, is loaded into the panel units 15 and 15' through ports (not shown) in the top of the panel members 21, 23'. After the ballast is loaded the ports are permanently sealed by friction welding a circuit plug into them with conventional friction welding techniques. As can be seen from FIGS. 1 and 3, the hinge element 41 on panel unit 15 mates with the hinge element 42' of the panel unit 15'. In turn the hinge element 42 of the panel unit 10 mates with the hinge element 41' of the panel unit 10'. Each hinge element 41, 41' actually includes a single hinge projection 63, 63' which is about one and three-quarter inches wide. Each hinge element 42, 42' includes double projections 66, 66' and 62, 62' which are about one and one-half inches wide.
Each of the projections 62, 62', 63, 63' and 66, 66' has a transverse, hinge-bolt hole 43, 43' drilled through it. The hinge-bolt holes 43, 43' are approximately three-eighths of an inch in diameter. A single bolt 45 extends through these bolt holes, as best shown in FIG. 2, to pivotly interconnect the hinge element 42 of panel unit 15 with the hinge element 41' of panel unit 10', and the hinge element 41 of panel unit 15 with the hinge element 42' of panel unit 15'. A nut 46 and lock washer 47 inside it secure the bolt 45 in its hinging relationship.
Encircling the bolt 45 between the hinge projections 66 and 66' is a tube 50 of hard plastic, such as polyethylene. The inside diameter of the tube 50 is seven-sixteenths of an inch. The length of the tube 50 is such that it fits closely but loosely between the projections 66 and 66'. The tube 50 wall thickness is substantial, preferably three-sixteenths of an inch. As such, the tube is relatively rigid along its length, which is fifteen inches, the distance between the hinge elements, which are somewhat wider than the leg members 31, 31' and 32, 32'.
Referring now to FIG. 4, another embodiment of the barricade is illustrated at 110. The barricade 110 is very similar to the barricade 10 previously described except that it is considerably narrower, i.e., its panel units 115 and 115' are narrower. There overall width is thirteen inches. As a result, the distance between opposed hinge element projections 162, 162' is only six and one-half inches.
In the barricade 110 two bolts 145 and 146 are used as hinge pins, as illustrated. These bolts 145 and 146 are externally threaded along their lengths which is about five inches, and have external pitch diameters of seven-sixteenths of an inch.
The plastic tube 150, which encircles the inner end of each bolt 145 and 146 is actually threaded lengthwise onto each bolt. These bolts 145 and 146 are forced through corresponding hinge projection holes to hinge the panel units 115 and 115' together. The lengths of the bolts 145 and 146 are such that the tube 150 is not supported by them along the middle three to five inches of its length. Because the tube wall thickness is substantial, three-sixteenths of an inch in the present illustration, as has been pointed out, the tube 150 readily supports the barricade 110 when used as a handle. In this regard, the bolts 145 and 146 are preferably about five inches long.
While the preferred embodiment of the invention has been disclosed, it is understood that the invention is not limited to the disclosed example. Modifications in addition to those discussed can be made without departing from the invention. The scope of the invention is indicated in the appended claims, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
|
A plastic traffic barricade comprises two integrally molded, generally planar panel units each having two upstanding legs interconnected by a panel member and each having a hinge projection mating with a hinge projection on the other panel unit and a hinge pin extending thru the mated hinge projections and a handle member extending between the mated pair of hinge projections.
| 4
|
BACKGROUND OF THE INVENTION
This invention relates to olefin isomerization. In one of its more specific aspects, this invention relates to selective isomerization of olefins.
More particularly, the present invention relates to a process for the preparation of useful hydrocarbons by catalytic conversion of n-butylenes.
MTBE (methyl tertiary butyl ether) is an effective octane booster. It is made from isobutylene and methanol. The present sources of isobutylene for MTBE production are mainly from by products of steam, catalytic cracker, and propylene oxide production. However, these supplies are limited. Other possible sources are by isomerization of n-butenes taken from steam or catalytic crackers and by dehydrogenation of isobutane taken from field butanes or produced by isomerization of n-butane.
Olefin isomerization processes can be directed towards either skeletal isomerization or double bond isomerization. Skeletal isomerization is concerned with reorientation of the molecular structure in respect to the formation or elimination of side chains. Double bond isomerization is concerned with relocation of the double bond between carbon atoms while maintaining the backbone of the carbon structure. Most isomerization processes give rise only to double bond isomerization.
The minimum Bronsted Acid strengths (and equivalents in H 2 SO 4 ) required for various acid-catalyzed conversions of hydrocarbons are indicated in the table below.
Minimum Bronsted Acid Strength Required For The Acid-Catalyzed Conversions of Hydrocarbons
______________________________________H.sub.R Required Reaction Type______________________________________< +0.8 Cis-trans Isomerization of Olefins1.2 wt % H.sub.2 SO.sub.4< -6.6 Double-bond Migration48 wt % H.sub.2 SO.sub.4< -11.6 Skeletal Isomerization68 wt % H.sub.2 SO.sub.4< -16.0 Cracking of Alkanes88 wt % H.sub.2 SO.sub.4______________________________________
It is frequently necessary to convert olefins into other olefins having a different skeletal arrangement. For example, normal butenes are converted into isobutene for polymerization, alkylation, disproportionation, etc. Similarly, normal amylenes must be converted to isoamylenes prior to dehydrogenation to isoprene.
While a number of catalytic materials possess some activity for such a conversion, not all possess sufficient selectivity to be economical. Because the feeds are generally the relatively reactive olefins, many catalysts cause undesirable side reactions such as polymerization or cracking. Consequently, there is a continuing interest in the development of new skeletal isomerization catalysts and processes for isomerizing alkanes as well as alkenes to improve efficiencies and to give optimum results for various industrial requirements. A comprehensive review is provided by V. R. Choudhary in "Catalytic Isomerization of n-butene to Isobutene," Chem. Ind. Dev, pp. 32-41 (1974).
It is generally known that n-paraffins with, for example, 4 to 7 carbon atoms can be converted to the corresponding isomeric paraffins by using suitable acid catalysts in the temperature range of from 100° to 250° C. Examples of this process are the numerous isomerization processes used in the petrochemical and mineral oil industries for increasing the octane number of light, paraffinic mineral oil fractions. Furthermore, it is known that, in contrast to this, olefins of the same number of carbon atoms cannot be converted to the corresponding isoolefins except under difficult conditions, for example at very high temperatures and with poor yield. The attempts hitherto described in the literature for the direct isomerization of the skeleton of e.g. n-butene to give isobutene or e.g. of n-pentene to give isopentenes over catalysts arranged in a fixed bed are characterized by only initially high yields and selectivities, which diminish and deteriorate considerably after a short period of operation, often after only a few hours. The deterioration in the yields and selectivities is generally attributed to the loss of actively effective catalyst surface or to the loss of active centers. In addition to this, high coking rates, formation of oligomers and cracking reactions are observed.
As is known, butylenes or butenes exist in four isomers: butene-1, cis-butene-2, its stereo-isomer transbutene-2, and isobutene. Conversions between the butenes-2 are known as geometric isomerization, whereas those between butene-1 and the butenes-2 are known variously as position isomerization, double-bond migration, or hydrogen-shift isomerization. These three isomers are not branched and are known collectively as normal or n-butenes. Conversion of the n-butenes to isobutene, which is a branched isomer, is widely known as skeletal isomerization. The same general terminology is used when discussing skeletal isomerization of other n-alkanes and olefins, as well as paraffinic compounds such as n-alkenes.
Isobutene has become more and more important recently as one of the main raw materials used in the production of methyl tert-butyl ether (MTBE), an environmentally-approved octane booster to which more and more refiners are turning as metallic additives are phased out of gasoline production. However, processes for the skeletal isomerization of olefins e.g., to produce isobutene, are relatively non-selective, inefficient, and short-lived because of the unsaturated nature of these compounds. On the other hand, positional and skeletal isomerization of paraffins and alkyl aromatics are fairly well established processes, in general utilizing catalysts typically comprising metallic components and acidic components, under substantial hydrogen pressure. Since paraffins and aromatics are stable compounds, these processes are quite successful. The heavier the compounds, in fact, the less severe the operating requirements. Olefins, however, are relatively unstable compounds. Under hydrogen pressure, they are readily saturated to the paraffinic state.
Furthermore, in the presence of acidity, olefins can polymerize, crack and/or transfer hydrogen. Extensive polymerization would result in poor yields, and short operating cycles. Similarly, cracking would reduce yield. Hydrogen transfer would result in saturated and highly unsaturated compounds, the latter being the common precursors for gum and coke. Any theoretical one step process for producing skeletal isomers of, for example, n-butenes, would have to be concerned with the unwanted production of butanes and the reverse problem of production of butadienes. In addition to these problems, it is well known that skeletal isomerization becomes more difficult as hydrocarbons get lighter.
Skeletal isomerization of olefins is known to be accomplished by contacting unbranched or lightly branched olefins with acidic catalysts at elevated temperatures. The process is generally applicable to the isomerization of olefins having from 4 to about 20 carbon atoms and is especially applicable to olefins having from 4 to about 10 carbon atoms per molecule. The process may be used to form isobutene from normal butenes, methyl pentenes and dimethyl butenes from normal hexenes, and so forth.
Thus, among the objects of this invention are improved processes for the skeletal isomerization of n-butylene and olefins, especially for the isomerization of n-butylene to form isobutylene.
A more specific object is an easily prepared, stable, active multifunctional isomerization catalyst and processes for the skeletal isomerization of hydrocarbon species including olefins.
Other objects and advantages of the invention will be apparent from the following description, including the drawing and the appended claims.
DISCLOSURE STATEMENT
Known skeletal isomerization catalysts include aluminas and halogenated aluminas, particularly F- or Cl-promoted aluminas. Supports employed in such catalysts are either alumina or predominantly alumina due mainly to the high acidity of alumina. See Choudhary, V. R., "Fluorine Promoted Catalysts: Activity and Surface Properties", Ind. Eng. Chem., Prod. Res. Dev., 16(1), pp. 12-22 (1977) and U.S. Pat. No. 4,400,574. Numerous catalysts employ a metal or metal oxide in conjunction with a halide-treated metal oxide. For example, U.S. Pat. No. 4,410,753 discloses isomerization catalysts comprising Bi 2 O 3 on fluorided alumina and U.S. Pat. No. 4,433,191 discloses skeletal isomerization catalysts comprising a Group VIII metal on halided alumina. Many of the catalysts including halide-treated components require periodic addition of halide materials to maintain catalyst activity; for example, see U.S. Pat. Nos. 3,558,734 and 3,730,958. An average yield for isobutene of 25 weight percent (within an observed range of 17 to 33 percent) is typically reported when using halided catalysts, based upon a review of various patents cited in this disclosure.
Amoco has patents disclosing that n-butane can be converted to isobutylene in one step, i.e. by dehydrogenation n-butenes to isobutylene. For example, see U.S. Pat. Nos. 4,435,311 and 4,433,190 and other co-assigned patents referred to therein. The catalysts employed contain an AMS-1B borosilicate (also called [B]-ZSM-5 or Boralite C) and a noble metal such as platinum. This process is economically quite attractive because two catalytic reactions, dehydrogenation and isomerization, are carried out in one step by a bifunctional catalyst. Such reactions could potentially solve the surplus n-butane problem and produce high-octane MTBE.
Various techniques have been employed to improve the effectiveness of materials such as alumina and silica as structural isomerization catalysts. For example, U.S. Pat. No. 3,558,733 discloses methods for activating alumina catalysts with steam, U.S. Pat. No. 4,405,500 discloses catalysts prepared by controlled deposition of silica on alumina and U.S. Pat. No. 4,587,375 discloses a steam-activated silicalite catalyst. In addition, various metal oxides have been used to improve the effectiveness of catalysts based upon alumina, silica or the like.
Zeolitic materials, especially in their hydrogen forms, are known to behave as strong acids. Due to their narrow yet regular pore size they are quite effective in catalyzing olefin polymerization. Unfortunately the pores are soon plugged due to deposition of polymeric materials and frequent catalyst regeneration is necessary to maintain activity.
Natural and synthetic zeolites have been widely used as catalysts, catalyst supports and the like for processes of hydrocarbon conversion. Additional components such as metals, in the elemental, oxide or cation form are often included in such catalysts. For example, U.S. Pat. No. 3,849,340 discloses a "catalytic composite" comprising a mordenite having a silica/alumina ratio of at least 40:1 and a metal component selected from copper, silver and zirconium. U.S. Pat. No. 4,608,355 also discloses hydrocarbon conversion catalysts formed by compositing a clay matrixing material with a zeolite containing cations of Group IB metals such as silver. The presence of such cations is said to give the zeolite improved resistance to high sintering temperatures encountered in catalyst fabrication. The metal loaded zeolites can be mixed with a porous matrix and calcined prior to use. These catalysts are stated to be useful in processes such as catalytic cracking, the conversion of oxygenates to hydrocarbons, and the like.
U.S. Pat. No. 4,433,190, assigned to Standard Oil Co. (Indiana), discloses processes for the conversion of alkanes such as n-butane to dehydrogenated and isomerized products by contact with catalysts containing AMS-1B crystalline borosilicates containing ions or molecules of catalytically active elements such as noble metals. These borosilicates have topological structures similar to those of ZSM-5 zeolites. The products can include isobutylene, n-butene and isobutane.
U.S. Pat. No. 4,503,292, also assigned to Standard Oil Co. (Indiana), discloses processes for converting n-alkenes to isoalkenes using catalysts containing AMS-1B borosilicate as at least 50 weight percent of the catalyst composition. The borosilicate can be cation-exchanged with hydrogen or metals selected from Groups IB, IIA, IIB, IIIA, VIB and VIII as well as manganese, vanadium, chromium, uranium and rare earth elements. The borosilicate can also be impregnated with metals of Groups IB, IIA, IIB, IIIA, IVB, VB, VIB, VIIB and VIII and rare earth elements.
U.S. Pat. No. 4,435,311, also assigned to Standard Oil Co. (Indiana) discloses a process for regenerating catalysts containing AMS-1B borosilicates and noble metals by contacting them with water. The process can be carried out during the process of conversion of feedstocks such as alkanes and alkenes to isomerized products such as isoolefins. Similar conversion processes employing catalysts containing such borosilicates are disclosed in U.S. Pat. Nos. 4,777,310; 4,503,282; 4,499,325 and 4,499,326, all assigned to Standard Oil or Amoco Corp.
U.S. Pat. No. 4,656,016 discloses silicalites and similar silica-based molecular sieves which contain boron or other amphoteric elements in quantities sufficient to adjust the acidity of the sieves, plus catalytic metals such as copper, nickel, cobalt, tungsten, platinum and palladium. The reactions which can be catalyzed by such materials are listed in column 4, including hydrogenation/dehydrogenation of hydrocarbons and conversion of olefins into "high-octane fuel products." Columns 9 and 10 contain descriptions of silicalites containing boron in the framework structure, referred to as "Boralites A, B, C and D." These species are identified as having structures resembling those of zeolites NU-1, Beta, ZSM-5 and ZSM-11, respectively, by Taramasso et al in "Molecular Sieve Borosilicates", in Proceedings, 5th Intl. Conference on Zeolites, pp. 40-48, Naples, 1980 (L. V. Rees, ed.) - (Heyden, London, 1980).
U.S. patent application Ser. No. D# 79,413 discloses that normal olefins such as n-butenes and normal alkanes such as n-butane can be converted to branched olefin species such as isobutylene by skeletal isomerization over catalysts preferably containing metals selected from Groups IB, IIB, IIIB, IVB, VB, VIB, VIIB, VIII and the rare earth elements which are deposited upon borosilicate zeolites having pore sizes of at least about 5 Angstroms and containing boron in the framework structure thereof. The borosilicates have sufficient acidity to catalyze the skeletal isomerization of both normal alkanes and normal olefins. The borosilicate zeolites may be synthesized using ammonium or tetra-alkyl ammonium ions as organic templates.
U.S. patent application Ser. No. (D#79,415) discloses that normal olefins such as n-butenes can be converted to iso-olefins such as isobutylene by skeletal isomerization over catalysts of boron-beta zeolites having pore sizes of at least about 5 Angstroms and containing boron in the framework structure thereof. The boron-beta zeolites have sufficient acidity to catalyze the skeletal isomerization of normal olefins.
SUMMARY OF THE INVENTION
In accordance with the present invention, a multifunctional catalyst composition for the skeletal isomerization of normal olefins comprises at least one borosilicate zeolite. A binder of an inorganic oxide such as alumina, silica, silica-alumina, clays and combinations thereof can optionally be employed with the borosilicate zeolite.
The borosilicate zeolites are prepared by a process comprising the steps of:
(a) preparing a basic reaction mixture of at least about Ph 9 comprising in suitable proportions a silicon source, a boron source and an organic template;
(b) heating the reaction mixture in a closed vessel under conditions of temperature, autogenous pressure and time effective to produce a crystalline product containing boron oxides in the framework structure thereof;
(c) recovering the crystalline product; and
(d) calcining the crystalline product under conditions effective to remove the organic template without substantial damage to the framework structure of the crystalline product, whereby the n-olefins are converted to olefins.
To achieve the calcining effect which removes the organic template without damaging the crystal structure, the product is preferably subjected to at least one period of calcining in an inert atmosphere such as nitrogen, followed by at least one period of calcining in an atmosphere containing oxygen. The zeolites can be converted to the hydrogen form by cation-exchanging with ammonium ion to remove sodium, then calcining to remove ammonia. The exchange step can be eliminated if certain organic templates containing tetraalkyl ammonium ions are used, as calcining drives off ammonia and organic residues, with hydrogen ions remaining.
Such boron-substituted zeolites, optionally, in combination with dehydrogenation metals as described below, can be employed in catalysts having activity for the structural isomerization or dehydroisomerization of normal alkanes such as butane, the dehydrogenation of isoalkanes such as isobutane and the structural isomerization of normal alkenes such as n-butenes. Such catalysts can be used to treat mixed feedstreams containing such species to products rich in isoolefins such as isobutene. Byproducts including such species can be recycled to the reactor for additional passes so as to maximize the conversion to the desired product(s). The isoolefins are desired reactants in the production of alkyl tertiary-alkyl ethers such as methyl tertiary-butyl ether, and processes for the production of such ethers can be integrated with the hydrocarbon conversion processes of the present invention.
Further in accordance with the invention, processes chain olefins by skeletal isomerization comprise steps of contacting the olefins and/or alkanes (which can be at least about 20 weight percent of a mixed feedstock) under skeletal isomerization conditions with a multifunctional catalyst of the invention. The catalyst can include a boron-substituted zeolite containing sufficient boron to provide sufficient acidity in the zeolite to catalyze the skeletal isomerization of normal alkenes, preferably without substantial cracking. Optionally, the catalyst includes at least one dehydrogenation metal selected from the group consisting of Groups IB, IIB, IIIB, IVB, VB, VIB, VIIB and VIII of the Periodic Table, plus rare earth metals. Preferably the metal is a noble metal selected from platinum, palladium, iridium, rhodium and ruthenium. Preferred embodiments include combinations of metals which are more effective in catalysts to be used at relatively high temperatures, for example noble metals in combination with rhenium. The boron-substituted zeolite should have a pore size of at least about 5 Angstroms, and preferably is characterized by a topological structure selected from the group consisting of ZSM-5, ZSM-11, NU-1, Beta, Omega (MAZ), FAU and mordenite (MOR) zeolites.
Operable conditions include temperatures in the range of about 300° to 650° C., preferably 450° to 550° C.; pressures ranging from about 0.5 to about 40 psi and weight hourly space velocities (WHSV) ranging from about 0.1 to about 20 weight of olefin/weight of catalyst per hour. The normal olefins and/or alkanes can have from 4 to about 12 carbon atoms, preferably about 4 to 6, and preferably include n-butene and/or n-butane.
In a preferred embodiment, the normal olefins are contained in a feedstock which also contains branched o olefins, and the product of the skeletal isomerization step is reacted with an alkanol having from 1 to about 5 carbon atoms (such as methanol or ethanol) under catalytic conditions effective to produce at least one methyl tertiary-alkyl ether, such as methyl tertiary-butyl ether, or ethyl tertiary-butyl ether.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an X-ray diffraction spectrum of uncalcined and calcined boron-beta zeolite.
FIGS. 2A and 2B are scanning electron micrographs illustrating calcined baron-beta zeolites.
FIG. 3 is a graph of the Conversion or Selectivity (C %) vs. time on stream (hrs) of normal-alkene on boron-beta zeolite.
FIG. 4 is a graph of the Conversion or Selectivity (C %) vs. Time on Stream (hours) of C4 Raffinate on boron-beta zeolite.
DETAILED DESCRIPTION OF THE INVENTION
As discussed above, the skeletal isomerization catalysts of the present invention employ medium to large pore zeolites containing boron in the framework structures. For the purposes of this application, a medium pore zeolite is one with a channel of at least about size greater than 5 Å, while the large pore channels are greater than 5.6 Å; the zeolite is preferably one with channels of 7.0 to 7.4 Å. Typical materials of this structural type would include: mordenite, faujasite, X, Y, and L zeolites, mazzite, ZSM-4, ZSM-5, ZSM-11, zeolite omega, zeolite beta, ZSM-20, NU-1 and gmelinite.
The medium to large pore boron zeolites useful in the present invention are preferably selected from the groups of topologically-related zeolite structures listed below in Table I and published in the Atlas of Zeolite Structure Types by Meier and Olson, published on behalf of the Structure Commission of the International Zeolite Association by Butterworths & Co. Ltd. (London, 1988), following rules set up by a Commission of Zeolite Nomenclature of the International Union of Pure and Applied Chemistry.
TABLE I______________________________________FAU MOR MAZ *______________________________________Faujasite Mordenite Mazzite NU-1X (Linde) Ptilolite Omega BetaY (Linde) ZeolonN-YZSM-20______________________________________ * No code assigned to this group.
Zeolite ZSM-20 is described in U.S. Pat. Nos. 3,972,983 and 4,021,331 and zeolite beta in U.S. Pat. No. 3,303,069 and Re. 28,341; zeolite L is disclosed in U.S. Pat. No. 3,216,789, zeolite omega is disclosed in U.S. Pat. No. 4,241,036, ZSM-4 is disclosed in U.S. Pat. No. 3,578,723, zeolite X is disclosed in U.S. Pat. No. 2,882,244 and zeolite Y is disclosed in U.S. Pat. No. 3,130,007; reference is made to these patents for details of these zeolites, their preparation and properties. Many suitable forms of these zeolites can be employed, including variations in silica/alumina ratio, silicon/boron ratio, cell size and the like.
Synthesis of Boron Substituted Zeolites
NU-1, Beta, ZSM-5, and ZSM-11 zeolites can be prepared by the same family of organic templates, tetraalkylammonium ions. The formation of each phase depends on the type of template used, on the reaction conditions, and on the gel composition. Table II below shows the types of zeolites and boron-zeolites which can be produced with tetraalkylammonium templates. ZSM-5 can be synthesized in the presence of TPA and TEA ions, while ZSM-11 can be synthesized in the presence of TBA ion. Both of these pentasil structures have frameworks containing two intersecting channel systems with 10-ring openings. For ZSM-11 the two channel systems are straight, but for ZSM-5 one channel is straight and the other one is zigzag or sinusoidal. See, e.g. Coudurier et al, J. Catalysis, Vol. 108, p. 1 (1987). [B]-ZSM-11 zeolites are presently preferred since they have outperformed [B]-ZSM-5, possibly at least in part because of the more open pore structure.
NU-1 and Beta zeolites can be synthesized in the presence of TMA and TEA ions, respectively. The structure of Beta has been solved recently. It has a three dimensional interconnected tunnel system with 12-ring openings. The structure of NU-1 is not clear, but it seems to have a dual pore system with 10-rings and 8-rings based upon adsorption results reported by Dewing et al. in Catal. Rev. Sci. Eng., Vol. 27, pp. 461 (1985).
TABLE II______________________________________Synthesis of Zeolites in the Presence ofTetraalkylammonium Ions.Template (Al, Si) zeolite (B, Si) zeolite______________________________________TMA NU-1 Boralite A/[B]-NU-1TEA Beta and ZSM-5 Boralite B/[B]-Beta and Boralite C/[B]-ZSM-5TPA ZSM-5 Boralite C/[B]-ZSM-5TBA ZSM-11 Boralite D/[B]-ZSM-11______________________________________ TMA = tetramethylammonium ion, TEA = Tetraethylammonium ion, TPA = tetrapropylammonium ion, and TBA = Tetrabutylammonium ion.
Also preferred are zeolites with three dimensional pore structures such as the various forms of zeolite Y, since greater access to the reactants is offered. Zeolites characterized by the structure of zeolite Y are also preferred because they have been employed effectively in the examples herein.
When the zeolites are prepared in the presence of organic cations they are initially catalytically inactive, possibly because the intracrystalline free space is occupied by organic cations from the forming solution. They may be activated by heating in an inert atmosphere at 540° C. for one hour, for example, followed by base exchange with ammonium salts followed by calcination at 540° C. in air. The presence of organic cations in the forming solution may not be absolutely essential to the formation of the zeolite but these cations to favor the formation of the desired crystal structures.
In commercial practice, the zeolite crystallites would be bound together within a matrix comprising alumina, silica-alumina, clay or admixtures thereof. Normally, the finished catalyst would contain at least 10 up to about 85 weight percent of such a binder or matrix. The alumina which is used for the matrix material for the catalyst system of the present invention can be any suitable grade of crystalline or amorphous alumina which is substantially inert. Since the boron zeolites employed have moderate acidity, acidic aluminas should be avoided. The alumina matrix should have a specific surface area of at least about 50 m 2 /g, preferably in the range of from about 50 to about 500 m 2 /g, and most preferably from about 100 to about 350 m 2 /g.
Silica-alumina materials which can be used as binders can be prepared in the same manner as amorphous silica-alumina catalysts, e.g., by adding the zeolite component to a silica-alumina slurry, spray drying, washing the product and drying. Optionally, a clay diluent can be present in the silica-alumina slurry. Such matrixes can be prepared by admixing colloidal alumina (boehmite) and colloidal silica, allowing the matrix properties to vary over a wide range from catalytically inert to active. The activity, thermal stability, surface area and pore distribution of the matrix can be controlled by varying the amounts and particle size distributions of the respective colloids. Further guidance for the preparation of zeolite catalysts containing high porosity matrixes such as silica-alumina can be found in the section by Magee and Blazek on "Zeolite Cracking Catalysts" in ACS Monograph 171, Zeolite Chemistry and Catalysts (J. Rabo, Ed.; Am. Chem. Soc., Wash, D.C. 1976).
The zeolite can also be composited with a porous clay matrix material which has suitable binding properties and is resistant to the temperature and other conditions employed in the process. The composite is then calcined to confer the required physical strength. Naturally occurring clays can be composite with the zeolite and these clays can be used in the raw state as originally mined or initially subjected to calcination, acid treatment, chemical modification or purification.
Examples of suitable clays which can be used include the bentonite and kaolin families. Bentonites are mixtures of clays, mainly montmorillonites, which may also contain kaolinite clays. The Wyoming bentonites and montmorillonites are preferred because of their relatively high purity. Kaolin clays include, for example, the Dixie, McNamee-Georgia and Florida clays and others in which the main mineral constituent is halloysite, kaolinite, dickite, nacrite or anauxite. Other clays may also be found to be suitable for use in the present process.
The amount of clay or other matrix material relative to zeolite in the composite will determine, to a certain extent, the physical strength of the final catalyst, especially its attrition resistance and crushing strength. The mechanical properties of the catalyst can therefore be modified by appropriate choice of clay/zeolite ratio, with greater amounts of clay generally conferring better mechanical properties. On the other hand, larger amounts of clay mean that less of the zeolite with its desired, attendant properties will be available to participate in the eventual reaction. A balance will therefore be struck, in most cases, between activity and mechanical properties. Normally, the amount of zeolite will not exceed 50 percent by weight of the composite and in most cases it will not exceed 40 percent by weight and may be lower, e.g. 25 percent by weight or even 15 percent by weight.
The zeolite may conveniently be composited with the clay or other matrix materials by forming an aqueous slurry of the zeolite or zeolites containing the Group IB, VIII or other metal with the clay, spray drying the slurry to form microspheres and then calcining. The zeolite may be in the form of a gel. If the catalyst is to include more than one zeolite, the zeolite may form a cogel with themselves. If one of the zeolites in the zeolite combination is capable of being produced by treatment of a clay, the zeolite may be composited with the clay slurry and the slurry spray dried to form solid zeolite/clay microspheres which are then calcined to confer the desired strength. The clay in the composite may then be converted to the zeolite in the conventional way, e.g. by treatment with sodium hydroxide and heating, followed by ion-exchange, if desired. The mixing and homogenizing steps which may be used in the preparation of the zeolite-matrix mixtures are conventional and need not be described; the spray drying may also be carried out in the conventional manner.
Spent catalysts can be regenerated by heating in a similar oxygen-containing gas, such as air, at temperatures ranging from about 200° C. to about 700° C. This process is significantly simpler than that required for halided metal oxide catalysts, in which a separate step of replacing the halide component must be employed.
The skeletal isomerization processes of this invention are carried out by contacting the feed with the catalyst, using any suitable contacting techniques, at temperatures at which skeletal isomerization of the feed of olefins occurs. The feed is preferably maintained in the vapor phase during contacting. The reactor temperature is preferably in the range of about 300° to about 650° C., more preferably about 450° to about 550° C. The weight hourly space velocity (WHSV) is not narrowly critical but will generally be within the range of about 0.1 to about 20 hr -1 , preferably from about 1 to about 10 hr -1 . Any convenient pressure can be used, with the lowest practical pressure preferred in order to minimize side reactions such as polymerization. Preferred pressures are within the range of about 0.2 to about 500 psi, more preferably about 1 to about 30 psi.
The isomerization feedstock contains at least one alkene. Alkenes having 7 or more carbon atoms are generally more likely to crack into light gases than to undergo skeletal isomerization. The alkenes may have terminal or internal double bonds. Butene feedstocks may contain 1-butene, 2-butene or mixtures thereof. Examples of other normal alkenes which are useful feedstocks are 1- and 2-pentenes; 1-, 2- and 3-hexenes; 1-, 2-, and 3-heptenes; and 1-, 2-, 3-, and 4-octenes.
Particular feedstocks contemplated for use in the present process are fractions containing butenes, e.g., n-butenes. Isobutene present in such fractions is commonly converted by catalytic reaction with methanol to produce methyl tertiary-butyl ether ("MTBE"). MTBE is separated by distillation, leaving a residual C 4 cut. Isobutene present in such fractions may also be oligomerized to produce oligomers which are then separated, again leaving a residual C 4 cut. In either MTBE production or oligomerization, a mixture of n-butenes and isobutene remains in the residual material. It is desirable to produce additional isobutene from the residual material and return the isobutene for further conversion by the reactions mentioned above.
The isomerization feed stream can contain inert gaseous diluents (e.g. paraffins, N 2 , steam, etc.). The diluent may be present in any desired proportion, e.g., up to about 80 weight percent of the feed stream. Hydrogen can be present in the feed stream in addition to such diluents, and with or without steam can have beneficial effects on the product yield and selectivity as illustrated in Examples 76 to 78.
Selection of isomerization conditions is dependent on the olefins to be isomerized. In general, lower temperatures are used for feeds containing larger olefin molecules. Depending on the specific skeletal isomerization catalysts chosen to carry out the steps of the invention, any suitable reaction technique can be utilized, such as fixed bed reaction, fluidized bed reaction, liquid phase batch and continuous operations, and the like. Conventional methods can be used to separate the materials present in the reaction effluent, including fractionation, crystallization, adsorption, and the like. Fractionation is generally preferred. Saturated materials which accumulate in the system can easily be removed by suitable techniques well known in the art.
In one aspect of the process according to the invention, the conversion of n-alkenes into isoalkenes, preferably n-butenes into isobutene, almost up to the establishment of thermodynamic equilibrium is achieved. This equilibrium, between 400° to 500° C., is about 36 to 40 percent by weight in the case in which the pure system of the n-butenes and isobutene is considered. This equilibrium is frequently not achieved in the case of a single contact of the mixture to be employed according to the invention with the catalyst to be employed during the invention. However, in a particular variant of the process, the product stream leaving the catalyst bed can be divided up, and only one part is directly conveyed to the working-up process, while the other part is again conducted over the catalyst bed. This division of the product stream for recycling can vary within wide limits, for example between the proportions 1:9 to 9:1 of worked-up or recycled material. In this process, a high recycling rate implies a smaller throughput, relative to a constant catalyst charge and constant remaining reaction conditions, but brings a desired shift of the spectrum of components in favor of the isoalkene, e.g. of the isobutene, almost to the thermodynamic equilibrium. On the other hand, a lower recycling rate implies a higher throughput but a poorer approach to the thermodynamic equilibrium. A decision concerning the amount of the recycling rate depends, other process parameters being constant, above all on the composition of the starting hydrocarbon mixture which is available. However, with the catalysts according to the invention, the process can, in general, be operated without a high recycling rate. This can be optimized by simple preliminary experiments.
EXAMPLES
The invention is further illustrated by reference to the following non-limiting examples.
EXAMPLE I
Synthesis of [B]-ZSM-11 Zeolites
A 25 gram quantity of Ludox AS40 (DuPont, 40% SiO 2 ) was added slowly with vigorously stirring to a mixture of solution which contained 2.07 g of H 3 BO 3 , 52.89 g of 55% tetra-n-butylammonium hydroxide (TBAOH) solution, and 189 ml of water. The addition of Ludox gave a curdy, gelatinous, milky slurry. The molar composition of the gel was:
3.36((TBA) 2 O),1.0(B 2 O 3 ),10(SiO 2 ),680(H 2 O) The solution had a Ph of 13.0. The mixture was transferred to a Teflon liner and sealed in a steel autoclave. The autoclave was kept in an oven at 165° C. for 7 days. After that it was cooled and its contents were filtered. The recovered white crystalline material was washed with copious amounts of water and was dried at 110° C. for 16 h. The dried sample was calcined at 592° C. under nitrogen for 4 hours and then under air for another 2 hours to remove the organic template. The yield was 7.12 g and the sample contained 44.2% Si and 0.24% B. Thus, the approximate weight ratio of silicon to boron (Si/B) was 71.
EXAMPLE II
Synthesis og Boron-Beta Zeolite
50 g of Ludox AS40 (DuPont, 40% SiO 2 ) was added slowly with vigorously stirring to a mixture of solution which contained 0.97 g of H 2 HO 2 , 25.22 g of 40% tetra-n-ethylammonium hydroxide (TEAOH) solution, and 244 ml of water. The addition of Ludox gave a curdy, gelatinous, molky solution. The molar composition of the gel was:
15.0 (TEA) 2 O, 1.0 (E 2 O 3 ), 30 (SiO 2 ), 1800 (H 2 O).
The solution had a pH of 13.0. The mixture was transferred to a teflon liner and sealed in a steel autoclave. The autoclave was kept in an oven at 165° C. for seven (7) days. After that, it was cooled and its contents were filtered. The recovered white crystalline material was washed with copious amounts of water and was dried at 110° C. for 16 hours. The dried sample was calcined at 592° C. under nitrogen for 4 hours and then under air for another 2 hours to remove the organic template. Table III, below, and FIG. 1 show the XRD of the uncalcined zeolite. Below, Table IV and FIG. 1 show the XRD of the calcined zeolite. FIGS. 2A and 2B show the SEM of the calcined zeolites.
TABLE III______________________________________XFD Data of Synthesized[B]-Beta d space (A) 100 I/Io______________________________________ 11.34 37 11.19 38 4.08 10 3.90 100 3.47 5 3.26 13 2.98 10 2.89 3 2.64 3 2.04 7______________________________________
TABLE IV______________________________________XRD Data of Calcined[B]-Beta d space (A) 100 I/Io______________________________________ 11.47 100 11.25 68 6.54 10 6.01 12 5.87 5 4.07 9 3.90 55 3.47 6 3.27 9 2.98 5______________________________________
EXAMPLE III
Conversion of 1-Butene to Isobutylene on Boron-Beta Zeolites
In this example, the procedure of Example II is used herein and the results are shown below in Table V.
TABLE V______________________________________Catalyst [B]-Beta, 1.28% BReaction conditions:500 C., 1 atm,4.7 WHSV, 1.64 N2/1-buteneTime on stream, hr 17* Conversion, C % 18(30)Selectivity, C %Isobutylene 65(63)C1 to C3 22(25)C5+ 10(9)* Yield of isobutylene, 11(19)carbon %______________________________________ * Average results shown first, results of 1st cut shown in parentheses.
Table III above, and FIG. 3 show results of the conversion of 1-butene to isobutylene on (B)-Beta zeolite. The run lasted 17 h. Average results are 18% conversion, 65% isobutylene selectivity, and 11% isobutylene yield. Results of the first cut are 30% conversion, 63% isobutylene selectivity, and 19% isobutylene yield.
EXAMPLE IV
Conversion of (C4) Raffinate to Enriched Isobutylene on Boron-Beta Zeolite Catalyst
The same procedure as used in Example II was used in this Example. The results are presented below in Table VI.
TABLE VI______________________________________Catalyst [B]-Beta, 1.28%Reaction conditions:500° C., 1 atm,4.7 WHSV, 1.64 N2/1-buteneFeed Composition:33% i-butane, 15% n-butane, 17% 1-butene,17% t-2-butene, 14% c-2 butene, 4% others.Time on stream, hr 2* n-Butenes Conversion, C % 46(50)Selectivity, C %Isobutylene 55(51)C1 to C3 31(35)C5+ 11(10)Yield of isobutylene, 25(26)carbon %______________________________________ * Average results shown first, results of 1st cut shown in parentheses.
Table VI above shows results of a C4 raffinate feedstock on Boron-Beta Zeolite. The run lasted 2 hrs. The average results were 46% conversion, 55% isobutylene selectivity, and 26% isobutylene yield.
|
Normal olefins such as n-butenes can be converted to iso olefins such as isobutylene by skeletal isomerization over catalysts of boron-beta zeolites having pore sizes of at least about 5 Angstroms and containing boron in the framework structure thereof. The boron-beta zeoliteS have sufficient acidity to catalyze the skeletal isomerization of normal olefinsto iso-olefins. The catalysts can be used to produce iso-olefins for reaction with alcohols in integrated processes to produce alkyl tertiary alkyl ethers such as MTBE.
| 2
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of optimizing system performance in flexible interleaving memory mode.
[0003] 2. Description of the Related Art
[0004] As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option available to users is information handling systems. An information handling system generally processes, compiles, stores, and/or communicates information or data for business, personal, or other purposes thereby allowing users to take advantage of the value of the information. Because technology and information handling needs and requirements vary between different users or applications, information handling systems may also vary regarding what information is handled, how the information is handled, how much information is processed, stored, or communicated, and how quickly and efficiently the information may be processed, stored, or communicated. The variations in information handling systems allow for information handling systems to be general or configured for a specific user or specific use such as financial transaction processing, airline reservations, enterprise data storage, or global communications. In addition, information handling systems may include a variety of hardware and software components that may be configured to process, store, and communicate information and may include one or more computer systems, data storage systems, and networking systems.
[0005] Known information handling systems may include a flexible memory interleaving mode of operation that in one instantiation is referred to as a flex mode. In a flexible memory interleaving mode of operation mode, some of memory of the information handling system can be interleaved and other portions of memory of the information handling system can be non-interleaved. When memory is interleaved, separate memory banks are used for odd and even addresses so that a next byte of memory can be accessed while a current byte is being refreshed. When memory is non-interleaved, sequential portions of the same memory back are used for writing odd and even addresses.
[0006] Using a flexible memory interleaving mode of operation in which some of the memory is interleaved and some of the memory is non-interleaved, can lead to performance issues within the information handling system if the operating system uses the non-interleaved memory more than the interleaved memory.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, a method of using flex mode which optimizes the use of interleaved memory before any non-interleaved memory is used is disclosed.
[0008] More specifically, In one embodiment, the invention relates to a method for optimizing performance of memory in an information handling system which includes determining whether memory within the information handing system is being accessed in a flexible interleaving memory mode of operation, when the memory is being accessed in the flexible interleaving memory mode of operation, identifying which of the memory is configured as interleaved memory and which of the memory is configured as non-interleaved memory, and configuring the memory such that the interleaved memory is accessed prior to the non-interleaved memory being accessed.
[0009] In another embodiment, the invention relates to an apparatus for optimizing performance of memory in an information handling system which includes means for determining whether memory within the information handing system is being accessed in a flexible interleaving memory mode of operation, means for identifying which of the memory is configured as interleaved memory and which of the memory is configured as non-interleaved memory when the memory is being accessed in the flexible interleaving memory mode of operation, and means for configuring the memory such that the interleaved memory is accessed prior to the non-interleaved memory being accessed.
[0010] In another embodiment, the invention relates to an information handling system which includes a processor, memory coupled to the processor and flexible interleaving memory mode optimization system. The flexible interleaving memory mode optimization system determines whether memory within the information handing system is being accessed in a flexible interleaving memory mode of operation, identifies which of the memory is configured as interleaved memory and which of the memory is configured as non-interleaved memory when the memory is being accessed in the flexible interleaving memory mode of operation, and configures the memory such that the interleaved memory is accessed prior to the non-interleaved memory being accessed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention may be better understood, and its numerous objects, features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference number throughout the several figures designates a like or similar element.
[0012] FIG. 1 shows a block diagram of an information handling system.
[0013] FIG. 2 shows a block diagram of memory configured with optimized flex mode addressing.
[0014] FIG. 3 shows a block diagram of another example of memory configured with optimized flex mode addressing.
[0015] FIG. 4 shows a block diagram of another example of memory configured with optimized flex mode addressing.
DETAILED DESCRIPTION
[0016] Referring briefly to FIG. 1 , a system block diagram of an information handling system 100 is shown. The information handling system 100 includes a processor 102 , input/output (I/O) devices 104 , such as a display, a keyboard, a mouse, and associated controllers, memory 106 including volatile storage such as random access memory (RAM) and non-volatile storage such as a hard disk drive, other storage devices 108 , such as a floppy disk and drive and other memory devices, and various other subsystems 110 , all interconnected via one or more buses 112 . The memory 106 also includes associated memory controllers for the volatile and non-volatile storage. The information handling system 100 also includes a basic input output system (BIOS) 128 as well as a flexible interleaving memory mode optimization system 130 stored on the non-volatile storage device 106 and executed by the processor 102 .
[0017] For purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, ROM, and/or other types of nonvolatile memory. Additional components of the information handling system may include one or more disk drives, one or more network ports for communicating with external devices as well as various input and output (I/O) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communications between the various hardware components.
[0018] Referring to FIG. 2 , a block diagram of memory configured with optimized flex mode addressing is shown. More specifically, the memory 106 includes a memory controller 210 as well as a plurality of banks of memory 212 , 214 . The banks of memory are not balanced, i.e., one of the banks 212 includes more memory than the other bank 214 . For example, one of the banks of memory 212 might have two memory modules such as single in-line memory modules (SIMMs) or dual in-line memory modules (DIMMs) installed, while the other bank of memory 214 has only a single memory module installed. Alternately, for example, one of the banks of memory might have a faulty memory module, thus causing the memory module to appear to not be installed. This is an arrangement which typically would preclude the use of interleaved memory. For example, in one embodiment, channel 0 of the memory controller 210 is coupled to a bank of memory having two 1 GB memory modules 220 . Channel 1 of the memory controller is coupled to a bank of memory having one 1GB memory module 222 .
[0019] By using the flexible interleaving memory mode optimization system 130 , the memory controller 210 is configured such portions of the banks of memory 212 , 214 that are balanced may be interleaved, while the remainder of the bank of memory 212 that does not have corresponding memory in the other bank is non-interleaved. More specifically, in the described embodiment, in the system memory map, 0-2 GB are interleaved and 2-3 GB are non-interleaved. To ensure that the operating system gives priority to the interleaved memory, the BIOS sets up an advanced configuration and power interface (ACPI) static resource affinity table (SRAT) to describe memory from 0-2 GB as being “close” to the processor 102 and sets up ACPI SRAT tables to describe memory from 2-3 GB as being far away from the processor 102 . By identifying the interleaved memory as closes memory, the operating system gives priority to this memory when writing to memory, thus improving performance. The BIOS 128 controls which memory is interleaved and which memory is non-interleaved and configures the memory controller 210 accordingly.
[0020] Referring to FIG. 3 , a block diagram of another example of memory configured with optimized flex mode addressing is shown. More specifically, the memory 106 includes a memory controller 210 as well as a plurality of banks of memory 212 , 214 . The banks of memory are not balanced, i.e., one of the banks 212 includes more memory than the other bank 214 . In this example, one of the banks of memory 212 might have a smaller memory module installed (e.g., a 256 MB memory module), while the other bank of memory 214 has a larger memory module installed (e.g., a 512 MB memory module). Alternately, a portion of one of the memory modules might be faulty, thus causing it to appear to be smaller. This is an arrangement which typically would preclude the use of interleaved memory.
[0021] By using the flexible interleaving memory mode optimization system 130 , the memory controller 210 is configured such portions of the banks of memory 212 , 214 that are balanced may be interleaved, while the remainder of the bank of memory 214 that does not have corresponding memory in the other bank is non-interleaved. More specifically, in the described embodiment, in the system memory map, 0-511 MB are interleaved and 512-767MB are non-interleaved. To ensure that the operating system gives priority to the interleaved memory, the BIOS sets up an advanced configuration and power interface (ACPI) static resource affinity table (SRAT) to describe memory from 0-511 as being “close” to the processor 102 and sets up ACPI SRAT tables to describe memory from 512-767 BB as being far away from the processor 102 . By identifying the interleaved memory as closes memory, the operating system gives priority to this memory when writing to memory, thus improving performance. The BIOS 128 controls which memory is interleaved and which memory is non-interleaved and configures the memory controller 210 accordingly.
[0022] The present invention is well adapted to attain the advantages mentioned as well as others inherent therein. While the present invention has been depicted, described, and is defined by reference to particular embodiments of the invention, such references do not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts. The depicted and described embodiments are examples only, and are not exhaustive of the scope of the invention.
[0023] For example, the above-discussed embodiments include software modules that perform certain tasks. The software modules discussed herein may include script,batch, or other executable files. The software modules may be stored on a machine-readable or computer-readable storage medium such as a disk drive. Storage devices used for storing software modules in accordance with an embodiment of the invention may be magnetic floppy disks, hard disks, or optical discs such as CD-ROMs or CD-Rs, for example. A storage device used for storing firmware or hardware modules in accordance with an embodiment of the invention may also include a semiconductor-based memory, which may be permanently, removably or remotely coupled to a microprocessor/memory system. Thus, the modules may be stored within a computer system memory to configure the computer system to perform the functions of the module. Other new and various types of computer-readable storage media may be used to store the modules discussed herein. Additionally, those skilled in the art will recognize that the separation of functionality into modules is for illustrative purposes. Alternative embodiments may merge the functionality of multiple modules into a single module or may impose an alternate decomposition of functionality of modules. For example, a software module for calling sub-modules may be decomposed so that each sub-module performs its function and passes control directly to another sub-module.
[0024] Also, while examples of the optimization are shown with two banks of memory, it will be appreciated that an information handling system having more than two banks of memory may also use the method for optimizing system performance in flexible interleaving memory mode. For example, FIG. 4 shows a block diagram of a plurality of memory controllers coupled to a northbridge type controller. Some of the memory controllers control memory that is interleaved, while other memory controllers control memory that is non-interleaved. The flexible interleaving memory mode optimization system enables the operating system to access the interleaved memory before accessing the non-interleaved memory.
[0025] Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects.
|
A method for optimizing performance of memory in an information handling system which includes determining whether memory within the information handing system is being accessed in a flexible interleaving memory mode of operation, when the memory is being accessed in the flexible interleaving memory mode of operation, identifying which of the memory is configured as interleaved memory and which of the memory is configured as non-interleaved memory, and configuring the memory such that the interleaved memory is accessed prior to the non-interleaved memory being accessed is disclosed.
| 6
|
FIELD OF THE INVENTION
The present invention relates to an apparatus for automatically changing cans of a spinning machine, such as a drawing frame or a carding machine.
PRIOR ART OF THE INVENTION
Conventionally known is an apparatus for automatically changing cans which is disclosed in, for example, Japanese Patent Application Laid-open Specification No. 18928/1977 and in which traverse bars which are reciprocal along the cans transporting direction are moved forward so that full cans and empty cans are forwarded by a distance equal to the distance between two adjacent cans by means of a plurality of can transporting arms which are connected to the traverse bars and which are maintained in a single horizontal plane while they are at their operating positions. As a result, the full cans are discharged from can tables, and the empty cans located next to the discharged full cans are then transported onto the can tables. After the can transporting arms are turned to their vertically located stand-by positions so that they do not interfere with the cans, the can transporting arms are moved backward, and then they are returned to their horizontally located operating positions.
In the above-mentioned conventional apparatus for automatically changing cans, however, all of the can transporting arms are maintained in the same horizontal plane when the traverse bars are moved forward so as to discharge the cans, and accordingly, the full cans filled with fiber bundles, such as slivers, and having a high center of gravity, and the empty cans having a low center of gravity, cannot be abutted with the can transporting arms at their appropriate pushing positions. As a result, sometimes, cans may be inclined from the vertical position and cannot be transported stably.
Even if the size of the cans are the same, the coefficient of friction between the bottom of the empty can and the floor surface over which the empty can is slid may differ when the material, for example, plastic, iron plate or fiber, constituting the bottom of the can is varied. Accordingly, it is necessary to alter the height where the can transporting arm is abutted with the can in accordance with the material of the bottom of the empty can so that the can is always stably transported.
Especially, it should be noted that, when an empty can located at the second position from a head is transported onto the can table, the empty can must pass through a clearance located between the can table and the floor over which the can is slid, and that sometimes a small vertical step is formed between the can table and the floor. In the latter case, the empty can is stably transported only if the corresponding can transporting arm is set at a height lower than that of the remaining can transporting arms.
Furthermore, since spinning speeds have increased recently, the annular clearance formed between the upper edge of the can and the spinning head surface of the spinning machine must be small so that the spun fibers are prevented from being scattered from the can through the annular clearance due to centrifugal force. In this case, if the abutting height of the can transporting arm is inappropriate, the can may be inclined when it is pushed by the can transporting arm, and accordingly, the inclined can becomes stuck between the can table and the spinning head surface.
In addition, when the predetermined amount of a fiber bundle which is to be collected in a can is changed or when a can having a diameter different from a previous one is used, the height of the center of gravity of the can may be varied, and accordingly, the can transporting arm must be abutted with the can at an appropriate height in accordance with said change in the center of gravity.
SUMMARY OF THE INVENTION
An object of the present invention is to eliminate the disadvantages which are inherent in the prior art. More specifically, the object of the present invention is to provide an apparatus for automatically changing cans of a spinning machine in which the can transporting arm for discharging a full can and the can transporting arm for feeding an empty can are constructed in such a manner that their height can be adjusted, whereby the can transporting arms are abutted with the full can and the empty can at their appropriate heights so that the cans are stably transported.
In the present invention, the object is achieved by an apparatus for automatically changing cans of a spinning machine comprising a movable support frame which can be reciprocated along the can transporting direction, and a plurality of can transporting arms which are substantially equidistantly arranged on the support frame and which can alternately be located at operating positions where the arms transport the cans and stand-by positions where the arms do not interfere with the cans, whereby, when the support frame is moved forward, the can transporting arms are maintained at their operating positions so as to transport the cans, and then, after the can transporting arms are returned to their stand-by positions from their operating positions, the support frame is moved backward. The apparatus further comprises an arm height adjusting member by which the individual heights of the can transporting arms in their operating positions where the arms abut with the cans are adjustable while the transporting arms in their stand-by positions are almost at the same level as each other.
BRIEF DESCRIPTION OF THE DRAWINGS
Several embodiments which are constructed in accordance with the present invention will now be explained with reference to the accompanying drawings, wherein:
FIG. 1 is a side view of an embodiment of an apparatus for automatically changing cans according to the present invention;
FIG. 2 is a perspective view of the apparatus for automatically changing the cans of FIG. 1;
FIG. 3 is an enlarged elevational view of a pair of can transporting arms installed in the apparatus of FIG. 1;
FIG. 4 is a side view of a part of a can transporting arm;
FIG. 5 is a cross sectional view taken along line V--V in FIG. 4 which illustrates the locational relationship between a recessed portion formed on the can transporting arm of FIG. 4 for pushing a full can and projections formed on a stop ring;
FIG. 6 is a cross sectional view of a part of another can transporting arm which is similar to FIG. 5 and which illustrates the locational relationship between a recessed portion formed on a can transporting arm for pushing an empty can and projections formed on a stop ring;
FIG. 7 is a plan view of the apparatus in FIG. 1 which illustrates a condition just before the apparatus for changing cans is operated;
FIG. 8 is a plan view of the apparatus in FIG. 1 which illustrates a condition just after the apparatus for changing cans has been operated;
FIG. 9 is a partial elevational view of a part of still another can transporting arm of another embodiment according to the present invention;
FIG. 10 is a side view of FIG. 9;
FIG. 11 is a side view of a part of a can transporting arm of a further embodiment of the present invention;
FIGS. 12 through 15 are side views of still another embodiment which sequentially illustrate the operation of said embodiment according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, can guide plate 1 has can guide rails 2 mounted thereon (only one guide rail 2 is illustrated in FIG. 1). The can guide rails 2 have an L-shape cross section as illustrated in FIG. 3, and pairs of the rails 2 are secured to the top surface of the guide plate 1 so that vertical walls of rails 2 are parallel to each other. Referring to FIG. 1 again, a pair of turn tables 3 (only one of which is illustrated in FIG. 1) is rotatably disposed beneath a spinning head H of a spinning machine so that a can located at a spinning position can be rotated on a plane in which the upper surface of the guide plate 1 is included. The turn tables 3 serve as the can table of the present invention.
Roller guide rails 4 have a C shaped cross section as illustrated in FIG. 3 and are supported on the upper surfaces of support brackets 5 which are made of plate members and which are projected from the guide plate 1 so that the roller guide rails 4 are parallel to each other. As illustrated in FIG. 3, support blocks 6 and 7 are formed in a T shape and rotatable support rollers 8 which are rotatable in vertical planes along inner bottom surfaces 4a of the roller guide rail 4. The support blocks 6 and 7 further support brackets 9 by which four horizontal rollers 9a (see FIG. 2) are rotatably supported so that the rollers 9a rotate along inner side walls 4b of the roller guide rail 4. Referring to FIG. 2, traverse bars 10 and 11 are supported in parallel so that they are relatively immovable in an axial direction but are rotatable about the axes thereof. As illustrated in FIG. 2, connecting members 12 and 13 are secured to front and rear ends of the traverse bars 10 and 11, respectively, in such a manner that the rotation of the traverse bars 10 and 11 is permitted but relative axial movement of the traverse bars 10 and 11 is not permitted.
Referring to FIG. 2, can transporting arms 14, 15, 16, 17 and 18 are rotatably supported on the traverse bars 10 and 11, and the distances between two adjacent can transporting arms 14 through 18 are the same. In FIGS. 4 through 6, the front sides of the base portions of the can transporting arms 14 through 18 have recessed portions 19 which extend in directions vertical to the corresponding can transporting arms 14 through 18. In FIG. 4, a pair of stop rings 20 and 21 are rotatably engaged with the traverse bar 10 or 11 and are secured to the traverse bar 10 or 11 at the sides of the can transporting arm 14, 15, 16, 17 or 18 by means of set bolts 22. The inner surface of the stop ring 20 which faces the recessed portion 19 formed on the can transporting arm 14, 15, 16, 17 or 18 has two projections 23 which are diametrically located as illustrated in FIGS. 5 and 6 and which engage with the recessed portion 19 as illustrated in FIG. 5.
In the above-described embodiment, some of the positions of the stop rings 20 are set by means of the set bolts 22 so that, when the can transporting arm 14 illustrated at the left in FIG. 1 is in a vertically downward position as illustrated by a solid line in FIG. 5, the projections 23 formed on the stop rings 20 become abutted with upper and lower side walls 19a of the recessed portion 19 as illustrated in FIG. 5. As a result, when the traverse bar 10 is rotated clockwise by an angle α, which is usually 90 degrees, the projections 23 press against the side walls 19a of the recessed portion 19, and accordingly, the can transporting arm 14 is swung clockwise (in FIG. 5) by an angle θ which is equal to α, i.e., usually 90 degrees, and is brought to a horizontal position which is illustrated by a two-dot and dash line in FIG. 5.
Furthermore, in the above-described embodiment of the present invention, the remaining stop rings 20 are secured to the traverse bar 10 or 11 so that, when the can transporting arms 15 through 18 illustrated in FIG. 1 are positioned vertically downward, as illustrated by a solid line in FIG. 6, the projections 23 of the stop rings 20 are located at positions which are distant from the side walls 19a of the recessed portion 19 by an angle β+Δβ, which is equal to 30 degrees in this embodiment. An angle β denotes the deviation of the common center of circles illustrated by a solid line and a two-dot and dash line, and an angle Δβ denotes a change of the abutting position due to a rotation of the stop rings 20. As a result of the above-explained construction, when the traverse bar 10 is rotated clockwise by the angle α, which is usually 90 degrees as described above, in FIG. 6, the projections 23 become abutted with the side walls 19a of the recessed portions 19 after they are swung by an angle which is equal to β+Δβ. Accordingly, the can transporting arms 15 through 18 are swung by an angle θ 0 to a position illustrated by a two-dot and dash line in FIG. 6, wherein θ 0 is obtained as follows. ##STR1##
A driving mechanism for horizontally reciprocating the traverse bars 10 and 11 and the can transporting arms 14 through 18 will now be explained with reference to FIG. 2. A movable block 24 is engaged with the center of the traverse bars 10 and 11 in such a manner that the rotation of the traverse bars 10 and 11 about the axes thereof is permitted but the relative axial movement of the traverse bars 10 and 11 is not permitted and that a thrust load acting on the traverse bars 10 and 11 is received by the movable block 24. A pair of sprocket wheels 26 are supported by the support brackets 5 via bearings (not shown), and an endless transmitting member, such as an endless chain 25 or an endless toothed belt, is wrapped around the sprocket wheels 26. A chain link 25a of the endless chain 25 is connected to the lower portion of the movable block 24 is illustrated in FIG. 1. A first reversible motor M 1 for horizontally reciprocating the traverse bars 10 and 11 is disposed on the guide plate 1, and the rotational movement of the first reversible motor M 1 is transmitted to one of the sprocket wheels 26 through a sprocket wheel 27 connected to the shaft of the reversible motor M 1 , another endless transmitting member, such as an endless chain 28, and a sprocket wheel 29 disposed coaxially with one of the sprocket wheels 26. A second reversible motor M 2 for rotating the can transporting arms 14 through 18 is fixed on the lower rear side of the connecting member 12, and the rotational movement of the reversible motor M 2 is transmitted to the traverse bar 11, through a pulley 30 connected to a spindle of the second reversible motor M 2 , a belt 31 wrapped around the pully 30, an intermediate pulley 32, an intermediate gear 33 disposed coaxially with the intermediate pulley 32, and a gear 34 connected to the traverse bar 11 and meshing with the intermediate gear 33. The rotational movement of the intermediate gear 33 is also transmitted to the traverse bar 10 through an idler gear 35 meshing with the intermediate gear 33, and a gear 36 connected to the traverse bar 10 and meshing with the idler gear 35.
In FIG. 3, stoppers 37 are formed on the side walls of the support bracket 5 and serve to restrict the position of the can transporting arms 14 through 18 connected to the parallel traverse bars 10 and 11 when the arms 14 through 18 are located at the vertical stand-by positions.
The operation of the apparatus for automatically changing cans which has been constructed in the foregoing manner will now be explained. In FIGS. 1, 2 and 7, a condition is illustrated wherein the traverse bars 10 and 11 are moved backward, i.e., to the right, and the can transporting arms 14 are rotated by means of the projections 23 (FIG. 4) formed on the stop rings 20 to horizontal positions (see FIG. 2) and the can transporting arms 15 through 18 are maintained at positions inclining from a horizontal plane by the angle θ 0 (FIG. 6) of 60 degrees by means of the projections 23, and in addition, as illustrated in FIG. 7, the full cans C f are arranged on the turn tables 3 (FIG. 1), the upper surfaces of which are aligned with the guide plate 1 and empty cans C e are arranged on the guide plate 1 located at the right of the turn tables 3, so that the cans C f and C e correspond to the can transporting arms 14 through 18. In this condition, when a predetermined amount of fiber bundles, such as slivers, are collected within the cans C f located on the turn tables 3, an auto counter (not shown) which is fixed to the spinning head H (FIG. 1) and which has a conventionally well known construction transmits a full signal. When the full signal is transmitted, a control circuit which is not illustrated but which is well known in the field to which the present invention relates operates so that the first reversible motor M 1 (see FIGS. 1 and 2) is rotated in a normal direction, and accordingly, because of the normal rotation of the first reversible motor M 1 , the chain 25 is rotated in a direction illustrated by an arrow A in FIGS. 1 and 2. Then the movable block 24, the traverse bars 10 and 11, the support blocks 6 and 7, the connecting members 12 and 13, and the can transporting arms 14 through 18, are moved forward as a whole, i.e., to the left in FIGS. 1, 2 and 7, along the roller guide rails 4. As a result, the full cans C f which were located on the turn tables 3 (FIG. 1) are pushed forward, i.e., to the left in FIGS. 1, 2 and 7, by means of the horizontally located can transporting arms 14 and are discharged from the turn tables 3. The empty cans C e located next to the full cans C f are transported onto the turn tables 3 by means of the can transporting arms 15, and the subsequent empty cans C e are also moved forward, i.e., to the left in FIGS. 1, 2 and 7, by a distance equal to the distance between two adjacent cans by means of the can transporting arms 16 through 18.
When the can transporting arms 14 through 18 are moved to the positions illustrated in FIG. 8 and the changing of the cans C f and C e is completed, the first reversible motor M 1 (FIGS. 1 and 2) is stopped so that the forward movement of the traverse bars 10 and 11 and the can transporting arms 14 through 18 is stopped. Just after the first reversible motor M 1 is stopped, the second reversible motor M 2 is started to rotate in a normal direction, and due to the rotational movement of the second reversible motor M 2 , the traverse bar 11 is rotated clockwise in FIG. 3 via the pulley 30 (FIG. 2), the belt 31, the pulley 32, the gears 33 and 34 and the can transporting arms 14 through 18 connected to the traverse bar 11 are also swung as indicated by an arrow B in FIG. 3. The rotational movement of the gear 33 (FIG. 2) is transmitted to the traverse bar 10 via the gears 35 and 36, and accordingly, the traverse bar 10 and the can transporting arms 14 through 18 connected thereto are swung as indicated by an arrow C in FIG. 3. When the traverse bars 10 and 11 are rotated by the angle α, which is usually 90 degree, the projections 23 formed on the stop rings 20 are also rotated by the angle α, and accordingly, the can transporting arms 14 are rotated by the angle θ (90 degrees) from their horizontally located operating positions, one of which is illustrated by the two-dot and dash line in FIG. 5, to the stand-by positions, one of which is illustrated by a solid line in FIG. 5, due to the force of gravity on the can transporting arms 14. When the traverse bars 10 and 11 are rotated by the angle α (90 degrees), the can transporting arms 15 through 18 are rotated by the angle θ 0 (60 degrees) from the inclined operating positions, one of which is illustrated by the two-dot and dash line in FIG. 6, to the vertical stand-by positions, one of which is illustrated by the solid line in FIG. 6 and the movement of the can transporting arms 15 through 18 is restricted by the stoppers 37 (FIG. 3). However, the projections 23 formed on the stop rings 20 illustrated in FIG. 6 are further rotated by the angle β+Δβ, which is equal to 30 degrees, so that the projections 23 are distanced from the side walls 19a of the recessed portions 19 and positioned as illustrated by the solid lines in FIG. 6.
After the can transporting arms 14 through 18 are moved to the vertically downward stand-by positions where they do not interfere with the empty cans C e (FIGS. 1, 7 and 8), the second reversible motor M 2 (FIGS. 1 and 2) is stopped so that the rotational movement of the traverse bars 10 and 11 is stopped. Thereafter, the first reversible motor M 1 is driven again in a reverse direction, so that the traverse bars 10 and 11 and the can transporting arms 14 through 18 are moved backward, i.e., to the right in FIGS. 1, 2 and 8, by a distance equal to the distance between two adjacent empty cans C e , and then the first reversible motor M 1 is stopped.
After the backward movement of the can transporting arms 14 through 18 are completed, the second reversible motor M 2 is rotated in a reverse direction. Accordingly, the can transporting arms 14 through 18 are returned to their original horizontal positions illustrated in FIGS. 1, 2 and 7 in a manner opposite to the foregoing rotational movement to the vertically downward stand-by positions. Thus one cycle for changing cans is completed.
The above-explained embodiment of the present invention is constructed in such a manner that the can transporting arms 14 through 18 are rotatably supported on the traverse bars 10 and 11, that the projections 23 formed on the stop rings 20 are engaged with the recessed portions 19 formed at the base portions of the can transporting arms 14 through 18, and that the distance between the projections 23 and the side walls 19a of the recessed portions 19 can be adjusted at a desired value by securing the stop rings 20 to the traverse bars 10 and 11 by means of set bolts 22. Accordingly, the rotational angles θ and θ 0 of the can transporting arms 14 through 18, which angles are defined as angles formed by the can transporting arms 14 through 18 when they are positioned in the vertically downward stand-by positions and the can transporting arms 14 through 18 located at the operating positions when the traverse bars are rotated by an angle can voluntarily be adjusted. As a result, it is possible to adjust the abutting heights of the can transporting arms 14 and 15 through 18 at any desired operating positions in accordance with whether the cans are full cans C f or empty cans C e , so that both the full cans C f and the empty cans C e can stably be transported.
It is possible to realize the present invention in other embodiments as follows.
A. Either the can transporting arms 14 for pushing the full cans C f or the can transporting arms 15 through 18 for pushing the empty cans C e are fixedly secured to the traverse bars 10 and 11. It is preferable that the can transporting arms 14 are directly secured to the traverse bars 10 and 11 by means of a securing means, such as set bolts 22 threaded to the threaded holes of the arms 14 or keys 52 inserted into key ways 14a and 10a formed on the can transporting arms 14 and the traverse bars 10 as illustrated in FIGS. 9 and 10. (Only one traverse bar 10 and only one can transporting arm 14 are illustrated in FIGS. 9 and 10.) In this embodiment, since the can transporting arms 14 or 15 through 18 which are directly secured to the traverse bars 10 and 11 are swung together with the guide bars 10 and 11, the operational positions of the can transporting arms 14 or 15 through 18 can be adjusted by changing the rotational angle α of the traverse bars 10 and 11.
B. In the previously explained embodiments, the can transporting arms 14 through 18 located at the stand-by positions are in a vertically downward position. Instead, the can transporting arms 14 through 18 may be projected vertically upward when they are located at the stand-by positions.
C. In the embodiment explained with reference to FIGS. 1 through 8, the can transporting arms 14 through 18 are returned from their operational positions to their stand-by positions by means of the force of gravity thereon, however, it is also possible to install a means which positively moves the can transporting arms 14 through 18 to their stand-by positions. An example of the positively moving means is illustrated in FIG. 11 wherein a torsion coil spring 51 is disposed between the stop ring 21 and the side of the can transporting arm 14 which side faces the stop ring 21, so that the can transporting arm 14 is normally urged towards its stand-by position.
D. In the embodiment explained with reference to FIGS. 1 through 8, the can transporting arms 14 through 18 are rotated by means of the second reversible motor M 2 . It is also possible that a specially designed cam mechanism is utilized so that the cam mechanism cooperates with the traverse bars and so that the can transporting arms 14 through 18 are rotated by means of said cam mechanism while they are reciprocated. An embodiment of this type will now be explained with reference to FIGS. 12 through 15. Traverse bars 10 and 11 have a construction similar to that of the traverse bars 10 and 11 explained with reference to FIGS. 1 through 8 and are horizontally reciprocated by means of a single driving source, such as the first reversible motor M 1 (FIG. 1) or a pneumatic cylinder (not shown). The traverse bars 10 and 11 have can transporting arms 14 and 15 rotatably mounted thereon. Support blocks 6 and 7 and stop rings 40 engaged with the traverse bars 10 and 11 are so constructed that they restrict the axial relative movement of the can transporting arms 14 and 15. Stoppers 41 which become abutted with the upper surfaces of the base portions of the can transporting arms 14 and 15 are secured to the inner sides of the support blocks 6 and 7 by means of set bolts 42 in such a manner that the stoppers 41 are vertically adjustable and that the operating heights of the can transporting arms 14 and 15 can be adjusted. Thus the can transporting arm 14 for pushing the full can C f are adjusted at a high level, and the can transporting arms 15 for pushing the empty can C e adjusted at a low level. Cam 43 for actuating the can transporting arms 14 and 15 has recessed portions 43a equidistantly formed thereon, and the cam 43 is disposed on the guide plane 1 in parallel with the traverse bars 10 and 11. Levers 45 for operating the can transporting arms 14 and 15 have an L-shaped cross section and are rotatably supported by means of shafts 44 on the stop rings 40 which are engaged with the traverse bars 10 and 11. Lower ends of the levers 45 have rollers 46 rotatably supported thereon, which rollers 46 are in contact with the cam surface of the cam 43. The upper ends of the levers 45 have rollers 47 rotatably supported thereon, which rollers 47 are in contact with the upper surfaces of the base portions of the can transporting arms 14 and 15.
The apparatus for changing cans, illustrated in FIGS. 12 through 15, operates as follows. When the traverse bars 10 and 11 are moved forward, i.e., to the left in FIGS. 12 through 15, from the retracted position illustrated in FIG. 12, the cans C f and C e are transported by means of the can transporting arms 14 and 15 as illustrated in FIG. 13. During this movement, the rollers 46 supported on the levers 45 for operating the can transporting arms 14 and 16 are released from the recessed portions 43a formed on the cam 43 for actuating the can transporting arms 14 and 15, and the levers 45 are rotated counterclockwise (in FIGS. 12 through 15) about the shaft 44. Accordingly, as illustrated in FIG. 14, the full cans C f (only one is illustrated in FIGS. 12 through 15) are discharged from the turn tables 3 (only one is illustrated in FIGS. 12 through 15) which have a construction similar to that of the turn tables 3 illustrated in FIG. 1, and the empty cans C e (only one is illustrated in FIGS. 12 through 15) located next to the full cans C f are transported onto the turn tables 3. Then, since the rollers 46 supported on the levers 45 for operating the can transporting arms 14 and 15 engage with other recessed portions 43a formed on the cam 43 for actuating the can transporting arms 14 and 15, the base portions of the levers 45 become positioned vertically. When the traverse bars 10 and 11 are moved backward, i.e., to the right, from the position illustrated in FIG. 14, the rollers 46 supported on the levers 45 are released from the recessed portions 43a formed on the cam 43, and the levers 45 are rotated counterclockwise in FIGS. 12 through 15 about the shaft 44 so that the rollers 47 press the upper surfaces of the base portions of the can transporting arms 14 and 15 downward. As a result, the can transporting arms 14 and 15 are turned upward so that they do not interfere with the empty cans C e . When the traverse bars 10 and 11 are further moved backward, i.e., to the right in FIGS. 12 through 15 and the rollers 46 engage with the recessed portions 43a located rearward, the levers 45 for operating the can transporting arms 14 and 15 are rotated counterclockwise in FIG. 12, and as a result, the can transporting arms 14 and 15 are returned to their original positions as illustrated in FIG. 12.
|
An apparatus for automatically changing cans of a spinning machine, such as a drawing frame or a carding machine. The apparatus comprises: a movable support frame which can be reciprocated along the can transporting direction; and a plurality of can transporting arms which are substantially equidistantly arranged on the support frame and which can alternately be located at operating positions where the arms transport the cans and stand-by positions where the arms do not interfere with the cans, whereby, when the movable support frame is moved forward, the can transporting arms are maintained at the operating positions so as to transport the cans, and then, after the can transporting arms are returned to their stand-by positions from their operating positions, the support frame is moved backward. The apparatus is characterized in that it further comprises an arm height adjusting member by which individual heights of the can transporting arms in the operating positions where the arms are abutted with the cans are adjustable while the can transporting arms in the stand-by positions are almost at the same level as each other.
| 3
|
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royality.
BACKGROUND OF THE INVENTION
This inention relates to the field of security door assemblies of the quickly removable type.
In military and other security conscious uses, there frequently exists a need for an aperture closing door and door frame assembly which enables at least moderate security against both tampering and forceful entry attempts, but which is nevertheless quicky and easily removed from its mountings. Door of this type are frequently employed, for example, at the entrance(s) of conference rooms used for militarily secured briefings and other meetings. The removal of such doors is, however, often desired to allow maximum dimension usage of the door frame aperture or for repair and replacement of the door mechanism or other portions of the door assembly or for temporary conversion of the room to other uses. Many such door arrangements also require consideration of the door operating friction along with the incorporation of sealing arrangements to preclude air leakage through the space surrounding the door body--the space between door body and door frame members. Security considerations in such door assemblies additionally often make the use of vertically-oriented door bolts preferably to the normal horizontally-oriented bolt.
The patent art includes several examples of doors, door lock mechanisms, and door suspension arrangements. This patent art includes the patent of Millard F. Brown, U.S. Pat. No. 0,343,794, which shows the use of rack and pinion mechanisms to extend or retract horizontally disposed bolt locks upon rotation of a single knob located on the door face.
This art also includes the patent of Thomas Talyor, U.S. Pat. No. 547,387, which shows the use of a single knob or shaft to achieve rack and pinion extension of lock bolt members located on all four sides of a rectangular door member.
This art also includes the patent of Abraham Bahry et al, U.S. Pat. No. 3,991,595, which concerns the use of a single key operated pinion to drive a gear that is cam-wise connected to a plurality of lock bolt members extending to the four sides of the door.
This art also includes the patent of George H. Scheik, U.S. Pat. No. 726,577, which shows use of extendable and retractable lock bolt members operating from a single shaft and arranged as the pivoting pins in a separatable hinge structure.
Another hinge and lock bolt arrangement is shown in the patent of Wilhelm K. Schmidt, U.S. Pat. No. 1,972,575, which concerns a door having linearly movable lock bolt members, one located at each lateral extremity of the door and usable as both the lock bolt member and as a hinge pin member, depending upon the positioning selected for the bolt actuating mechanism. The lock bolts of the Schmidt invention further include a camming arrangement for applying pressure to a resilient sealing member located intermediate the door and door frame members.
Additional objects and features of the invention will be understood from the following description and the accompanying drawings.
These and other objects of the invention are achieved by a bidirectionally pivoting, removable security door apparatus which includes the combination of a door frame member annularly disposed around the internal perimeter of a door closable opening, the frame member defining a rectangular aperture having edges of length L and width W, a rectangular door body member of clearance diminished L and W edge dimensions receivable in predetermined small annular air gap clearance relationship within the frame member aperture, a first hinge pivot assembly received within the door body member adjacent a first L dimensioned edge thereof and including a rack and pinion retractable pivot pin portion extending from within the body member parallel with the L dimensioned edges through a first W dimensioned door edge across one W dimensional leg of the annular air gap into a first W dimensional frame member edge, a first friction limiting bearing member received in the first frame member W dimensioned edge surrounding the first pivot pin portion therein, a second hinge pivot assembly received within the door body member adjacent the first L dimensioned edge thereof, axially aligned with the first hinge pivot assmbly and physically segregated therefrom, also including a rack and pinion retractable pivot pin portion extending from within the body member parallel with the L dimensioned edges through the second W dimensioned door edge across the second W dimensioned leg of the annular air gap into the second W dimensioned frame member edge, a second friction limiting bearing member received in the second frame member W dimensioned edge surrounding the second pivot pin portion therein, a first striker plate member received in the first frame member W dimensioned portion adjacent the second L dimensioned edge thereof and including a first plunger receiving aperture therein, a first rack and pinion actuated bolt assembly having a first elongated plunger bolt member located within the door body member adjacent and parallel of the second L dimensioned edge thereof and extendable from within the body member parallel with the L dimensioned edges through the first W dimensioned leg of the annular air gap into the first W dimensioned frame member edge first striker plate member, a second strike plate member received in the second frame member W dimensioned portion adjacent the second L dimensioned edge thereof and including a second plunger receiving aperture therein, a second rack and pinon actuated bolt assembly having a second elongated plunger bolt member located within the door body member adjacent and parallel of the second L dimensioned edge thereof and extendable from within the body member parallel with the L dimensioned edges through the second W dimensioned leg of the annular air gap into the second W dimensioned frame member edge second striker plate member, resilient urging means connected with the first and second rack and pinion actuated bolt assemblies for urging the plunger members toward a predetermined position thereof, rotational stop means connected with the rack and pinion actuated bolts for terminating the travel limit of the plunger bolt members at predetermined position limits, resilient sealing means attached to the door body member along at least the first L dimensioned edge thereof and extending across the air gap between the door edge and frame edge for sealing the air gap.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a composite view of a door and door frame arrangement made in accordance with the invention.
FIG. 2 shows additional details of the locking mechanism for the FIG. 1 door.
FIG. 3 shows additional details of the hinge mechanism for the FIG. 1 door.
DETAILED DESCRIPTION
In FIG. 1 of the drawings there is shown an overall perspective view of a medium security door 100 and an accompanying door frame 102. The frame 102 of the FIG. 1 door is mounted in a closable opening of a planar surface that is shown in represented form at 101. The door 100 includes a top edge portion 124, a vertical edge portion 126 and oppositely disposed edge portions 125 and 128. The frame 102 in FIG. 1 includes a top edge portion 106, a vertical edge portion 104, and oppositely disposed edges 108 and 110, respectively. The frame edge portions 106, 108, 104, and 110 are preferably arranged to have width and length dimensions of W and L, respectively, and the door edges 124, 128, 126, and 125 to have dimensions of W and L which are clearance diminished by a small amount in order to provide operating or movement clearance space for the door, as is indicated at 152 and 154. An annular clearance space therefore surrounds the door 100 and lies intermediate the door 100 and the frame 102.
Received in the interior of the door 100 are a pair of hinge mechanisms 112 and 114, and the locking mechanism 115. The hinge mechanisms cooperate with friction limiting bearing members mounted on the frame 102, one of these friction limiting bearing members is shown at 120 in FIG. 1. The locking mechanism 115 cooperates with a striker plate 123 located in the top edge portion 106 of the frame 102 and with a similar striker plate located in the opposite or lower edge 108 which is not shown in FIG. 1.
Each of the hinge mechanisms 112 and 114 includes a pivot pin member 116 and 118 which crosses the annular air gap or air space intermediate the door and frame members and is received in the friction limiting bearing 120 and the companion lower bearing which is not shown in FIG. 1. The lock mechanism 115 includes a pair of plunger bolt members 121 and 122 which are guided or limited in movement direction by a pair of guide blocks for each plunger bolt member. The blocks 134 and 136 guide the plunger bolt 121 and the blocks 130 and 132 guide the plunger bolt 122. The plunger bolt members include a beveled or double-beveled end surface 138 and 140. The plunger bolts also pass through a pair of apertures 142 and 144 in the top and bottom edges of the door 100 in reaching the striker plate 123 and the similar lower strike plate. The plunger bolts 121 and 122 are actuated by a rotational gear 156 in rack and pinion fashion; the travel limits of the rotational gear 156 are determined by a rotational stop and spring mechanism which is indicated at 158 in FIG. 1.
The FIG. 1 door and frame apparatus also includes a resilient sealing arrangement such as the lengths of weather stripping 146, 148 and 150 which serve to seal the annular space intermediate the door 100 and frame member 102 on at least one of the lengthwise edges 125. Similar sealing arrangements can be employed around other perimeter portions of the door 100 as needed for complete sealing of the annular air gap. The three lengths of weather stripping 146, 148, and 150 are shown to be mounted in a curved edge portion of the door 100. This curved edge enables pivoting of the door around the hinge pins 116 and 118 without corner collision between the door and frame member and with at least one of the weather strip lengths 146, 148 and 150 being thereby always engaged with the frame edge 110.
FIG. 2 of the drawings is taken from an alternate perspective angle in comparison with FIG. 1 and shows additional details of the locking mechanism 115 of FIG. 1. Repeated portions of the FIG. 1 apparatus appearing in FIG. 2 are given the same numbers as used in the FIG. 1 drawing, while newly appearing details first shown FIG. 2 are given numbers in the 200 series. In FIG. 2 therefore, the plunger bolt 121 is shown to include a series of teeth 200, which engage similar teeth located on the periphery of the rotational gear 156. Another set of teeth is located in the plunger bolt member 122 and these teeth also engage the teeth on the periphery of the rotational gear 156, at the interface indicated at 201 in FIG. 2. Rotational movement of the gear 156 is provided by way of a shaft which is located along the center line 208 and which connects with the knob or handle arrangement shown at 206 in FIG. 2. The extent of rotation of the gear 156 and thus the amount of vertical movement of the plunger bolt members 121 and 122 is determined by a coil spring mechanism which includes a rotational stop arrangement. The coil spring is indicated at 158 in FIGS. 1 and 2 and the rotational stop at 159. The spring portion of this apparatus is used to bias the plunger bolt members 121 and 122 toward one predetermined end, preferably the withdrawn position of the plunger bolt members. Withdrawal rotation of the gear 156 is indicated by the arrow 204 in FIG. 2.
Also visible in FIG. 2 are the friction limiting inserts 202 and 210 which are received in the guide blocks 130, 132, 134 and 136 intermediate the block material and the plunger bolts. These inserts may be in the form of bushings made of such material as a fluorinated hydrocarbon, i.e. Teflon® material made by E. I. duPont de Nemours Co. of Wilmington, Delaware, for example. the inserts 202 and 210 of course, allow easy low friction axial movement of the plunger bolts 121 and 122 upon rotation of the gear 156.
The beveled ends of the plunger bolt members 121 and 122, the ends 138 and 140, are shown more clearly in FIG. 2. These beveled ends of course, cooperate with beveled surfaces located on the striker plate 123 to enable movement of the latch mechanism 115 in response to encountering the door frame member, that is, upon a latch extended door closure event. For a doubly swinging or bidirectionally swinging door, a double-beveled end for the plunger bolt members 121 and 122 may be preferably to the single bevel shown in FIG. 2.
Additional details concerning one of the hinge mechanisms 112 and 114, the upper hinge mechanism 114 are shown in FIG. 3 of the drawings. The hinge mechanism 114 includes the previously identified hinge pin 118 which is received in an axially constrained movement path that is oriented parallel to one of the long edges of the door 100. Axial movement of the hinge pin 118 is provided by rotation of a gear 306 having teeth 307 which engage a mating set of teeth 309 in the hing pin 118. Rotatio of the gear 306 is accomplished by the release lever 302 which is engaged witht he gear 306 by way of a set of splines 308 located in the release lever aperture and a mating set of splines 314 on the gear shaft 320. The gear shaft 320 is, of course, held in vertically and horizontally fixed position with only rotation as a degree of movement freedom in order that rotational movement of the release lever 302 as indicated at 312 will accomplish axial movement of the hinge pin 118.
Preferably, the release lever 302 is mounted in a recessed position at or below the surface of the door 100 on the edge portion thereof. In this position access to the release lever 302 requires that the door be in one of the extreme open positions. The rotation imparted to the splined shaft 320 and the gear 306 by the release lever 302 is indicated by the arrow 316 in FIG. 3. This rotational movement provides axial movement of the hinge pin 118 within the edge opening 318.
The door 100 may be fabricated of metal, wood, combinations of metal and wood or of plastics, or from other fabrication materials as are known in the art. The hinge and lock mechanisms 112, 114, and 115 are of course, preferably made of steel or brass or high-strength materials. The hinge pins 116 and 118 and the plunger bolt members 121 and 122 are preferably fabricated of hardened material such as high-carbon steel, in order to provide resistance against cutting and other abuse. The door frame 102 may be fabricated of metal, wood, or other materials known in the art.
User of the four elongated and preferably hardened members, that is, the hinge pins 116 and 118, and the plunger bolt members 121 and 122 as a four-point engagement between the door 100 and the frame 102 of course, provides a rigid and secure structure which is susceptible to violation only with extreme methods. Use of the four vertical shafts to lock the door 100 in the frame 102 is capable of making the FIG. 1 door highly resistant to forcing by impact or prying. Prying, for example, requires two persons working simultaneously to be accomplished.
The disclosed door apparatus may also be arranged to use solenoid or motor-driven mechanisms to achieve movement of the lock bolts or indeed, even of the hinge pin members. The friction limiting bearings described in the several locations of the invention may be arranged through the use of low-friction materials such as bronze, babbitt, the above-mentioned Teflon® material, or other bearing materials, and may of course, also employ ball or roller bearings, all as are known in the bearing art.
The size of the disclosed door apparatus is, of course, a matter of design choice. Actual embodiments of the invention may depart from the room size door contemplated in the description herein in either the smaller or larger direction and thereby may encompass such diverse door uses as a door for a small portable safe, the door for a small security compartment in a building (e.g., cable vault) and the larger doors for equipment moving operations. Corresponding variations in the size of huge pins, plunger bolts, and other elements of the door structure are, of course, contemplated for these embodiments. The recited door sizes and uses are of course intended to be exemplary rather than limiting in nature.
While the apparatus and method herein described constitute a preferred embodiment of the invention, it is to be understood that the invention is not limited to this precise form of apparatus or method, and that changes may be made therein without departing from the scope of the invention, which is defined in the appended claims.
|
A quickly demountable security-conscious door having a four-pin engagement with the adjacent door frame and having a plurality of rack and pinion mechanisms for movement of the hinge pin and lock bolt members into engagement positions with respective receptacles located in the door frame member. The door includes weather stripping provisions, operating knob rotational limits, and operating shaft spring assistance and uses Teflon® or other low-friction materials in appropriate frictional engagement positions.
| 4
|
This application is a division of application Ser. No. 591,124, filed 3-19-84, now U.S. Pat. No. 4,580,436.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to the field of actuators for four bar linkages and, in particular, the present invention is concerned with actuators for translating the linkage of an articulating frame press from a first position to a second position.
2. Description of the Prior Art
Linear actuators for translating a four bar linkage from one position to another, as applied in presses, are known. U.S. Pat. Nos. 3,154,009; 3,651,754; and 3,641,929 disclose a linear actuator for translating the motion of a press with an articulating frame from one position to another. These devices all employ a press frame that has opposed links, or legs of equal length, with the legs remaining parallel to their opposed legs throughout the translation of the press frame from one position to another. This parallelogram configuration makes it relatively simple to attach one end of a linear actuator such as a cylinder to the base and another end of the cylinder to a link of the frame and actuate the frame from one position to another with a continuous linear motion of the actuator. My invention U.S. Pat. No. 4,329,867 discloses an articulating frame press which comprises a four bar linkage having legs of uneaqual length. In U.S. Pat. No. 4,329,867 a rotary actuator was disclosed for translating the press from a first position to a second position. To articulate the press or translate from a first position to a second position, utilizing a rotary actuator such as a rack and pinon or hydraulic motor, it is necessary that the rotary actuator reverse its motion at a point between the first position and the second position because the rotary motion of the legs, relative to the base, is reversed during the translation. This requires a sophisticated control for the rotary actuator so that at a precise position of the frame the motion of the rotary actuator is reversed. This adds complication and expense. In the present invention, a linear actuator is interconnected between opposing links of a four bar linkage so that when one link has reversed its motion and is rotating toward the opposed link, the opposed link is continuing its rotation toward the one link at a sufficient rate to exceed the rate of rotation of the one link and allow actuation of the four bar linkage with a continuous motion of the linear actuator.
3. Information Disclosure Statement
The aforementioned prior art including the applicant's U.S. Pat. No. 4,329,867 in the opinion of the applicant and the applicant's attorney, represents the closest prior art and/or information of which the applicant and his attorney are aware.
SUMMARY OF THE INVENTION
The present invention, which will be described in greater detail hereinafter, comprises a press for forming complimentary parts, the press having a frame consisting of a four bar linkage which is translatable from a first position to a second position. The frame comprises a base, a first pair of spaced apart legs having an upper end and a lower end with the lower end of the legs pivotally supported by the base. The second pair of spaced apart legs are positioned a distance from the first pair of spaced apart legs. The second pair of spaced apart legs are shorter than the first pair of legs and have their lower end pivotally supported by the base. An upper platen is pivotally supported by the upper end of the first pair and second pair of legs. The base, the first pair of legs, the second pair of legs, and the upper platen comprise the frame of the press which is translatable from a first position, with the legs extending vertically upward, to a second position wherein the upper platen has been translated laterally to a position at the side of the base and facing slightly upward. In the second position, the base and the platen are accessible from overhead without obstruction.
The present invention includes a linear actuator pivotally secured at one end to one of the first pair of legs and at another end to one of the second pair of legs so that the press frame can be articulated from the first position to the second position with a continuous non reversing linear motion of the actuator.
It is therefore a primary object of the present invention to provide a new and improved linear actuator for an articulating frame press.
It is a further object of the present invention to provide a linear actuator for an articulating frame press that translates the frame from one position to another position with a continuous linear motion.
It is an additional object of the present invention to provide a booster cylinder to assist the actuator when the articulating frame is in its maximum overhung position.
Further objects, advantages, and applications of the present invention will become apparent to those skilled in the art to which this invention pertains, when the accompanying description of one example of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawing.
DESCRIPTION OF THE DRAWING
In the drawing, like reference numbers refer to like parts throughout the several views and wherein:
FIG. 1 illustrates a side view of an articulating frame press utilizing a linear actuator of the present invention;
FIG. 2 illustrates the beginning of articulation of the frame press from the position shown in FIG. 1;
FIG. 3 illustrates further translation of the press articulating frame press with the upper platen shown in a vertical position;
FIG. 4 illustrates the press of FIG. 1 with the frame articulated fully to the second position; and
FIG. 5 illustrates a broken side view of the articulating frame press of FIG. 2 with a booster cylinder provided.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, there is illustrated in FIGS. 1 through 4 one example of the present invention in the form of an articulating frame press 10 for forming complimentary parts. The press 10 is translatable from a first position illustrated in FIG. 1 to a second position which will be described in greater detail hereinbelow. The frame of the press 10 comprises a base 12 which rests on the floor, a first pair of spaced apart legs 14 having an upper end 16 and a lower end 18 with the lower end 18 pivotally supported by the base 12. A second pair of spaced apart legs 20 are provided having an upper end 22 and a lower end 24 pivotally attached to the base of their lower end. An upper platen 26 comprises a third leg which is pivotally supported by the upper ends 16 of a first pair of legs 14 and the upper end 22 of the second pair of legs 20. The base 12, the first pair of legs 14, the second pair of legs 20, and the third leg or upper platen 26 comprise the frame of the articulating frame press 10. The press 10 includes a lower platen 28 which is carried by the base and is movable between the base 12 and the upper platen 26 by means of a press cylinder 30. A die is provided having an upper part 32 attached to the upper platen 26 and a lower part 34 attached to the lower platen 28. When the lower platen 28 is moved to a working relationship with the upper platen 26 the upper and lower parts of the die are brought together and form a complimentary part therebetween.
The press 10 is translatable from a first position as shown in FIG. 1 to a second position as shown in FIG. 4 by means of a linear actuator 36. When the press 10 is in its first position the upper and lower parts of the die 32, 34 are in alignment and can produce complimentary parts when material is inserted between the die parts and the lower platen 28 approaches the upper platen 26 squeezing the marterial between the die parts. When the press frame 10 has been translated to the second position as shown in FIG. 4 of the drawing, the upper platen 26 has been rotated in a counter clockwise direction approximately 112° and displaced transversely, relative to the lower platen 28, which places the upper platen 26 at the side of the press facing slightly upward. This allows overhead access to the upper platen 26 and the lower platen 28 allowing the upper and lower parts of the die to be installed, replaced, or worked on simultaneously.
The press 10 is translatable from the first position shown in FIG. 1 of the drawing to the second position shown in FIG. 4 of the drawing by means of the linear actuator 36. In a preferred embodiment the linear actuator 36 comprises a hydraulic cylinder 38 having a piston movable within the cylinder and a rod 40 attached to the piston. The rod 40 extends from the cylinder, or is retracted into the cylinder, to generate a linear motion. Inserting fluid into a rod end port 46 causes the linear actuator 36 to retract, and porting fluid into a cylinder end port 48 causes the rod 40 to extend and thus, the linear actuator 36 to extend. In the preferred embodiment the linear actuator 36 is pivotally attached at one end to the first leg 14 at a point spaced from the first leg lower end 18, and pivotally attached at another end to the second leg 20 at a point spaced from the second leg lower end 24. In the first position of the press 10, as shown in FIG. 1, the linear actuator 36 is extended, and retracting of the linear actuator causes the linkage to translate from the first to the second position.
FIG. 2 of the drawing illustrates the press 10 articulated to an intermediate position between the first position and the second position wherein the second leg 20 and the upper platen 26 extend in a straight line which rotates the first leg 14 clockwise to a maximum angle about its lower end 18. If the press 10 is articulated in either direction from the position shown in FIG. 2 either toward the first position or toward the second position, the first leg 14 will rotate counter clockwise about its lower end 18. It can be seen that in articulating press 10 from its first position shown in FIG. 1 to the second position shown in FIG. 4 that the first leg 14 first rotates clockwise about its lower end 18 to the position shown in FIG. 2, and then rotates counter clockwise to the vertical position shown in FIG. 4 of the drawing upon completion of the articulation of press 10 from the first position to the second position.
FIG. 3 of the drawing illustrates a second intermediate position between the first position illustrated in FIG. 1 of the drawing and the second position illustrated in FIG. 4 of the drawing wherein the upper platen 26 is in a vertical position and the second leg 20 has rotated in a clockwise direction to its maximum position and, any translation from the position shown in FIG. 3, either toward the first position or the second position, induces a counter clockwise rotation of the second leg 20 about its lower end 24. As the press frame is translated from the position shown in FIG. 3 to the position shown in FIG. 4, only a small amount of counter clockwise rotation of the second leg 20 is encountered, while a substantially greater amount of angular movement of the first leg 14 is required. Consequently, while the counter clockwise movement of the second leg 20, between the position shown in FIG. 3 and the position shown in FIG. 4, would require an extension of the linear actuator 36, the angular motion of the first leg, between the position shown in FIG. 3 and the position shown in FIG. 4, requires a substantially greater amount of linear contraction of the linear actuator 36, so that the net result of the frame articulation between the position shown in FIG. 3 and the position shown in FIG. 4 requires a net contraction of the linear actuator 36.
When the press 10 is articulated from its first position, shown in FIG. 1, to the intermediate position, shown in FIG. 3, it can be shown, by careful study of the drawing, that the angular rotation of the second leg 20, between the first position and the position shown in FIG. 3, is substantially greater than the angular rotation of the first leg 14 so that the clockwise rotation of the first leg 14, in translating from the position shown in FIG. 1 to the position shown in FIG. 2, is offset by the greater angular rotation of the second leg 20 about its lower end 24 which results in a continuous net contraction of the linear actuator 36 in translating the press frame from the position shown in FIG. 1 to the position shown in FIG. 2. Consequently, a continuous contraction of the linear actuator 36 causes a smooth translation of the press 10 from the position shown in FIG. 1 to the position shown in FIG. 2 and to the position shown in FIG. 3 of the drawing. Translation of the press 10 from the position shown in FIG. 3 to the second position as shown in FIG. 4 of the drawing requires only a slight counter clockwise rotation of the second leg 20 about its lower end 24, while a substantially greater amount of angular rotation of the first leg 14 about its lower end 18 is required. While counter clockwise rotation of the second leg 20 about its lower end 24 requires an extension of the linear actuator 36 this tendency is more than offset by the greater angular rotation of the first leg 14 about its lower end 18, requiring a greater amount of linear contraction of the linear actuator 36 resulting in a net contraction of the linear actuator 36 between the position shown in FIG. 3 and the position shown in FIG. 4. Consequently, a contraction of the linear actuator 36 results in a smooth translation of the press 10 from its first position shown in FIG. 1 of the drawing to the position shown in FIG. 4 of the drawing.
As can be best shown in FIG. 2 of the drawing, a pair of guide rods 50, 52 are secured to the lower platen 28. These guide rods 50, 52 engage a pair of guide bushings 54, 56 as the platen 28 moves upward. These guide rods 50, 52 and guide bushings 54 56 serve to align the upper and lower platens and to precisely align the die upper part 32 with the die lower part 34 to form a precision part. It can be seen that if the guide rod 52 were the same length as the guide rod 50 the upper platen 26 would strike the guide rod 52 as the press frame is translated from the position shown in FIG. 1 to the position shown in FIG. 2 of the drawing. To avoid a collision between the upper platen 26 and the guide rod 52, the guide rod 52 is shortened to provide the necessary clearance. To avoid having a large gap between the bushing 56 and the end of the guide rod 52, the bushing 56 is positioned below the platen 26 as shown.
The force required to articulate the frame 10 can be determined by the amount of overhung load generated by the transverse translation of the upper platen 26. Examination of the various figures of the drawings shows that in FIG. 2 the platen 26 is translated transversely to its maximum position. In the position shown in FIG. 2, the maximum amount of pressure in cylinder 38 is required to actuate the press from one position to another. FIG. 5 of the drawing illustrates a booster means 60 which can be employed to assist in the actuation of the press when a heavy die upper part 32 is employed. The addition of the booster means 60 substantially reduces the size and operating pressure required in the hydraulic cylinder 38. The booster means 60 comprises a booster cylinder 62 having a cylinder end 64 pivotally attached to the base 12 by means of a base extension 68. The booster cylinder 62 further includes a rod end 66 pivotally secured to one of said pair of spaced legs 14 at the lower end 18. When a light die upper part 32 is secured to the upper platen 26 and the force required to articulate the frame is light, the booster cylinder 62 can be rendered inactive by hydraulically interconnecting the rod end port 70 with the cylinder end port 72 and thus, the full actuation of the press frame is controlled by the hydraulic cylinder 38. When a heavy die upper part 32 is employed and the pressure becomes excessive in the cylinder 38 the cylinder 62 can be actuated by applying pressure to cylinder port 72 and thus, the actuating pressure in hydraulic cylinder 38 can be substantially reduced.
It can thus be seen that the present invention has provided a new and improved device for actuating an articulating frame press from a first position wherein the platens are aligned to a second position wherein the upper platen is displaced transversely from the lower platen, allowing the upper and lower platens to be reached from overhead without obstruction. It is also apparent, to those skilled in the art of the kinematics of four bar linkages, that a new and improved actuator is provided for four bar linkages which allows actuation of the linkage from a first position to a second position utilizing a linear actuator, and requiring only a continuous uni-directional actuation of the actuator to achieve the translation from the first position of the linkage to a second position of the linkage.
It should be understood by those skilled in the art of articulating frame presses and four bar linkages that other forms of the applicant's invention may be had, all coming within the spirit of the invention and the scope of the appended claims.
|
A four bar linkage is movable from a first position to a second position by a continuous motion of a linear actuator. The linkage comprises a first leg and a second leg shorter than the first leg spaced from and parallel to the first leg in the first position. The first and second legs are supported at their lower end by being pivotally attached to a base, and the upper ends of the first and second legs pivotally support an upper platen at their upper end. The first and second legs, the base, and the upper platen comprise the elements of a four bar linkage. The linkage is translated from a first position where the first and second legs are parallel and extend vertically upward to a second position wherein the platen is rotated up to 90° or more and is displaced laterally from the base and can face to the side and upward allowing access to the base and the upper platen from overhead.
| 1
|
RELATED APPLICATIONS
[0001] This application for patent claims the benefit of provisional application 61/801,485 filed on Mar. 15, 2013.
FIELD OF THE INVENTION
[0002] The present invention generally relates to the field of identity authentication, specifically the authentication of users for online and other application account access and registration.
BACKGROUND OF THE INVENTION
[0003] The identification and authentication of users by a combination of a username or username and password (or knowledge) has been a consistent aspect of multi-user computing systems since at least the early 1960's. This likely original use was to identify and authenticate system users and the amount of expensive computation time used on these shared systems. Ironically, it has been reported that one of these original users also hacked the password authentication on these early systems to steal computing resources for his graduate school project.
[0004] Nearly 50 years later, although implemented with a variety of cryptography technologies and for an increasingly wide variety of applications, the user experience has remained the same, or worsened. Unlike in 1962, today's users have a multitude of accounts and passwords to remember. According to a large scale study done by Microsoft in 2007, within the controlled group of users, the average user accessed roughly 25 different systems online which require passwords. The study reported that the average number of actual distinct passwords used by the participants was 6.5, however, across only 3.9 sites each. Average participant users each typed on average 8 passwords every day. Other studies report both higher numbers of average accounts and lower numbers of user-generated passwords.
[0005] Already overwhelmed by the mental gymnastics that mere routine online usage was asking of them, the burden appears to be unbounded. Web account and resource users are increasingly asked or required to use more complex passwords, with restrictions such as a minimum length, a combinations of letters, numbers, non-alphanumeric characters, and/or a mix of upper and lower case characters.
[0006] In order to cope with this increasingly daunting memorization task, users have developed various strategies, from keeping lists of passwords, or using just one or two easily memorized passwords, to the liberal use of post-it notes attached to their monitor.
[0007] The typical user password memory assistance strategies such as 1) repeated user entry of a password during the day, perhaps from multiple locations, 2) the usage of a password for multiple authentications, and 3) the physically vulnerable use of password lists and post-it notes in shared office space, each pose security risks. For example, the more times and locations a user is required to enter passwords during the day, the more frequently they become vulnerable to attacks such as malicious key-logging Trojans, password phishing, or man-in-the-middle attacks over shared or wireless networks, among many others. And when users access multiple secure sites using the same password, a stolen password for one site is stolen for all of them.
[0008] Real world examples of password security breaches and malicious password threats are everywhere. In a single notorious password data breach in 2007, on Rockstar.com, a gaming site, 32 million user passwords were stolen and posted online publically the same day. Another style of attack, phishing, where the attacker impersonates a known web site or entity identity known to the target, seems to be proliferating virtually unabated, despite well publicized warnings. According to Fraudwatch International, between just Feb. 15 and Mar. 15 of 2013, no less than 25 widespread online banking password phishing attacks were launched, with the attackers posing as major international banks. In an elaborate attack on PayPal users, the website address and even security certificate were spoofed for the fake site, and many users unsuspectingly entered their credentials into the spoofed interface.
[0009] Of course these problems are well known and considerable efforts have been made to improve either the username/password authentication model, or the technical implementation security. Technical improvements in cryptography have improved the ability to withstand brute force attacks, and the use of certificate authorities has made phishing attacks and man-in-the middle attacks more difficult. Unfortunately, few solutions have been adopted to address the high volume of passwords and use of repeated passwords as they are generally more cumbersome for users. Thus the convenience for the user must be considered carefully when developing identity authentication methods.
[0010] The common (special) case where a user wants to securely access web sites from a single, private, presumably secure computer, has presented an opportunity for new technical solutions. One solution utilizes browser cookies and tokenized credentials for users. When users return to these web sites which they have already provided credentials to access, they have the option to not use any credentials for the repeat access, see U.S. Pat. No. 5,727,163 Weiss. An extension of this solution for placing merchant orders online by the so-called 1-click ordering, see U.S. Pat. No. 5,960,411 Hartman, et. al. Such credentials could be reasonably kept secret from other users of the computer system by cryptographic tokens however, the user must be logged out of the secure site to preserve any privacy or security. Thus these methods still rely upon the still highly problematic username/password credential model. Also, although unusual, but perhaps not for long, attacks on SSL cryptography, including decrypting these credential tokens, has been documented in the literature.
[0011] Another technical innovation, which assists users in managing the complex use of passwords is known as a password key-ring, or password manager. This utility is a software application and database that store encrypted and tokenized information corresponding to a user's passwords and associated resources which are to be authenticated, U.S. Pat. No. 5,655,077 Jones, et. al. U.S. Pat. No. 7,076,095 Hahn, US Appl. 2004/0193925 Safriel, and Roboform from Siber Systems (www.roboform.com). Although useful, these solutions utilize complex implementations, require diligence by the user to incorporate infrequently visited secure online resources, and remain vulnerable to a number of attacks such as malicious Trojan key-loggers.
[0012] Not all online resources necessitate the same level of security or privacy. This provides an opportunity for innovative solutions which are currently undeveloped. At present, no system or method is available that utilize the wide variations in online resource privacy needs in order to provide a user identified access without the use of any explicitly entered, tokenized or otherwise transmitted password or other unique authentication factor (biometric, smartcard, etc.).
SUMMARY OF THE INVENTION
[0013] The current invention departs in several fundamental ways from the above and other currently available methods for user identification, authenticated login and account registration. Embodiments of the current invention are specifically designed for online resources and application functions which have minimal or no privacy concerns, but are extendable to a range of privacy and security levels. One basic implementation of the current invention is coined “the no password login.”
[0014] In an exemplary embodiment, no local browser cookie or other locally stored user information is needed to confirm a user's identity. Instead, the identification is provided entirely by user recall and selection of the identified correct account while entering user recalled personal information. The online application utilized for identification/authentication searches the secure server database of registered users, which is in real time to make the process even more natural and immediate for users. No traditional username or password is needed for basic access. Generally, just a few keystrokes need to be typed, until a sufficiently low number of choices are presented that the identification may be selected by the user. Also, to maintain privacy during the process, identification choices are presented to the user in a highly redacted format. Once basic access is granted, no information is sent or shared by the system (through the application interface) unless further authenticated for release. Account feedback and confirmation are sent by email.
[0015] Among many of the utilities of the current invention, the ubiquitous task for retrieving forgotten passwords, which consists of first authenticating a user ID via email, then resetting the password, and finally interacting with secure user services is no longer needed. Instead password retrieval (for access to more secure resources than are available at the basic level) is reduced to: the user request, and the confirmation/authentication email response.
[0016] In accordance with the present invention, the problem of providing an extremely simple and secure method for users to login to secure applications to perform tasks with minimal or no privacy concerns is solved by partitioning privacy levels of access such that a minimum of keystrokes provides access to a basic service level for the identified and authenticated user, without compromising user privacy. The basic level of account access to services is identified and authenticated by a predictive search of user records based on information input by the user with minimum recall effort. As the information is entered by the user, a real-time search of records is performed by the web application and the user is presented choices from a group of potential records. At the basic access level, these choices reveal only a self-identifiable obscured version of personal information. Once self-identified, the user is considered authenticated for this basic level. The user can only perform those tasks which do not compromise security or reveal un-redacted personal or other private information.
[0017] Other embodiments of the invention can be extended to multiple levels of user access depending on the sensitivity of the information and privacy concerns inherent in the use of the online resources. The dimension of secure access coincides with two dynamic and configurable user input query dimensions, the complexity or secrecy of the required identification information input by the user, and the number of identification challenge-response pairings. Such dimensions are configurable by either the resource administration according to their information security concerns, or by the users themselves according to their privacy concerns.
[0018] In other embodiments, customer identification information is compiled and indexed from disparate available resources in addition to previously registered users for an account. During real-time searching for user identification, unregistered customers are also identified. In various embodiments, identified customers are automatically registered to an account, and assigned credentials. In various embodiments auto-registered new account users are notified of the new account registration and provided immediate access limited initially to an assigned privacy level. In other embodiments, no account is created, but the identified user is allowed to perform certain functions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows a flow chart depicting an embodiment for a basic “no password” login, allowing the user basic privileges without revealing or reflecting any personal or private information back to the user. In this embodiment, users may choose to register an account or not, but in both cases may proceed according to the chosen identity.
[0020] FIG. 2 shows a block diagram depicting the component modules of a basic embodiment.
[0021] FIG. 2A shows a block diagram depicting the component modules of an embodiment which includes incorporation of customer identification resources from multiple sources.
[0022] FIG. 3 shows a flow chart depicting an embodiment of the detailed process of interaction between the client browser, application server, and user information and configuration database. An embodiment which incorporates identification of unregistered identities and automated registration is also shown.
[0023] FIG. 3A shows an embodiment for authenticated user interaction without creating an account for the user.
[0024] FIG. 4 shows an embodiment with an online application browser interface which includes the “find yourself” or “instant access” user input field for initiating the “no password” login.
[0025] FIG. 5 shows an embodiment with an online application browser interface for user information registration.
[0026] FIG. 6 shows an embodiment with an online application interface, where the user identification information (email address) is being input but prior to a threshold for the defined maximum number of choices is low enough for display to the user.
[0027] FIG. 7 shows an online application interface, where the user identification information (email) is being input and identity choices available from the user information database. Identity choices available from the user information index are presented with personal identifying information obscured for privacy and security. In this embodiment, users with multiple true identifications (i.e. an individual with different cars, email accounts, etc.) may select the relevant choice among their own identified information.
[0028] FIG. 8 shows an online application interface depicting a confirmation or verification screen after a “no password” login user including the result of the user interaction (appointment date/time) but obscuring the personal identifying information.
DETAILED DESCRIPTION OF THE INVENTION
[0029] In an exemplary embodiment of the invention, an online application for scheduling service appointments is used for identifying a registered user and rapidly scheduling a service appointment with just a few strokes from a user, and without requiring the use of a traditional username and password. The process reveals no sensitive or personal information to the identified user while using this level of authentication. The process may be securely performed from any device since at no time does the user enter his or her username or password credentials, and neither are stored or transmitted in clear text, encrypted or token form.
[0030] In this embodiment, two levels of authentication are implemented for identified/authenticated users. At the basic level, users may identify themselves by entering the beginning portion of virtually any personal information into the “find yourself” or “instant access” field. In this embodiment the secondary, or higher level of user access requires a traditional username and password to be entered by the user for such access.
[0031] In this embodiment, the basic authentication level allows the user to schedule a service appointment with a minimal amount of keystrokes and reveals only obscured personal information for selecting the identity ( FIG. 6 , FIG. 7 ), and the make/model of the previously registered vehicle intended for the service appointment. Similarly, when confirming the appointment, only obscured personal information is shown to the user ( FIG. 8 ). An alternate version of this embodiment provides a higher level of privacy, the “instant access” or “find yourself” field of the online application requiring the user to input lesser known personal information, such as the vehicle VIN ( FIG. 6 ).
[0032] In other embodiments, these different levels of privacy/security provided for the partitioned user levels (the basic level, in the previous embodiment) can be extended to many levels of protection while maintaining the very simple and rapid usage and eliminating traditional password entry. These various levels, from basic upwards, utilize increasingly esoteric personal information which would be known at the highest level to only the intended user.
[0033] An additional dimension of security in other embodiments of the invention may be provided by requiring additional challenge-response information entry in the same manner as the first “find me” field information entry. For example, the initial challenge response asks for entry of one the user's identifying information from the choice of, for example, vehicle license plate or driver's license number, and a second information challenge-response asks for the other information from the same set.
[0034] In another embodiment, a CAPTCHA challenge-response mechanism is employed to eliminate robot access employed either for data mining or malicious purposes. As with the above embodiments, no entry, storage or transmission of the user's traditional username or password is needed for security levels employing the invention.
[0035] In these and other embodiments, the information needed for the challenge-response identity queries, as well as the obscuring of information reflected in the identity choices presented to the user, are configurable by the user and/or the online application administration. Thus the safeguards for user information privacy and safeguards for sensitive information are fully configurable according to individual needs.
[0036] In other embodiments, customer data sources other than from registered accounts are aggregated into a single index. Users identified as customers, but without registered accounts may be given an opportunity for automatic registration. In still other embodiments, no online accounts are used and customers are authenticated with one of the described embodiments and allowed to substantively without any account registration, by the utilization of known customer detailed information.
[0037] FIG. 1 depicts a flowchart outlining a typical implementation of the invention. Initially 100 , a user may not recall if they are registered or a customer, and simply begins using the “instant access” or “find yourself” personal information input 102 . The system then displays the matching registered user records or indexed unregistered customers 103 (in obscured form) from which the user may or may not find an identifying record 104 . If the user is not registered (or a customer), they may optionally 105 begin the registration process 106 by entering personal information. In various embodiments, the user may also enter site specific information (such as license plate numbers and vehicle make and model for the automobile service appointment exemplary model) 108 . They may optionally then configure privacy settings regarding reflected information and communication with the user 110 . In various embodiments the information is stored and indexed securely on only the remote server 112 . In these embodiments, users are provided full access after optionally registering. 113
[0038] In this embodiment, as data is entered into the field 102 , the application continuously searches the indexed customer data for matching records 104 utilizing a database management system (defined as being inclusive of an operable database), and when limited to a number of records below a threshold value of records, the application filters and obscures information from the records such that they become unrecognizable to anyone other than the identified user 114 . The user then selects the correct choice from the list, authenticating and identifying themselves with just a few keystrokes and a single click 116 . The user is then logged into the application at the partitioned “basic” level, wherein no personal information is reflected back to the user 118 . As previously mentioned, this knowledge based challenge-response pairing may be as simple as providing a user's real name, email, or phone number ( FIG. 6 ), or be limited to far more esoteric identity information, such as a license plate or driver's license number, or the last 4 digits of the user's Social Security Number.
[0039] FIG. 2 depicts an exemplary component breakdown for the system. Shown is the application and database server 200 , and the client browser 202 , which acts as the user interface host. The server 200 components include a module executing the application servlet 204 , such as Apache Tomcat for executing Java or Java Server Pages, a database of indexed user information, privacy and administration business rules 206 , a search module for searching this database 208 , and a module implementing the information redaction and challenge-response business rules 210 . Also included is a user registration module which populates the database 208 with the user's personal and site relevant information 212 .
[0040] FIG. 2A depicts an exemplary embodiment which incorporates customer database information in addition to registered users 202 A. The local system 200 A consists of an indexing system and database 204 A which queries registered user data 202 A, and external customer databases such as compiled retailer customer data 208 A and manufacturer customer data 210 A that may have been compiled from warranty registration information. Specialized indexing systems such as Sphinx 204 A are designed for efficient real time searches 206 A.
[0041] FIG. 3 details the interaction between the client browser 300 and the application server 302 . For registered users or other indexed customers, the process begins with the continuous real-time monitoring of the “instant access” or “find yourself” field 304 . Users input digits or characters corresponding to the requested identifying information 306 , and in real-time, the application matches the input against user records 308 or indexed non-registered customer data 309 , according to configured challenge-response business rules and privacy settings 310 . Records matching the input are filtered and obscured 310 and displayed to the user as identity choices 314 . Clicking on the appropriate choice of identity logs the user into the basic operation level for that account 316 , allowing that user to perform limited functions or retrieve limited information 318 . Prior to acting upon a user records or affirmative acting in the name of the identified user 324 , the application may send the user an email for secondary confirmation 320 , 322 . In various embodiments unregistered customers identified by the user are auto-registered 311 and the customer is sent login credentials by email for confirmation and later authenticated use 320 .
[0042] FIG. 3A depicts an embodiment providing users an identified access to system capabilities (making an appointment, checking delivery status, etc.) without any account registration of users or customers. In this embodiment, the process steps split between the client browser 300 A and the application server 302 A are a subset of the steps from the process as depicted in the embodiment from FIG. 3 . After monitoring 304 A user input 306 A this embodiment only matches user input against the indexed customer information 308 A. Filtering of matching results 310 A, display of the obscured matches 314 A, and user selection 312 A are the same as in FIG. 3 . In this embodiment, self-identified users are provided access according to the configuration without any account login 316 A. The remaining process steps 318 A- 324 A are analogous to the account based process in FIG. 3 , and the embodiment here is also for making a service appointment 324 A.
[0043] FIG. 4 depicts an exemplary embodiment of the invention as an application interface 400 . Shown is the “instant access” or “find yourself” field 402 , a mechanism for logging in with a traditional username/password pair 404 , and a link to the registration interface 406 . In this embodiment of the invention, the user is allowed to use name, email, phone number, or vehicle identification number (“VIN”), as the identifying information used for access 402 .
[0044] FIG. 5 shows the registration interface used in this exemplary embodiment of the invention 500 . User personal information is 502 is input by the user through this interface. Other embodiments provide the user the ability to configure privacy, communication, and an unlimited variety of personal information relevant to the function of the customer interaction.
[0045] FIG. 6 depicts the application interface 600 for the exemplary embodiment during the real time challenge-response identification matching process. Shown in the “find yourself” or “instant access” field 606 is the user input of a partial name (the characters “Pika”), and the real-time number of matching records (“found 102” 604 ) which exceeds the (configurable) threshold for presenting obscured choices to the user.
[0046] FIG. 7 depicts the application interface for the exemplary embodiment of the invention 700 during the real time challenge-response identification matching process. Shown in the “find yourself” or “instant access” field 704 is the user input of a partial email address (the characters “Pika.Pika”), and the real-time obscured presentation 706 of matching records (“found 8” 702 ) from which the user is to choose their identity. In this embodiment, the user is presented with multiple entries for the same customer, but with additional information (the customer vehicle) from which to choose an account or particular customer product to process (make a service appointment) 708 . If this implementation had been configured limiting the user input identity choices to a vehicle license plate, this would certainly be more esoteric information and would provide a higher level of access restriction or control.
[0047] In various embodiments, once the user identifies himself or herself, various actions may be performed. In the exemplary embodiment, a customer's vehicle is scheduled for service. In various embodiments, the user can choose a particular service advisor, discounted service times, shuttle service, and describe their service needs. In these embodiments, user personal information remains obscured.
[0048] In various embodiments, including the exemplar appointment scheduling system, as shown in FIG. 8 is the appointment confirmation user interface screen 800 . In this embodiment of the invention, the user must confirm the appointment time and date 806 , along with the vehicle 804 and obscured personal information 902 . If the user recognizes error in the personal information or communication preferences, they may login to the higher security level access through a traditional username and password 908 . Additional security may be provided at this level by requiring the user to respond to a secondary confirmation email before the appointment is actually calendared by the service entity.
[0049] In other embodiments of the invention, the application is utilized to make restaurant reservations, salon appointments, or schedule country club golf tee times. In another embodiment of the invention, the application provides package tracking information without reflecting the delivery address or sender information. In another embodiment of the invention, the user requests renewals of library materials. In other embodiments of the invention employing the additional security of enhanced and multiple identity challenge-response pairs, the user makes routine optometrist, doctor, dentist, or dental hygienist appointments. All of the above embodiments can also be utilized to review upcoming appointment times in redacted form or with an additional intermediary partitioned access level higher than basic, but not with the full user credentials.
[0050] In other embodiments of the invention, the user can access delivery status information, make personal appointments, cancel newspaper or mail delivery during vacations, use online fantasy sports or other gaming sites. In various embodiments, the user may be permitted to participate in game play with or without their game identity redacted, or the user activities may by more limited, depending on user configurable settings, or the games administrative business model.
[0051] The implications of the present invention's numerous potential configurations and embodiments are far reaching. Numerous routine and benign online activities which currently require traditional username/password authentication are now available without any of the well documented security risks posed by the proliferation of password usage. By providing users an acceptably and extremely convenient alternative to the traditional model, benefits accrue for the user's security with unaffiliated third party sites, since they are less likely to have password duplication vulnerability. Embodiment variations which provide user authentication and interaction without any user accounts are any even further departure from tradition cumbersome and vulnerable user/password authentication and has countless applications.
[0052] Although the invention has been described in terms of the preferred and exemplary embodiments, one skilled in the art will recognize many embodiments not mentioned here by the discussion and drawing of the invention. Interpretation should not be limited to those embodiments specifically described in this specification.
[0053] The Commissioner is hereby authorized to charge any fees which may be required with respect to this application to Deposit Account No. 505949.
|
The longstanding problems of user password management and security, and user authentication are addressed. Disclosed is a system and method for providing a means for a user to identify themselves with configurable levels of authentication in order to receive limited access or services while protecting user privacy. As a user inputs information related to their identity into an interface, the system searches an indexed database which may include both registered users and/or unregistered customers indexed from disparate data sources. The system presents the user matching results from the search in an obscured form from which the user selects and authenticates his or her identity. Unregistered users identified during the process may be automatically registered in certain embodiments, or no account may be needed in other embodiments
| 7
|
BACKGROUND OF THE INVENTION
[0001] This invention relates to ultrasonic surgical instruments and associated methods of use. More particularly, this invention relates to high-efficiency medical treatment probes for ultrasonic surgical aspirators. These probes increase the ability to fragment and emulsify hard and soft tissue in a clinical environment while reducing unwanted heat and collateral tissue damage.
[0002] Over the past 30 years, several ultrasonic tools have been invented which can be used to ablate or cut tissue in surgery. Such devices are disclosed by Wuchinich et al. in U.S. Pat. No. 4,223,676 and Idemoto et al in U.S. Pat. No. 5,188,102.
[0003] In practice, these surgical devices include a blunt tip hollow probe that vibrates at frequencies between 20 kc and 100 kc, with amplitudes up to 300 microns or more. Such devices ablate tissue by either producing cavitation bubbles which implode and disrupt cells, tissue compression and relaxation stresses (sometimes called the jackhammer effect) or by other forces such as micro streaming of bubbles in the tissue matrix. The effect is that the tissue becomes liquefied and separated. It then becomes emulsified with the irrigant solution. The resulting emulsion is then aspirated from the site. Bulk excision of tissue is possible by applying the energy around and under an unwanted tumor to separate it from the surrounding structure. The surgeon can then lift the tissue out using common tools such as forceps.
[0004] The probe or tube is excited by a transducer of either the piezoelectric or magnetostrictive type that transforms an alternating electrical signal within the frequencies indicated into a longitudinal or transverse vibration. When the probe is attached to the transducer, the two become a single element with series and parallel resonances. The designer will try to tailor the mechanical and electrical characteristics of these elements to provide the proper frequency of operation. Most of the time, the elements will have a long axis that is straight and has the tip truncated in a plane perpendicular to the long axis, as shown in FIG. 1 . This is done for simplicity and economic considerations. In almost all applications, whether medical or industrial, such an embodiment is practical and useful. However, in applications such as the debridement of burns, wounds, diabetic ulcers or ulcers induced by radiation treatments, the blunt straight probe has been shown to be less effective in removing the hard eschar buildup that occurs when the wound is healing. This eschar buildup must be removed so that the healthy tissue is exposed and allowed to close the wound to provide complete healing with minimal scar tissue formation. Also, the small diameter tip, since it is cannulated, has a small annular area with limits energy transmission into the wound. This extends the length of the procedure and causes operator fatigue and patient discomfort.
[0005] Therefore, it is desired to provide a probe that can be mated to an ultrasonic surgical aspirator which increases the efficiency of emulsification, does not heat up the operative site and lowers the time of operation.
OBJECTS OF THE INVENTION
[0006] An object of the present invention is to provide an improved ultrasonic surgical instrument for use in debridement of wounds.
[0007] A more particular object of the present invention is to provide such an instrument in the form of a probe that may be used in conjunction with ultrasonic surgical aspirators to debride wounds.
[0008] Another relatively specific object of the present invention is to provide an improved ultrasonic surgical instrument with a form that enhances surgical efficiency and reduces the time required to complete at least some kinds of debridement procedures.
[0009] It is a further object of the present invention to provide such an improved ultrasonic surgical instrument with irrigation or suction capability.
[0010] It is an additional object of the present invention to provide an improved ultrasonic surgical instrument that may be used in debriding deep wounds such as cuts and puncture wounds.
[0011] An additional object of the present invention is to provide an improved ultrasonic surgical instrument that has liquid directing channels for greater heat reduction at the distal face and to prevent liquid jetting or spraying from the tissue probe interface.
[0012] These and other objects of the invention will be apparent from the drawings and descriptions herein. Although every object of the invention is attained in at least one embodiment of the invention, there is not necessarily any embodiment which attains all of the objects of the invention.
SUMMARY OF THE INVENTION
[0013] A probe for use as an ultrasonically vibrating tool is disclosed with a central bore coincident with the longitudinal axis. The proximal end of said bore communicates with a bore in the ultrasonic handpiece using methods well known to the art, such as a male/female thread combination. The probe is shaped such as to provide both a resonant frequency of operation in the range for which the electronic generator was designed and an amplitude of vibration at the distal face which is desired for proper tissue ablation. Such amplitudes have generally been shown to be in the range of 30 to 300 microns. Again, the technique needed for calculating said shapes is well known to the art and outside the scope of this disclosure.
[0014] Probe heads or ends in accordance with the present invention incorporate either a substantially symmetrical distal end or a distal end with a pronounced asymmetry. Each end has attributes that increase its effectiveness on varying tissue pathologies.
[0015] Probe ends pursuant to the present invention are further modified to improve the liquid flow to the probe/tissue interface such as to reduce the bulk temperature rise of the tissue and prevent clogging of the liquid passageway. Probe ends are further modified to produce energy directors that impart energy from the sides of the probes instead of only at the distal face of the probe. Such energy directors, when contacting skin or tissue, will increase volume of tissue treated per unit time and thereby reduce the operating time of the procedure.
[0016] In one embodiment of the present invention, an ultrasonic medical probe comprises an elongate shaft formed integrally with a head portion having a distal end face oriented at least partially transversely to a longitudinal axis of the shaft. The shaft is provided with an internal longitudinal channel or bore extending to the end face. The end face is formed with an indentation communicating with the channel or bore at a distal end thereof, whereby liquid is guided over an extended surface of the end face relative to the channel or bore.
[0017] The head portion may be enlarged in a transverse direction relative to the shaft. In that event, the end face has an elongated shape, while the indentation is elongate and forms a groove in the end face of the head portion. This groove may extend parallel to or in a length dimension of the end face.
[0018] When the channel or bore is connected to a suction source, fluid in the indentation flows toward the channel or bore. When the channel or bore is connected to a source of irrigation liquid, liquid in the indentation flows away from the channel or bore.
[0019] Pursuant to a feature of the present invention, the end face is inclined or beveled relative to the longitudinal axis of the probe.
[0020] In another embodiment of the present invention, an ultrasonic medical probe comprises an elongate shaft formed integrally with a head portion having a distal end face oriented at least partially transversely to a longitudinal axis of the shaft. The head portion also has a lateral surface extending substantially parallel to the longitudinal axis of the probe. The lateral surface is provided with at least one outwardly or radially extending projection. The projection enables the application of ultrasonic cavitation energy to a tissue surface that is in contact with the lateral or side surface of the probe head.
[0021] Pursuant to a feature of the present invention, the projection is one of a plurality of projections extending from the lateral surface. The projections may be identical to one another and staggered from one another along the lateral surface of the probe head. The projections may have a shape that is pyramidal, semi-cylindrical, wedge-shaped, or plate-like. The projections may lie down against the lateral surface of the probe head, in the nature of fish scales, flaps, or flattened plates.
[0022] The projections may take the form of ridges. The projections or ridges may extend perimetrally or circumferentially about the probe head. Preferably, however, the projections or ridges are disposed only along one side (or possibly two sides, in some applications) of the probe head. The probe head may take a prismatic form, with the energy-directing projections or ridges formed along one (or two) lateral surfaces thereof. This placement of the energy-directing projections facilitates use of the probe in surgical procedures, inasmuch as it is easier for the surgeon to keep track of the location of the projections to ensure that the projections come into contact only with target debridement tissues.
[0023] It is contemplated that the projections may be finely distributed over a lateral face of the probe head so as to form a knurled surface. Such a knurled surface is similar to that found on a metal filing tool.
[0024] As discussed above, the shaft and the probe head may be provided with an internal longitudinal channel or bore extending to the end face of the probe head, with the end face being formed with an indentation communicating with the channel or bore at a distal end thereof. The indentation extends laterally relative to the channel or bore, whereby liquid is guided over an extended surface of the end face relative to the channel or bore.
[0025] The indentation may be elongate and form a groove in the end face of the head portion. Where the head portion has an elongated shape, the groove may extend parallel to a length dimension of the end face.
[0026] A surgical method in accordance with the present invention utilizes a probe vibratable at at least one ultrasonic frequency, the probe having a distal end face oriented at least partially transversely to a longitudinal axis of the shaft. The method comprises bringing the distal end face into contact with organic tissues of a patient, energizing the probe to vibrate the end face at the ultrasonic frequency during the contacting of the tissues with the distal end face, and channeling liquid between the contacted tissues and a longitudinal bore in the probe, during the contacting of the tissues with the distal end face, via an indentation in the end face communicating with the bore.
[0027] Where the bore is connected to a suction source, the channeling of liquid includes guiding liquid from the contacted tissues to the bore.
[0028] Where the bore is connected to a source of irrigation liquid, the channeling of liquid comprises guiding liquid to the contacted tissues from the bore.
[0029] A surgical method in accordance with another feature of the present invention utilizes a probe vibratable at at least one ultrasonic frequency, where the probe has a distal end face oriented at least partially transversely to a longitudinal axis of the shaft, a lateral surface extending substantially perpendicularly to the end face and substantially parallel to the longitudinal axis, and at least one outwardly or radially extending projection extending out from the lateral surface. The method comprises bringing the lateral surface together with the projection into contact with organic tissues of a patient and, during the contacting of the tissues with the lateral surface and the projection, energizing the probe to vibrate the lateral surface and the projection at the ultrasonic frequency.
[0030] Pursuant to another feature of the present invention, the bringing of the lateral surface together with the projection into contact with organic tissues of a patient includes inserting a distal end portion of the probe into a fissure or recess in an organ of the patient and moving the probe so that the lateral surface and the projection contact a wall of the fissure or recess.
[0031] According to another feature of the present invention, the bringing the lateral surface together with the projection into contact with organic tissues of a patient includes manipulating the probe so that the lateral surface is oriented substantially parallel to the organic tissues and so that the end face is oriented substantially perpendicularly to the organic tissues immediately prior to an engaging of the organic tissues with the lateral surface and the projection. In one embodiment of the present invention, an ultrasonic medical probe comprises an elongate shaft formed integrally with a head portion having a distal end face oriented at least partially transversely to a longitudinal axis of the shaft. The shaft is provided with an internal longitudinal channel or bore extending to the end face. The end face is formed with an indentation communicating with the channel or bore at a distal end thereof, whereby liquid is guided over an extended surface of the end face relative to the channel or bore.
[0032] The head portion may be enlarged in a transverse direction relative to the shaft. In that event, the end face has an elongated shape, while the indentation is elongate and forms a groove in the end face of the head portion. This groove may extend parallel to or in a length dimension of the end face.
[0033] When the channel or bore is connected to a suction source, fluid in the indentation flows toward the channel or bore. When the channel or bore is connected to a source of irrigation liquid, liquid in the indentation flows away from the channel or bore.
[0034] Pursuant to a feature of the present invention, the end face is inclined or beveled relative to the longitudinal axis of the probe.
[0035] In another embodiment of the present invention, an ultrasonic medical probe comprises an elongate shaft formed integrally with a head portion having a distal end face oriented at least partially transversely to a longitudinal axis of the shaft. The head portion also has a lateral surface extending substantially parallel to the longitudinal axis of the probe. The lateral surface is provided with at least one outwardly or radially extending projection. The projection enables the application of ultrasonic cavitation energy to a tissue surface that is in contact with the lateral or side surface of the probe head.
[0036] Pursuant to a feature of the present invention, the projection is one of a plurality of projections extending from the lateral surface. The projections may be identical to one another and staggered from one another along the lateral surface of the probe head. The projections may have a shape that is pyramidal, semi-cylindrical, wedge-shaped, or plate-like. The projections may lie down against the lateral surface of the probe head, in the nature of fish scales, flaps, or flattened plates.
[0037] The projections may take the form of ridges or knurls. Preferably, the projections are disposed along only a portion of the lateral surface area of the probe head. For example, where the probe head is prismatic with three or more planar lateral faces, the energy-direting projections are disposed along less than all of the lateral faces of the probe head. More preferably, the projections are disposed along only one or two lateral faces of the probe head.
[0038] As discussed above, the shaft and the probe head may be provided with an internal longitudinal channel or bore extending to the end face of the probe head, with the end face being formed with an indentation communicating with the channel or bore at a distal end thereof. The indentation extends laterally relative to the channel or bore, whereby liquid is guided over an extended surface of the end face relative to the channel or bore.
[0039] The indentation may be elongate and form a groove in the end face of the head portion. Where the head portion has an elongated shape, the groove may extend parallel to a length dimension of the end face.
[0040] A surgical method in accordance with the present invention utilizes a probe vibratable at at least one ultrasonic frequency, the probe having a distal end face oriented at least partially transversely to a longitudinal axis of the shaft. The method comprises bringing the distal end face into contact with organic tissues of a patient, energizing the probe to vibrate the end face at the ultrasonic frequency during the contacting of the tissues with the distal end face, and channeling liquid between the contacted tissues and a longitudinal bore in the probe, during the contacting of the tissues with the distal end face, via an indentation in the end face communicating with the bore.
[0041] Where the bore is connected to a suction source, the channeling of liquid includes guiding liquid from the contacted tissues to the bore.
[0042] Where the bore is connected to a source of irrigation liquid, the channeling of liquid comprises guiding liquid to the contacted tissues from the bore.
[0043] A surgical method in accordance with another feature of the present invention utilizes a probe vibratable at at least one ultrasonic frequency, where the probe has a distal end face oriented at least partially transversely to a longitudinal axis of the shaft, a lateral surface extending substantially perpendicularly to the end face and substantially parallel to the longitudinal axis, and at least one outwardly or radially extending projection extending out from the lateral surface. The method comprises bringing the lateral surface together with the projection into contact with organic tissues of a patient and, during the contacting of the tissues with the lateral surface and the projection, energizing the probe to vibrate the lateral surface and the projection at the ultrasonic frequency.
[0044] Pursuant to another feature of the present invention, the bringing of the lateral surface together with the projection into contact with organic tissues of a patient includes inserting a distal end portion of the probe into a fissure or recess in an organ of the patient and moving the probe so that the lateral surface and the projection contact a wall of the fissure or recess. According to another feature of the present invention, the bringing the lateral surface together with the projection into contact with organic tissues of a patient includes manipulating the probe so that the lateral surface is oriented substantially parallel to the organic tissues and so that the end face is oriented substantially perpendicularly to the organic tissues immediately prior to an engaging of the organic tissues with the lateral surface and the projection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] FIG. 1 is a cross sectional view of a prior art ultrasonic probe for use with an ultrasonic aspirator.
[0046] FIG. 2A is partially a side elevational view and partially a cross-sectional view of an ultrasonic probe in accordance with the present invention.
[0047] FIG. 2B is a distal end elevational view of the probe of FIG. 2A .
[0048] FIG. 2C is partially a top elevational view and partially a cross-sectional view of the probe of FIG. 2A .
[0049] FIG. 3A is partially a side elevational view and partially a cross-sectional view of another ultrasonic probe in accordance with the present invention.
[0050] FIG. 3B is a distal end elevational view of the probe of FIG. 3A , showing a modification in the form of an elongate groove in a distal end face of the probe head.
[0051] FIG. 3C is a view similar to FIG. 3A showing the groove of FIG. 3B .
[0052] FIG. 3D is a partial cross-sectional view taken along line III-III in FIG. 3C .
[0053] FIG. 4 is partially a side elevational view and partially a cross-sectional view of a further ultrasonic probe in accordance with the present invention.
[0054] FIG. 4A is partial view, on a larger scale, of a lateral surface of a head of the probe of FIG. 4 , taken in region IV-IV of FIG. 4 .
[0055] FIGS. 4B-4D are side elevational views of the probe head of FIG. 4 , showing respective modifications of formations along the lateral surface thereof.
[0056] FIG. 4E is a perspective view of the probe head depicted in FIG. 4D .
[0057] FIG. 5 is partially a side elevational view and partially a cross-sectional view of yet another ultrasonic probe in accordance with the present invention.
DETAILED DESCRIPTION
[0058] Several probes are disclosed which embody the improvements described herein. FIG. 1 shows a probe 10 which is known to the art and is currently manufactured for use with an ultrasonic aspirator. This probe 10 is basically shaped with an exponential or Gaussian taper. Probe 10 is cannulated and has an integral male thread (not shown) at the proximal end (proximate the operator). This thread communicates with a female threaded bore (not illustrated) in the transducer 12 . By tightening the probe 10 onto the transducer 12 and using standard wrenches for final torquing, the transducer and probe essentially become one resonant body. Bores of the probe 10 and transducer 12 communicate with one another. The probe 10 is generally constructed of an acoustically efficient metal or ceramic. Titanium is the most commonly used material, but other material has been employed with success. Material choice does not have a significant impact upon the embodiments of this disclosure.
[0059] The distal end of the prior art probe 10 is truncated in a plane P 1 perpendicular to the longitudinal axis 14 of the resonant body (probe and transducer). Since the probe 10 is cannulated, a distal end face 16 takes the form of an annular surface with a small cross sectional area. The shape of the probe 10 allows the probe to become a velocity transformer, i.e., the probe will amplify the input vibrations from the transducer 12 by a fixed value, called a gain factor, determined by the geometry of the probe. For example, if the probe 10 had a gain factor of 10, the probe would multiply the input vibration of the transducer, for example 30 microns, to a final amplitude at the distal end of the probe of 300 microns. This phenomenon is well known to the art. By placing the distal end face 16 of probe 10 against organic tissue of a patient, the tissue will be disrupted through cavitation and mechanical effects. By adding saline or water to the tissue-probe interface, cooling of the tissue is achieved and the tissue is emulsified into the liquid and is more easily aspirated either through the center of the probe 10 , if the center bore is connected to the aspirator or by separate suction cannulae if the center bore is connected to the irrigant source.
[0060] However, the distal end of probe 10 in its conventional configuration is not conducive to ablating large volumes of tissue in short periods of time. By increasing the surface area of distal end face 16 , a probe can be constructed which will ablate tissue faster and allow for a shorter operation. This is especially advantageous when debriding wounds such as bedsores, diabetic ulcers, burn wounds, etc.
[0061] FIGS. 2A-2C show a probe 18 with a shaft 19 and an enlarged distal head 20 . More particularly, probe head 20 may be asymmetrical such that the cross sectional shape is rectangular or oval (see FIG. 2B ). This asymmetry allows the probe 18 to maintain a higher gain factor and be more able to be inserted into smaller wounds. The surface area of a distal end face 22 of probe head 20 is greatly increased over the prior art probe ( FIG. 1 ) and will naturally ablate tissue at a higher rate. The shape of the probe head 20 allows access to irregularly shaped wound beds, such as cuts or fissures with slit openings.
[0062] Although the probe of FIGS. 2A-2C has been shown to have higher performance over prior art, further improvements may be made. FIG. 3A depicts a probe 24 having a shaft 25 and an asymmetrically enlarged head 26 with a truncated or beveled distal end face 28 located in a plane P 2 that is not perpendicular to a longitudinal axis 30 of the probe. This probe 24 has been shown to improve performance in removing the hard eschar buildup of burn wounds, which must be removed in order to expose healthy tissue.
[0063] One problem that is encountered in such probe designs, whether the probe head is truncated in a perpendicular plane P 1 such as head 20 or in a plane P 2 inclined relative to the instrument axis 30 such as probe head 26 , is the bore opening 32 or 34 may become blocked with tissue. This blockage prevents aspiration of the emulsified tissue, if the respective bore 36 or 38 is connected to a vacuum source (not shown) or blocks the flow of cooling fluid out of the probe, if the bore is attached to a pressurized liquid source (not shown). Because of the pressure buildup, the liquid has a tendency to jet or stream from the probe tissue interface, causing the irrigant to be sprayed around the room instead of onto the wound bed. Also, if the distal end face of the probe is very large, the liquid may not cover the entire face, even if the opening 32 , 34 at the end of the probe is not blocked.
[0064] In order to improve the performance of the probe 24 in this regard, a channel, groove, indentation, or notch 40 is provided in the face 28 of the probe, as shown in FIGS. 3B, 3C and 3 D. This channel 40 reduces the likelihood of blockage of an output opening 42 of the probe bore 38 by locating this opening or outlet proximally from the distal end face 28 of the probe head 26 , while allowing the liquid to fill the channel 40 and cover the remaining distal surface area more fully. Many alternative shapes of channels may be employed in the distal end faces of ultrasonic probes without changing the concepts outlined herein. In the illustrated example, channel or groove 40 extend parallel to or in a length dimension of the end face 28 .
[0065] When bore 38 is connected to a suction source (not shown), fluid in the channel 40 flows toward the bore 38 . When the channel or bore 38 is connected to a source of irrigation liquid (not shown), liquid in the channel 40 flows away from the bore 38 .
[0066] Regardless of the shape of the distal surface or end faces of the probes as discussed hereinabove, the probes are limited in their ability to ablate tissue by the fact the only area where this ablation can occur is at the distal end face. The sides or lateral surfaces of the probes are generally disposed parallel to the longitudinal axes and parallel to the direction of ultrasonic compression wave transmission. When tissue touches these lateral surfaces, no ablation occurs since the motion is a sliding or rubbing action, which does not transmit sufficient energy into the tissue to cause emulsion or ablation. It is therefore desired to improve ultrasonic tissue ablation probes so that energy may be transmitted from one or more lateral faces or side surfaces of the probe heads so that more tissue may be ablated per unit time.
[0067] FIGS. 4 and 4 A show a probe 44 which is identical to probe 24 of FIGS. 3B-3D with the addition of outwardly or radially extending projections 46 serving as energy guides or directors disposed along at least one lateral or side surface 48 of a probe head 50 . Preferably, probe head 50 has a prismatic shape with four planar lateral surfaces or faces 48 , projections 46 being disposed only along one or two of the lateral surfaces. As depicted in FIG. 4 , energy-directing projections 46 are disposed only along two opposing lateral surfaces 48 . Where projections occur along only one or at most two lateral surfaces 48 , it is easier for the user to avoid contact with non-target tissues.
[0068] Probe head 50 may be integrally formed with a shaft portion 49 of probe 44 . Alternatively, probe head 50 may be formed as a separate piece that is firmly attached to shaft 49 , e.g., via mating screw threads (not shown) or a force or friction fit. These same alternatives also apply to probe heads 20 , 26 , 66 .
[0069] Projections 46 may have a fine geometrical configuration and distribution so as to form the respective lateral surface 48 into a knurled surface as one would find, for example, on a metal file. Or projections 46 may be a series of ridges or knurls on probe head 50 . Alternatively, as shown in FIG. 4B , projections or energy directors 46 may be pyramidal sections fashioned from the base metal of the probe 44 that project out in a substantially perpendicular direction from a longitudinal axis 51 of the probe. More specifically, projections or energy directors 46 are a series of parallel ridges or knurls each of triangular cross-section extending transversely to a direction of ultrasonic wave propagation. Projections or energy directors 46 may include a first set of parallel ridges 46 a and a second set of ridges 46 b that is staggered relative to the first set. Each set of wedge- or triangle-shaped projections or ridges 46 a , 46 b defines a corresponding set of grooves (not separately designated) each of triangular cross-section extending transversely to a direction of ultrasonic wave propagation. The resulting faceted surfaces of projections or ridges 46 a , 46 b impart a vector force on the target tissue when the probe 44 vibrates, which will cause cavitation and emulsification of the tissue when it contacts the faceted surfaces.
[0070] As illustrated in FIGS. 4B-4E , lateral surface 48 may be provided with energy-directing projections or ridges 52 , 54 , 56 of different geometrical shapes. Projections or ridges 52 are convex, for instance, semi-cylindrical. Projections or ridges 54 define concave grooves or recesses 58 . Projections 56 are flattened plates or flaps that lie against lateral surface 48 in the natural of fish scales. These energy directors or projections 52 , 54 , 56 allow faster tissue ablation by creating a much larger active surface area at the distal end of the probe 44 .
[0071] In cases where a probe tip must be smaller than that allowed by the described embodiment, such as when small and/or deep bedsores or wounds must be debrided, the probe tip may be improved to allow faster ablation as well. FIG. 5 shows a probe 60 in the configuration of a tubular end or head 62 . Probe 60 is provided circumferentially along a cylindrical lateral or side surface 64 or probe head 62 with a plurality of pyramidal energy-directing projections 66 . Projections 66 may be small such as that which occurs in a knurled surface, for example, on a metal file. The energy directors 66 will impart vector forces on the tissue when in contact with the wound bed such that emulsion and ablation will occur around the probe as well as in front of it. Such probes have been shown to increase the speed of ablation and thereby significantly reduce the time of operation. Again, such energy directors may be purely pyramidal, or have concave or convex faces.
[0072] All said probes in this embodiment might be designed by those skilled in the art using known tools and techniques.
[0073] In a method of using the above-described probes for debriding and cleaning wounds, sores and ulcers with ultrasound energy, an operator assembles the ultrasonic surgical aspirator with the probes, connects the central bore to a pressurized liquid source which can be adjusted to provide a controlled flow at the probe tip, turn on the system to provide between 30 and 350 microns of probe tip displacement, and touches the tip and the energy directors to the tissue to be ablated, causing cavitational and mechanical forces to be imparted to said tissue which ablates the tissue, thereby debriding and cleansing the wound bed. Aspiration may be accomplished simultaneously or separately from ultrasonic ablation by connecting a flue or sheath around said probe, as in FIG. 6 , that is in turn connected to a vacuum source and then the emulsified tissue is aspirated through this annular space. Conversely, the flue or sheath may be eliminated and the aspirate removed via separate suction cannulae.
[0074] A surgical method utilizing probe 24 or 44 or another probe provided in an end face with a channel, groove, indentation, or notch such as channel 40 is operated to vibrate at an ultrasonic frequency. The distal end face 22 , 28 of the probe is brought into contact with organic tissues of a patient. The probe is energized to ultrasonically vibrate the end face 22 , 28 during the contacting of the tissues with the distal end face, and liquid is channeled between the contacted tissues and longitudinal bore 36 , 38 , during the contacting of the tissues with the distal end face, via indentation or channel 40 .
[0075] A surgical method utilizing probe 44 or 60 comprises bringing the lateral surface 48 or 64 together with projections, ridges, or knurls 46 , 66 into contact with organic tissues of a patient and, during the contacting of the tissues with the lateral surface and the projections, energizing the probe to vibrate the lateral surface 48 , 64 and the projections 46 , 66 at a predetermined ultrasonic frequency. This method may include inserting a distal end portion of the probe into a cut, fissure or recess in an organ of the patient and moving the probe so that the lateral surface 48 , 64 and the projections 46 , 66 contact a wall of the fissure or recess.
[0076] Altneratively or additionally, the probe is manipulating so that the lateral surface 48 , 64 is oriented substantially parallel to the organic tissues and so that the distal end face is oriented substantially perpendicularly to the organic tissues immediately prior to an engaging of the organic tissues with the lateral surface 48 , 64 and the projections 46 , 66 .
[0077] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
|
An ultrasonic medical probe comprises an elongate shaft formed integrally with a head portion having a distal end face oriented at least partially transversely to a longitudinal axis of the shaft. The shaft is provided with an internal longitudinal channel or bore extending to the end face. The end face is formed with an indentation communicating with the channel or bore at a distal end thereof, whereby liquid is guided over an extended surface of the end face relative to the channel or bore. The head portion also has a lateral surface extending substantially parallel to the longitudinal axis of the probe. The lateral surface is provided with at least one outwardly or radially extending projection. The projection enables the application of ultrasonic cavitation energy to a tissue surface that is in contact with the lateral or side surface of the probe head.
| 0
|
This application is a division of Ser. No. 11/536,001 filed on Sep. 28, 2006.
TECHNICAL FIELD
This invention pertains to welding electrodes for electrical resistance welding. More specifically this invention pertains to the formation of concentric geometric features on the welding face of the electrode for improved electrical contact with the workpiece.
BACKGROUND
Current automotive vehicle manufacturing operations include, for example, the joining of two sheet metal layers by spot welding. Vehicle body panels such as doors, hoods, deck lids and liftgates are often assembled by joining inner and outer panels stamped from sheet metal of suitable metal alloys. Ferrous or aluminum alloys are often used. The thickness of each sheet metal layer may vary from less than one millimeter to more than four millimeters. Electrical resistance spot welding is often used to join such inner and outer panels or other metal parts.
In the case of sheet metal body components, flats or flanges of two or three components are placed together and then a series of spot welds penetrating from the top sheet layer through into the bottom layer are made to securely attach the panels. Welding practices have been developed for such spot welding operations. Good welding practices are particularly critical in joining aluminum sheet alloys because of the high electrical and thermal conductivity of the material and the omnipresent oxide coating on the surface. Similar welding challenges arise in the welding of other light metal workpieces such as parts made of magnesium alloys. The spot welding operation is accomplished by assembling the parts in a suitable fixture and pressing welding electrodes against opposite sides of the overlying or touching parts at the intended weld location. The welding electrodes usually provide both clamping force and current commutation for the weld.
Copper or copper alloy welding electrodes are often used in welding aluminum alloy workpieces. U.S. Pat. No. 6,861,609, titled Welding Electrode for Aluminum Sheets and assigned to the assignee of this invention, illustrates some such welding electrodes.
As illustrated in the '609 patent, the electrodes are often round cylinders with a welding face at one end shaped to engage the workpieces. The welding electrodes are part of a welding apparatus including a welding head or gun that can be moved and actuated to press two aligned and opposing electrodes against the assembled workpieces. The apparatus then delivers a momentary welding current to the electrodes to affect the weld. Workpiece metal layers between the electrodes are momentarily melted by electrical resistance heating to form a weld nugget joining the layers. The clamping force, the value of the welding current (often single phase alternating current, 60 Hz, or rectified direct current) and current duration (several cycles of the 60 cycle current) are also specified for the electrodes to be used and the welding task.
In vehicle manufacturing or other industrial process, each welding gun is typically used to make a rapid succession of welds, for example, around the periphery of two or more overlying panels. The high electrical and thermal conductivity in combination with the insulating nature of the naturally-formed surface oxides of aluminum alloys (or magnesium alloys) makes them difficult to weld using spot welding practices previously developed for steel alloys. In the case of light metal alloys, the spot welding process is sensitive to a large number of variables beyond the normal welding parameters of electrode configuration, electrode force, weld time, and weld current. These other variables include sheet surface oxidation, sheet surface cleanliness, sheet surface topography as well as process variations such as alignment of the electrodes to the sheet, location of electrodes relative to the sheet edge and part radius, metal fit up, gun stiffness, alignment of electrodes on the gun, electrode surface roughness, and wear of the electrode surface.
The welding faces of some electrodes are roughened by blasting with small steel or sand particles or abrasion with a coarse abrasive paper as illustrated in the '609 patent. The roughened surface is characterized by randomly distributed craters with peak to valley dimensions, for example, in the range of 5 to 30 micrometers and with substantially the same range of peak to peak spacing. This texture permits the electrode face to penetrate an oxide film on the workpiece surface to reduce electrode resistance (and overheating) at the contact surface of the electrode and part. But, whether textured or not, the tips or welding faces of the electrodes may be altered by erosion or by adhesion and buildup of workpiece material after several welds. Welding operations must then temporarily cease while the electrode faces are cleaned, or re-shaped, or re-dressed. The redressing of grit blasted electrode faces, for example, can require many tens of seconds of off-line processing.
There is a need to provide a resistance welding electrode with a contoured welding face that improves electrical contact with a workpiece surface and the reliability of resistance welding, and decreases the time required for re-dressing of the welding face during welding operations. Such an electrode would be useful in many welding applications and would be particularly useful in welding light metal alloy workpieces with their oxide surface films.
SUMMARY OF THE DISCLOSURE
This invention is applicable to electrodes or electrode caps or welding face surfaces especially for electrical resistance welding. Such electrode members often have round cylindrical bodies for easy securing in the electrode holder of a welding gun. An end of the electrode may be tapered from the diameter of the body to form a welding face. The welding face of the electrode may be machined so that the welding surface comprises concentric circular geometric features (ridges or grooves) instead of the random roughened surface achieved by grit blasting. Suitably, a pattern of concentric circular ridges or grooves starts at the center of the welding face and extends radially outwardly over the face of the electrode. The circular contours may extend from the welding face onto a tapered portion of the electrode because a tapered portion of the electrode may be brought into engagement with a part to be welded.
The concentric ridges or grooves are formed, respectively, to have circular surfaces projecting outwardly from the face of the electrode or inwardly into the face of the electrode so that these formed surfaces engage and possibly penetrate the surface layer or film of a workpiece. Each (or some) of the concentric ridges or grooves may be separated from their radially-spaced neighbors by a flat ring-shaped surface in the face of the electrode. By way of example, the circular ridges or grooves are suitably formed to have a peak-to-base height in the range of about 20 to 200 μm with a peak-to-peak or base-to-base spacing (depending on the profile of the ridges or grooves) of 80 μm to 1500 μm. This circularly contoured welding face pattern is easily formed on new electrodes.
Thus, a single-step process is provided that simultaneously provides the benefits of both electrode dressing, i.e., electrode reshaping, good alignment, electrode surface cleanliness, etc., with the benefits of a texturing process, i.e., improved mechanical stability, low contact resistance, and reduced external expulsion. This may be achieved by preparing (for example, machining) electrode dressing blades to cut or otherwise produce a circular contoured surface on the welding face (at least) of the electrode tip. This circular pattern is achieved by putting a series of fine grooves or ridges into the face of a dressing blade. For example, the circular grooves may have cross-sections that are semi-circular or saw-tooth (triangular) or sinusoidal in configuration. During electrode dressing, these grooves/ridges cut and produce corresponding ridges or grooves on the dressed surfaces of the electrode. As an example, grooves or channels can be machined into a tool steel blade using EDM machining.
The concentric circular ridge or groove design for the electrode cap provides improved welding performance of the electrode. It is also a textured pattern that can be restored very rapidly to the electrode face as it is re-dressed for continued welding operations.
Other objects and advantages of the electrodes will become apparent from a detailed description of some exemplary preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of aligned and opposing welding electrodes engaging assembled sheet metal panels for a resistance welding operation.
FIG. 2 is a schematic representation of the electrodes of FIG. 1 positioned to have their welding faces re-dressed by a cutter blade shaped for cutting concentric round ridges in the faces of the tools.
FIG. 3 is an enlarged view of a cutter blade positioned under a welding electrode for the formation of concentric round ridges in the face of the tool.
FIG. 4 is an enlarged view of an electrode with a tapered conical tip and a machined crowned welding face with a ridge-containing surface.
FIG. 5 is an enlarged view of an electrode with a truncated hemispherical tip portion and a crowned welding face with a machined ridge-containing surface.
FIG. 6 is an enlarged view of a portion of the face of the welding electrode of FIG. 3 showing two of the ridge rings and an intervening “flat” area in the welding face of the electrode.
DESCRIPTION OF PREFERRED EMBODIMENTS
A welding electrode cap (or welding face) design is provided that is useful for forming spot welds in metal workpieces. The welding electrode cap is useful in spot welding operations generally, and it offers advantages for welding light metal workpieces such as aluminum alloy and magnesium alloy sheet materials. These materials often have an oxide film on surfaces contacted by the aligned and opposing electrodes and it is preferred that the electrode faces be shaped to engage and pierce the oxide film during welding.
In the manufacture of car doors, deck lids, liftgates, and the like, for example, it is often the practice to form these parts of complementary inner and outer sheet metal panels. The panels are of complex curvature for overall design effect and to contain any necessary electrical wiring and/or hardware between them. The formed panels usually have flanges at their peripheral edges for joining. An inner panel is placed against an outer panel and the assembled workpieces positioned for the formation of a series of progressively formed electrical resistance spot welds in a bonding pattern along their flanges. In one type of welding operation, the assembled panels might be moved and positioned between the welding arms of a stationary pedestal welding machine In another type of welding operation, the assembled panels might be held in a fixed position and a robot progressively move a welding gun around the periphery of the workpieces to sequentially form the welds.
FIG. 1 illustrates a welding operation in which a spot weld is to be formed at a welding site 14 (shown as a dashed line weld nugget to be formed) in two juxtaposed aluminum alloy panels 10 , 12 (only the overlapping edges of panels 10 and 12 are shown for simplification of the illustration). An upper welding gun arm 16 has an electrode holder 18 that holds welding electrode 20 in shank 22 . The welding electrode is often water-cooled by means not illustrated. Welding gun arm 16 is part of a fixed welding apparatus or robot-carried welding apparatus, not shown. A lower welding arm 24 is also carried on the welding apparatus. Lower welding arm 24 has an electrode holder 26 that holds welding electrode 28 in shank 30 .
Welding electrode 20 carried by the upper welding arm 16 is shown in spot weld forming engagement with the outer (upper in FIG. 1 ) surface of panel 10 and welding electrode 28 carried by lower welding arm 24 is shown engaging the outer (lower) surface of panel 12 . In a spot welding operation electrical current of suitable current value and duration is passed between the tips of opposing and aligned electrodes 20 , 28 through the overlying panels 10 , 12 at weld site 14 . The electrodes 20 , 28 are pressed together, suitably in a predetermined pressure schedule, to press the panels 10 , 12 together at the weld site 14 and to obtain a suitable preprogrammed momentary current flow for resistance heating of the metal at the weld site 14 . Metal in the current path is momentarily melted. The welding current is stopped; the molten metal rapidly loses heat to the water-cooled electrodes and the surrounding panel material and solidifies as a weld nugget joining panels 10 , 12 at weld site 14 . The opposing electrodes 20 , 28 are then withdrawn.
This welding sequence is usually completed in a matter of a second or so. The panels or electrodes are moved to a nearby weld site and the process is repeated until a suitable predetermined number of spot welds are formed to secure panels 10 and 12 . Then another workpiece assembly is brought into proximity of the welding apparatus and a new sequence of welds formed. As will be described, the faces of the electrodes play a role in forming of each weld and in the efficiency of the ongoing welding process.
The welding faces of the electrodes gradually become eroded and/or accumulate unwanted deposits. The welding apparatus is then usually temporarily withdrawn from “on-line” operation so that the faces of the electrodes can be repaired or an electrode replaced.
In this example, electrode 28 is identical to electrode 20 , but the electrodes are not necessarily the same shape. Electrode 20 is further illustrated in FIGS. 2 , 3 , 4 , and 6 . Referring to FIG. 3 , electrode 20 has a round body 40 with a hollow receptacle 42 adapted to receive a shank 22 for insertion into holder 18 of a welding arm 16 . And electrode 20 has a tapered transition section 44 with a spherically crowned welding face 46 . A series of concentric circular ridges 48 are formed in and constitute the welding face surface 46 of welding electrode 20 . The pattern of circular ridges 48 (or in another embodiment, grooves) may extend onto the tapered surface 44 of electrode 20 , but this is not illustrated in FIG. 3 .
FIG. 4 illustrates a portion of the body 40 and tapered end portion 44 of electrode 20 in cross-section. Referring to FIG. 4 , and by way of example, the diameter (dimension A in FIG. 4 ) of electrode body 40 is often about 12.5 mm to 22.2 mm The diameter of the electrode body is usually not critical but it must be strong enough to withstand the 700 to 1500 pound (or so) weld force applied for welding a variety of aluminum gauges, and it must be at least the diameter of the welding face 46 .
The planar diameter (dimension B in FIG. 4 ) of the spherically crowned or domed welding face 46 of electrode 20 is, for example, between about 6 and 12 mm Welding face 46 may preferably be rounded or crowned with an exemplary radius (dimension C in FIG. 4 ) of about 25.4 mm
A plurality of round concentric ridges 48 ( FIGS. 3 , 4 , and 6 ) are formed in the spherically crowned welding face 46 of electrode 20 . These ringed-ridges 48 extend radially outward from the center of weld face 46 , the longitudinal axis (axis 47 in FIG. 6 ) of round cylindrical electrode 20 . In a preferred embodiment, each contoured ridge 48 is nearly semi-circular in cross-section (see FIG. 6 ), with its cross-sectional circumference arising upwardly from the surface of the crowned profile of face 46 with a sloped “flat” ring 49 (or base) on the spherically crowned surface between each contoured ridge ring 48 . Of course, each contoured ridge 48 and each intervening flat ring 49 is of increasing radius as it is formed radially outwardly from the center of the electrode face 46 . By way of example, the diameter of the base of each contoured ringed ridge may be about 125 micrometers and the width of each intervening flat ring may also be about 125 micrometers.
In a preferred embodiment, the contoured rings are machined in the crowned face of the electrode. As illustrated in FIG. 2 , a single piece cutter blade 50 is prepared with two cutting surfaces 52 , 54 for cutting upraised concentric rings in the welding face surfaces of two electrodes 20 , 28 . The welding arms have positioned the welding faces of welding electrodes 20 , 28 against the cutting surfaces 52 , 54 , respectively. This operation could be for the purpose of forming the concentric rings on new welding electrodes or for re-dressing the welding faces of used electrodes. The end 56 of the cutting surfaces 52 , 54 of cutter blade 50 extends to the aligned longitudinal axes of electrodes 20 , 28 .
Cutter blade 50 is carried in a rotating cutting tool (not shown) that rotates the cutter blade 50 around the aligned center axes of the opposing electrodes. FIG. 3 presents an enlarged view of a portion of FIG. 2 with the lower electrode 28 removed to better illustrate the lower cutting surface 54 of cutting blade 50 . The end 56 of the blade is at the center axis of the aligned electrodes. The electrodes are pressed against the cutting surfaces 52 , 54 of cutting blade 50 which rotates around its end 56 to cut concentric circular ridges 48 and intervening flat rings 49 and in the faces of the electrodes 20 , 28 .
Cutting surfaces of blade 50 are curved in complementary conformance with the domed face surfaces of electrodes 20 , 28 and provided with cutting surfaces for forming or re-forming the concentric contours in the electrode faces. The cutter surfaces 52 , 54 may be shaped by electrical discharge machining or other suitable process to have curved circular cutter teeth 59 spaced by intervening “flat” (actually sloped) recessed cutter surfaces 58 . Cutter teeth 59 and recessed cutter surfaces 58 are sized and located along cutter surfaces 52 , 54 for forming the contoured faces (e.g., face 46 ) in electrodes 20 , 28 . Cutter teeth 59 are illustrated in FIG. 3 as extending straight across cutter surface 54 of cutter 50 , but they may be curved for more accurate cutting of ridges 48 in electrode 20 . The welding face of each electrode then has formed upstanding concentric rings of ridges of semicircular cross-section separated by concentric flat ring spaces. Two of these ridges 48 with an intervening flat ring 49 , starting from the center of the crowned face of electrode 20 , are illustrated in FIG. 6 .
The rings of ridges 48 start at the center of the round welding face 46 and become progressively radially larger across the face. Ridges 48 are used to improve engagement of welding face 46 with the surface of a work piece to be welded. They assist in gripping the workpiece and penetrating a surface oxide layer. They improve electrical conductivity and reduce overheating and oxidation of the workpiece surface.
Electrode face ridges 48 may be formed in different continuous concentric or spaced concentric shapes such as, for example, saw tooth (triangular) or sinusoidal shapes. While the formation of the contoured surface has been illustrated by the use of a rotating cutter blade other surface shaping methods may be used.
FIG. 5 illustrates (in cross-section) a different electrode shape with a different face contour. Electrode 60 has a round cylindrical body 62 with a hemispherical tip 64 having the radius of the body portion 62 . The hemispherical tip 64 is truncated and spherically crowned using a larger radius than the tip radius to form domed face 66 on the rounded hemispherical peripheral tip 64 . By way of example, the diameter (dimension A in FIG. 5 ) of electrode body 60 may be about 12.5 to 22.2 mm The planar diameter (i.e., in plan view, dimension B in FIG. 5 ) of the welding face 66 of electrode 60 is, for example, about 6 to 12 mm Welding face 66 may preferably be rounded or crowned with an exemplary radius (dimension C in FIG. 4 ) of about 20 to 150 mm or greater. The concentric rings of ridges 68 formed in the welding face 66 are of triangular cross-sectional shape. In this example no relatively flat ring surfaces (like surfaces 49 in FIG. 6 on hemispherical face 46 of electrode 20 ) have been formed between the concentric, circular, radially spaced, triangular-cross section ridges 68 .
The forming or dressing of the concentric rings of ridges or grooves on the welding faces (and, optionally, the tapered side surfaces of the faces) of the welding electrodes can be done following different strategies. Obviously, provision must be made in the original length of the electrode body and tip portions to accommodate repeated removal of material if the welding face of the electrode is to be repeatedly redressed. For example, in one strategy, if the grooves/ridges on the electrode can be brought into registry with the ridges/grooves on the cutting blade during dressing, then a small amount of metal can be removed to refinish the electrode without completely re-cutting the ridges/grooves. Experience in spot welding aluminum in production runs has shown that as little as 50 μm of metal can be removed to refinish the weld face. Where the size of the electrode permits a total depth of cut of 8 mm into the electrode face, which is also possible, this would result in up to 160 dresses. Where obtaining registry between the electrode and dressing blade is not possible and new ridges/grooves need to be cut for each dressing, then the size of the ridge/groove features should be such that they can be cut without removing an excessive amount of the electrode face. In this case, to achieve a reasonable number of dresses on an electrode (>40), less than ˜200 μm of metal would be removed per dress and still maintain an adequate amount of copper (˜2 mm) before penetrating the water passage. This would suggest that the ridges/groove features to be machined into the electrode should have a peak-to-peak height of at most 200 μm. In general, to be effective the weld face should incorporate a minimal number of ridges/grooves, i.e., three or more. To accommodate three concentric ridges/grooves on an electrode face, for example, 8 mm in diameter the maximum spacing between each feature would be about 1500 μm. For complete re-cutting of the electrode face, the grooves/ridge features would most likely have a peak-to-peak height of 20 μm to 200 μm with a spacing of 80 μm to 1500 μm, respectively.
Besides machining of grooves or ridges into the cutter face, the cutter could be designed from the outset with a textured face such as a saw tooth wave or sine wave. This would be able to produce even rougher surfaces for a given peak-to-peak height of the texture, but may be much more difficult to produce than the previous designs.
A simpler alternative to machining grooves or ridges into the cutting face of the blade would be to grind the cutting face with a rough grinding tool that puts a random set of grooves and ridges into the dressing blade. During dressing, a mirror image pattern of these features will be produced on the electrode surfaces. Since registry of the features of the blade and electrode might be more difficult to obtain in this case, the peak-to-peak height of the machined blade should be less than ˜200 μm.
For blades that contain multiple cutting flutes (2 or more on a single electrode face), it may become apparent that the texturing pattern on the cutting flutes does not produce the desired pattern on the electrode face because it is not possible to perfectly align the flutes with each other and the electrode face. In this case, only one of the cutting flutes could be designed to produce the texture while the other flutes are machined so they do not contact the electrode face. Alternatively, the multiple flutes could be designed to each texture a different radial area of the electrode face leaving the remainder of the face undisturbed.
Use of welding electrodes with concentric contoured welding faces can significantly improve process robustness and weld quality for resistance spot welding of light metals. This is achieved by producing geometrically consistent, clean electrode surfaces that will be perfectly aligned on the weld gun. In addition, the surface texture produced on the welding electrodes will mechanically stabilize the welding process and significantly reduce surface expulsion, which not only harms weld quality, but detrimentally impacts paint surface quality.
In general it is preferred to form welding electrodes of copper or copper alloys because of the strength and electrical conductivity properties which are very useful in making spot welds using electrical resistance heating.
The welding electrodes have been described in terms of certain preferred embodiments but other welding face shapes may be used.
|
A cutting tool that can cut concentric ringed features (e.g. protruding ridges or intruding grooves) onto a weld face of an electrical resistance welding electrode is disclosed. The cutting tool includes a cutter blade that can be rotated about the electrode weld face. The cutter blade has at least one cutting surface configured to cut the concentric ringed features onto the weld face when the cutting surface is rotated relative to the weld face while engaged therewith.
| 8
|
[0001] This application claims priority from Canadian Patent Application Nos. 2,355,513 and 2,355,540, both filed on Aug. 20, 2001, and incorporated herein by reference. The invention relates to the field of automated sewing machines, and more specifically to automated sewing machines that are controlled by external computers over high speed networks.
BACKGROUND OF THE INVENTION
[0002] It is assumed in the following description that sewing includes all forms of thread manipulation, such as embroidering, button holing and the like.
[0003] Existing automated sewing machines for commercial and industrial use may be classified into two main categories. The first category includes automated machines that have an integrated control panel and a dedicated on-board computer, that reads design files describing a sewing or embroidery pattern from a floppy drive, that allow for limited manipulation of the design, and that control machine operations to produce the design. The second category includes automated sewing machines that typically have a RS-232 communications port for the purpose of receiving design data or files from an external computer. Being stored temporarily, the files are then interpreted and sewn by the machine.
[0004] A disadvantage of both of these categories of machines is that they rely on slow interfaces that are coupled to an on-board computer that reads design files, interprets the files, and then operates the machine. The use of slow interfaces such as RS-232 limits machine networking capabilities and operational flexibility. Moreover, such the dedicated nature of the on-board computer represents a barrier to creating low cost, automated machines.
[0005] Recent domestic sewing and embroidery machine models sold to consumers for household use may allow for communication of data files from a personal computer (“PC”) via a serial connection. However, compared to traditional home sewing machines, these newer machines have proven to be quite expensive. These machines are limited in functionality and quality as machine designers have been forced to compromise their operational and mechanical specifications in order to achieve a lower target price. In these machines, the serial connection serves merely as a relatively slow means for transferring an entire or partial data file to the machine. That is, the serial connection is typically not adequate for providing real time control from an external host control system or to support networking. In addition to controlling machine operation, the dedicated on-board computer must perform the functions of reading a design file and interpreting it and responding to the minimal human machine interface (“HMI”) that is typically resident on the machine's control panel.
[0006] There is thus a need to reduce the price limitations while improving the operational limitations of current sewing systems.
[0007] A still further need exists for a cost-effective automated sewing machine system that will allow for efficient networking and machine control.
SUMMARY OF THE INVENTION
[0008] In accordance with this invention, there is provided a sewing machine comprising:
[0009] (a) one or more motion means to effect a sewing function, each motion means having a dedicated motion control processor responsive to sewing commands addressed to said motion control processor, for controlling said motion means to effect said sewing function; and
[0010] (b) a high speed communications interface for exchanging information between each said motion control processor and an external computer, whereby said sewing commands are determined by the external computer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Embodiments of the invention may best be understood by referring to the following description and accompanying drawings in which:
[0012] [0012]FIG. 1 is a block diagram illustrating an automated sewing machine system in accordance with an embodiment of the invention; and
[0013] [0013]FIG. 2 is a schematic diagram showing a networked arrangement of sewing machines according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] In the following description, numerous specific details are set forth to provide a thorough understanding of the invention. However, it is understood that the invention may be practiced without these specific details. In other instances, well-known structures and/or processes have not been described or shown in detail in order not to obscure the invention. In the description and drawings, like numerals refer to like structures or and/or processes.
[0015] The invention provides an automated sewing machine system that includes a high-speed communications interface to an external network or computer for control of sewing machine functions. The high-speed communications interface may include Ethernet, USB, or IEEEE1394 (Firewire, iLink).
[0016] Advantageously, the invention allows control electronics to be located in a low cost PC system thereby allowing for the removal of expensive on-board, embedded or integrated control computers from sewing machines. This provides considerable cost savings and increased system operation flexibility.
[0017] System. Referring to FIG. 1, there is shown a block diagram illustrating an automated sewing machine system 100 in accordance with an embodiment of the invention. The automated sewing machine system 100 includes an external computer 110 , an automated sewing machine 120 , and an interface cable 130 between the computer 110 and automated sewing machine 120 .
[0018] The external computer 110 may include a central processing unit or CPU, memory, and a display. The input device may be a keyboard, mouse, trackball, or similar device. The CPU may include dedicated coprocessors and memory devices. The memory may include RAM, ROM, databases, or disk devices. And, the display may include a computer screen or terminal device.
[0019] The automated sewing machine 120 includes a serial interface connector 140 , motion means such as integrated motors 160 with associated sensors 161 , intelligent input/output (“I/O”) boards 170 with associated solenoids/relays 171 and sensors 172 , and motion control processors such as intelligent driver boards 180 for motors 181 . The integrated motors 160 , I/O boards 170 , and intelligent driver boards 180 are connected to a serial network 150 . The serial network 150 is connected to the external computer 110 through the serial interface connector 140 and interface cable 130 . The automated sewing machine 120 or its internal electronics 160 , 161 , 170 , 171 , 172 , 180 , 181 may also include a central processing unit or CPU, memory, and a display. The input device may be a keyboard, mouse, trackball, or similar device. The CPU may include dedicated coprocessors and memory devices. The memory may include RAM, ROM, databases, or disk devices. And, the display may include a computer screen or terminal device.
[0020] The automated sewing machine system 100 has stored therein data representing sequences of instructions which when executed cause the method described herein to be performed. Of course, the sewing machine system 100 may contain additional software and hardware a description of which is not necessary for understanding the invention.
[0021] The automated sewing machine 120 includes electronics 160 , 161 , 170 , 171 , 172 , 180 , 181 necessary for machine control and a high speed connection 130 , 140 in the form of an Ethernet interface, a USSB interface, or an IEEE 1394 l interface. The automated sewing machine 120 and/or its internal electronics 160, 161, 170, 171, 172, 180, 181 includes software for receiving machine commands from an external source such as the external computer 120 via the high-speed connection 120, 130. The automated sewing machine 120 and/or its internal electronics 160, 161, 170, 171, 172, 180, 181 also includes software for sending machine control or status commands to an external computer 120, be it a host PC, a PDA, or another machine with an embedded CPU or host computer, via the high-speed connection 130, 140, 150.
[0022] The automated sewing machine system 100 operates as follows. Being connected to an external computer 110 , the automated sewing machine's internal electronics 160 , 161 , 170 , 171 , 172 , 180 , 181 receive initialization and motion and sewing commands via the high-speed interface 130 , 140 , 150 . The internal electronics 160 , 161 , 170 , 171 , 172 , 180 , 181 then execute machine operations based on the received commands while monitoring machine functioning, responding to alarms provided by safety systems (not shown), or sewing machine sensors 161 , 172 , and providing machine operation or status feedback to the external computer 110 via the high-speed interface 130 , 140 , 150 .
[0023] The motion and sewing commands and parameters received by the internal electronics 160 , 161 , 170 , 171 , 172 , 180 , 181 contain all the information required by the automated sewing machine 120 to sew or cut a desired design. The machine's internal electronics 160 , 161 , 170 , 171 , 172 , 180 , 181 take the motion and sewing commands and parameters and generate the desired action. Sensors 161 , 181 in the system feedback information to the external computer 120 concerning machine operation. This fedback information may be used to refine subsequent motion and sewing commands and parameters.
[0024] An advantage of the present invention is the high-speed interface 130 , 140 , 150 that is integrated with the automated sewing machine 120 . As mentioned, this interface 130 , 140 , 150 may be an Ethernet interface, a USB interface, or an IEEE1394 interface. The interface 130 , 140 , 150 provides high-speed communications allowing for real-time or near real-time control and monitoring of the automated sewing machine 120 by an external computer, PDA or other machine 110 . This allows the automated sewing machine 120 to be optimized to perform The functions of sewing, cutting, etc. the desired design as specified by the external computer 120 .
[0025] Another advantage of the invention is that the high-speed serial network or bus 150 allows the automated sewing machine 120 to have distributed control functionality. For example, each motor 181 included in the machine 120 includes a controller 160 , 180 having a unique identification (“ID”), for responding only to commands received with that unique identification from the external computer 120 . In this way, the motors 181 may be connected to a single bus 150 and respond only to commands having their unique ID while ignoring others command. By using such distributed control functionality the cost of the automated sewing machine 120 is typically reduced while its flexibility is increased.
[0026] Referring to FIG. 2, there is shown a block diagram illustrating an automated sewing machine network 200 in accordance with an embodiment of the invention. The automated sewing machine network 200 includes an external computer 110 which is coupled to multiple automated sewing machines 120 via an interface cable network 130 . Each automated sewing machine 120 includes internal electronics including intelligent driver boards or motion control processors 180 and motors 181 . The external computer 110 connects to each machine's internal network 150 via a serial interface 140 . Through the automated sewing machine network 200 , 150 , an external computer 110 can send commands (i.e. Command 1 , Command 2 , . . . , Command X) to addressed machines and/or machine components (e.g. ID 1 , ID 2 , . . . , ID N) on the network. The computer 110 can be separate from or attached to a given machine 120 . All control commands and responses are transmitted along the serial network 150 within the machine 120 . Intelligent devices such as motion control processors 180 may have one or more network interfaces that allow connection to the network backbone 150 . The network 200 , 150 may have a daisy chain, multi drop, or tree structure. This is an advantage over existing automate sewing machines that typically a central controller within the machine that is connected to multiple motor drivers and I/O interfaces.
[0027] In an alternate embodiment, the automated sewing machine includes on-board controller (not shown) that is coupled between the serial interface connector 140 and serial network 150 . This on-board controller acts as an intermediary between the external computer 110 and serial network 150 and it may include a central processing unit or CPU, memory, and a display. The input device may be a keyboard, mouse, trackball, or similar device. The CPU may include dedicated coprocessors and memory devices. The memory may include RAM, ROM, databases, or disk devices. And, the display may include a computer screen or terminal device.
[0028] With this alternate embodiment, the automated sewing machine's control, monitoring, and design manipulation electronics and software are again separated from the machine's internal electronics 160 , 161 , 170 , 171 , 172 , 180 , 181 . The on-board controller performs the function of command exchange with the external computer 110 . The external computer 110 handles the function of interpreting the desired design and transforming it into motion commands. It also provides an interface for machine parameter adjustment and monitors machine sensors 161 , 172 , providing safety and user feedback functions.
[0029] Advantageously, this embodiment also provides an automated sewing machine 120 without an internal control system for interpreting design files and for generating and providing motion commands to the machine's internal electronics, with the exception of safety related mechanisms. By using an external control system or computer 110 , the automated sewing machine 120 requires minimal electronics to execute motion and to sense operation. A dedicated, feature rich, user interface for the automated sewing machine 120 becomes unnecessary and this user interface may be using the external computer 110 . The function of modifying designs based on direct user interaction is performed using the external computer. This reduces cost, complexity and size, allowing for advances in design and market penetration. The external control control system or computer 110 may include an inexpensive, mass produced PC which will allow for diversity and flexibility through continued independent advances in software and hardware.
[0030] Data Carrier Product. The sequences of instructions which when executed cause the method described herein to be performed by the automated sewing machine system 100 of FIG. 1 can be contained in a data carrier product according to an embodiment of the invention. This computer software product can be loaded into and run by the automated sewing machine system 100 of FIG. 1.
[0031] Computer Software Product. The sequences of instructions which when executed cause the method described herein to be performed by the automated sewing machine system 100 of FIG. 1 can be contained in a computer software product according to an embodiment of the invention. This computer software product can be loaded into and run by the automated sewing machine system 100 of FIG. 1.
[0032] Integrated Circuit Product. The sequences of instructions which when executed cause the method described herein to be performed by the automated sewing machine system 100 of FIG. 1 can be contained in an integrated circuit product including a coprocessor or memory according to an embodiment of the invention. This integrated circuit product can be installed in the automated sewing machine system 100 of FIG. 1.
[0033] Although preferred embodiments of the invention have been described herein, it will be understood by those skilled in the art that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims.
|
A sewing machine comprising one or more motion means to effect a sewing function, each motion means having a dedicated motion control processor responsive to sewing commands addressed to said motion control processor, for controlling said motion means to effect said sewing faction; and a high speed communications interface for exchanging information between each said motion control processor and an external computer, whereby said sewing commands are determined by the external computer.
| 3
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional application of application Ser. No. 10/313,239, filed Dec. 5, 2002; the application also claims the priority, under 35 U.S.C. §119, of Austrian utility model application GM 692/2002, filed Oct. 18, 2002 and German application No. 20216059.9, filed Oct. 18, 2002; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a brush head for one-time use with bundled bristles.
WO 01/15587 A1 describes a toilet brush with such a brush head that features a sleeve that can be attached to the front end of a handle and in which sleeve a bundle of bristles is fastened The brush head as a whole consists of a water-soluble material, e.g. of pulp, paper, or the like, with each bristle being formed by a rolled-up strip of paper or the like. After use, the brush head is stripped off, or, respectively, thrown off and can thus be flushed off together with the wastewater. The brush heads can be kept in storage in a dispenser, with the bristle bundle being held together by a protective cover that is to be removed prior to use.
BRIEF SUMMARY OF THE INVENTION
The invention made it its task to provide a brush head that is easy to manufacture. According to the invention, this is achieved by forming the bristle bundle from a single metal strip. The bundle of bristles is thus one piece, meaning that the bristle, do not need to be manufactured and bundled individually but can rather be created through incisions.
A basically rectangular, flat metal strip can be folded into the desired cross section shape of the bristle bundle. Through zigzag folding, the bundle of bristles may not only have a square or rectangular cross section shape but even approximate a round one. Furthermore, an essentially round brush head can be achieved by winding the rectangular strip of material in spiral shaper or, respectively, by rolling it into a cylinder and providing it with longitudinal ribs.
Furthermore, the flat strip of material may feature ribs that radiate from a central section. In this case, the geometric shape of this strip of material can be selected at will, and the strip could even be round. In the case of a non-round strip, bristles of varying lengths may result.
In a preferable model, the flat strip of material is provided with incisions or stampings from which the bristles result. The incisions extend in particular over approximately one to three quarters of the width of the strip of material, leaving a continuous, solid border strip comprising the remainder of the width that can be stuck onto a holder or a handle or the like for a separable connection and/or mounting. Preferably, this marginal strip also provides the cohesion of the bundle of bristles by treating the surface areas that touch each other during the folding, rolling or winding process with water-soluble glue. Cohesion may also be achieved by way of a sleeve that the wound, rolled up and/or folded bundle of bristles is inserted into while being connected to the sleeve along the marginal strip.
If the bristles are modeled in radiating fashion on a central section, the central section is inserted into the sleeve, causing the bristles to essentially rise parallel to each other. Again, the sleeve can be stuck onto the holder or the handle.
In order to facilitate the insertion into the sleeve and, respectively, to make it more difficult for the gluing to come apart, a provision may be added by rounding at least one of the two corners on the material strip opposite the bristles.
Another preferred model provides for the uncut longitudinal marginal area of the material strip to have a narrower and a wider part. The length of the wider part corresponds approximately to the circumference of the bristle bundle, allowing the wider part to be rolled into a sleeve during the rolling of such a material strip that can then be attached to the holder or the like.
The material strip consists in particular of pulp or the like, i.e. material that will swell or disintegrate in water, permitting the bristles to form only at the time of the first wetting. Therefore it is possible to place the incisions in such a manner that they remain connected by material bridges that quickly break during wetting and allow the individual bristles to form or that, respectively, release them. These material bridges prevent any expansion of the flee bristle ends due to the tensions occurring during the rolling or folding of the material strip
In an initial model, the incisions comprise, for example, only part of the thickness of the material strip allowing for an uncut, solid continuous surface to remain. When the material strip is wound or rolled to the bundle of bristles, the continuous surface may be located inside or outside since the wet material bridges will disintegrate in any event. If the continuous surface is located on the inside, the incisions will open because of the curvature, and the individual bristles will be visibly indicated
In a second model the incisions may penetrate the entire thickness, and each incision is divided by a ridge into two segments of equal length. The ridges complement each other to a narrow area continuing across the length of the material strip.
The material strip may be soaked with a cleaning or disinfecting agent at least within the area of the bristles
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in brush head, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
In the following, the invention is described in detail in three sample models by way of the figures shown in the attached drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 showing an oblique view of a flat material strip,
FIG. 2 showing a partially wound up material strip
FIG. 3 showing detail A in an enlarged representation,
FIG. 4 showing a bundle of bristles with an attachable sleeve,
FIGS. 5-7 showing representations identical to FIGS. 1-3 in a second embodiment;
FIG. 8 showing a variant of a bristle bundle
FIG. 9 showing a horizontal projection of a third embodiment of the material strip,
FIG. 10 showing a partially wound material strip of the third embodiment,
FIG. 11 showing a horizontal projection of a fourth embodiment of the material strip,
FIG. 12 showing a schematic representation of the production of a fifth embodiment, and
FIG. 13 showing another variant of a bristle bundle manufactured in this manner.
DETAILED DESCRIPTION OF THE INVENTION
The flat, substantially rectangular material strip 1 shown in FIGS. 1 , 5 , 9 , or 12 made of pulp or similar material that will swell through water absorption and thereby lose its stability and finally disintegrate is provided in an initial segment with bristle 3 forming incisions 4 . The segment provided with the incisions 4 comprises approximately two to three quarters of the width of the material strip 1 , assuring that the remaining marginal segment 2 is closed which in FIGS. 1 , 5 , or 9 features at least one rounded or beveled corner 10 . The incisions 4 represent bristles 3 . In the model according to FIG. 1 , as shown in detail A in FIG. 3 , the incisions 4 comprise only a part of the thickness of the material strip, accounting for the fact that on the one surface 6 they are visible, but not on the other surface 5 ( FIG. 2 ). Therefore, each incision 4 is delineated in its depth by a material ridge that forms the continuous surface 5 .
If, as shown in FIG. 2 , the material strip 1 is rolled up, the bundle of bristles 11 is created when the continuous surface 5 is located on the inside. Tile incisions 4 widen somewhat during the rolling process, and the bristles are clearly visible even though they are connected via the inside material ridges. Cohesion of the rolled-up bundle of bristles 11 is provided by a water-soluble glue that is applied to the marginal area 2 prior to the rolling up process. At least the one corner 10 is rounded or beveled that is located oil the outside of the rolled-up bundle of bristles 11 ( FIG. 4 ), meaning that, on the one hand, the glue on the corner 10 will detach less easily before its time due to outside mechanical influences and, on the other hand, that the bristle bundle 11 can be inserted more easily into a sleeve 12 . The sleeve 12 can either be part of the brush head and can also be made of a material that will disintegrate in water, in which case the sleeve can be stuck onto a holder or handle in detachable fashion, or it already represents the receiving end of tile holder or handle.
The model according to FIGS. 5 through 7 differs from the model according to FIGS. 1 through 3 only in that the incisions 4 , while comprising the entire thickness of the material strip 1 , they are, divided into two segments 8 and 9 , with a material bridge remaining between segments 8 and 9 that appears as a continuous ridge. The lengths of segments 8 and 9 could be in the ratio of 1.1 to 2:1.
FIG. 8 shows a variant of a bristle bundle 1 I that is formed through zigzag folding of the material strip 1 , in which case the distances between the folding edges increase from both sides towards the center of the material strip 1 . Distances of equal width between the folding edges lead to bristle bundles 1 I with a square or a rectangular cross section area.
FIGS. 9 and 10 show another material strip 1 whose uncut marginal area 2 is graduated. A wider section 13 comprises a length that corresponds approximately to the circumference of the bristle bundle 11 , meaning that the sleeve 12 is formed from this part 13 during the rolling process. The material bridges are again formed by the ridge 7 , but they could also result from incisions 4 not exceeding the thickness. For stabilization of the sleeve 12 , an overlapping strap 14 could be provided on at least one side
In the model according to FIG. 11 , the flat material strip 1 features a round basic shape from which the bristles 3 are cut out in radiating fashion. Incisions 4 reaching close to the central section 15 permit the folding of the flat material strip to a bristle bundle 11 when the central section 15 is pressed into a sleeve 12 . These incisions 4 , too, can be limited to part of the thickness of the material strip through the formation of material bridges. The central section 15 may feature a hole, if necessary, in order to provide an empty space for the material during the erection of the bristles 3 .
The material bridges formed by the continuous surface 5 or, respectively, by the ridge 7 ensure the cohesion of the bristle bundle during the winding, rolling, or folding of the material, meaning that the non-conglutinated bristles 3 , in particular tile free ends of the exterior bristles will not spread outwardly. Therefore, the bristle bundle 11 features an essentially uniform cross section over its entire length so that it can be stored and/or handled in a storage package, a dispenser or the like without any protective cover or the like
FIG. 13 shows another variant of a bristle bundle that features a hollow cylindrical basic shape ill whose walls, for example, eight protruding ridges or, respectively, ribs 21 are formed. Between each two ridges or, respectively, ribs 21 , incisions 4 are provided that extend over two to three quarters of the height of the cylinder, with the rib sections separated by the incisions 4 forming the bristles 3 . The non-incised marginal area of the bristle bundle 11 can either be inserted into a sleeve 1 and conglutinated, similar to the model according to FIG. 1 . Since the bristle bundle 11 is hollow-cylindrical, the non-incised marginal area can also be stuck directly onto a holder or the like.
The incisions 4 can extend all the way across the thickness, as can be seen in FIG. 13 since, due to the stiffening U-shaped cross section of the individual bristles 3 , they need not be held together through material bridges. If desired, material bridges can still be provided in one of the versions described above.
FIG. 12 shows schematically the production of the bristle bundle according to FIG. 13 . The flat rectangular material strip 1 is rolled into a hollow cylinder 15 without any prior incisions and glued together along its abutting edges. The diameter of the hollow cylinder 15 is considerably larger than the diameter of the cylindrical core 16 that is used for the shaping and on which longitudinal ribs 17 are formed. Eight radially movable press elements 18 that in the work area are wedge-shaped provide an initial section with a Cutting edge 19 and a subsequent section with narrow frontal area 20 that is recessed from the cutting edge 19 . The press elements 18 , three of which are shown in FIG. 12 , press, in particular one after the other, the hollow-cylindrical material strip 1 between the longitudinal ribs 17 of the core 16 whereby the material strip is pressed against the surface of the core 16 . The cutting edges 19 of the press elements 18 thereby produce the incisions 4 while the dull frontal areas 20 only shape or, respectively, compress the material strip.
When used, for example, on a toilet brush, the bristle bundle is wetted, and the wetness as well as the cleaning action soften the material and break the thin material bridges that may have been provided, with the bristle bundle opening up like a brush. After use, the brush head can be stripped off the holder and flushed away together with the wastewater.
|
A brush head for one-time use is equipped with a bundle of bristles that is fashioned from a flat strip of material that disintegrates in water. The strip is formed with incisions defining therebetween the bristles of the brush. Material bridges connect the bristles to one another and they break up upon being wetted before said bristles disintegrate.
| 0
|
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. P 44 38 885.3, filed Oct. 31, 1994, which is incorporated herein by reference.
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. P 44 38 885.3, filed Oct. 31, 1994, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for measuring the sliver thickness in a drawing frame, particularly in a regulated drawing frame. The apparatus includes a sliver guiding device for guiding a plurality of simultaneously inputted fiber slivers at the inlet of the drawing frame. At least parts of the inner wall faces of the guiding device converge such that the side-by-side running slivers are brought together to form a sliver assembly in which the slivers assume a side-by-side contacting relationship in a single plane. Downstream of the guiding device, as viewed in the direction of sliver run, a roller pair is arranged which defines a nip through which the sliver assembly passes. By virtue of the frictional engagement in the nip, the roller pair pulls the sliver assembly through the sliver guiding device. Downstream of the roller pair the slivers diverge from one another. The sliver guiding device is associated with a biased, movable sensor element which, together with an operationally stationary counterelement, constitutes a constriction for the throughgoing sliver assembly. The sensor element executes excursions as the thickness of the sliver assembly changes. The displacements of the sensor element are applied to a transducer which, in response, generates control pulses. The counterelement situated opposite the sensor element may be adjusted and immobilized in its adjusted position.
In a known arrangement, in the absence of slivers in the sliver guiding assembly, the sensor element, urged by a biasing spring, moves into the outlet passage of the sliver guiding device and assumes a position close to, or even in contact with, the counterelement.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus of the above-outlined type in which an access from the exterior to the inner space of the sliver guiding device is facilitated, particularly for the purpose of cleaning or startup.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the apparatus for measuring sliver thickness in a drawing frame includes a sliver guiding device having converging inner wall faces for bringing a plurality of simultaneously introduced slivers together to form a sliver assembly constituted by side-by-side positioned running slivers arranged in a plane. The apparatus further includes a sensor element and a counterelement laterally contacting the sliver assembly from opposite sides. The sensor element has an operative position and a servicing position; in the servicing position the apparatus outlet is free for access from the exterior. The sensor element is urged into a resilient contact with the sliver assembly whereby the sensor element undergoes excursions upon variation of thickness of the sliver assembly. There is further provided a setting arrangement for selectively positioning the sensor element into the operative or servicing position. The sensor element and the counterelement together define a constriction through which the sliver assembly passes. A transducer converts excursions of the sensor element into electric pulses. A withdrawing roller pair supported downstream of the sliver guiding device pulls the sliver assembly through the sliver guiding device.
By virtue of the fact that the sensor element may be swung outwardly to a position (servicing position) in which the outlet of the sliver guiding device is free, the conditions for startup manipulations, such as introducing the slivers and passing them through the outlet, are improved in a simple and advantageous manner. Also, the access to the inside of the sliver guiding device for cleaning purposes is ameliorated.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1a is a schematic side elevational view, with block diagram, of a regulated drawing frame, incorporating the invention.
FIG. 1b is an enlarged top plan view of a component illustrated in FIG. 1a, showing further details.
FIG. 2 is a sectional top plan view of the component illustrated in FIG. 1b, showing further details.
FIG. 3a is a sectional top plan view of a preferred embodiment, showing structural details and illustrating the construction in a first setting.
FIG. 3b is a view similar to FIG. 3a, illustrating the construction in a second setting.
FIG. 4 is a sectional top plan view of a preferred embodiment, showing structural details and illustrating the construction in a third setting by virtue of component replacement.
FIG. 4a is an enlarged top plan view of a detail of FIG. 3a.
FIG. 5 is a perspective view of a sliver guiding device according to a preferred embodiment of the invention.
FIGS. 6a and 6b are sectional top plan views of another preferred structural embodiment of the invention, showing two different operational positions.
FIGS. 7a and 7b are sectional top plan views of yet another preferred structural embodiment of the invention, showing two operational positions.
FIGS. 8, 9 and 10 are schematic sectional top plan views of three additional preferred embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1a illustrates a high production drawing frame which may be, for example, an HS 900 model, manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany. A plurality of slivers 3, paid out from non-illustrated coiler cans, enter a sliver guiding device 2, through which they are drawn and further advanced by a pair of cooperating withdrawing rollers 4 and 5. In their travel through the sliver guiding device, the slivers 3 move past a measuring member 6. The drawing frame 1 includes an upper inlet roller 7 and a lower inlet roller 8 which are associated with the pre-drawing zone 9 delimited at the downstream end by the upper predrawing roller 10 and the lower predrawing roller 11. Between the roller pair 10, 11 as well as a roller pair formed of the upper main drawing roller 13 and the lower main drawing roller 15 the main drawing zone 12 extends. The lower main drawing roller 15 is associated with a second upper main drawing roller 14. Such an arrangement is referred to as a four over three drawing system.
The drafted slivers 3, after passing through the roller pair 14, 15, reach the inlet of a sliver guide 16 and are drawn through a sliver trumpet 17 arranged at the downstream end of the sliver guide 16 by cooperating delivery rolls 18, 18'. In the sliver trumpet 17 the slivers are combined into a single sliver deposited into a non-illustrated coiler can. The main drawing rollers 13, 14, 15 and the delivery rollers 18, 18' are driven by a main motor 19 controlled by a computer 21. The signals generated by the measuring member 6 at the sliver guiding device 2 are applied to the computer 21 and are converted into control signals which are applied to a regulating motor driving the withdrawing rollers 4, 5 as well as the rollers 7, 8, 10 and 11 of the pre-drawing zone 9. According to the signals of the measuring unit 6, representing the fluctuating thickness values of the sliver assembly formed of the slivers 3, the computer 21 sends control signals to the regulating motor 20 which accordingly varies the rpm's of the rollers 4, 5, 7, 8, 10 and 11.
Turning to FIG. 1b, in the top plan view illustrated therein the upper withdrawing roller 4 is not shown for clarity. The slivers 3 are brought together in the sliver guiding device 2 to form the sliver assembly in which the individual slivers are in a mutually contacting relationship and extend in a single plane. The measuring unit 6 symbolically shown in FIG. 1a includes a sensor element 22 which is rotatably supported by a bearing 30 for swinging motions in a direction parallel to the single plane in which the slivers 3 of the sliver assembly lie. The structure and function of the sensor element 22 will be described later.
Opposite the sensor element 22 a counterelement 34 is provided which is adjustable to vary, in cooperation with the sensor element 22, the passage width of a constriction 23 at the outlet end of the sliver guiding device 2. As will be described later, the counterelement 34 is adjustable by swinging it about a pivot 36 in a direction parallel to the single plane in which the slivers 3 of the sliver assembly lie. The counterelement 34 may be immobilized in its adjusted position, as will also be described later.
FIG. 2 shows how the individual slivers 3 are brought together by the sliver guiding device 2 to assume therein a side-by-side contacting relationship to form the sliver assembly and how they are sensed in the constriction 23 by means of the sensor element 22. The sensor element 22 has a lever arm 31a which is exposed to the pulling force of a tension spring 32 and is coupled with a measuring element 33 which may be a plunger-and-solenoid arrangement. Another lever arm 31b laterally continuously engages with its free end the sliver assembly formed of slivers 3. Thickness changes in the throughgoing fiber quantities of the slivers 3 are thus sensed as volume changes. Departing from FIG. 1b, the withdrawing rollers 4 and 5 are arranged vertically, that is, the slivers are laterally clamped by the nip 26 of the rollers 4 and 5.
FIGS. 3a, 3b and 5 show the apparatus for measuring the thickness of a sliver assembly formed of slivers 3. The guiding device 2 has four walls 2a, 2b, 2c and 2d, of which at least two oppositely located walls converge towards one another in the downstream direction, that is, in the sliver advancing direction L. The walls 2a-2d cause the slivers 3 to converge and assume a side-by-side position in a single plane to form the sliver assembly. As the sliver assembly exits from the device 2, it enters the withdrawing rollers 4 and 5 after which the sliver assembly is dissolved as the individual slivers 3 assume a divergent course. In the downstream zone of the sliver guiding device the pivotal sensor element 22 is arranged which, together with the facing counterelement 34 forms the constriction 23 for the sliver assembly. The change in position of the sensor element 22 caused by a thickness variation of the sliver assembly applies mechanical signals to a transducer 33 which, accordingly, emits electric control pulses.
The counterelement 34 is pivotal in the direction of the arrows A, B about the axis of a rotary bearing (pivot pin) 36 parallel to the plane in which the slivers 3 are arranged side-by-side. The rotary bearing 36 is arranged at the outlet end of the guide wall 2c, as best seen in FIG. 3a. The counterelement 34 may be adjusted and immobilized in the adjusted position, for example, by a setscrew 35 having a stem 37 engaging the counterelement 34 at a location spaced from the pivot pin 36. The setscrew 35 is held in a support bracket 35'. The support bracket 35' and the rotary bearing 36 are secured in threaded bores 42 in a base plate 40 by means of screws 41a, 41b, and are laterally shiftable to new adjusted positions as indicated by the arrows C and D. The sensor element 22 and the counterelement 34 project through the lateral walls 2b and 2c. By means of the setscrew 35 the counterelement 34 is rotated about the rotary axis 36, for example, when the processed sliver type is changed (the drawing frame 1 is inoperative during such changing operation), so that the distance between the counterelement 34 and the sensor element 22 is, in the constriction 23, changed from the distance a (FIG. 3a) to the distance b (FIG. 3b). At the same time, the angle α between the wall 2c and the counterelement 34 is also changed. The sensor element 22 biased by the spring 32 engaging the lever arm 31a of the sensor element 22 reacts to all changes of thicknesses of the throughgoing slivers 3, as a result of which the distance between the sliver engaging tip of the sensor element 22 and the finely adjusted counterelement 34 varies as a function of the thickness fluctuations.
As seen in FIG. 3a, the sliver guiding device 2 has two opposite, converging side walls 2b, 2c having an inlet width c and an outlet width d. The side wall 2b lies with its outer face against a web-like holding element 38 which, as best shown in FIG. 5, is secured to a base plate 39. The holding element extends perpendicularly to the base plate 39 and parallel to the side wall 2b.
In the construction shown in FIG. 4, the sliver guiding device 2 of the earlier described embodiment is replaced by a sliver guiding device 2' having a greater inlet width c' and a greater outlet width d' than the respective dimensions c and d of the sliver guiding device 2. The converging walls of the sliver guiding device 2' are inclined at a different angle than in the sliver guiding device 2. As an alternative, it may be feasible to nest a smaller sliver guiding device in a permanently attached sliver guiding device of larger dimensions. A replacement of a sliver guiding device 2' for a sliver guiding device 2 is effected, for example, because of a change in the type of the sliver to be processed by the drawing frame.
Reverting to FIG. 5, the guide wall 2a in the zone of the constriction 23, that is, in the zone of the outlet of the sliver guiding device 2 for the fiber slivers 3, has a zone 2a' which faces a zone 2d' of the guide wall 2d. The lateral walls 2b and 2c include a slot in the zone of the constriction 23 so that the sensor element 22 and the counterelement 34 may project therethrough and may engage, under pressure, laterally opposite sides of the sliver assembly composed of the side-by-side arranged slivers 3. The base surface 2d' merges into the base plates 39 and 40 situated externally of the sliver guiding device 2.
Turning to FIGS. 6a and 6b, the sensor element 22 is a lever pivotal about the bearing 30 and has lever arms 31a and 31b extending in opposite directions from the bearing 30. The lever 31 is swingable as indicated by the arrows E and F. At the end of the lever arm 31a, the sensor element 22 is engaged by a tension spring 32, whose other end is secured to a single-arm adjusting lever 43 which is rotatable about a pivot 44 in the direction of the arrows G and H. The free outer end of the lever 43 may form a manually engageable handle. The pivot 44 is secured to the base plate 39. In case the setting lever--which may be immobilized by detents--is moved from its position shown in FIG. 6a in the direction of the arrow H into the position shown in FIG. 6b, the securing location of the spring 32 is changed, whereby the bias and thus the spring force exerted on the sensor element 22 is altered. The base plate 39 has detents 45 and 46 such as slots and bolts for determining positions for the setting lever 43.
FIGS. 7a and 7b show a single-arm pivotal setting lever 47 which is swingable in the direction of the arrows I and K about a pivot 48 secured to the base plate 39. One end of a tension spring 50 is connected to the setting lever 47 at a location 51, while the other end of the tension spring 50 is secured to a stationary spring support 52. On the setting lever 47 a carrier element, for example, a pin 53 is provided which is connected with the lever arm 31a of the lever 31 forming the sensor element 22. In case the setting lever 47 is moved from its position shown in FIG. 7a in the direction of the arrow I into the position shown in FIG. 7b, then by virtue of the pressure by the pin 53 the lever arm 31a is shifted, as a result of which the sensor arm 31 is pivoted and thus the distance between the sensor element 22 and the counterelement 34 is increased from a (FIG. 7a) to e (FIG. 7b). In this manner, the opening in the zone of the fiber outlet is significantly increased to what may be termed as a servicing opening e. The servicing opening e facilitates a thread-in operation for the slivers 3 upon a start of operation or readily permits a cleaning of the inner surfaces of the sliver guiding device 2. The immobilizing or detent devices for the setting lever 47 (such as wall apertures) are designated at 54 and 55.
In FIG. 8, the rotary bearing 36 supporting the counterelement 34 and the setting device including the setscrew 35 are mounted on a shifting element 56, whose position may be changed and which may be immobilized by screws received in threaded bore holes 42 of the base plate 40, as shown in FIG. 3a. Between the side walls 2b and 2c of the sliver guiding device 2 on the one hand and the sensor element 22 and the counterelement 34 on the other hand, respective rubber seals 62 and 61 are arranged, as also shown in FIG. 3a.
According to FIG. 9, the counterelement 34 is rotatably mounted on the bearing 36.
Turning to FIG. 10, the counterelement 34 is provided with a slot 57 through which a screw 58 extends. This arrangement provides for both a pivotal and a linear shifting motion of the counterelement 34. The screw 58, in addition to functioning as a pivot and a linear guide, also serves for immobilizing the counterelement 34 in its set position.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
|
An apparatus for measuring sliver thickness in a drawing frame includes a sliver guiding device having converging inner wall faces for bringing a plurality of simultaneously introduced slivers together to form a sliver assembly constituted by side-by-side positioned running slivers arranged in a plane. The apparatus further includes a sensor element and a counterelement laterally contacting the sliver assembly from opposite sides. The sensor element has an operative position and a servicing position; in the servicing position the apparatus outlet is free for access from the exterior. The sensor element is urged into a resilient contact with the sliver assembly whereby the sensor element undergoes excursions upon variation of thickness of the sliver assembly. There is further provided a setting arrangement for selectively positioning the sensor element into the operative or servicing position. The sensor element and the counterelement together define a constriction through which the sliver assembly passes. A transducer converts excursions of the sensor element into electric pulses. A withdrawing roller pair supported downstream of the sliver guiding device pulls the sliver assembly through the sliver guiding device.
| 3
|
BRIEF SUMMARY OF THE INVENTION
In order to enable the realization of nut and bolt connections, in particular deep under the water surface, the invention provides a method herein described in addition to an apparatus also herein described. The invention also provides a bolt designed specially for the application of the invented method.
BRIEF DESCRIPTION OF THE DRAWING
In the drawings:
FIGS. 1-8 show successive steps of the underwater displacement of a pipe piece;
FIGS. 9 and 10 show respectively a top and side view of an apparatus according to the invention;
FIG. 11 shows a nut magazine;
FIGS. 12 and 14 show side views of a preferred embodiment of the apparatus according to the invention in successive method steps;
FIGS. 13 and 15 show a partial top view of FIGS. 12 and 14 respectively;
FIG. 16 shows a partial exploded view of FIG. 10 showing the area labeled XVI of FIG. 10;
FIG. 17 shows a partial exploded sectional view of FIG. 16 showing the area labeled XVII of FIG. 16;
FIGS. 18 and 19 show views of partial exploded views of FIG. 14 showing the area labeled XIX of FIG. 14 .
FIG. 20 shows a partial cross-sectional front view of a preferred embodiment of the apparatus of the present invention;
FIGS. 21 and 22 show an exploded partial elevation and side view of FIG. 10 showing area XXI of FIG. 10;
FIG. 23 shows a section along the line XXIII—XXIII of FIG. 22 on larger scale;
FIG. 24 shows a partial exploded view of FIG. 17 showing area XXIV of FIG. 17;
FIG. 25 shows a section corresponding with FIG. 20 relating to a preferred embodiment of the apparatus according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In the method according to the invention, for instance two pipe pieces 100 which lie on a seabed 101 at a depth of for instance 1 km are displaced by means of yokes 106 (FIGS. 1-8) such that they come to lie mutually in line and mutually connect with their flanges 102 . One yoke 106 at a time is herein placed horizontally by means of its telescopic legs 103 provided with pivoting feet 105 (FIGS. 1, 2 ). A gripper frame 104 is displaced in transverse direction of pipe pieces 100 relative to yoke 106 by means of hydraulic cylinders 107 to a position above a pipe piece 100 . Then the yoke 106 is moved downward, a gripper 108 supported by gripper frame 104 is closed round pipe piece 100 by means of a cylinder 109 and yoke 106 with pipe piece 100 is raised, whereafter pipe piece 100 is displaced.
These operations can be repeated, optionally while yoke 106 is moved in longitudinal direction of feet 105 and pipe piece 100 by means of hydraulic cylinders 110 (FIG. 9 ).
When pipe pieces 100 lie mutually in line, which is controlled from a Remote Operated Vehicle (ROV) 111 (FIG. 10 ), a positioning frame 112 lowered from a ship is placed above a pipe piece 100 on legs 113 . Positioning frame 112 transports a nut wrench 2 and a bolt wrench 3 which are placed on pipe pieces 100 . Positioning frame 112 further carries pump means for hydraulic fluid for driving the diverse hydraulic motors of wrenches 2 and 3 .
Nut wrench 2 comprises an upper half 115 of a nut magazine 4 which is fixedly mounted on a wrench frame 114 and from which two lower quarters 116 are suspended by means of cylinders 117 for swivelling between the opened position of FIG. 11 and a closed position engaging round a pipe piece 100 . Wrench frame 114 is supported on a pipe piece 100 via a saddle 118 . Nut magazine 4 has for instance 16 compartments 5 distributed over the periphery and having a hexagonal profile, in each of which compartments is received one nut 6 which is urged outward by a spring 119 but which is held so rigidly in its closely dimensioned compartment 5 by means of rubber friction rings 120 (FIGS. 18, 19 ) that spring 119 cannot overcome this friction.
The bolt wrench 3 (FIG. 16) comprises a wrench frame 121 which is provided with floater bodies 122 and which is lowered onto a pipe piece 100 by means of a saddle 123 . A saddle-shaped supporting head 124 is slidable in axial direction relative to saddle 123 by means of hydraulic cylinders 125 . Saddle 123 can be anchored to a pipe piece 100 by means of hydraulically energized transverse pins 47 . A frame 133 mounted to supporting head 124 by means of a ring bearing 127 is rotated into an angular position by means of a gear ring 128 and driving gear 129 such that four wrenches 30 mounted on frame 126 and disposed in each case at mutual angular distances of 900 are situated opposite bolt holes 8 of flanges 102 . The supporting head 124 is then displaced relative to wrench frame 121 until the bolts 9 protrude into bolt holes 8 . Displacing of supporting head 124 is measured by means of a wire 49 trained round a pick-up 48 . In order to place bolt holes 8 of flanges 102 in line, the pipe pieces 100 are optionally twisted slightly by pivoting the yokes 106 (in which pipe pieces 100 are held) relative to each other using pipe pieces 100 as pivot axis.
Together with wrench frame 114 , nut magazine 4 is moved relative to saddle 118 toward bolts 8 by means of hydraulic cylinders 130 (FIGS. 14, 15 ) until a positioning cavity 131 of nut magazine 4 strikes against a positioning pin 132 of a flange 102 . The compartments 5 with nuts 6 are hereby centered relative to bolt holes 8 . Bolts 9 drive nuts 6 inside counter to spring action, whereby the friction of rings 120 is overcome.
Each wrench 30 comprises in a housing 7 a socket 32 which is urged by means of a spring 34 into the position shown in FIG. 17 on a nut 35 and which is driven by a hydromotor 40 via its gear ring 37 and toothed wheels 38 , 39 . Each screw bolt 9 has a protruding grooved end 62 and a fixed ring 63 at a small distance from nut 35 . Present is FIG. 17 at the free end of the grooved end 62 is a welded clamp 64 consisting of a number of, for instance three, clamping pieces 65 which have conical surfaces 67 and 68 . Surfaces 67 co-act with the conical surface 73 of a piston 69 of a double-action cylinder 70 which is fixed by means of bolts 66 to a piston piece 61 . Surfaces 68 co-act with a conical surface 73 of the piston piece 61 of piston 74 of a hydraulic, double-action cylinder 72 . Clamping pieces 65 are urged apart by tangential pressure springs 75 arranged in each case in each separating surface.
Piston 69 carries a bolt 77 which in the clamping position of clamping pieces 65 (also the clamping position of piston 69 ) lies opposite an electrical sensor 78 mounted on cylinder 70 and thus indicates the clamping position.
The ring 63 fixed for instance by glueing or locking comprises axial pins 81 which are urged away from nut 35 against stops 85 by springs 80 and received in continuous holes 83 and which, when energized by sliding sleeve 87 moves into arcuate recesses 89 of nut 35 (FIGS. 17, 24 ).
Piston 74 is sealed with at least one sealing ring relative to sliding sleeve 87 which is guided over threaded end 62 by means of a plastic lining 88 .
Piston 74 is locked against rotation by means of axial rods 96 .
During insertion of bolts 9 into flanges 102 (FIG. 12) the clamps 64 are closed and the pins 81 of fixed ring 63 engage into nut 35 .
During arranging of nuts 6 (FIG. 14) clamps 64 are disengaged from bolts 9 and nuts 35 are driven by means of sockets 32 and motors 40 in order to rotate the bolts 9 which are coupled to nuts 35 via pins 81 and fixed rings 63 and thus screw them into the nuts 6 .
When nuts 6 are screwed against a flange 102 the supporting head 124 , and thus also housings 7 , are moved away from flanges 102 by means of cylinders 125 so that the fixed rings 63 are moved away from nuts 35 and the disengaged nuts 35 move toward flanges 102 with further driving by motors 40 .
While bolts 9 are held fast by clamps 64 and cylinders 72 are energized to place bolts 9 under axial tension, nuts 35 are driven by means of motors 40 in order to screw the flanges 102 firmly against each other.
After release of clamps 64 the bolt wrench 3 can be removed, four other bolts 9 can be placed therein by means of the ROV and these can be inserted into flanges 102 in a different angular position of ring bearing 127 relative to supporting head 124 .
Instead of using a nut wrench 2 a flange 102 can be provided at each bolt hole 8 with a nut compartment 10 mounted thereon (FIG. 20) in which is situated a nut 6 urged toward flange 102 by a spring 119 .
Although the described hydraulically driven clamp 64 is recommended, another, for instance mechanically driven, clamp can also be used.
A nut wrench 12 as shown in FIGS. 21-23 of the drawings can be used as an alternate embodiment of the invention to connect or disconnect the pipe pieces. The wrench frame 13 thereof is placed on a pipe piece 100 by means of two saddles 14 and 15 which can each be clamped fixedly to pipe piece 100 by means of a hydraulically operated transverse pin 16 respectively 17 . By fixedly clamping the saddle 14 displaceable relative to wrench frame 13 to pipe piece 100 , the wrench frame 13 can be displaced relative to saddle 14 and, conversely, in the case of a fixedly clamped saddle 15 the saddle 14 is forward displaceable in order to perform the required step movements. (Wrench frame 14 of FIG. 12 is also displaceable in the same manner).
The zero position of the angular displacement can be realized by means of a V-shaped angle section 22 which co-acts with a pin 23 welded to pipe piece 100 . Because the weight of nut wrench 12 is compensated by a floater body 24 , nut wrench 12 can be swivelled slightly relative to pipe piece 100 by means of the ROV.
A tool head 18 can be set in the required angular position by means of a ring bearing 25 mounted thereon, a gear ring 19 and a driving gear 20 , wherein a plurality of, for instance four, nut wrenches 21 lie in line with bolt holes 8 .
Each wrench 21 comprises a housing 26 and a nut magazine 27 mounted rotatably and a slidably therein and urged toward flange 102 by a spring 28 , which magazine is adapted to receive a plurality of, for instance four, nuts 6 (FIGS. 18 , 19 ) and has for this purpose a hexagonal internal profile. Nut magazine 27 is driven via its gear ring 29 and a driving gear 31 .
Hydraulic motors are present for the diverse drives.
Nut magazine 27 contains a push member 41 which is provided with three L-shaped leaf springs 42 which in the return direction act as pins, in addition to a rubber friction ring 43 . When tool head 18 is in its starting position, the saddle 15 has axially in line with nut magazine 27 a pusher 44 which in each case is driven by a cylinder 45 and which shifts by one nut width at a time the push member 41 and the nuts 6 which are present.
In combination with this wrench 21 a wrench 46 is used in each case which is identical to wrench 30 , except that the now superfluous fixed ring 63 is preferably omitted. Bolts 9 are inserted into holes 8 , a nut 6 is screwed on in each case, a nut 35 is screwed in each case against a flange 102 , bolts 9 are tightened by energizing cylinder 72 and nut 35 is screwed further to flange 102 , all of this while the bolts 9 in question are held fast by means of clamps 64 . Clamps 64 are thereafter released to remove wrenches 126 from bolts 9 .
Wrenches 126 are once again filled with bolts 9 by means of the ROV and these are inserted into other holes 8 when wrenches 126 are swivelled through an angle, whereafter nuts 6 from nut wrenches 21 are screwed thereon from the other side.
In order to hold nuts 6 positioned in their compartment, instead of friction rings 120 on the nuts 6 rubber strips can be arranged on the inner walls of nut compartments 5 , for instance in the middle of the hexagons in axial direction of nuts 6 , which strips bring about a considerable friction between nuts 6 and the inner walls of compartments 5 .
If only one nut and bolt connection has to be made, for instance because a bolt 9 must be replaced, the same wrench 3 can be used, wherein only one of the wrenches 6 is then driven. Control and driving of each wrench is dependent on the others for this purpose.
|
A method and apparatus for connecting two pieces of pipe having flanges when the pipe pieces are located deep under a water surface. A movable bolt wrench is provided which has a number of wrenches mounted in a frame corresponding to the bolt holes on the flanges of the pipe pieces. Bolts located in the bolt wrenches are aligned with the bolt holes of the flanges and inserted into the bolt holes. A nut wrench is also provided containing nuts which, when aligned, are threaded onto the ends of the bolts associated with the bolt wrench. After the bolt and nut connections are made, these bolts and nuts are tightened by the operation of the bolt and nut wrenches.
| 5
|
This is a continuation-in-part of U.S. patent application Ser. No. 09/134,128, filed on Aug. 14, 1998 now U.S. Pat. No. 6,230,838.
FIELD OF THE INVENTION
This invention relates to apparatus for unlatching power door locks and lowering power windows of a motor vehicle in emergency situations. More particularly, the present invention relates to emergency vehicle exit systems having sensor-diagnostic circuits to periodically verify the integrity of the condition sensors thereof.
BACKGROUND OF THE INVENTION
Since about the mid 1980s, an increasing number of motor vehicles have been equipped with power windows and power door locks. Once considered optional accessories, these features are now installed in a majority of all new motor vehicles. Generally, the power window feature is operational only when the key is set in the run position and the accessories are receiving power from the battery. The power door locks are operational, regardless of the ignition key's position, as long as the motor vehicle is receiving power from the battery.
As a result of the installation of power windows and power door locks in most automobiles, two new safety hazards now exist. Firstly, in the event of an accident resulting in the incapacitation of the vehicle's electrical power system, the conscious motor vehicle operator is often unable to open the doors or lower the windows. In many cases, there are structural damages to the door frames or to the door posts which are significant enough to prevent the manual opening of the doors from the inside. In the past, the only remedy for this situation was the breaking of a window from the inside, which was only possible when the proper tool was accessible inside the vehicle.
Secondly, in the event of an accident which results in the physical incapacitation or loss of consciousness of the vehicle operator or a passenger, there could be no able person inside the vehicle to unlock the doors or lower the windows. This represents a serious safety concern for the rescue personnel wanting to access the injured persons. In the past, the only remedy was the manual breaking of a window from the outside or the use of the Jaws of Life™. However, the breaking of a motor vehicle window from the outside is likely to project shattering glass inside the vehicle, which could worsen fresh injuries on the occupants, or further harm the occupants.
These two safety concerns, basically, have created a need for emergency vehicle exit apparatus to automatically take control of the power door locks and power windows of a vehicle in emergency situations.
An apparatus for unlatching power door locks and lowering power windows generally comprises an electronic module and a plurality of condition sensors mounted at various strategic locations on the vehicle body. When these condition sensors and the wiring between the sensors and the electronic module are exposed to the weather, to vibration and to road splashes, deterioration of the sensors and wiring could occur. Therefore, a preferred feature in such emergency vehicle exit system is the provision of a circuit to periodically test the conditions of the sensors and the associated wiring, in order to detect and quickly repair a defective function of the system.
In that respect, it is believed that when an emergency vehicle exit system is equipped with one or more vehicle immersion sensors, these sensors are most vulnerable to deterioration for being continuously exposed to the weather conditions. Therefore another preferred feature of such system is that the immersion sensors must be reliable, durable and suitable for being interrogated by a sensor-diagnostic circuit.
Examples of vehicle exit systems available in the prior art to unlatch power door locks and lower power windows after an accident are described in the following documents:
U.S. Pat. No. 4,381,829 issued on May 3, 1983 to B. Montaron;
U.S. Pat. No. 4,785,907 issued on Nov. 22, 1988 to K Aoki et al.
U.S. Pat. No. 5,327,990 issued on Jul. 12, 1994 to A. B. Busquets;
U.S. Pat. No. 5,547,208 issued on Aug. 20, 1996 to J W Chappell et al.
U.S. Pat. No. 5,574,315 issued on Nov. 12, 1996 to H J Weber;
Although several vehicle emergency exit systems are available in the prior art, it is believed that these prior systems are deficient in at least the features of having immersion sensors that are resistant to the weather conditions and having immersion sensors that are capable of being interrogated by a diagnostic circuit. As such, it is believed that a need still exists for a system in which the conditions sensors are more durable and reliable than the prior art detectors. Furthermore, it is also believed that a need exists for an emergency vehicle exit system which has means to periodically verify the conditions of the sensors that are exposed to rude environment and warn the vehicle operator of these conditions.
SUMMARY OF THE INVENTION
The rescue assist safety system according to the present invention, hereinafter referred to as the RAS system, is designed to provide an immediate and visible escape route out of a damaged vehicle, and to provide easier access to passengers by medical and rescue personnel. The RAS system is designed to be installed in new vehicles at the factory, or to be installed as a retrofit accessory in older vehicles, by licensed auto-mechanics.
In a broad aspect of the present invention, there is provided a system for automatically lowering power windows and unlatching power door locks of a motor vehicle in the event of an accident. The system comprises a circuit having relays for actuating the power door locks and the window lowering motors of the motor vehicle. The RAS system also comprises;
a) a vehicle immersion sensor connected to the circuit and having means to operate the relays immediately upon being exposed to a vehicle immersion condition;
b) a vehicle fire detector connected to the circuit and having means to operate the relays immediately upon being exposed to a vehicle fire condition;
c) a vehicle inversion detection switch connected to the circuit and having means to operate the relays after a set delay from being exposed to a vehicle inversion condition; and
d) a combination of a vehicle impact detection switch connected to the circuit, and a timer connected to the circuit and to the vehicle impact detection switch for operating the relays after a fixed delay upon the vehicle impact detection switch being exposed to a vehicle impact condition.
The present invention is advantageous for preventing the entrapment of people in a damaged vehicle, in four of the worst life-endangering situations, without affecting the retention of these people inside the vehicle during the development of the accidents preceding these situations.
In another aspect of the present invention, the RAS system comprises a means for interrogating some of the hazardous condition sensors, for the purpose of periodically verifying the integrity of these sensors. This feature is appreciable for ensuring a proper operation of the sensors that are exposed to rude environmental conditions, outside or under an automobile body for example.
In accordance with another aspect of the present invention, the impact detection switch is made of a hollow metal housing having a hole there though and a spring wire extending through that hole. The metal housing and the spring wire are respectively connected to an input and an output of this impact detection switch. An impact of a predetermined magnitude on the switch deflects the spring wire and momentary closes the switch for activating the RAS system. This novel impact detection switch is manufacturable in a miniature format for mounting directly on a printed circuit board.
In yet another aspect of the present invention, the vehicle inversion detection switch comprises a metal cup connected to a first part of the circuit, a metal cone mounted inside the cup in a spaced-apart relationship with the metal cup, and being connected to a second part of the circuit, and a metal ball movably held inside the metal cup, between the metal cup and the metal cone. The metal cup and the metal cone jointly define a circular hollow segment of revolution having converging surfaces defining a first gap being larger than a diameter of the metal ball and a second gap being smaller than the diameter of the metal ball. When the switch is tilted on its side or inverted upside down, the metal ball moves between the first gap and across the second gap to connect the first and second parts of the circuit. In the preferred configuration, the metal cup contains a viscous insulating fluid for dampening a motion of the metal ball between the first gap and the second gap.
This inversion detection switch is advantageous for having a built-in timer for retarding the operation of the RAS system upon being moved in a tilted or an inverted position. This switch is also advantageous for being manufacturable in a miniature format for mounting directly on a printed circuit board.
In yet a further aspect of the present invention, the immersion sensor comprises a diode mounted in a reversed biased mode and having bare lead wires which can be shorted across when immersed in water. The diode is enclosed in a perforated splash guard to prevent a false short circuit signal when the vehicle is driving through a puddle or in rain. This type of immersion sensor is advantageous for its simplicity, for its low cost of manufacture and especially for its ability to be interrogated by a diagnostic circuit, for the purpose of testing its condition.
Other advantages and novel features of the present invention will become apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of this invention is illustrated in the accompanying drawings, in which like numerals denote like parts throughout the several views, and in which:
FIG. 1 is a diagram of the circuit for the preferred RAS system;
FIG. 2 is a partial perspective illustration of the circuit module comprised in the preferred RAS system;
FIG. 3 is a cross-section view of the circuit module taken along line 3 — 3 in FIG. 2, showing a cross-section view of the impact detection switch and an exploded cross-section view of the inversion detection switch;
FIG. 4 is a cross-section view of the inversion detection switch in an assembled mode, as seen along line 3 — 3 in FIG. 2;
FIG. 5 is a side view of the fire detector comprised in the preferred RAS system;
FIG. 6 is a side view of an immersion sensor comprised in the preferred RAS system;
FIG. 7 is a cross-section view of the immersion sensor as seen along line 7 — 7 in FIG. 6 ;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is firstly made to FIG. 1, illustrating the circuit of the preferred RAS system. In this circuit, IC 1 is a model 556 timer chip and IC 2 is a MC4011 Quad Dual input NAND Gate chip. In the preferred RAS system there are four types of condition detectors. S 1 is an impact detection switch; S 2 is a fire detector; S 3 is an inversion detection switch, and S 4 is an immersion sensor. The structure and operation of these condition detectors will be explained later, particularly when making reference to FIGS. 2-7.
In the preferred circuit, Q 1 and Q 3 are transistors of the type 2N3904 NPN; Q 2 is a transistor of the type ECG 262 PNP Darlington Pair amplifier; C 1 , C 6 , C 7 , C 8 are 10 μf35 WVDC electrolytic capacitors; C 2 , C 4 and C 5 are 0.05 μf ceramic capacitors, and C 3 and C 9 are 0.01 μf ceramic capacitors. D 1 , D 2 , D 3 , D 4 , D 5 , D 10 , D 11 , D 12 and D 13 are 1N914 diodes. D 6 , D 7 , D 8 , D 9 and D 14 are light emitting diodes with built-in resistors. R 1 , R 4 , R 7 and R 13 are 1M Ohm, ¼ watt resistors; R 2 and R 6 are 22 K Ohm, ¼ watt resistors; R 3 , R 8 and R 14 are 10 K Ohm, ¼ watt resistors; R 9 and R 10 are 4.2K Ohm, ¼ watt resistors, and R 11 and R 12 are 1K Ohm, ¼ watt resistors.
Also comprised in the preferred circuit as illustrated in FIG. 1 are three relays K 1 , K 2 and K 3 connected to the power door lock solenoids and to the power window motors of a vehicle. K 1 , K 2 and K 3 are 12 volt DC, PC relays (DPDT 5 A at 120 volt AC). Because each window or door lock circuit must remain isolated by the RAS system on a single relay, three relays are used. The relay K 1 is used to operate the power door lock solenoids; K 2 is used to operate the right window lowering motors, and the relay K 3 is used to operate the left window lowering motors.
In the preferred circuit, F 1 is a 30 ampere fuse. The label PWR or the symbol next to it denotes a 12 volt DC power input, and the label GRN or the accompanying symbol denotes a ground connection. B 1 is a double contact push button and K 4 is a 12 volt DC, DPDT relay. B 1 and K 4 are part of the sensor-diagnostic circuit which will be explained in greater details later.
The preferred RAS system is activated in the case of; vehicle impact, fire in one of the engine, trunk or passenger compartment, vehicle inversion or vehicle immersion. The details of operations of the RAS system in each of these four eventualities are described as follows:
Collision
In the case of a vehicle impact, the preferred RAS system sets up two delays; the first delay is to retard the activation of the circuit, and the other delay is to limit the time the circuit is active.
The first delay is activated by a signal from the impact detection switch S 1 . The switch S 1 connects the first trigger input of IC 1 (pin 6 ) to ground. The pins on timer chip IC 1 are numbers in a counterclockwise direction from pin 1 A. This causes the normally low (0 volt) output of pin 5 to go high (12 volt). This high voltage remains on the output pin 5 until the time constant circuit of capacitor C 1 and resistor R 1 charges up to approximately ⅔ of the supply voltage. At that time, capacitor C 1 is discharged through pin 2 of the timer, forcing pin 5 to go low. This low voltage is felt through capacitor C 5 to pin 8 , the trigger input of the second stage timer. At the same time, pin 9 , the output pin of the second stage timer goes high. This high is passed through the diode D 1 and through the resistor R 9 to the base of transistor Q 1 . Transistor Q 1 turns on, passing a ground GRN through to the base of transistor Q 2 . Then, Q 2 energizes the three relays K 1 , K 2 and K 3 causing the relays to apply 12 volt DC power to the door lock solenoids and to the window lowering motors, energizing them and forcing the doors to unlock and the windows to start to open. This 12 volt DC power remains on until the time constant circuit of the second stage timer, that is the combination of the resistor R 7 and capacitor C 6 , charges up to approximately ⅔ of the supply voltage. At that time the capacitor C 6 discharges, forcing pin 9 to go low again, turning Q 1 and Q 2 off. The three relays K 1 , K 2 and K 3 are then switched off to return the door lock solenoids and the window motors to normal operation. In this arrangement, the two delays can be varied according to the preference of a manufacturer, for different models of vehicles for example, by changing the value of the resistors R 1 and R 7 and of the capacitors C 1 and C 6 in each of the time constant circuits.
The purpose of the first timer is to ensure that the vehicle has come to a complete stop before lowering the windows and unlatching the door locks. The purpose of the second timer, which causes the de-energizing of the relays K 1 , K 2 and K 3 soon after the windows have been lowered and the doors have been unlocked, is to prevent any ignition or explosion of any fuel which could start to leak as a result of an accident.
The purposes of capacitors C 2 and C 4 are to set up the control voltages for the timer circuits. Comparators inside IC 1 detect when the voltages on capacitors C 1 or C 6 are equal to the voltage charge on capacitors C 2 and C 4 respectively and force the two time constant capacitors to discharge.
Fire Threat
In case of a fire in the vehicle compartment in which the fire detector S 2 is located, the detector S 2 , when heated, passes 12 volt DC power to the transistor Q 1 , turning this transistor on. This forces the transistor Q 2 to turn on, which again energizes the three relays, K 1 , K 2 and K 3 , thereby immediately unlocking the doors and causing the windows to open. The window lowering motors are turned on and remain on as long as the vehicle's ignition system is operative and the switch is heated above the threshold temperature.
Vehicle Inversion
The vehicle inversion detection switch S 3 has a built-in timer causing a 30 second or so delay in its activation. This built-in timer is to prevent the unlocking of the doors and the opening of the windows while the vehicle might still be tumbling or even slowly rolling over. After 30 seconds or so of inversion, a 12 volt DC power source is connected to the base of transistor Q 1 , turning it on. This again causes transistor Q 2 to turn on, activating the three relays, K 1 , K 2 and K 3 , thereby causing the doors to unlock and the windows to open.
Vehicle Immersion
In case of a vehicle immersion, any one of the immersion sensors S 4 containing one of the diodes D 2 , D 3 , D 4 and D 5 detects an abnormal level of water along a portion of the vehicle. It will be appreciated that a number of immersion sensors S 4 can be mounted at various locations on an automobile body to effectively detect the immersion of the vehicle body in water. Each of the diodes D 2 , D 3 , D 4 , D 5 or other diodes, is mounted in a reverse biased mode and has both lead wires exposed to the ambient conditions. When the diode is shorted across, upon immersion of the diode in water, a 12 volt DC power is immediately applied to the base of transistor Q 1 , turning it on. Transistor Q 1 causes transistor Q 2 to turn on energizing the three relays K 1 , K 2 and K 3 , causing the doors to unlock and the windows to start to open. The window motors will continue to be activated as long as the vehicle's ignition system is operative and at least one diode is immersed. The windows may only partially open by the time the battery or the electrical system of the vehicle is submerged and shorted out in salt water for example, but this partial opening is nonetheless sufficient to allow the pressure inside the vehicle to equalize with the outside pressure, allowing the victims or a rescuer to open the doors with ease.
Other features of the preferred RAS system include a false triggering prevention sub-system and an immersion sensor diagnostic circuit. These two features are explained as follows:
False Triggering Prevention Sub-System
In a first aspect, false triggering of the circuit is prevented by the capacitors C 8 and C 9 . These two capacitors act as filters, passing any transient voltage spikes to ground. This is to prevent the timer circuits of IC 1 from seeing the negative portion of a spike as a trigger input and activating themselves. In a second aspect, the initial energizing of the ignition system of a vehicle causes similar spikes on the vehicle's ignition system which could cause improper activation of the timer circuits of IC 1 in a similar manner. To prevent this, resistor R 13 and capacitor C 7 are incorporated in the preferred RAS system. The time constant provided by this timer circuit keeps one input of the NAND gate (pin 2 ) on the IC 2 chip at a low for a nominal period of time when the vehicles ignition is first turned on. The pins on IC 2 are numbered in a counterclockwise direction starting from pin 1 B. This low on pin 2 causes the output pin 3 of the IC 2 chip to be high. This high turns the transistor Q 3 on, which places a ground on the reset pins 4 and 10 of the timer chip IC 1 . This in turn prevents the two timing circuits of IC 1 from operating, preventing false triggering of the entire circuit. The holding of the IC 1 chip in this state for a short period of time prevents the triggering of the timers in IC 1 until the supply voltage has stabilized.
Another feature of the RAS system is that the circuit module is connected to a 12 volt DC power source PWR that is energized only when the vehicle's ignition system is in the run or in the accessory mode position, but not when the starter motor is engaged. This is to prevent the triggering of the system's timers when the starter motor is engaged and the voltage drops considerably. This is also to prevent vehicle theft which could otherwise occur by tampering with one of the external sensors. The light emitting diode D 14 is mounted at a convenient location in sight of the driver and provides a visual indication of power on the RAS system.
Immersion Sensor Diagnostic Circuit
The immersion sensors S 4 must be mounted high enough inside the car or inside the wheel wells of the vehicle, so that they will not be shorted out by road splashes, rain or light water mist associated with the driving of a vehicle in various weather conditions. Although the immersion sensors are not activated by intermittent contacts with water, these sensors must be mounted in locations where the potential of a vehicle immersion is readily detected. These sensors are therefore subjected to deterioration from being exposed to rude environmental conditions. In the preferred RAS system, a sensor-diagnostic circuit has been provided to periodically verify the integrity of these sensors. Furthermore, the immersion sensors S 4 are responsive to interrogation by the diagnostic circuit.
The sensor-diagnostic circuit comprises a push button B 1 , the relay K 4 and the light-emitting diodes D 6 , D 7 , D 8 and D 9 , which are individually connected in series with the immersion sensor diodes D 2 , D 3 , D 4 and D 5 respectively. Upon operating the push button Bi, the relay K 4 is energized, and applies a voltage in a reverse direction through D 2 -D 5 , and D 6 -D 9 , lighting up D 6 -D 9 and thereby providing a visual indication as to the continuity of each of the diodes D 2 -D 5 and its associated wiring. The button B 1 and the light-emitting diodes can be mounted at any convenient locations on or at the vicinity of the circuit module, such that they are readily accessible to periodically manually test the integrity of the immersion sensors S 4 . The diodes D 10 , D 11 , D 12 , D 13 are used in this circuit as bridges around the light emitting diodes, to allow an emergency immersion signal from one of the immersion sensors S 4 to reach the transistor Q 1 , when the diagnostic circuit is in the normally closed position as illustrated in FIG. 1 .
The push button B 1 is mounted onto a double contact block wherein one of the contacts is used to apply a ground to the pin 2 on the IC 2 chip, thus holding IC 1 is a reset condition, while the testing of the immersion sensors is being performed. It will be appreciated that push button B 1 can be used to energize other relays (not shown), to operate other light emitting diodes (not shown) for the purpose of similarly testing the integrity of the wiring connected to all the sensors and detectors that are mounted in a vehicle, at a distance from the circuit module and that are subject to deterioration.
Referring now to FIGS. 2-7, the physical characteristics of the RAS system will be described in greater details. Referring firstly to FIG. 2, the circuit module 20 of the preferred RAS system comprises a printed circuit board 22 , on which the chips IC 1 and IC 2 are mounted. The relays K 1 , K 2 , and K 3 are also preferably mounted directly on the printed circuit board 22 . The circuit module 20 is preferably mounted under the dashboard of a vehicle where a connection thereof to the vehicle's wiring system is most easily effected.
Power to the printed circuit board, as well as all other inputs and outputs described herein are connected to the printed circuit board 22 through a connection strip 24 on the edge of the printed circuit board, to which a wiring harness (not shown) is readily mountable.
In the preferred RAS system, the impact detection switch S 1 and the inversion detection switch S 3 are mounted directly to the printed circuit board 22 , as illustrated in FIGS. 2, 3 and 4 . The configurations of these switches allow for their miniaturization, such that they take minimum space of the printed circuit board.
The preferred impact detection switch S 1 is a mechanical device which is used to detect a sudden change in velocity of a moving object, in any direction, on a single plane. The impact detection switch S 1 comprises essentially a hollow metal housing 30 having a hole 32 through its top surface and a signal spring wire 34 extending through the hole 32 . The signal wire 34 and the housing 30 are connected to the circuit board onto connections 36 , 38 , from which one is a 12 volt DC power source and pin 6 on the IC 1 chip, and the other is ground.
When there is a change in velocity of the vehicle in which the RAS system is mounted, with sufficient force to overcome the stiffness of the signal spring wire 34 , the spring wire displaces in the opposite direction of the change in velocity, and touches the side of the hole 32 , thereby closing the switch circuit. The impact detection switch S 1 causes a signal to occur in the event of a collision from any direction perpendicular to the spring wire 34 .
In summary, the impact detection switch S 1 transmits a ground signal to the input of the chip IC 1 . This ground signal triggers the first stage of a cascaded timer function inside the chip IC 1 . After a predetermined delay, the circuit passes 12 volt DC from the vehicle's ignition system to the relays K 1 , K 2 and K 3 , energizing them and causing all door locks to unlatch and all windows to open.
The preferred fire detector S 2 is comprised of a bimetallic strip 40 mounted on a base 42 , such as illustrated in FIG. 5 . When the strip is heated to a certain degree, it bends downward to make a contact between two terminals 44 , 46 and applies 12 volt DC power to the transistor Q 1 to immediately unlatch the power door locks and lower the power window.
Referring back to FIGS. 3 and 4, the inversion detection switch S 3 consists of a conductive metal path between 12 volt DC power to the transistor Q 1 . This switch is made of a tapering cup 50 in which is mounted a cone-shaped contact disc 52 . A metal ball 54 is loosely retained inside the cup 50 . In use, the cup 50 is full of insulating oil 56 and is held to the lower side of the printed circuit board 22 by outside fasteners 58 . A gasket 62 is provided between the cup 50 and the printed circuit board 22 . The cone 52 is also held to the printed circuit board by means of a central fastener 64 . An O-ring 68 is preferably provided on the central fastener 64 to prevent any loss of insulating oil along the central fastener 64 . The cup 50 and the cone 52 are connected to different potential by means of the outside and central fasteners 58 , 64 , and their connections to different conductive paths 70 and 72 on the printed circuit board 22 .
Referring now particularly to FIG. 4, the cup 50 and the cone 52 have different tapering angles and jointly define a circular hollow segment of revolution 74 , which has a first gap 76 and a second gap 78 . The first gap 76 is larger than a diameter of the metal ball 54 , and the second gap 78 is smaller than the diameter of the metal ball 54 . Therefore, when the switch S 3 is tilted to its side or inverted upside down, the metal ball moves to establish a contact between the cup 50 and the cone 52 . On the other hand, a non-conductive condition exists when the switch lays in the upright position as illustrated. The viscosity of the insulating oil is selected such that a delay of about 30 seconds is obtained before triggering a signal to the transistor Q 1 following a vehicle inversion. It will be appreciated that the printed circuit board 22 must be mounted in a level position or near a level position to ensure an optimum operation of the inversion detection switch S 3 .
As mentioned before, each of the preferred immersion sensors S 4 consists of one of the diodes D 2 , D 3 , D 4 or D 5 mounted in a reverse biased mode and encased in a splash-proof casing 80 , as illustrated in FIGS. 6 and 7. Each immersion sensor S 4 is mounted in the engine compartment, behind the bumpers, or under the wheel wells of a motor vehicle, by means of a collet clip 82 or otherwise. Each sensor is mounted high enough so that it cannot be immersed by driving through a puddle or through rain water. When the sensor is immersed in fresh water or salt water, it is shorted out, allowing a 12 volt signal to appear on the transistor Q 1 and causing the RAS system to energize the relays K 1 to K 3 , immediately unlatching the door locks and opening the vehicle's windows. The splash-proof casing 80 is a perforated casing enclosing a diode, D 2 for example. The lead wires 84 , 86 , to the diode D 2 are bare over a short distance such that the diode can be shorted across when immersed in water. The diode D 2 is held fixed inside the perforated casing 80 by stiff insulated wires 88 that are held in a plug 90 which is preferably made of a resinous material and molded inside the base of the perforated casing 80 .
As to other sensors, other detectors, and other manner of usage and operation of the present invention, the same should be apparent from the above description and accompanying drawings, and accordingly, further discussion relative to these aspects of the invention would considered repetitious and is not provided.
While one embodiment of the present invention has been illustrated in the accompanying drawings and described herein above, it will be appreciated by those skilled in the art that various modifications, alternate constructions and equivalents may be employed without departing from the spirit and scope of the invention. Therefore, the above description and the illustrations should not be construed as limiting the scope of the invention which is defined by the appended claims.
|
The present invention consists of a system for automatically lowering power windows and unlatching power door locks of an automobile after an accident. The system is responsive immediately to a vehicle immersion condition or a vehicle fire condition. The system is responsive after a set delay to a vehicle inversion condition or a vehicle impact. A second timer deactivates the system as soon as the doors are unlocked and the windows are at least partly opened following a vehicle impact. The system is advantageous for preventing the entrapment of people in a damaged vehicle, in four of the worst life-endangering situations, without affecting the retention of these people inside the vehicle during the development of the accidents preceding these situations. A diagnostic circuit is also provided for interrogating some of the hazardous condition sensors for the purpose of periodically verifying the integrity of these sensors.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of application Ser. No. 10/770,940, filed Feb. 3, 2004.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates generally to actuators for ergonomic systems and, more particularly, to actuator systems for seat adjustments.
2. Related Art
[0005] Ergonomic supports for seats, such as lumbar and bolster systems, are typically moved by means of actuators that can be operated by hand or driven by a motor. Four-way power lumbar devices, with an arching mode and a translation mode, have traditionally required a motor for each mode of operation. In comparison, the invention set forth by U.S. Pat. No. 6,050,641 is a four-way power lumbar system that requires only a single-motor and reduces the duplication of gearbox components. Prior to this invention, U.S. Pat. Nos. 5,197,780 and 5,217,278 had only described four-way lumbar devices that were manually operated by a single control knob.
[0006] While these devices are an improvement over the conventional four-way lumbar devices that required multiple motors or multiple control knobs, the highly competitive markets for furniture and automotive seats place a premium on continued optimization of devices that provide comfort and convenience for seat occupants. In particular, there is a need for improved actuation systems that are less prone to failures and more efficiently transfer power to the actuators. For example, with regard to the manually-operated four-way lumbar systems, the gearing systems are inefficient because, in addition to the gears, they have a transmission that requires at least one non-gear alignment device to maintain the proper engagement between the driver gear and the driven gears. Therefore, such devices have an alignment device that is necessary for the convenient operation of the lumbar system and increase the potential for a failure in the system.
[0007] Additionally, there is a need for actuation systems that are more modular, increasing the commonality of parts between two-way and four-way power lumbar devices, manually-operated and motor-driven actuation systems, and lumbar systems and bolster systems. For example, the prior art actuation units and driven gears are designed to fit within a single housing along with the driver gears and the transmission system, thereby limiting the range of motion that is capable for the actuation units themselves. Different types of lumbar devices and bolster devices are typically designed to provide different levels of support and often require different levels of actuation, thereby affecting the size of the actuators. The prior art devices do not easily allow for changing the actuators according to various sizing requirements, and the confined housing could prevent the same actuation system from being used for different lumbar devices or for a lumbar device and a bolster device. Therefore, entirely different actuation systems would need to be designed, and separately manufactured, depending on the actuators' usage, range of motion, and sizing.
SUMMARY OF THE INVENTION
[0008] It is in view of the above problems that the present invention was developed. The invention is a dual drive actuation system that can combine existing two-way manual actuators with a gearing system to switch between multiple actuators. Additionally, the dual drive actuation system can be powered by a motor, and a solenoid can be used to switch the gearing system between the actuators. The dual drive actuation system can be used with different actuators that are changed based on their required usage, sizing and range of motion.
[0009] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and together with the description, serve to explain the principles of the invention. In the drawings:
[0011] FIG. 1 illustrates the dual drive actuation system of the present invention;
[0012] FIG. 2 illustrates the dual drive actuation system installed in a seat with a lumbar device;
[0013] FIG. 3 illustrates the dual drive actuation system installed in a seat with a bolster device and a headrest device;
[0014] FIG. 4 illustrates the dual drive actuation system according to another embodiment of the present invention;
[0015] FIG. 5 illustrates the dual drive actuation system of the present invention depicting the gear arrangement and gear teeth positioning;
[0016] FIG. 6 illustrates the dual drive actuation system installed in a seat with the bolster device, headrest device, and a pair of dual drive actuation devices;
[0017] FIG. 7 illustrates the dual drive actuation system installed in a seat with the bolster device, headrest device, and a pair of dual drive actuation devices having worm driver gear arrangements; and
[0018] FIG. 8 illustrates the dual drive actuation system installed in a seat with a lumbar device, with the dual drive actuation device positioned in a seat back.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Referring to the accompanying drawings in which like reference numbers indicate like elements, FIG. 1 illustrates an embodiment of the dual drive actuation system 10 . In this embodiment, the dual drive 10 includes a pair of actuators 12 , 14 that have a respective pair of actuated bevel gears 16 , 18 and a drive shaft 20 that has a pair of driver bevel gears 22 , 24 . The position 26 of the drive shaft 20 is shifted to alternatively engage the actuated bevel gears 16 , 18 with the driver bevel gears 22 , 24 . The driver bevel gears 22 , 24 can be a double-sided bevel gear 28 , as exemplified in FIG. 1 , with the gear teeth facing away from each other in opposite directions.
[0020] FIG. 5 illustrates the gear arrangement and gear teeth positioning. When the drive shaft 20 shifts towards an actuator 12 , one side of the double-sided bevel gear 22 respectively engages with its corresponding actuated bevel gear 16 while the other side 24 disengages from its corresponding actuated bevel gear 18 , and vice versa. The engagement of bevel gears between the actuators 12 , 14 and the drive shaft 20 simplifies the gearing system because the bevel gears have opposing surfaces on the driver side and driven side. These opposing surfaces also serve as a mechanical stop to constrain the drive shaft 20 to whichever actuated bevel gear is engaged, eliminating any need for a biasing spring, retaining device, or any other stop mechanism in addition to the bevel gears themselves.
[0021] As also exemplified in FIGS. 1 and 5 , a solenoid 30 or any other type of control unit or its equivalent can be used to control the position 26 of the drive shaft 20 , and a motor 32 or any other type of power unit or its equivalent can be used to power the drive shaft 20 . By changing the position 26 of the drive shaft 20 , the solenoid 30 selectively moves the double-sided bevel gear 28 between the actuators 12 , 14 . The motor 32 powers a rotating shaft 34 that engages the drive shaft 20 through a set of gears, such as a pinion 36 attached to the motor's shaft 34 which meshes with a spur 38 attached to the drive shaft 20 .
[0022] The actuators 12 , 14 can manipulate the adjustment devices ( FIGS. 2, 3 , & 8 ) with a respective pair of bowden cables 40 , 42 . The dual drive actuation system 10 is modular because the actuators 12 , 14 can be switched depending on the adjustment device being manipulated. For example, different types of lumbar supports are typically designed to provide different levels of support and often require different levels of actuation. Additionally, in any given four-way lumbar, it is likely that the arching mechanism requires a different level of actuation than the translation mechanism. Similarly, different types of bolster devices may also require different levels of actuation, and the level of actuation designed for a bolster device in a seat is likely to be different from the level of actuation for a lumbar device in the same seat. Even though these different adjustment devices can each have a different actuation requirement, the actuators 12 , 14 can all be a part of the same family with actuated bevel gears 16 , 18 that mesh with the driver bevel gears 22 , 24 . Accordingly, the actuators 12 , 14 can be selected from this group of modular actuators that have different maximum levels of actuation but have the same actuated bevel gears 16 , 18 . The same actuators used for a manually-operated dual drive actuation system can also be used for a motor-driven dual drive actuation system, further increasing the commonality of parts and thereby reducing the cost of the systems.
[0023] Among the different types of actuators that can be used to manipulate seat adjustment devices are those that operate with bowden cables, such as those described in U.S. Pat. Nos. 5,638,722 and 6,053,064 and in pending U.S. application Ser. No. 10/008,896. A family of bowden cable actuators can provide a range of maximum cable travel lengths, such as 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, and 50 mm. As discussed above, different levels of actuation could be required depending on the adjustment device being manipulated, and one actuator 12 could have one maximum cable travel length 44 while the other actuator 14 could have the same or different maximum cable travel length 46 .
[0024] As illustrated in FIG. 2 , the dual drive actuation device 10 can be installed in a seat 48 with a four-way lumbar system 50 . Referring simultaneously to both FIGS. 2 and 8 , one can see that the dual drive actuation device 10 may be positioned in any portion of the seat 48 . Similarly, as illustrated in FIG. 3 , the dual drive actuation device 10 can be installed in a seat 48 with a bolster system 52 . The dual drive actuation device 10 can generally be used to manipulate the seat back 54 and seat cushions 56 . The dual drive actuation device 10 can also be used to manipulate a headrest 58 .
[0025] Another embodiment of the dual drive actuation system 10 with a bolster system is illustrated in FIG. 6 . FIG. 6 shows a pair of dual drive actuation devices 10 that are used to manipulate the seat back 54 and seat cushions 56 . The headrest 58 , as shown in FIG. 6 , has a pair of support springs. The pair of dual drive actuation devices 10 can be oriented in any position allowing user comfort, seat stability, and lumbar control.
[0026] Another embodiment of the dual drive actuation system 10 is illustrated in FIG. 4 . In the embodiment illustrated in FIG. 1 , the solenoid 30 moves the position 26 of the beveled driver gear 28 to selectively engage the actuators 12 , 14 . In comparison, according to general aspects of the embodiment in FIG. 4 , the solenoid 30 moves the position 60 of the actuators 12 , 14 to selectively engage the worm driver gear 62 . As illustrated by both embodiments, the power 64 for the motor 32 that drives the actuators 12 , 14 can be separate from the solenoid control 66 . Generally, the worm driver gear 62 and the beveled driver gear 28 form part of a drive unit which engages the motor 32 and transfers its power to the actuators 12 , 14 . Accordingly, the drive unit can be any type of driver gear 28 , 62 or other driver unit or their equivalents that engage the motor 32 and transfers its power to the actuators 12 , 14 . The solenoid 30 uses a transmission system to change the positions 26 , 60 and thereby switch the driving force supplied by the motor 32 to each individual actuator 12 , 14 . In the first embodiment, the drive shaft 20 serves as the transmission for moving the driver bevel gear 28 . In the second embodiment, a pinion link 68 serves as the transmission to move the actuators 12 , 14 . The pinion link 68 connects one end of the actuators 12 , 14 which are on either side of the worm driver gear 62 . Each one of the actuators 12 , 14 has a threaded rod 70 , 72 in screwed engagement with a respective threaded block 74 , 76 . Each one of the threaded rods 70 , 72 has a worm gear 78 , 80 .
[0027] In operation, the solenoid 30 moves the position 60 of the pinion link 68 , which is connected to and moves the ends of the threaded rods 70 , 72 to selectively engage the respective worm gears 78 , 80 to the driver gear 62 . The motor 32 has a shaft 82 that drives a spur gear 84 . The driver gear 62 is attached to and rotates with the spur gear 84 . Therefore, when either one of the worm gears 78 , 80 is engaged with the driver gear 62 , the respective threaded rod 70 , 72 is rotated and the corresponding threaded block 74 , 76 translates along the length of the actuator 12 , 14 .
[0028] The threaded blocks 74 , 76 have brackets 86 , 88 that can attach to the end of a cable 90 , 92 or another linkage between the actuators and the seat adjustment device. The dual drive 10 illustrated in FIG. 4 provides another type of modular design for the actuators 12 , 14 . Of course, the actuators 12 , 14 could have different lengths depending on their usage, thereby limiting the maximum extension of the cables 90 , 92 that is provided by the threaded rods 70 , 72 . Additionally, even if the threaded rods 70 , 72 have the same length, the actuators 12 , 14 can provide a range of limits for the maximum extension using electronic controls. For example, the actuators 12 , 14 can use the position of the threaded block 74 , 76 in combination with a potentiometer or switch 94 , 96 as a limit on the maximum extension.
[0029] Another embodiment using the worm driver gear arrangement of the dual drive actuation device 10 is shown in FIG. 7 . FIG. 7 shows a pair of dual drive actuation devices 10 that are used to manipulate the seat back 54 and seat cushions 56 . The headrest 58 , as shown in FIG. 7 , has a pair of support springs. The pair of dual drive actuation devices 10 can be oriented in any position allowing user comfort, seat stability, and lumbar control.
[0030] In view of the foregoing, it will be seen that the several advantages of the invention are achieved and attained. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
[0031] As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. For example, although the drive shaft has a double-sided bevel gear attached at one end, a pair of bevel gears with opposing faces could alternatively be attached to the drive shaft. Similarly, although a solenoid is used within the control unit, a “muscle cable” or any other type of switch device or their equivalents could be used. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.
|
A dual drive actuation system includes a driver gear, a pair of actuators with driven gears, and a transmission for switching the driver gear between the pair of actuators. The transmission is controlled by a solenoid, and the driver gear is powered by a motor. The dual drive actuation system can be used with different actuators that are changed based on their required usage, sizing and range of motion.
| 8
|
BACKGROUND OF THE PRESENT INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to thalidomide derivatives, the method of producing thereof, and the application thereof as an active pharmaceutical ingredient.
[0003] 2. Description of Related Arts
[0004] In 1953, thalidomide was synthesized and extensively used as a depressant and preventive medicine for vomiting in pregnant women. In the early 1960s, the serious reproductive toxicity had been identified. However, some of the properties of thalidomide, such as the inhibition in the releasing of Tumor Necrosis Factor-α (TNF α ), anti-angiogenesis and anti-inflammatory characteristics, make it more effective in the treatment of erythema nodosum leprosum (ENL), cutaneous erythematosus lupes (Arch. Dermatol, 1993, Vol. 129 P. 1548-1550), persistent erythematosus lupes (The Journal of Rheumatology, 1989, 16, P. 923-92), Behcet's syndrome (Arch. Dermatol. 1990, vol. 26, P. 923-927), Crohn's disease (Journal of Pediatr. Gastroenerol. Nurt. 1999, vol. 28, P. 214-216) and rheumatoid arthritis (Journal of Rheumatology, 1988, vol. 25, P. 264-969). Furthermore, thalidomide has been extensively used in clinical trials for the treatment of malignant tumors when these tumors show strong angiogenesis and chemotherapy refractory. In 1998, the FDA of the United States approved the use of thalidomide for treating ENL. In addition, the reproductive toxicity of thalidomide has been completely controlled by birth-control, especially in those patients who are in critical condition. However, since thalidomide is only slightly soluble in water(0.012mg/mL, Arch. Pharm., 321, 371 (1988)), the bioavailability of thalidomide was poor, and posed a barrier for the administration of thalidomide extra-gastrointestinally. Also, the pharmacological research of thalidomide was affected.
[0005] Snider et al. tried to improve the solubility of the thalidomide by directly linking amino acids onto it, although such method can generate compounds with increased water-solubility. Nonetheless, even if the water-solubility of some compounds even increase to 300 mg/ml (CN1215397A), these precursors of thalidomide were not stable in the water ( Bioorganic and Med. Chem. 9(5), 1297-1291, 2001), and can only be injected immediately after the solution was prepared. Dr. Eger's group had linked the thalidomide with p-dialkylamino benzoates and got their hydrochloride salts (DE 4211812 A1). Although the water solubility of these hydrochloride salts of the thalidomide derivatives are much higher than that of thalidomide, they are easy to be de-salted and precipitated out as their correspond bases from their aqueous solutions at pH7.5, indicating a decrease of their water solubility in condition close to physiological pH.
SUMMARY OF THE PRESENT INVENTION
[0006] A main object of the present invention is to provide novel water-soluble thalidomide derivatives for overcoming the shortcomings of the current technique. The thalidomide derivatives of the present invention are soluble in water to a certain extent within the range of physiological pH and stable in the gastric or enteric tract, thus increasing bioavailability when administered orally, and also enabling these derivatives to be administered outside the gastrointestinal tract, e.g. intravenous or intramuscular injection.
[0007] The thalidomide derivatives of the present invention is composed of compounds and various salts of relative inorganic and organic acids, with the formula as follows:
[0008] wherein: R represents CHR 1 NR 2 R 3 , CHR 1 NR 4 C(O)CHR 5 NR 2 R 3 , heterocyclic W and CHR 5 NR 4 C(O)W.
[0009] wherein: R 1 , R 4 and R 5 independently represent H and C 1-4 alkyl group; R 2 and R 3 independently represent C 1-4 alkyl group, or R 2 and R 3 together represents 1,3-propylene, 1,4-butylene, 1,5-pentaethylene, and 1,6-hexamethylene; and W represents 4-, 5-, 6-, 7- or 8-mumbered saturated or unsaturated heterocycles, and more particularly, W represents 2-pyridyl, 3-pyridyl, 4-pyridyl, 2-imidazopyridyl, 3-imidazopyrimidinyl, 4-imidazopyridyl or heterocycles of formula (II), formula (III), formula (IV) and formula (V), wherein X represents O, S, NR 1 , wherein R 1 represents H or C 1-4 alkyl group, and Y represents 1,2-ethylene, 1,3-propylene, 1,4-butylene, 1,5-pentylene, 1,6-hexatylene and hetero-atom containing bi-terminal subunits such as CH 2 OCH 2 , CH 2 SCH 2 or CH 2 NR 6 CH 2 etc., wherein R represents H or C 1-4 alkyl group.
[0010] When representing C 1-4 alkyl including linear or branched chain alkyl radical, R 1 , R 4 , R 5 and R 6 can be substituted by OH, COOH, C(O)NH 2 , NHC(O)(C 1-4 alkyl), NH 2 , NH(C 1-4 alkyl), N(C 1-4 alkyl) 2 , NHC(O)NH 2 , NHC(NH)NH 2 , OC 1-4 alkyl, SC 1-4 alkyl, phenyl or unsubstituted phenyl group.
[0011] When R 2 and R 3 represent C 1-4 alkyl including linear or branched alkyl radical chain, each or both of them can be substituted with OH, COOH, C(O)NH 2 , NHC(O)C 1-4 alkyl, NH 2 , NHC 1-4 alkyl, N(C 1-4 alkyl) 2 , NHC(O)NH 2 , NHC(NH)NH 2 , OC 1-4 alkyl, SC 1-4 alkyl or other groups such as substituted or unsubstituted phenyl, etc.
[0012] R 2 and R 3 are used together to represent 1,3-propylene, 1,4-butylene, 1,5-pentylene and 1,6-hexatylene, and these subunits can be substituted by OH, COOH, C(O)NH 2 , NHC(O)C 1-4 alkyl, NH 2 , NHC 1-4 alkyl, N(C 1-4 alkyl) 2 , NHC(O)NH 2 , NHC(NH)NH 2 , OC 1-4 alkyl, SC 1-4 alkyl. But the compounds in which both R 2 and R 3 represent H are not included in the present invention.
[0013] When W is used to represent heterocycles, the heterocycles comprise 4-, 5-, 6-, 7-, and 8-mumbered saturated, unsaturated or aromatic heterocycles containing one or more heteroatom, such as N, O, S, and these heterocycles can be substituted by OH, COOH, C(O)NH 2 ,NHC(O)C 1-4 alkyl, NH 2 , NHC 1-4 alkyl, N(C 1-4 alkyl) 2 , NHC(O)NH 2 , NHC(NH)NH 2 , OC 1-4 alkyl, SC 1-4 alkyl, C 1-4 alkyl, etc.
[0014] The compounds in formula (I) which are suitable to be used as a precursor of thalidomide are those in which the R in formula (I) represents CHR 1 NR 2 R 3 where R 1 represents H, CH 3 , CH(CH 3 ) 2 , CH(CH 3 )CH 2 CH 3 or CH 2 CH(CH 3 ) 2 , especially where R 1 represents H, CH 3 , CH(CH 3 ) 2 , and the R 2 and R 3 independently represent CH 3 , CH 2 CH 3 , as well as the R 1 and R 3 come together to represent 1,4-butylene or 1,5-pentylene, etc.
[0015] Some compounds of the formula (I) in which R represents CHR 1 NR 4 C(O)CHR 5 NR 2 R 3 , are suitable to be used as precursors of the thalidomide. These comprise of the compounds in which R 1 and R 5 independently represent H, CH 3 , CH(CH 3 ) 2 , CH 2 CH(CH 3 ) 2 or CH(CH 3 )CH 2 CH 3 ; R 4 represents H, CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , or CH(CH 3 ) 2 ; R 2 and R 3 independently represent CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , CH(CH 3 ) 2 , or R 2 and R 3 come together to represent 1,4-butylene or 1,5-pentylene. Compounds, which are especially suitable to be used as the precursors of the thalidomide, include those where R 1 and R 5 independently represent H, CH 3 or CH(CH 3 ) 2 ; R 4 represents H, CH 3 , or CH 2 CH 3 , R 2 or R 3 independently represent CH 3 or CH 2 CH 3 ; or R 2 and R 3 come together to represent 1,4-butyl or 1,5-pentylene.
[0016] The compounds in formula (I) which are suitable to be used as a precursor of thalidomide are those in which the R in formula (I) represents W wherein W represents 2-pyridyl, 3-pyridyl, 4-pyridyl, 2-pyrimidyl, 4-pyrimidyl, 5-pyrimidyl, 2-tetrahydropyrrolyl, 2-(N-methyl) tetrahydropyrrolyl, 2-(N-ethyl) tetrahydropyrrolyl, 2-(N-propyl) tetrahydropyrrolyl, or 2-(N-isopropyl) tetrahydropyrrolyl. The compounds especially suitable to be used as the precursors of the thalidomide are those which W represents 3-pyridyl, 4-pyridyl, 2-tetrahydropyrrolyl, 2-(N-methyl) tetrahydropyrrolyl, and 2-(N-ethyl) tetrahydropyrrolyl.
[0017] The compounds in formula (I) which are suitable to be used as a precursor of thalidomide are those in which the R in formula (I) represents CHR 5 NR 4 C(O)W wherein R 4 represents H, CH 3 , CH 2 CH 3 , R 5 represents H, CH 3 , CH(CH 3 ) 2 , and W represents 2-pyridyl, 3-pyridyl, 4-pyridyl, 2-pyrimidyl, 4-pyrimidyl, 5-pyrimidyl, 2-tetrahydropyrrolyl, 2-(N-methyl)tetrahydropyrrolyl, 2-(N-ethyl)tetrahydropyrrolyl, 2-(N-propyl) tetrahydropyrrolyl, or 2-(N-isopropyl)tetrahydropyrrolyl. The compounds especially suitable to be used as the precursors of the thalidomide are those which R 4 represents H, CH 3 , CH 2 CH 3 , R 5 represents H, CH 3 , CH(CH 3 ) 2 and W represents 3-pyridyl, 4-pyridyl, 2-tetrahydropyrrolyl, 2-(N-methyl) tetrahydropyrrolyl, and 2-(N-ethyl) tetrahydropyrrolyl.
[0018] The present invention also relates to the method of preparing thalidomide derivatives of formula (I). The steps of the method involves the reaction between the N-hydromethyl thalidomide and carboxylic acid HO 2 CCHR 1 NR 2 R 3 or HO 2 CCHR 1 NR 4 C(O)CHR 5 NR 2 R 3 or HO 2 CW or HO 2 CCHR 5 NR 4 C(O)W, with the carbodimide or carbonyldimidazole as the condensation agent, at room temperature for 2˜18 hours. The mole ratio between the N-hydromethyl thalidomide and the carboxylic acid said above is 3˜1: 1˜3, and the mole ratio between the N-hydromethyl thalidomide and the condensation agent carbodimide or carbonyldimidazole is 3˜1: 1˜3, with or without the catalyst pyridine derivatives or other organic base, and more particularly the 4-dimethy-1aminopyridine or 4-(1-pyrrolyl)pyridine. The dosage of the catalyst is between 1-20% mole of the N-hydromethyl thalidomide, and the above reaction is conducted in the organic solvents such as dichloromethane, chloroform, acetone, N,N-dimethyl formamide, dimethyl sulfoxide, ethylene glycol dimethyl ether, tetrahydrofuran, or pyridine.
[0019] The second method for the production of the precursors of thalidomide in formula (I) presented in this invention is by conducting the reaction between N-hydromethyl thalidomide and HO 2 CCHR 1 Br or HO 2 CCHR 1 NR 4 C(O)CHBrR 5 under the stated conditions (above) at room temperature for 2˜18 hours. Then react the products of the above reaction with 1˜3 fold amount of amine or amine salt for 2˜24 hours, using an organic base (such as pyridine, triethylamine etc.) or inorganic base (such as sodium carbonate, sodium bicarbonate etc.) as an acid-consuming agent, and carrying the reaction in an organic solvent such as dichloromethane, chloroform, acetone, N,N-dimethyl formamide, dimethy sulfone, ethylene glycol dimethyl ether, tetrahydrofuran or acetonitrile.
[0020] The indication of the thalidomide derivatives in formula (I) comprises, but is not limited to erythema nodosum lepresom, cutaneous erythematosus lupes persistent erythmatosus lupes, behcet's syndrome, crohn's disease, rheumatoid arthritis, abnormal myeloidosis syndrome and tumors (including, but not limited to multiple myeloma, lymphoma leukemia and hepatocarcinoma).
[0021] In addition to the thalidomide derivatives of formula (I) in this invention, some medical adjuvant material including carrier, bulk additive, dissolving-help agent, diluent, coloring material, adhesion agent etc., or other pharmaceutical active ingredient, can be used for complex formulation. The selection of the adjuvants and the dosage of the adjuvants are dependent on the pattern of the medicine administration, e.g. on whether the medicine is administered gastrointestinally, intravenously, intraperitoneally, intradermally, intramuscularly, intranasally or topically.
[0022] These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Abbreviation:
[0024] DCC: dicyclohexylcarbodimide; DCM: dichloromethane; TFA: trifluoroacetic acid; CDCl 3 : deuteriochloroform; HCl: hydrochloride.
EXAMPLE 1
[0025] (S)-2-(diethylaminoacetamido)-3-methyl Butyric Acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester Hydrochloride.
[0026] A. Bromoacetic Acid Activated Ester
[0027] Dissolve the bromoacetic acid (4.3 g, 30 mmol) and hydroxymethylsuccinimide (4.03 g, 35 mmol) in DCM(25 ml), agitating on electromagnetic stirrer over night at room temperature with one addition of the DCC (7.42 g, 36 mmol) . Remove solid (cyclohexylurea) by filtration, wash the filter cake several times with DCM, then wash the pooled filtrate 3 times with saturated sodium chloride water solution (30 ml/each), dried with anhydrous magnesium sulfate, discard the desiccant, remove solvent by rotary evaporation, give a white solid (5 g, 70%).
[0028] B. (S)-2-(bromoacetamido)-3-methyl-butyric Acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester.
[0029] Dissolving the (S)-2-amino-3-methyl butyric acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester (1.80 g, 4.7 mmol) into the DCM solution (20 ml), and adding the activation ester of the bromoacetic acid (1.04 g, 4.7 mmol), the reaction mixture is agitated on a electromagnetic stirrer over night at room temperature. Wash the reaction solution 3 times with saturated sodium chloride water solution, dry with anhydrous magnesium sulfate, remove drying agent by filtration, remove solvent from the filtrate at vacuum give the crude product. The crude product was purified with silica gel column (mobile phase used as ethyl acetate:petroleum ether=1:1) to give a white solid (1.3 g) with a yield of 54%, 1 H NMR (CDCl 3 , ppm) δ 7.88-7.90 (m, 2H), 7.78-7.80(m, 2H), 6.86(t, 1H, J=8.4 Hz), 5.87-5.95(m, 2H), 5.03-5.07(m, 1H), 4.52-4.58(m, 1H), 3.90-3.93(m, 2H), 3.00-3.07(m, 1H), 2.80-2.86(m, 2H), 2.16-2.22(m, 2H), 0.89-1.00(m, 6H).
[0030] C. (S)-2-(diethylaminoacetylamino)-3-methyl Butyric Acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester.
[0031] Dissolve the (S)-2-(bromoacetylamino)-3-methyl butyric acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester (120 mg, 0.24 mmol) into DCM (8 ml). Slowly add the diethylamine solution (0.04 ml, 0.387 mmol) drop-by-drop into the above solution while agitating, and keep agitating at room temperature, discard the dissolvent and the residual diethylamine by spinning evaporation, the mixture solid product is purified through silica get column (mobile phase is ethyl acetate:petroleum ether=3:1), the product is 100 mg, the rate of production is 83%, 1 H NMR (CDCl 3 , ppm) δ 7.94(d, 1H, J=8.4 Hz), 7.88-7.90 (m, 2H), 7.76-7.78(m, 2H), 5.83-5.94(m, 2H), 5.03-5.07(m, 1H), 4.55-4.59(m, 1H), 2.97-3.20(m, 3H), 2.60-2.80(m, 2H), 2.57(q, 4H, J=6.8 Hz), 1.044(t, 3H, J=6.8 Hz), 1.038(t, 3H, J=6.8 Hz), 0.91-0.95(m, 3H), 0.87(d, 3H, J=6.8 Hz); MS: (EI) M + 500.
[0032] D. Salt-forming Reaction
[0033] Dissolve the compound (76 mg, 0.15 mmol) from the reaction C in DCM (10 ml), add 15% HCl/methanol solution (5 mL) drop-by-drop into the abovementioned DCM solution, remove solvent in vacuum to obtain 82 mg white foam. The water solubility of this solid is >150 mg/ml, and aqueous solution stability is: t 1/2 >8 hours.
EXAMPLE 2
[0034] (S)-2-(dimethylaminoacetamido)-3-methyl Butyric Acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester Hydrochloride.
[0035] Prepare the above compound by using the synthesis method in the example 1, but the diethylamine in example 1 is replaced by dimethylamine (yield: 53%). 1 H NMR (CDCl 3 , ppm) δ 7.87-7.89 (m, 2H), 7.76-7.78(m, 2H), 7.61(d, 1H, J=9.2 Hz), 5.92(d, 1H, J=9.2 Hz), 5.86(d, 1H, J=9.2 Hz), 5.03-5.07(m, 1H), 4.55-4.58(m, 1H), 2.97-3.06(m, 3H), 2.82-2.87(m, 2H), 2.31(s, 6H), 2.16-2.22(m, 2H), 0.95(d, 3H, J=6.8 Hz), 0.87(d, 3H, J=6.8 Hz);MS (EI) M + 472. The solubility of this compound in water is >150 mg/mL, and its aqueous solution stability is: t 1/2 >8 hours.
EXAMPLE 3
[0036] (S)-2-(1-piperidinylacetamido)-3-methyl Butyric Acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester Hydrochloride.
[0037] This compound is produced by using the synthesis method of the example 1 except the diethylamine is substituted by piperidine (yield: 50%). 1 H NMR (CDCl 3 , ppm) δ 7.87-7.90 (m, 2H), 7.76-7.82(m, 3H), 5.84-5.95(m, 2H), 5.03-5.07(m, 1H), 4.53-4.59(m, 1H), 3.03-3.07(m, 1H), 2.97(s, 2H), 2.80-2.90(m, 2H), 2.40-2.58(m, 4H), 2.16-2.25(m, 2H), 1.55-1.68(m, 4H), 1.38-1.50(m, 2H), 0.87-0.97(m, 6H); MS (EI) M + 512. The water solubility f this compound is >150 mg/mL, and its aqueous solution stability is: t 1/2 >8 hours.
EXAMPLE 4
[0038] Diethylaminoacetic Acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester Hydrochloride.
[0039] A. Bromoacretic Acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3′-yl)isoindoline-1,3-dione Ester
[0040] Dissolve the bromoacetic acid (138.95 mg, 1 mmol) and 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione (288 mg,1 mmol) into the DCM(20 ml), electromagnetic agitating at room temperature, and add the total amount of DCC (206 mg, 1 mmol) at one time, keep reacting over night. Then, remove the cyclohexylurea by filtration, wash the filter cake several times with DCM. The pooled filtrate was washed with the saturated sodium chloride aqueous solution (30 ml/each) and dried with anhydrous magnesium sulfate. After removal of the desiccant by filtration and solvent by rotary evaporation, 390 mg of white solid was obtained with a yield of 95%. 1 H NMR (CDCl 3 , ppm) δ 7.87-7.90(m, 2H), 7.75-7.78(m, 2H), 6.17(d, 1H, J=9.6 Hz), 6.09(d, 1H, J=9.6 Hz), 5.09-5.14(m, 1H), 4.85(s, 2H), 3.02-3.17(m, 1H), 2.80-2.95(m, 2H), 2.17-2.28(m, 1H).
[0041] B. Diethylaminoacetic Acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester.
[0042] Dissolve the bromoacetic acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester (409.2 mg,1 mmol) in the DCM (10 ml). While stirring, 1M diethylamine solution in THF (1.2 ml) was added drop-by-drop at room temperature. After addition, keep stirring for 2 hours. Then remove the solvent and residual diethylamine by rotary vacuum evaporation. The crude product was purified by using silica gel column (mobile phase is: ethyl acetate:petroleum ether=2:1) to give 128 mg of white solid with a yield of 32%. 1 H NMR (CDCl 3 , ppm): δ 7.88-7.90 (m, 2H), 7.77-7.79(m, 2H), 5.89(d, 1H, J=9.2 Hz), 5.84(d, 1H, J=9.2 Hz), 5.02-5.06(m, 1H), 3.35(s, 2H), 3.00-3.10(m, 1H), 2.78-2.94(m, 2H), 2.62-2.67(m, 4H), 2.14-2.17(m, 1H), 1.02-1.06(m, 6H); MS (EI): 401 (M + ).
[0043] C. Salt-formation Reaction of Compound
[0044] Dissolve diethylaminoacetic acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester (76 mg, 0.19 mmol) in DCM solution (10 ml), add 15%HCl/methanol solution (10 mL), remove the solvent by rotary evaporation to give 80 mg of white foam. Recrystallization from isopropyl ether/ethanol to give white crystal. MP: 118-122° C. Its water solubility is >150 mg/mL, and its aqueous solution stability is: t 1/2 >8 hours.
EXAMPLE 5
[0045] Dimethylaminoacetic Acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester Hydrochloride Salt
[0046] This compound (yield: 43%) is produced by replacing the diethylamine with dimethylamine and by using the synthesis method same as that in the example 4. 1 H NMR (CDCl 3 , ppm) δ 7.88-7.90 (m, 2H), 7.77-7.79(m, 2H), 5.91(d, 1H, J=9.8 Hz), 5.87(d, 1H, J=9.8 Hz), 5.03-5.07(m, 1H), 3.22(s, 2H), 3.00-3.10(m, 1H), 2.78-2.94(m, 2H), 2.36(s, 6H), 2.15-2.20(m, 1H);MS (EI) M + 373.The solubility of this compound in water is >150 mg/mL, and its aqueous solution stability is: t 1/2 >4 hours.
EXAMPLE 6
[0047] (S)-2-diethylamino-3-methyl butyric acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester
[0048] Dissolve the (S)-2-amino-3-methyl butyric acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester (90 mg, 0.23 mmol) in acetonitrile (8 ml), then add ethyl iodide (74 mg, 0.48 mmol) into the solution, agitate the resulted mixture over night at 80° C. Remove the solvent by rotary evaporation to give a crude product, purify the crude product by using silica gel column (mobile phase is ethyl acetate:petroleum ether=1:1) to give a white solid (30 mg, 31%). 1 H NMR (CDCl 3 , ppm): δ 7.88-7.90 (m, 2H), 7.77-7.79(m, 2H), 5.89(d, 1H, J=9.2 Hz), 5.84(d, 1H, J=9.2 Hz), 5.02-5.06(m, 1H), 3.45(m, 1H), 3.00-3.10(m, 1H), 2.78-2.94(m, 2H), 2.62-2.67(m, 4H), 2.14-2.17(m, 2H), 1.02-1.06(m, 6H), 0.87-0.97(m, 6H); MS (EI) 443 (M + ).
EXAMPLE 7
[0049] (S)-Proline 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester TFA Salt.
[0050] Dissolve the (S)-tert-butoxycarbonyl proline (374 mg, 1.74 mmol) and 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione (500 mg, 1.7 mmol) in the DCM (30 ml), electromagnetic stirring at room temperature with one addition of DCC (350.2 mg, 1.7 mmol) and DMAP(p-dimethylaminopyridine)(25 mg), keep reacting over night. Remove the cyclohexylurea by filtration, and wash the filter cake several times with DCM. The pooled filtrate was washed with water and saturated NaCl aqueous solution, dried with anhydrous magnesium sulfate. Remove desiccant by filtration and solvent by rotary evaporation to give a crude product. Purify the crude product using column (solid phase is silica, mobile phase is chloroform:acetone=9:2) to give (S)-tert-butoxycarbonyl proline 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester as a white solid (658 mg, 80%).
[0051] Dissolve (S)-tert-butoxycarbonyl proline 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester (658 mg, 1.35 mmol) in the 25%TFA/DCM(20 mL). After electromagnetic stirring for 4 hours at room temperature, remove the DCM and most of TFA by rotary evaporation, dry in vacuum to to give (S)-Proline 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester TFA salt as a foam (500 mg, 100%). 1 H NMR (CDCl 3 , ppm): δ 9.80(brs, 1H), 9.0(brs, 1H), 7.90-8.00(m, 4H), 5.75-5.95(m, 2H), 5.35-5.42(m, 1H), 4.38-4.48(m, 1H), 3.15-3.30(m, 2H), 3.04-3.15(m, 1H), 2.80-2.92(m, 1H), 2.50-2.70(m, 1H), 2.12-2.28 (m, 2H), 1.80-2.00(m, 3H); MS (EI): 385 (M + ).
EXAMPLE 8
[0052] (S)-2-(isonicotinamido)-3-methy butyric acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester
[0053] Dissolve (S)-2-amino-3-methyl butyric acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester (200 mg, 0.5 mmol) and isonicotonic acid N-hydroxymethylsuccinimide ester (120 mg, 0.54 mmol) in DCM (20 ml). Keep stirring at room temperature after triethylamine (1 ml) added at one time over night. Then, transfer the reaction solution into DCM(30 ml), wash this solution three time with saturated sodium hydrogen carbonate aqueous solution (30 ml/each time), then washed with saturated sodium chloride aqueous solution (30 ml), dry with the desiccant anhydrous magnesium sulfate. Remove the desiccant by filtration and remove the solvent by rotary evaporation to give the crude product which give a white solid (239 mg, 97%) after purification through silica gel column (mobile phase is: chloroform:acetone=5:2). 1 HNMR (CDCl 3 , ppm): δ 9.04(d, 1 H, J=11.2 Hz), 8.72(s, 1H), 8.13(d, 1H, J=8.0 Hz), 7.87-7.90(m, 2H), 7.76-7.78(m, 2H), 7.41(dd, 1H, J=8.0, 11.2 Hz), 6.73(d, 1H, J=9.6 Hz), 5.86-5.98(m, 2H), 5.05-5.08(m, 1H), 3.00-3.15(m, 1H), 2.80-2.95(m, 2H), 2.12-2.28 (m, 1H), 2.10-2.20(m, 2H), 0.97-1.05(m, 3H), 0.85-0.88(m, 3H).
EXAMPLE 9
[0054] (S)-2-(isonicotinamido)propionic Acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester
[0055] Dissolve the (S)-2-(isonicotinamido)propionic acid (582.5 mg, 3 mmol) and 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione (864 mg, 3 mmol) in DCM (25 ml), toward where add DCC (618 mg, 3 mmol) at one time during electromagnetic stirring at room temperature, keep the agitation over night. Remove the cyclohexylurea by filtration, wash the filter-cake several times with DCM. The pooled filtrate was washed three times with saturated sodium chloride aqueous solution (30 ml/time), dried with the desiccant anhydrous magnesium sulfate. After removal of the solvent by rotary evaporation to give crude product, which give 975 mg white solid (yield 70%) after purification using silica gel column (mobile phase: dichloromethane:acetone=5:2). 1 H NMR (CDCl 3 , ppm): δ 9.14(s, 1H), 8.75(d, 1H, J=4.8 Hz), 8.23(d, 1H, J=10.4 Hz), 7.87-7.90(m, 2H), 7.76-7.78(m, 2H), 7.47(dd, 1H, J=4.8, 10.4 Hz), 7.15(d, 1H, J=9.6 Hz), 5.90-6.05(m, 2H), 5.07-5.12(m, 1H), 4.78-4.92(m, 1H), 3.00-3.15(m, 1H), 2.75-2.95(m, 2H), 2.12-2.20 (m, 1H), 1.50-1.56(m, 3H).
EXAMPLE 10
[0056] Isonicotinic Acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester
[0057] Isonicotinic acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester is produced using the synthesis method in example 9 and using the isonicontinic acid to substitute the (S)-2-(isonicotinamiino) propionic acid (yield 70%). 1 H NMR (CDCl 3 , ppm): δ 9.2(s, 1H), 8.78(d, 1H, J=4.0 Hz), 8.29(d, 1H, J=8.0 Hz), 7.87-7.90(m, 2H), 7.75-7.78(m, 2H), 7.41(dd, 1H, J=4.0, 8.0 Hz), 6.17(d, 1H, J=9.6 Hz), 6.09(d, 1H, J=9.6 Hz), 5.09-5.14(m, 1H), 3.02-3.17(m, 1H), 2.80-2.95(m, 2H), 2.17-2.28(m, 1H).
EXAMPLE 11
[0058] (S)-1-Ethylproline 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione Ester.
[0059] (S)-1-Ethylproline 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester is prepared using the synthesis method of the example 6 with the (S)-2-amino-3-methyl butyric acid 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester substituted by (S)-proline 2-(1-(hydroxymethyl)-2,6-dioxopiperidin-3-yl)isoindoline-1,3-dione ester (yield 73%). 1 H NMR (CDCl 3 , ppm): δ 7.86-7.95(m, 4H), 5.75-5.95(m, 2H), 5.35-5.42(m, 1H), 4.12-4.18(m, 1H), 3.43(q, 2H, J=8.4 Hz), 2.92-3.15(m, 3H), 2.80-2.92(m, 1H), 2.50-2.70(m, 1H), 2.00-2.18 (m, 2H), 1.75-1.90(m, 3H), 1.09(t, 3H, J=8.4 Hz); MS (EI): 413 (M + ).
[0060] One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
[0061] It will thus be seen that the objects of the present invention have been fully and effectively accomplished. Its embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure form such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
|
Thalidomide derivative (I) and their bases or salts are new: where R represents CHR 1 NR 2 R 3 , CHR 1 NR 4 C(O)CHR 5 NR 2 R 3 , W or CHR 5 NR 4 C(O)W, where R 1 , R 4 and R 5 represent independently each other H, C 1-4 alkyl, R 2 is a C 1-4 alkyl, R 3 is a C 1-4 alkyl, or R 2 and R 3 together represents 1,3-propylene, 1,4-butylene, 1,5-pentylene, 1,6-hexylene, W represents 4-, 5-, 6-, 7-, or 8-mumbered, saturated or unsaturated heterocycle. The invention also relates to processes of production thereof and the use of thereof as an active pharmaceutical ingredient.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/398,592 filed on Jun. 28, 2010, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to automatic cleaners for liquid-containing bodies and more particularly, although not necessarily exclusively, to tracked cleaners for pools and spas.
BACKGROUND OF THE INVENTION
[0003] U.S. Pat. No. 4,449,265 to Hoy illustrates an example of a wheeled automatic swimming pool cleaner. Powering the wheels is an impeller comprising an impeller member and pairs of vanes. Evacuating the impeller causes water within a swimming pool to interact with the vanes, rotating the impeller member. The impeller is reversible, with the impeller member apparently moving laterally when the pool cleaner reaches an edge of a pool to effect the rotation reversal.
[0004] U.S. Pat. No. 6,292,970 to Rief, et al., describes a turbine-driven automatic pool cleaner (“APC”). The cleaner includes a turbine housing defining a water-flow chamber in which a rotor is positioned. Also included are a series of vanes pivotally connected to the rotor. Water interacting with the vanes rotates the rotor in one direction (clockwise as illustrated in the Rief patent), with the vanes pivoting when encountering “debris of substantial size” to allow the debris to pass through the housing for collection.
[0005] U.S. Patent Application Publication No. 2010/0119358 of Van Der Meijden, et al. discloses fluid-powered devices that may, for example, function as motors for APCs. Versions of the devices include paired paddles, with each paddle of a pair connected to the other paddle of a pair via a shaft. When a first paddle of a pair in a particular manner relative to flowing fluid, the other paddle of the pair is oriented approximately normal to the first paddle.
SUMMARY OF THE INVENTION
[0006] The present invention provides innovative developments in the field of APCs. In particular, for APCs having tracks as part of their motive assemblies, the tracks may be formed so that their internal surfaces include teeth. The teeth may engage shift mechanisms for purposes of changing direction of movement of the cleaners.
[0007] Additionally, a shift mechanism may include a cam designed to push a shifter in either of two directions so as to engage a different one of two (mitre) drive gears. Direction of travel of the APC depends on which drive gear is engaged. Beneficially, engaging one drive gear produces forward motion, whereas engaging the other drive gear produces rearward, or reverse, motion.
[0008] Moreover, left and right sides of the APC differ for driving purposes. In some versions of the invention, different numbers of cams and teeth appear at one side of the cleaner as compared to the other side. Consequently, motion of the APC will not be constant, but instead will vary as a function of time.
[0009] Lower portions of APCs of the present invention may include one or more bladed “fans” or “scrubbers.” Preferably, the blades are at least somewhat flexible; as such, they may accommodate larger items of debris being evacuated from the pool into the cleaner body. Positioning the scrubbers on either side of the debris inlet to the body also provides a wider cleaning path for the APC and produces vortexes actively inducing debris-laded water to flow toward the inlet. The scrubbers additionally produce downward force in operation, helping offset buoyancy forces and assisting the APC in remaining in contact with a to-be-cleaned surface.
[0010] Cleaners of the present invention also may include easily-opening bodies. Certain versions incorporate a hood, or top, that may be moved to access internal body components; a presently-preferred version has a hinged top that may pivot to permit such access. Among other things, an easily-opening body facilitates removal of debris retained within the body.
[0011] It thus is an optional, non-exclusive object of the present invention to provide improved APCs.
[0012] It is another optional, non-exclusive object of the present invention to provide reconfigured tracks for track-driven APCs.
[0013] It is also an optional, non-exclusive object of the present invention to provide tracks having teeth on their internal surfaces.
[0014] It is a further optional, non-exclusive object of the present invention to provide shift mechanisms for non-robotic APCs.
[0015] It is, moreover, an optional, non-exclusive object of the present invention to provide shift mechanisms in which cams cause shifters to engage differing drive gears.
[0016] It is an additional optional, non-exclusive object of the present invention to provide bladed scrubbers producing downward force in opposition to upward buoyancy forces.
[0017] It is yet another optional, non-exclusive object of the present invention to provide APCs with easily-opening bodies.
[0018] Other objects, features, and advantages of the present invention will be apparent to those skilled in relevant fields with reference to the remaining text and the drawings of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a perspective, generally side view of an exemplary scrubber of an APC of the present invention.
[0020] FIG. 2 is a perspective, generally side view of an exemplary motive assembly of an APC of the present invention.
[0021] FIG. 3 is a perspective, generally top view of portions of an exemplary body of an APC of the present invention.
[0022] FIGS. 4-7 are perspective views of a shifting drive mechanism of an APC of the present invention.
[0023] FIG. 8 is a perspective, generally bottom view of scrubbers (such as that of FIG. 1 ) of an APC of the present invention.
[0024] FIGS. 9-11 are various views of an alternate inlet of an APC of the present invention.
[0025] FIG. 12 is a perspective, generally bottom view of an APC of the present invention showing scrubbers and the inlet of FIGS. 9-11 .
DETAILED DESCRIPTION
[0026] Illustrated in FIGS. 1 and 8 is exemplary scrubber 10 of the present invention. Scrubber 10 may include blades 14 , shaft 18 and, optionally, mitre or other gear 22 . In use, scrubber 10 desirably rotates about shaft 18 so as to move water or other liquid toward inlet 26 of body 30 of automatic pool cleaner 34 . Such rotation may be caused by interaction of gear 22 with a corresponding gear or other device typically located within body 30 .
[0027] Blades 14 preferably are “semi-rigid” in nature. As used herein, “semi-rigid” means that blades 14 have sufficient flexibility to accommodate passage into inlet 26 , without blockage, of at least some larger types of debris often found in outdoor swimming pools. The term also means that blades 14 nevertheless have sufficient rigidity to move volumes of water toward inlet 26 as they rotate about shaft 18 . A presently-preferred material from which blades 14 may be made is molded thermoplastic polyurethane, although other materials may be used instead.
[0028] FIGS. 1 and 8 depict the presence of eight blades 14 extending radially from shaft 18 and equally spaced about the circumference of the shaft 18 . Fewer or greater numbers of blades 14 may be employed as appropriate, however. Scrubber 10 additionally optionally may include wear surface 38 that may, at times, contact the surface to be cleaned.
[0029] Shown in FIG. 8 are two scrubbers 10 positioned opposite inlet 26 . In some versions of the invention, blades 14 of one scrubber 10 rotate clockwise about corresponding shaft 18 , while blades 14 of the other scrubber 10 rotate counterclockwise. Resulting is vortex action tending to induce debris-laden water toward inlet 26 . Such rotation also produces downforce biasing cleaner 34 toward a pool floor or other surface to be cleaned. In other versions, blades 14 of the one scrubber 10 rotate counterclockwise, with blades 14 of the other scrubber 10 rotating clockwise. In yet other versions of the invention, only one scrubber 10 may be utilized as part of cleaner 34 .
[0030] FIG. 2 depicts aspects of motive assembly 46 of the present invention. Assembly 46 may include (closed-loop) track 50 having external and internal surfaces 54 and 58 , respectively. It also may include pulley or drive wheel 62 and undriven wheels 66 and 70 . An assembly 46 will be present at each of the left and right sides of cleaner 34 .
[0031] External surface 54 of track 50 may contain treads 74 in any configuration suitable for facilitating movement of cleaner 34 . Of note, moreover, internal surface 58 of track 50 may include teeth 78 , which may be or comprise projections or protrusions of any suitable shape or size. As shown in FIG. 2 , teeth 78 may be spaced longitudinally along internal surface 58 and generally laterally centrally located. In use, internal surface 58 bears against respective circumferential surfaces 82 and 86 of undriven wheels 66 and 70 . To accommodate the presence of teeth 78 , wheels 66 and 70 may have laterally centrally-located circumferential grooves 90 and 94 in which teeth 78 are freely received.
[0032] By contrast, teeth 78 are designed to engage drive wheel 62 . Accordingly, clockwise rotation of drive wheel 62 (as shown in FIG. 2 ) will move track 50 so that cleaner 34 moves to the left of the drawing of FIG. 2 . Counterclockwise rotation of drive wheel 62 will move track 50 so that cleaner 34 moves to the left of the drawing of FIG. 2 . Thus, both forward and rearward motion of cleaner 34 may be achieved.
[0033] Illustrated in FIG. 3 are portions of exemplary body 30 of the present invention. Body may comprise lower section 98 and upper section 102 . In the version of cleaner 34 depicted in FIG. 3 , upper section 102 may contain outlet 106 through which water may exit the cleaner 34 . Upper section 102 additionally may include a swivel about outlet 106 for attachment of a hose.
[0034] Upper section 102 further preferably is moveable relative to lower section 98 so as to expose interior 110 of body 30 . So exposing interior 110 facilitates both access to components of cleaner 34 within body 30 (including, if desired, a fluid-powered motor of the type disclosed in the Van Der Meijden application) and inspection and removal of any damaged centrally-located parts. It also may facilitate removal of debris lodged in interior 110 . As shown in FIG. 3 , upper section 102 may be connected to lower section 98 using hinges 114 ; accordingly, it may pivot relative to lower section 98 . Other means of exposing interior 110 of body 30 may be employed instead, however, as appropriate or desired.
[0035] Additional aspects of motive assembly 46 are illustrated in FIGS. 4-7 . Opposite shaft 116 from drive wheel 62 is first gear 118 . Oriented generally perpendicular to shaft 116 is shaft 122 on which second gear 126 and third gear 130 are located. Second and third gears 126 and 130 are fixed to shaft 122 so that they rotate together as the shaft 122 rotates, with rotation of shaft 122 caused by a hydraulic motor or other propulsion source.
[0036] First gear 118 is intended alternately to engage second gear 126 and third gear 130 . By engaging a rotating second gear 126 , for example, first gear 118 will be caused to rotate in a particular direction (e.g. counterclockwise), in turn rotating shaft 116 in the same direction. By contrast, if first gear 118 engages a rotating third gear 130 , first gear 118 and shaft 116 will be caused to rotate in the opposite direction (i.e. clockwise). Because it is fixed to shaft 116 , drive wheel 62 rotates as does the shaft 116 . Thus, merely by changing the engagement of first gear 118 , cleaner 34 may be caused to change its direction of travel from forward to reverse (or vice-versa).
[0037] In FIG. 4 , first gear 118 is shown as not engaging either second gear 126 or third gear 130 —in essence in a neutral position in which drive wheel 62 is not rotating. However, boss 134 , which surrounds shaft 116 , may pivot about shaft 138 so as to translate shaft 116 to its left or right, in turn causing first gear 118 to engage either second gear 126 or third gear 130 . If boss 134 pivots to the left of FIG. 4 , first gear 118 engages second gear 126 . Pivoting of boss 134 to the right of FIG. 4 causes first gear 118 to engage third gear 130 .
[0038] A cam and gearing assembly 142 may be used to cause boss 134 to pivot either left or right about shaft 138 . Moreover, because two motive assemblies 46 preferably are used for a cleaner 34 (one on each side of body 30 , as mentioned earlier), their cam and gearing assemblies 142 may differ somewhat. Consequently, motion (direction, speed, or both) of one drive wheel 62 may differ at times from motion of the other drive wheel, causing cleaner 34 to move in non-linear manner.
[0039] FIGS. 9-12 illustrate alternate inlet 26 ′ of the present invention. Inlet 26 ′ is either formed as part of lower section 98 of body 30 or attached to the lower section 98 (as shown in FIG. 12 ) intermediate scrubbers 10 . Included as part of inlet 26 ′ may be both fluid opening 150 and scoop 154 , the latter configured to improve pick-up of debris. In particular, scoop 154 may comprise a rounded protrusion or bump 158 and an elongated, curved wall 162 (the continuation of which, denoted element 166 , may also be curved if desired). Bump 158 increases velocity of debris-laden water being pushed by scrubbers 10 toward opening 150 , while wall 162 effectively conveys (“scoops”) that water to the opening 150 .
[0040] The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention. As one of many examples of possible modifications, one or more cam and gearing assemblies 142 may be adjustable or programmable by a user of cleaner 34 . The contents of the Hoy and Rief patents and of the Van Der Meijden application are incorporated herein in their entireties by this reference.
|
Automatic pool cleaners (APCs) and components thereof are detailed. The APCs may include tracks for movement, with the tracks having teethed internal surfaces. The APCs additionally may supply shift mechanisms for purposes of changing direction of their movement and incorporate bladed scrubbers and easily-opening bodies.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of determining respective segment times between corresponding pairs of equally spaced marks provided on a rotating body, especially a transducer disk, connected to a camshaft of an internal combustion engine.
2. Prior Art
For regulating internal combustion engines, the rpm of the crankshaft and/or camshaft of the engine is always needed. From the position of these shafts, when trigger signals for certain components must be generated can be determined. For example, the time when current must be supplied to a particular injection valve so that the most optimal possible combustion event can proceed in the associated cylinder is dependent on the position of the crankshaft and/or camshaft of a Diesel engine.
To determine the angular position of the crankshaft and/or camshaft of an internal combustion engine, sensors are typically used that each scan a transducer wheel connected to the crankshaft and the camshaft, respectively. The two transducer wheels typically have a characteristic sequence of angle markings or slits on their circumference. As these angle markings or slits move past the stationary sensors, voltages are induced in the sensors, and from the course of these voltages over time, the surface area of the applicable transducer disk can be derived. The sensor voltages are typically converted into square-wave signals to make them easier to evaluate. The position of each of the signal edges corresponds to a certain rpm of the crankshaft or camshaft.
In Diesel engines currently in use, the transducer disk connected to the crankshaft, in a rotating cylinder engine, has 60-3·2 teeth, and the distribution of the teeth or angle markings is such that three gaps are formed, and between each two gaps there are 18 teeth, spaced apart by equal angles from one another. The disk connected to the camshaft has six slits, for six cylinders, and the slits are spaced apart by equal angles. A seventh slit is disposed between the first and second slits and serves as a reference marking; it is only slightly distant from the first slit, for instance by a camshaft angle of 15°.
When the engine is started, it is brought to a starting rpm with the aid of a starter. The crankshaft and the camshaft then rotate at a relatively constant rpm; it is well known that the crankshaft rotates at twice the speed of the camshaft. No later than after one revolution of the camshaft, a synchronization can be effected, since the seventh tooth is recognized as the synchronizing tooth. From this instant on, during normal operation, the correct injection can be begun. The requisite trigger signals are output by the engine control unit, which processes the output signals of the sensors. For instance, the engine control unit trips the delivery of current to the injection valves or the onset of pumping at the correct instant, thus enabling optimal regulation of the engine. Since the transducer disk on the crankshaft has many teeth, a signal is produced that has pulses in rapid succession; exact engine regulation is thus possible, in the normal situation. If under unfavorable conditions the crankshaft sensor fails, emergency operation should be possible with the camshaft sensor alone.
SUMMARY OF THE INVENTION
It is an object of the present invention to enable reliable starting and continued operation of the engine without a crankshaft signal, especially in starting. It is also the object of the invention however, to disclose a general method in which reliable engine regulation, especially in starting, can be performed using a relatively coarse angle signal.
This object is attained by a method for determining segment times required for controlling an internal combustion engine provided with a camshaft, the method comprising the steps of:
a) providing a transducer disk connected to the camshaft with a plurality of markings on it which are equally spaced from each other around the transducer disk so that the transducer disk rotates with the camshaft;
b) measuring respective segment times between corresponding pairs of the markings on the transducer disk by means of a camshaft sensor;
c) triggering corresponding fuel injection events and thus combustion events in the internal combustion engine in order to trip acceleration events at a substantially constant camshaft rotation speed; and
d) determining, in response to the triggering of step c), a resulting acceleration quotient for a current segment time, this acceleration quotient equaling the current segment time divided by a formerly measured segment time immediately prior to the current segment time; and
e) correcting a following segment time obtained during the measuring by means of the acceleration quotient for the current segment time.
The method however is not performed when the internal combustion engine has a crankshaft with a crankshaft sensor for measuring crankshaft rotation speed and a crankshaft sensor signal from the crankshaft sensor is detected.
The method according to the invention for determining segment times has the advantage that in conjunction with a conventional internal combustion engine control unit, it enables reliable engine regulation even in the absence of a crankshaft sensor signal, and that particularly in starting it enables fast, accurate determination of trigger pulses. In simple engines that have only a transducer disk connected to the camshaft, fast and reliable regulation is also possible, and again this is especially true for starting.
These advantages are attained in that the segment times, which are determined in accordance with the chronological spacing between two markings spaced apart by the same angle from one another; in starting, at a substantially constant rpm, a first acceleration event is first tripped, and the associated segment time T k and the associated acceleration quotient Q k are calculated, and after that two further acceleration events are tripped, and the first acceleration event is taken into account by means of the first, adapted acceleration quotient, while the second acceleration event is determined from a newly determined segment time. After that, three successive acceleration events are tripped, and the rpm change in the first two acceleration events is determined with the aid of the acceleration quotient, while the third acceleration event is again determined from the associated segment time. After that, a dynamic correction of the expected segment times can be performed.
Further advantages of the invention are attained by the provisions recited in the dependent claims. It is especially advantageous that the acceleration phases are tripped by supplying current to the selectable injection valve or injection valves. In conventional engines, the method of the invention can advantageously be performed as an emergency operation provision, if the crankshaft incremental sensor is defective. In simple systems, which have only a low-resolution transducer, an improvement in the accuracy of control is achieved with the method of the invention, because acceleration-dictated changes in the rpm can be detected and compensated for or adapted.
BRIEF DESCRIPTION OF THE DRAWING
An exemplary embodiment of the invention is shown in the drawing and will be described in further detail in the ensuing description. FIG. 1 is a diagrammatic view of components of an internal combustion engine that are needed to perform the method of the invention, and FIG. 2 shows method-oriented signals, including the associated times, in a method for emergency starting in the absence of a crankshaft sensor signal according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the components of an internal combustion engine that are needed for comprehension of the invention. In detail, reference numeral 10 indicates the crankshaft of the internal combustion engine, and 11 a transducer disk connected to the crankshaft 10 ; on its circumference, the transducer disk has many angle markings 12 , which are spaced apart from one another by an angular spacing 13 . At least one of the spacings between two identical angle markings is larger and corresponds for instance to two missing angle markings.
The camshaft 15 has a transducer disk 16 , which has slits 17 on its circumference that have the same spacing from one another. In addition, there is a further slit 18 , which is used for synchronization and is approximately 15° away from one of the regular slits 17 . For the exemplary embodiment of a six-cylinder internal combustion engine shown in FIG. 1, there are typically six slits 17 and three reference markings 14 .
The crankshaft and the camshaft are connected to one another via a drive mechanism 19 . The camshaft 15 typically rotates at half the speed of the crankshaft 10 .
For scanning the two transducer disks 11 , 16 , stationary sensors 20 , 21 , for instance inductive sensors, are provided, which furnish an output signal S 1 , S 2 , which a signal processing has a course that corresponds to the surface structure of the two transducer disks. The evaluation of the signals S 1 and S 2 is done in the control unit 22 of the engine, which in a known manner includes both at least one microprocessor and suitable memory means. As a function of the signals S 1 , S 2 furnished by the sensors 20 , 21 , the control unit 22 calculates trigger pulses, for instance for delivering current to the injection valves or for the onset of fuel pumping. These trigger signals are delivered to the various components via connections 23 . Via connections 24 , the control unit 22 can be supplied with additional information about the engine operating state or about the surroundings in which the engine is located. This additional information can be taken into account in calculating the trigger signals and is furnished by suitable sensors, for instance.
With the engine components shown in FIG. 1, regulation of the engine can be performed, for a given functionality of the two sensors 20 and 21 . After the engine is started, the crankshaft and the camshaft are first brought, by a starter, not shown, to a constant rpm. Rotating the transducer disks 11 , 16 generates signals in the sensors 20 , 21 , and from the chronological succession of the signals, the rpm of the crankshaft or camshaft can be determined, and as a consequence of the characteristic pulse trains, synchronization can be done, at the latest after one revolution of the camshaft, which means after two revolutions of the crankshaft, so that in the control unit 22 , an unequivocal association between the crankshaft and the camshaft is known. Thus the position of the cylinders is also known, and the trigger signals needed, for instance for the injection, or for the ignition in the case of an engine with externally supplied ignition, can be output.
If a defect occurs in the sensor 20 that scans the incremental sensor 11 connected to the crankshaft, the control unit receives information only from the sensor 21 . If this defect already appears when the engine is started, then to carry out emergency operation, the method of the invention is performed in the control unit, or in other words in the microprocessor of the control unit 22 .
The method of the invention will now be explained in terms of an adaptive segment time determination in a Diesel engine, for the case where the engine is put into operation with a defective crankshaft sensor. In that case, emergency operation can be achieved only from the information, furnished to the sensor 21 , about the position of the camshaft. The acceleration events are tripped in that during starting, once the engine has been brought to a substantially constant speed by the starter, a targeted magnet valve triggering is tripped, and the acceleration that ensues after the first delivery of current to it is determined.
In general, during staring without an incremental sensor signal, approximate information about the current angular position of the camshaft and thus of the crankshaft as well is indeed available, but the exact angular positions are not known, and so the magnet valves after the initial ignitions are supplied with current at the wrong instant. The reason for this is that the segment signal furnishes only seven pulses per camshaft revolution. Emergency starting cannot be done in that case, especially at low temperatures.
In FIG. 2, the procedure according to the invention for emergency starting without a crankshaft sensor signal is plotted. An arrow indicates the segment pulses (SEG pulses) generated by the camshaft sensor 21 . Synchronization has taken place, but the synchronization pulse is not shown. The times at which the segments appear are marked t x , where x ranges from 0 to 15. Between the segment pulses, which are 60° apart in terms of the camshaft angle, information on the camshaft rpm is plotted, showing the following options: rpm n approximately constant (n-const.); acceleration (accel.); and deceleration (decel.). The delivery of current to one or more magnet valves is shown in the lower portion of FIG. 2 . This delivery of current takes place between each two segment pulses. It is correct for a specific cylinder, but is still imprecise at first; nevertheless, it does lead to an injection and thus to a combustion event and to an acceleration of the camshaft. Instead of a delivery of current, the control unit can also output some other trigger signal, via the connection 23 , that leads to combustion and thus to acceleration of the camshaft.
In terms of the graph in FIG. 2, the camshaft rotates at approximately constant rpm between t 0 and t 1 , and between t 1 and t 2 . It is brought to this rpm with the aid of the starter. The first current delivery B 1 causes an acceleration. Between the segment pulses t 2 and t 3 , the camshaft is accelerated. For system-dictated reasons, a deceleration, i.e., a drop in the rpm, occurs again between the segment pulses t 3 and t 4 . The periods of time between the times t 0 and t 1 , t 1 and t 2 , etc. are called the segment time T k . These times are each calculated by the engine control unit, in accordance with the equation T k =t k −t k−1 .
Along with the segment time, an acceleration quotient is formed, which is determined only in those time intervals when an acceleration has actually occurred. After the current delivery B 1 , the acceleration quotient Q k =T k /T k−1 is thus determined, in which case Q 3 =T 3 /T 2 . The associated segment times are T 3 =t 3 −t 2 , and T 2 =t 2 −t 1 . The acceleration coefficient Q 3 thus calculated is stored in memory and taken into account in the next segment time adaptation.
As soon as the control unit recognizes that the rpm is again constant, a second current delivery B 2 of an injection valve is triggered; this leads to injection of fuel and thus to combustion and hence acceleration. After the next segment pulse, a further current delivery B 3 is effected, once again producing an acceleration. Since from the first determination of the acceleration quotient Q 3 the acceleration for a current delivery is known, it is possible at time t 5 to calculate the equation T 6 =T 5 ·Q 3 . This acceleration occurs as a result of the current delivery B 2 . After a further current delivery B 3 , after which fuel is injected into the next cylinder, a further acceleration occurs. The associated acceleration coefficient Q 7 is calculated by the equation Q 7 =T 7 /T 6 . The two current deliveries B 2 and B 3 , which each lead to two accelerations and two decelerations, lead in the end to adapted segment times T k+x =T k+x−1 ·Q k .
Once the adapted segment time can be determined, three successive current deliveries B 4 , B 5 and B 6 are next performed; beginning at instant t 10 , these lead to three successive accelerations. The course of acceleration is now known. At instant t 10 , the segment time can be calculated, by the equation T 11 =T 10 ·Q 3 , and at instant t 11 the segment time T 12 can be calculated, but the equation T 12 =T 11 ·Q 7 . After the injections and successful ignitions, which are effected by the current deliveries B 4 , B 5 and B 6 and have led to three accelerations, it is possible at instant t 13 to trip further accelerations, i.e., injections, which lead to a runup of the rpm; in the process, a go transition to a conventional dynamic correction of the segment time is made, with which the rpm increase is then compensated for. This conventional segment time correction is done by the formula.
With the adaptive segment time determination described, a dynamic correction of the expected segment time T k+1 can thus be done, and the wrong segment times after the first and second ignition during starting, which were calculated with the dynamic correction, can in turn be corrected. The acceleration quotients Q k are therefore adapted and used for correcting the segment time. In engine starting, the segment time is accordingly calculated by the equation T k+x =T k+x−1 ·Q k .
The segment times, the acceleration quotients, and the adapted segment times are all sorted in memory means of the control unit 22 , as long as they are needed for calculation purposes. The end of the adaptive segment time correction is signalled to the control unit computer by a status display, for example.
The method of the invention has been explained in terms of a Diesel engine. It can be extended in principle to other internal combustion engines as well; in that case, the acceleration events are tripped by actuation of the injection valves and injection of fuel into the cylinders. In simpler engines, which include only one segment disk connected to the camshaft, the method of the invention can be used not only as an emergency operation method but also as a general, simplified method. The preferred embodiment, however, is its use in a modern internal combustion engine in the event of a failure of the crankshaft incremental sensor, to enable emergency operation and in particular also to enable reliable engine starting if the crankshaft sensor is defective.
|
The method for determining segment times (T k ) required for controlling an internal combustion engine includes providing a transducer disk ( 17 ) connected to a camshaft of the engine with a plurality of markings equally spaced from each other on the transducer disk; measuring respective segment times (T k ) between detection of corresponding pairs of markings on the transducer disk ( 17 ) by means of a camshaft sensor ( 21 ); triggering fuel injection events and combustion events in order to trip acceleration events at a substantially constant camshaft rotation speed; determining a resulting acceleration quotient (Q k ) for a current segment time as a quotient of the current segment time divided by a preceding segment time and correcting a following segment time by means of the acceleration quotient (Q k ) for the current segment time. The method is not performed when the internal combustion engine has a crankshaft with a properly working crankshaft sensor for measuring crankshaft rotation speed.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from co-pending Provisional Patent Application Ser. No. 60/736,651 entitled “Disposable Protective Canine Sock/Boot Made of Light Weight, Waterproof, Flexible Latex or Polymer Material and Requires No Fasteners”, filed on Nov. 14, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates to paw protection for canines, and more particularly to a slip-on, waterproof, disposable, canine sock/boot for protecting the animal from insects, chemicals, liquids, soil, heat/cold, and medical problems.
BACKGROUND OF THE INVENTION
[0003] In recent years dog owners have become better educated regarding dangers to a dog's paw, such as snow-melting chemicals on the sidewalk in the winter, lawn chemicals, red ants and pad rashes. In an effort to keep their pets safe, more dog owners have been putting their pet in a “dog boot”. A typical boot consists of fabric stitched into the shape of a paw with a padded sole and a Velcro, zipper or strap closure.
[0004] The problems with such conventional products are that they are expensive, dogs don't like to wear them and they can fall off and get lost. The reason such boots fall off is that they don't bend and move with the dog's paw and leg, so that all of the straps and other closures need to remain loose enough to allow the dog's paw to bend. However, such looseness makes it impossible to tighten the closures enough to keep the boots on. When a dog owner loses one such boot, he must buy another set of four boots, which can be expensive.
[0005] Additionally, such boots are unfortunately not waterproof, so that they cannot protect the paws against any liquid. Furthermore, they typically approach the problem of creating dog boots by designing human-type shoes to fit canines. Thus, dogs dislike them because they cannot feel the ground through the padded sole, which makes them insecure and less sure-footed.
[0006] There are a number of dog boots that are currently known and old in the art. As discussed above, they usually revise human-type shoes to fit canines. Thus, they typically have numerous components such as padded soles and straps, zippers, Velcro or other mechanical closures. Examples of such prior art include U.S. Pat. No. 5,408,812, which discloses a dog boot having numerous components including securing straps and buckles, and is moisture-resistant but not waterproof U.S. Pat. No. 5,495,828 also discloses an animal boot that has many components, such as liners and a fastening strap.
[0007] The animal boot shown in U.S. Pat. No. 6,470,832 B1 similarly has a multi-element design, including fasteners for the flexible sole and a strap, which is non-waterproof. U.S. Pat. No. 6,526,920 B1 discloses another non-waterproof, multi-element design for hunting dogs, which includes a thick rubber sole, zippers and straps. Similar observations apply to the multi-component dog boot disclosed in U.S. Pat. No. 5,148,657.
[0008] Other multi-element configurations include the dog booties with polyacrylamide granules between layers of fabric to keep the paws cool in U.S. Pat. No. 5,452,685; the canine footwear with a rubberized sole of U.S. Pat. App. Pub. No. US 2005/0241188 A1 and US 2005/0188925 A1; a dog boot with many surfaces and elements shown in U.S. Pat. App. Pub. No. US 2005/0092260 A1; a dog boot shown in U.S. Pat. No. 6,546,704 B1which uses layers of various materials and surface textures and a stabilizer strap; and footwear for hooved animals as shown in U.S. Pat. No. 5,528,885.
[0009] U.S. Pat. No. 4,744,333 and U.S. Pat. No. 4,633,817 both disclose protective footwear for animals that include a complex suspender system that goes over the animal's back, as well as a yarn sock and a deerskin boot. Similarly, the paw coverings of U.S. Pat. No. 5,676,095 utilizes a harness, and is a device for covering cats' paws to prevent them from damaging furniture with their claws.
[0010] U.S. Pat. App. Pub. No. 2003/0164145 A1 discloses a paw covering comprising a tube-shaped, condom-like sleeve formed of latex. The device rolls up the dog's paw like a condom and fits tightly around the paw. It has the objective of protecting the dog owner's house from getting soiled by dirty dog paws, when the dogs come in from the outside. However, such a device may also pose problems in that the shapes of the paws, the dogs' claws and dew claws may prevent the tube-shaped device from rolling onto the paw. Additionally, even if the device did roll on, it may then easily roll off during use. Also, the device does not have the purpose of protecting the dog's paws.
[0011] U.S. Pat. App. Pub. No. 2004/0133144 A1 shows an animal cast and bandage protector for covering a cast or bandage to keep it dry and clean. However, it essentially functions as a cast/bandage covering rather than as a dog boot. U.S. Pat. App. Pub. No. 2006/0042563 A1 discloses an animal paw cover for keeping the paws clean. It is water-resistant and is constructed using heat sealed edges. It is contoured to the shape of a paw, rather than being comfortably loose, and it does not have the purpose of protecting the animals' paws. U.S. Pat. App. Pub. No. 2006/0037561 A1 discloses an animal boot utilizing a number of elements including a reinforced toe and a sock or sleeve, that must extend up the dog's leg past the elbow.
[0012] Consequently, a device for providing simple, effective, and waterproof protection for the paws of canines, which also slips on and off easily with no closures and remains on, and that dogs do not resist wearing, is highly desired.
SUMMARY OF THE INVENTION
[0013] A disposable dog boot having a single, seamless piece of flexible latex or polymer material having a bulbously shaped, bottom closed end and a top open end of a smaller cross-section, wherein when a paw of the dog is slipped into the boot, the bottom end covers and loosely conforms to the paw to protect the paw, and the top end flexibly and removably secures, through the material's elasticity, the boot to a leg of the dog.
[0014] It is embodied in another mode of the invention a method of protecting the paw of a dog having producing a disposable dog boot as a single, seamless piece of flexible latex or polymer material, having a bulbously shaped, bottom closed end and a top open end of a smaller cross-section; and slipping the paw into the boot, whereby the bottom end covers and loosely conforms to the paw to protect the paw, and the top end flexibly and removably secures, through the material's elasticity, the boot to a leg of the dog.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For a fuller understanding of the invention, reference is made to the following description taken in connection with the accompanying drawings, in which:
[0016] FIG. 1 is a perspective view of the canine sock/boot of the present invention; and
[0017] FIG. 2 is a side elevational view showing the canine sock/boot of the present invention as worn on a dog's paw.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] As shown in the figures, the present invention relates to protective wear for canine paws that protects the paws from dangers such as the elements, chemicals, liquids, insects, soil, heat/cold, ice, and pad rashes, post-surgical infections and other medical problems. In particular, the sock/boot 10 for canines of the present invention is bulb-shaped and has a closed, bulbous bottom end 20 and an open, top end 30 .
[0019] The top end 30 has a short, tube-like opening, having a smaller cross-section than the rest of the sock/boot 10 . The material of the sock/boot is rolled over once at the top end 30 to form a rim 40 .
[0020] The sock/boot device is made of a latex or polymer material that is very flexible, lightweight and waterproof. As an example, the material may be one that is commercially available (e.g., in the manufacture of balloons). The thickness may be the thickness of a standard latex balloon, or thicker. A thickness greater than the thickness of a standard balloon may be produced by dipping the formers (the balloon molds) twice into the latex or polymer material (called “double dipping”), or by some other means as is well known in the art.
[0021] The sock/boot protective wear is one-piece and entirely seamless. It can be made in a variety of sizes or widths and lengths. The appropriate size can then be selected according to the width of the canine's paws. The sock/boot can also be made with various colors or patterns.
[0022] In use, the narrower top end 30 is widened, and the dog's paw is inserted into the narrow opening toward the wider bulbous area 20 . Then, the narrower top end 30 is released to snugly secure the sock/boot to the dog's leg, as shown in FIG. 2 . Thus, the sock/boot is slipped over the paw in a fashion similar to that of a person putting on a sock. As illustrated in FIG. 2 , the bottom end 20 comfortably conforms to the shape of the paw, while remaining loose.
[0023] When the canine walks or runs, the sock/boot remains securely on the canine's leg. It does not come off during such usage. However, due to the flexibility and elasticity of the latex or polymer material, it does not cut off the canine's circulation, and it allows the canine to make such movements naturally.
[0024] Then, one can easily take off the sock/boot, by simply pulling it off. Thus, a protective canine sock/boot is provided that is simple and requires no fasteners or closures. It can be easily slipped over the animal's paw and then taken off. Yet, it remains snugly secured to the dog's leg and does not fall off, during use.
[0025] As described above, all of the canine boots currently on the market use various devices to fasten the boots to the legs or paws. Such devices include straps, zippers, Velcro, buttons, elastic bands or other additional closure devices. Consequently, the prior art boots are difficult to put on and often fall off during use. Such a problem leaves the canine unprotected and the dog owner with only three remaining dog boots. The dog owner then needs to purchase another set of four dog boots, just to replace the missing single boot. The sock/boot of the present invention avoids such very common and expensive problems.
[0026] Furthermore, the sock/boot of the present invention is disposable or semi-disposable. Depending on durability against wear and tear, it may also be reused many times. Thus, the dog owner can cheaply and easily provide continuous paw protection, while replacing a lost or worn out sock/boot cheaply and easily.
[0027] As described above, another conventional problem is that canines very frequently resist wearing protective paw coverings. The primary reason that canines resist wearing such boots is that they are typically made like a human's shoe, with padding in the sole and closure devices. With such a conventionally constructed boot, the canine cannot feel the ground through the boot. This feels most discomforting to the canine.
[0028] The sock/boot of the present invention eliminates this problem by being very flexible and thereby bending where the canine's paw bends. While still providing protection, the unpadded sole allows the canine to feel the ground, thereby providing a sense of security and sure-footedness. Due to such novel features, dogs that previously have not been able to wear other conventional dog boots, have been accepting of the sock/boot of the present invention.
[0029] In addition to its use as everyday protective wear, it can also be used to protect or cover wounded or injured paws, or more generally, to keep the paws clean from outdoor dirt. Thus, it can accomplish both animal paw protection and protection of the owner's furniture and house against outdoor dirt, etc.
[0030] The foregoing description of the embodiments of this invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments of the invention to the form disclosed, and, obviously, many modifications and variations are possible. All such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims.
|
A disposable dog boot comprising a single, seamless piece of flexible latex or polymer material having a bulbously shaped, bottom closed end and a top open end of a smaller cross-section, wherein when a paw of the dog is slipped into the boot, the bottom end covers and loosely conforms to the paw to protect the paw, and the top end flexibly and removably secures, through the material's elasticity, the boot to a leg of the dog.
| 0
|
PRIORITY CLAIM TO A RELATED APPLICATION
[0001] This application claims the benefit of copending U.S. Provisional Patent Application No. 62/000,868 entitled “Oxidation of Americium in Acidic Solution,” filed May 20, 2014, which is incorporated by reference herein.
STATEMENT REGARDING FEDERAL RIGHTS
[0002] This invention was made with government support under Contract No. DE-AC52-06NA25396 awarded by the U.S. Department of Energy. The government has certain rights to in the invention.
FIELD OF THE INVENTION
[0003] The present invention relates generally to actinide separation and more particularly to oxidation of americium in acidic solution to facilitate a separation of americium from other elements including but not limited to fission products and other actinides.
BACKGROUND OF THE INVENTION
[0004] The presence of long-lived radioisotopes of americium (“Am”) and radio-decay of particular isotopes of Am (such as Am-241 to the long-lived Np-237 and Am-243 to Pu-239) contribute to the thermal loading in a repository and to the radiotoxicity of used nuclear fuel. A simple method to separate Am from fission product lanthanides could reduce the cost of separation options for partitioning minor actinides from used nuclear fuel.
[0005] One approach for separating the americium present in used nuclear fuel involves oxidization of Am(III) to Am(IV), Am(V), or Am(VI). These higher oxidation states are accessible for Am but not for the lanthanides or for the curium present in used nuclear fuel. Am(VI) in the form of AmO 2 2+ , for example, can be separated selectively from trivalent lanthanides (Ln(III)) using a range of techniques based on oxidation state discrimination. A challenge with this approach involves identifying oxidants that are suitable for forming and stabilizing the Am(IV), Am(V), and/or Am(VI) long enough to perform the separation. Sodium bismuthate (NaBiO 3 ), for example, has been reported to oxidize Am(III) selectively to Am(VI) in nitric acid solutions. The Am(VI), which is in the form of AmO 2 2+ , is extracted selectively from nitric acid using an organic extractant such as tributylphosphate (TBP) or diamylamylphosphonate (DAAP). Drawbacks to using sodium bismuthate as an oxidant are its low solubility (it must be used as a slurry), and slow oxidation kinetics. The solid bismuthate salts must be filtered from the process solution before proceeding with other processing steps.
[0006] If ozone (O 3 ) could be used instead of sodium bismuthate to oxidize Am(III) selectively to Am(VI), the bismuthate filtration step would be eliminated. Ozone is a gaseous oxidant, and it decomposes to form oxygen (which is also gas). Therefore, the use of ozone would not result in additional by-products that would have to be treated along the processing stream. Ozone is relatively inexpensive to prepare and is already used routinely for other oxidation processes on a large scale (e.g. for treating wastewater on an industrial scale). Although the oxidation of americium(III) to americium(VI) using ozone is thermodynamically favorable, in practice, it has been demonstrated that ozone is not a suitable oxidant for oxidizing Am(III) to Am(VI) in acidic solution.
SUMMARY OF THE INVENTION
[0007] To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, a process is provided for oxidizing americium(III) to americium(VI). The process includes providing a aqueous acidic composition comprising americium(III) and a mineral acid and exposing the composition to a combination of ozone and silver ions under conditions suitable for oxidation of the americium(III) to americium(VI). Combinations of ozone with cobalt ion, or ozone with cerium ion are also expected to be suitable for the oxidation of americium(III) to americium(VI).
[0008] A process for separating americium from a lanthanide is also provided. This process includes providing an aqueous acidic composition comprising americium(III) and at least one lanthanide and/or curium, exposing the aqueous acidic composition to silver ions and ozone under conditions suitable for oxidizing the americium(III) to americium(VI), and thereafter separating the americium(VI) from at least one lanthanide, curium, and/or silver.
[0009] A composition is also provided that comprises a homogeneous mixture of silver ions, ozone, nitric acid, and water.
DETAILED DESCRIPTION
[0010] An embodiment process is provided for oxidizing Am(III) to Am(IV) in nitric acid that uses ozone in combination with silver ions. The ozone together with the silver ions provide a suitable combination for oxidizing americium(III) to americium (VI) in acidic solution.
[0011] An embodiment process is also provided for separating americium from a composition that includes americium along with other components such as, but not limited to, other actinides (curium, for example), and lanthanides. This embodiment process includes using silver ions and ozone to oxidize the americium(III) to americium(VI) in the composition followed by separating the americium(VI) from the other components.
[0012] The oxidation reactions described herein may be performed using aqueous mineral acid. Mineral acids include nitric acid, hydrochloric acid, perchloric acid, phosphoric acid, sulfuric acid, and mixtures of these acids. In an embodiment, the oxidation of Am(III) to Am(IV) was demonstrated using nitric acid. The americium is present typically in these aqueous mineral acids as a plurality of radioisotopes of americium, including but not limited to radioisotope Am-243, which has a half life (t 1/2 ) of 7380 years. The concentration of the nitric acid in these solutions was in a range of from 0.001 molar to 6 molar.
[0013] The oxidation state of the americium was determined spectrophotometrically using a CARY 6000i or a CARY 5-UV-vis-NIR spectrophotometer. Americium concentrations were standardized in 2 M K 2 CO 3 using a characteristic absorbance band for Am(III) at 508 nm with a molar absorptivity (c) of 330 M −1 cm −1 . The absorbance bands in nitric acid are shifted slightly relative to the bands in carbonate solutions, and molar absorptivities for Am(III) (ε(503 nm)=386.7), Am(V) (ε(513 nm)=72.5), and Am(VI) (ε(666 nm)=24.6) in nitric acid solutions were adopted from the literature.
[0014] Ozone was produced using ozone generator model HC-30 (OZONE SOLUTIONS). This ozone generator uses pure O 2 as the feed source and can produce from 5 weight percent ozone to 12 weight percent ozone at a flow rate of 1-10 liters per minute. The maximum concentration of ozone for long-term operations was approximately 10%; higher concentrations of ozone could be produced for short-term operation. The ozone concentration was quantified using in-line ozone monitor model UV-106H (OZONE SOLUTIONS). The ozone monitor determined the concentration of ozone via UV absorbance. A slip-stream of ozone was sparged through 1-2 ml of an americium solution in a 4 ml borosilicate vial using a ⅛ inch TEFLON needle. Aliquots were removed periodically for analysis by UV spectrometry and were replaced after the analysis.
[0015] An initial set of tests were performed to verify the unsuitability of ozone alone as an oxidant for oxidizing Am(III) to Am(VI) in nitric acid solutions. Nitric acid having a concentration in a range of from 0.001 M to 1 M nitric acid was used. After four hours of testing, no evidence of oxidation of Am(III) oxidation to Am(VI) in 0.001 M nitric acid to 1 M nitric acid with ozone concentrations up to 10 weight percent was observed via UV-vis spectroscopy. These test results are consistent with what others have found, namely that ozone alone is nota suitable oxidant for oxidizing Am(III) to Am(VI) in acidic solution.
[0016] Having confirmed the reported lack of suitability of ozone alone for oxidation of Am(III) to Am(VI) in acidic solution, we thought that it might be possible to find some combination of ozone with one or more materials that together would be suitable for oxidizing Am(III) to Am(VI) in acidic solutions. We found that a combination of ozone with silver ions was suitable for oxidizing Am(III) to Am(VI) in acidic solutions. Reaction of Am(III) with this combination of ozone with silver ions resulted in quantitative oxidation of the Am(III) to Am(VI) in nitric acid solutions in a range of 0.01 M nitric acid to 3 M nitric acid solution. We also found that at least partial oxidation was achieved in 6 M nitric acid solutions. We expect that other metal ions besides silver ions, in combination with ozone, will also be suitable for oxidizing americium(III) to americium(VI). One such combination expected to be suitable is a combination of ozone with cobalt ions (e.g. cobalt(II) and/or cobalt(III). Another such combination is a combination of ozone with cerium ions (e.g. cerium(III) and/or cerium(IV)).
[0017] The rate of oxidation of Am(III) to Am(VI) with ozone in the presence of silver ions is dependent on the concentration of the nitric acid. The rate of oxidation of Am(III) to Am(VI) in nitric acid solution appears to be slower at higher concentrations of nitric acid. For example, 96% of the Am(III) was oxidized to Am(VI) after 3 hours in 0.01 M HNO 3 . By contrast, 86% of the Am(III) was oxidized to Am(VI) after 24 hours in 1M HNO 3 . Only 25% of the Am(III) was oxidized to Am(VI) after 24 hours in 3M HNO 3 .
[0018] When the flow of ozone to the solution was stopped, the Am(VI) underwent a reduction to Am(III). The reduction was stepwise; the Am(VI) species present in solution first undergoes reduction to Am(V). The Am(V) undergoes a slower reduction to Am(III).
[0019] The rate of reduction of Am(VI) appears to follow pseudo-first order kinetics. The rate of reduction varies with the concentration of the nitric acid. In dilute nitric acid solutions, the Am(VI) begins to reduce immediately after stopping the flow of ozone to the reaction mixture. Approximately 40% of the Am(VI) reduces to Am(V) during the first 15 hours. The reduction rates in 0.01 M HNO 3 are comparable to the reduction rates that we measured in 1M HClO 4 . At higher (3 molar, for example) acid concentrations, there was an induction period of approximately 5 hours before the Am(VI) begins to reduce, and only 15% of the Am(VI) reduces to Am(V) in the first 15 hours and only 25% over the first 24 hours.
[0020] Once the Am(VI) undergoes reduction, the reduced species of Am(III) can be re-oxidized to Am(VI) if the flow of ozone to the solution, which also contains silver ions, is restarted.
[0021] Various extraction and/or ion exchange techniques may be used for separating americium. After performing an oxidation of Am(III) to Am(VI) in a nitric acid solution using ozone and silver ions, we performed a partial extraction of the Am(VI) from the solution using a dilute solution of the extractant diamylamylphosphonate (“DAAP”) in dodecane. Alternatively, Am(VI) may be separated from trivalent lanthanides and/or curium using a column of an ion exchange resin—the Am(VI) would be preferentially adsorbed to the resin while the trivalent lanthanides and/or curium would preferentially elute and remain in solution as cationic species in solution.
[0022] Extraction of hexavalent actinides (i.e. An(VI)) from acidic solutions using dilute solutions of organic phosphonates in organic solvents (kerosene, dodecane, for example) has been reported. Tributyl phosphate (“TBP”), dibutylbutylphosphonate (“DBBP”) and DAAP have been tested for extraction of Am(VI) from nitric acid (after oxidation of Am(III) to Am(VI) using a slurry of sodium bismuthate). After performing an oxidation of Am(III) to Am(VI) using ozone and silver ions in aqueous nitric acid, the Am(VI) was extracted (i.e. separated) using DAAP. The separation of the Am(VI) was performed as follows: ozone was bubbled through a 3 molar aqueous nitric acid solution that contained americium(III). This resulted in oxidation of the americium(III) to americium(VI). A solution of 1 molar DAAP in dodecane was pre-equilibrated with a 3 M aqueous nitric acid solution containing silver ions. Following the oxidation, an equal volume of the 1 molar solution of DAAP in dodecane was added and the resulting solution was mixed for about 15 seconds using a vortex mixer. The phases were allowed to separate and then were placed into separate vials. An analysis by UV-Vis spectroscopy indicated that approximately 30% of the americium(VI) had been extracted.
[0023] We also tried to extract silver ions from nitric acid solutions using DAAP. A 1M solution of DAAP in dodecane was pre-equilibrated with a solution of nitric acid and silver ions. After the pre-equilibration, solutions of nitric acid and silver ions were contacted with an equal volume of the pre-equilibrated 1M solution of DAAP in dodecane. A series of extractions were performed using various concentrations of HNO 3 , up to a maximum of about 8M HNO 3 . Sometimes extraction procedures included mixing for 15 seconds using a vortex mixer. Other times, extraction procedures included stirring on a laboratory stir plate for 24 hours. The concentration of silver ions was quantified using ICP-AES (“Inductively Coupled Plasma-Atomic Emission Spectroscopy”). For this series of analyses, the silver containing samples were diluted to the appropriate concentration with 2% HNO 3 and analyzed on a Thermo Electron iCAP 6500 DUO ICP connected to a Cetac ASX520 autosampler. We found that DAAP extracted less than 0.1% of the silver, which indicates that DAAP does not significantly extract silver(I). Further support was found when we prepared a solution containing silver ions and nitric acid, exposed the solution to ozone (to oxidize the silver(I) to a higher oxidation state (silver(II) and/or silver(III)), and then added some of the 1M DAAP/dodecane solution and mixed everything for 15 seconds using a vortex mixer. After the phases were allowed to separate, they were partitioned into separate vials and examined spectroscopically. No silver(II) was detected in either the phase with DAAP/dodecane or the nitric acid phase. Prior experiments show that silver(I) is not extracted with DAAP/dodecane while americium was extracted into the DAAP/dodecane phase. These results indicate the ability to separate Am(VI) from silver ions using DAAP.
[0024] Although the present invention has been described with reference to specific details, it is not intended that such details should be regarded as limitations upon the scope of the invention, except as and to the extent that they are included in the accompanying claims.
|
A process is for oxidizing americium(III) to americium(VI) includes providing a aqueous acidic composition comprising americium(III) and a mineral acid and exposing the composition to ozone and silver ion under conditions suitable for oxidation of the americium(III) to americium(VI). Nitric, acid is a suitable mineral acid for the process. Extraction of the americium from the silver is possible using organic phosphonate extractant.
| 8
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of, and claims priority to and the benefit of, co-pending U.S. patent application Ser. No. 13/927,756, filed Jun. 26, 2013, which claimed priority from U.S. patent application Ser. No. 12/711,885, filed Feb. 24, 2010, and which claimed priority from U.S. Provisional Application Ser. No. 61/153,096, filed Feb. 24, 2009, the full disclosures of which are hereby incorporated by reference herein for all purposes.
BACKGROUND
1. Field of Invention
The device and method described herein concerns the field of simulating medical procedures. More specifically, a device is described that provides a modular manner of simulating different surgical procedures.
2. Description of Related Art
Some newly developed medical procedures and/or devices are sufficiently innovative that their practice requires experienced medical practitioners to undergo specific training to become proficient with the new procedure. The training for the new medical procedures, such as surgery, may incorporate devices that model anatomy. Simulating a procedure on a model rather than a patient is significantly safer and less expensive. A drawback of currently known models is they often represent a unique or single portion of anatomy. Additionally, currently known models are typically inflexible and not adjustable for multiple orientations.
SUMMARY OF INVENTION
The device and method described herein includes a surgical simulation device. In an embodiment, a surgical simulation device includes simulated tissue, an aperture support offset a distance from the simulated tissue that comprises a curved dome that covers the simulated tissue, and an aperture formed through the aperture support and facing the simulated tissue so that when a surgical procedure is simulated on the simulated tissue, a surgical instrument is inserted through the aperture to simulate inserting the surgical instrument through an incision in tissue.
In an embodiment, disclosed is an anatomical model for use in simulating a surgical procedure that has a base having an upper surface, a curved dome having an inner surface facing the upper surface of the base and which defines a space, simulated tissue coupled to the base that is set a distance from the upper surface in the space and set back a distance from the dome, and an aperture strategically disposed in a sidewall of the dome, so that when a surgical procedure is simulated on the simulated tissue, a surgical instrument is inserted through the aperture to simulate inserting the surgical instrument through an incision
BRIEF DESCRIPTION OF DRAWINGS
Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a side perspective view of training for a surgical procedure using a simulation device.
FIG. 2A is a perspective view of a simulation assembly with simulated tissue and a substrate.
FIG. 2B is a perspective view of an alternative embodiment of a simulation assembly with simulated tissue and a substrate.
FIG. 3 is a perspective view of a simulation device and simulation assembly in a housing.
FIG. 4 is a side perspective view of a simulation device and simulation assembly in a housing and cannulas protruding through the housing.
FIGS. 5A and 5B are side perspective views of the device of FIG. 4 having sutures in the simulated tissue and simulated substrate.
FIGS. 6A and 6B are side perspective views of a simulation assembly in horizontal and vertical orientations in a housing with simulated tissue sutured to simulated substrate.
FIGS. 7A and 7B are upper and lower side perspective views of a base.
FIG. 8 is a perspective view of an example substrate with a circumscribing ring.
FIG. 9 is a side perspective view of an example of a disc.
FIG. 10 is a perspective view of an embodiment of a yoke.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
With reference now to FIG. 1 , an example of a surgical simulation device 10 is shown in a perspective view. In this embodiment the surgical simulation device 10 includes a base 12 with a cylindrically shaped disc 13 mounted from below. The upper surface of the disc 13 registers with an aperture formed axially through the base 12 . The upper surface of the base 12 features a central circumferential taper toward the aperture. A lateral side is formed at the outer periphery of the base 12 where it projects substantially perpendicular to the axis of the base 12 . A bore 16 is shown extending laterally into the lateral side of the base 12 . The disc 13 is coaxially rotatable within the base 12 and provides a mounting surface for a yoke 14 . The yoke 14 shown is a “U” shaped member having a mid-portion mounted on the upper surface of the spindle 13 . The yoke 14 curves between the mid-portion and its opposing ends so that the opposing ends project away from the base 12 . An elastic member 18 is shown looping around both ends of the yoke 14 and suspended above and perpendicular to the base 12 . In other embodiments, the member 18 may be fully rigid or inelastic. The elastic member 18 , which in one example represents connective tissue, can be readily placed on or off the yoke 14 for simulating a surgical procedure. An example simulated surgical procedure is shown where a surgical instrument 15 is being manually manipulated to knot a demonstration cord 20 around the elastic member 18 for drawing together both sides of the elastic member 18 . The surgical instrument 15 and cord 20 are depicted for demonstration purposes, however actual surgical instruments and suture materials may also be included with the embodiment of FIG. 1 .
An example of a simulation assembly 22 is shown in perspective view in FIG. 2A and having a shaped piece of simulated tissue 24 mounted on a substrate 26 . As shown, the simulated tissue 24 is generally planar and profiled at its corner portions so that it resembles a clover leaf. In this example the simulated tissue 24 can represent a rotator cuff. Example materials for the simulated tissue 24 include elastomers such as rubber and foam, as well as felt, cloth, combinations thereof and the like. The substrate 26 includes a hemispherical upper portion 27 shown set on a cylindrical lower portion 29 ; the simulated tissue 24 is mounted on the upper portion. A band of simulated tissue 28 circumscribes the outer periphery of the cylindrical lower portion 29 . The substrate 26 can be used for simulating bone. The substrate 26 material can be rigid but allow for suturing (example materials include foam, such as a polyurethane foam) but may be made of other materials as well such as a polystyrene or polystyrene like material.
An alternative example of a simulation assembly 22 A is illustrated in a side perspective view in FIG. 2B . In this example the simulation assembly 22 A includes a substrate 26 A having a frusto-conical upper portion 27 A and a cylindrically shaped lower portion 29 A depending from the lower surface of the upper portion 27 A. The upper portion 27 A has a planar upper surface on which simulated tissue 24 is attached. The upper portion 27 A has lateral sides that taper radially outward from between the upper surface to the lower surface of the upper portion 27 A.
FIG. 3 provides in side perspective view an examples of the simulation assembly 22 mounted onto the yoke 14 of the simulation device 10 . A ring 31 is shown circumscribing the substrate 26 , bores (not shown) in the yoke 14 register with bores through the side wall of the ring 31 . Fasteners 30 are shown provided that extend through the registered bores in the yoke 14 and ring 31 and into the substrate 26 . The fasteners 30 can be threaded with matching threads in the bore in the ring 31 , or can be pin like members that pass through the bores in the ring 31 . Optionally, the fasteners 30 , when applied, can compress the ring 31 to bind the assembly 22 therein instead of piercing the substrate 26 .
In the configuration of FIG. 3 , the assembly 22 may pivot about an axis A X aligned with the fasteners 31 ; the assembly 22 may also rotate about an axis A Y of the base 12 and the disc 13 . In an example, the disc 13 is coaxial with the axis A Y and thus rotates within the base 12 about the axis A Y . Provided with this embodiment is a housing 32 shown secured to the base 12 and enclosing the simulation assembly 22 . In the example illustrated, the housing 32 lower end is open and encircles the outer periphery of the base 12 , the housing 32 extends upward from the base 12 substantially parallel with the axis A Y and curves inward to form a dome like upper portion over the simulated tissue 24 . Alternatively, the housing 32 can have an upper end with other shapes, such as conical, cylindrical or asymmetric and can have an outer surface that is uneven or includes undulations. In yet another alternative, the housing 32 can be clear, translucent, or opaque and/or may include strips that have at least a portion supported in a space around the simulation assembly 22 .
Referring now to FIG. 4 , the housing 32 is equipped with apertures 36 and cannulas 34 are shown inserted through the apertures 36 . Thus in FIG. 4 , the housing 32 serves as a support for the aperture 36 . Alternatively, an aperture support can be any member for supporting an aperture 36 in space and offset from the simulation assembly 22 . Examples include a planar web element having an end supported on a surface proximate the simulation assembly 22 that extends to a location offset from the simulation assembly 22 . Grommets 38 as shown may optionally be set within the apertures 36 . The cannulas 34 , which are obtainable from most medical supply sources, provide conduits for insertion of surgical instruments (not shown) through the housing 32 and into the simulation assembly 22 . Thus a surgical procedure can be simulated by directing cannulas 34 at the simulation assembly 22 and inserting surgical instruments through the cannulas 34 to simulate a procedure on the simulation assembly 22 . In an example, the housing 32 represents patient or subject tissue through which surgical instruments are inserted and the apertures 36 can each represent an incision.
FIGS. 5A and 5B , which are similar to the illustration in FIG. 4 , further include sutures 40 shown formed through the simulated tissue 24 and the substrate 26 . The sutures 40 were formed with a surgical device inserted through a cannula 34 mounted in the housing 32 . Referring now to FIG. 5B , the simulation assembly 22 is shown pivoted about the axis A X and oriented transverse from its orientation of FIG. 5B . Accordingly, the pivoting ability of the simulation assembly 22 on the yoke 14 provides flexibility for different simulation orientations. FIGS. 5A and 5B depict simulated examples of a completed arthroscopic rotator cuff repair. In an example, the simulated tissue 24 , 28 represents mammal soft tissue, such as epidermis, connective tissue, muscle, tendons, ligaments, combinations thereof, and the like. Optionally, the substrate 26 represents hard tissue, such as an osseous or osseous like material.
Further orientation flexibility is demonstrated in FIGS. 6A and 6B where the simulation assembly 22 is shown with its lower side disposed in a plane substantially parallel with axis A Y ( FIG. 6A ) and its lower side facing the housing ( FIG. 6B ). In both views sutures 40 are provided through the simulated tissue 28 and the substrate 26 lower surface. FIGS. 6A and 6B portray examples of a completed glenoid labrum repair. Thus the simulation assembly 22 can be fully rotated about both A X and A Y axes to position the assembly 22 into arty desired orientation thereby providing for a simulated surgical procedure from multiple directions.
FIG. 7A illustrates a perspective and view of an example of the base 12 . The base 12 as shown is a disc-like member with its radius greater than its length or thickness and includes an annulus 126 aligned with its axis. Side bores 122 , 124 are shown laterally extending through the base 12 ; side bore 124 extends from the base 12 outer periphery to the annulus 126 . Vertical bores 128 are shown formed upward into the base 12 from its bottom surface. A lip 129 can optionally be included on the base 12 periphery at its lower end. The annulus 126 is shown circumscribed by a recess 122 at its lower entrance. The side bore 124 may be fitted with a resilient member 125 , such as a spring, and a detent element 123 , wherein the member 125 urges the detent element 123 from the side bore 124 into the annulus 126 . FIG. 7B illustrates a side sectional view of the disc 12 . Here the lip 129 is shown extending radially outward past the enter radius of the annulus 126 .
FIG. 8 illustrates in a perspective side view an example of a substrate 26 with an accompanying ring 31 . The substrate 26 is shown having an upper bore 262 shown formed into the upper portion 27 of the substrate 26 and substantially aligned with the axis A Y . The upper bore 262 can be threaded to couple with an attachment for the simulated tissue 24 (see FIG. 3 ). Side bores 310 are shown formed through the side wall of the ring 31 for coupling the ring 31 to the lower portion 29 of the substrate 26 . The bores 310 can be smooth or threaded and dimensioned to receive fasteners 30 therein.
A side perspective view of an example of the disc 13 is provided in FIG. 9 . As shown, the disc 13 includes a cylindrically shaped spindle 132 set substantially coaxial with an axis A D of the disc 13 . A disc like flange 130 projects radially outward from the lower end of the spindle 132 . A slot 134 is provided on the upper surface of the spindle 132 and transverse to the axis A D of the disc 13 . The slot 134 , as shown, is formed to receive the mid-portion of the yoke 14 . A bore 138 shown formed coaxial with the axis A D extends through the spindle 132 from the bottom of the slot 134 . A threaded fastener, not shown, can be inserted into the bore 138 to secure the yoke 14 within the slot 134 . Bores 136 are illustrated formed in the outer periphery of the spindle 132 and oriented generally towards the axis A D . The spindle 132 is insertable into the annulus 126 of the base 12 and can axially rotate therein. Rotating the disc 13 with respect to the base 12 selectively registers the bores 136 with the side bore 124 ; the pushing force supplied by the resilient member 125 urges the detent element 123 (see FIG. 7A ) to enter an aligned bore 136 when registered with the side bore 124 . Applying a rotational torque onto the base 12 can disengage the detent element 123 from the registered bare 136 enabling the disc 13 to rotate within the base 12 and into a different angular orientation. The disengaging force required to disengage from locking detent element 123 can prevent the base 12 from freely rotating about its axis A X . The amount of force necessary to compress the resilient member 125 will dictate the disengaging rotational force.
FIG. 10 illustrates an example of the yoke 14 in a side perspective view. As shown, the yoke 14 is a generally curved member having a bore 140 formed through at roughly its midsection 148 . The bore 140 is shown as threaded to receive a fastener (not shown), which may be threaded, for attachment to the disc 13 . The line yoke 14 curves with distance from its midsection 148 with its ends 142 a distance apart and away fern the midsection 148 . The yoke 14 as shown is an elongated member having a generally rectangular cross section. Curved recesses 146 , that may receive the elastic member 18 , are shown provided on the lateral sides of each of the ends 142 . Also shown formed on the ends are bores 144 oriented towards one another and normal to the bore 140 . The bores 144 may be registered with bores 310 so fasteners 30 can be inserted through the registered bores 144 , 310 .
In an embodiment, a simulation assembly 22 combined with a simulation device 10 can be used as a trainer for shoulder arthroscopy. The use of arthroscope and/or surgical cannulas is optional. The embodiments of the simulation device 10 , and all portions thereof described herein can be used to perform surgical procedures such as knot tying, suturing techniques, suture anchor insertion, suture management, rotator cuff repair, anterior glenoid labrum (Bankart) repair, posterior glenoid labrum repair, SLAP repair, and combinations thereof. The simulated tissue may be flexible and include in its composition single as well as dual density EPF foam and other bone simulation materials. Red sponge rubber, neoprene, and Veltex® can be used as simulation tissue. Colors of the simulation tissue, or other components of the simulation device 10 , can be changed to match particular or desired color schemes. The surgical simulations can be semi-anatomic or schematic, can simulate left or tight body anatomy, can be oriented to represent “beach chair” or lateral decubitus position without repositioning the base.
It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. It is not necessary that the supports have an annular opening, optionally the supports may comprise a shoulder or be semi-circular. In the drawings and specification, there have been disclosed illustrative embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
|
A system for simulating a surgical procedure, which includes a housing covering an anatomical model. The model is made up of simulated tissue supported on a base assembly that allows pivoting and rotation of the simulated tissue. The simulated tissue includes a portion that represents soft tissue, such as dermal tissue, muscle, connective tissue and the like, and a portion that represents hard tissue, such as osseous tissue. The housing includes apertures through which a surgical instrument may be inserted for simulating a procedure on the simulated tissue. Cannulas may be set within the apertures.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 08/330,422, filed Oct. 28,1994, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to tables.
It is common experience for one to find a table assembled by a manufacturer with a particular table top panel and particular table legs, or one or more table pedestals, and the like. The manufacturer will specifically fit and couple these particular components with one another. A table will typically come from the manufacturer either preassembled or previously assembled and disassembled with specific table top and leg components packaged together, including the requisite screws or the like to reassemble the table at the point of use.
This common method of unitized packaging of an assembled table or a previously matched table top and leg components inherently limits a customer's selection from available tables, however. A table supplier has a finite volume of inventory space and can stock only the quantity of inventory that will fit in the given inventory space. This, then, inherently limits the variety of table choices available to a customer, unless the customer is willing to wait for and pay for a custom table.
SUMMARY OF THE INVENTION
Accordingly, a modular table assembly according to the invention has a table top or panel member with a bottom surface. A plurality of receptacle sets are provided on the bottom surface of the table top. And, a plurality of leg sets are provided, each one of the leg sets corresponds to a respective one of the plurality of receptacle sets with a selected one of the plurality of leg sets being coupled with its respective receptacle set to assemble a table having a selected leg design style.
In one aspect of the invention, an end of each leg that is coupled with the table top has a cooperating key that corresponds to and is seated in its respective receptacle. In another aspect of the invention, at least one of the legs has a passage extending along a length of the leg, between a table end of the leg and an opposing base end of the leg. In a further aspect of the invention, the passage includes a member that defines a side of the passage. The member is flexible to be displaced from a first position in which the passage is substantially closed-sided to a second position in which the passage is open-sided to receive an item into or remove an item from the passage, through the side of the passage. The member is also resilient to return to the first position from the second position. In an additional or an alternative aspect of the invention, the passage includes an opening and a guide, each at one of two opposing ends of the leg. The guide directs an item from the other end of the leg to the opening at the one end of the leg.
These and other features, objects, and benefits of the invention will be recognized by those who practice the invention and by those skilled in the art, from the specification, the claims, and the drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom plan view of a table top panel, showing alternative perimeter shapes in phantom;
FIG. 2 is the view of FIG. 1 showing only a first one of a number of discreet receptacle sets;
FIG. 3 is a perspective view of two post-type legs configured for use with the receptacle set shown in FIG. 2;
FIG. 4 is a perspective view of two panel-type legs configured for use with the receptacle set shown in FIG. 2;
FIG. 5 is a perspective view of an alternative panel leg configured for use with the receptacle set shown in FIG. 2.;
FIG. 6 is an exploded perspective view of one of the post-type legs of FIG. 3;
FIG. 7 is a cross-sectional view along section line VII--VII of the table end plate of FIG. 6;
FIG. 8 is a cross-sectional view of the wire way attachment shown in FIG. 6;
FIG. 9 is an exploded perspective view of one of the panel-type leg assemblies shown in FIG. 4;
FIG. 10 is an enlarged detail, shown in fragmentary perspective view, of the wire way member of FIG. 9;
FIG. 11 is a cross-sectional view along reference line XI--XI of the edge coupling plate of FIG. 9;
FIG. 12 is an exploded perspective view of the leg assembly shown in FIG. 5;
FIG. 13 is a side elevational view of a side coupling plate shown in FIG. 12;
FIG. 14 is a bottom plan view of the side coupling plate of FIG. 13;
FIG. 15 is a cross-sectional view along line XVI--XVI of FIG. 14;
FIG. 16 is the view of FIG. 1 showing only a second one of a number of discreet receptacle sets;
FIG. 17 is a perspective view of two small panel legs configured for use with the receptacle set shown in FIG. 16
FIG. 18 is an exploded perspective view of one of the legs shown in FIG. 17;
FIG. 19 is the view of FIG. 1 showing only a third one of a number of discreet receptacle sets;
FIG. 20 is a perspective view of four pedestal legs configured for use with the receptacle set shown in FIG. 19;
FIG. 21 is a cross-sectional view along section line XXI--XXI of a leg base, shown in FIG. 22; and
FIG. 22 is an exploded perspective view of a pedestal leg, shown in FIG. 20.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A table according to the invention is assembled by the selection of a table top 30 (FIG. 1), or the like, and the selection of a requisite number of leg elements from a plurality of leg element sets, including post-type legs 32 (FIGS. 3 and 6), panel legs 34 and 36 (FIGS. 4 and 9), panel legs and 38 and 38' (FIGS. 5 and 12), small panel legs 40 (FIGS. 17 and 18), and pedestal legs 42, 44, 46, and 48 (FIGS. 20 and 22), for example.
More particularly with reference to FIG. 1, table top or panel member 30 has a bottom surface 50 and a plurality of receptacle sets provided on the bottom surface. The receptacle sets may be conveniently provided by routing into the bottom surface 50. Table top 30 may be provided with circular recesses 52 and ovoid recesses 54 which are arranged on the bottom surface of table top 30 to define a first receptacle set 56, which is more clearly shown in FIG. 2. Table top 30 may also be provided with pairs of ovoid recesses 60 arranged on bottom surface 50 to define a second receptacle set 62, which is more clearly shown in FIG. 16. Finally, an array of generally keyhole-shaped recesses 66 may be arranged on bottom surface 50 to define a third receptacle set 68, which is more clearly shown in FIG. 19.
Again referring to FIG. 1, table top 30 may have a generally rectangular shape with rounded ends as shown by the solid perimeter line 70, may have a true rectangular shape as shown by the phantom line 72, or may have a truncated ovoid or elliptical shape as indicated by the phantom line 74, for example. Of course, table top 30 may also have any other selected perimeter shape and size. The shape of table top 30 as shown in the drawing figures is for illustration purposes only. Table top 30 may be constructed of any suitable table top material, including, solid or laminated wood or plastic materials which may or may not in turn be finished with a veneer or the like, for example.
In use, one may select a table top 30 of desired configuration and material construction and select a set of cooperating leg elements of desired style or design. For simplicity in describing one of the myriad of combinations of table top and leg sets, that is provided by a modular table assembly according to the invention, drawing FIG. 2 shows the ovoid table top of FIG. 1 with only the first receptacle set 56. Likewise, FIG. 16 shows only the second receptacle set 62, and FIG. 19 shows only the third receptacle set 68. With further reference to drawing FIGS. 2-15, the first receptacle set 56 (FIG. 2) is noted to accommodate a selection of leg sets, including post legs 32 and panel legs 34-38 (FIGS. 3-5).
Each post leg 32 (FIGS. 3 and 6) defines a table support pedestal having a table end 80 with a coupling place 82, an opposing base end 84 which may have various alternative leg feet 86, and a column portion 88 extending between the coupling plate 82 and leg foot 86. The coupling plate 82 is conveniently formed of a moldable material, including the various structural and engineering plastics and the various casting metals and alloys, such as aluminum A319, for example. As expressly shown in the drawing figures, a circular plate configuration of the coupling plate 82 readily lends itself to convenient manufacture both in terms of forming the coupling plate 82, itself, and in terms of forming the corresponding circular recesses 52 in bottom surface 50 of table top 30. The coupling plate 82 has a circumferential flange 90 (FIGS. 3, 6, and 7) that defines a mounting surface 92 to abut bottom surface 50 of table top 30. An alignment key 94 extends beyond the flange 90 and mounting surface 92, from the coupling plate 82. The alignment key 94 and circular recesses 52 have corresponding shapes and dimensions for cooperating engagement and seating of the alignment key 94 in a recess 52. Thus, each post leg 32 that is used with table top 30, a quantity of six as shown in FIG. 2, is readily located on the table top panel 30, at the point of sale. The circumferential flange 90 has an array of preferably evenly distributed screw holes 96 extending through the flange 90 for convenient screw attachment of the coupling plate 82 to the table top panel 30 with self boring wood screws 98 or the like. Extending opposite to the alignment key 94, the coupling plate 82 also has an assembly nipple 100 for cooperating engagement with a recessed seat 102 provided at either end of the column portion 88.
The column portion 88 is generally an elongated member and may be configured with any desirable table leg shape from a plain cylinder to an ornate turning, for example. The column portion 88 may be formed of any suitable structural or engineering material, including metals, woods, or plastics, for example. The specific material selected to form the column portion 88 may ultimately be dictated by aesthetic preferences. The column portion 88 is conveniently coupled with the coupling plate 82 by inserting the assembly nipple 100 into the recessed seat 102 at one end of the column portion 88 and securing the coupling plate and column portion together with a screw or bolt 104 or the like.
At the base end 84 of the column portion 88, a selected leg foot 86 is coupled with the column portion 88 by seating an assembly nipple 106 provided on the leg foot 86 into the recessed seat 102 at the base end of the column portion 88 and attaching the leg foot 86 with another screw or bolt 104. or the like, similar to the attachment between the coupling plate 82 and the column portion 88 as described above. The leg foot 86 may also be configured with a variety of shapes and formed of various materials, as discussed in greater detail above regarding coupling plate 82, with aesthetic preferences significantly affecting the specific shape and material selected to form the leg foot 86.
It will be apparent to one who is familiar with table legs and the like that alternative structure and methods for interconnecting the coupling plate 82, the column portion 88, and the leg foot 86 are available. Such alternatives may include, but not be limited to, a cooperating screw thread coupling between the coupling plate 82 and the column portion 88 and between the leg foot 86 and the column portion 88. Also, one may interconnect the coupling plate 82, the column portion 88, and the leg foot 86 with a through rod, extending through the column portion 88, between the coupling plate 82 and the leg foot 86.
Each post leg 32 may be provided with an optional, snap-on wire way 110 (FIGS. 6 and 8). The wire way 110 is preferably a single, elongated member with a first arcuate portion 112 and a second arcuate portion 116. The first arcuate portion defines an open-sided channel 114 that is shaped and sized for snap-fit fastening with or attachment to the column portion 88. The second arcuate portion 116 that extend outward from the first arcuate portion 112 and curves back toward the first arcuate portion 112 to define a wire way passage 118 between the first 112 and second 116 arcuate portions. In a first position, the wire way passage 118 is substantially closed-sided (FIG. 8). At least the second arcuate portion 116, however, is flexible to be displaced from the first position to a second position in which the wire way passage 118 is open-sided to receive an item into or remove an item from the passage 118. At least the second arcuate portion 116 is also resilient to return from the second or open position to the first or substantially closed position. To obtain a wire way structure that achieves the use discussed here, the wire way 110 may be formed by a variety of methods and of various resilient and flexible materials. The wire way as specifically disclosed in the Figures and described here is conveniently produced by extruding a polyvinylchloride (PVC) plastic and cutting the extrusion to a desired length for use.
In addition to the post leg 32 described above, panel legs 34-38 (FIGS. 4 and 5) may also be used with the first receptacle set 56 (FIG. 2). Each of the panel legs 34-38 are quite similar to one another with only small differences among them. Thus, panel leg 34 will be discussed in greater detail with only the differences of panel legs 36 and 38 being discussed further below.
Similar to post leg 32, panel leg 34 (FIGS. 4 and 9) is generally a table support pedestal with a column portion 120 extending between a table end 122 and a base end 124. The column portion 120 may be of any suitable construction to provide a table support of desired design, including solid, laminated, and framed construction, for example. The column portion 120 may also be fabricated of any suitable material, including metals, plastics, and woods, for example. The ultimate construction and material choices will, as always, be significantly affected by the desired aesthetic result. Panel leg 34 has two edge coupling plates 126 at the table end 122 of the leg 34 to couple the leg 34 with the bottom surface 50 of table top 30.
As with the coupling plate 82 of the post leg 32, the edge coupling plate 126 is conveniently formed of a moldable material, including the various structural and engineering plastics and the various casting metals and alloys, such as aluminum A319, for example. The edge coupling plate 126 is also preferably a circular plate member having a circumferential flange 128 defining a mounting surface 130, with an array of screw holes 132 extending through the flange 128 for attachment to bottom surface 50 with screws 98. The flange 128 of the edge coupling plate 126 is interrupted, however, by a radially extending mounting slot 134 that is sized and dimensioned to receive an edge of the column portion 120.
A planar plate portion 136 of the coupling plate defines each side of the mounting slot 134 and is provided with screw holes 138 for screw fastening attachment of the mounting plate 126 to the column portion 120. A generally circular or semi-circular alignment key 140 extends beyond the mounting surface 130, defined by the circumferential flange 128. The alignment key 140 is shaped and sized for cooperating engagement with and seating of alignment key 140 in the circular recesses 52 of the first receptacle set 56. The alignment key 140 also extends at least partially over the mounting slot 134 to define a stop surface 142 for positive location of the column portion 120 with respect to the edge coupling plate 126. Further, the alignment key 140 may be provided with a projecting ridge 144 or other indexing feature and the table end 122 of the column portion 120 may be provided with a cooperating recess 146 to further facilitate positive location of the column portion 120 with respect to the edge coupling plate 126.
At the base end 124 of panel leg 34, a leg foot 148 and a trim member 150 may be provided and attached to the column portion 120 in accordance with desired aesthetics. One of many suitable configurations includes fabricating the leg foot 148 as a structural foundation member with the trim member 150 being an overlaying decorative piece, for example. Each of the leg foot 148 and the trim member 150 may be fabricated of any suitable material.
A wire way may also be provided for panel leg 34 by attaching a hollow, elongated member 160 (FIGS. 9 and 10) to a side of the column portion 120. More preferably, the wire way or elongated member 160 is set into a groove 162 that corresponds to the cross-sectional shape of the wire way 160, defined in a side of the column portion 120. The wire way 160 may be glued, screwed, or taped with double-sided tape or the like into the groove 162 as is commonly known and understood by those of ordinary skill in the art. More particularly, the wire way 160 is preferably a substantially closed-sided member having a slotted side 164 that is defined by at least one flexible member 166, but more preferably two flexible members 166. In a first position, the flexible members 166 substantially close the side 164 of the wire way passage 168. The flexible members 166 are flexible to be deflected to a second position in which the passage is open to receive an item 170, such as a cord or cable or the like, into or remove an item from the passage 168. The flexible members 166 are resilient to return to the first position from the second position when an item is not being transferred into or out of the passage 168. As with the wire way I 10 for the post leg 32, discussed in greater detail above, the wire way 160 may be fabricated by a number of methods from various materials. The wire way 160 may be conveniently fabricated as a length of a dual durometer extrusion of PVC to define a substantially rigid plastic member with resilient flexible members 166.
As is seen in FIG. 4, panel leg 36 is substantially the same as panel leg 34, except that a center portion of the column portion is removed to define two column portions 176. Further, the wire way 160 may also be relocated to an inside edge of one or both of the resulting two column portions 176. Pedestal legs 38 and 38' (FIGS. 5 and 12) are also substantially the same as pedestal leg 34, except that the wire way 160 is relocated to an edge of the column portion 178 and one of the two edge coupling plates 126 is replaced with a side coupling plate 180 (FIGS. 5 and 12-15). The side coupling plate 180 is generally a half of the edge coupling plate 126.
The side coupling plate 180 (FIGS. 5 and 12-15) is fabricated of a suitable material to provide a semi-circular plate member having a semi-circumferential flange 182 and two mounting tabs 194 that define a mounting surface 184 to abut bottom surface 50 of table top 30. The semi-circumferential flange 182 is provided with an array of screw holes 186 to screw mount the side coupling plate 180 to bottom surface 50 of the table top 30 with screws 98. The side coupling plate 180 also has a diametrical side surface 188 with screw holes 190 and each tab 194 has a screw hole 192, to screw mount the side coupling plate 180 the column portion with tabs 194 seating in recesses 146.
An alignment key 200 extends beyond the mounting surface 184 defined by the semi-circumferential flange 182 and tabs 194, at a top edge of the side surface 188. The alignment key 200 is a generally ovoid member that is configured and sized for cooperating engagement with and seating into the ovoid recesses 54 of first receptacle set 56. The ovoid recess 54 extends along an axis 202 that generally aligns with a circular recesses 52 of the first receptacle set 56.
More particularly regarding drawing FIGS. 16-18, an ovoid table top panel member 30 with only the second receptacle set 62 is shown in FIG. 16. The second receptacle set 62 includes pairs of ovoid recesses 60 that extend along axes 204. The second receptacle set 62 accommodates a selection of leg sets having a table end configuration similar to that of small panel legs 40 (FIGS. 17 and 18) and the like. Each of legs 40 defines a table support pedestal having a table end 210 with a pair of side coupling plates 180, an opposing base end 212 which may have various foot and trim components, similar to panel legs 34, and a column portion 214 extending between the opposing table end 210 and base end 212. The side coupling plate 180 is disclosed in detail above.
Similar to the panel leg 38, the table end 210 of the column portion 214 is provided with indexing recesses 146 that receive the tabs 194 of side coupling plates 180. The table end 210 of the small pedestal leg; 40 has two side coupling plates 180 and thus, presents two alignment keys 200. The cooperating leg receptacles 60 are, therefore, a pair of ovoids configured with corresponding shape and dimensions for cooperating engagement and seating of the two alignment keys 200 in the recess 60. Also as discussed above, side coupling plates 180 are attached to bottom surface 50 of table top panel 30 with screws 98. Further, the legs 40 may be provided with a wire way 160 as is also discussed in greater detail above.
More particularly regarding; drawing; FIGS. 19-22, FIG. 19 shows table top panel 30 with only the third receptacle set 68. Preferably, an array of at least three generally keyhole-shaped recesses 66 define the third receptacle set 68. Each elongated recessed 66 extends along; an axis 216. Each elongated recess 66 is oriented so its axis 216 intersects the axis 216 of each other elongated recess 66 at a common point. The third receptacle set 68 is noted to accommodate a selection of pedestal legs 42-48. Each of these pedestal legs 42-48 is quite similar. Legs 42, 44, and 46 are, in fact, substantially the same with only a substitution in column portion 220 generally distinguishing one from another. Thus, pedestal leg 46 will be discussed in greater detail below, with only the differences among the legs being specifically discussed further.
Pedestal leg 46 has a table end 222 with a spider coupling member 224, an opposing base end 226 which may have various alternative base members 228, and a column portion 220 extending between the table end 222, and the base end 226. The spider 224 is conveniently formed of a moldable material, including various structural and engineering; plastics and the various casting metals and alloys, such as aluminum A319, for example. As is expressly shown in the drawing Figures, the spider 224 may be provided with four radially extending arms 230, each of which terminates at a hand portion 232. Each hand 232 presents a generally keyhole-shaped mounting surface 234 to abut the bottom surface 50 of the table top panel 30. Thus, each recess 66 has a corresponding keyhole-shape that is dimensioned for cooperating engagement and seating of each hand 232 of the spider 224 into the recess 66. Each hand 232 is provided with an array of screw holes 236, by which the spider 224 is screw fastened with screws 98 to the table top 30. The arms 230 of the spider 224 preferably extend radially outward to the hand portions 232 from a central hub 238 which is offset and spaced away from the table top 30.
The column portion 220 of pedestal leg 46 includes an elongated member that defines a hollow tube 240. The tube 240 may have virtually any cross-sectional shape and may be constructed of any of various appropriate materials, including woods, plastics, and metals, for example. Those who practice the invention may, however, find that some cross-sectional shapes may lend themselves more naturally to the assembly of the pedestal leg 46 than alternative shapes. The tube 240 is mated or coupled with the spider 224 by inserting the offset hub 238 and a portion of the arms 230 into an open end 242 of the tube 240.
The column portion 220 may also provide a wire way through an opening 248 through spider hub 238, through the tube 240, and out an opening 254 at the base end 226. A guide 244 may also be provided in tube 240 to direct an item from table end 222 to the opening 254 at the base end 226. The guide 244 is particularly useful with a tube 240 that has a relatively large diameter. The guide 244 may be constructed of any of various appropriate materials and most preferably has an elliptical shape, although other shapes may be found to function adequately.
Each end of tube 240 is provided with a trim ting 246 that may be constructed as a length of an open-sided channel member extruded of PVC plastic, or the like. Similarly, the opening 254 is also provided with a trim ring 256. Of course, those who practice the invention will realize that other materials and construction techniques may be suitable to provide alternative trim rings.
The base 228 of the pedestal leg 46 may be any functionally suitable and aesthetically pleasing foundation member. As specifically disclosed in the drawing Figures, base 228 is generally a circular disc member that is cast with a suitable material, such as aluminum A319. The base 228 may alternatively be cast of some other suitable metal or a plastic and may also be formed as a turning from wood stock, for example. As is specifically shown in the drawing FIGS. 20-22, base 228 is most preferably formed with an array of concentric ridges or steps 250. The ridges or steps 250 are spaced to correspond with the tube 240 and to provide a positive locating stop to position the base 228 and the tube 240 relative to one another.
As shown in drawing FIG. 22, the spider 224, the column 220, and the base 228 are preferably interconnected with a pair of threaded rods 252. The rods 252 extend through holes 258 in the base 228, extend up through tube 238 and holes 260 that are provided in the guide 244, and extend through holes 262 in the hub 238 of the spider 224. Cooperating washers 264 and nuts 266 are fastened at each end of the rods 252 to secure the pedestal leg 46 together.
As is clearly shown in drawing FIG. 20, pedestal legs 42 and 44 differ from pedestal leg 46 by the substitution of different sized tubes 240' and 240". Pedestal leg 48 differs from pedestal leg 46 by the substitution of an alternative column portion and an alternative base.
With the preceding description of the table top panel 30 and the various legs, namely, post legs 32 (FIGS. 3 and 6), panel legs 34 and 36 (FIGS. 4 and 9), panel legs and 38 and 38' (FIGS. 5 and 12), small panel legs 40 (FIGS. 17 and 18), and pedestal legs 42, 44, 46, and 48 (FIGS. 20 and 22), the many design possibilities provided by the selection, mixing, and matching of the legs with the table top will be understood. It will also be understood by those who practice the invention and by those skilled in the art, that various modifications and improvements may be made to the invention without departing from the spirit of the disclosed concept. The scope of protection afforded is to be determined by the claims and by the breadth of interpretation allowed by law.
|
A modular table assembly and kit include a table top panel member with a plurality of discrete receptacle sets disposed on the panel. A plurality of leg sets is provided with each one of the leg sets corresponding to a respective one of the plurality of receptacle sets. Whereby, a selected leg set is coupled with its respective receptacle set to assemble a desired table design. The selected leg set may include to least one pedestal with a column portion extending between a table end and a base end. The table end of the leg includes a key that seats in it respective receptacle to locate the leg relative to the table top. Further, the pedestal may include a wire way passage extending between the table end and the base end to conceal and conduct a wire or cable or the like.
| 0
|
This application is a continuation of application Ser. No. 07/565,185, filed Aug. 8, 1990, now abandoned, which is a continuation of application Ser. No. 07/305,179, filed Feb. 2, 1989, abandoned.
BACKGROUND OF THE INVENTION
The present invention provides a method and apparatus for drilling a borehole with an optionally rectilinear or arcuate center line into earth formations.
Tools of this type, which are used for navigational drilling without tool change, are known to be available in various designs.
In order to create an angle of deflection--which at the same time determines the build-up rate to be achieved--for the rotation axis of the drill bit shaft during directional drilling, the first and the second stabilizer of a first well-known tool (U.S. Pat. No. 4,465,147) are arranged eccentrically on the casing--which has the shape of a straight tube--of the rotary drilling tool. In directional drilling operations, such a design imparts a deflection, which determines the angle of deflection, to the casing.
In a second well-known tool (U.S. Pat. No. 4,739,842), the stabilizers are concentrically arranged on the casing of the rotary drilling tool, and the casing is provided with sections deflected relative to the principal axis of the tool, which define two bends which face in opposite directions and which in combination with each other determine the angle of deflection. According to a further development of this tool, as also disclosed in the aforementioned U.S. Pat. No. 4,739,842, the deflection of the casing regions can be designed in such a way that only one single bend between the two stabilizers determines the angle of deflection.
Instead of one or two bends in the region of the casing between the first and the second stabilizer, a third well-known tool of the type mentioned in the introduction provides for a bend between the rotary drilling bit and the first stabilizer (U.S. Pat. No. 4,492,276). This bend is formed in such a way that the bit shaft is carried in the lower area of the casing--which has the form of a straight tube--at an angle relative to the axis of this casing and exits at a slant from the end of the casing.
In a fourth well-known tool (U.S. Pat. No. 4,485,879), the bit shaft is carried in the casing of the rotary drilling tool, with its rotation axis being laterally and parallelly offset with respect to the axis of the casing.
The present invention provides a method and apparatus which has a higher accuracy of tracking and a higher penetration rate during directional drilling while at the same time reducing its wear.
SUMMARY OF THE INVENTION
Methods and apparatus in accordance with the present invention utilize a downhole drilling tool which includes a drill bit, a downhole motor, a deflection member imparting an angle of deflection of the drill bit relative to the axis of the drill string above the drilling tool assembly, and at least first and second stabilization points, which may or may not be of a dimension greater than the remainder of the drilling tool. When the drilling tool is to be utilized for generally straight ("rectilinear") hole drilling, the entire drill string will be rotated to affect the drilling. When arcuate (or "navigational") drilling is desired, the drill string will be fixed in a position such that the deflection member orients the bit in the desired direction of travel, and rotation of the bit (and thus drilling) will be accomplished through use of the downhole motor. With methods and apparatus in accordance with the present invention, the axis of the bit shaft will be oriented generally tangentially (for example, 90-91°), to the radius of the arc of the intended borehole path. Particular preferred embodiments of the invention may utilize one or more bends to achieve the above relation of the bit axis to the radius of the arcuate borehole path.
With use of an apparatus according to this invention, the resulting component forces exerted on the guiding direction of the rotary drilling bit are considerably reduced during directional drilling as a result of the special orientation of the axis of the bit shaft of the rotary drilling bit, which is responsible for a more wear-resistant operation and a higher penetration rate. This applies particularly to a design of the rotary drilling tool for a build-up rate of 2°/30 inches and more. At the same time, a much greater tracking accuracy for the rotary drilling bit is achieved during directional drilling not only in uniform rock formations but also in successively different rock formations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a truncated schematic view, partially in vertical section, of a tool for optional straight hole drilling and directional drilling with a rotary drilling tool according to this invention during directional drilling operations.
FIG. 2 depicts a schematic representation of a first embodiment of a rotary drilling tool in accordance with the present invention in a drilling hole produced by means of directional drilling and having an arcuate center line.
FIG. 3 depicts a schematic cross-sectional view of the upper portion of the rotary drilling tool according to FIG. 2.
FIG. 4 depicts a schematic cross-sectional view of the lower portion of the rotary drilling tool according to FIG. 2, with this lower portion being a continuation of the corresponding upper portion of the representation according to FIG. 3.
FIGS. 5 to 11 are schematic representations similar to those shown in FIG. 2 to further illustrate seven alternative embodiments of a rotary drilling tool in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The tool shown as a schematic diagram in FIG. 1 consists of a rotary drilling tool 2 which is located in a borehole 1 and whose casing 3 is connected at its upper end to drill string 4. Drill string 4 is clamped into a rotary table 5 of a drilling rig 6. Rotary table 5 is fitted with a driving and blocking device 7 by means of which the chuck of rotary table 5, and thus of drill string 4, can be put into continuous rotation or can be aligned by means of a limited rotary movement and subsequently be secured into position so as to not be able to turn.
The embodiment of a rotary drilling tool 2 illustrated in FIGS. 1 to 4 has a casing or housing 3 which consists of several components or sections 8, 9, 10, 11, 12 which are screw-jointed to each other. Along one section of its length, casing section 10 is designed as a stator 13 of a deep-hole motor with rotor 14. In the practical example shown in FIGS. 3 and 4, deep-hole motor 13, 14 is a displacement motor operating according to the Moineau principle; however, it may also be a turbine or a motor of any suitable construction.
Rotor 14 is connected to the upper end of a bit shaft 16 by means of a propeller shaft 15 which is located in casing section 11. This bit shaft 16 rotates in bearings 17, 18 of casing section 12 which forms a bearing block. In the embodiment of the rotary drilling tool according to FIGS. 1 to 4, the bit shaft has a rotation axis 19 which is at a small angle relative to the surrounding casing axis 20 of casing section 12. In correspondence with this slanted bearing, bit shaft 16 whose outer end is fitted with a rotary drilling bit 21 exits at a slant from the lower end of casing 3.
In its lower section, near rotary drilling bit 21, rotary drilling tool 2 is fitted with a first stabilization point 22 in the form of a stabilizer 24 which is attached to casing section 12 and which has a number of stabilizer blades or ribs that are distributed throughout its circumference. At a certain distance from and above this first stabilization point 22, rotary drilling tool 2 has a second stabilization point 25 which is also formed by a conventional stabilizer 24 which is located on casing section 8. The imaginary central points of these stabilization points 22, 25, in combination with an imaginary central point of the rotary drilling bit 19a, define the course of an imaginary center line for borehole 1, which in the areas of borehole 1 drilled in the course of directional drilling takes an arcuate course.
The center line (not shown in the drawing for reasons of clarity) of the area of borehole 1, which in FIGS. 2 and 5 to 11 is shown to be curvilinear, has its base at point 26 and has an arc center which is substantially removed in distance.
The distance of the arc center from the arcuate center line of an area of borehole 1 produced by means of directional drilling is measured on the basis of the build-up rate (BUR=2α/D in o /meter) for which the rotary drilling tool is designed. α denotes the angle--opening up into the direction of rotary drilling bit 21--between the imaginary connecting line of the central point 19a (which coincides with base 26) of rotary drilling bit 21 with the imaginary central point of the borehole at the level of the first stabilization point 22 and an imaginary lower extension of the rectilinear connecting line of the imaginary central points of borehole 1 at the level of the first and the second stabilization 22, 25. D denotes the distance between the imaginary central point of the second stabilization point 25 and the mentioned central point 19a of rotary drilling bit 21. The build-up rate is preferably a minimum of approximately 2°|30 meters, corresponding to a distance from the arc center to the center line of the borehole of approximately 850 meters.
As all other modifications of this invention, illustrated or imaginable, rotary drilling tool 2 is designed in such a way that in directional drilling operations, rotation axis 19 of bit shaft 16 has an orientation relative to an imaginary rectilinear connecting line 28 between the arc center and base 26 of the arcuate center line of borehole 1--which can be drilled with the rotary drilling tool--with a clearance angle β of approximately 90° as a lower limit. The "clearance angle" is the angle between the bit axis and the radius of the curve to be drilled at the position of the bit in the borehole. Thus, in effect, angle β of 90° represents the bit axis being tangential to the arcuate path of the borehole.
Thus, this type of orientation establishes the rotational axis 19 of bit shaft 16 as a tangent to the arcuate center line of borehole 1 at the level of base 26, with the result that the resulting component forces exerted upon rotary drilling bit 21 are reduced to a minimum. In the conventionally known tools discussed earlier herein, these component forces are considerably greater since in these tools, the rotation axis 19 of bit shaft 16 forms a secant to the arcuate center line of a borehole drilled by means of directional drilling, with intersections with the center line, which are located above base 26.
Clearance angle 8 may also be slightly larger than 90°, and thus may range between approximately 90° and 91°. This "lead" makes it possible to compensate for bending strains which a rotary drilling tool may be subjected to as it is introduced into a partially drilled borehole, e.g., in the course of a round trip.
Between the first and the second stabilization points 22, 25, rotary drilling tool 2 has a bend 29, and in the area between rotary drilling bit 21 and the first stabilization point 22, there is a second bend 30. Preferably, both bends 29, 30 (in the principal axis defined by several individual sections connected to each other) are located in the integral casing section 12, in which the lower stabilization point 22 is to be found, and both bends 29, 30 face into the same direction, namely toward the arc center.
In rotary drilling tool 2, bend 29 is formed by a cocked upper threaded pipe connection 31 of casing section 12, and the second bend 30 is formed by the inclined bearing 17, 18 of bit shaft 16 in casing section 12. The sum of the values of both angles of bend corresponds to the value of the angle of deflection α, and the build-up rate is calculated on the basis of the angles of bend. In the presence of several bends, it is, however, possible to assign different values to the angles, thus making it possible to take special structural arrangements into consideration. Preferably, it is bend 29 which is used to determine the build-up rate while bend 30 is mainly responsible for the desired clearance angle β. Thus, for example, the angle of bend of bend 29 may measure 1.5° and more, while the angle of bend of bend 30 may, for example, amount to 0.6° or less.
The location of both bends within one single casing section 12, as suggested for rotary drilling tool 2, simplifies the structural design since all other casing sections 8 to 11 located higher up can consist of straight-line pipes.
FIG. 5 illustrates an alternative embodiment of a rotary drilling tool 102 in which, in addition to bend 29, a further bend 32 is provided between the first stabilization point 22 and the second stabilization point 25. Both bends 29, 30 may face into the same direction of bend or may, as shown in FIG. 5, face in opposite directions, with bend 32 facing away from the arc center of the arcuate center line of borehole 1 and with bend 29 having a direction of bend facing this borehole center. This type of arrangement of the directions of bend reduces and eliminates an eccentricity of the imaginary center point of rotary drilling bit 21 relative to an imaginary rectilinear lower extension of the upper section 27 of the principal axis of the tool. Furthermore, this type of arrangement of the directions of bend is to be preferred for drilling operations in which rotary drilling bits 21 with a small diameter and a low clearance are used.
Otherwise, the embodiment of the tool according to FIG. 5 corresponds largely to that according to FIG. 4; therefore, corresponding reference numbers are used customarily for corresponding structural components. Both bends 29, 32 are located within one casing section 11 which may be molded in the form of one integral section, or casing section 11 may consist of three separated sections with cocked threaded pipe connections.
FIG. 6 illustrates another embodiment of a rotary drilling tool 202 which differs from rotary drilling tool 2 in that instead of bend 29, it has a different bend 33 which is located between the rotary drilling bit 21 and the first stabilization point 22. Like bend 30, this other bend 33 may be structurally designed identically to bends 29, 30 (FIG. 2). Again, both bends 30, 33 are located within casing section 12; however, the first stabilization point 22 is to be found in casing section 11.
FIG. 7 illustrates another alternative embodiment of a rotary drilling tool 302 which is essentially the same as that shown in FIG. 6, with the exception that bend 33 faces into a direction of bend opposite to that of bend 30. Bend 33 has a direction of bend facing away from the arc center, and the lower bend 30 has a direction of bend facing the arc center.
FIG. 8 shows an embodiment of a rotary drilling tool 402 which has only one bend 29, which corresponds to bend 29 of rotary drilling tool 2, between stabilization points 22, 25. As an additional measure, the lower stabilization point 22 is formed by stabilizer 424 which is undersized compared to a stabilizer which, relative to a given rotary drilling bit 21, is designed in standard size. Furthermore, rotary drilling tool 402 as shown in the embodiment of FIG. 8 is fitted with a bit shaft 16 which is seated coaxially in casing section 12.
Another alternative embodiment of rotary drilling tool 502 is depicted in FIG. 9 and is similar to that shown in FIG. 8, with the difference that the lower stabilization point 22 is formed by stabilizer 524 which is eccentrically arranged on casing section 12.
Yet another alternative embodiment of rotary drilling tool 602 is illustrated in FIG. 10. Rotary drilling tool 602 is designed in such a way that the first stabilization point 22 is located on rotary drilling bit 21 and forms an integral part thereof, e.g., by inserting a stabilization component after the cutting element and molding it to the bit. Otherwise, rotary drilling tool 602 has one single bend 29 between the two stabilization points 22, 25; this single bend 29 may correspond in its construction to bend 29 as shown in FIG. 4.
FIG. 11 finally shows another alternative embodiment of a rotary drilling bit 702 in which the upper stabilization point 25 is not formed by a stabilizer of conventional form or shape but by a stabilization region of casing 3 or its casing section 8. At the same time, this stabilizer is undersized compared to the standard stabilizer. In a borderline case, as illustrated, the diameter of this stabilizer may correspond to the diameter of casing 3. As is the case for rotary drilling tool 2 according to FIG. 2, rotary drilling tool 702 has a bend 29 in the region between stabilization points 22, 25 and a bend between rotary drilling bit 21 and the first stabilization point 22 whose structural form may be identical to that of rotary drilling tool 4.
Instead of bends which define a predetermined angle of bend, such as is the case if bit shaft 16 is carried in slanted bearing 17, 18 or if the threaded pipe connections 31 are cocked, it is also possible to provide bends which are formed only in the course of the directional drilling operation. These bends form under stress in special casing sections to which the formation of the bends is restricted due to the fact that these particular sections are provided with a special flexibility.
|
The present invention relates to a method and apparatus for navigational driling in earth formations, the apparatus including a downhole drilling assembly having a drill bit driven by a downhole motor and a deflection element or elements in the assembly for imparting an angle of deflection to the drill bit relative to the drill string above the drilling assembly. At least two stabilization points for the drilling assembly in the borehole are used, with the drill bit, to define an arcuate path for the drilling assembly when the downhole motor is operating but the drill string is not rotating. When the drill string is rotated, the drilling assembly drills a substantially straight or linear borehole.
| 4
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to video processing of compressed video information, and more particularly, to a method and device for regulating the computation load of an MPEG decoder.
[0003] 2. Description of Related Art
[0004] Video information is typically compressed to save storage space and decompressed in a bit stream for a display. Thus, it is highly desirable to quickly and efficiently decode compressed video information in order to provide motion video. One compression standard which has attained widespread use for compressing and decompressing video information is the Moving Pictures Expert Group (MPEG) standard for video encoding and decoding. The MPEG standard is defined in International Standard ISO/IEC 11172-1, “Information Technology—Coding of moving pictures and associated audio for digital storage media at up to about 1.5 Mbit/s”, Parts 1, 2 and 3, First edition Aug. 01, 1993 which is hereby incorporated by reference in its entirety.
[0005] In general, a goal of many video systems is to quickly and efficiently decode compressed video information so as to provide motion video. Currently, computation load of processing a frame is not constrained by the decoding algorithm in the MPEG2 decoding processor. However, due to the irregular computation load behavior of MPEG2 decoding, the peak computation load of a frame may exceed the maximum CPU load of a media processor, thereby causing frame drops or unexpected results. As a consequence, when an engineer implements MPEG2 decoding on a media processor, he or she needs to choose a processor that has a performance margin of 40%-50% above the average decoding computation load in order to have a smooth operation in the event that the peak computation load occurs. This type of implementation is uneconomical and creates a waste of resources as the undesirable peak computation load does not occur that frequently. Hence, without complexity prediction or estimation of frame, slice, or macroblock computational loads, it is impossible for video system engineers to regulate the peak computational demands of some MPEG bit streams.
[0006] Therefore, there is a need to provide complexity prediction algorithms for an MPEG2 decoder implemented on a media processor.
SUMMARY OF THE INVENTION
[0007] The present invention relates to a method and system for improving decoding efficiency of an MPEG digital video decoder system by scaling the decoding of an encoded digital video signal.
[0008] The present invention provides a method of regulating the computation load of an MPEG decoder in a video processing system. The method includes the steps of retrieving the header information of the macroblocks in the compressed video data stream whose motion vectors exhibit a magnitude greater than a predetermined threshold value. The method also includes the step of selectively adjusting the computation load of each functional block of the MPEG decoder according to predetermined criteria. As a consequence, substantial computational overhead is desirably avoided.
[0009] The present invention relates to a programmable video decoding system, which includes: a variable length decoder (VLD) configured to receive and decode a stream of block-based data packets, wherein the VLD being operative to output quantized data from said decoded data packets; a complexity estimator configured to extract the header information from the block-based data packets and further configured to execute a video complexity algorithms based on the extracted header information; an inverse quantizer coupled to receive the output of the VLD to operatively inverse quantize the quantized data received from the VLD; an inverse discrete cosine transformer (IDCT) coupled to the output of the inverse quantizer for transforming the dequantized data from frequency domain to spatial domain; a motion compensator (MC) configured to receive motion vector data from the quantized data and to generate a reference signal; and, an adder for receiving the reference signal and the spatial domain data from the IDCT to form motion compensated pictures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A more complete understanding of the method and apparatus of the present invention may be had by reference to the following detailed description when taken in conjunction with the accompanying drawings wherein:
[0011] [0011]FIG. 1 shows one embodiment of the processor for regulating the computation load in decompressing video information.
[0012] [0012]FIG. 2 is a flowchart depicting the operations steps within the processor of FIG. 1.
[0013] [0013]FIG. 3 is a flow chart illustrating the estimation of computation load of a processor according to the present invention;
[0014] FIGS. 4 ( a )-( c ) illustrate the format of the macroblock-type information;
[0015] [0015]FIG. 5 illustrates a table showing different computation weight assigned to various types of header information according to the present invention; and, FIGS. 6 ( a )-( b ) illustrate an actual simulation of complexity estimation of a video sequence in accordance with the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0016] In the following description, for purposes of explanation rather than limitation, specific details are set forth such as the particular architecture, interfaces, techniques, etc., in order to provide a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced in other embodiments, which depart from these specific details. For the purpose of simplicity and clarity, detailed descriptions of well-known devices, circuits, and methods are omitted so as not to obscure the description of the present invention with unnecessary detail.
[0017] [0017]FIG. 1 illustrates major components of an MPEG video decoder 10 capable of recovering decoded video samples according to an exemplary embodiment of the present invention. It is to be understood that compression of incoming data is performed prior to arriving to the inventive decoder 10 . Compressing video data is well known in the art that can be performed in a variety of ways, i.e., by discarding information to which the human visual system is insensitive in accordance with the standard set forth under the MPEG2 coding process. MPEG2 is a second generation compression standard capable of encoding video programs into a 6 Mbits/sec bit stream and packetizing a number of 6 Mbits/sec channel streams into a single higher rate signal transport stream. Picture elements are converted from spacial information into frequency domain information to be processed.
[0018] There are three types of frames of video information which are defined by the MPEG standard, intra-frames (I frame), forward predicted frames (P frame) and bidirectional-predicted frames (B frame). The I frame, or an actual video reference frame, is periodically coded, e.g., one reference frame for each fifteen frames. A prediction is made of the composition of a video frame, the P frame, to be located a specific number of frames forward and before the next reference frame. The B frame is predicted between the I frame and predicted P frames, or by interpolating (averaging) a macroblock in the past reference frame with a macroblock in the future reference frame. The motion vector is also encoded which specifies the relative position of a macroblock within a reference frame with respect to the macroblock within the current frame.
[0019] Frames are coded using a discrete cosine transform (DCT) coding scheme, which encodes coefficients as an amplitude of a specific cosine basis function. The DCT coefficients are quantized and further coded using variable length encoding. Variable length coding (VLC) 12 is a statistical coding technique that assigns codewords to values to be encoded. Values having a high frequency of occurrence are assigned short codewords, and those having infrequent occurrence are assigned long codewords. On the average, the more frequent shorter codewords dominate so that the code string is shorter than the original data.
[0020] Accordingly, upon receiving the compressed coded frames as described above, the decoder 10 decodes a macroblock of a present P frame by performing motion compensation with a motion vector applied to a corresponding macroblock of a past reference frame. The decoder 10 also decodes a macroblock of a B frame by performing motion compensation with motion vectors applied to respective past and future reference frames. Motion compensation is one of the most computationally intensive operations in many common video decompression methods. When pixels change between video frames, this change is often due to predictable camera or subject motion. Thus, a macroblock of pixels in one frame can be obtained by translating a macroblock of pixels in a previous or subsequent frame. The amount of translation is referred to as the motion vector. As the I frame is encoded as a single image with no reference to any past or future frame, no motion processing is necessary when decoding the I frame.
[0021] Video systems unable to keep up with the computational demands of the above decompression burden frequently drop entire frames. This is sometimes observable as a momentary freeze of the picture in the video playback, followed by sudden discontinuities or jerkiness in the picture. To this end, the embodiments of FIG. 1 provides complexity prediction for reducing the processing requirements associated with decompression methods, while maintaining the quality of the resulting video image.
[0022] Returning now to FIG. 1, the MPEG video decoder 10 according to the present invention for scaling the decoding includes: a variable length decoder (VLC) 12 ; an inverse scan/quantizer circuit 14 ; a scalable switch 15 ; an inverse discrete cosine transform (IDCT) circuit 16 ; an adder 18 ; a frame buffer 20 ; a complexity estimator 22 ; and, a motion compensation module 24 . In operation mode, the decoder 10 receives a stream of compressed video information, which is provided to the VLC decoder 12 . The VLC decoder 12 decodes the variable length coded portion of the compressed signal to provide a variable length decoded signal to the inverse scan (or zig-zag)/quantizer circuit 14 , which decodes the variable length decoded signal to provide a zig-zag decoded signal. The inverse zig-zag and quantization compensates for the fact that while a compressed video signal is compressed in a zig-zag run-length code fashion. The zig-zag decoded signal is provided to the inverse DCT circuit 16 as sequential blocks of information. This zig-zag decoded signal is then provided to the IDCT circuit 16 , which performs an inverse discrete cosine transform on the zig-zag decoded video signal on a block by block basis to provide decompressed pixel values or decompressed error terms. The decompressed pixel values are provided to adder 18 .
[0023] Meanwhile, the motion compensation module 24 receives motion information and provides motion-compensated pixels to adder 18 on a macroblock by macroblock basis. More specifically, forward motion vectors are used to translate pixels in previous picture and backward motion vectors are used to translate pixels in future picture. Then, this information is compensated by the decompressed error term provided by the inverse DCT circuit 16 . Here, the motion compensation circuit 24 accesses the previous picture information and future picture information from the frame buffer 20 . The previous picture information is then forward motion compensated by the motion compensation circuit 24 to provide a forward motion-compensated pixel macroblock. The future picture information is backward motion compensated by the motion compensation circuit 24 to provide a backward motion-compensated pixel macroblock. The averaging of these two macroblocks yields a bidirectional motion compensated macroblock. Next, the adder 18 receives the decompressed video information and the motion-compensated pixels until a frame is completed and provides decompressed pixels to buffer 20 . If the block does not belong to a predicted macroblock (for example, in the case of an I macroblock), then these pixel values are provided unchanged to frame buffer 20 . However, for the predicted macroblocks (for example, B macroblocks and P macroblocks), the adder 18 adds the decompressed error to the forward motion compensation and backward motion compensation outputs from the motion compensation circuit 24 to generate the pixel values which are provided to frame buffer 20 .
[0024] It should be noted that the construction and operation of the embodiment, as described in the preceding paragraphs, are well known in the art, except that the inventive decoder 10 further includes a complexity estimator 22 . The complexity estimator 22 provided in the decoder 10 according to the present invention is capable of providing an estimation of frame, slice, or macroblock computational loads within the decoder 10 . Hence, the function of the complexity estimator 22 is to predict the computation load current frame, slice, or macroblock before actually executing MPEG2 decoding blocks (except the VLD operation). With this type of prediction, the present invention allows to design a complexity control mechanism to guarantee a smooth operation of a multimedia system implemented on a media processor. That is, the inventive decoder provides scalability by allowing trade-off between the usage of available computer resources; namely, the IDCT 16 and the MC24.
[0025] [0025]FIG. 2 illustrates the basic operation steps that enable to estimate and to adjust the computation load of the IDCT 16 and the MC24. To accomplish this, the present invention utilizes macroblock-type information to predict the computational overhead that may occur and to adaptively control the computing complexity of the IDCT 16 and/or the MC 24, so that a lesser computational burden is presented to the decoder 10 . The complexity measurement is defined by the total number of machine cycles to run the software on a specific coprocessor. Accordingly, in block 30 , the header information of macroblock is retrieved from the incoming signals received by the decoder 10 . In block 40 , the retrieved header information is analyzed to estimate the required computation load of the IDCT 16 and/or the MC24. In general, depending on the type of information being processed, the components of the decoder 10 is burdened by several tasks. At times when the process is performing fewer tasks and is less burdened, the computation load of the decoder will be reduced in the present invention by scaling the computation load of the IDCT 16 and/or the MC 24.
[0026] Now, the provision of estimating the computation load to support dynamic prediction and scaling the decoding process according to the present invention will be explained in detailed description. The following flow chart of FIG. 3 shows the operation of a software embodiment of complexity estimator. This flow chart is generally applicable to a hardware embodiment as well.
[0027] As seen in FIG. 3, a stream of compressed video information is received by the inventive decoder 12 in step 100 . In step 110 , the header information of current macroblock is retrieved prior to executing the MPEG2 decoding operation. The format of macroblock-type information is shown in FIGS. 4 ( a )-( c ). Upon receiving the header information, the complexity estimator 22 makes a determination of the performance capabilities of the decoder 12 in step 120 . That is to say, the complexity estimator 22 a determines different grades of performance for the IDCT 16 and the MC 24 based on the header information and the available computing resources of the decoder 10 . To this end, four different parameters out of the VLD header are extracted in order to estimate the complexity. These four parameters are analyzed independently to assign varying computation weight as explained below.
[0028] In step 130 , a different computation weight (C type ) is assigned to the inverse DCT 16 depending on the type of macroblock received by the decoder 10 . Referring to FIG. 4, if macroblock_type=intra, the corresponding computation weight is assigned to zero as the intra coded macroblock only requires the computation by the IDCT 16 , and not through the macroblock_type. If the current macroblock is not motion compensated but coded, the corresponding computation weight is W as the computation load involving looking up previous blocks and copying them to current blocks requires less computation than the motion compensated scenario. If the current macroblock is motion compensated but not coded, the corresponding computation weight is 2 W. If the current macroblock is interpolate motion compensated and coded, the corresponding weight is 3 W as the computation load is higher than any other type due to the requirement of retrieving forward vector(s) and backward vector(s).
[0029] In step 140 , the motion vector magnitude derived from the header information is compared to a pre-set threshold value to determine whether different grades (C mv ) of performance for the IDCT 16 and MC 24 are required. In another word, for a large motion vector, the memory access and write time from the previous block to the current block is longer than that of a short motion vector. Hence, if the motion vector magnitude is greater than a threshold value, the computation load corresponds to W 1 , otherwise, assigned to zero. As a consequence, significant computational resources can be saved by providing relative IDCT 16 or MC24 performance for macroblocks with motion vectors whose magnitude exceeds a predetermined threshold level, by scaling the CPU load of IDCT 16 and/or the MC 24 while maintaining optimal performance.
[0030] In step 150 , the motion vector count retrieved from the header information is examined to determine whether different grades (C mvc ) of performance for the IDCT 16 and the MC 24 are required. Here, a different computation weight is assigned as the two-vector MC requires decoding algorithm to access two different memory areas, instead of one for the one-vector MC. That is, if the motion vector is a field-type vector, the estimated complexity is higher than that of a frame-type vector since the field-type vector count is two instead of one of that of the frame-type vector. Hence, the computation weight, W 2 , is increased proportionally according to the count number detected in the header information.
[0031] In step 160 , the number of non-zero DCT coefficients or block number of the coded block pattern (CBP) from the header information are examined to determine whether different grades (C BN /C CBP ) of performance for the IDCT 16 and the MC 24 are required. That is, depending on the sparseness of DCT coefficients, the inventive MPEG decoder is able to tailor the IDCT computation load to a minimum. Thus, the computation load, W 3 , is computed based on the number of non-zero DCT coefficients detected from the header information. Alternatively, the computation load, W 4 , which is proportional to the CBP count may be utilized. The CBP count indicates how many blocks are being coded.
[0032] After retrieving those parameters from the stream and assigning them with a proper weight, it is now possible to accurately estimate the computational requirement of macroblock decoding. In step 170 , the result of computation weight factors are aggregated, and an average minimum computation load (C base ) is added in step 170 . Then, the complexity estimator 22 increase/reduce the IDCT computation and/or the motion compensation burdens based on the estimation load (C est ). Depending on the level of performance prediction detected from the macroblock header in step 180 , the computation load of either the IDCT circuit 16 or the motion compensation circuit 24 is set to a relatively high level if the performance of processor is presently gauged to be relatively high, and conversely, the computation load is set to a relatively low level if the performance of the processor is gauged to be relatively low. That is, if the computation load estimated in step 180 based on the accumulated weight factors corresponds to 120 mega cycles per second and the available processing capability of the decoder 10 is limited to 100 mega cycles per second, the ration between these two values (i.e., 100/120=80%) is used as the scale factor for the IDCT 16 computation and/or the MC24 computation. Thus, for example, only 80% of the CPU load of IDCT 16 can be dedicated to process the incoming data of the decoder 10 . In this way, both the IDCT 16 and/or the MC 24 can be selectively adjusted to scale down the computation load to avoid frame drop or unexpected results associated with exceeding the maximum CPU load of the decoder 10 . It is noted that the amount of scaling the CPU loads of the components of the decoder 10 can be varied according to the predetermined criteria (or weight factor) set by an operator and the available process capabilities of the decoder.
[0033] As described above, the computation load can vary dynamically with changes in current system performance which occur as the system becomes loaded with tasks and then relieved of such tasks. Furthermore, it is noted that at the slice or frame level, one just needs to add macroblocks computation estimation together. Hence, the same computation or motion compensation can be achieved at the frame or slice level, by calculating an overall scale factor of the computation estimates of macroblock_type information within a frame or a slice.
[0034] The result of complexity estimation of a video sequence (Molens.cod bitstream) is illustrated in FIGS. 6 ( a ) and ( b ). As shown in both figures, the top graph represents the performance of actual TriMedia (Philips™) MPEG2 decoder and the bottom graph represents the estimation load according to the present invention. FIG. 6( a ) represents a comparison between actual CPU cycles of decoding the Molens sequence on a TriMedia 1300 and the inventive estimated CPU cycles, where as FIG. 6( b ) represents a comparison between the CPU cycles of non-DCC (dynamic complexity control) MPEG2 decoding of the Molens sequence and that of inventive DCC (dynamic complexity control) decoding. The result shows a correlation factor of about 0.97 between them.
[0035] The foregoing has disclosed a method of adaptively performing IDCT computation or motion compensation in a video decoder. The disclosed method advantageously reduces the processing requirements associated with decompression methodology. Accordingly, decompression efficiency is increased while not overly degrading the ultimate video image. Furthermore, while the preferred embodiments of the present invention have been illustrated and described, it will be understood by those skilled in the art that various changes and modifications may be made, and equivalents may be substituted for elements thereof without departing from the true scope of the present invention. Therefore, it is intended that the present invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out the present invention, but that the present invention includes all embodiments falling within the scope of the appended claims.
|
A method and system of regulating the computation load of an MPEG decoder in a video processing system are provided. The video processing system processes the header information of a compressed video data stream including a plurality of macroblocks with a motion vector associated therewith. Then, the computation load of each functional block of the MPEG decoder is adjusted according to predetermined criteria; thus, substantial computational overhead is desirably avoided.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No. 11/517,859, entitled “Electronics Package Suitable for Implantation”, filed Sep. 7, 2006, which claims benefit of U.S. Provisional Application No. 60/778,833, filed Mar. 3, 2006, entitled “Biocompatible Bonding Method and Electronics Package Suitable for Implantation,” and which is a continuation in part of U.S. patent application Ser. No. 10/236,396, filed Sep. 6, 2002, entitled “Biocompatible Bonding Method and Electronics Package Suitable for Implantation” which is a continuation-in-part of U.S. patent application Ser. No. 10/174,349, filed on Jun. 17, 2002, entitled “Biocompatible Bonding Method and Electronics Package Suitable for Implantation,” and which claims benefit of U.S. Provisional Application No. 60/372,062, filed on Apr. 11, 2002, entitled “Platinum Deposition for Electrodes,” the disclosures of all are incorporated herein by reference.
FEDERALLY SPONSORED RESEARCH
[0002] This invention was made with government support under grant No. R24EY12893-01, awarded by the National Institutes of Health. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] This invention relates to an electrode array or flexible circuit, electronics package and a method of bonding a flexible circuit or electrode array to an integrated circuit or electronics package.
BACKGROUND OF THE INVENTION
[0004] Arrays of electrodes for neural stimulation are commonly used for a variety of purposes. Some examples include U.S. Pat. No. 3,699,970 to Brindley, which describes an array of cortical electrodes for visual stimulation. Each electrode is attached to a separate inductive coil for signal and power. U.S. Pat. No. 4,573,481 to Bullara describes a helical electrode to be wrapped around an individual nerve fiber. U.S. Pat. No. 4,837,049 to Byers describes spike electrodes for neural stimulation. Each spike electrode pierces neural tissue for better electrical contact. U.S. Pat. No. 5,215,088 to Norman describes an array of spike electrodes for cortical stimulation. U.S. Pat. No. 5,109,844 to de Juan describes a flat electrode array placed against the retina for visual stimulation. U.S. Pat. No. 5,935,155 to Humayun describes a retinal prosthesis for use with a flat retinal array.
[0005] Packaging of a biomedical device intended for implantation in the eye, and more specifically for physical contact with the retina, presents a unique interconnection challenge. The consistency of the retina is comparable to that of wet tissue paper and the biological media inside the eye is a corrosive saline liquid environment.
[0006] Thus, the device to be placed against the retina, in addition to being comprised of biocompatible, electrochemically stable materials, must appropriately conform to the curvature of the eye, being sufficiently flexible and gentle in contact with the retina to avoid tissue damage, as discussed by Schneider, et al. It is also desirable that this device, an electrode array, provides a maximum density of stimulation electrodes. A commonly accepted design for an electrode array is a very thin, flexible conductor cable. It is possible to fabricate a suitable electrode array using discrete wires, but with this approach, a high number of stimulation electrodes cannot be achieved without sacrificing cable flexibility (to a maximum of about 16 electrodes).
[0007] A lithographically fabricated thin film flex circuit electrode array overcomes such limitations. A thin film flex circuit electrode array can be made as thin as 10 um (<0.0005 inches) while accommodating about 60 electrodes in a single circuit routing layer. The flex circuit electrode array is essentially a passive conductor ribbon that is an array of electrode pads, on one end, that contact the retina and on the other end an array of bond pads that must individually mate electrically and mechanically to the electrical contacts of a hermetically sealed electronics package. These contacts may emerge on the outside of the hermetic package as an array of protruding pins or as vias flush to a package surface. A suitable interconnection method must not only serve as the interface between the two components, also provide electrical insulation between neighboring pathways and mechanical fastening between the two components.
[0008] Many methods exist in the electronics industry for attaching an integrated circuit to a flexible circuit. Commonly used methods include wire-bonding, anisotropic-conductive films, and “flip-chip” bumping. However, none of these methods results in a biocompatible connection. Common materials used in these connections are tin-lead solder, indium and gold. Each of these materials has limitations on its use as an implant. Lead is a known neurotoxin. Indium corrodes when placed in a saline environment. Gold, although relatively inert and biocompatible, migrates in a saline solution, when electric current is passed through it, resulting in unreliable connections.
[0009] In many implantable devices, the package contacts are feedthrough pins to which discrete wires are welded and subsequently encapsulated with polymer materials. Such is the case in heart pacemaker and cochlear implant devices. Flexible circuits are not commonly used, if at all, as external components of proven implant designs. The inventor is unaware of prior art describing the welding of contacts to flex circuits.
[0010] Attachment by gold ball bumping has been demonstrated by the Fraunhofer group (Hansjoerg Beutel, Thomas Stieglitz, Joerg Uwe Meyer, “Versatile ‘Microflex’-Based Interconnection Technique,” Proc. SPIE Conf on Smart Electronics and MEMS, San Diego, Calf., March 1998, vol. 3328, pp 174-82.) to rivet a flex circuit onto an integrated circuit. A robust bond can be achieved in this way. However, encapsulation proves difficult to effectively implement with this method. Because the gap between the chip and the flex circuit is not uniform, underfill with epoxy is not practical. Thus, electrical insulation cannot be achieved with conventional underfill technology. Further, as briefly discussed earlier, gold, while biocompatible, is not completely stable under the conditions present in an implant device since it “dissolves” by electromigration when implanted in living tissue and subject to an electric current (see M. Pourbaix, Atlas of Electrochemical Equilibria in Aqueous Solutions, National Association of Corrosion Engineers, Houston, 1974, pp 399-405.).
[0011] Widespread use of flexible circuits can be found in high volume consumer electronics and automotive applications, such as stereos. These applications are not constrained by a biological environment. Component assembly onto flex circuits is commonly achieved by solder attachment. These flex circuits are also much more robust and bulkier than a typical implantable device. The standard flex circuit on the market is no less than 0.002 inches in total thickness. The trace metallization is etched copper foil, rather than thin film metal. Chip-scale package (CSP) assembly onto these flex circuits is done in ball-grid array (BGA) format, which uses solder balls attached to input-output contacts on the package base as the interconnect structures. The CSP is aligned to a corresponding metal pad array on the flex circuit and subjected to a solder reflow to create the interconnection. A metallurgical interconnect is achieved by solder wetting. The CSP assembly is then underfilled with an epoxy material to insulate the solder bumps and to provide a pre-load force from the shrinkage of the epoxy.
[0012] Direct chip attach methods are referred to as chip-on-flex (COF) and chip-on-board (COB). There have been some assemblies that utilize gold wirebonding to interconnect bare, integrated circuits to flexible circuits. The flipchip process is becoming a reliable interconnect method. Flipchip technology originates from IBM's Controlled Collapse Chip Connection (C4) process, which evolved to solder reflow technique. Flipchip enables minimization of the package footprint, saving valuable space on the circuit, since it does not require a fan out of wirebonds. While there are a variety of flipchip configurations available, solder ball attach is the most common method of forming an interconnect. A less developed approach to flipchip bonding is the use of conductive adhesive, such as epoxy or polyimide, bumps to replace solder balls. These bumps are typically silver-filled epoxy or polyimide, although electrically conductive particulate of select biocompatible metal, such as platinum, iridium, titanium, platinum alloys, iridium alloys, or titanium alloys in dust, flake, or powder form, may alternatively be used. This method does not achieve a metallurgical bond, but relies on adhesion. Polymer bump flip chip also requires underfill encapsulation. Conceivably, polymer bump attachment could be used on a chip scale package as well. COB flipchip attach can also be achieved by using gold stud bumps, as an alternative to solder balls. The gold bumps of the chip are bonded to gold contacts on the hard substrate by heat and pressure. A recent development in chip-to-package attachment was introduced by Intel Corporation as Bumpless Build Up Layer (BBUL) technology. In this approach, the package is grown (built up) around the die rather than assembling the die into a pre-made package. BBUL presents numerous advantages in reliability and performance over flipchip.
[0013] Known technologies for achieving a bond between a flexible circuit and an electronics package suffer from biocompatibility issues. Novel applications of a biomedical implant that utilize a flexible circuit attached to a rigid electronics package require excellent biocompatibility coupled with long term mechanical attachment stability, to assure long lived reliable electrical interconnection.
[0014] Known deposition techniques for a bond, such as an electrically conductive metal bond or “rivet” are limited to thin layers. Plating is one such known method that does not result in an acceptable bond. It is not known how to plate shiny platinum in layers greater than approximately 1 to 5 microns because the dense platinum layer peels off, probably due to internal stresses. Black platinum lacks the strength to be a good mechanical attachment, and also lack good electrical conductivity.
[0015] Known techniques for bonding an electronic package to a flex circuit do not result in a hermetic package that is suitable for implantation in living tissue. Therefore, it is desired to have a method of attaching a substrate to a flexible circuit that ensures that the bonded electronic package and flex circuit will function for long-term implant applications in living tissue.
SUMMARY OF THE INVENTION
[0016] An implantable electronic device comprising a hermetic electronics control unit that is typically mounted on a substrate that is bonded to a flexible circuit by an electroplated platinum or gold rivet-shaped connection. The resulting electronics assembly is biocompatible and long-lived when implanted in living tissue, such as in an eye or ear.
[0017] The novel features of the invention are set forth with particularity in the appended claims. The invention will be best understood from the following description when read in conjunction with the accompanying drawings.
OBJECTS OF THE INVENTION
[0018] It is an object of the invention to provide a hermetic, biocompatible electronics package that is attached to a flexible circuit.
[0019] It is an object of the invention to attach a hermetically sealed electronics package to a flexible circuit for implantation in living tissue.
[0020] It is an object of the invention to attach a hermetically sealed electronics package to a flexible circuit for implantation in living tissue to transmit electrical signals to living tissue, such as the retina.
[0021] It is an object of the invention to provide a hermetic, biocompatible electronics package that is attached directly to a substrate.
[0022] It is an object of the invention to provide a method of bonding a flexible circuit to a substrate with an electroplated rivet-shaped connection.
[0023] It is an object of the invention to provide a method of plating platinum as a rivet-shaped connection.
[0024] Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 illustrates a perspective cutaway view of an eye containing a flexible circuit electrode array.
[0026] FIG. 2 is a side view of an electronics package.
[0027] FIG. 3 illustrates a cutaway side view of an electronics package.
[0028] FIG. 4 is a top view of a flex circuit without the electronics package.
[0029] FIG. 5 presents a side view of a flex circuit with the electronics package.
[0030] FIG. 6A - FIG. 6E is a series of illustrations showing the steps of bonding of the hybrid substrate to the flexible circuit with adhesive underfill.
[0031] FIG. 7A - FIG. 7E is a series of illustrations showing the steps of bonding the hybrid substrate to the flexible circuit with adhesive underfill.
[0032] FIG. 8A - FIG. 8F is a series of illustrations showing the steps of bonding the hybrid substrate to flexible circuit by weld staple bonding.
[0033] FIG. 9A - FIG. 9D is a series of illustrations showing the steps of bonding the hybrid substrate to flexible circuit.
[0034] FIG. 10A - FIG. 10L is a series of illustrations showing the steps of electrically and adhesively bonding the flexible circuit to a hermettic rigid electronics package.
[0035] FIG. 11 is a side view of a flexible circuit bonded to a rigid array.
[0036] FIG. 12 is a side view of an electronics control unit bonded to an array.
[0037] FIG. 13A - FIG. 13C is a series of illustrations showing the steps of bonding the hybrid substrate with rivets to flexible circuit.
[0038] FIG. 14 is an electroplating equipment schema.
[0039] FIG. 15 is a three-electrode electroplating cell schema.
[0040] FIG. 16 is a plot of showing the plating current density decrease with hole size.
[0041] FIG. 17 a is a scanning electron micrograph of a polyimide surface before plating magnified 850 times.
[0042] FIG. 17 b is a scanning electron micrograph of electrochemically deposited rivets magnified 850 times.
[0043] FIG. 18A - FIG. 18E is a series of illustrations showing the steps of bonding of the hybrid substrate to the flexible circuit with adhesive underfill.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] The following description is the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
[0045] The present invention provides a flexible circuit electronics package and a method of bonding a flexible circuit to a hermetic integrated circuit which is useful for a number of applications, including implantation in living tissue as a neural interface, such as a retinal electrode array or an electrical sensor. The tissue paper thin flexible circuit 18 , FIG. 1 , transmits electrical signals to the eye 2 by means of electrodes that are located in a stimulating electrode array 10 , that are in contact with the retina 14 . It is obvious that in addition to a stimulating electrode array or sensing electrode, the electrodes may be contacts connecting to remote electrodes. FIG. 1 illustrates the electronics control unit 20 in a perspective cutaway view of an eye 2 containing a flexible circuit electrode array 18 . The electronics control unit 20 is hermetically sealed. The electronics control unit 20 may be a hermetic ceramic case with electronics inside, or it may be a hermetically sealed integrated circuit, or any other environmentally sealed electronics package. The stimulating electrode array 10 is implanted on the retina 14 . Flexible circuit ribbon 24 connects the stimulating electrode array 10 to the electronics control unit 20 .
[0046] The flexible circuit ribbon 24 preferably passes through the sclera 16 of the eye 2 at incision 12 . Another embodiment of the invention is the flexible circuit ribbon 24 replaced by alternative means of electrical interconnection, such as fine wires or thin cable. The lens 4 of the eye 2 is located opposite the retina 14 . A coil 28 , which detects electronic signals such as of images or to charge the electronics control unit 20 power supply, located outside the eye 2 , near the lens 4 , is connected to the electronics control unit 20 by wire 30 .
[0047] FIG. 2 illustrates a side view of the hermetic electronics control unit 20 and the input/output contacts 22 that are located on the bottom of the unit 20 . The input/output contacts 22 are bonded in the completed assembly to the flexible circuit 18 . Thick film pad 23 is formed by known thick film technology, such as silk screening or plating.
[0048] FIG. 3 illustrates a cutaway side view of the hermetic electronics control unit 20 . The pad 23 facilitates attachment of wire 30 , and is preferably comprised of a biocompatible material such as platinum, iridium, or alloys thereof, and is preferably comprised of platinum paste. Wire 30 is preferably bonded to pad 23 by welding. The microelectronics assembly 48 is mounted on the hybrid substrate 44 . Vias 46 pass through the substrate 44 to input/output contacts 22 . Electrical signals arrive by wire 30 and exit the electronics control unit 20 by input/output contacts 22 .
[0049] A top view of the flexible circuit 18 is illustrated in FIG. 4 . Electrical signals from the electronics control unit 20 (see FIG. 3 ) pass into bond pads 32 , which are mounted in bond pad end 33 . Flexible electrically insulating substrate 38 is preferably comprised of polyimide. The signals pass from the bond pads 32 along traces 34 , which pass along flexible circuit ribbon 24 to the stimulating electrode array 10 . The array 10 contains the electrodes 36 , which are implanted to make electrical contact with the retina 14 of the eye 2 , illustrated in FIG. 1 . An alternative bed of nails embodiment for the electrodes 36 is disclosed by Byers, et al. in U.S. Pat. No. 4,837,049.
[0050] In FIG. 5 , the hermetic electronics control unit 20 is illustrated mounted to flexible circuit 18 . In order to assure electrical continuity between the electronics control unit 20 and the flexible circuit 18 , the electrical control unit 20 must be intimately bonded to the flexible circuit 18 on the bond pad end 33 . A cutaway of the electronics control unit 20 ( FIG. 5 ) illustrates a bonded connection 42 . The flexible electrically insulating substrate 38 is very thin and flexible and is able to conform to the curvature of the retina 14 ( FIG. 1 ), when implanted thereon.
[0051] Methods of bonding the flexible insulating substrate 18 to the hermetic electronics control unit 20 are discussed next.
[0000] Platinum Conductor in Polymer Adhesive
[0052] A preferred embodiment of the invention, illustrated in FIG. 6 , shows the method of bonding the hybrid substrate 244 to the flexible circuit 218 using electrically conductive adhesive 281 , such as a polymer, which may include polystyrene, epoxy, or polyimide, which contains electrically conductive particulate of select biocompatible metal, such as platinum, iridium, titanium, platinum alloys, iridium alloys, or titanium alloys in dust, flake, or powder form.
[0053] In FIG. 6 , step a, the hybrid substrate 244 , which may alternatively be an integrated circuit or electronic array, and the input/output contacts 222 are prepared for bonding by placing conductive adhesive 281 on the input/output contacts 222 . The rigid integrated circuit 244 is preferably comprised of a ceramic, such as alumina or silicon. In step b, the flexible circuit 218 is preferably prepared for bonding to the hybrid substrate 244 by placing conductive adhesive 281 on bond pads 232 . Alternatively, the adhesive 281 may be coated with an electrically conductive biocompatible metal. The flexible circuit 218 contains the flexible electrically insulating substrate 238 , which is preferably comprised of polyimide. The bond pads 232 are preferably comprised of an electrically conductive material that is biocompatible when implanted in living tissue, and are preferably platinum or a platinum alloy, such as platinum-iridium.
[0054] FIG. 6 , step c illustrates the cross-sectional view A-A of step b. The conductive adhesive 281 is shown in contact with and resting on the bond pads 232 . Step d shows the hybrid substrate 244 in position to be bonded to the flexible circuit 218 . The conductive adhesive 281 provides an electrical path between the input/output contacts 222 and the bond pads 232 . Step c illustrates the completed bonded assembly wherein the flexible circuit 218 is bonded to the hybrid substrate 144 , thereby providing a path for electrical signals to pass to the living tissue from the electronics control unit (not illustrated). The assembly has been electrically isolated and hermetically sealed with adhesive underfill 280 , which is preferably epoxy. Studbump Bonding.
[0055] FIG. 7 illustrates the steps of an alternative embodiment to bond the hybrid substrate 244 to flexible circuit 218 by studbumping the hybrid substrate 244 and flexible electrically insulating substrate 238 prior to bonding the two components together by a combination of heat and/or such as ultrasonic energy. In step a, the hybrid substrate 244 is prepared for bonding by forming a studbump 260 on the input/output contacts 222 . The studbump is formed by known methods and is preferably comprised of an electrically conductive material that is biocompatible when implanted in living tissue if exposed to a saline environment. It is preferably comprised of metal, preferably biocompatible metal, or gold or of gold alloys. If gold is selected, then it must be protected with a water resistant adhesive or underfill 280 .
[0056] Alternatively, the studbump 260 may be comprised of an insulating material, such as an adhesive or a polymer, which is coated with an electrically conductive coating of a material that is biocompatible and stable when implanted in living tissue, while an electric current is passed through the studbump 260 . One such material coating may preferably be platinum or alloys of platinum, such as platinum-iridium, where the coating may be deposited by vapor deposition, such as by ion-beam assisted deposition, or electrochemical means.
[0057] FIG. 7 , step b presents the flexible circuit 218 , which comprises the flexible electrically insulating substrate 238 and bond pads 232 . The flexible circuit 218 is prepared for bonding by the plating bond pads 232 with an electrically conductive material that is biocompatible when implanted in living tissue, such as with a coating of platinum or a platinum alloy. Studbumps 260 are then formed on the plated pad 270 by known methods. Step c illustrates cross-section A-A of step b, wherein the flexible circuit 218 is ready to be mated with the hybrid substrate 244 .
[0058] FIG. 7 , step d illustrates the assembly of hybrid substrate 244 flipped and ready to be bonded to flexible circuit 218 . Prior to bonding, the studbumps 260 on either side may be flattened by known techniques such as coining. Pressure is applied to urge the mated studbumps 260 together as heat is applied to cause the studbumps to bond by a diffusion or a melting process. The bond may preferably be achieved by thermosonic or thermocompression bonding, yielding a strong, electrically conductive bonded connection 242 , as illustrated in step e. An example of a thermosonic bonding method is ultrasound. The bonded assembly is completed by placing an adhesive underfill 280 between the flexible circuit 218 and the hybrid substrate 244 , also incrcasing the strength of the bonded assembly and electrically isolating each bonded connection. The adhesive underfill 280 is preferably epoxy.
[0000] Weld Staple Interconnect
[0059] FIG. 8 illustrates the steps of a further alternative embodiment to bond the hybrid substrate 44 to flexible circuit 18 by weld staple bonding the substrate 244 and flexible electrically insulating substrate 38 together. In step a, a top view of the flexible circuit 18 is shown. Flexible circuit 18 is comprised of flexible electrically insulating substrate 38 , which is preferably polyimide, and bond pads 32 having a through hole 58 therethrough each bond pad 32 and through the top and bottom surfaces of flexible circuit 18 . The bond pads 32 are comprised of an electrically conductive and biocompatible material which is stable when implanted in living tissue, and which is preferably platinum or a platinum alloy, such as platinum-iridium.
[0060] FIG. 8 , step b presents section A-A, which is shown in the illustration of step a. The through holes 58 pass completely through each bond pad 58 , preferably in the center of the bond pad 58 . They are preferably formed by plasma etching. The bond pads 58 are not covered on the top surface of flexible circuit 18 by flexible electrically insulating substrate 38 , thereby creating bond pad voids 56 .
[0061] FIG. 8 , step c shows the side view of hybrid substrate 44 with input/output contacts 22 on one surface thereof. The hybrid substrate 44 is positioned, in step d; to be bonded to the flexible circuit 18 by placing the parts together such that the input/output contacts 22 are aligned with the bond pads 32 . Then wire 52 , which is preferably a wire, but may equally well be a ribbon or sheet of weldable material that is also preferably electrically conductive and biocompatible when implanted in living tissue, is attached to input/output contact 22 and bond pad 32 to bond each aligned pair together. The wire 52 is preferably comprised of platinum, or alloys of platinum, such as platinum-iridium. The bond is preferably formed by welding using the parallel gap welder 50 , which moves up and down to force the wire 52 into the through hole 58 and into contact with input/output contact 22 . This process is repeated for each aligned set of input/output contacts 22 and bond pads 32 , as shown in step e.
[0062] The weld staple interconnect bonding process is completed, as shown in step f, by cutting the wire 54 , leaving each aligned set of input/output contacts 22 and bond pads 32 electrically connected and mechanically bonded together by staple 54 .
[0000] Tail-Latch Interconnect
[0063] FIG. 9 illustrates yet another embodiment for attaching the hybrid substrate 244 to a flexible circuit 218 by using a tail-ball 282 component, as shown in step a. The hybrid substrate 244 is preferably comprised of a ceramic material, such as alumina or silicon. In one embodiment, a wire, preferably made of platinum or another electrically conductive, biocompatible material, is fabricated to have a ball on one end, like the preferred tail-ball 282 illustrated in step a. The tail-ball 282 has tail 284 attached thereto, as shown in the side view of step a. The tail-ball 282 is aligned with input/output contact 222 on hybrid substrate 244 , in preparation to being bonded to flexible circuit 218 , illustrated in step b.
[0064] The top view of step b illustrates flexible electrically insulating substrate 238 , which is preferably comprised of polyimide, having the through hole 237 passing completely thorough the thickness and aligned with the tail 284 . The bond pads 232 are exposed on both the top and bottom surfaces of the flexible circuit 218 , by voids 234 , enabling electrical contact to be made with input/output contacts 222 of the hybrid substrate 244 . The voids are preferably formed by plasma etching.
[0065] The side view of FIG. 9 , step c, which illustrates section A-A of step b, shows the hybrid substrate 244 in position to be bonded to and aligned with flexible circuit 218 . The tails 284 are each placed in through hole 237 . Pressure is applied and the tail-balls 282 are placed in intimate contact with bond pads 232 and input/output contacts 222 . Step c illustrates that each of the tails 284 is bent to make contact with the bond pads 232 . The bonding process is completed by bonding, preferably by welding, each of the tails 284 , bond pads 232 , tail-balls 282 , and input/output contacts 222 together, thus forming a mechanical and electrical bond. Locking wire 262 is an optional addition to assure that physical contact is achieved in the bonded component. The process is completed by underfilling the gap with an electrically insulating and biocompatible material (not illustrated), such as epoxy.
[0000] Integrated Interconnect by Vapor Deposition
[0066] FIG. 10 illustrates a further alternative embodiment to creating a flexible circuit that is electrically and adhesively bonded to a hermetic rigid electronics package. In this approach, the flexible circuit is fabricated directly on the rigid substrate. Step a shows the hybrid substrate 44 , which is preferably a ceramic, such as alumina or silicon, having a total thickness of about 0.012 inches, with patterned vias 46 therethrough. The vias 46 are preferably comprised of frit containing platinum.
[0067] In step b, the routing 35 is patterned on one side of the hybrid substrate 44 by known techniques, such as photolithography or masked deposition. It is equally possible to form routing 35 on both sides of the substrate 44 . The hybrid substrate 44 has an inside surface 45 and an outside surface 49 . The routing 35 will carry electrical signals from the integrated circuit, that is to be added, to the vias 46 , and ultimately will stimulate the retina (not illustrated). The routing 35 is patterned by know processes, such as by masking during deposition or by post-deposition photolithography. The routing 35 is comprised of a biocompatible, electrically conductive, patternable material, such at platinum.
[0068] Step c illustrates formation of the release coat 47 on the outside surface 49 of the hybrid substrate 44 . The release coat 47 is deposited by known techniques, such as physical vapor deposition. The release coat 47 is removable by know processes such as etching. It is preferably comprised of an etchable material, such as aluminum.
[0069] Step d illustrates the formation of the traces 34 on the outside surface 49 of the hybrid substrate 44 . The traces 34 are deposited by a known process, such as physical vapor deposition or ion-beam assisted deposition. They may be patterned by a known process, such as by masking during deposition or by post-deposition photolithography. The traces 34 are comprised of an electrically conductive, biocompatible material, such as platinum, platinum alloys, such as platinum-iridium, or titanium-platinum. The traces 34 conduct electrical signals along the flexible circuit 18 and to the stimulating electrode array 10 , which were previously discussed and are illustrated in FIG. 4 .
[0070] Step e illustrates formation of the flexible electrically insulating substrate 38 by known techniques, preferably liquid precursor spinning. The flexible electrically insulating substrate 38 is preferably comprised of polyimide. The flexible electrically insulating substrate electrically insulates the traces 34 . It is also biocompatible when implanted in living tissue. The coating is about 5 um thick. The liquid precursor is spun coated over the traces 34 and the entire outside surface 49 of the hybrid substrate 44 , thereby forming the flexible electrically insulating substrate 38 . The spun coating is cured by known techniques.
[0071] Step f illustrates the formation of voids in the flexible electrically insulating substrate 38 thereby revealing the traces 34 . The flexible electrically insulating substrate is preferably patterned by known techniques, such as photolithography with etching.
[0072] Step g illustrates the rivets 51 having been formed over and in intimate contact with traces 34 . The rivets 51 are formed by known processes, and are preferably formed by electrochemical deposition of a biocompatible, electrically conductive material, such as platinum or platinum alloys, such as platinum-iridium.
[0073] Step h illustrates formation of the metal layer 53 over the rivets 51 in a controlled pattern, preferably by photolithographic methods, on the outside surface 49 . The rivets 51 and the metal layer 53 are in intimate electrical contact. The metal layer 53 may be deposited by known techniques, such as physical vapor deposition, over the entire surface followed by photolithographic patterning, or it may be deposited by masked deposition. The metal layer 53 is formed of an electrically conductive, biocompatible material, which in a preferred embodiment is platinum. The patterned metal layer 53 forms traces 34 and electrodes 36 , which conduct electrical signals from the electronics control unit 20 and the electrodes 36 (see FIGS. 4 and 5 ).
[0074] Step i illustrates the flexible electrically insulating substrate 38 applied over the outside surface 49 of the rigid substrate 44 , as in step e. The flexible electrically insulating substrate 38 covers the rivets 51 and the metal layer 53 .
[0075] Step j illustrates the hybrid substrate 44 having been cut by known means, preferably by a laser or, in an alternative embodiment, by a diamond wheel, thereby creating cut 55 . The portion of hybrid substrate 44 that will be removed is called the carrier 60 .
[0076] The flexible electrically insulating substrate 38 is patterned by known methods, such as photolithographic patterning, or it may be deposited by masked deposition, to yield voids that define the electrodes 36 . The electrodes 36 transmit electrical signals directly to the retina of the implanted eye (see FIG. 4 )
[0077] Step k illustrates flexible circuit 18 attached to the hybrid substrate 44 . The carrier 60 is removed by utilizing release coat 47 . In a preferred embodiment, release coat 47 is etched by known means to release carrier 60 , leaving behind flexible circuit 18 .
[0078] Step l illustrates the implantable electronic device of a flexible circuit 18 and an intimately bonded hermetic electronics control unit 20 . The electronics control unit 20 , which contains the microelectronics assembly 48 , is hermetically sealed with header 62 bonded to rigid circuit substrate 44 . The header 62 is comprised of a material that is biocompatible when implanted in living tissue and that is capable of being hermetically sealed to protect the integrated circuit electronics from the environment.
[0079] FIG. 11 illustrates an electronics control unit 320 attached to flexible electrically insulating substrate 338 , which is preferably comprised of polyimide, by bonded connections 342 . The electronics control unit 320 is preferably a hermetically sealed integrated circuit, although in an alternative embodiment it may be a hermetically sealed hybrid assembly. Bonded connections 342 are preferably conductive adhesive, although they may alternatively be solder bumps. The bond area is underfilled with an adhesive 380 . Rigid stimulating electrode array 310 is attached to the flexible electrically insulating substrate 338 by bonded connections 342 .
[0080] FIG. 12 illustrates an electronics control unit 320 attached to rigid stimulating electrode array 310 by bonded connections 342 . The bond area is then underfilled with an adhesive 380 , preferably epoxy. Bonded connections 342 are preferably conductive adhesive, although they may alternatively be solder bumps.
[0081] The bonding steps are illustrated in FIG. 13 for a flex circuit assembly that is bonded with rivets 61 that are created in situ by a deposition process, preferably by electroplating. T he rivets 61 are rivet-shaped electrical connections. The substrate 68 is shown generally in FIG. 13 . It is comprised of the hybrid substrate 44 , which is preferably a ceramic, such as alumina or silicon. The silicon would preferably be coated with a biocompatible material to achieve biocompatibility of the silicon, which is well known to slowly dissolve when implanted in living tissue.
[0082] The hybrid substrate 44 preferably contains vias 46 that pass through the thickness of the hybrid substrate 44 , see FIG. 13 , step (a). Vias 46 are not required to enable this invention, and are not present in alternative embodiments. It is preferred that the hybrid substrate 44 be rigid, although alternative embodiments utilize a non-rigid substrate. The vias 46 are integral with electrically conductive routing 35 that has been placed on the surface of the hybrid substrate 44 by known techniques. The routing is preferably comprised of a stable biocompatible material, such as platinum, a platinum alloy, or gold, most preferably platinum.
[0083] A flexible electrically insulating substrate 38 is preferably comprised of two layers of an electrically insulating material, such as a polymer. Known preferred polymer materials are polyimide or Parylene. Parylene refers to polyparaxylylene, a known polymer that has excellent implant characteristics. For example, Parylene, manufactured by Specialty Coating Systems (SCS), a division of Cookson Electronic Equipment Group, located in Indianapolis, Ind., is a preferred material. Parylene is available in various forms, such as Parylene C, Parylene D, and Parylene N, each having different properties. The preferred form is Parylene C.
[0084] The flexible electrically insulating substrate layers 38 are preferably of approximately equal thicknesses, as illustrated in FIG. 13 , step (a). A trace 65 is also illustrated in FIG. 13 , step (a), where trace 65 may be at least one, but preferably more than one, trace 65 that is electrically conductive. The traces 65 are integrally bonded to bond pads 63 . The bond pads 63 each have a bond pad hole 64 therethrough, which is in approximate alignment with first hole 57 in first electrically insulating substrate 37 and second hole 59 in the second flexible electrically insulating substrates 38 , such that there is a hole, with centers approximately aligned, through the thickness of the flexible assembly 66 .
[0085] The flexible assembly 66 is placed next to the hybrid substrate in preparation for bonding, FIG. 13 , step (b). The flexible assembly aligned holes that are formed by first substrate holes 57 , bond pad holes 64 , and second substrate holes 59 are aligned with the routing 35 . In a preferred embodiment, there is at least one via 46 , although no via 46 is required. In a preferred embodiment, an adhesive layer 39 is applied to adhesively bond the assembly together. The adhesive is preferably epoxy, silicone, or polyimide. In alternative embodiments, the assembly is not adhesively bonded.
[0086] As illustrated in FIG. 13 , step (c), a rivet 61 is formed in each flexible substrate hole to bond the assembly together. The rivets 61 are preferably formed by a deposition process, most preferably electroplating. The rivets 61 are comprised of a biocompatible, electrically conductive material, preferably platinum, although alternative embodiments may utilize platinum alloys (e.g. platinum-iridium or platinum-rhodium), iridium, gold, palladium, or palladium alloys. It is most preferred that rivet 61 be comprised of electroplated platinum, called “plated platinum” herein.
[0087] Referring to FIGS. 14 and 15 , a method to produce plated platinum according to the present invention is described comprising connecting a common electrode 402 , the anode, and a bonded assembly 70 , the cathode, to a voltage to current converter 406 with a wave form generator 430 and monitor 428 , preferably an oscilloscope. The common electrode 402 , bonded assembly 70 , a reference electrode 410 , for use as a reference in controlling the power source, which is comprised of a voltage to current converter 406 and a waveform generator 430 , and an electroplating solution are placed in a electroplating cell 400 having a means for mixing 414 the electroplating solution. Power may be supplied to the electrodes with constant voltage, constant current, pulsed voltage, scanned voltage or pulsed current to drive the electroplating process. The waveform generator 430 and voltage to current converter 406 is set such that the rate of deposition will cause the platinum to deposit as plated platinum, the rate being greater than the deposition rate necessary to form shiny platinum and less than the deposition rate necessary to form platinum black.
[0088] Because no impurities or other additives, such as lead, which is a neurotoxin and cannot be used in an implantable device, need to be introduced during the plating process to produce plated platinum, the plated material can be pure platinum. Alternatively, other materials can be introduced during the plating process, if so desired, but these materials are not necessary to the formation of plated platinum.
[0089] Referring to FIGS. 14 and 15 , the electroplating cell 400 , is preferably a 50 ml to 150 ml four neck glass flask or beaker, the common electrode 402 , or anode, is preferably a large surface area platinum wire or platinum sheet, the reference electrode 410 is preferably a Ag/AgCl electrode (silver, silver chloride electrode), the bonded assembly 70 , or cathode, can be any suitable material depending on the application and can be readily chosen by one skilled in the art. Preferable examples of the bonded assembly 70 include, but are not limited to, platinum, iridium, rhodium, gold, tantalum, titanium or niobium, preferably platinum.
[0090] The means for mixing 414 is preferably a magnetic stirrer ( FIG. 15 ). The plating solution is preferably 3 to 30 millimoles ammonium hexachloroplatinate in 0.4 moles of disodium hydrogen phosphate, but may be derived from any chloroplatinic acid or bromoplatinic acid or other electroplating solution. The preferable plating temperature is approximately 24-26° C.
[0091] The electroplating system for pulsed current control is shown in FIGS. 14 and 15 . While constant voltage, constant current, pulsed voltage or pulsed current can be used to control the electroplating process, pulsed current control of the plating process is preferable for plating rivets 61 , which have a height that approximates their diameter. The preferable current range to produce plated platinum, which varies from about 50 to 2000 mA/cm 2 , is dependent on the whole dimensions, FIG. 16 , where the response voltage ranges from about −0.45 volts to −0.85 volts. Applying power in this range with the above solution yields a plating rate in the range of about 0.05 um per minute to 1.0 um per minute, the preferred range for the plating rate of plated platinum. The average current density may be determined by the equation y=19572x −1.46 , where y is the average current density in mA/cm 2 and x is the hole diameter in microns. Pulsed current control also allows an array of rivets to be plated simultaneously achieving uniform rivet properties.
[0092] As plating conditions, including but not limited to the plating solution, surface area of the electrodes, pH, platinum concentration and the presence of additives, are changed the optimal control parameters will change according to basic electroplating principles. Plated platinum will be formed so long as the rate of deposition of the platinum particles is slower than that for the formation of platinum gray and faster than that for the formation of shiny platinum.
[0093] It has been found that because of the physical strength of plated platinum, it is possible to plate rivets of thickness greater than 30 microns. It is very difficult to plate shiny platinum in layers greater than approximately several microns because the internal stress of the dense platinum layer cause the plated layer to peel off.
[0094] On a hybrid substrate 44 , a thin-layer routing 35 , preferably platinum, is sputtered and then covered with about 6 um thick flexible assembly 66 , preferably polyimide, with holes in the range from 5 um to 50 um. On each sample, preferably about 100 to 700 or more such holes are exposed for plating of rivets 61 , see FIG. 17 a.
[0095] SEM micrographs record the rivet surface appearance before plating. The surface is chemically and electrochemically cleaned before plating.
[0096] The electrodes in the test cell are arranged, so that the bonded assembly 70 (cathode) is physically parallel with the common electrode 402 (anode). The reference electrode 410 is positioned beside the bonded assembly 70 . The plating solution is added to electroplating solution level 411 . The solution is comprised of about 18 millimoles ammonium hexachloroplatinate in about 0.4 moles phosphate buffer solution. The amount of solution used depends on the number of rivets 61 to be plated. The means for mixing 414 , preferably a magnetic stirrer, is activated.
[0097] A voltage waveform is generated, preferably with a 1 msec pulse width as a 500 Hz square wave, which is converted to a current signal through a voltage to current converter 406 .
[0098] The pulse current is applied to the plating electrode versus anode. The electrode voltage versus Ag/AgCl reference electrode is monitored using an oscilloscope (Tektronix TDS220 Oscilloscope). The current amplitude is adjusted so that the cathodic peak voltage reaches about −0.6v versus the Ag/AgCl reference electrode 410 . During plating, the electrode voltage tends to decrease with plating time. The current amplitude is frequently adjusted so that the electrode voltage is kept within −0.5 to −0.7v range versus Ag/AgCl reference electrode 410 . When the specified plating time is reached, he current is eliminated. The cathode is rinsed in deionized water thoroughly. Typical plating time is in the range of about 5 to 60 minutes, preferably 15 to 25 minutes.
[0099] The plated surface is examined under an optical microscope. Optical photomicrographs are taken at both low and high magnifications to record the image of the surface. The plated samples are profiled with a surface profilometer to measure the dimensions of the plated rivet. The total plated rivet has a total height of about 8 to 16 um.
[0100] After plating, the pulsing current amplitudes are averaged for the total plating time and recorded. It is has been demonstrated that the current density increases exponentially with sample hole decrease. The smaller the sample holes, the higher the current density required (see FIG. 16 ).
[0101] An illustrative example of a plated platinum rivet according to the present invention are micrographs produced on a Scanning Electron Microscope (SEM) at 850x taken by a JEOL JSM5910 microscope, FIGS. 17 a and 17 b.
[0102] A further preferred embodiment of the invention, illustrated in FIG. 18 , shows the method of bonding the hybrid substrate 244 to the flexible circuit 218 using electrically conductive adhesive 281 , such as a polymer, which may include polystyrene, epoxy, or polyimide, which contains electrically conductive particulate of select biocompatible metal, such as platinum, iridium, titanium, platinum alloys, iridium alloys, or titanium alloys in dust, flake, or powder form.
[0103] In FIG. 18 , step a, the hybrid substrate 244 , which may alternatively be an integrated circuit or electronic array, and the input/output contacts 222 are prepared for bonding by placing conductive adhesive 281 on the input/output contacts 222 . The conductive adhesive 281 , which includes at least one bump, is cured to become hard. A second conductive adhesive 281 a is applied on top of the first cured conductive adhesive 281 . Preferably on each bump of conductive adhesive 281 an additional bump is applied to raise the bumps of conductive adhesive. The rigid integrated circuit 244 is preferably comprised of a ceramic, such as alumina or silicon. In step b, the flexible circuit 218 is preferably prepared for bonding to the hybrid substrate 244 by placing conductive adhesive 281 on bond pads 232 . Alternatively, the adhesive 281 may be coated with an electrically conductive biocompatible metal. The flexible circuit 218 contains the flexible electrically insulating substrate 238 , which is preferably comprised of polyimide. The bond pads 232 are preferably comprised of an electrically conductive material that is biocompatible when implanted in living tissue, and are preferably platinum or a platinum alloy, such as platinum-iridium.
[0104] FIG. 18 , step c illustrates the cross-sectional view A-A of step b. The conductive adhesive 281 is shown in contact with and resting on the bond pads 232 . Step d shows the hybrid substrate 244 in position being bonded to the flexible circuit 218 . The conductive adhesive 281 resting on the bond pads 232 and the conductive adhesive 281 a resting on the cured conductive adhesive 281 resting on the contacts 222 , are cured to yield one conductive adhesive 281 / 281 a / 281 . The conductive adhesive 281 / 281 a / 281 provides an electrical path between the input/output contacts 222 and the bond pads 232 . Step c illustrates the completed bonded assembly wherein the flexible circuit 218 is bonded to the hybrid substrate 244 , thereby providing a path for electrical signals to pass to the living tissue from the electronics control unit (not illustrated). The conductive adhesive 281 / 281 a / 281 is higher than in the embodiment shown in FIG. 6 and the distance between the hybrid substrate 244 and flexible circuit 218 is larger. In step e the assembly has been electrically isolated and hermetically sealed with adhesive underfill 280 , which is preferably epoxy. Since the distance between the hybrid substrate 244 and flexible circuit 218 is larger the underfill 280 is higher in this embodiment.
[0105] The method of manufacturing an implantable electronic device comprises the following steps:
[0106] a) applying conductive adhesive 281 on one or more contacts 222 on a substrate 244 , and curing the conductive adhesive 281 ;
[0107] b) applying one or more layers of conductive adhesive 281 a on the cured conductive adhesive 281 ;
[0108] c) applying conductive adhesive 281 on one or more bond pads 232 on a flexible assembly 218 ;
[0109] d) aligning the contacts 222 on the substrate with the bond pads 232 on the flexible assembly;
[0110] e) curing the conductive adhesive 281 connecting the contacts 232 on the substrate 244 with the bond pads 232 on the flexible assembly 218 ; and
[0111] f) filling the remaining space between the substrate and the flexible assembly with adhesive underfill 280 , and curing the underfill 280 .
[0112] Each layer of conductive adhesive applied on the substrate is preferably cured prior to aligning with the conductive adhesive applied on the flexible assembly. A biocompatible non-conductive adhesive underfill is preferably applied between the substrate and the flexible assembly.
[0113] The adhesive connecting the contacts on the substrate with the bond pads on the flexible assembly contains epoxy or polyimide filled with electrically conductive biocompatible metal in dust, flake, or powder form. The electrically conductive biocompatible metal preferably comprises silver, gold, platinum, iridium, titanium, platinum alloys, iridium alloys, titanium alloys in, or mixtures thereof. The adhesive connecting the contacts on the substrate with the bond pads on the flexible assembly can alternatively be coated with an electrically conductive biocompatible metal.
[0114] The adhesive underfill is cured at a pressure of 50 PSI to 100 PSI. The adhesive underfill is preferably cured at a pressure of 60 PSI to 90 PSI. The adhesive underfill is more preferably cured at a pressure of 70 PSI to 85 PSI. The curing process carried out under pressure yields an adhesive with very limited amount of gas bubbles and improved adhesion. The adhesive underfill is cured under pressure at a temperature of 20° C. to 30° C. for 3 h to 50 h. The adhesive underfill is alternatively cured at a temperature of 70° C. to 100° C. for a time of 10 min to 2 h.
[0115] The height of one or more conductive adhesives on the substrate determines the distance between the substrate and the flexible assembly. The conductive adhesive on the substrate which comprises one or more layer and is preferably in the form of bumps is preferably cured before being aligned with the uncured bumps on the flexible assembly. The hard bumps of conductive adhesives on the substrate push into the soft bumps of the flexible assembly as deep as possible prior to the final curing process. Therefore, the higher the hard bumps on the substrate are the larger is the distance between the substrate and the flexible assembly.
[0000] The implantable electronic device comprises:
[0116] a) a substrate 244 having one or more contacts 222 and two or more layers of conductive adhesive 281 / 281 a on the contacts 222 ;
[0117] b) a flexible assembly 218 having one or more bond pads 232 and one or more layers of conductive adhesive 281 on the bond pads 232 ;
[0118] c) the conductive adhesive 281 connecting the contacts 222 on the substrate 244 with the bond pads 232 on the flexible assembly 218 ; and
[0119] d) adhesive underfill 280 in the remaining space between the substrate 244 and the flexible assembly 218 .
[0120] The substrate comprises a biocompatible ceramic. The biocompatible ceramic comprises alumina. The substrate is rigid and is an electrically insulated substrate circuit. The flexible assembly is a thin substrate circuit. The conductive adhesive provides an electrical path between the input/output contacts and the bond pads. The adhesive underfill is nonconductive and contains epoxy.
[0121] Furthermore, it has been found that because of the physical strength of plated platinum, it is possible to plate rivets 61 of thickness greater than 16 um. It is very difficult to plate shiny platinum in layers greater than approximately 1 to 5 um because the internal stress of the dense platinum layer which will cause plated layer to peel off.
[0122] The following example is illustrative of electroplating platinum as a rivet 61 , according to the present invention.
EXAMPLE
[0123] A flexible electrically insulating substrate comprised of a first substrate 37 and a second substrate 38 of polyimide having a total thickness of 6 um. It had 700 first substrate holes 57 , an equal number of matching bond pad holes 64 , and an equal number of matching second substrate holes 59 , all in alignment so as to create a continuous hole through flexible assembly 66 that terminates on routing 35 , arranged in 100 groups of seven on about 40 um centers, FIG. 4 a . The hybrid substrate 44 was alumina and the routing 35 was platinum. The bond pad 63 was platinum.
[0124] The assembly was cleaned by rinsing three times in 10% HCl. It was further prepared by bubbling for 10 seconds at ±5V at 1 Hz in phosphate buffered saline Finally, it was rinsed in deionized water.
[0125] The electroplating set up according to FIGS. 14 and 15 was comprised of an electroplating cell 400 that was a 100 ml beaker with an electroplating solution level 411 at about the 75 ml level. The solution was 18 millimoles of ammonium hexachloroplatinate in 0.4 moles phosphate buffer solution.
[0126] The means for mixing 414 was a magnetic stirrer, which was activated. The voltage waveform of 1 msec pulse width as a square wave was generated by an HP 33120A waveform generator, which is converted to current signal through a voltage to current converter 406 . The pulse current was 1 msec in pulse width at 500 Hz square wave.
[0127] The pulse current was applied on the plating electrode bonded assembly 70 versus common electrode 402 . The electrode voltage versus Ag/AgCl reference electrode 410 was monitored using as a monitor 428 a Tektronix model TDS220 oscilloscope. The current amplitude was increased so that the bonded assembly 70 (cathode) peak voltage reached −0.6v versus the Ag/AgCl reference electrode 410 . During plating, the electrode voltage decreased with plating time.
[0128] The average current density was 660 mA/cm 2 , which generated response voltages of −0.5 to −0.7 volts, where the voltage was controlled by the current. A 1 msec pulse width square wave was generated by an HP 33120A Arbitrary Waveform Generator. The pulse was converted to a current signal through a voltage to current converter 406 . The pulse current was typically about 1 msec in pulse width as a 500 Hz square wave. The resulting plated platinum rivet 61 was about 32 um diameter on the button end and about 15 um tall, with about 9 um of the height extending above the polyimide substrate. The plated platinum rivet was dense, strong, and electrically conductive.
[0129] Scanning Electron Microscope (SEM)/energy dispersive analysis (EDAX™) analysis were performed on the rivets 61 . SEM micrographs of the plated surface were taken showing its as-plated surface, FIG. 17 b . Energy dispersed analysis demonstrated that the rivet 61 was pure platinum, with no detectable oxygen.
[0130] The above described is the preferred embodiment of the current invention, however the platinum electrodeposition described in co-pending application “Platinum Electrode and Method for Manufacturing the Same,” application Ser. No. 10/226,976, filed on Aug. 23, 2002, now U.S. Pat. No. 6,974,533, and incorporated herein by reference, is also effective for forming electrochemically deposited rivets.
[0131] The rivet 61 ( FIG. 13 ) forms an electrically conductive bond with the routing 35 and with the bond pad 63 . It is obvious that the bonded assembly may be stacked with other bonded assemblies forming multiple stacked assemblies with increased stacking density.
[0132] Accordingly, what has been shown is an improved flexible circuit with an electronics control unit attached thereto, which is suitable for implantation in living tissue and to transmit electrical impulses to the living tissue. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described.
|
The invention is directed to a method of bonding a hermetically sealed electronics package to an electrode or a flexible circuit and the resulting electronics package that is suitable for implantation in living tissue, such as for a retinal or cortical electrode array to enable restoration of sight to certain non-sighted individuals. The hermetically sealed electronics package is directly bonded to the flex circuit or electrode by electroplating a biocompatible material, such as platinum or gold, effectively forming a plated rivet-shaped connection, which bonds the flex circuit to the electronics package. The resulting electronic device is biocompatible and is suitable for long-term implantation in living tissue.
| 7
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to devices utilized to control the spread of ectoparasite-borne diseases and, more particularly, to an improved apparatus for feeding and applying pesticides onto animals, particularly wildlife such as deer.
[0003] 2. Description of the Background
[0004] A variety of diseases are transmitted to humans and animals by ectoparasites such as ticks. Certain species of wildlife, such as white-tailed deer, propagate and harbor large populations of ectoparasites in direct proximity to areas populated by humans and their domesticated pets. An effective strategy for the prevention of disease transmission through the control of ectoparasites includes the pesticidal treatment of such wildlife found in and around human-populated areas. Unfortunately, direct treatment can be challenging, especially with species that are not easily captured, restrained or otherwise handled directly. Thus, access to wildlife in order to control ectoparasites remains a challenging problem,
[0005] There have been prior efforts to develop devices that passively (and surreptitiously) apply pesticides to wildlife. One noteworthy example by a subset of the present inventors is described in U.S. Pat. No. 5,367,983 to Pound et al. As shown in FIG. 1 , the Pound et al. '983 patent discloses an apparatus for feeding and applying pesticides onto animals, particularly wildlife such as deer. This device includes a feed supply bin 20 that spills feed into either side of an open-topped receptacle 10 . A pair of spaced apart vertical support members 30 carry pesticide applicators 31 positioned near the sides of the receptacle 10 . Pesticide applicators 31 are positioned on each of the support members 30 , and are adapted to apply pesticide onto an animal upon contact therewith. Pesticide is automatically supplied, for example, from pesticide reservoirs 50 at the lower end of each applicator 31 that wick pesticide into the absorbent material of the applicator. While the concept of the Pound et al. '983 device is excellent, the structural features leave room for improvement both functionally and to achieve manufacturing economy. For example, the vertical support members 30 in the aforementioned apparatus are rigid and may obstruct (or certainly do not adapt to) wildlife as they crane their heads and/or necks to feed and, therefore, may not apply adequate pesticide. Moreover, the design suggested by Pound et al. '983 was intended for sheet metal construction, thereby resulting in sharp edges that might cut the animals and susceptibility to oxidation. In addition, the entire product had to be fully assembled at the factory and shipped as a unit. This was very heavy and expensive. It has been found that a more economical modular design more suited for molded construction allows ready solutions to the foregoing problems (the Pound '983 design is not well-suited for molding). A modular molded product is comparatively lightweight, and the components can be shipped for user-assembly, thereby saving significant shipping and manufacturing costs. Therefore, there remains a need for a like device possessing an improved means for accommodating wildlife of all sizes (inclusive of all species of deer, cattle, antelope, elk, etc.), and which is formed by a simple, scalable, durable and economically mass-producible design which can be manufactured wholly or partly by molding in order to provide for more widespread use.
SUMMARY OF THE INVENTION
[0006] It is an object of the invention to provide an improved means for applying pesticides to wildlife that employs simple, durable modular componentry that is economical to manufacture, lightweight for economical shipping (the prior metal version was heavy and expensive to assemble), easy to assemble for user assemblage, and more rugged and durable in the field.
[0007] It is another object to provide a plastic-molded means for applying pesticides to wildlife as described above that avoids sharp and rusty edges to maintain the safety of the animals and operators.
[0008] It is still another object to provide an improved means for maximizing the per capita application of pesticide to deer, utilizing flexible applicators that adapt to and can accommodate animals that vary greatly in physical size, without obstructing them.
[0009] In accordance with the above objects, the present invention is designed for the application of pesticides to animals as they feed. In use, the apparatus of this invention is positioned in the locus or vicinity of the animals to be treated with feed loaded in the feed bin. Animals attracted to the apparatus to feed will be subjected to the application of a pesticide upon their head, neck, ears, and/or, where applicable, antlers or horns upon contact with one or more of a plurality of applicators.
[0010] Without being limited thereto, corn and other non-absorbent pelletized feeds are preferred. Attractions such as apple aromas may also be added to the feed as are conventional in the art.
[0011] While the apparatus may be used for applying pesticides to a wide variety of animals, including domesticated species, it is particularly valuable for the treatment of wild or captive animals, in particular those species that have antlers or horns (e.g. deer, antelope, elk, goats, cattle), as well as those that do not (swine, sheep, etc.). The preferred embodiment of the present invention is an economically-designed apparatus fabricated of a variety of lightweight, rigid materials (e.g. molded plastics) to provide the durability required by the nature of its usage. The main sub-assemblies of the present invention are well-adapted for molded fabrication and include a dual-compartment feed trough/receptacle, a feed bin, a plurality of pesticide applicators, and an optional pesticide reservoir/feed system.
[0012] Animal feed placed in the feed bin is dispensed into the trough/receptacle through an opening at the bottom of the bin. For the application of a pesticide to a feeding animal, a plurality of pesticide applicators are positioned proximate the two compartments of the trough/receptacle. The applicators are positioned such that as an animal feeds, some part of its head, neck and/or ears will contact one or more of the applicators. The applicators may be dosed with pesticide simply by wetting on a periodic basis (weekly), or automatically by an internal reservoir/feed system. To ensure contact between the animal and at least one applicator, the applicators are positioned relatively close together near the trough/receptacle feeding compartments. This creates limited side-long access through which the animal must crane their necks to reach the feeding compartment. The applicators are mounted on flexible masts that adapt to and can accommodate animals that may vary greatly in physical size, without obstructing them, thereby ensuring a full application of pesticide without exerting undue force on the applicators or the trough/receptacle.
[0013] The modular molded product employs a simple, durable, economically mass-producible design with lightweight components that can be shipped for user-assembly, thereby reducing shipping and manufacturing costs. In the field the device has greater utility because it accommodates wildlife of a variety of sizes, poses no threat of harm to the animals, and maximizes the per capita application of pesticide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and certain modifications thereof when taken together with the accompanying drawings in which:
[0015] FIG. 1 is a front view of a prior art apparatus for feeding and applying pesticides onto animals from U.S. Pat. No. 5,367,983 to the inventors herein.
[0016] FIG. 2 is a perspective fully-assembled view of an apparatus 15 for applying pesticides to wildlife according to a first embodiment of the present invention.
[0017] FIG. 3 is a perspective partial-assembly exploded view of the apparatus 15 of FIG. 2 .
[0018] FIG. 4 is a perspective partial-assembly exploded view of the apparatus 15 of FIG. 2 .
[0019] FIG. 5 is a top perspective view of the apparatus 15 of FIGS. 2-4 .
[0020] FIG. 6 is a cross-sectional view of a flexible applicator 40 including support member 44 and applicator sleeve 41 according to a first embodiment of the present invention.
[0021] FIG. 7 is a cross-sectional view of the flexible applicator 40 flexible applicator 40 support members 44 flexible applicator 400 f FIG. 6 shown in a deflected condition due to the introduction of a side load or force.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] FIGS. 2-5 are, respectively, a perspective fully-assembled view, two perspective partial-assembly exploded views ( FIGS. 3-4 ), and a top view ( FIG. 5 ) of the apparatus 15 for applying pesticides to wildlife according to a first embodiment of the present invention.
[0023] The major structural components of the apparatus 15 have been simplified to five modular snap-fit plastic (e.g., polyethylene) component parts, including a lid 34 , feed bin 30 , feed trough/receptacle assembly 20 , a plurality of flexible applicators 40 anchored in the feed trough/receptacle assembly 20 , and two adjustable gate assemblies 53 for limiting access to the feed trough/receptacle assembly 20 . This modular embodiment facilitates packaging of the unassembled components and shipping in two compact boxes, rather than a fully assembled product. The simple snap-fit design allows the end-user to complete the assembly. Shipping costs are drastically reduced because non-freight carriers may be used. Assembly costs are reduced, and the replacement cost of expendable parts is reduced. The modular components are described in more detail below.
[0024] As best seen in FIG. 3 , the molded plastic feed trough/receptacle assembly 20 is formed with side walls 21 , a bottom 22 , and two feeding compartments 24 . Presently, the feed trough/receptacle assembly 20 is rotationally molded, albeit blow- or injection-molding may also be suitable. The depth of each feeding compartment 24 is preferably sufficiently shallow to allow the animal to see over the top edge of the side walls 21 while feeding. Support legs and/or a base stabilizer (not shown in the Figures) may be used to prevent the tipping over of the apparatus 15 and to allow the trough/receptacle 20 to be positioned at some distance above the ground for ease of access by the appropriate animals, and notches 25 or sleeves may be molded into the trough/receptacle 20 as shown to seat the support legs.
[0025] In accordance with the present invention, the trough/receptacle 20 is fabricated of one piece molded in high density cross-linked polyethylene or high density polyethylene plastic with integral side walls 21 , bottom 22 , and recessed feeding compartments 24 , and molded sleeves 25 for press-fit insertion of support legs.
[0026] The feed bin 30 is open-topped and open-bottom, and the trough/receptacle 20 is formed with a central plateau that segregates the feeding compartments 24 and partially blocks the open-bottom of the feed bin 30 such that when the feed bin 30 is seated on the trough/receptacle 20 there are two opposing apertures left open at the bottom of the feed bin 30 from which feed drains evenly into the feeding compartments 24 . The recessed feeding compartments 24 are formed with an outwardly-angled surface for directing the feed downwardly and sideways away from the feed bin 30 toward the sides. The low-friction polyethylene of the feeding compartments 24 coupled with downward sloping surfaces has significantly less friction than galvanized metal surfaces, thus improving the flow of corn down the slopes.
[0027] The supply of animal feed for the apparatus 15 comes from the molded plastic feed bin 30 that is positioned above the trough/receptacle 20 and is dispensed from the bin 30 into the feeding compartments 24 where it may be accessed by animals, through the opposing apertures or openings at the lower end of the bin 30 . Preferably, a pair of guillotine divider gates 23 are inserted into corresponding notches formed in the sides of the trough/receptacle 20 to partially block access to the bin 30 . These gates 23 may be adjustable up/down to vary the size of the opening, or may be fixed and interchangeable (with varying apertures) in order to regulate the flow of the feed from the bin 30 . This helps to prevent large amounts of feed from being dispensed into the feeding compartment 24 at one time. Limiting the size of the openings to control the amount of feed dispensed into the feeding compartments 24 prevents the animal from rapidly consuming large amounts of feed and thus aids in keeping the animal at the apparatus 15 for a longer period of time. The use of adjustable gates 23 is preferred when it is envisioned that different feeds may be employed. It is also noteworthy that the floors 22 of the feeding compartments 24 are recessed below the feed slopes leading from the feed bin into feeding compartments 24 . This in combination with the gates 23 aid in preventing water and moisture from creeping back into the feed bin 30 , or from falling into the feeding compartments 24 , thereby soaking the corn.
[0028] Protection of the feed in the feed bin 30 is afforded by a plastic cover or lid 34 that may be friction fit, or pivotally attached to the bin 30 , and secured in place via two latching brackets 35 . The position of the bin 30 relative to the trough/receptacle 20 is not critical; it may be positioned approximately centrally or adjacent an end of the trough/receptacle 20 .
[0029] In accordance with the present invention, the feed bin 30 is fabricated of lightweight, rigid molded plastic (preferably also high density cross-linked polyethylene or high density polyethylene plastic) with annular reinforcing ribs 29 . The feed bin 30 is preferably anchored to the receptacle 20 by a friction-fit shroud 33 that fits over the sidewalls of the receptacle 20 . As best seen in FIG. 3 , the outwardly extending shroud 33 is integral to the base of the feed bin 30 and is formed as a substantially horizontal plate with angled edges conforming to the sides of receptacle 20 to anchor it onto the receptacle 20 . The shroud 33 extends partially over the bin opening.
[0030] Both the feed bin 30 and trough/receptacle 20 are fully recyclable, may be made in any color, and include non-removable and non-fading EPA pesticide warning labels integrally formed into the plastic. The shape of the trough/receptacle 20 and the number of feeding compartments 24 may be varied, and other shapes (e.g. circular, oval, square) having more or fewer feeding areas may be utilized.
[0031] As seen in FIGS. 2 and 4 , adjustable gate assemblies 53 are provided over top the feeding compartments 24 to limit access thereto. Each gate assembly 53 comprises a secondary cover 54 fixedly attached to the feed bin shroud 33 , and covering a bottom adjustable plate 55 . Adjustable plate 55 is attached to mounting holes in the feed trough/receptacle 20 , and adjustable plate 55 is provided with a corresponding series of adjustment holes for screw-attachment. By sliding the plate 55 forward or backward feed access can be restricted in discrete increments (for example, 0″, ½″, 1″, and 1½″). The secondary cover 54 is then secured in place (via set screws or the like) to cover the slide plate 55 , and in this manner the adjustable gate assemblies 53 as a whole vary the feeding animals access to the feeding compartments 24 . The intent here is to limit access as much as possible so that the feeding animal needs to tilt their head to dig under the gate assembly 53 in order to reach the feed in feeding compartments 24 . This ensures that the animal makes full contact with flexible applicators 40 (to be described) all of which carry pesticide.
[0032] Each flexible applicator 40 (four are shown) comprises a support member 44 equipped with an absorbent applicator sleeve 41 . The support members 44 are positioned adjacent the outlying corners of each feeding compartment 24 , opposite the feed bin opening, and each is slidably inserted into a conforming sleeve formed in trough/receptacle 20 . Preferably, the base of each support member 44 is equipped with a detent pin for positive locking-engagement with the sleeves of trough/receptacle 20 . In the illustrated embodiment, four pesticide applicator sleeves 41 are slidably inserted, one on each support member 44 , likewise positioned at the corners of feed bin 30 . One skilled in the art will understand that the number of support members 44 and applicator sleeves 41 can be varied in accordance with the number of feeding compartments 24 . Pesticide applicator sleeves 41 extend upwardly above the upper edge of the trough assemblies' side walls 21 . Pesticide applicator sleeves 41 are similar to paint rollers, and each is slidably inserted onto a corresponding support member 44 , which in turn is installed into a corresponding molded sleeve in trough/receptacle 20 . The pesticide applicator sleeves 41 may be secured in place on support members 44 by detent caps 42 . Pesticide applicator sleeves 41 are adapted to apply pesticide onto an animal upon contact.
[0033] Both the feed bin 30 and trough/receptacle 20 are preferably configured to be shipped separately and economically (for example, multiple feed bins 30 may be stacked), but otherwise the size/shape may be varied to meet a wide variety of application-specific parameters. Thus, the device may be shipped partially assembled for complete assembly by the user. Final assembly proceeds as follows:
[0034] 1. Secure feed bin 30 to the trough/receptacle 20 with four (2 each side) screws and four flat washers as shown (for example, ¼×20×1″ screws). Install legs (not shown) in sleeves 25 in the trough/receptacle 20 .
[0035] 2. Slide each divider gate 23 into the slot at each end of the trough/receptacle 20 . Assure that the divider gates 23 are fully seated.
[0036] 3. Place adjustable plate 55 over mounting holes in the trough/receptacle 20 . In the illustrated embodiment adjustable plate 55 has four sets of adjustment holes. By sliding the plate 55 forward or backward feed access can be restricted by 0″, ½″, 1″, and 1½″.
[0037] 4. Place secondary cover 54 over the adjustable plate 55 with mounting holes aligned to the adjustable plate 55 and the trough/receptacle 20 . Assemble as shown in FIG. 4 , and install nine ¼″×20×1″ screws, and an equal number of flat washers. Repeat this procedure at both ends to install both secondary covers 54 .
[0038] 5. Install four support members 44 into sleeves in the trough/receptacle 20 . The detent pins should snap into corresponding lock holes in the sleeves to hold the support members 44 in place.
[0039] 6. Slide pesticide applicator sleeves 41 over each of the four support members 44 and install detent caps 42 overtop. Again, the detent pin of support members 44 should snap into lock holes in the caps 42 to hold the caps 42 in place.
[0040] 7. Place container lid 34 onto feed bin 30 and secure the lid 34 to feed bin 30 with the latches 35 .
[0041] 8. Fill the feed bin 30 and wet the pesticide applicator sleeves 41 with liquid pesticide.
[0042] Given the foregoing assembly, when attempting to feed, animals access the feeding compartments 24 from either side of the apparatus by inserting their heads between a support member 44 and the feed bin 30 . The animals are effectively forced by gate assemblies 53 to turn their head sideways, thereby ensuring better contact with an applicator sleeve 41 . The back of the head, the neck, and/or the ears of the animal will contact one of the applicator sleeves 41 during the feeding process, resulting in the application of the pesticide. Further enhancement of the pesticide application process occurs if the animal chooses to deliberately and/or vigorously rub against the applicators 41 while feeding. The application of the pesticide to the aforementioned areas of the animal provides significant ectoparasite control because they are the locations that usually harbor the greatest number of ticks.
[0043] FIGS. 6 and 7 are cross-sectional views of an exemplary flexible applicator 40 including support member 44 and applicator sleeve 41 according to the preferred embodiment of the present invention. FIG. 6 shows support member 44 and applicator sleeve 41 in an unloaded condition (i.e. not subject to a side load or force), while FIG. 7 shows them in a deflected condition due to the introduction of a side load or force (i.e. caused by a feeding animal).
[0044] As can be seen in both FIG. 6 and FIG. 7 , the support members 44 are adapted to flex slightly such that they accommodate the head, neck, or ears of a feeding animal. In accordance with the illustrated embodiment of the support member 44 , this is accomplished by forming the support member with a spring-loaded rocker-base to allow a limited degree of rocking, with a tendency to right itself to an erect position when not biased. To this end each support member 44 further comprises an assembly of conventional PVC tubing components including a section of pipe 143 with a removable upper detent cap 42 . The cap 42 is held in place by a conventional thumb-detent pin 142 inserted into the pipe section 143 and protruding out through aligned holes in both the pipe section 143 and cap 141 . Thus, by depressing the detent pin 142 the cap may be easily removed to insert or replace the applicator 41 when necessary (by slidable insertion onto pipe section 143 ). The pipe section 143 extends downward to a rocker base 146 which may be a conventional threaded PVC pipe coupling. The pipe section 143 is seated loosely in the rocker base 146 and is not affixed, and so remains free to pivot therein by approximately +/−20 degrees in any direction. The pipe section 143 is biased into the rocker base 146 by an extension spring 145 that is extended between two pins 144 A & 144 B. The first pin 144 A is inserted through the pipe section 143 midway along its length, while the second pin 144 B is inserted with a 90 degree offset through the rocker base 146 beneath the pipe section 143 . Thus, spring 145 compresses the pipe section 143 into the rocker base 146 and maintains it in an erect orientation when not influenced by outside pressure. The threaded rocker base 146 may be inserted directly into the sleeves in the trough/receptacle 20 (see FIG. 4 ). The spacing and height of the support members 44 , as well as the diameter of the applicators 41 , can vary and may be readily determined by one skilled in the use of the apparatus 15 . The spacing of the support members 44 /applicators 41 and the feed bin 30 is sufficient to entice an animal to pass its head through an opening in order to access a feeding compartment 24 , but the recessed feed tray forces the animal to crane its neck such that the neck, ears, and/or back of the head of the animal will contact one or more of the applicators 41 during the feeding process. The height of the support members 44 /applicators 41 should be great enough to extend above the animal's head when feeding. The flexibility of the support members 44 /applicators 41 allows an animal possessing antlers, horns, etc. to feed just as easily as one that does not have them.
[0045] FIG. 6 shows support member 44 and applicator sleeve 41 in an unloaded condition (i.e. not subject to a side load or force), while FIG. 7 shows them in a deflected condition due to the introduction of a side load or force (i.e. caused by a feeding animal).
[0046] One skilled in the art will understand that alternate support members 44 and applicators 41 are possible without departing from the scope and spirit of the present invention. For example, rather than a rocker base 46 the pipe section 143 may be rigidly mounted but formed of flexible material to allow bending, such as a solid rubber cylinder, a hollow rubber tube section, or a cylindrical spring fabricated of rust-resistant metal or plastic.
[0047] The applicators 41 may be constructed to deliver liquid (wet), solid or particulate (dry powder) pesticides. Virtually any pesticide may be applied including insecticides, specifically acaricides. However, only EPA approved/allowed pesticides may legally be used, and those that are specifically listed below are EPA approved. In the illustrated embodiment, the applicator sleeve 41 is an absorbent material that is periodically saturated (e.g. when the feed storage bin 30 is refilled) with pesticide. An absorbent material such as Draylon™ fabric wrapped about a tubular plastic or cardboard core is suitable for this purpose. A ½″-¾″ nap fabric works well (and retains the tickicide for a full week), and a bonded plastic core lasts longer than cardboard cores. The applicators 41 are periodically dosed with pesticide simply by wetting with tickicide on a weekly basis. The preferred tickicide is EPA approved 4 Poster (tm) liquid tickicide which is 10% permethrin-based. Alternatively, rather than periodic wetting, an optional on-demand automatic feed/delivery system may be used as described below.
[0048] The optional pesticide feed/delivery system is more suitable in remote locations where weekly maintenance is undesirable. In accordance an embodiment incorporating a gravity-fed delivery system, the supply of pesticide to the applicators may occur through a pesticide reservoir connected with the top of each applicator sleeve 41 through a conduit. To prevent dripping and/or excess accumulation of pesticide on the applicators 41 , pressure activated flow control valves may be provided to open and allow the flow of pesticide onto the applicators 41 when pressure, or a side load/force, is applied upon the applicator sleeve 41 by the feeding animal. Preferred valves include, but are not limited to, conventional spring-loaded pinch valves. In addition, a shut-off valve may also be provided to disrupt flow completely. One skilled in the art will understand that a variety of other liquid-based delivery systems may be utilized. For example, a pesticide reservoir may be located within the molded body of the trough/receptacle 20 below the lower end of each applicator sleeve 41 (or each pair of applicators), with pesticide being wicked into the absorbent material of the applicator sleeve 41 . In yet another alternative embodiment, a pressure activated pump or a pressurized container may be utilized to transfer pesticide from a reservoir to the applicators 41 . These variations are considered to be within the scope and spirit of the present invention.
[0049] Furthermore, solid pesticides may also be used. In this case, the applicators 41 may be plastic strips impregnated with dry pesticide, the strips being wrapped or wound around each support member 44 . Pesticide-laden materials/strips suitable for use in this embodiment include, but are not limited to, Taktic strips impregnated with amitraz and commercially available from Hoechst Roussel Agri-Vet Company of Sommerville, N.J.
[0050] In all such cases the apparatus 15 may be used for the control of a variety of animal/wildlife-borne ectoparasites including, but not limited to, ticks (e.g. deer ticks, cattle fever ticks, ear ticks), mites (e.g. ear mites), lice, fleas, and flies (e.g. horn flies, stable flies).
[0051] Having now fully set forth the preferred embodiment and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. It is to be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein.
INDUSTRIAL APPLICABILITY
[0052] There is a significant commercial demand for an improved feeder device that concurrently applies pesticides to wildlife to control the spread of ecto-parasite-borne diseases and, more specifically, a feeder/applicator that accomplishes these goals by a simple, durable molded design that can be economically manufactured and mass-produced to provide for more widespread use. The present invention fulfills this demand with a multi-part molded design that combines a refillable feeding bin with flexible pesticide applicators for the application of pesticides to animals as they feed from the bin, the applicators accommodating animals that vary greatly in physical size. The feeder/applicator of this invention is positioned in the locus or vicinity of the animals to be treated. Animals attracted to the apparatus to feed will be subjected to the application of a pesticide upon their head, neck, ears, and/or, where applicable, antlers or horns upon contact with one or more of the applicators.
|
A device ( 15 ) for the application of pesticides to animals as they feed and that accommodates wildlife of all sizes, poses no threat of harm to the animals, and maximizes the per capita application of pesticide. Whole kernel corn (or other feed) placed in a feed bin ( 30 ) is dispensed into a trough/receptacle ( 20 ) through an opening at the bottom of the bin. The trough/receptacle ( 20 ) is surrounded by pesticide applicators ( 40 ) such that as an animal feeds, some part of its head, neck and/or ears will contact one or more of the applicators. The applicators ( 40 ) are flexible and rotatable, so that animals attracted to the apparatus to feed are subjected to the application of a pesticide upon their head, neck, ears, and/or, where applicable, antlers or horns, the flexible and rotatable applicators ( 40 ) maximizing pesticide application with minimal stress to both the animal and device. The device employs a modular molded polyethylene design that is durable, economical, mass-producible, lightweight, and can be shipped for user-assembly, thereby reducing shipping and manufacturing costs.
| 0
|
BACKGROUND OF THE INVENTION
The present invention is used for high speed data transmission, and especially for optical fiber data transmission systems that multiplex and distribute high speed data.
Here, the prior art of channel selection method described in Japanese Patent Laid-Open No.42929 (1991) is explained.
FIG. 10 is a block diagram showing the channel selection method described in the above-mentioned Published Unexamined Patent Application.
In this figure, 101 is a transmitter.
102 to 105 are data transmission circuits for receiving data from data input terminals D1 to D4 respectively and outputting the data at respective timing.
106 is a bit multiplexing circuit for time division multiplexing data output from the data transmission circuits 102 to 105 and outputting a serial transmission data to a reception side.
107 is a first frequency divider for frequency dividing a transmission clock into 1/4 and supplying pulses of which timing are different each other to the data transmission circuits 102 to 105.
108 is a clock generation circuit for supplying the transmission clock to the bit multiplexing circuit 106, the frequency divider 107 and the reception side.
109 is a channel information addition circuit for detecting channel information input from a channel information input terminal CH1 and supplying this channel information to the bit multiplexing circuit 106, the frequency divider 107 and the clock generation circuit 108. The channel information consists of channel numbers and information on number of all channels.
110 is a receiver.
111 is a data reception circuit for selecting channels in the serial transmission data and extracting data of a specified channel.
112 is a clock reception circuit for receiving the transmission clock.
113 is a gate circuit for opening and closing at every one clock based on the channel information and channel selection information input into a channel selection input terminal CHS and controlling the transmission clock.
114 is a second frequency divider for frequency dividing the clock from the gate circuit 113 into 1/4.
115 is a channel information detection circuit for detecting channel information from among reception data.
OUT is an output terminal of reception data.
Next, operation of the above-mentioned channel selection method is explained.
First, the clock generation circuit 108 generates a clock signal at transmission speed of the system trunk line within the transmitter 101.
The frequency divider 107 frequency divides the clock signal into 1/4 and supplies the divided clock signals to the data transmission circuits 102 to 105.
The data transmission circuits 102 to 105 output bit data at different timing in parallel.
The bit multiplexing circuit 106 time division multiplexes outputs from the data transmission circuits 102 to 105 to make them a serial data.
On the other hand, the channel information addition circuit 109 receives channel information from the channel information input terminal CH1 and gives channel information to the bit multiplexing circuit 106 via the clock generation circuit 108 and the frequency divider 107.
Then, the bit multiplexing circuit 106 adds channel information on the above-mentioned serial data to make a serial transmission data and transmits the serial transmission data to the receiver 110 in synchronizing with the transmission clock.
The data reception circuit 111 in the receiver 110 extracts and receives data of the specified channel from among the serial transmission data transmitted in synchronizing with the above-mentioned transmission clock.
The synchronization signal used for this extraction operation is the transmission clock, which has been received in the clock reception circuit 112, divided into 1/4 in the frequency divider 114 as shown in FIG. 11.
Where, in FIG. 11, A is transmission side, B is reception side, a is a serial transmission data in which parallel data of channels 1 to 4 are multiplexed, b is a transmission clock and c is a transmission clock that is frequency divided into 1/4.
Next, channel switching operation is explained.
FIG. 12 and FIG. 13 are figures to explain channel switching operation.
Where, in these figures, a is a transmission clock, b is a frequency division output output from the frequency divider 114 and c is a serial transmission data.
First of all, for carrying out channel switching, currently receiving channel number and number of all channels are recognized by detecting channel information from a current channel in the channel information detection circuit 115.
Here, the case of switching channel from channel 1 to channel 4 is considered as shown in FIG. 12.
In this case, the gate circuit 113 firstly prohibits 3 clocks (=4 clocks-1 clock) among 4 clocks of the transmission clocks and outputs the result to the frequency divider 114. Thus, channel 1 is switched to channel 4.
In FIG. 12, the three clocks, which are drawn by dotted lines on the frequency division output b, show the prohibited clocks, numbers on the serial transmission data c are data according to channel numbers and each channel number marked by a circle shows data of the channel number that is received.
FIG. 13 shows the case of switching channel from channel 3 to channel 1.
In this case, the gate circuit 113 firstly prohibits 2 clocks (=4 clocks-(3 clocks-1 clock)) among 4 clocks of the transmission clocks and outputs the result to the frequency divider 114. Thus, channel 3 is switched to channel 1.
Like this, in the prior art, the transmission side must add all channel information onto a transmission data and the reception side must extract channel information from an arbitrary channel and control channel selection.
By this reason, the prior art has a problem that the circuit becomes complicated and the receiver becomes large for signal processing. In addition, if signals of which transmission speed are not same are mixed, the signal processing becomes more complicated.
SUMMARY OF THE INVENTION
It is the first object of the present invention to provide an art for channel selection enabling to easily select a channel from among a plurality of channels.
It is the second object of the present invention to simplify transmission and receiver selecting and receiving a channel from among a plurality of channels in its structure and miniaturizing its size.
It is the third object of the present invention to provide a art for channel selection enabling to easily select a channel from among a plurality of channels of different transmission speed.
The objects of the present invention are achieved by a method for channel selection comprising: (a) step of setting at least one channel among N channels as a reference channel, generating a transmission signal by time division multiplexing discrimination information for discriminating the reference channel with data of other channels and transmitting the transmission signal; and (b) step of receiving the transmission signal, detecting temporal location of the reference channel in the N channels based on the discrimination information included in the transmission signal and selecting an arbitrary channel based on a relative time difference between the temporal location of reference channel detected and temporal location of the arbitrary channel in the N channels.
In the channel selection art of the present invention, at least one channel among N channels is set as a reference channel and this reference channel is selected after transmitted. The present invention features that temporal location of the reference channel in a time division multiplexed data is detected and an arbitrary channel in the N channels is selected.
These and other objects, features and advantages of the invention will become more apparent upon a reading of the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the first embodiment of the present invention.
FIG. 2 is a timing chart of the first embodiment of the present invention.
FIG. 3 is a block diagram of the second embodiment of the present invention.
FIG. 4 is a block diagram of the third embodiment of the present invention.
FIG. 5 is a block diagram of the fourth embodiment of the present invention.
FIG. 6 is a timing chart of the fourth embodiment of the present invention.
FIG. 7 is a block diagram of the fifth embodiment of the present invention.
FIG. 8 is a timing chart of the fifth embodiment of the present invention.
FIG. 9 is a timing chart of the fifth embodiment of the present invention.
FIG. 10 is a figure for explaining a prior art.
FIG. 11 is a figure for explaining a prior art.
FIG. 12 is a figure for explaining a prior art.
FIG. 13 is a figure for explaining a prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First of all, the first embodiment of the present invention is explained.
The first embodiment is a case that (N-1) channels and a reference channel are supposed and all of these channels are time division multiplexed in the same transmission speed.
FIG. 1 is a block diagram of the first embodiment.
In this figure, A is a data transmitter, B is a data receiver and c is a synchronization signal phase control means.
1 is a discrimination information generator for generating discrimination information 1a. This discrimination information 1a is a fixed cyclic pulse string, for example, 101010 . . . . The channel having this discrimination information generator 1 is a reference channel.
2 1 to 2 n-1 are (N-1) data generators for generating data 2 1 a to 2 n-1 a, respectively.
3 is a time division multiplexing circuit for time division multiplexing the discrimination information 1a and data 2 1 a to 2 n-2 a.
4 is an optical transmitter for converting output of the time division multiplexing circuit 3 to light and transmits it via an optical fiber 5.
6 is an optical receiver for converting a light signal transmitted to electric information.
7 is a transmission clock signal extraction circuit for extracting a transmission clock signal from the electric information.
8 is a frequency divider for frequency dividing the transmission clock signal into 1/N and generating synchronization signals according to each transmission speed of discrimination information 1a and data 2 1 a to 2 n-1 a.
9 is a synchronization signal phase changing circuit for changing phase of the synchronization signal according to an instruction from a synchronization signal phase control circuit 12 described later.
10 is a data extraction circuit for selecting a channel synchronized with phase of a synchronization signal from the synchronization signal phase changing circuit 9 and extracting data of the channel.
11 is a reference channel detection circuit for monitoring each output of the channel output from the data extraction circuit 10 and detecting a reference channel by discriminating a signal string of discrimination information.
12 is a synchronization signal phase control circuit for outputting a control signal that changes phase of the synchronization signal one time slot each. In addition, it stores the phase of synchronization signal synchronized with the reference channel based on a detection signal from the reference channel detection circuit 11.
Next, operation of the first embodiment configured as above is explained.
FIG. 2 is a timing chart for explaining the operation of the first embodiment.
First, in the data transmitter A, the discrimination information 1a and the data 2 1 a to 2 n-1 a are time division multiplexed as shown in FIG. 2, a transmission signal is transmitted. Where, in FIG. 2, F is a reference channel, M is an arbitrary channel, F k is k-th bit of the reference channel F and M k is k-th bit of the channel M. Also, in case of time division multiplexing, M k always locates on the M-th time slot behind from F k .
In the data receiver B, the optical receiver 6 converts the transmission signal to electric information.
At this time, that is, when the data receiver B starts up, the synchronization signal phase control circuit 12 outputs a control signal changing phase of the synchronization signal one time slot each to the synchronization signal phase changing circuit 9 and changes the phase of synchronization signal.
Then, the reference channel detection circuit 11 monitors data of each channel extracted in the data extraction circuit 10, detects the reference channel from among the data by finding out a unique signal string of discrimination information and outputs a detection signal to the synchronization signal phase control circuit 12.
Then, the synchronization signal phase control circuit 12 stores the phase synchronized with the reference channel, as shown in FIG. 2, as a reference channel and fixes phase of the synchronization signal output from the synchronization signal phase changing circuit 9 on the reference phase.
Next, it is supposed that the synchronization signal phase control circuit 12 is requested to select an arbitrary channel, for example channel M.
Here, the synchronization signal phase control circuit 12 calculates a time difference between the reference channel F and the channel M, in other words, it counts number of time slots from the reference channel F to the channel M.
Considering the case shown in FIG. 2, the number of time slots from the reference channel F to the channel M is M.
Therefore, the synchronization signal phase control circuit 12 outputs a control signal to shift the reference phase M time slots to the synchronization signal phase changing circuit 9 as shown in FIG. 2.
Then, the synchronization signal phase changing circuit 9 shifts the phase of the synchronization signal (reference phase) M time slots to the channel M and outputs a synchronization signal synchronized with the channel M to the data extraction circuit 10.
Continuously, the data extraction circuit 10 extracts and outputs data of the channel M from among electric information based on the synchronization signal synchronized with the channel M.
Comparing with a prior receiver, the receiver by this embodiment enables to minimize receiver size to about 1/20 and reduce its cost to about 1/10.
Next, the second embodiment is explained.
The second embodiment is the same as the first embodiment except for the synchronization signal phase control means c in the first embodiment.
FIG. 3 is a block diagram of the second embodiment. Where, the component having the same configuration as that of the first embodiment is given the same code number.
13 is a second frequency divider for frequency dividing a transmission clock signal into 1/N and generating a synchronization signal according to each transmission speed of discrimination information 1a and data 2 1 a to 2 n-1 a. Then, it resets frequency division operation at input timing of the reset signal output from the synchronization signal phase control circuit 14 described later, and generates a new cyclic synchronization signal.
14 is a second synchronization signal phase control circuit for outputting a reset signal synchronized with a transmission clock signal, that is, each time slot.
Next, operation of the second embodiment is explained. Where, the operation to extraction of a transmission clock signal is the same as that of the first embodiment, so explanation for it is omitted.
First, while delaying the reset signal one time slot, the synchronization signal phase control circuit 14 outputs the delayed reset signal when the receiver starts up.
Then, the frequency divider 13 outputs a synchronization signal of which phase is shifted one time slot from the synchronization signal before being reset. It continues this operation until detection of a reference channel. When the reference channel is detected, the synchronization signal phase control circuit 14 stores the phase at this time as a reference phase and fixes the phase of the synchronization signal output from the frequency divider 13 on the reference phase.
Here, it is supposed that the synchronization signal phase control circuit 14 is requested to select an arbitrary channel, for example, channel M.
The synchronization signal phase control circuit 14 calculates a time difference between the reference channel F and the channel M, in other words, it counts number of a time slots from the reference channel F to the channel M.
Considering the case shown in FIG. 2, the number of time slots from the reference channel F to the channel M is M. Therefore, the synchronization signal phase control circuit 14 outputs a reset signal at the timing of M-th time slot from the reference channel.
Then, the frequency divider 13 starts frequency dividing in a new phase and outputs a synchronization signal synchronized with the channel M to the data extraction circuit 10 as shown in FIG. 2.
Continuously, the data extraction circuit 10 extracts and outputs data of the channel M from among electric information based on the synchronization signal synchronized with the channel M.
Next, the third embodiment is explained.
The third embodiment is the same as the first embodiment except for the synchronization signal phase control means c in the first embodiment.
FIG. 4 is a block diagram of the third embodiment. Where, the component having the same configuration as that of the first embodiment is given the same code number.
15 is a variable frequency divider that has two frequency division modes, 1/N and 1/(N+1).
Usually, it frequency divides a transmission clock signal with the frequency division mode of 1/N. However, if a control signal of the synchronization signal phase control circuit 16 described later is input, it frequency divides the transmission clock signal with the frequency division mode of 1/(N+1) for cycles instructed by the control signal and then frequency divides the transmission signal with the frequency division mode of 1/N again.
16 is a third synchronization signal phase control circuit. Receiving request for selecting an arbitrary channel, it counts number of time slots from a reference channel to the arbitrary channel and outputs a control signal instructing the number counted as the number of periods to the frequency division changing frequency divider 15.
Next, operation of the third embodiment is explained. Where, the operation to extraction of a transmission clock signal is the same as that of the first embodiment, so explanation for it is omitted.
First, while increasing the number of periods to be instructed one by one, the synchronization signal phase control circuit 16 outputs control signals until the reference channel is detected when the receiver starts up.
Then, the variable frequency divider 15 continues to output in turn synchronization signals of which phases are shifted one time slot each other.
When the reference channel detection means detects a reference channel, the synchronization signal phase control circuit 16 stores the phase at that time as a reference phase and fixes the phase of the synchronization signal output from the variable frequency divider 15 on the reference phase.
Here, it is supposed that the synchronization signal phase control circuit 16 is requested to select an arbitrary channel, for example, channel M.
The synchronization signal phase control circuit 16 calculates a time difference between the reference channel F and the channel M, in other words, it counts number of time slots from the reference channel F to the channel M.
Considering the case shown in FIG. 2, the number of time slots from the reference channel F to the channel M is M. Therefore, the synchronization signal phase control circuit 16 outputs a control signal of which number of cycles is M to the variable frequency divider 15.
The variable frequency divider 15 received the control signal changes the frequency division mode to 1/(N+1) and frequency divides the transmission signals for M cycles by this frequency division mode 1/(N+1), then switches the frequency division mode to 1/N and frequency divides the transmission signals by this frequency division mode again.
Then, the phase of the synchronization signal synchronizes with the channel M as shown in FIG. 2.
Continuously, the data extraction circuit 10 extracts and outputs data of the channel M from among electric signal based on the synchronization signal synchronized with the channel M.
Next, the fourth embodiment is explained.
FIG. 5 is a block diagram of the fourth embodiment. Where, the same component of which configuration is the same as that of the first embodiment is given the same code number.
In the fourth embodiment, the data transmitter A of the first embodiment is added by the second discrimination information generator 50 and the data receiver B of the first embodiment is added by the second reference channel detector 51.
The second discrimination information generator 50 generates different discrimination information from that generated by the discrimination information generator 1.
Where, in the fourth embodiment, it is supposed that the reference channel according to discrimination information generated by the discrimination information generator 1 is the first reference channel and the reference channel according to discrimination information generated by the second discrimination information generator 50 is the second reference channel.
In addition, the first reference channel and the second reference channel are time division multiplexed so that they appear at even time intervals as shown in FIG. 6, that is, the first reference channel and the second reference channel appear at every N/2 time slot if N is an even number or at every (N±1)/2 time slot if N is an odd number.
The second reference channel detector 51 discriminates the discrimination information generated by the second discrimination information generator 50 and detects the second reference channel.
Next, operation of the embodiment configured like this is explained.
In the data transmitter A, at first, the first discrimination information 1a, the second discrimination information 50a and data 2 1 a to 2 n-2 a are time division multiplexed as shown in FIG. 6, and a transmission signal is transmitted. In this figure, F1 is the first reference channel, F2 is the second reference channel, M is an arbitrary channel, F1 k is k-th bit of the reference channel F1 and M k is k-th bit of the channel M. In addition, in case of time division multiplexing, M k always locates M time slots behind from the F1 k .
In the data receiver B, the optical receiver 6 converts the transmission signal to electric information.
At this time, in other words, when the data receiver B starts up, the synchronization signal phase control circuit 12 outputs a control signal to shift phase of the synchronization signal one time slot by one time slot to the synchronization signal phase changing circuit 9 and changes the phase of the synchronization signal.
Then, the reference channel detection circuit 11 and the reference channel detection circuit 51 monitors data of each channel extracted in the data extraction circuit 10, detects the reference channel by finding out a unique signal string of discrimination information and outputs a detection signal to the synchronization signal phase control circuit 12.
Here, it is supposed that the reference channel detection circuit 11 has detected the reference channel F1 earlier than the reference channel detection circuit 51.
Then, the synchronization signal phase control circuit 12 stores the phase synchronized with the reference channel F1 as shown in FIG. 6, fixes the phase of the synchronization signal output from the synchronization signal phase changing circuit 9 on the reference phase.
Continuously, the synchronization signal phase control circuit 12 is requested to select an arbitrary channel, for example, channel M.
Here, the synchronization signal phase control circuit 12 calculates a time difference between the reference channel F1 and the channel M, in other words, it counts number of time slots from the reference channel F1 to the channel M.
Considering the case shown in FIG. 6, the number of time slots from the reference channel F1 to the channel M is M. Therefore, the synchronization signal phase control circuit 12 outputs a control signal to shift the reference phase M time slots to the synchronization signal phase changing circuit 9 as shown in FIG. 2.
Next, the synchronization signal phase changing circuit 9 shifts the phase of the synchronization signal (reference phase) M time slots, and outputs a synchronization signal synchronized with the channel M to the data extraction circuit 10.
Finally, the data extraction circuit 10 extracts and outputs data of the channel M from the electric information based on the synchronization signal synchronized with the channel M.
By the above operation, the reference channel can be detected rapidly even if number of the channels to be transmitted becomes large.
Next, the fifth embodiment is explained.
FIG. 7 is a block diagram of the fifth embodiment. In FIG. 7, the component configured same as that of the first embodiment is given the same code number.
The fifth embodiment is a case having plural types of data transmission speed.
Using concrete figures, the fifth embodiment is explained.
In the data transmitter A, the reference channel generator 1 generates a digital signal, 101010 . . . , of 150 Mb/s transmission speed.
93 NTSC coders 70 1 to 70 93 output compressed signals of 50 Mb/s transmission speed.
4 HDTV coders 71 1 to 71 4 output compressed signals of transmission speed 1.25 Gb/s. These signals are input to the time division multiplexing circuit 3, multiplexed in each bit and in turn to transmission speed 10 Gb/s and transmitted by the optical transmitter 4 as light information.
In the data receiver B, the optical receiver 6 converts the light information transmitted through the optical fiber 5 to electric information. The electric information is branched into two. One of the branched signal is input to the data extraction means 72, another is input to the transmission clock signal extraction circuit 7 and becomes 10 GHz transmission clock signal.
The transmission clock signal of 10 GHz is input to the first frequency divider 74.
Then, it is frequency divided into 1/8 by the first frequency divider 74 to be a synchronization signal of 1.25 GHz. Further, it is frequency divided into 1/8 by the second frequency divider 75 to be a synchronization signal equivalent to 150 MHz.
Output of the first frequency divider 74 is input to the first synchronization signal phase changing circuit 76 and its phase is changed by the synchronization signal phase control circuit 80. Where, the temporal quantity of change of phase is equivalent to 1/8 of 10 GHz in each one step.
Output of the second frequency divider 75 is input to the second synchronization signal phase changing circuit 77 and its phase is changed by the synchronization signal phase control circuit 80. Where, the temporal quantity of change of phase is equivalent to 1/64 of 10 GHz in each one step.
Next, each synchronization signal is input to the first and second data extraction circuits 78 and 79 in the data extraction means 72. By decreasing or increasing the number of steps of phases, the channel of which data must be extracted can be selected.
Further explaining, as shown in FIG. 8, the first data extraction circuit 78 inputs data of 10 Gb/s transmission speed and outputs 1.25 Gb/s transmission speed data according to the output of the first synchronization signal phase changing circuit 76. Therefore, the HDTV compressed signal can be obtained by the first data extraction circuit 78.
Continuously, as shown in FIG. 8, the second data extraction circuit 79 inputs the 1.25 Gb/s transmission speed data output from the first data extraction circuit 78 and outputs 150 Mb/s transmission speed data according to the output of the second synchronization signal phase changing circuit 77. Therefore, the NTSC compressed signal can be obtained by inputting a signal from the second data extraction circuit 79 to 1:3 DEMUX circuit 81, extracting three 50 Mb/s signals in the 1:3 DEMUX circuit 81 and extracting only NTSC compressed signal selected from the three signals.
Next, a concrete operation is explained.
First of all, a reference channel is detected when the data receiver B start up.
For detecting this reference channel, the 10 Gb/s transmission speed data is input to the first data extraction circuit 78, then 1.25 Gb/s transmission speed data is output according to the output the first synchronization signal phase changing circuit 76.
The second synchronization signal phase changing circuit 77 outputs a 150 MHz synchronization signal while shifting phase of the 150 MHz synchronization signal every one time slot, totally 8 time slots, according to the synchronization signal phase control circuit 80.
The second data extraction circuit 79 received the 1.25 Gb/s transmission data outputs 150 Mb/s transmission data according to a synchronization signal from the second synchronization signal phase changing circuit 77.
Then, the 150 Mb/s transmission data is input to the reference channel detection circuit 11 and 8 channels are monitored from among the 64 channels shown in FIG. 9 by the reference channel detection circuit 11.
Next, the synchronization signal phase control circuit 80 instructs the first synchronization signal phase changing circuit 76 so as to output the 1.25 GHz synchronization signal, as shifting its phase every one time slot. The first data extraction circuit 78 outputs 1.25 Gb/s transmission speed data according to the output of the first synchronization signal phase changing circuit 76.
The second synchronization signal phase changing circuit 77 outputs the 150 MHz synchronization signal, as shifting its phase every one time slot, totally 8 time slots, according to instruction of the synchronization signal phase control circuit 80.
The second data extraction circuit 79 received the 1.25 Gb/s transmission speed data outputs 150 Mb/s transmission speed data according to the synchronization signal from the second synchronization signal phase changing circuit 77.
By the above operation, the reference channel detection circuit 11 received the 150 Mb/s transmission speed data monitors the different 8 channels from the latest detected 8 channels.
Like this, until having obtained a code string such as 101010 . . . , the reference channel detection circuit 11 continues the above operation to detect the reference channel.
When the reference channel is detected, the second synchronization signal phase changing circuits 76 and 77 adjust phase of each synchronization signal to the reference channel as shown in FIG. 8. In other words, the phase of the synchronization signal of 1.25 GHz and the phase of the synchronization signal of 150 MHz are fixed on the phase selecting bit of the reference channel.
Here, the case of selecting channel 2 of HDTV is considered.
First, when request to select channel 2 of HDTV is input to the synchronization signal phase control circuit 80, the synchronization signal phase control circuit 80 counts number of time slots from the reference channel to channel 2 of HDTV. In this case, the number of time slots is two as shown in FIG. 9.
Next, the synchronization signal phase control circuit 80 outputs a control signal to shift the phase of the synchronization signal of 1.25 GHz of which phase is fixed on the reference channel as shown in FIG. 9 two time slots to the first synchronization signal phase changing circuit 76.
The first synchronization signal phase changing circuit 76 shifts phase of the synchronization signal of 1.25 GHz two time slots.
By this operation, the synchronization signal of 1.25 GHz synchronizes with channel 2 of HDTV and data of channel 2 of HDTV is extracted from the first data extraction circuit 78.
Next, a case that a request to select NTSC channel 32 is input to the synchronization signal phase control circuit 80 is considered.
First, the synchronization signal phase control circuit 80, as shown in FIG. 9, outputs an instruction to the first synchronization signal phase changing circuit 76 to shift phase of the 1.25 GHz synchronization signal 5 time slots from the reference channel so as to extract data of 24 channels including the NTSC channel 32.
By this operation, the first synchronization signal phase changing circuit 76 shifts phase of the 1.25 GHz synchronization signal 5 time slots from the reference channel and outputs a result to the first data extraction circuit 78.
Then, data of 24 channels including the NTSC channel 32 of 1.25 Gb/s transmission speed are extracted by the first data extraction circuit 78.
Continuously, the synchronization signal phase control circuit 80, as shown in FIG. 9, outputs an instruction to the second synchronization signal phase changing circuit 77 to shift phase of the 150 MHz synchronization signal 5 time slots from the reference channel so as to extract data of NTSC channels 1, 32 and 63 from the 1.25 Gb/s transmission speed data output from the first data extraction circuit 78.
By this operation, the second synchronization signal phase changing circuit 77 shifts phase of the 150 MHz synchronization signal 5 time slots from the reference channel and outputs a result to the second data extraction circuit 79.
Then, the second data extraction circuit 79 extracts data of NTSC channels 1, 32 and 63 from the 1.25 Gb/s transmission speed data.
Next, these data are input to a 1:3 DEMUX circuit 81 and decimated, thus only data of NTSC channel 32 is extracted.
Receiver sensitivity by the present invention as optical receiver is -25 dBm. Its performance is practically equivalent to a prior optical receiver.
It is to be noted that the 1:3 DEMUX circuit 81 is used in this embodiment for extracting NTSC data, however, it is possible to use a frequency divider generating 50 MHz synchronization signal and a synchronization signal phase control circuit controlling 50 MHz synchronization signal instead of the 1:3 DEMUX circuit 81.
|
The present invention provides a method and device for channel selection for setting at least one channel among N channels as a reference channel, detecting temporal location of the reference channel in a reception side, selecting an arbitrary channel using a relative time difference between the detected temporal location of the reference channel and that of the channel to be selected.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to propulsion systems for vertical and short takeoff and landing (V/STOL) aircraft. More particularly, the invention relates to mechanisms for vectoring or directing the flow of exhaust from such propulsion systems.
2. Description of the Related Art
A class of V/STOL aircraft use lift fans or lift engines to generate the thrust needed to cause the aircraft to take-off vertically as well as to move laterally through the air. The exhaust gases from the lift fans are directed, or vectored, in various directions in order to move the aircraft laterally and longitudinally.
One method of directing exhaust flow requires the use of louvers that can be moved to direct the air flow forwardly or rearwardly away from the lift fan. Such an arrangement is described in U.S. Pat. No. 5,312,069. However, as louvers are moved, they tend to obscure or close off part of the exhaust area. This is disadvantageous as it will tend to cause a loss of thrust power.
Another approach is to use a ball and socket joint to provide flow deflection. If ball and socket joints are used for movement of a nozzle, the joints are subject to wear at the points where the joint attaches to the socket. Further, such joints may not seal properly leading to loss of thrust.
SUMMARY OF THE INVENTION
The present invention provides a novel mechanism and methods for directing the flow of exhaust gases associated with a V/STOL aircraft. In a preferred embodiment, the mechanism includes a pair of constant area nozzles associated with a plenum chamber that receives and contains exhaust gases. The nozzles are independently rotatable within circular exhaust openings in the plenum chamber to direct exhaust exiting from the plenum chamber in preselected directions such as vertically downward or directions forward or aft of the vertical plane.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view, partially in cross-section, of the forward end of an exemplary V/STOL aircraft depicting placement of a lift fan, input power shaft and an exhaust system having a plenum with dual exhaust nozzles as constructed in accordance with the present invention.
FIG. 2 a is a side view of portions of the exhaust system wherein the exhaust nozzles are configured to direct exhaust vertically downwardly.
FIG. 2 b is an upward-facing bottom view of the components shown in FIG. 2 a.
FIG. 3 is a side view of portions of the exhaust system wherein the exhaust nozzles are configured to direct exhaust 20 degrees aft.
FIG. 4 a is a side view of portions of the exhaust system wherein the exhaust nozzles are configured to direct exhaust 60 degrees aft.
FIG. 4 b is an upward-facing bottom view of the components shown in FIG. 4 a.
FIG. 5 a is a side view of portions of the exhaust system wherein the exhaust nozzles are configured to direct exhaust 15 degrees forward.
FIG. 5 b is an upward-facing bottom view of the components shown in FIG. 5 a.
FIG. 6 is a side cross-sectional view of an exemplary nozzle shown apart from the remainder of the exhaust assembly.
FIG. 6A is an end-on view of the proximal end of the nozzle taken along lines A—A in FIG. 6 .
FIG. 6B is an end-on view of the distal end of the nozzle taken along lines B—B in FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
General details concerning the construction and operation of V/STOL aircraft and their propulsion systems are described in U.S. Pat. Nos. 5,209,428; 5,312,069; 5,320,305 and 4,901,947, all of which are assigned to the assignee of the present invention. These patents are each incorporated herein by reference.
FIG. 1 illustrates the forward portion of an exemplary V/STOL aircraft 10 having a fuselage 12 with a longitudinal axis 13 . The fuselage 12 contains a cockpit 14 , landing wheels 16 and other known features. The fuselage 12 defines an air intake vent 18 upon its upper surface. A vertically-disposed, bladed lift fan 20 is retained within the fuselage 12 to receive air from the intake bell mouth 18 . The lift fan 20 is a thrust engine that generates thrust for the aircraft 10 . It will be understood with reference to U.S. Pat. No. 5,209,428 that the lift fan 20 is operably interconnected with a more rearwardly-located engine section (not shown) that is also used for propulsion of the aircraft 10 . The details of the more rearwardly-located fan section will not be described here. An input power shaft 22 transmits rotational power from the main engine (not shown) of the aircraft 10 to the lift fan 20 for rotation of the blades within the fan 20 . The lift fan 20 is surrounded by a cylindrical housing 21 with exhaust flow tubing 23 disposed beneath. As a result, exhaust gases generated by the lift fan 20 are directed through exhaust flow tubing 23 .
A plenum chamber 24 is located below the lift fan 20 and exhaust flow tubing 23 for the collection of exhaust gases generated by the lift fan 20 . The construction of the plenum chamber 24 is best appreciated with reference to FIGS. 2 a and 2 b wherein the underside of the structure is shown in detail. The plenum chamber 24 has an outer shell that defines a pair of curved exhaust tubes 26 , 28 that each terminate at a lower end in a circular exhaust opening 30 . The circular openings 30 are located one behind the other along the axis 13 of the aircraft 10 , as FIG. 2 b of the drawings shows. The circular openings 30 are also angled laterally and longitudinally from the vertical plane. The two openings have the same angle longitudinally, but opposing matched angles laterally. A preferred angle of lateral offset from the vertical plane is 40 degrees.
A forward nozzle 32 and a rear nozzle 34 are rotationally affixed to the circular openings 30 . Due to the “one behind the other” arrangement of the circular openings 30 , the forward nozzle 32 is located forwardly from the rear nozzle 34 along the axis 13 of the aircraft 10 . A single nozzle 32 is depicted in FIGS. 6, 6 A and 6 B. It is noted that the nozzles 32 , 34 are tubular and provide a transition from a circular cross section at the plenum (see FIG. 6A) to an oval shape at the exit, as shown in FIG. 6 B. The oval shape is advantageous and preferred as it helps the nozzles 32 , 34 lie flatter against the lower surface of the plenum chamber 24 when the nozzles 32 , 34 are rotated to more extreme angles, such as the 60 degree angle depicted in FIGS. 4 a and 4 b . Each of the nozzles 32 , 34 have a proximal end 36 having an opening that is circular in shape so as to complimentary to the circular openings 30 . The circular shape of the opening is created by cutting the nozzle at an angle from the longitudinal axis of the nozzle. The distal end 38 of each of the nozzles 32 , 34 has an opening that is cut perpendicular to the longitudinal axis of the nozzle (see FIGS. 6 and 6B) and, therefore, has a substantially oval shape. Vanes 40 , of a type known in the art, are retained within the proximal ends 36 of the nozzles 32 , 34 to assist exhaust flow through the nozzles 32 , 34 .
The plenum chamber and nozzles 32 , 34 can be considered collectively to provide an exhaust assembly or system 42 for vectoring exhaust gases generated by the lift fan 20 . It is noted that the plenum chamber 24 and the nozzles 32 , 34 are located beneath the aircraft 10 and centrally between the two lateral sides of the aircraft 10 . Thus, the nozzles 32 , 34 are located proximate the center of gravity for the aircraft 10 .
Each of the nozzles 32 , 34 are rotatable on a bearing assembly (not shown) within their respective circular openings 30 by toothed gearing, which is not shown in detail as the construction and operation of such is well known. It is noted that various styles of bearing assemblies and gearing, including rack-and-pinion and worm gearing may be used to actuate the nozzles 32 , 34 and cause them to selectively rotate within the circular openings 30 .
In operation, the nozzles 32 , 34 may be oriented, or directed, to various angled positions by rotation of the nozzles 32 , 34 within their openings 30 . FIGS. 2 a and 2 b depict the nozzles 32 , 34 oriented so that the distal end 38 of each nozzle 32 , 34 is directed in a vertically downward position as would be used during the take-off phase of operation for the aircraft 10 .
FIG. 3 illustrates the exhaust assembly 42 in a configuration wherein the nozzles 32 , 34 are oriented to direct exhaust from the plenum chamber 24 at an angle of about 20 degrees rearward of vertical plane 44 . To achieve this position, the nozzles 32 , 34 have been rotated within their respective circular openings 30 until the nozzles 32 , 34 are oriented at the appropriate angle. The orientation of the circular exit plane determines the range of motion for the nozzles 32 , 34 .
FIGS. 4 a and 4 b show the exhaust assembly 42 in a configuration wherein the nozzles 32 , 34 are oriented so that exhaust from the plenum chamber 24 is directed rearwardly from the vertical plane at an angle of approximately 60 degrees. To achieve this position, the nozzles 32 , 34 have again been rotated within their respective circular openings 30 until the nozzles 32 , 34 are oriented at the appropriate angle.
In FIGS. 5 a and 5 b , the exhaust assembly 42 in a configuration wherein the nozzles 32 , 34 are oriented so that exhaust from the plenum chamber 24 is vectored forwardly from the vertical plane at an angle of approximately 20 degrees. To achieve this position, the nozzles 32 , 34 have been further rotated within their respective circular openings 30 until the nozzles 32 , 34 are oriented at the appropriate angle.
From the above description, it can be seen that the exhaust assembly 42 permits exhaust gases to be vectored from the plenum chamber 24 at angles within a range from 20 degrees forward of vertical plane 44 to 60 degrees aft of vertical plane 44 . Generally, 180 degrees of rotation will vector the thrust from stop to stop.
During adjustment of the nozzles 32 , 34 from position to position, the nozzles 32 , 34 are rotated in opposite directions from one another so that the lateral thrust forces generated by the exhaust gases being emitted from the nozzles 32 , 34 will offset one another and, thereby, reduce or eliminate the inducement of yawing moments to the aircraft 10 . It is also noted that the nozzles 32 , 34 provide a constant area for exhaust of gases regardless of the orientation of the nozzles 32 , 34 with respect to the plenum chamber 24 , in contrast to arrangements like louvers, which vary exhaust area with deflection angle.
It will be apparent to those skilled in the art that modifications, changes and substitutions may be made to the invention shown in the foregoing disclosure. Accordingly, it is appropriate that the appended claims be construed broadly and in the manner consisting with the spirit and scope of the invention herein.
|
A mechanism and methods for directing the flow of exhaust gases associated with a V/STOL aircraft. A pair of constant area nozzles are associated with a plenum chamber that receives and contains exhaust gases. The nozzles are independently rotatable within circular exhaust openings in the plenum chamber to direct, or vector, exhaust exiting from the plenum chamber in preselected directions such as vertically downward or directions forward or aft of the vertical plane.
| 1
|
RELATED APPLICATIONS
[0001] This application claims the priority benefit of provisional applications entitled CYCLIC OLEFIN POLYMER COMPOSITIONS FOR USE IN TEMPORARY WAFER BONDING PROCESSES, application Ser. No. 61/924,442, filed Jan. 7, 2014, and ULTRATHIN POLYSILOXANE COATINGS AS LOW-FORCE MECHANICAL RELEASE LAYERS FOR ADHESIVELY BONDED MICROELECTRONICS SUBSTRATES, application Ser. No. 61/952,945, filed Mar. 14, 2014, each of which is incorporated by reference herein. This application is also a continuation-in-part of CYCLIC OLEFIN POLYMER COMPOSITIONS AND POLYSILOXANE RELEASE LAYERS FOR USE IN TEMPORARY WAFER BONDING PROCESSES, application Ser. No. 14/590,531, filed Jan. 6, 2015, which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] This invention relates to release layers and bonding materials for temporary wafer bonding processes. More particularly, the invention generally relates to the use of a lamination process to apply pre-formed dry films for temporary wafer bonding purposes.
[0004] Description of the Prior Art
[0005] Wafer bonding materials protect device features on the front side of a device substrate, and provide adhesion to a carrier substrate and mechanical support for the thinned wafers during backside processing. 3D-IC processing, especially with through-silicon via (“TSV”) and through-glass via (“TGV”) technology, requires temporary wafer bonding materials to survive processes at high temperatures and high vacuum, such as plasma-enhanced chemical vapor deposition (“PECVD”). This technology also requires that the materials can be removed easily from the wafers after processing. Additionally, lower cost of ownership is needed for the 3D-IC to be adopted by the manufacturers.
[0006] Integrated circuit and semiconductor packaging manufacturers are continually looking for temporary wafer bonding technology with low cost of ownership, that uses materials capable of surviving processing at high temperatures and under high vacuum, and that can be easily cleaned after processing. So far, no single technology/material can satisfy all these requirements. Cyclic olefin copolymer (COC) bonding materials are one class of materials that are commonly used. These COCs, such as those formulated using TOPAS® and APEL® materials, are produced by chain copolymerization of cyclic monomers with ethene. These COC materials are good for some applications, but it is very difficult to obtain a clear solution in commonly-used solvents such as d-limonene and mesitylene, and it can also be difficult to clean them off the substrates after processing.
[0007] In some temporary bonding schemes, such as ZoneBOND® zonal bonding from Brewer Science, Inc. (described in US Patent Publication No. 2009/0218560 and application Ser. No. 12/819,680, both of which are hereby incorporated by reference), carrier wafers may require pretreatment with a coating before the wafers are bonded together. Previously, a halogenated silane in a fluorinated solvent, such as 3M FC-40 Fluorinert™ electronic liquid, was used for carrier wafer preparation. However, the silane/FC-40 solution is not a practical coating material because it is unstable, and FC-40 is restricted for use in microelectronics manufacturing because of environmental concerns. Vapor deposition of fluorinated silanes has been used previously to treat the surfaces of silicon wafers. However, vapor deposition is a process that is costly because of both the time involved and the expensive, high-quality tooling it requires.
[0008] There is a need for additional bonding methods and materials that overcome the shortcomings described above.
SUMMARY OF THE INVENTION
[0009] In one or more embodiments, a temporary bonding method is provided. The method involves providing a stack comprising:
a first substrate having a back surface and a front surface; a bonding layer adjacent the front surface, with the bonding layer being formed from a composition comprising a cyclic olefin polymer dissolved or dispersed in a solvent system; and a second substrate having a first surface. The first and second substrates are separated without subjecting the stack to heat.
[0013] In one or more embodiments, the invention provides a temporary bonding method comprising:
[0014] providing a stack comprising:
a first substrate having a back surface and a front surface; a bonding layer adjacent the front surface; and a second substrate having a first surface, with the first surface including a polysiloxane nonstick layer adjacent the bonding layer.
The first and second substrates are then separated.
[0018] In one or more embodiments, the invention provides an article comprising a first substrate having a back surface and a front surface. There is a bonding layer adjacent the front surface. The article also comprises a second substrate having a first surface, with the first surface including a polysiloxane nonstick layer adjacent the bonding layer.
[0019] In one or more embodiments, the invention provides a temporary bonding method comprising:
[0020] (i) providing a free-standing film comprising a cyclic olefin polymer;
[0021] (ii) forming a stack at a temperature of at least 100° C., wherein the stack comprises a first substrate having a back surface and a front surface; a bonding layer adjacent the front surface, the bonding layer being formed from the free-standing film; and a second substrate having a first surface; and
[0022] (iii) separating the first and second substrates.
[0023] In one or more embodiments, the invention provides a temporary bonding method comprising:
[0024] (i) providing a bonding film comprising a cyclic olefin polymer;
[0025] (ii) forming a stack at a temperature of at least 100° C., wherein the stack comprises a first substrate having a back surface and a front surface; a bonding layer adjacent the front surface, the bonding layer being formed from the bonding film; and a second substrate having a first surface; and
[0026] (iii) separating the first and second substrates.
[0027] In one or more embodiments, the invention provides a temporary bonding method comprising:
[0028] (i) providing a bonding film;
[0029] (ii) applying a wetting liquid onto (a) a first substrate having a back surface and a front surface and/or (b) a second substrate having a first surface;
[0030] (iii) forming a stack at a temperature of at least 100° C., wherein the stack comprises the first substrate; a bonding layer adjacent the front surface, the bonding layer being formed from the bonding film; and the second substrate; and
[0031] (iv) separating the first and second substrates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a cross-sectional view of a schematic drawing showing a preferred embodiment of the invention;
[0033] FIG. 2 is a schematic depicting a wet lamination system;
[0034] FIG. 3 is a graph depicting the thermogravimetric analysis (“TGA”) data of the bonding material from Example 18;
[0035] FIG. 4 is a scanning acoustic microscope image of the wafer bonded in Example 19;
[0036] FIG. 5 is a photograph of the wafer pair of Example 20 after 300° C. heat treatment;
[0037] FIG. 6 is an IR image of the thinned wafer pair of Example 21 after a PECVD process; and
[0038] FIG. 7 is a scanning acoustic microscope image of the bonded wafer pair of Example 23 after a 260° C., 30-minute heat treatment on a hotplate;
[0039] FIG. 8 is a photograph of the wafer of Example 26 after lamination at 200° C.;
[0040] FIG. 9 is a photograph of the wafer of Example 27 after lamination at 160° C.;
[0041] FIG. 10 is a photograph of the wafer of Example 29 after vacuum lamination at 150° C.;
[0042] FIG. 11 is a photograph of the wafer of Example 30;
[0043] FIG. 12 depicts the thickness and total thickness variation for the spin-coated and laminated wafers of Example 31; and
[0044] FIG. 13 is a photograph of the wafer of Example 32 after wet lamination at 80° C.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Release Layers
[0045] In one embodiment, a release layer is utilized. Several types of release layers can be utilized with the present invention, as explained in more detail below, but one preferred type is a nonstick layer. Preferred compositions for use in forming a nonstick release layer according to the invention comprise siloxane polymers and copolymers (both copolymers with siloxanes as well as copolymers with non-siloxanes). Preferred siloxanes are those selected from the group consisting of epoxyl, ethoxyl, acrylic, hydroxyl, vinyl, and amine, and mixtures thereof. Especially preferred siloxanes are epoxycyclohexylethylmethylsiloxane-dimethylsiloxane copolymers (ECMS-327 from Gelest), ECMS-924 (Gelest), VDT-5035 (Gelest), EBP-234 (Gelest), AMS-2202 (Gelest), AMS-1203 (Gelest), and mixtures thereof. The composition preferably comprises from about 0.01% to about 8.0% by weight, more preferably from about 0.05% to about 5.0% by weight, and even more preferably from about 0.1% to about 0.8% by weight siloxane, based upon the total weight of the composition taken as 100% by weight. Preferably, the polymer has a weight average molecular weight of from about 200 Daltons to about 4,000,000 Daltons, more preferably from about 1,000 Daltons to about 400,000 Daltons, and even more preferably from about 2,000 Daltons to about 40,000 Daltons.
[0046] The nonstick compositions also preferably comprise a catalyst. Suitable catalysts include those selected from the group consisting of photoacid generators, thermal acid generators, and mixtures thereof. Especially preferred catalysts include K-PURE® TAG-2689 from King Industries or 1, 1′-azobis(cyclohexanecarbonitrile). The nonstick composition preferably comprises from about 0.002% to about 0.1% by weight catalyst, more preferably from about 0.005% to about 0.1% by weight catalyst, and even more preferably from about 0.008% to about 0.1% by weight catalyst, based upon the total weight of the composition taken as 100% by weight.
[0047] The nonstick compositions also comprise an industry-accepted, safe solvent, which is typically a polar solvent. Suitable solvents include those selected from the group consisting of propylene glycol monomethyl ether (“PGME”), d-limonene, ethyl 3-ethoxypropionate, propoxy propanol (“PnP”), propylene glycol methyl ether acetate (“PGMEA”), ethyl lactate, and mixtures thereof. The composition preferably comprises from about 90% to about 99.99% by weight solvent, more preferably from about 92% to about 99.5% by weight solvent, and even more preferably from about 95% to about 99% by weight of this solvent, based upon the total weight of the nonstick composition taken as 100% by weight. One especially preferred solvent mixture is a mixture of PGME (from about 5% to about 40% by weight) and d-limonene (from about 60 to about 95% by weight).
[0048] In one embodiment, the nonstick composition is essentially free of silanes. That is, the nonstick composition comprises less than about 0.5%, preferably less than about 0.1%, and more preferably about 0% by weight silanes, based upon the total weight of the nonstick composition taken as 100% by weight. In another embodiment, the nonstick composition consists essentially of, or even consists of, a siloxane, a catalyst, and solvent (preferably a polar solvent). The nonstick composition is formed by simply mixing the above ingredients together.
Bonding Compositions
[0049] The bonding material comprises a polymer or a blend of polymers dissolved or dispersed in a solvent system. Other additives such as antioxidants, surfactants, tackifiers, and toners may be included in the bonding material, depending upon the desired coating, bonding, and debonding performance.
[0050] In one embodiment, the polymer or blend of polymers are selected from the group consisting of polymers and oligomers of cyclic olefins, epoxies, acrylics, styrenics, vinyl halides, vinyl esters, polyamides, polyimides, polysulfones, polyethersulfones, cyclic olefins, polyolefin rubbers, polyurethanes, ethylene-propylene rubbers, polyamide esters, polyimide esters, polyacetals, and polyvinyl buterol, with the most preferred being cyclic olefin polymers. Suitable cyclic olefin polymers include those prepared from a single monomer, such as norbornene, by metathesis polymerization techniques and then hydrogenated to produce the final product. Particularly preferred COP materials include those commercialized under the names Zeonex® 5000 and Zeonex 480R.
[0051] The polymer or polymer blend should be present in the bonding composition at levels of from about 1% by weight to about 60% by weight, more preferably from about 20% by weight to about 40% by weight, and even more preferably from about 25% by weight to about 35% by weight, based upon the total weight of the bonding composition taken as 100% by weight. Preferably, the polymer has a weight average molecular weight of from about 1,000 Daltons to about 200,000 Daltons, more preferably from about 5,000 Daltons to about 150,000 Daltons, and even more preferably from about 10,000 Daltons to about 100,000 Daltons.
[0052] Suitable solvent systems include hydrocarbon solvents such as those selected from the group consisting of d-limonene, mesitylene, cyclooctane, and bicyclohexyl. The solvent or solvents should be present in the composition at levels of from about 40% by weight to about 99% by weight, more preferably from about 60% by weight to about 80% by weight, and even more preferably from about 65% by weight to about 75% by weight, based upon the total weight of the composition taken as 100% by weight.
[0053] Suitable antioxidants include phenolic antioxidants such as those selected from the group consisting of 1,3,5-trimethyl-2,4,6-tris (3,5-di-tert-butyl-4-hydroxybenzyl) benzene (sold as Irganox ® 1330) and benzenepropanoic acid, 3,5-bis(1,1-dimethylethyl)-4-hydroxy-1,6-hexanediyl ester (Irganox® L-109). The antioxidant should be present in the composition from about 0.05% by weight to about 10% by weight, more preferably from about 1% by weight to about 5% by weight, and even more preferably from about 2% by weight to about 4% by weight, based upon the total weight of the composition taken as 100% by weight.
[0054] In a preferred embodiment, the bonding compositions are essentially free of cyclic olefin copolymers. That is, the bonding composition comprises less than about 0.5%, preferably less than about 0.1%, and more preferably about 0% by weight cyclic olefin copolymers, based upon the total weight of the bonding composition taken as 100% by weight.
[0055] In another embodiment, the bonding compositions are essentially free of pinene and poly(pinene). That is, the bonding composition comprises less than about 0.5%, preferably less than about 0.1%, and more preferably about 0% by weight pinene and poly(pinene), based upon the total weight of the bonding composition taken as 100% by weight.
[0056] In another embodiment, the bonding compositions are essentially free of rosin esters. That is, the bonding composition comprises less than about 0.5%, preferably less than about 0.1%, and more preferably about 0% by weight rosin esters, based upon the total weight of the bonding composition taken as 100% by weight.
[0057] In another embodiment, the bonding compositions are essentially free of silicones. That is, the bonding composition comprises less than about 0.5%, preferably less than about 0.1%, and more preferably about 0% by weight silicones, based upon the total weight of the bonding composition taken as 100% by weight.
[0058] In one embodiment, the bonding compositions consist essentially of, or even consist of, a cyclic olefin polymer, antioxidant, and solvent. In a further embodiment, the bonding compositions consist essentially of, or even consist of, a cyclic olefin polymer, antioxidant, solvent, and any surfactants, toners, and/or tackifiers.
[0059] The compositions are formed by simply mixing the above ingredients so as to create a substantially uniform mixture of the ingredients. Preferably, any additional ingredients, such as antioxidants, are dissolved in the solvent first, and the polymer or polymers are added last. Advantageously, this results in the formation of visually clear solutions. Furthermore, wafer pairs bonded with these bonding compositions are able to survive (i.e., there are no defects in the bond line) treatment on a hot plate at about 300° C. for about 30 minutes. These bonding materials also provide excellent overall total thickness variation (“TTV,” less than about 3 μm for 50-μm bond line) and can survive a 200° C. PECVD process.
Inventive Method
[0060] Referring to FIG. 1( a ) (not to scale), a precursor structure 10 is depicted in a schematic and cross-sectional view. Structure 10 includes a first substrate 12 . Substrate 12 has a front or device surface 14 , a back surface 16 , and an outermost edge 18 . Although substrate 12 can be of any shape, it would typically be circular in shape. Preferred first substrates 12 include device wafers such as those whose device surfaces comprise arrays of devices (not shown) selected from the group consisting of integrated circuits, MEMS, microsensors, power semiconductors, light-emitting diodes, photonic circuits, interposers, embedded passive devices, and other microdevices fabricated on or from silicon and other semiconducting materials such as silicon-germanium, gallium arsenide, gallium nitride, aluminum gallium arsenide, aluminum indium gallium phosphide, and indium gallium phosphide. The surfaces of these devices commonly comprise structures (again, not shown) formed from one or more of the following materials: silicon, polysilicon, silicon dioxide, silicon (oxy)nitride, metals (e.g., copper, aluminum, gold, tungsten, tantalum), low k dielectrics, polymer dielectrics, and various metal nitrides and silicides. The device surface 14 can also include at least one structure selected from the group consisting of: solder bumps; metal posts; metal pillars; and structures formed from a material selected from the group consisting of silicon, polysilicon, silicon dioxide, silicon (oxy)nitride, metal, low k dielectrics, polymer dielectrics, metal nitrides, and metal silicides.
[0061] A composition is applied to the first substrate 12 to form a bonding layer 20 on the device surface 14 , as shown in FIG. 1( a ) . Bonding layer 20 has an upper surface 21 remote from first substrate 12 , and preferably, the bonding layer 20 is formed directly adjacent the device surface 14 (i.e., without any intermediate layers between the bonding layer 20 and substrate 12 ). Although bonding layer 20 is shown to cover the entire device surface 14 of first substrate 12 , it will be appreciated that it could be present on only portions or “zones” of device surface 14 , as shown in U.S. Patent Publication No. 2009/0218560.
[0062] The bonding composition can be applied by any known application method, including dip coating, roller coating, slot coating, die coating, screen printing, draw-down coating, or spray coating. Additionally, the coatings may be formed into free-standing films before application to the device substrate or carrier substrate surface. One preferred method involves spin-coating the composition at speeds of from about 200 rpm to about 3,000 rpm (preferably from about 500 rpm to about 2,000 rpm) for a time period of from about 5 seconds to about 120 seconds (preferably from about 10 seconds to about 60 seconds). After the composition is applied, it is preferably heated to a temperature of from about 40° C. to about 250° C., and more preferably from about 90° C. to about 220° C. and for time periods of from about 60 seconds to about 90 minutes (preferably from about 180 seconds to about 60 minutes). Depending upon the composition used to form the bonding layer 20 , baking can also initiate a crosslinking reaction to cure the layer 20 . In some embodiments, it is preferable to subject the layer to a multi-stage bake process, depending upon the composition utilized. Also, in some instances, the above application and bake process can be repeated on a further aliquot of the composition, so that the first bonding layer 20 is “built” on the first substrate 12 in multiple steps. The resulting layer 20 should have an average thickness (average taken over five measurements) of from about 1 μm to about 200 μm, more preferably from about 10 μm to about 150 μm, and even more preferably from about 30 μm to about 120 μm.
[0063] The materials from which bonding layer 20 is formed should be capable of forming a strong adhesive bond with the first and second substrates 12 and 24 , respectively. Anything with an adhesion strength of greater than about 50 psig, preferably from about 80 psig to about 250 psig, and more preferably from about 100 psig to about 150 psig, as determined by ASTM D4541/D7234, would be desirable for use as bonding layer 20 , with the exemplary compositions having been described above.
[0064] A second precursor structure 22 is also depicted in a schematic and cross-sectional view in FIG. 1( a ) . Second precursor structure 22 includes a second substrate 24 . In this embodiment, second substrate 24 is a carrier wafer. That is, second substrate 24 has a front or carrier surface 26 , a back surface 28 , and an outermost edge 30 . Although second substrate 24 can be of any shape, it would typically be circular or rectangular in shape and sized similarly to first substrate 12 . Preferred second substrates 24 include silicon, sapphire, quartz, metals (e.g., aluminum, copper, steel), and various glasses and ceramics. Suitable carrier substrates should have a similar coefficient of thermal expansion (CTE) to the device substrate.
[0065] A composition is applied to the second substrate 24 to form a release (preferably nonstick, in this embodiment) layer 32 on the carrier surface 26 , as shown in FIG. 1( a ) . (Alternatively, structure 22 can be provided already formed.) Nonstick layer 32 has an upper surface 33 remote from second substrate 24 , and a lower surface 35 adjacent second substrate 24 . Preferably, the nonstick layer 32 is formed directly adjacent the carrier surface 26 (i.e., without any intermediate layers between the second bonding layer 32 and second substrate 24 ).
[0066] The nonstick composition can be applied by any known application method, with one preferred method being spin-coating the composition at speeds of from about 500 rpm to about 5,000 rpm (preferably from about 500 rpm to about 2,000 rpm) for a time period of from about 5 seconds to about 120 seconds (preferably from about 30 seconds to about 90 seconds). After the composition is applied, it is preferably heated to a temperature of from about 100° C. to about 300° C., and more preferably from about 150° C. to about 250° C. and for time periods of from about 30 seconds to about 5 minutes (preferably from about 90 seconds to about 3 minutes). Nonstick layer 32 preferably has an average thickness of less than about 1 μm, preferably from about 0.1 μm to about 1 μm, and more preferably from about 1 μm to about 25 μnm.
[0067] Referring to structure 22 of FIG. 1( a ) again, although nonstick layer 32 is shown to cover the entire surface 26 of second substrate 24 , it will be appreciated that it could be present on only portions or “zones” of carrier surface 26 similar to as was described with bonding layer 20 . Regardless, the dried/cured layer 32 will have a high contact angle with water, which effects polymer release during the debonding step (discussed below). Typical contact angles (measured as described in Example 10) will be at least about 60°, preferably from about 60° to about 120°, more preferably from about 90° to about 110°, and even more preferably from about 100° to about 110°. The nonstick layer 32 also preferably has an adhesion strength of less than about 50 psig, preferably less than about 35 psig, and more preferably from about 1 psig to about 30 psig, determined as described above.
[0068] Structures 10 and 22 are then pressed together in a face-to-face relationship, so that upper surface 21 of bonding layer 20 is in contact with upper surface 33 of nonstick layer 32 ( FIG. 1( b ) ). While pressing, sufficient pressure and heat are applied for a sufficient amount of time so as to effect bonding of the two structures 10 and 22 together to form bonded stack 34 . The bonding parameters will vary depending upon the composition from which bonding layer 20 is formed, but typical temperatures during this step will range from about 100° C. to about 400° C., and preferably from about 150° C. to about 250° C., with typical pressures ranging from about 100 N to about 20,000 N, and preferably from about 1,000 N to about 10,000 N, for a time period of from about 1 minute to about 20 minutes, preferably from about 2 minutes to about 10 minutes, and more preferably from about 3 minutes to about 5 minutes.
[0069] In an alternative embodiment, it will be appreciated that bonding layer 20 could be applied to upper surface 33 of nonstick layer 32 , using the application process described previously, rather than being applied to surface 14 of first substrate 12 . In this instance, the first substrate 12 would then be subjected to the above bonding process so as to bond surface 14 of first substrate 12 to bonding layer 20 , which was previously formed on upper surface 33 of nonstick layer 32 .
[0070] Regardless of which embodiment was used to form the bonded stack 34 , the first substrate 12 can now be safely handled and subjected to further processing that might otherwise have damaged first substrate 12 without being bonded to second substrate 24 . Thus, the structure can safely be subjected to backside processing such as back-grinding, chemical-mechanical polishing (“CMP”), etching, metallizing, dielectric deposition, patterning (e.g., photolithography, via etching), passivation, annealing, and combinations thereof, without separation of substrates 12 and 24 occurring, and without infiltration of any chemistries encountered during these subsequent processing steps. Not only can bonding layer 20 survive these processes, it can also survive processing temperatures up to about 450° C., preferably from about 200° C. to about 400° C., and more preferably from about 200° C. to about 350° C.
[0071] Once processing is complete, the substrates 12 and 24 can be separated by any number of separation methods (not shown). One method involves dissolving the bonding layer 20 in a solvent (e.g., limonene, dodecene, PGME). Alternatively, substrates 12 and 24 can also be separated by first mechanically disrupting or destroying bonding layer 20 using laser ablation, plasma etching, water jetting, or other high energy techniques that effectively etch or decompose bonding layer 20 . It is also suitable to first saw or cut through the bonding layer 20 or cleave the layer 20 by some equivalent means. Furthermore, it will be appreciated that other layers (not shown) might be included in the stack, and debonding could take place at that other layer instead of at bonding layer 20 . For example, a cleaning layer might be included, and debonding could be carried out by dissolving that cleaning layer. As another example, a laser release layer could be included, and debonding could be effected by laser ablation across that laser release layer.
[0072] In situations where a bonding composition other than a cyclic olefin polymer-containing composition is utilized, a suitable separation method involves heating the bonded stack 34 to temperatures of at least about 100° C., preferably from about 150° C. to about 220° C., and more preferably from about 180° C. to about 200° C. It will be appreciated that at these temperatures, the bonding layer 20 will soften, allowing the substrates 12 and 24 to be separated (e.g., by a slide debonding method, such as that described in U.S. Patent Publication No. 2008/0200011, incorporated by reference herein).
[0073] It will be appreciated that embodiments using the inventive cyclic olefin polymer-containing compositions avoids the need to heat the bonding layer 20 prior to separation. That is, after processing has been completed, the stack 34 can be separated without any heat exposure, using a low-force mechanical debonding method. In this instance, the stack 34 is exposed to temperatures of less than about 100° C., preferably less than about 75° C., more preferably less than about 50° C., even more preferably less than about 30° C., and most preferably about ambient temperatures (and certainly no lower than ambient temperatures), prior to and during the separating. It will be understood that a lack of heat exposure during separation does not exclude heat exposure that occurs during the stack processing, prior to separation, but simply that heat exposure stops after processing is complete. So, for example, the heat exposure that might have occurred during stack processing will have ended at least about 60 seconds, and more preferably at least about 300 seconds prior to stack separation.
[0074] Regardless of which of the above means is utilized, a low mechanical force (e.g., finger pressure, gentle wedging) can then be applied to completely separate the substrates 12 and 24 . After separation, any remaining bonding layer 20 can be removed with a solvent capable of dissolving the particular layer 20 . In fact, the inventive bonding layer 20 is highly removable by conventionally-used solvents. That is, the bonding layer 20 can be at least about 95% removed, preferably at least about 98% removed, and more preferably about 100% removed, upon being in contact with a typical cleaning solvent (e.g., d-limonene) at ambient temperatures for a time period of from about 1 minute to about 10 minutes, and preferably from about 3 minutes to about 5 minutes.
[0075] In the above embodiments, the nonstick layer 32 is shown on a second substrate 24 that is a carrier wafer, while bonding layer 20 is shown on a first substrate 12 that is a device wafer. It will be appreciated that this substrate/layer scheme could be reversed. That is, the nonstick layer 32 could be formed on first substrate 12 (the device wafer) while bonding layer 20 is formed on second substrate 24 (the carrier wafer). The same compositions and processing conditions would apply to this embodiment as those described above. Additionally, the use of the nonstick layer 32 is optional. Bonding layer 20 could be used alone, without the presence of nonstick layer 32 . Bonding layer 20 could also be used with additional bonding materials, structural support layers, other types of release layers (as noted previously, including, but not limited to, mechanical debonding, laser debonding, and thermal or chemical debonding), lamination aid layers, tie layers (for adhesion to initial substrate), contamination control layers, and cleaning layers. Preferred structures and application techniques will be dictated by application and process flow.
[0076] Polymeric structural support layers that can be used in combination with the COP bonding materials can comprise monomers, oligomers, polymers, suspended particles, and/or combinations thereof. Examples of suitable monomers, oligomers, and polymers include those selected from the group consisting of cyclic olefin polymers and copolymers, polyimides, polyisobutylenes, hydrocarbon resins, epoxy resins, fluoropolymers, polysulfones, polyethersulfones, polyether ether ketones, polyhydroxyethers, and polyvinylbutyrals. Suitable suspended particles include those selected from the group consisting of alumina, ceria, titania, silica, zirconia, graphite, and nanoparticles, sol-gel particles, and mixtures thereof. Preferred compositions will be structurally rigid at the temperature of use as indicated by glass transition temperature, coefficient of thermal expansion, and modulus.
[0077] Mechanical carrier release layers (in addition to, or in lieu of, the polysiloxane layers discussed above) used in conjunction with the COP bonding materials can be composed of monomers, oligomers, and/or polymers. Examples of suitable monomers, oligomers, and polymers include cyclic olefin polymers and copolymers, polyisobutylenes, hydrocarbon resins, epoxy resins, fluoropolymers, polyimides, polysulfones, polyhydroxyethers, polyvinylbutyrals, amorphous fluoropolymers with high atomic fluorine content such as fluorinated siloxane polymers, fluorinated ethylene-propylene copolymers, tetrafluoroethylene hexafluoropropylene, vinylidene fluoride terpolymer, hexafluoropropylene, vinyldene fluoride copolymer, vinylidene fluoride polymer, and polymers with pendant perfluoroalkoxy groups.
[0078] Laser carrier release layers used in conjunction with the COP bonding materials can be composed of monomers, oligomers, and/or polymers. One example of a suitable laser release layer is polyimides.
Inventive Methods with Pre-Formed Dry Films and Wet Lamination
[0079] In further embodiments, the present invention involves a process of lamination, preferably wet lamination, to apply a thermoplastic or other polymeric dry bonding material film onto a substrate for temporary wafer bonding applications. Generally, the process bonds an active or device substrate to a carrier substrate in order to protect the device substrate during backside processing. Compared to traditional hot roll lamination or vacuum lamination used to apply dry bonding film onto silicon or glass wafer substrates, wet lamination technology enables the lamination of dry bonding material films with higher melt flow characteristics at a lower temperature and reduces voids formation compared to dry film lamination.
[0080] As discussed below in further detail, the present invention can be directed to a lamination method for temporary wafer bonding applications that utilizes a step of pre-wetting a substrate and then laminating a bonding film to the pre-wet substrate.
[0081] In various embodiments of the present invention, the bonding layer 20 depicted in FIG. 1( a ) can be in the form of a pre-formed dry film before application to the device substrate or a carrier substrate surface. These pre-formed bonding films may be a single-layer film of only a polymeric bonding material film. Alternatively, the bonding films could be a two-layer structure comprising a polymeric bonding material film adjacent to a carrier film. In other embodiments, the bonding film could also be a three-layer structure comprising a polymeric bonding material film adjacent to a carrier film on one side and a protection film on the other side. Carrier films can comprise materials including, but not limited to, polyethylene terpthalate (PET) and Kapton® polyimide films.
[0082] Advantageously, the pre-formed bonding films can take multiple forms, including, but not limited to, continuous free-standing films, sheets of free-standing film, continuous film coating on a base film, sheets of film coating on a base film, and other shapes dictated by substrate dimension. Generally, the preferred form will be dictated by application and process flow.
[0083] The pre-formed bonding films may be produced from any of the compositions described above in regard to the bonding layer 20 depicted in FIG. 1( a ) . In various embodiments, the pre-formed bonding films can be created from a variety of formulations including, but not limited to, solvent-based dispersions, solvent-based solutions, water-based dispersions, water-based solutions, hot melt polymer systems devoid of volatile solvent constituents, and thermal- or radiation-curable mixtures.
[0084] Additionally, the bonding material films can be created using multiple means of formation, including, but not limited to, solvent-cast slot die coating, extrusion slot die coating, screen printing, knife-over-roll coating, gravure printing, flexographic printing, inkjet printing, curtain coating, blown film, spray coating, doctor blade coating, wire wound rod coating, and metering bar coating. For the two-layer and three-layer bonding film, slot-die coating is an especially preferred creation method, and for the single-layer bonding film, extrusion is an especially preferred creation method.
[0085] Once the bonding material formulation is deposited in the desired dimension, it can be converted into the bonding film using multiple means, including, but not limited to, solvent evaporation by heat, curing reactions by heat, curing reactions by applied radiation, and curing reactions by moisture. When heat is used to remove the solvent, a drying process of from about 60° C. to about 200° C. is performed after coating to form the dry film. The final thickness of the bonding material film is preferably from about 5 μm to about 100 μm, and more preferably from about 10 μm to about 80 μm. In one embodiment, a protection film is laminated on top of the bonding material film after film formation to protect the bonding material film and avoid oxidation.
[0086] The carrier film component can be composed of monomers, oligomers, and/or polymers, and should also be free of volatile components once in film form. Examples of suitable monomers, oligomers, and polymers include those selected from the group consisting of untreated polyethylene terephthalate (PET), silicone treated polyethylene terephthalate, polyimide, polyethylene, and polycarbonate.
[0087] The protection film component can be composed of monomers, oligomers, and/or polymers, and should also be free of volatile components once in film form. Examples of suitable monomers, oligomers, and polymers include those selected from the group consisting of untreated polyethylene terephthalate (PET), silicone treated polyethylene terephthalate, polyethylene, and polypropylene.
[0088] It should be noted that the pre-formed bonding films are distinct from dicing tapes and other tapes commonly utilized in the art. Unlike dicing tapes, which are adhesive at room temperature and, therefore, may be applied at such temperatures; the pre-formed bonding films only adhere to other substrates when heated during a lamination or compression process. In other words, the pre-formed bonding films do not generally exhibit adhesive properties at room temperatures. For instance, prior to being subjected to any lamination process, compression process, or any other process used to form the stacks described herein, the pre-formed bonding films may exhibit an adhesive strength at 25° C. of less than 1 B, preferably less than 0 B, as measured according to ASTM D3359.
[0089] The pre-formed bonding film can be applied to the first or second substrate using any known method, with preferred methods including hot roll lamination and compression bonding. In one embodiment, a pre-wet step is utilized prior to the application of the bonding material film to the carrier or device substrate. If a three-layer film structure is used, then the protective film is removed prior to the lamination of the film to the substrate.
[0090] The utilization of a wet lamination system allows the lamination to take place at a lower temperature, which can reduce stress on the bonded substrates and increase throughput.
[0091] When a pre-wet step is used, a wetting station can be utilized to apply the pre-wet liquid. One exemplary wetting station comprises a sponge roller made of polyurethane foam or melamine foam that absorbs the pre-wetting liquid first then transfers that pre-wetting liquid onto the surface of the substrates to form a thin layer of liquid film prior to lamination. This wetting station also serves to absorb or transfer excess liquid off of the substrate surface. Alternatively, the pre-wet liquid could be cast on the substrate, such as by spin coating. The thickness of the pre-wet liquid is preferably from about 0.1 μm to about 5 μm. FIG. 2 shows a diagram of a wetting station used in conjunction with a hot roll laminator.
[0092] Generally, the pre-wetting liquid acts to displace air to eliminate void formation and also plasticize the bonding material film and make it adhere more strongly to the substrate. The pre-wetting liquid could be a non-polar organic liquid such as d-limonene or dodecene, or it could be a polar organic liquid such as cyclopentanone or cyclohexanone.
[0093] The bonding film is then applied onto the pre-wet substrate. One especially preferred application method involves hot roll laminating at a temperature from about 60° C. to about 200° C., preferably from about 80° C. to about 140° C., and more preferably from about 80° C. to about 120° C., with a lamination speed of from about 0.1 meter per minute to about 3 meters per minute, and preferably from about 0.3 meter per minute to about 2 meters per minute, and a lamination pressure of from about 0 kg/cm 2 to about 5 kg/cm 2 , and preferably from about 1 kg/cm 2 to about 3 kg/cm 3 .
[0094] If a two-layer bonding film is utilized, the carrier film can be removed after lamination. The substrate is then optionally baked at a temperature from about 50° C. to about 250° C., preferably from about 100° C. to about 200° C., for a time of from about 0.5 minutes to about 20 minutes, preferably from about 1 minute to about 10 minutes.
[0095] Alternatively, the dry bonding film may be cut to the size of the device and carrier substrate and placed between the substrates before bonding them in a face-to-face configuration, rather than laminating the bonding film to one substrate and then bonding to the second substrate.
[0096] The first and second substrates are then bonded in a face-to-face configuration. One preferred method of bonding the first and second substrates is by using a compression bonder. Preferred bonding temperature are from about 50° C. to about 370° C., more preferably from about 100° C. to about 250° C., most preferably from about 150° C. to about 200° C. Preferred bonding forces are from about 500 N to about 8000 N, more preferably from about 1000 N to about 5000 N, and most preferably from about 2000 N to about 3000 N. Preferred bonding times are from about 30 seconds to about 5 minutes, and more preferably from about 2 minutes to about 4 minutes.
[0097] The bonded substrates can then be subjected to subsequent thinning or other processing. For example, the device substrate can be thinned to a thickness of from about 50 μm to about 100 μm. After thinning, typical backside processing, including backgrinding, photolithography, via etching, passivation, metallization, PECVD, and combinations thereof, may be performed.
[0098] After backside processing has occurred, the device substrate can be separated from the carrier substrate. The substrates may be separated by heating to a temperature sufficient to soften the bonding layer. Alternatively, the bonding material or a release layer may be removed or weakened by the use of a laser, after which the substrates may be separated. Regardless of whether the bonding or release composition is softened or decomposed, the separation can be accomplished by simply applying force to slide or lift the substrates apart.
[0099] Following separation, the bonding composition remaining on the substrates can be easily removed by rinsing with solvent followed by spin-drying or simply peeling the bonding composition layer film off the substrate.
[0100] Optionally, the front side of the first and/or second substrates may be treated to form a release surface. Suitable treatment methods include coating with a laser sensitive or laser decomposable material, or coating with a fluoro- or silane-based releasing agent.
[0101] It will be appreciated that the use of a pre-formed dry film to bond substrates offers some important advantages over the prior art. For example, this aspect of the invention allows one to form a low-TTV film prior to application, with that film remaining solvent-soluble after processing. These films also allowed for much thicker applications than typical spin-coated bonding materials.
EXAMPLES
[0102] The following examples set forth preferred methods in accordance with the invention. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention.
Example 1
Formulation of a 0.5% ECMS-327 Siloxane Solution
[0103] To a 250 ml glass bottle, 0.02 gram of K-PURE® TAG-2689 (King Industries Inc. Norwalk, Conn.) and 19.9 grams of propylene glycol monomethyl ether (“PGME,” Ultra Pure, Inc., Castroville, Calif.) were added. The solution was mixed for 5-10 minutes until all of K-PURE® TAG-2689 dissolved. Next, 79.58 grams of d-limonene (Florida Chemical Co. Winter Haven, Fla.) and 0.5 gram of ECMS-327 (polysiloxane, structure shown below; Gelest, Morrisville, Pa.) were then added to the solution. The final solution was mixed for 30-60 minutes until all of polysiloxane was dissolved, after which the solution was filtered once through 0.1-μm disk filter (Whatman Inc., Florham Park N.J.). The total concentration of polysiloxane in this solution was 0.5% by weight.
[0000]
Example 2
Formulation of a 0.5% ECMS-924 Siloxane Solution
[0104] To a 250 ml glass bottle, 0.02 gram of K-PURE® TAG-2689 (King Industries Inc. Norwalk, Conn.) and 19.9 grams of PGME (Ultra Pure, Inc., Castroville, Calif.) were added. The solution was mixed for 5-10 minutes until all of K-PURE® TAG-2689 dissolved. 79.58 grams of d-limonene (Florida Chemical Co. Winter Haven, Fla.) and 0.5 gram of ECMS-924 (polysiloxane, Gelest, Morrisville, Pa.) were then added to the solution. (The structure of this polymer is similar to that shown for Example 1, with the difference in numbers denoting a difference in molecular weights.) The final solution was mixed for 30-60 minutes until all of polysiloxane dissolved and then was filtered once through 0.1-μm disk filter (Whatman Inc., Florham Park N.J.). The total concentration of polysiloxane in this solution was 0.5% by weight.
Example 3
Formulation of a 0.5% VDT-5035 Siloxane Solution
[0105] To a 250 ml glass bottle, 100 grams of PGME (Ultra Pure, Inc., Castroville, Calif.), 0.5 gram of VDT-5035 (Gelest, structure shown below; Morrisville, Pa.), and 0.025 gram of 1, 1′-azobis(cyclohexanecarbonitrile) (Sigma-Aldrich, St Louis, Mo.) were added. The final solution was mixed for 30-60 minutes until all of polysiloxane dissolved. The total concentration of polysiloxane in this solution was about 0.5% by weight.
[0000]
Example 4
Formulation of a 0.5% EBP-234 Siloxane Solution
[0106] To a 250 ml glass bottle, 100 grams of PGME (Ultra Pure, Inc., Castroville, Calif.), 0.5 gram of EBP-234 (Gelest, structure shown below; Morrisville, Pa.), and 0.027 gram of K-PURE® TAG-2689 were added. The final solution was mixed for 30-60 minutes until all of polysiloxane dissolved. The total concentration of polysiloxane in this solution was about 0.5% by weight.
[0000]
Example 5
Formulation of a 0.6% ECMS-327 Siloxane Solution
[0107] To a 250 ml plastic bottle, 0.02 gram of K-PURE® TAG-2689 (King Industries Inc. Norwalk, Conn.) and 4.969 grams of PGME (Ultra Pure, Inc., Castroville, Calif.) were added. The solution was mixed for 5-10 minutes until all of K-PURE® TAG-2689 dissolved. 94.411 grams of 3-ethoxypropionate (EEP, Sigma-Aldrich Inc., St. Louis, Mo.) and 0.6 gram of ECMS-327 (polysiloxane, Gelest, Morrisville, Pa.) were then added to the solution. The final solution was mixed for 30-60 minutes until all of polysiloxane dissolved and then was filtered once through a 0.1-μm disk filter (Whatman Inc., Florham Park N.J.). The total concentration of polysiloxane in this solution was 0.6% by weight.
Example 6
Formulation of a 0.1% ECMS-327 Siloxane Solution
[0108] To a 250 ml plastic bottle, 0.004 gram of K-PURE® TAG-2689 (King Industries Inc. Norwalk, Conn.) and 4.9948 grams of PGME (Ultra Pure, Inc., Castroville, Calif.) were added. The solution was mixed for 5-10 minutes until all of K-PURE® TAG-2689 dissolved. Next, 94.9012 grams of 3-ethoxypropionate (EEP, Sigma-Aldrich Inc., St. Louis, Mo.) and 0.1 gram of ECMS-327 (polysiloxane, Gelest, Morrisville, Pa.) were then added to the solution. The final solution was mixed for 30-60 minutes until all of polysiloxane dissolved and then was filtered once through 0.1-μm disk filter (Whatman Inc., Florham Park N.J.). The total concentration of polysiloxane in this solution was 0.1% by weight.
Example 7
Formulation of a 0.2% ECMS-327 Siloxane Solution
[0109] To a 250 ml plastic bottle, 0.008 gram of K-PURE® TAG-2689 (King Industries Inc. Norwalk, Conn.) and 4.9896 grams of PGME (Ultra Pure, Inc., Castroville, Calif.) were added. The solution was mixed for 5-10 minutes until all of K-PURE® TAG-2689 dissolved. Next, 94.8024 grams of 3-ethoxypropionate (EEP, Sigma-Aldrich Inc., St. Louis, Mo.) and 0.2 gram of ECMS-327 (polysiloxane, Gelest, Morrisville, Pa.) were added to the solution. The final solution was mixed for 30-60 minutes until all of the polysiloxane had dissolved, followed by filtering once through 0.1-μm disk filter (Whatman Inc., Florham Park N.J.). The total concentration of polysiloxane in this solution was 0.2% by weight.
Example 8
Formulation of a 0.6% AMS-2202 Siloxane Solution
[0110] To a 250 ml plastic bottle, 49.7 grams of PGME (Ultra Pure, Inc., Castroville, Calif.) and 0.3 gram of AMS-2202 (Gelest, structure shown below; Morrisville, Pa.) were added. The final solution was mixed for 30-60 minutes until all of polysiloxane dissolved. The total concentration of polysiloxane in this solution was about 0.6% by weight.
[0000]
Example 9
Formulation of a 0.6% AMS-1203 Siloxane Solution
[0111] To a 250 ml plastic bottle, 49.7 grams of PGME (Ultra Pure, Inc., Castroville, Calif.) and 0.3 gram of AMS-1203 (Gelest, Morrisville, Pa.) were added. The final solution was mixed for 30-60 minutes until all of polysiloxane dissolved. The total concentration of polysiloxane in this solution was about 0.6% by weight.
Example 10
Testing of Siloxane Solutions
[0112] The solutions formulated in Examples 1 to 9 were spin-coated onto 100-mm silicon wafers by spinning at 1,500 rpm with 10,000 rpm/s ramp for 30 seconds, and then baked at 205° C. for 60 seconds. All wafers had good coat quality via visual observation. The thickness was measured with ellipsometer. The contact angle with water was measured using VCA Optima Tool from AST Products, Inc. Billerica, Mass. The results are listed in the Table 1.
[0000]
TABLE 1
Solution appearance, thickness, and
contact angle of siloxane solutions.
Sample
Solution appearance
Thickness, Å
Contact angle
Example 1
Clear
123
105°
Example 2
Clear
105
101°
Example 3
Clear
108
106°
Example 4
Clear
104
96°
Example 5
Clear
120
104°
Example 6
Clear
16
96°
Example 7
Clear
32
106°
Example 8
Clear
287
103°
Example 9
Clear
305
103°
Example 11
Bonding Testing of Siloxane Solution from Example 1 with Cylic Olefin Polymer
[0113] The solution formulated in Example 1 was spin-coated onto 200-mm silicon wafers by spinning at 1,500 rpm with 10,000 rpm/s ramp for 30 seconds, and then baked at-205° C. for 60 seconds. The contact angle of the fully-coated wafer was determined to be 105. A 50-μm film of the cyclic olefin polymer bonding material from Example 16 was coated onto another 200-mm silicon wafer by spin-coating at 1,000 rpm with a 3,000 rpm/s ramp for 30 seconds, and then baking at 60° C. for 3 minutes, 160° C. for 2 minutes, and 205° C. for 2 minutes.
[0114] The two wafers were bonded in a face-to-face relationship at 200° C. for 3 minutes in a heated vacuum and under pressure chamber with 1,800 N of bonding pressure on an EVG510 bonder. After cooling to room temperature, the bonded wafers were separated easily by a peeling process using a ZoneBOND® separation tool.
Example 12
Bonding Testing of Siloxane Solution from Example 5 with Cyclic Olefin Polymer
[0115] The solution formulated in Example 5 was spin-coated onto 200-mm silicon wafers by spinning at 1,500 rpm with 10,000 rpm/s ramp for 30 seconds, and then baked at 205° C. for 60 seconds. The contact angle of the fully-coated wafer was measured to be 105. A 50-μm film of the cyclic olefin polymer bonding material from Example 16 was coated onto another 200-mm silicon wafer by spin-coating at 1,000 rpm with a 3,000 rpm/s ramp for 30 seconds, and then baking at 60° C. for 3 minutes, 160° C. for 2 minutes, and 205° C. for 2 minutes.
[0116] The two wafers were bonded in a face-to-face relationship at 200° C. for 3 minutes in a heated vacuum and under pressure chamber with 1,800 N of bonding pressure on an EVG510 bonder. After cooling to room temperature, the bonded wafers were separated easily by a peeling process using a ZoneBOND separation tool.
Example 13
Bonding and Backside Processing Testing of Siloxane Solution from Example 5 with Cyclic Olefin Polymer
[0117] The solution formulated in Example 5 was spin-coated onto 200-mm silicon wafers by spinning at 1,500 rpm with 10,000 rpm/s ramp for 30 seconds, and then baked at 205° C. for 60 seconds. The contact angle of the fully-coated wafer was measured to be 105. A 50-μm film of the cyclic olefin polymer bonding material from Example 16 was coated onto another 200-mm silicon wafer by spin-coating at 1,000 rpm with a 3,000 rpm/s ramp for 30 seconds, and then baking at 60° C. for 3 minutes, 160° C. for 2 minutes, and 205° C. for 2 minutes.
[0118] The two wafers were bonded in a face-to-face relationship at 200° C. for 3 minutes in a heated vacuum and under pressure chamber with 1,800 N of bonding pressure on an EVG510 bonder. The wafer pair was then cooled down to room temperature. The wafer pair was subjected to a backgrinding process, which thinned the device wafer to 50 μm in thickness. The wafer pair was then heat-treated for 30 minutes at 260° C. and cooled again to room temperature.
[0119] The bonded wafers were separated easily by a peeling process using a ZoneBOND® separation tool.
Example 14
Bonding Testing of Siloxane Solution from Example 5 with WaferBOND® HT-10.10 Material
[0120] The solution formulated in Example 5 was spin-coated onto 200-mm silicon wafers by spinning at 1,500 rpm with a 10,000 rpm/s ramp for 30 seconds, and then baked at 205° C. for 60 seconds. The contact angle of the fully-coated wafer was measured to be 105. A 50-μm film of WaferBOND® HT-10.10 material (Brewer Science, Inc.) was coated onto another 200-mm silicon wafer by spin-coating at 400 rpm with a 500 rpm/s ramp for 35 seconds, and then baking at 120° C. for 3 minutes and 180° C. for 4 minutes.
[0121] The two wafers were bonded in a face-to-face relationship at 180° C. for 3 minutes in a heated vacuum and under pressure chamber with 1,800 N of bonding pressure on an EVG510 bonder. After cooling down to room temperature, the bonded wafers were separated easily by a peeling process using a ZoneBOND® separation tool.
Example 15
Bonding and Backside Processing Testing of Siloxane Solution from Example 5 with WaferBOND® HT-10.10 Material
[0122] The solution formulated in Example 5 was spin-coated onto 200-mm silicon wafers by spinning at 1,500 rpm with 10,000 rpm/s ramp for 30 seconds, and then baked at 205° C. for 60 seconds. The contact angle of the fully-coated wafer was measured to be 105. A 50-μm film of WaferBOND® HT-10.10 material (Brewer Science, Inc.) was coated onto another 200-mm silicon wafer by spin-coating at 400 rpm with a 500 rpm/s ramp for 35 seconds, and then baking at 120° C. for 3 minutes and 180° C. for 4 minutes.
[0123] The two wafers were bonded in a face-to-face relationship at 180° C. for 3 minutes in a heated vacuum and under pressure chamber with 1,800 N of bonding pressure on an EVG510 bonder. The wafer pair was then cooled down to room temperature. The wafer pair was subjected to a backgrinding process, which thinned the device wafer to 50 μm thickness. The wafer pair was then heat treated for 30 minutes at 260° C. and cooled again to room temperature. The bonded wafers were then separated easily by a peeling process using a ZoneBOND® separation tool.
Example 16
Formulation of Bonding Material 1
[0124] First, 1.8 grams of Irganox® 1330 antioxidant (Sigma-Aldrich, Mo.) was dissolved in 138.2 grams of d-limonene (Florida Chemical Company, Fla.). Then, 60 grams of ZEONEX® 5000 cyclic olefin polymer (Zeon Corporation, Japan) was added to the solution, and the solution was rotated on a rotating wheel until the polymer was fully dissolved. The solution was then filtered with a 0.2-μm Meissner Vangard filter.
Example 17
Formulation of Bonding Material 2
[0125] First, 1.8 grams of Irganox® 1330 antioxidant was dissolved in 140 grams of d-limonene. Then, 54 grams of ZEONEX® 5000 and 6 grams of ZEONEX® 480R cyclic olefin polymers (Zeon Corporation, Japan) were added to the solution, and the solution was rotated on a rotating wheel until the polymer was fully dissolved. The solution was then filtered with a 0.2-μm Meissner Vangard filter.
Example 18
Thermal Stability Testing of Bonding Material
[0126] The bonding material from Example 16 was spin coated onto an eight-inch wafer at 750 rpm, with 3,000 rpm/s acceleration for 30 seconds. The wafer was then baked at 60° C. for 2 minutes, 160° C. for 2 minutes, and 200° C. for 13 minutes. The film was scratched off of the wafer for TGA. TGA was performed using a 10° C./min ramp in air. The result is in FIG. 3 . The decomposition temperature was 436° C., and the 2% weight loss point was at 363° C.
Example 19
Bonding of Substrates Using Bonding Material
[0127] In this Example, a 50-μm coat of the bonding material from Example 16 was coated on an eight-inch Si wafer by spin coating the material at 1,000 rpm, with 3,000 rpm/s acceleration for 30 seconds. The wafer was then baked at 60° C. for 3 minutes, 160° C. for 2 minutes, and 200° C. for 2 minutes. A carrier Si wafer was coated with Brewer Science® ZoneBOND® 3500-02 anti-stiction material by spin coating at 1,250 rpm, with 250 rpm/s acceleration for 30 seconds. The carrier wafer was then baked at 160° C. for 3 minutes. The wafer pair was then bonded at 200° C., 1,800 N for 3 minutes under vacuum (<5 mbar) using an EVG Model 510 bonder. The bonded pair was examined with a scanning acoustic microscope from Sonoscan. The images showed that the wafer pair was bonded well, and there were no voids detected ( FIG. 4 ).
Example 20
Heat Treatment of Wafer Pair Bonded with Bonding Material from Example 16
[0128] In this Example, a 50μm coating of the bonding material from Example 16 was coated on an eight-inch silicon wafer by spin coating the material at 1,000 rpm, with 3,000 rpm/s acceleration for 30 seconds. The wafer was then baked at 60° C. for 3 minutes, 160° C. for 2 minutes, and 205° C. for 2 minutes. A glass carrier wafer was coated with Brewer Science® ZoneBOND® 3500-02 anti-stiction material by spin coating at 1,250 rpm, with 250 rpm/s acceleration for 30 seconds. The carrier wafer was then baked at 160° C. for 3 minutes. The wafer pair was then bonded at 200° C., 1,800 N for 3 minutes under vacuum (<5 mbar) in an EVG510 bonder. The bonded pair was then placed on a hot plate at 300° C. for 30 minutes. There were no voids or defects observed after the heat treatment, as can be seen in FIG. 5 . After heat treatment, the wafers were separated with a Brewer Science® peel debonder without edge soaking or cleaning.
Example 21
PECVD of Bonded, Thinned Wafer Pair
[0129] In this Example, a 50-μm coat of the bonding material from Example 16 was coated on an eight-inch Si wafer by spin coating the material at 1,000 rpm, with 3,000 rpm/s acceleration for 30 seconds. The wafer was then baked at 60° C. for 3 minutes, 160° C. for 2 minutes, and 200° C. for 2 minutes. A glass carrier was coated with Brewer Science® ZoneBOND® 3500-02 anti-stiction material by spin coating at 1,250 rpm, with 250 rpm/s acceleration for 30 seconds. The carrier wafer was then baked at 160° C. for 3 minutes. The wafer pair was then bonded at 200° C., 1,800 N for 3 minutes under vacuum (<5 mbar) in EVG510 bonder. The device wafer was thinned to 50-μm thickness using a commercial DISCO® brand wafer grinding tool. A SiOx layer was deposited on the thinned wafer in a PECVD chamber at 200° C. for 2 minutes. The wafer pair was bonded very well, and there were no voids detected by IR observation ( FIG. 6 ).
Example 22
Cleaning of Bonding Material After Debonding
[0130] In this Example, a 50-μm film of the material from Example 16 was coated on an eight-inch blank silicon wafer. The silicon carrier wafer was coated with Brewer Science® ZoneBOND® 3500-02 anti-stiction material. The wafer pair was then bonded at 210° C., 1,800 N for 3 min under vacuum (<5 mbar) using an EVG Model 510 bonder. The wafer pair was then debonded on Brewer Science peel debonder at room temperature. The device wafer was then cleaned on a Brewer Science® Cee® 200FX spin coater with 400 ml of d-limonene using a central dispense process with the conditions listed in Table 2. After cleaning, the wafer was visually clean under green light with no residue.
[0000]
TABLE 2
Cleaning process to remove 50-μm layer
of bonding material after debonding.
Spin speed
Acceleration
Time
Step
rpm
rpm/sec
second
Dispense
1
500
250
10
d-limonene
2
20
300
20
d-limonene
3
0
20
60
4
1000
750
240
d-limonene
5
1200
500
35
Example 23
Heat Treatment of Wafer Pair Bonded with Material from Example 17
[0131] In this Example, a 44-μm coating of the bonding material from Example 17 was coated on an eight-inch silicon wafer by spin coating the material at 1,000 rpm, with 3,000 rpm/s acceleration for 30 seconds. The wafer was then baked at 60° C. for 3 minutes, 160° C. for 2 minutes, and 200° C. for 2 minutes. A carrier Si wafer was coated with the release material of Example 7 by spin coating at 1,500 rpm, with 10,000 rpm/s acceleration for 30 seconds. The carrier wafer was then baked at 205° C. for 1 minutes. The wafer pair was then bonded at 200° C., 1,800 N for 3 minutes under vacuum (<5 mbar) using an EVG510 bonder. The bonded pair was then placed on a hot plate at 260° C. for 30 minutes. There were no voids or defects observed after the heat treatment as can be seen in FIG. 7 . After heat treatment, the wafers were separated with a Brewer Science® peel debonder without edge soaking or cleaning.
Example 24
Laser Debonding of Wafer Pair Bonded with Material from Example 16 after Heat Treatment
[0132] In this example, a 50-μm coating of the bonding material from Example 16 was coated on an eight-inch silicon wafer by spin coating the material at 1,000 rpm, with 3,000 rpm/s acceleration for 30 seconds. The wafer was then baked at 60° C. for 3 minutes, 160° C. for 2 minutes, and 200° C. for 2 minutes. A carrier glass wafer was coated with an experimental polyimide laser release material (Brewer Science, Inc.) by spin coating at 2,500 rpm with 5,000 rpm/s acceleration for 60 seconds. The carrier wafer was baked at 300° C. for 5 minutes, and the wafer pair was then bonded at 200° C. and 1,800 N for 3 minutes under vacuum (<5 mbar) using an EVG510 bonder. There were no voids or defects observed by visual inspection after bonding. The wafer pair was then laser debonded at a wavelength of 308 nm and a fluence of 175 mJ/cm 2 on a SUSS laser debonding tool. A second wafer pair, coated and bonded at the same conditions as above, was also successfully laser debonded on a Kingyoup laser debonding tool at 3.2 W. The wavelength of the Kingyoup tool was 355 nm.
Example 25
Creation of Bonding Material Films
[0133] A slot die coater (Asia Metal Industries Inc, Taiwan) was used to cast BrewerBOND® 305 or 305-30 material onto a 50 μm polyethylene terephthalate (PET, BP21, Nan Ya Plastics Corporation, Taiwan) carrier film using the processing parameters shown in Table 3. The solvent-cast bonding material composition was dried in a hot air oven at 150° C. for about 10 minutes to obtain the pre-formed bonding material film with thicknesses from 5 μm to 100 μm.
[0000]
TABLE 3
BrewerBOND ®
Dry Film
Vis-
Die
Pump
Line
Material
Thickness
cosity
Gap
Speed
Speed
305
85 μm
7000 cP
500 μm
22.4 rpm
0.5 m/min
305-30
50 μm
3000 cP
300 μm
11.4 rpm
0.5 m/min
20 μm
140 μm
18.8 rpm
1.0 m/mi
Example 26
Hot Roll Lamination of Dry Bonding Material Film at 200° C.
[0134] A 50 μm thermoplastic dry bonding film made in Example 25 was then laminated onto a 200 mm silicon wafer using a Tai-Ing, TI-L730 hot roll laminator under following conditions: roller temp of 200° C., speed of 0.5 meter per minute, and pressure of 1 kg/cm 2 . The base polyethylene terephthalate (PET) film was removed from the laminated wafer after lamination. No voids or delamination were detected after removal of the base PET film. FIG. 8 shows an image of the bonding film laminated onto the silicon wafer.
Example 27
Hot Roll Lamination of Dry Bonding Material film at 160° C.
[0135] A 50 μm thermoplastic dry bonding film made in Example 25 was then laminated onto a 200-mm silicon wafer using a Tai-Ing, TI-L730 hot roll laminator under following conditions: roller temp of 160° C., speed of 0.25 meter per minute, and pressure of 1 kg/cm 2 . The base PET film was removed from the laminated wafer after lamination. There was significant delamination at the wafer edge after removal of the base PET film. FIG. 9 shows an image of the bonding film partially laminated onto the silicon wafer.
Example 28
Hot Roll Lamination of Dry Bonding Material Film on Glass Panel
[0136] A 20 μm thermoplastic dry bonding film made in Example 25 was then laminated onto a 350 mm×400 mm of glass panel using a Tai-Ing, TI-L730 hot roll laminator under following conditions: roller temp of 200° C., speed of 0.5 meter per minute, and pressure of 1 kg/cm 2 . The base PET film was removed from the laminated panel after lamination.
Example 29
Vacuum Lamination of Dry Bonding Material Film at 150° C.
[0137] A 75 um thermoplastic dry bonding film made in Example 25 was then laminated onto a 200 mm silicon wafer using vacuum laminator under following conditions: lamination temperature of 150° C., lamination force of 2400 N, and lamination time of 3 minutes. The base PET film was removed from the laminated wafer after lamination. FIG. 10 shows an image of the bonding film partially laminated onto the silicon wafer.
Example 30
Bonding Using Dry Bonding Material Film
[0138] A 100 μm thermoplastic dry bonding film made in Example 25 was cut into a 200 mm wafer shape using a hot knife. The base PET film was removed from the bonding film and then was placed between a device wafer and a carrier wafer. The wafers were then bonded using a vacuum laminator under following conditions: lamination temperature of 200° C., lamination force of 2000 N, and lamination time of 3 minutes. FIG. 11 shows a CSAM image of the bonded wafer stack and showed a void-free bond.
Example 31
Comparison of Spin-Coated and Laminated Substrates
[0139] A 50 μm thermoplastic dry bonding film made in Example 25 was laminated onto a 200 mm silicon wafer. A second 200-mm silicon wafer was also spin-coated with BrewerBOND® 305 material to create a 50 μm coat. The total thickness variation (TTV) of both wafers was then measured using a drop gauge to measure the film thickness across the substrate surfaces. FIG. 12 shows the measurement of the thickness and total thickness variation for the spin-coated and laminated wafers. The laminated wafer showed lower TTV than the spin-coated wafer.
Example 32
Wet Lamination of Bonding Material at 80° C.
[0140] A 50 μm thermoplastic dry bonding film made in Example 25 was then laminated onto a 200 mm silicon wafer using a Tai-Ing, TI-L730 hot roll laminator after pre-wetting the silicon wafer with d-limonene solvent using the following conditions: roller temp of 80° C., speed of 0.25 meters per minute, and pressure of 1 kg/cm 2 . The base polyethylene terephthalate (PET) film was removed from the laminated wafer after lamination. After lamination, the silicon wafer was baked for 5 minutes at 200° C. to remove the pre-wetting liquid. No voids or delamination were detected after removal of the base PET film. FIG. 13 shows an image of the bonding film laminated onto the silicon wafer.
|
The invention broadly relates to cyclic olefin polymer bonding compositions and release compositions, to be used independently or together, that enable thin wafer handling during microelectronics manufacturing, especially during a full-wafer mechanical debonding process. The release compositions comprise compositions made from siloxane polymers and copolymers blended in a polar solvent, and that are stable at room temperature for longer than one month. The cyclic olefin polymer bonding compositions provide high thermal stability, can be bonded to fully-treated carrier wafers, can be mechanically or laser debonded after high-temperature heat treatment, and are easily removed with an industrially-acceptable solvent. Wafers bonded according to the invention demonstrate lower overall post-grind stack TTV compared to other commercial bonding materials and can survive 200° C. PECVD processing.
| 2
|
This is a division of application Ser. No. 08/401,940, filed Mar. 10, 1995 abandoned.
BACKGROUND OF THE INVENTION
The invention concerns a drive unit for vehicles. The drive unit has an engine and a retarder, wherein the retarder is in constant drive connection with the engine. The coolant in a coolant circuit at the same time comprises the working medium of the retarder, and the retarder can be utilized as a coolant pump. Such a drive unit is known from DE 37 13 580 C1.
While such a drive unit has a number of positive properties, it is solely suited for use at high required overall braking output, notably in sustained braking operation, and with an appropriate expensive configuration, specifically of the retarder and pertaining cooling system.
The problem underlying the invention is to fashion an automotive drive unit wherein, notably in sustained braking operation of a vehicle, a stable braking performance is realized with a concurrent low construction space demand for the individual drive elements, and wherein it is possible to provide a sensitive braking of the vehicle
SUMMARY OF THE INVENTION
This problem is solved by the features of the present invention. Retarders are generally installed in the drive train of the vehicle either in the direction of power flow behind the gearbox as an independent unit, or integrated in a shift gear. According to the present invention, however, the retarder precedes the gearbox, for which reason "retarder" is meant to be understood as a so-called primary retarder which in traction operation precedes the gearbox in the power flow, and whose effect on the driven wheels depends on the shift state.
The intentional combination of a primary retarder operable as a coolant pump with an engine brake system provides several advantages. One of these is the already known advantage of a retarder allowing operation as a coolant pump. Another advantage is that by having the retarder precede the engine brake system, a sensitive adjustment of the braking moment may be made, even at low overall braking output demand.
According to the invention, the retarder is combined with an engine brake in an overall braking unit (OBU) in such a way that the retarder, in terms of time, can engage before the engine brake in a braking operation. In other words, a first braking share is delivered by the retarder and a second braking share by the engine brake system. The size of the latter is preferably so chosen that the two shares account each for one-half of the overall braking output, with the share contributed by the retarder allowing preferably a continuously variable adjustment.
A differentiation is generally required between three cases:
1) the required braking output is less than 50%, based on the available overall braking output which can be delivered by the two brake systems;
2) the required braking output is 50% of the available overall braking output that can be delivered by the two brake system;
3) the required braking output is greater than 50%, based on the available overall braking output that can be delivered by the two brake systems.
In the first case, the overall braking output is delivered solely by the pump retarder. The braking output share delivered by the pump retarder preferably allows a continuously variable adjustment. This can be realized by a suitable design of the drive unit.
In the second case, the braking output is delivered solely by the engine brake system, while in the third case a share of 50% is delivered by the engine brake system and the remaining share by the retarder, preferably continuously adjustable. Preferably, the retarder is configured for maximally 50% of a possibly required overall braking output.
Options for varying the braking moment in braking operation are the utilization of an appropriate valve combination at the retarder outlet, or shifting the stator impeller.
The retarder is preferably filled constantly to capacity. This enables achieving a high braking moment at favorable retarder dimensions, which is reflected in low space demand.
Achieved is an optimum braking performance--especially as regards the stability of the braking operation--, the option of dispensing with a separate coolant circulation pump in the coolant circuit and, thus, saving construction space, the utilization of the retarder as fan drive, as well as the utilization of the accruing heat for heating the passenger compartment, and essentially the avoidance of output losses in nonbraking operation, that is, in traction operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The intentional solution to the problem will be explained hereafter with the aid of the figures, wherein:
FIGS. 1a through 1d show braking output diagrams of the individual brake systems and of the overall brake system including retarder and engine brake system.
FIG. 2a, shows an inventional drive unit wherein the ratio of feed and drain cross sections of the retarder and the braking moment are varied by means of a valve;
FIG. 2b is a view of the braking system of FIG. 2a, partially cut away, showing portions of the system in greater detail.
FIG. 3a shows an alternative embodiment wherein the braking moment may be varied by means of a continuously adjustable choke valve; and
FIG. 3b shows a braking output diagram of the embodiment of FIG. 3a.
FIG. 4 shows an alternative embodiment wherein the braking moment may be varied by shifting the stator impeller.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1a and 1b depict possible braking output diagrams of the sustained braking systems of pump retarder and engine brake system. FIG. 1a shows the braking output diagram of a pump retarder, for which purpose the braking output of the pump retarder P ret is plotted over the engine speed n mot . The diagram reveals various braking moment characteristics that can be realized:
1) the braking output, or braking moment, at cut-in and cut-out of the pump retarder with a specific degree of filling;
2) the stepped adjustability of the braking moment of the pump retarder by varying the degree of filling or by other construction measures;
3) the continuous adjustability of the braking moment of the pump retarder by varying the degree of filling or by other construction measures, for instance shifting the stator impeller.
The first case is described in the braking output/ engine speed diagram (P ret -n mot diagram) only by the curve max and, viewed theoretically, by the X-axis of the diagram. For a specific degree of filling at retarder cut-in, the braking moment characteristic in the diagram corresponds to the one signified max. Retarder cut-out, that is, either in draining or, in pump operation, at a ratio of feed to drain cross section of the retarder of about 1, is described by a braking moment characteristic which, viewed theoretically, corresponds to the X-axis of the diagram.
In the second case, a specific number of different braking moment characteristics between the abscissa of the diagram and the max characteristic for the maximum braking moment can be run with the retarder.
In the third case, every characteristic in the field between the abscissa and the characteristic for the maximum braking moment can be run.
FIG. 1b depicts the braking output available with an engine brake system. Its braking output is normally not continuously variable. Engine brake system cut-in corresponds here to the characteristic max and cut-out to the X-axis, that is, the braking output share of the engine brake system equals zero.
FIG. 1c shows the application of the inventional method of arranging the pump retarder before the engine brake system at an overall braking output demand of less than 50% in an engine speed (n mot )/overall braking output diagram (P ges ). Understood as overall braking output P ges is here the sum of the braking output shares P ret and P mot . Since the pump retarder of the invention always precedes the engine brake system in sustained braking operation, the total braking output at a required overall braking output P ges <50% is delivered solely by the pump retarder. Plotted in the illustrated braking diagram are the braking output shares of the pump retarder P ret that correspond to the overall braking output P ges . The braking output share contributed by the pump retarder is continuously adjustable here from 0% to the required overall braking output. Several output curves are plotted for explanation in the illustrated diagram.
FIG. 1d shows the braking output diagram for the case of a required overall braking output P ges of the sustained braking system that is greater than 50% of the overall braking output P ges of 100% that is available at fully utilized capacity of the two sustained braking systems. The braking output share contributed by the engine brake system is preferably limited to 50% of the overall braking output P ges , while the remaining braking output share may be added continuously by the pump retarder. In the illustrated diagram, 50% of an overall braking output of P ges =80% is contributed by the engine brake system, while the remaining 30% is added by continuous cut-in of the pump retarder. The output of 50% delivered by the engine brake system, so to speak, allows a black/white cut-in.
FIGS. 2a, 3a and 4 illustrate different designs of a drive unit for controlling the braking moment of a retarder according to DE 44 08 349 A1. Not illustrated in these designs are the necessary control and regulating units and components for realizing the retarder arrangement ahead of the motor brake system.
FIG. 2a shows an embodiment of the inventive drive unit 1 wherein the pump retarder control options are limited to cut-in and cut-out; that is, there is only a single setting available for the braking moment. The drive unit 1 is comprised of an engine 2, which for use in the vehicle is preferably fashioned as an internal combustion engine, a gearbox (not illustrated here) and a retarder 4. The retarder 4 is in constant drive connection with the engine 2, notably its crankshaft, for instance by means of a reduction gear 5. The retarder precedes the gearbox in the direction of power flow. For the arrangement of the retarder on the engine different designs are possible, for realizing the rotationally fixed connection of retarder and engine crankshaft.
Engine 2 and retarder 4 feature a joint cooling circuit 6 whose coolant 7 serves at the same time as the operating fluid of the retarder. The retarder 4 is usable as a coolant pump, for which reason the retarder 4 is signified hereafter as pump retarder 4. Further elements of the vehicle and of the drive unit are not illustrated here. Due to its arrangement before the gearbox, in the direction of power flow, the pump retarder 4 remains in all states of operation coupled to the engine, for which reason it can be utilized also as a circulation pump for the coolant 7, with no power-consuming and heat-generating idling ventilation output accruing in the retarder. Engine braking system 29 is shown in physical relation to engine 2. FIG. 2b shows features of the engine braking system 29 of FIG. 2a in greater detail, illustrating throttle 30 and exhaust or discharge manifold 31.
A cooler 8 with a fan 3 is provided in the coolant circuit 6. The fan 3 can be powered by the engine 2 or, however, also by the retarder 4, but this is not illustrated here. A line 9 extends from the outlet 10 of the cooler 8 to the fluid inlet 11 of the retarder 4, while a line 12 extends from the fluid outlet 13 of the retarder to the fluid inlet 14 of the cooler 8 by way of engine 2.
To realize only a single setting for the braking moment share of the pump retarder, a valve 16 is provided in the line 12 and a switching valve 15 in a pertaining bypass, the two making it possible to provide a maximum flow cross section of line 12 between the fluid outlet 13 of the retarder and engine in a first position of the switching valve 15, while in a second position of the switching valve 15 a choke type constriction becomes effective between retarder 4 and engine 2, causing a heavy resistance on the retarder. To that end, valve 15 is fashioned, e.g., as a two-way valve.
The first switching position corresponds to the nonbraking operation, that is, the pump retarder circulates the coolant 7 in the cooling circuit. The second switching position corresponds to the braking operation, i.e., the pump retarder generates a high braking moment. The ratio between feed and drain cross section to and from the retarder ranges in the braking operation preferably from 4 to 7, in the nonbraking operation from 0.5 to 2. To be understood as feed and drain cross section are also the flow cross sections in the feed and drain lines.
FIG. 3a depicts a section of a drive unit analogous to FIG. 2, but modified for the case of an available continuous adjustment of the braking moment share P ret of the pump retarder. Therefore, the same elements are referenced as before. Only the pump retarder 4 as well as the feed, i.e., the line 9, and the drain from the pump retarder 4 to the engine 2--the line 12--are indicated schematically here. A continuously adjustable choke valve 20 is arranged in the drain line 12. It enables a continuously variable constriction of the flow cross section of line 12 between pump retarder 4 and engine 2. The flow cross section of line 12, or the flow cross section in the valve, allows continuous adjustment from a maximum flow cross section in nonbraking operation up to a very slight flow cross section in braking operation.
The ratio of feed to drain cross section of the retarder, that is, the ratio of flows cross sections of the lines 9 and 12, or the cross sections effected by the valve, is in nonbraking operation preferably 1; that is, both flow cross sections are essentially equal. In braking operation, a ratio between 4 and 7 should preferably be selected, that is, the cross section of the feed is in braking operation 4 to 7 times as large as the drain cross section in braking operation.
Available here as well, however, is the alternative (not illustrated) of arranging the choke valve 20 in the feed, that is, in the line 9. But the cross section of the feed line, that is, line 9, must in this case be chosen 4 to 7 times as large as the cross section of the drain line 12. In the pump operation, the cross section of the feed line needs to be constricted for realizing the required cross-sectional ratio, in order to obtain essentially equal flow cross sections in both lines. In the braking operation, the flow cross section of the feed line, i.e., line 9, needs to be enlarged such that it is 4 to 7 times as large as the flow cross section in the drain, that is, line 12, in order to allow a resistance to be effective on the pump retarder.
FIG. 3b illustrates in diagram form the continuous adjustability of the braking moment such as can be realized with this type of arrangement.
FIG. 4 depicts a section of a drive unit analogous to FIG. 2, but modified for the case of a possible continuous adjustability of the braking moment share P ret of the pump retarder by shifting the stator impeller. Therefore, the same elements are referenced identically. Indicated schematically here are only the pump retarder 4 and the feed, i.e., line 9, and the drain from the pump retarder 4 to the engine 2--line 12. The braking moment is controlled here by shifting the stator impeller relative to the rotor impeller of the retarder. A valve arrangement 25 serves to switch from nonbraking to braking operation. This valve arrangement includes the valves 26 and 27, with the switching valve 26 arranged in the bypass around valve 27.
The switching valve 26 has two positions. These allow in a first position a maximum flow cross section in the line 12 between retarder fluid outlet 13 and the engine, while in a second position of the switching valve 26 a choke type constriction becomes effective between retarder 4 and engine 2, which causes a heavy resistance at the retarder. To that end, valve 26 is fashioned, e.g., as a two-way valve. Valve 27 is not adjustable.
The first switching position corresponds to the nonbraking operation, that is, the pump retarder circulates the coolant 7 in the cooling circuit. The second switching position corresponds to the braking operation, that is, the pump retarder generates a high braking moment.
In the braking operation, illustrated here, the stator impeller 21 and the rotor impeller 22 are arranged preferably coaxially for the maximum braking moment that can be generated. In the nonbraking operation, the pump retarder circulates the coolant 7 in the coolant circuit 6, due to the rotor impeller rotation. The braking moment in the braking operation is controlled by moving the stator impeller 21 with the aid of suitable means to a position eccentric to the rotor impeller 23, for example with the aid of an actuator 28. Stator impeller shifting options are known from the following documents:
1. DE 31 13 408 C1
2. DE 40 10 970 A1
Therefore, these elements are not addressed further in detail.
The braking output diagram for the braking output share of the retarder corresponds to that described in FIG. 3b.
|
A drive unit for vehicles with an engine and a gearbox, and with a hydrodynamic retarder. The retarder is in constant drive connection with the engine. The unit includes a coolant circuit whose coolant is at the same time the working medium of the retarder, and the retarder can be utilized as a coolant pump. The retarder is arranged before the gearbox, and the retarder can be united with an engine brake to an overall brake unit (OBU). The overall brake unit is configured such that the retarder can in a braking operation engage sooner than the engine brake.
| 5
|
FIELD OF THE INVENTION
This medical timing system for use during pregnancy is related to the field of diagnostic medical instruments and is more particularly related to electronic digital computer programmed devices for monitoring the occurence of biomedical events relating to childbirth and allowing the practice of procedures for natural childbirth.
BACKGROUND OF THE INVENTION
The timing of the interval between contractions during pregnancy labor has been used in the past in order to allow and expectant mother to determine when to call a doctor or go to a hospital. Such timing has been used by doctors and nurses in determining the proximity of birth. Thus, data on the time sequence of contractions--their duration and the interval between the successive start of each contraction--is an aid to the medical staff in determining the progress of labor and is a clue to when the expectant mother should go to the doctor's office for an examination or to the hospital for delivery. The measured durations and intervals aid in accurate determination of the apparent progress of labor. Additional clues--not used herein--to the medical staff on the progress of labor are the intensity of the contraction and the dilation of the cervix. In preparation for pregnancy labor, rehearsal techniques have been used (such as the Lamaze method) by expectant mothers and their coaches (typically the expectant fathers) in which a sequence of breathing exercises, message maneuvers, etc. of predetermined durations are performed in order to simulate the procedures for prepared childbirth. It is also known that the occurence of movements by the fetus indicates the health and state of development of the fetus.
A method for keeping track of labor contractions used in the past involved observing an ordinary wristwatch or stopwatch and manually writing down (as on pencil and paper) the times when contractions occurred. Often a coach would assist the expectant mother by observing the timepiece and writing down the times, since the expectant mother may be experiencing pain, loss of sleep, or may otherwise be incapable of making reliable measurements. However, the measuring ability of a coach who is fatigued or has lost sleep (which is often the case) may also be unreliable. This prior method has disadvantages in that manual subtraction computations are required (if an ordinary wristwatch is used) and the writing down of times requires light to see by (a disadvantage in the dark of night). Another inconvenience with this prior method is that a pencil, paper, and timepiece must be available at all times in order to measure and record the occurence of contractions.
A number of modern methods have been developed to assist expectant parents in preparing for childbirth. Such techniques as the Lamaze method may help provide for a more natural, painless childbirth. The natural childbirth methods may include rehearsal sessions in which the expectant mother (who is not then presently experiencing contractions) and a coach may go through a practice simulation of one or more of the phases of labor and the appropriate procedures. Such a rehearsal simulation proceeds in the classroom under the instruction of a training leader who announces, for a phase of labor, (at times chosen by the leader) the timing of labor contractions and describes the appropriate procedures so that the expectant mother and her coach may react and perform the procedures described. In order for the simulation to be realistic, it is preferable that the timing of the simulation should closely mimic the natural biological timing of labor. However, the timing of the simulation should not be so regular so as to allow the expectant mother or her coach to consciously or unconsciously anticipate the occurence of simulated contractions. The duration of the labor contractions and the time period between labor contractions are indicators of the progress of labor and as a predictor of when birth may be expected. Timing may be used in such methods to determine whether the expectant mother is experiencing the early, middle, or late phases of pregnancy. The phase of pregnancy, as determined by contraction timing, is used to guide the expectant mother so that preferred procedures (such as breath control exercises by the expectant mother, or specialized massages by a coach) may be performed at times appropriate to each phase of the pregnancy. After the birth has occurred, it may be important for the mother to regulate the duration of breastfeeding in accordance with instructions which may be given by a doctor to protect the health of the child and/or the mother. For example, it is desirable to prevent tissue irritation of the mother's breasts by limiting the feeding time, whil maintaining sufficient nutrition for the child.
SUMMARY OF THE INVENTION
The medical timing system of this invention is a biomedical instrument which acts as a guide in determining the time when birth is imminent, to aid the doctor in indicating the health of the fetus, for recording the activity of the fetus, and for providing the practice of natural childbirth procedures. The system includes a programmed digital computer processor for controlling the operation of the system and for providing a precise method of measuring and storing data relating to the occurrence of biomedical events. The program used for the processor allows the system to function in any one of three primary operating modes: a labor pain timer mode for recording the occurence and sequence of labor contractions, a fetus movement counter mode for counting the number of fetal movements during a time period, and a contraction rehearsing mode for simulating a series of labor contractions.
The system also has a manually operable timing switch connected electrically to the computer so that the user of the system may indicate to the system when biomedical events have occurred. The push button timing switch has a lock-down notch feature so that long duration time intervals may be measured without causing undue fatigue to the user of the instrument. The timing switch then may be released by a slight backward movement of the switch until the lock-down notch is released and a spring action of the timing switch pushes the switch upward to release the timing switch when the finger (thumb) is removed from the switch. The display may be used to present data relating to the mode of operation of the instrument, alerting signals, the occurrence and computations made by the system. A manually actuated readout button is also electrically connected to the computer and which serves to control the presentation of data in a display connected to the computer processor. The readout button and timing switch also serve to allow the user to select the operating mode of the system. The monitoring and training instrument of this invention is housed in a small, portable, hand-held housing which fits in the user's hand for easy operation.
During the labor pain timer mode, the computer processor of the system uses its random access memory for recording contraction time intervals and durations in response to actuation of the timing switch by the user (the expectant mother or her coach). The duration of a labor contraction is used in this description to mean the time period during which a labor contraction is felt by an expectant mother, and the interval of labor contractions is used in this description to mean the time period elapsed between the starting of one contraction and the start of the next sequential contraction. Once stored in memory, the time duration and interval measurements may be retrieved and displayed in the digital display so that medical personnel can analyze and evaluate the sequence of measurements to aid in determining the progress of labor. It is important that the contraction measurements be accurately made, stored and reproduced in order that the medical determinations be based on the valid measurements. The instrument of this invention is particularly effective in this regard in that the contraction duration and interval computations are made automatically and the measurements are reliably recorded for future evaluation. In practice, an expectant mother or her coach may operate the instrument in order to record the occurance of labor contractions, and the measurements so recorded may be transferred to a physician or other person for medical diagnosis. The transfer of the recorded measurements may occur by simply handing the instrument itself over to the medical personnel or through the use of a mode of indirect digital data communications. Because the measurement recording or storage is performed automatically by the instrument of this invention, it is inherently a more reliable process than the prior method involving the use of paper and pencil writings made by an expectant mother or her coach. The display of the instrument preferably produces its own light so that the instrument may be used in the dark, allowing the mother and father to sleep between contractions without having to turn a light on and off in order to record contraction times. Because the instrument is self-contained, the user need not continuously have available a timepiece, paper, and pencil as with prior methods of recording the occurrence of labor contractions or fetal movements. The simplified operation of the system lessens the chances or errors due to interruptions or distractions such as a telephone, doorbell, children's needs, etc. Because of the easy operation afforded by the construction of the instrument of this invention (especially the multi-purpose push-button timing switch and readout button), the instrument may be used by the expectant mother herself without requiring the help of another person. An anticipation alert warning is provided by the system (if the optional operation of the alert warning is selected) in advance of the time when a contraction may be expected so that she does not lose "control". If the anticipation alert warning is to be given, it is given in the embodiment shown herein at a time which is a predetermined anticipation time period (ten seconds) less than the immediately previously measure interval added to the time of starting the just previous contraction.
During the fetus movement counter mode, the computer processor of the system uses its random access memory to keep a count of the number of times that the timing switch is depressed during a time period. The system has a predetermined time period (twenty minutes) for counting, which may be shortened by the user through operation of the timing switch and readout button. The processor serves to compute the ratio of the number of fetal movements per unit time and to cause the results to be presented on the display connected to the computer. The system also allows the optional use of a buzzer connected to the computer in order to audibly indicate when the predetermined time period has elapsed. The purpose of monitoring the frequency of fetal movements in this mode is to indicate the health and activity of the unborn child, and to alert the expectant mother and her doctor to any unusual patterns of fetal activity.
During the contraction rehearsing mode, the processor of the system uses a stored pattern for simulated contractions from its read only memory. The simulated contraction pattern is randomized by the processor, and used to control the display connected to the processor so that the expectant mother and her coach may follow the simulated contractions. The system also allows the optional use of a buzzer connected to the computer in order to audibly indicate when the simulated contractions are to occur. The timing switch and readout button may be used together in order to allow the user to select from among three stored contraction patterns representing the early, middle, and late phases of pregnancy. The randomizing of the patten provided by the system is advantageous in providing some surprise to the expectant mother so that contractions are not anticipated. The fact that the rehearsing mode is easy to use and automatic is advantageous in increasing the likelihood that the expectant mother and her coach will perform the simulation techniques often. An optional breastfeeding timer mode may be used which allows the mother to select a set feeding time duration, and in which the processor presents a display of running time on a visual display and indicates when the set feeding time has elapsed so that the child's needs are met without undue irritation to the mother's breasts. An audible buzzer may be actuated for the processor in order to indicate running time and to indicate the end of the set feeding time duration.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of the medical timing 30 system of this invention.
FIGS. 2a and 2b are an electrical schematic diagram of the electronic circuitry of the medical timing system of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, the medical timing system 10 has an enclosure case 12 which is generally oval in shape and small in size so as to conveniently fit within the hand of a user. A manually actuatable timing switch 14 is positioned on the enclosure 12 so as to be easily and conveniently depressed by the thumb of the user when the enclosure 12 is held in the hand. The switch 14 includes a locking notch 16 mounted on the shaft thereof so that the switch 14 may be locked in a depressed condition by pushing downwards on the switch 14 and sliding the switch 14 forwards. The locking notch 16 of the switch 14 is similar in construction to the operation of locking pushbuttons used in commercially available home appliances, such as steam irons. The timing switch 14 is a manually operable swtich which is electrically connected to circuitry inside the enclosure case 12. The function of the swtich 14 is to indicate to the system 10, by means of external manual manipulation actuation by the user, the starting and stopping of labor contractions or the occurence of movement by the unborn child.
A display button 18 is provided on the face of the enclosure 12 in order to allow manual control over the functional mode of the system 10 and in order to control the nature of the information presented in a digital display 20. The readout button 18 is a manually operable electrical switch which is connected to circuitry inside the enclosure case 12. The timing switch 14 and readout button 18 are to be used together, cooperatively, to allow manual selection of the functional mode of the medical timing system 10. The display 20 is preferably a light emitting diode array having two seven segment digits and a decimal point after each of the digits. Although a liquid crystal type display could be used, it is preferable that a light emitting diode type be used in order that the display 20 provide it's own illumination for night time viewing, or that if a liquid crystal display is used, that illumination be provided by a separate internal light source.
As an alternative version, a pair of displays could be used to replace display 20 so that simultaneous display of two related types of data (such as measured labor contraction duration and interval) would be presented.
A power control switch 22 is provided on the enclosure 12 in order to connect batteries inside the enclosure 12 with electronic circuitry inside the enclosure 12, and in order to allow the electronic circuitry inside enclosure 12 to be reset to an initialized condition when the switch 22 is placed in an off position. The system 10 may be equipped with an external power source connector 24 which allows the batteries inside the enclosure 12 to be recharged through an external power source (not shown) such as a battery charger connected to an AC utility line.
In practice, the enclosure 12 is grasped in the hand of the user, who may be either the expectant mother or coach. The switch 22 is placed in an on position and the thumb of the user is utilized through control the timing switch 14 in order to record the times when labor contractions start and stop, or when movements of the unborn child are detected. The switch 14 is to be depressed when a contraction starts, held in a depressed condition for the duration of the contraction until the contraction stopped, and then returned to an undepressed position when the labor contraction stops. The readout button 18 is used in order to control the operation of the system 10 so that data stored inside the enclosure case 12 may be presented in the display 20.
Referring next to FIGS. 2A and 2B, the electrical circuitry of the system 10 inside the enclosure case 12 is shown. The circuitry includes the following commercially available integrated circuits:
______________________________________Number Type Description______________________________________U1 2716 Erasable Programmable Read Only Memory (EPROM)U2 TMS1099JLC MicroprocessorU3 2716 Erasable Programmable Read Only Memory (EPROM)U4 CD4011 Dual Nand GatesU5 75491 Quad Display DriverU6 75491 Quad Display DriverU7 75492 Quad InvertersU8 MAN84A Seven Segment LED DisplayU9 MAN84A Seven Segment LED Display U10 74C20 Dual Nand Gates U11 74C00 Quad Nand Gates______________________________________
In FIGS. 2a and 2b, pin numbers of each of the integrated circuits are shown adjacent to the integrated circuit symbols. Connections made between integrated circuits on the two figures (2a and 2b) are shown as the circuit number, followed by a dash, followed by the pin number to which connection is made. The microprocessor U2 is a programmable digital computer processor having internal random access memory and which is commercially available from Texas Instruments, Inc. of Dallas, Tex., U.S.A. The memory U1 is used to store the object code computer program which is disclosed herein and which is used to control the operation of the microprocessor U2. The memory U3 is used to decode the information output from the processor U2 in order to properly drive the displays U8 and U9. The gates of U10 and U11 form a memory doubler circuit 28 used to effectively double the memory addressing capacity of the processor U2 in addressing the memory U1. The circuits U5 and U6 are connected between the processor U2 and the light emitting digital displays U8 and U9. The gates of integrated circuit U4, together with a capacitor C1 and resistors R1 and R2 form a timing circuit 26 which is adjusted (by changing R1, R2 and C1) to produce pulses every one-sixteenth of a second (62.5 milliseconds) that are used by the processor U2 to keep track of time using well known programming techniques. Of course, the timing circuit 26 may be replaced by circuitry which senses a powerline frequency (such as 60 Hertz), or may be replaced by software steps which keep track of time delays or sequences of operations which are related to the cycle of time of the processor U2. A digital output (not shown) may be connected to the processor U2 in order to allow the system 10 to be connected through a digital data communications system in order to transfer the information collected by processor U2 to larger data processing systems. Such larger data processing systems may include centralized patient monitoring consoles at which a nurse may simultaneously monitor the status of several expectant mothers so that medical personnel may be dispatched and care provided when needed. The integrated circuit U7 is connected to the processor U2 in order to control the displays U8 and U9, to sense when the power supply (battery B1) voltage is low by using the voltage sensing circuitry 30 which includes zener diode D1, and to control actuation of the audible buzzer A1 through the transistor Q1. The switches S1, S2, and S3 shown in FIG. 2B correspond to timing switch 14, readout button 18, and power control switch 22 of FIG. 1, respectively.
The description presented herein shows a system 10 using a TMS1099JLC microprocessor U2 available from Texas Instruments, Inc. of Dallas, Tex., U.S.A. Such as system 10 requires that read only memory program storage devices be programmed for the labor pain timing mode and the rehearsing mode or for the labor pain timing mode and fetus movement counter mode; inasmuch as the program coding for all three modes is too voluminous for use with the TMS 1099 JLC microprocessor U2 because of addressing limitations with that device. An alternative embodiment for the invention may be constructed by replacing memory U1 with a pair of type 2716 read only memories having all inputs (A0-A10) and outputs (00-07) connected in parallel. Such a pair of read only memories would be selectively connected to provide information to the processor U2 through actuation of a toggle switch. The output enable (pin 20) and clip enable (pin 18) control lines of the type 2716 memories would be connected to the toggle switch so that only one of the memories would supply information to the processor at one time. The toggle switch would be mounted on the enclosure case 12 for manual actuation by the user. When the toggle switch is in its first position, the first alternative embodiment type 2716 memory (having code for the labor pain timer mode and code for the fetus movement counter mode) would be activated to provide programming for the processor U2. When the toggle switch is in its second position, the second alternative embodiment type 2716 memory (having code for the labor pain timer mode and code for the contraction rehearsing mode) would be activated to provide programming for the processor U2. Thus the user would place the toggle switch in its first position to allow contraction timing or fetal movement counting, and would put the toggle switch in its second position to allow contraction timing or a rehearsal of contraction simulations. A further embodiment of the invention may include a microprocessor and memory having sufficient capacity or arranged in such a way as to have coding for all three modes without requiring a manual toggle switch.
Included as a part of this specification are twenty-nine pages of computer printout sheets which form a listing in the Program Design Language (PDL) which describes the functional operation of the computer program of this invention in conformance with the guidelines described in the U.S. military specification MIL-STD-1679. The PDL listing is not a computer program itself and is not intended to be assembled or compiled into machine instructions. However, the PDL listing may be used as an aid by a computer programmer in writing a computer program for use in this invention. The object code computer program listing presented later herein used the functional approach disclosed in the PDL listing below.
Page 1 of the PDL listing is a table of contents for the PDL listing which describes the parts of the listing, including the five flow sections: Initialization, Labor Pain Timer Routines, Readout and Labor Pain Announcer, Labor Pain Rehearsing Routines, and Fetus Movement Counter Routines. After the five flow sections, the PDL listing includes cross-referencing tools which aid in the understanding of the PDL listing; i.e., a Data Index, a Flow Segment Index, and Segment Reference Trees. The PDL listing may be used in much the same way as computer program flow chart drawings have been used in the past in order to understand the functional operation steps performed by the invention, and the sequence in which the steps are performed.
The pages of the five sections of the PDL listing have a heading indicating the section name and page numbers, and subsection name unique to the page describing the functions performed by the subsection shown on the page, and have five vertical columns: a universal line number (ULN) column; a reference page column; a local line number column; and a listing text column. Separator pages (pages 2, 5, 9, 12 and 16) are provided before the start of each section of the PDL listing. The universal line numbers describe the position of each line of text with respect to the start of the entire listing, and the local line numbers describe the position of each line of text with respect to the start of each page (for example, on page 6 of the PDL listing, the universal line numbers span from 45 to 69 and the local line numbers span from 1 to 25. The reference page column lists the page at which a reference made in the PDL listing text may be found (for example, on page 6, universal line number (ULN) 65, a reference is made to "TIMIN" which may be found on page 7 (ULN 71) of the PDL listing). The text of the PDL listing is broken up into functional flow portions which are preceded by a label which is denoted by a subsequent colon, such as the three flow portions on page 6, denoted with the segment name, "Perform Labor Pain Timing Mode," of the PDL listing which are labeled NO SWITCH, LOOP B0, and LOOP B1. Nonfunctional, explanatory comment entries in the PDL listing are denoted by text preceded by pairs of periods, such as the text at ULN 155 on page 10 which noted "READOUT RELEASED."
Starting with page 20, an index is presented of various data items which are used as counters and the like in the PDL listing. The index is a list in which the name of each data item is preceded by the initials "DI", and in which the PDL listing pages on which the data item is referenced are placed below the data item name. After each page number in the data item listing, a functional description (the flow segment name) is presented to show how the data item is used on that page of the PDL listing, and underneath the description, the local line numbers at which the data item is referenced are presented. For example, on page 20.001 of the PDL listing, it is shown that the data index "Practice-Pattern" is used in performing the rehearsing mode flow segment at local line numbers 2, 4, 24, 25 and 26 of page 13; and is used in the output contraction data flow segment at local line number 1 of page 14.
Beginning with page 21, an index to the flow segments is presented in which the name of each flow segment is preceded by the page on which the segment appears in the PDL listing, and the letters "FS". Underneath each listed flow segment name in the index, the page number and referencing segment name of each flow segment in which the listed segment is referenced are presented. The local line numbers in which the reference is made in the referencing segment are listed under the referencing segment name. For example, the flow segment on page 4 ("Initialize Labor Pain Timer") is referenced by the local line number 16 of the flow segment on page 3 ("Power On Initialization"), as detailed at the top of page 21.001.
Referring next to page 22.001 of the PDL listing, a set of flow segment reference trees is presented in which three columns are presented: a logical segment number column, a defined segment number column (corresponding to the page number), and a flow segment name column. The tree has three major branches (shown at logical segment numbers 2, 14, and 17) which correspond to the three operating modes of the invention and which are denoted "Initialize Labor Pain Timer", "Perform Fetus Movement Counter Mode", and "Perform Rehearsing Mode". The segment reference tree shows, in a hierarchical fashion, the referencing which occurs between the flow segments representing the sequencing of operations performed by this invention. Flow segments which are used more than once in the PDL listing tree are preceded by a star or a dash and are followed by the logical segment number where first used (for example, at logical segment number 11, the flow segment "Perform labor Pain Timing Mode" is used, and which was first used at logical segment number 5). The flow segment reference tree shows, in an indented outline format, the sequences in which the PDL listing segments may be referenced. For example, since the segments "Perform Labor Pain Timing Mode" (logical line number 7) and "Monitor Timing Switch" (logical line number 8) are both indented beneath the segment "Perform Labor Pain Announcer Mode" (logical line number 6), either of the segments (logical line numbers 7 or 8) may be referenced from the segment at logical line number 6.
INITIALIZATION
When power is first applied to the circuitry of this invention (as by operating switch 22), operation of the program begins as described on page 3 of the PDL listing. The first operation performed on initialization (as shown at ULN15) is to set all of the circuitry to predefined initial conditions. If the voltage of the battery B1 is low, the display 20 is caused to flash a display symbol "LO". If the voltage of the battery B1 is not low, the display 20 is caused to flash a decimal point momentarily. The display 20 is used in the system 10 to present displays representing measurements and computations made by the system 10, and in order to acknowledge the operating status (such as the modes and features described herein) of the system 10.
The way in which the user of the system 10 selects the operating mode is outlined in ULN 23-30 of the PDL listing. Actuation of the timing switch 14 and the readout button 18 serves to select the mode of the system 10. The conditions of the switch 14 and button 18 are determined by the microprocessor U2 under control of a computer program which operates as described in the PDL listing. Although not specifically described in the PDL listing, time delays and rechecks are used by the steps shown at ULN 23-30 to make sure of the status of the switch 14 or button 18 and avoid errors due to switch contact bouncing. Also, the steps at ULN 23-30 allow a short period of time during which a user may actuate both switch 14 and button 18 in mode selection. If neither timing switch 14 nor readout button 18 is actuated, the steps shown in ULN 31-35 are performed so that the display 20 continues to show either "LO" or a flashing decimal point (depending on the voltage of battery B1) until either the switch 14 or button 18 is actuated. If the timing switch 14 alone is actuated, the medical timing system 10 will be placed in the labor pain timer mode (the description of which starts on page 4 of the PDL listing). If the timing switch 14 and readout button 18 are both actuated substantially simultaneously (and remain actuated for a short time), the fetus movement counter mode is entered (see page 17 of the PDL listing). Finally, if the readout button 18 alone is actuated, the contraction rehearsing mode is entered (see page 13 of the PDL listing). Once an operating mode has been selected by the switch 14 and button 18, the power to the microprocessor U4 must be cycled (on-off-on) through the use of the power control switch 22 in order to end the mode in use and select another mode.
LABOR PAIN TIMER MODE
Description of the labor pain timer mode begins on page 4 of the PDL listing. After the initialization of the medical timing system 10 as described above, and the selection of the labor pain timer mode through the actuation of the timing switch 14 alone, the current time is saved by the microprocessor U4 and the display 20 shows an "8.8." test pattern for one second in order to allow the user to verify that the display 20 is operating properly.
The processor U4 then initialized the contraction time count (at ULN 40) to one second, sets a flag to indicate first time, and sets a counter to one to indicate how many times the timing switch 14 has been depressed. This last operation of keeping track of the number of times that the timing switch 14 has been depressed is used to allow the labor pain announcer feature of the labor pain timer mode to be turned on and off by depressing the timing switch 14 for three times in a quick sequence, as will be described below. The computer program of this invention then jumps into a normal timing switch routine on the PDL listing page 7 at a special entry point (labeled FIRSTC) to bypass some operations the first time (PDL listing page 7, ULN 73).
On page 7 of the PDL listing, the normal timing switch 14 depression (after the first time that switch 14 is depressed) saves the current time (from the internal timekeeping routine of the software program which samples the timing pulses produced by timing circuit 26) as the start of contraction and sets the running counter (CONTRACTION-TIME) to zero (ULN 72). These operations are also indicated on page 4 of the PDL listing for use during the first loop of the routine, and thus those related steps on page 7 are bypassed during the first time through the routine.
On page 7 of the PDL listing, ULN 74-77 present the running time in the display 20 for a 250 ms duration during the contraction measurement. Running times greater than 99 seconds have the right hand decimal point lit in the display 20 to show the overflow. ULN 78-95 implement a waiting loop for a timer clock in the software program to tick over to the next integral second. The timer clock in the software program of this invention keeps a count of the timing signals received by processor U2 from the timing circuit formed by the gates of circuit U4. During this waiting time, the timing switch 14 is checked to make sure that the timing switch 14 is held in a depressed condition. Note that the timing switch 14 is to be held in a depressed condition during the time that a contraction is proceeding when the system 10 is in a labor pain timer mode. The timing switch 14 is to be left in an undepressed condition during the interval between contractions. When in the labor pain timer mode, the processor U2 keeps a record in its random access memory of the time of starting and stopping of each contraction so that such data may be processed to determine the time duration of each contraction, and to determine the time interval between sequentially adjacent contractions. If during the waiting loop shown at ULN 78-95, the timing switch 14 is released from its depressed condition, an exit is made to process and record the interval and duration information, as shown in page 8 of the PDL listing. If the timing switch 14 remains in a depressed condition during the waiting loop, the software timer clock is checked. When an integral second of the software timer clock has elapsed, the time count (CONTRACTION-TIME) is incremented, and tests are made inside the waiting loop in order to determine the type of presentation to make in the display 20. The intent of the tests made inside the waiting loop of ULN 78-95 is to cause the display 20 to present a running time indication on the second up to eleven seconds, and thereafter to present the running time every five seconds, with decimal points flashing for the intervening integral seconds. Thus, when in the labor pain timer mode, the display 20 is actuated by the processor U2 to present a visual display of the running time duration of the contraction. If the timing switch 14 is held down for more than 180 seconds, the display 20 ceases to present the running time.
When the timing switch 14 is released, thus indicating that the labor contraction has ended, the "process new interval" segment is entered on page 8 of the PDL listing. A test is made at ULN 98-109 to determine if the duration of the contraction just measured was less than a predefined minimum duration (23 seconds), and if so, the measured contraction is not considered to be a valid contraction since it is not considered to be medically significant. At this point, the count (PRESS-COUNT) of the depressions of switch 14 is incremented and checked. When the count of switch 14 depressions reaches 3 (in a small time interval as described below), the status of the labor pain announcer feature of the labor pain timer mode is checked. If the labor pain announcer feature was previously turned on, it is turned off at this time and the display 20 is caused to present a display "Cd" to verify to the user that the labor pain announcer feature has been turned off. If the labor pain announcer feature was previously off (as is the case when the system 10 is initialized by cycling the power on and off through actuation of the power control switch 22), and if the timing switch 14 has been depressed three times quickly (in the short time interval mentioned above), then the labor pain announcer feature is turned on and the display 20 shows a display "CC" to verify to the user that the labor pain announcer feature has been activated. Following the tests and actions shown on page 8 of the PDL listing, control in the software program next proceeds to page 6 of the PDL listing to monitor the timing switch 14 and readout switch 18 for the next depression of either.
If a false contraction was not detected by ULN 98 on page 8 of the PDL listing (that is, the timing switch 14 was depressed for more than 23 seconds), ULN 111-124 are performed to compute the time length of the previous interval since the last measured contraction. A first time flag is used in ULN 112 to bypass this computation since there would be no previous contraction if the contraction just measured was the first contraction which occurred. If the contraction just measured was not the first contraction which occurred, the time interval (from the start of the previous measured contraction to the start of the contraction just measured) is computed from the times which have been stored in the random access memory of the processor U2, and the interval time is rounded to the nearest minute (or rounded to the nearest tenth of a minute if the interval is less than seven minutes long) and saved in the random access memory of the processor U2. Interval breaks which are longer than twenty minutes in length are not considered to be medically significant and are recorded in the memory of the processor U2 as an abbreviation "LG". The labor pain announcer feature of the labor pain timer mode may be used if the measured interval between contractions was less than five minutes. If the labor pain announcer feature is to be used, the length of the last time interval between contractions will have subtracted from it a predetermined anticipation time (preferably ten seconds), and will be used as the time to check in operation of the labor pain announcer feature. If the labor pain announcer feature is to be used, a flag (the READINESS-FLAG) is set as in ULN 105.
Once the interval processing shown in ULN 111-124 has been performed, the steps shown in ULN 125-131 are performed to round off the contraction time to the nearest second, save the measured contraction time in the random access memory of the microprocessor U2, and display the measured contraction time in the display 20 for four seconds. If the measured contraction time was longer than 99 seconds, the symbol "LG" is saved in the memory of processor U2 instead of the actual measured contraction time, but the display 20 will show the actual measured contraction time (or measured contraction time up to a maximum of 180 seconds). The clock timer of the software program is then reset to the time of the start of the previous contraction and the first time flag (the flag which is checked in ULN 112) is cleared. Processing by the software computer program in the processor U2 then continues with the steps shown on page 6 of the PDL listing.
The steps shown on page 6 of the PDL listing are performed when neither the timing switch 14 nor the readout button 18 is depressed, in particular following release of the timing switch 14. A pointer to the current memory item for the recorded time to be displayed on the display 20 (for the readout feature) is then reset to point to the most recent recorded duration (on line 2 of page 6). Next, a counter (on line 4 of page 6) is set to three to provide a means of resetting the readout pointer and switch actuation counter (PRESS-COUNT) after a predetermined amount of time elapses. The main processing loop is then entered, starting with line 6 on page 6. As long as the switches 14 and 18 are not depressed, the system 10 program remains in the loop just described.
The steps shown in lines 6-12 of page 6 describe two major functions. First, a decimal point on the display 20 is flashed every five seconds. Second, the "3" count is decremented. When the "3" count goes to zero (after the flashing of decimal point three times), the readout counter and press counter are each reset. The press count reset means that three depressions of the timing switch must occur in less than 15 seconds to toggle the readout announcer feature on and off.
Lines 13-18 then describe the checking of the various parameters to determine if the labor pain announcer should become active. In particular, the announcer mode must be turned on and current elapsed time must be greater than or equal to the previously computed announcer time. Page 11 describes the labor pain announcer action and will be discussed later.
If the announcer was not activated, the switches are next checked in lines 19-24. If the timing switch is on, processing continues with the logic previously discussed (PDL page 7). If the readout switch is depressed, processing continues on PDL page 10 with "Readout Data". If no switches are set, the loop is repeated starting with line 6.
READOUT FEATURE
Page 10 of the PDL describes the readout operation. First, an integral one second boundary is reached. The only purpose of this is to allow proper operation of the specific display routines used and has no real significance.
Lines 3-6 check whether it is the first time or the end of display readout memory was reached through prior display activity. If either is true, "nn" is displayed to indicate "none" or "no more" and an exit is made to the idle loop routine on page 6 of the PDL.
If not the end of data, lines 7-12 display a "dU" for duration or "1n" for interval (depending on which parameter is next to be displayed), followed by a short pause. Note that the display alternately reads out labor pain durations and then intervals between them, starting with the most recent and working back in time until the end of recorded history (or end of available memory) is reached. Lines 14-20 first display the proper value from memory until the next integral second is reached. At this time the switches are checked. If the timing switch is on, an exit is made to page 7 of the PDL to monitor the new labor pain. If the readout switch is still set, the logic jumps to line 25 to check for the labor pain announcer time. If the readout switch was released, lines 22 and 23 are performed. This results in the display pointer being moved back to the next oldest entry and an exit to the idle loop routine on page 6.
Lines 26-31 describe the test for labor pain announcer. This is identical to the test on page 6, lines 13-18, and it will not be described again. If it is not time for the announcer, processing continues with a loop back to line 14 to display the current information some more. This loop continues as long as the readout switch is held down and no other event (such as a timing switch depression) occurs to interrupt the display loop.
LABOR PAIN ANNOUNCER FEATURE
When the time has elapsed, as previously described, to be 10 seconds less than the last recorded contraction interval, the logic on page 11 of the PDL is entered. Lines 1 and 2 first test if the announcer time was valid (less than five minutes and not already displayed). If not valid, an immediate exit back to page 6 of the PDL is made. Otherwise, the validity flag is cleared (so the announcement will not be repeated) and a time count of 10 is set on line 6.
Lines 7-18 describe the actions during the ten second count period. Essentially, a "C" is flashed twice per second (at a 4 Hz rate). This is followed, during the "off" time, by a check of the switches. If the timing switch is pressed, signaling the start of a new labor pain, an exit is made to page 7 to monitor it. After the ten seconds elapse, control returns to the idle loop routine one page 6 of the PDL.
LABOR PAIN REHEARSING MODE
This mode was entered following power up by depressing only the readout switch. Page 13 of the PDL listing describes the initialization of this feature. The rehearsing routines make use of an optional audible device A1 termed a "beeper" or "buzzer". There are three patterns which may be selected by the user corresponding roughly to early, middle and late labor. The buzzer A1 may be used with any of these. Line 2 initializes the pattern to "1" and the beeper A1 to "off".
Lines 4-16 describe the pattern selection logic. Essentially, the pattern type (P for normal, A for buzzer mode) and number (1, 2, or 3) are displayed as long as the readout switch is depressed. When the timing switch is simultaneously pressed, the buzzer mode is toggled off and on accompanied by a change of the display from P to A (or A to P) and a beep when it changes to an "A".
When the readout button 18 is released, a ten-second wait count is set up (line 18). During the ten-second period, the switches 14 and 18 are checked (lines 20-33). If the readout button 18 is depressed again, the pattern number is incremented and displayed again (lines 24-28) after which the ten-second counter will be reset to ten and the down count repeated. A loop back to line 4 is used to accomplish the display logic.
When ten seconds have elapsed with no switch depression, the current timer "seconds" count is captured and saved as a pseudorandom number to be used to augment the rehearsal durations and intervals (line 34). The pseudo random number so created acts as a substantially random augmentation signal which may be applied to the selected pattern so that the occurrence of simulated contractions will be realistic and will tend not to be anticipated by the expectant mother. Processing continues on page 14 of the PDL listing with the output of the simulated contraction.
On PDL page 14, the logic in lines 1-8 first loads the appropriate parameters (into a common memory area in the processor U2) corresponding to the pattern number last selected. Lines 10-15 then perform an alert that the contraction is about the start by flashing a "C" for four seconds along with the beeper if the buzzer mode was enabled. The duration to use is then fetched from memory and combined with the random number to be used as a duration length. The software program timer routine is reset to zero and a loop is entered to display time during the simulated contraction.
Lines 17-38 present the logic used to display the time every five seconds with decimal points flashed in between on integral second boundaries. In addition, the beeper sounds every fifteen seconds if it was enabled. If the readout switch is pressed, the simulated contraction stops and control returns to page 13 of the PDL, line 24, to change the pattern number. Finally, if the current time reaches the previously computed duration time, an exit is made to page 15 to await the interval length expiration before starting the next simulated contraction.
Page 15 of the PDL listing shows the logic when the simulated contraction is over. Lines 1-4 first signal the end of the contraction by flashing an "E" for two seconds and (if enabled) putting out a long beep. The memory pointer is then incremented to point to the interval time, this time fetched and combined with the random number, and the timer is reset to zero (lines 5-7). The loop consisting of lines 9-18 is then entered. This loop sequentially checks for readout switch pressed (with an exit to PDL page 13, line 24 if so), flashes a decimal point every five seconds, on the second, and checks for end of interval time.
When the interval is done, lines 20-24 increment the memory pointer to point to the next simulated contraction time. If the end of the stored constants has been reached, the random number is incremented by three and then adjusted to be between zero and nine. The memory pointer is then reset to the first stored duration time. In any case, the device continues with the output of the next simulated contraction on PDL page 14, line 10.
The sequence of simulated contractions and intervals is repeated as long as power is applied to the device. The user may change patterns at will as previously described.
FETUS MOVEMENT COUNTER MODE
This mode was entered following power up by depressing the readout and timing switches simultaneously.
Each time a fetal movement is felt, the expectant mother is to depress the timing switch. The device counts and accumulates these depressions. After a twenty-minute length of time, the ratio of movements per minute is computed and displayed. The display 20 is used in the fetus movement counter mode in order to display numbers representing the counting performed by the processor U2 in the form of the number of fetal movements measured by processor U2 per unit of time. The timing period may be stopped earlier if desired. Once stopped, the ratio may be re-displayed by again pressing the readout switch. An option is to use the buzzer to signal the passing of each minute and the end of the twenty minutes.
Page 17 of the PDL describes the initialization of this feature. Line 2 first sets the buzzer enabled and then displays "FA" as long as either the timing or readout switch is depressed. Once both switches are released, the display goes blank and a ten-second count is set up (lines 3-4). Lines 5-13 describe the activity during the ten-second wait. If the readout switch is pressed during this time, the buzzer option is turned off and a beep output to acknowledge the action. Once turned off, it cannot be turned on again for this mode without cycling power and starting over.
After the ten-second period is done, the count of timing switch depressions is cleared and processing continues on PDL page 18 with the counting of fetal movements. The elapsed number of minutes is displayed for a brief period (line 2). Lines 4-7 show the counting of timing switch depressions. Lines 8-10 test for early termination of the timing period. This is accomplished by pressing the readout and timing switches simultaneously. When this occurs, an exit is made to page 19 of the PDL. Otherwise, lines 11-19 describe the action when an integral minute has elapsed. If the time count is twenty minutes, the exit to PDL page 19 is taken. If the buzzer was not disabled, a short beep is output. Processing then loops to line 2 to display the new minute time.
If a minute did not elapse yet, a check for an integral multiple of ten seconds is made in lines 20-22. If the check proves true, the time is displayed (minutes elapsed) by looping back to line 2. If it was not a multiple of ten seconds, but was an intermediate five-second interval, lines 23-25 cause a decimal point to flash. Control then loops back to line 4 to await the next event.
When the fetus movement count time reaches twenty minutes (or is terminated early), page 19 of the PDL is entered. Lines 1-3 first signal the end of the timing period by beeping for a long interval (if the buzzer was not disabled). Lines 4-7 round the time to the nearest minute and assure that the minute count is at least one to provide a valid divisor for the ratio computation. The ratio is then computed. The computed ratio of fetal movements per unit time is an indicator of the apparent health of the unborn child. This is performed to the accuracy of tenths of movements per minute. Line 10 displays this computed ratio for four seconds. Note that ratios greater than 7.9 are displayed to the nearest whole number.
Lines 12-16 form a loop which has control until the readout switch is pressed. The switch depression causes a re-display of the previously computed ratio (at line 10). Power must be removed to exit from this loop.
BREASTFEEDING TIMER MODE
An optional mode which may be implemented with a computer program for use with the processor U2 in the hardware shown in FIGS. 1, 2a and 2b is a breastfeeding timer mode which acts to provide reminders to the mother during post-natal child care so that the child may be fed for predetermined time periods, as in compliance with medical instructions received from the doctor. The purpose of the breastfeeding mode is to present, in the display 20 (and optionally by actuating the buzzer A1), an indication reminder when feeding should end after the system 10 has been signaled that the breastfeeding has begun.
The breastfeeding timer mode may be included in a system 10 having the other modes discussed above and may be selected during the initialization of the system 10 by depressing the readout button 18 for three times in rapid succession, which also serves to signal to the system 10 that the breastfeeding has begun. The system 10 then (after selection of the breastfeeding timer mode) should display the preset feeding time duration (for example, twenty minutes) in the display 20 and allow the feeding time duration to be changed by the user through actuation of the readout button 18. For example, actuating the readout button 18 for a long depression would reduce the feeding time duration by one minute for each time that such a long depression were given by the user. Also, actuating the readout button 18 for a short depression would increase the feeding time duration by one minute for each time that such a short depression were given by the user. At the same time, the display 20 would show the feeding time duration as set by the user so that the user could operate the readout button 18 and display 20 in an interactive fashion to set the feeding time duration to accommodate medical requirements.
Approxmately ten seconds after the last depression of the readout button 18 was made in order to set the feeding time duration, the feeding time monitoring would begin inside the system 10 by the sampling of time pulses on the timing circuit 26, and such a start of feeding time would be indicated by the display of the symbol "F" in the display 20. Thereafter, the elapsed feeding time (in minutes) is presented in the display 20 every ten seconds, with the presentation in the display 20 of a single decimal point on the five second mark between the full displays. Activation of the audible buzzer A1 may be selected and deselected by manual actuation of the timing switch 14 and readout button 18 so that audible indications may be selectively, automatically produced at one-minute intervals, at the end of the feeding time period, or not at all (silence). Ending of the feeding time period is indicated to the user by the display 20 (which may flash the symbol "E") and (optionally) by beeping of the buzzer A1 (as described above). The elapsed feeding time continues to be presented in the display 20 by the processor U2 after the expiration of the feeding time period so that the user may keep track of how long feeding has continued.
CHILDBIRTH RECORDED INSTRUCTION FEATURES
Optional childbirth recorded instruction features may be provided in the system 10 by the addition of display devices to U8 and U9 in order to make a seven character alphanumeric display and the addition of commercially available speech synthesizer integrated circuits connected to the processor U2 and to an audio speaker. The seven character display would be useable during the labor pain timer mode or contraction rehearsing mode in order to display alphabetic character strings of entire words, commonly accepted abbreviations, or recognizable abbreviations. It is preferrable that approximately seven characters be provided in order that the display be readily understandable. The speech synthesizer circuitry would allow the system 10 to provide audible instructions to the expectant mother and her coach in order to supplement written and classroom instructions given. For example, audible instructions could be given during the labor pain timer mode by the processor U2 through the speech synthesizer circuitry in order to indicate to the expectant mother (a) when cleansing breaths should be taken at the beginning and end of each contraction, (b) the type of breathing which should be occuring at various stages, and (c) the proper breathing rate.
The seven character display would be constructed by connecting additional display devices in parallel with the devices U8 and U9 so that the additional display devices are multiplexed by connection to the unused outputs (R0, R1, R5 and R7) of the processor U2. The processor U2 would control the seven character display and the speech synthesis circuitry under program control by processing the data previously received and stored in memory by the processor U2 and sensing the inputs to the processor U2 in order to provide the proper output instructions to the expectant mother and coach.
THE OBJECT CODE LISTING
Also included as a part of this specification are five pages of computer printout sheets which form a hexadecimal listing of the object code computer program of this invention. The listing is made up of hexadecimal digits representing nibbles of the program content, with each two adjacent digits representing a byte. The object code listing is presented in a sequence of rows and columns in which each row is preceded at its left with a four digit row number corresponding to the address of the first byte in the row, and in which the addresses of the bytes in the rows increases from left to right, with adjacent bytes in the same row representing the contents of sequentially adjacent addresses. The addresses of memory contents represented in the object code listing increases from the top to the bottom of the columns.
The object code listing includes two sections entitled "MEMORY DUMP FOR EPROM1 (BASIC/PRACTICE)" and "MEMORY DUMP FOR EPROM2 (BASIC/FETAL MON)" which correspond to the program contents for embodiments of this invention which provide the labor pain timer mode and the contraction rehearsing mode, or the labor pain timer mode and the fetus movement counter mode, respectively.
Further included as a part of this specification is a one page hexadecimal listing (entitled "MEMORY DUMP FOR DISPLAY TRANSLATION EPROM") of the contents of the EPROM U3 used to drive the displays U8 and U9 based on the output of the processor U2. The format of the listing for memory U2 is the same as that described above for the object code program to be stored in the memory U1.
Alternative versions of the medical timer system 10 of this invention may be constructed by loading (into memory U1) one of the object code programs (entitled "MEMORY DUMP FOR REVISED EPROM 1 (BASIC/REHEARSAL)" and "MEMORY DUMP FOR REVISED EPROM 2 (BASIC/FETAL MON)") which are presented in a five-page computer program listing included as part of this specification, and which are functionally similar to the above-described programs excepting for the differences described below. The program labeled "MEMORY DUMP FOR REVISED EPROM 1 (BASIC/REHEARSAL)" includes the labor pain timing mode and the contraction rehearsing mode. The program labeled "MEMORY DUMP FOR REVISED EPROM 2 (BASIC/FETAL MON)" includes the labor pain timer mode and the fetus movement counter mode. These programs include computer code for activation of the audible buzzer A1 automatically upon entry to the labor pain timing mode so that an audible signal is produced every fifteen seconds during the time that a contraction is occuring, and so that the activation of the audible buzzer A1 may be deselected (and reselected) by actuation of the readout button 18 followed by actuation of the timing switch 14, so both switch 14 and button 18 are simultaneously actuated (which is acknowledged by an audible beep from buzzer A1). The busser A1 (if activated) serves to produce an audible noise to indicate the running time duration of the labor contraction. If the contraction announcer feature of the labor pain timing mode is selected, the buzzer A1 (when activated) will also be actuated by processor U2 to alert the expectant mother when a contraction is to be anticipated.
The "MEMORY DUMP FOR REVISED EPROM 1 (BASIC?REHEARSAL)" also includes code for actuation of the audible buzzer A1 automatically upon entry into the contraction rehearsing mode so that the buzzer A1 is actuated at the start of and the end of each simulated contraction, and so that the actuation of the buzzer A1 may be deselected (and reselected) by actuation of the readout button 18 followed by actuation of the timing switch 14 so that both switch 14 and button 18 are simultaneously actuated (which is acknowledged by an audible beep from buzzer A1).
The "MEMORY DUMP FOR REVISED EPROM 2 (BASIC/FETAL MON)" also includes code for actuation of the audible buzzer A1 automatically upon entry into the fetus movement counter mode so that the buzzer A1 is actuated when the predetermined counting time period (twenty minutes) has elapsed, and so that activation of the audible buzzer A1 may be deselected during the first ten seconds of the counting time period by actuation of the readout button 18 followed by actuation of the timing switch 14 so that both switch 14 and button 18 are simultaneously actuated.
|
A medical timing system has a programmed computer controlled display and audible buzzer, with inputs from a timing switch and a readout button which are connected together so that pregnancy labor pains may be timed, contraction patterns may be rehearsed by an expectant mother, and fetus movements may be counted. The medical timing system is preferably hand-held and compact so that the timing switch and readout button may be easily actuated and so that accurate and reliable timing measurements may be made and recorded through use of the system.
| 6
|
The present invention relates to a process for preparing 5′-acetylstavudine, an intermediate which is useful in the preparation of 2′,3′-didehydro-3′-deoxythymidine, an active principle with antiviral action which is commonly known as stavudine (D4T).
TECHNICAL FIELD OF THE INVENTION
Many processes for preparing stavudine have been described in the literature, such as, for example, those reported in: EP-A-0 340 778, EP-A-0 493 602, EP-A-0 501 511, WO 92/09599, EP-A-0 334 368, EP-A-0 519 464, EP-A-0 653 435, EP-A-0 653 436, EP-A-0 735 044, in Mansuri et al., J. Org. Chem. 1989, 54, 4780-4785 and in Classon et al., Acta Chem. Scand., B36, 1982, 251. Among these, EP-A-0 334 368, Mansuri et al. and Classon et al. describe the preparation of stavudine by deacetylation of 5′-acetylstavudine; in greater detail, both EP-A-0 334 368 and Mansuri et al. describe a process for preparing 5′-acetylstavudine (B) by reductive elimination of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine (A) in the presence of zinc as reducing agent and copper as activating agent, according to the reaction scheme given below.
5′-Acetylstavudine is then converted into the final product by hydrolysis with sodium methoxide in methanol. The synthetic scheme described in Classon et al. is substantially identical, the only difference being that the reductive elimination reaction is carried out in the presence of zinc as reducing agent and acetic acid as activating agent.
However, the two synthetic processes described above are relatively unsatisfactory, in particular on account of the reductive elimination reaction which gives only moderate yields and, thus, is difficult to apply at the industrial level; the purpose of the present invention is thus to find a process which allows the reductive elimination of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine in yields greater than those of the processes known in the art.
DESCRIPTION OF THE INVENTION
A process has now been found, and this constitutes the subject of the present invention, which makes it possible to prepare 5′-acetylstavudine in yields that are substantially greater than those of the processes described above; according to this process, 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine is converted into 5′-acetylstavudine by reductive elimination in the presence of zinc as reducing agent combined with an ammonium salt or a phosphonium salt as activating agent.
Among the various ammonium salts, the ones that are particularly preferred are the halides and sulphates; among the halides, those that are most indicated for carrying out the invention are selected from tributylamine hydrochloride, triethylamine hydrochloride, ammonium chloride, tributylamine hydrobromide, triethylamine hydrobromide and/or ammonium bromide.
Among the phosphonium salts, the ones that are preferred are the halides, in particular the bromides, for example such as triphenylphosphine hydrobromide.
As will be seen from the examples which follow, and which should be considered as purely illustrative of and non-limiting on the invention, zinc is generally used in an amount of between 1 and 4 equivalents and preferably between 1.5 and 2.4 equivalents, while the ammonium salt is used in an amount of between 0.2 and 2 equivalents and preferably between 0.5 and 1.5 equivalents.
The process according to the present invention may be carried out in the usual organic solvents used in reductive eliminations, such as alcohols, ethers, esters or dipolar aprotic solvents; among these, the preferred solvents are dipolar aprotic solvents such as, for example, DMF or DMSO and ethereal solvents such as, for example, THF, or mixtures thereof.
In the preferred embodiment of the invention, 1.5-2.4 equivalents of zinc powder are added to a solution at 20° C. of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine in DMF, DMSO or THF, or mixtures thereof. The reaction mixture is left stirring for about 10 minutes and 0.5-1.5 equivalents of the ammonium salt, preferably tributylamine hydrochloride, triethylamine hydrochloride, ammonium chloride, tributylamine hydrobromide, triethylamine hydrobromide or ammonium bromide, are then added; the system is then left to react at 30° C. for about 2 hours, until the reaction is complete.
As may be appreciated from the examples attached, the process according to the present invention allows the production of 5′-acetylstavudine in particularly high yields when compared those of processes known in the prior art; specifically, 5′-acetyl-10 stavudine may be obtained in yields of 56-67% working with 86-90 g of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine and in yields of greater than 70% by working with about 10 g of starting material; in contrast, the processes described in EP-A-0 334 368, Mansuri et al. and Classon et al. give yields of 44-52% by working using substantially smaller starting amounts of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine, that is to say more or less of the order of 1.6-2 g.
The 5′-acetylstavudine obtained according to the process of the present invention may then be converted into stavudine according to the various processes known in the art, such as, for example, those disclosed in EP-A-0 334 368, Mansuri et al. and Classon et al., which should thus be considered as included in the present description also as regards the preparation of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine.
EXAMPLE 1
Zinc powder (352 g) is added to a solution of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyl-uridine (90.8 g) in DMF (998 ml) at 20° C. The reaction mixture is left stirring for 10 minutes. Ammonium chloride (13.1 g) is then added. An exothermic reaction takes place, the temperature rises spontaneously to 35-40° C. and the system is left to react at 30° C. The solid is filtered off and the DMF is evaporated off under vacuum at 60-65° C. to give a dense oil. This material is taken up in tetrahydrofuran (700 ml) and stirred for 2 hours. The precipitate is filtered off and washed with tetrahydrofuran (100 ml). The solution thus obtained is evaporated to dryness and the solid thus obtained is taken in isopropanol (450 ml) and heated to reflux, distilling off the head fractions up to the boiling point of the isopropanol. The mixture is cooled slowly to 20-25° C. and left stirring at this temperature for 3 hours. The solid thus obtained is filtered off and washed with isopropanol (50 ml). The wet solid thus obtained is redissolved in hot isopropanol, decolorized with charcoal, filtered, left to cool slowly and allowed to crystallize at 20-25° C. The solid is filtered off, washed with isopropanol and dried under vacuum at 60° C. to give 34.2 g of acetylstavudine (yield relative to the theoretical amount=57.3%).
EXAMPLE 2
Zinc powder (20.8 g) is added to a solution of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine (86 g) in DMF (946 ml) at 20° C. The reaction mixture is left stirring for 10 minutes. Triethylamine hydrochloride (14.6 g) is then added. An exothermic reaction takes place, the temperature rises spontaneously to 35-40° C. and the system is left to react at 30° C. The solid is filtered off and the DMF is evaporated off under vacuum at 60-65° C. to give a dense oil. This material is taken up in tetrahydrofuran (700 ml) and stirred for 2 hours. The precipitate is filtered off and washed with tetrahydrofuran (100 ml). The solution thus obtained is evaporated to dryness and the solid thus obtained is redissolved in isopropanol (200 ml) and this solution is evaporated under vacuum. The residue is taken up in isopropanol (400 ml) and heated to reflux, distilling off the head fractions up to the boiling point of the isopropanol. The mixture is cooled slowly to 20-25C and left stirring at this temperature for 3 hours. The solid thus obtained is filtered off and washed with isopropanol (75 ml). The wet solid thus obtained is redissolved in hot isopropanol, decolorized with charcoal, filtered while hot, left to cool slowly and allowed to crystallize at 20-25° C. The solid is filtered off, washed with isopropanol and dried under vacuum at 60° C. to give 33.8 g of acetylstavudine (yield relative to the theoretical amount=60%).
EXAMPLE 3
2′-Deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine (86 g) is dissolved in THF (1l) at 20±5° C. and zinc powder (28.8 g) is then added. The reaction mixture is left stirring for 15 minutes. Tributylamine hydrochloride (70.6 g) dissolved in THF (290 ml) is added as quickly as possible. An exothermic reaction takes place. The reaction mixture is stirred at 30° C. until the reaction is complete, and is then cooled to 20° C. and stirred for 2 hours at this temperature, after which the suspension is filtered through Celite and washed with THF (100 ml). The solution thus obtained is evaporated under vacuum at 40° C. The solid thus obtained is taken up in isopropanol (150 ml) and concentrated under vacuum at 40° C., and the operation is repeated with further isopropanol (150 ml).
The residue thus obtained is taken up in isopropanol (400 ml) and heated to reflux until completely dissolved. This solution is cooled slowly to 20° C. and left stirring at this temperature for 3 hours. The solid is filtered off and washed with isopropanol (70 ml). The wet solid thus obtained is redissolved in hot isopropanol, left to cool slowly to 20-25° C. and stirred at this temperature. The solid is filtered off, washed with isopropanol (70 ml) and dried under vacuum at 50° C. to give 31.8 g of acetylstavudine (yield relative to theoretical amount=56.3%).
EXAMPLE 4
Zinc powder (32.3 g) is added to a solution of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine (100 g) in THF (1.4 1) and DMSO (80 ml) at 20° C. The reaction mixture is left stirring for 10 minutes. Tributylamine hydrochloride (78.4 g) is then added. An exothermic reaction takes place, the temperature rises spontaneously to 35-40° C. and the system is left to react at 30° C. until the reaction is complete. The solid is filtered off and the THF is evaporated off under vacuum at 60-65° C. to give a dense oil. The residue thus obtained is taken up in isopropanol (2×150 ml) and this solution is evaporated under vacuum. The residue is taken up in isopropanol (465 ml) and the solution is brought to reflux. The mixture is cooled slowly to 20-25° C. and left stirring at this temperature for 3 hours. The solid thus obtained is filtered off and washed with isopropanol (100 ml). The wet solid thus obtained is redissolved in hot isopropanol, decolorized with charcoal, filtered while hot, left to cool slowly and allowed to crystallize at 20-25° C. The solid is filtered off, washed with isopropanol (100 ml) and dried under vacuum at 60° C. to give 41.0 g of acetylstavudine (yield relative to the theoretical amount=65.4%).
EXAMPLE 5
Zinc powder (32.3 g) is added to a solution of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine (100 g) in THF (1.4 1) and DMSO (80 ml) at 20° C. The reaction mixture is left stirring for 10 minutes. Tributylamine hydrobromide (98.5 g) is then added. An exothermic reaction takes place, the temperature rises spontaneously to 35-40° C. and the system is left to react at 30° C. until the reaction is complete. The solid is filtered off and the THF is evaporated off under vacuum at 60-65° C. to give a dense oil. The residue thus obtained is taken up in isopropanol (2×150 ml) and this solution is evaporated under vacuum. The residue is taken up in isopropanol (465 ml) and the solution is brought to reflux. The mixture is cooled slowly to 20-25° C. and left stirring at this temperature for 3 hours. The solid thus obtained is filtered off and washed with isopropanol (100 ml). The wet solid thus obtained is redissolved in hot propanol, decolorized with charcoal, filtered while hot, left to cool slowly and allowed to crystallize at 20-25° C. for 3 hours. The solid is filtered off, washed with isopropanol (100 ml) and dried under vacuum at 60° C. to give 42.1 g of acetylstavudine (yield relative to the theoretical amount=67%).
EXAMPLE 6
In order to ascertain the possible influence of the acid activator on the yield of the reductive elimination reaction of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine, the reaction in the presence of zincitriethylamine hydrochloride was compared with a similar reaction carried out in the presence of zinc/trifluoroacetic acid; the trifluoroacetic acid was used at a concentration such as to minimize the pH measured in an aqueous solution of triethylamine hydrochloride (pH 5.6±0.2) at a concentration of 5.1 g/110 ml.
Reaction with triethylamine hydrochloride
Zinc powder (3.2 g) is added to a solution of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-20 methyluridine (10 g ) in 110 ml of DMF at 20° C. The reaction mixture is left stirring for 10 minutes. Triethylamine hydrochloride (5.1 g) is then added. An exothermic reaction takes place and the temperature rises spontaneously to 35-40° C. This mixture is left to react at 30° C. for 3 hours. At the end of the 3 hours, the conversion of the 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine into 5′-2 5 acetylstavudine was evaluated by HPLC. HPLC analysis (percentage areas): 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine (starting material)<0.5%, acetylstavudine 78.7%. Conversion yield determined by HPLC titre=73%.
Reaction with trifluoroacetic acid
Zinc powder (3.2 g) is added to a solution of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine (10 g) in 110 ml of dimethylformamide at 20° C. The reaction mixture is left stirring for 10 minutes. Trifluoroacetic acid is then added (1 ml of a 0.003% solution of trifluoroacetic acid in dimethylformamide). The amount of trifluoroacetic acid is that required to reproduce the calculated pH generated by the triethylamine hydrochloride under the conditions described in the above experiment. The reaction mixture is stirred for 15 minutes, without any increase in temperature being observed. The reaction mixture is then heated to 30-35° C. for 3 hours. At the end of the 3 hours the conversion of the 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine into 5′-acetylstavudine was evaluated by HPLC, and it was found that no conversion 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine into 5′-acetylstavudine had taken place (HPLC analysis of the reaction mixture: no acetylstavudine detectable).
Conclusions
As may be readily observed by the comparison between the yield for the reaction carried out in the presence of zinc/triethylamine hydrochloride (73%) and that for the reaction carried out in the presence of zinc/trifluoroacetic acid (no product formed), it may reasonably be concluded that the acidity of the reaction medium does not play an important role in activating the reductive elimination reaction of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine.
EXAMPLE 7
Zinc powder (3.2 g) is added to a solution of 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine (10 g) in THF (142 ml) and DMSO (8 ml) at 20° C. The reaction mixture is stirred for 10 minutes. Triphenylphosphine hydrobromide (12.1 g) is then added. An exothermic reaction takes place, the temperature rises spontaneously to 35-40° C. and the system is left to react at 30° C. until reaction is complete. At the end of the three hours, the conversion of the 2′-deoxy-2′-bromo-3′,5′-diacetyl-5-methyluridine into 5′-acetylstavudine was evaluated by HPLC. Conversion yield determined by HPLC titre=65%.
|
The present invention relates to a process for preparing 5′-acetylstavudine, an intermediate which is useful in the preparation of 2′,3′-didehydro-3′-deoxythymidine, an active principle with antiviral action which is commonly known as stavudine (D4T).
| 2
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] A pigment printing dyestuff for textile finishing comprises a cyclodextrin (CD) or cyclodextrin derivative in turn capable of including a scent as a guest molecule.
[0003] 2. The Prior Art
[0004] Cyclodextrins (CD) are cyclic oligosaccharides constructed of 6, 7 or 8 α(1-4)-linked anhydroglucose units. The α-, β- or γ-cyclodextrins, which are prepared by enzymatic conversion of starch, differ in the diameter of their hydrophobic cavity and are generally suitable for the inclusion of numerous lipophilic substances.
[0005] Cyclodextrin derivatives are prepared by chemical modification of the —OH groups of cyclodextrin. Examples of customary modifying chemistries are hydroxypropylation using propylene oxide and methylation using methyl halides. The cyclodextrin derivatives thus obtained are substantially more soluble in water than native cyclodextrins and are capable of solubilizing inherently water-insoluble, hydrophobic substances in an aqueous medium by inclusion and formation of water-soluble complexes.
[0006] Printing is local color dyeing in zones corresponding to a pattern. Conformation to these zones dictated by the engraved pattern is ensured by the thickening of the color. The type and size of the artistic design determine the printing process and the dyestuff paste application method. Each printing technique is carried out using a specific printing process, which is usually based on a uniform sequence of operations (printing, drying, steaming, washing).
[0007] The pigment printing process is known in textile finishing as an inexpensive technology which is easy to carry out. In it, patterns are applied to fabrics using suitable screen printing stencils, for example. Screen printing stencils are partially pervious, so that a printing dyestuff, generally a printing paste, can be applied by means of suitable squeegees on a printing machine. Pigment printing utilizes color dye pigments which are devoid of any chemical bonding to the substrate to be printed. In order that they may nonetheless be fixed on the substrate, a binder is employed to combine with the pigments to form a kind of colored film. Such binders are for example thermally crosslinkable acrylates, polyurethanes and butadiene-styrene copolymers. Other binders are known as well. To ensure crisp contours in opposition to the capillary forces of the substrate, the system is thickened with thickeners to values which are preferably between 5 000 and 20 000 cSt. It is customary to reduce abrasion by adding a silicone emulsion which additionally is capable of positively influencing the hand as well.
[0008] After application to the textile, the print is dried and fixed. This is preferably accomplished by treating the print at around 150-190° C. for several minutes, in the course of which the water in the printing paste evaporates and the binder is rendered insoluble by crosslinking. As a result, the color dye pigment is bound to the substrate. The print is not washed and so the pigment printing process creates virtually no wastewater. This process is therefore very popular for economic and ecological reasons; more than 50% of the world's printed yardage is produced in this way.
[0009] A printed fabric possesses visual appeal by virtue of color and design. But customers are increasingly desirous of additional, olfactory stimuli; that is, the fabric shall also have an appealing odor.
[0010] Odorants, however, are volatile, by their very nature. Perfumed fabric would thus very rapidly lose its odor. To remedy this disadvantage, it is known to include odorants in microcapsules and to incorporate these doped microcapsules in printing pastes. The microcapsules are then fixed by the binder as well. If, then, a fabric which has been printed in this way is rubbed, the microcapsules will burst and immediately release the scent. Due to the high costs of such perfumed microcapsules, this method is costly and limited to a single emission of odorant. It has therefore only found very restricted use.
SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to provide a pigment printing dyestuff for textile finishing that, after application to the textile, can be activated in the course of the wearing of the textile; possesses a long-lasting scent effect; and can be reactivated by reloading with odorant.
[0012] This object is achieved by a pigment printing dyestuff composition which includes a cyclodextrin or cyclodextrin derivative in turn capable of including a scent as a guest molecule.
[0013] The printing dyestuff composition according to the invention preferably comprises a cyclodextrin or cyclodextrin derivative complexed with a scent.
[0014] It is possible to use α-, β- or γ-cyclodextrin or derivatives thereof or mixtures thereof. Hydroxypropyl and methyl derivatives of α-, βor γ-cyclodextrin will be found to be particularly advantageous,
[0015] The printing dyestuff composition according to the invention preferably includes from 1 to 15% by weight of cyclodextrin or cyclodextrin derivative, based upon the total weight of the composition.
[0016] The printing dyestuff composition preferably includes from 0.1 to 1.5% by weight of a scent, based upon the total weight of the composition.
[0017] More particularly, the present invention provides a printing paste dyestuff composition, comprising
[0018] 70 g of methyl-β-cyclodextrin; dissolved in 400 g of deionized water; 7 g of perfume oil (a scent); 100 g of silicone dispersion; 100 g of polyurethane binder, 50 g of silicone oil emulsion; 1 g of dye; 192 g of deionized water; and 80 g of thickener.
[0019] Also, the present invention provides a printing paste dyestuff composition comprising
[0020] 70 g of hydroxypropyl-β-cyclodextrin; dissolved in 400 g of deionized water; 7 g of perfume oil (a scent); 100 g of silicone dispersion; 100 g of polyurethane binder; 50 g of silicone oil emulsion; 10 g/liter of dye; 183 g of deionized water; and 80 g of thickener.
[0021] In addition, the present invention provides a printing paste dyestuff composition comprising
[0022] a cyclodextrin derivative in an amount ranging from 1% to 15% by weight, based upon the total weight of the dyestuff composition; a scent in an amount ranging from 0.1% to 1.5% by weight, based upon the total weight of the dyestuff composition;
[0023] water in an amount ranging from 40% to 60% by weight, based upon the total weight of the dyestuff composition; and from 23.5% to 58.9% by weight of a dye and an ingredient selected from the group consisting of a silicone dispersion, a polyurethane binder, a silicone oil, a thickener, and mixtures thereof.
[0024] The term “scent” as used herein also comprehends essences and aromas, The scent is preferably selected from the group consisting of fruity notes based on citral (lemon scent), allyl caproate, rose oil, substances having rose scent, citral, substances having lemon scent, apple aroma, vanillin, cinnamaldehyde (pineapple), prenyl acetate (banana), heliotropin (cherry), agruma oils; herbal notes based on lavender oil, rosemary oil, thyme oil, sage oil, peppermint oil, eucalyptus oil, tea tree oil, camomile oil, spicy notes based on cinnamaldehydes (cinnamon), eugenol (clove flower); woody notes based on sandalwood oil, cedar oil, cyprus oil and rosewood oil; flowery scents based on ionone (violet), terpineol (lilac), phenylethyl alcohol/citronellol (rose), hydroxycitronellol (lily of the valley); alpha-hexylcinnamaldehyde/benzyl alcohol (jasmine), ylang-ylang oil (ylang-ylang); animalistic notes based on polycyclic and also macrocyclic compounds (musk); sweet, balsamic notes based on vanillin (vanilla), anethole (aniseed), benzaldehyde (almond), courmarin (moss, hay).
[0025] Useful printing dyestuffs include all known, customary pigment printing dyes. The pigment printing dyestuff is preferably a paste. More preferably, it is an aqueous pigment printing dyestuff or paste, of which aqueous pigment printing pastes are particularly preferred.
[0026] Cyclodextrins and cyclodextrin derivatives are soluble in water and therefore are readily incorporated into aqueous printing dyestuffs. Dissolved in water, they have the useful property of encapsulating water-insoluble odorants, so that these can be taken up in the aqueous system simply by stirring into an aqueous cyclodextrin solution.
[0027] The pigment printing dyestuff composition according to the invention is easily preparable by incorporating a cyclodextrin, a cyclodextrin derivative, a cyclodextrin or cyclodextrin derivative and subsequently a scent, a cyclodextrin-scent complex or a cyclodextrin derivative-scent complex in the printing dyestuff by stirring or kneading.
[0028] The incorporating is preferably effected at 20 to 60° C. under atmospheric pressure. The incorporating time is preferably between 1 and 30 minutes.
[0029] The cyclodextrin-scent complex can be produced not only during the making of the printing dyestuff composition by addition of a scent to an aqueous cyclodextrin-containing printing dyestuff but also separately using an aqueous cyclodextrin solution and then be incorporated in a customary printing dyestuff.
[0030] A cyclodextrin-scent complex is preparable in a conventional manner, for example from solution or by the paste method. An advantageous way is to prepare it from an aqueous solution or suspension of cyclodextrin or cyclodextrin derivative.
[0031] The CD concentration of the aqueous solution or suspension is between 1-60% by weight based upon the total weight of the aqueous solution or suspension. Preference is given to a CD concentration of 10-20% based upon the total weight of the aqueous solution or suspension. The weight ratio of scent to CD is between 1:100 and 1:1, preferably between 1:20 and 1:5. The batches are intensively stirred or kneaded, depending on the consistency.
[0032] The reaction temperature is customarily at 20-80° C. Preference is given to a reaction temperature of 20-60° C. and more preference to a reaction temperature of 20-40° C. The complexing time depends on the reaction temperature and is between a few minutes and several hours. Preference is given to a reaction time of 1 to 30 minutes.
[0033] The complexing is generally effected under atmospheric pressure. The complexing preferably takes place in a contained system in order that loss of scent during the complexing may be prevented.
[0034] Mixing this odorant-containing cyclodextrin solution with the customary ingredients of a pigment printing dyestuff composition gives a printing dyestuff having an individual scent note.
[0035] The printing dyestuff according to the intention is applied to the textile in a customary manner known for the corresponding non-cyclodextrin-containing printing dyestuff. The odorants present in the printing dyestuff are then applied to the textile in the form of their cyclodextrin complexes in the course of the printing and drying operation and are fixed by the binder present in the printing ink The invention thus also provides for the use of a printing ink according to the invention for printing textiles.
[0036] The printing inks according to the invention make it possible to produce attractive, fragrant, printed textiles in a simple and inexpensive manner.
[0037] The invention thus also provides textiles printed with a pigment printing ink according to the invention.
[0038] Odorants may be chosen to harmonize with the dye and the design. For instance, rose oil can be combined with a red pigment to print a floral motif, or lemon oil can be combined with a yellow pigment and apple aroma with a green pigment to print fruit motifs. The unity of visual and olfactory sensations creates an hitherto unattainable whole.
[0039] The printing dyestuff according to the invention, after it has been applied to the textile, offers two further advantages over the prior art:
[0040] Firstly, the odor components are released under the influence or heat and moisture, i.e., conditions which are the natural result of the wearing of garments. Robust mechanical action as in the case of microcapsules is not needed.
[0041] Secondly, the bound cyclodextrins are rechargeable with the scent, whereas microcapsules have to be irreversibly destroyed.
[0042] A textile printed with a pigment printing dyestuff Composition according to the invention can be provided with new scent simply by spraying with an aqueous scent solution or suspension, The scent is initially taken up by the cyclodextrin. As the printed garment is worn, the scent is then gradually released under the action of heat and moisture.
[0043] The invention thus further provides a process of spraying a textile according to the invention with an aqueous scent solution.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0044] The examples hereinbelow illustrate the invention.
EXAMPLE 1
[0045] A printing paste was prepared at room temperature by the following method:
[0046] 70 g of methyl-β-cyclodextrin (CAVASOL® W7 M) were dissolved in 400 g of deionized water. 7 g of rose type 131650 perfume oil from Kurt Kitzing GmbH, Wallerstein were added with stirring. After just 1 minute, the water-insoluble oil formed a clear solution in the cyclodextrin solution.
[0047] This solution was admixed with
[0048] 100 g of Finish CT 27 E (Wacker silicone dispersion),
[0049] 100 g of Emuldur DS 2360 (BASF polyurethane binder),
[0050] 50 g of Finish C 800 (Wacker silicone oil emulsion) and
[0051] 1 g of Helizarin Brilliant Red BBT (BASF).
[0052] Then
[0053] 192 g of deionized water and
[0054] 80 g of Appretan thickener 3308 (Clariant) were added to prepare 1 kg of printing paste.
[0055] The printing paste was subsequently homogenized by stirring with a bladed stirrer at 800 rpm for 10 minutes.
[0056] This printing paste according to the invention was applied through a screen printing stencil bearing a rose motif onto bleached 100% cotton knit and dried. The pink flowers exude an intense rose scent on contact with the naked forearm, for example, after adjustment to body heat and body moisture.
EXAMPLE 2
[0057] Example 1 was repeated with the following differences: the cyclodextrin used was hydroxypropyl-β-cyclodextrin (CAVASOL® W7 HP), the perfume oil was Citral 54450 from Drom and the dye used was Helizarin Yellow GTN (BASF), at 10 g per liter. This reduces the amount of water needed from 192 g to 183 g.
[0058] This paste according to the invention was printed onto a customary 65/35 polyester/cotton fabric in a lemon motif. The fruit design exuded a fresh fruity odor under conditions as mentioned in Example 1.
[0059] Accordingly, while only several embodiments of the present invention have been shown and described, it is obvious that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention.
|
A pigment printing dyestuff composition for textile finishing comprises a cyclodextrin or cyclodextrin derivative in turn capable of including a scent as a guest molecule.
| 3
|
TECHNICAL FIELD
[0001] The invention relates to a method for inflating a gas bag, a gas generator to carry out the method and an inflatable vehicle occupant restraint system operating by means of the proposed method.
BACKGROUND OF THE INVENTION
[0002] Vehicle occupant restraint systems comprising a gas generator and a gas bag are usually constructed such that the gas bag is inflated by the gas generator within a few milliseconds and the gas bag provides its protective effect after approximately 20 ms. This protective effect is, however, maintained only over a few milliseconds. Then the gas bag collapses. In so-called window bags, i.e. gas bags which cover the side windows of a vehicle across a large area, the so-called service time of the gas bag, i.e. the time during which it remains inflated and offers a protective effect, is extended in that the gas bag is constructed in a gas-tight manner. This gas-tightness is, however, only to be achieved with a high expenditure. A disadvantage also is that the inflated gas bag can be a hindrance when rescuing or on leaving the vehicle.
BRIEF SUMMARY OF THE INVENTION
[0003] The invention provides a method which provides for longer service times in a more reliable manner and avoids the above disadvantages. The method for inflating a gas bag according to the invention comprises the following steps: providing a gas generator for producing gas which is flowingly connected to said gas bag, providing at least one propellant charge within the gas generator, providing at least one igniter within the gas generator, the gas generator blowing gas into the gas bag over more than one second. The method, therefore, follows a contrary direction to the prior art, by not exclusively providing the entire quantity of gas within the shortest period of time, but rather by, for the first time, permanently blowing gas into the gas bag over a very long period of time until after the first contact of the occupant with the gas bag (primary impact). The invention is not only limited to side gas bags, rather the method is also able to be used in drivers', passengers' and knee gas bags.
[0004] Preferably the gas generator will provide so much gas after its activation that within a maximum of 30 ms, preferably 20 ms after activation of the gas generator, the gas bag is fully inflated.
[0005] Through the method proposed, such great demands with respect to tightness no longer have to be made on the gas bag, in order to increase its service time. Furthermore, it is possible that the gas bag automatically collapses after a few seconds and hence it is no longer a hindrance when the occupant is being rescued or when he is climbing out of the vehicle.
[0006] To carry out the method proposed, it is theoretically possible to use gas generators which provide the entire quantity of gas rapidly and introduce it into an intermediate reservoir which directs the gas to the gas bag with the desired chronological sequence.
[0007] Preferably, however, the method is carried out by means of one gas generator which for its part produces gas over more than one second, preferably even over three or five seconds. This time is the total time within which gas is blown out from the gas generator, it of course being possible that a plurality of propellant charges is used and between the igniting of individual propellant charges a specific time elapses, within which no gas flows out from the gas generator and within which therefore also no gas is generated.
[0008] As explained, the gas generator proposed is equipped with at least one propellant charge and at least one igniter, the propellant charge having such a nature and being accommodated in the gas generator such that it generates gas over more than one second, preferably over more than three or even more than five seconds. With three seconds, sufficient restraining energy is still made available in particular for a secondary impact; with five seconds, a sufficient protective effect is still present even in the case of a roll-over of the vehicle.
[0009] The gas generator proposed preferably has several propellant charges which are able to be activated chronologically in succession and which preferably are comprised of different fuels.
[0010] According to the preferred embodiment, a propellant charge is ammonium nitrate, a particularly slow-burning fuel.
[0011] The propellant charge of ammonium nitrate forms a propellant charge which is to be ignited after a primary propellant charge.
[0012] Preferably the gas generator is constructed such that the propellant charge to be ignited subsequently burns at a maximum of 2 bar combustion pressure, in order to thus ensure a slow burning. 2 bar is approximately the pressure inside the gas bag, which is necessary for restraining. This is therefore deliberately far from the higher combustion pressures usual hitherto, which are present on burning of the propellant charge.
[0013] The propellant charge which is to be activated first is constructed such and accommodated in the gas generator such that it burns completely within a maximum of 30 ms and therefore provides the quantity of gas necessary for the primary impact.
[0014] The propellant charge or propellant charges which are to be activated subsequently have either their own igniters or ignite by auto-ignition and staggered over time due to they being heated, so that a so-called ignition transfer takes place.
[0015] The propellant charge or propellant charges which are subsequently to be activated are preferably insulated thermally with respect to other propellant charges, although they are arranged for example adjoining each other. Thereby, the staggering of time on igniting of the individual propellant charges is to be achieved or increased. A thermally insulating wall and a thermally insulating packing in which the propellant charge is accommodated are provided for this. The thermal insulation is to be constructed such that only at the end or, preferably, after the end of the burning of the fuel of the previously activated propellant charge does the auto-ignition of the following propellant charge take place.
[0016] The inflatable vehicle occupant restraint system proposed, which operates by the method proposed, provides a gas generator and a gas bag which is inflated by the gas generator. The fabric and the coating of the gas bag are coordinated with the gas generator with regard to their gas-permeability such that the gas bag has a service time of at least three seconds. The service time should be defined by the time the gas bag has at least approximately 2 bar internal pressure.
[0017] Preferably, however, a service time of six seconds is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 shows a vehicle occupant restraint system operating in accordance with the method according to the invention, with a first embodiment of the gas generator according to the invention,
[0019] [0019]FIG. 2 shows a longitudinal sectional view through a second embodiment of the gas generator according to the invention,
[0020] [0020]FIG. 3 shows a longitudinal sectional view through a third embodiment of the gas generator according to the invention,
[0021] [0021]FIG. 4 shows a longitudinal sectional view through a fourth embodiment of the gas generator according to the invention and
[0022] [0022]FIG. 5 shows a longitudinal sectional view through a fifth embodiment of the gas generator according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] In FIG. 1 a vehicle occupant restraint system is illustrated, which has a gas generator 10 and a gas bag 12 , connected with it with regard to flow and able to be inflated by it. The gas bag 12 is a so-called window bag, i.e. a side gas bag having a large area and covering the side windows of the vehicle in the case of restraint. In FIG. 1 it is shown that the gas generator 10 is arranged inside the gas bag 12 , but it is also possible to connect gas generator 10 and gas bag 12 with each other with regard to flow via a gas-directing pipe.
[0024] The gas generator 10 is an elongated tubular gas generator, at one axial end of which an igniter 14 is arranged, which is connected with a control unit 16 which activates the igniter 14 . A so-called primary propellant charge 18 which adjoins the igniter 14 and is to be ignited first in the case of restraint, consists of rapidly burning fuel in tablet form. The propellant charge 18 is accommodated in a combustion chamber 20 . A conical filter cone 22 projecting into the interior of the combustion chamber 20 separates an expansion chamber 24 from the combustion chamber 20 . Adjoining the expansion chamber 24 is a filter chamber 26 with cylindrical filters 28 , in the outer region of which filter chamber the outer housing of the gas generator 10 has numerous outflow openings. Adjoining the axial end of the gas generator 10 opposed to the igniter 14 is a second propellant charge 30 which is to be ignited after the primary propellant charge 18 , which second propellant charge 30 is likewise in flow connection with the filter chamber 26 but in the non-activated state is separated from the filter chamber 26 by a thermally insulating wall 32 .
[0025] The gas bag 12 is coated on the inner face for example by means of a foil and is constructed such as to be almost (e.g. in parts) or completely gas-tight.
[0026] In the case of restraint, the gas generator inflates the gas bag according to the following method. The igniter 14 is activated and ignites the primary propellant charge 18 . The fuel burns within a few milliseconds and the generated gas flows via the conical filter 22 with a large area very rapidly into the expansion chamber 24 and the filter chamber 26 and arrives through the filter 28 into the gas bag 12 . The gas generator here provides a quantity of gas within a few milliseconds, which fully inflates the gas bag in approximately 20 ms. After the complete burning of the fuel of the propellant charge 18 , the propellant charge 30 ignites itself. This takes place in that the housing and also the wall 32 heat up intensively with the outflow of the gas. With a specific chronological delay, this heat also arrives at the propellant charge 30 , until the latter ignites itself. The propellant charge 30 has a fuel which burns substantially more slowly than that of the propellant charge 18 . The propellant charge 30 preferably consists of the very slow-burning ammonium nitrate. The wall 32 is constructed with regard to its thermally insulating characteristics such that it directs to the propellant charge 30 in less than one second that amount of energy which is necessary for auto-ignition of the propellant charge 30 . The latter then burns over more than one second, even preferably more than three seconds. The gas thus generated likewise arrives into the gas bag 12 via the filter chamber 26 . The gas generator 10 consequently blows gas into the gas bag 12 over more than one second, preferably over more than three seconds, which gas bag 12 has a correspondingly long service time.
[0027] The gas-permeability of the gas bag and the gas generator are coordinated with each other such that the gas bag has a service time of more than three seconds, which means that it develops a protective effect over more than three seconds and in so doing preferably has more than 2 bar internal pressure.
[0028] The burning of the fuel of the propellant charge 30 takes place with a combustion pressure of a maximum of 2 bar, whereby the burning time can be very long.
[0029] In the embodiments according to FIGS. 2 to 5 , for simplification the gas bag is no longer illustrated. For all the parts already explained hitherto, which also have a corresponding function in the following embodiments, the reference numbers already introduced are maintained. If the function or construction of the parts is different compared with the embodiment according to FIG. 1, then the corresponding parts are given a reference number increased by the number 100 .
[0030] In the embodiment according to FIG. 2, the filter chamber 26 is arranged at the opposite end of the gas generator 110 to the igniter 14 . The combustion chamber 120 not only contains the primary propellant charge 18 but also propellant charges 130 , 130 ′ and 130 ″ which are subsequently to be ignited and which are constructed in a ring shape and extend around the conical filter 122 . The individual propellant charges 130 to 130 ″ differ from each other in the geometry and/or the fuel composition.
[0031] After the igniting of the propellant charge 18 , the gas flows via the tip of the filter 122 into the expansion chamber 24 and the filter chamber 26 , from where it arrives into the gas bag and fully inflates the latter within a few milliseconds. During or at the end of the burning of the fuel of the propellant charge 18 , through the generated hot gas the propellant charge 130 , which is subsequently to be activated, is ignited. The corresponding gas likewise arrives via the filter 122 into the expansion chamber 24 and the filter chamber 26 . The burning time of the fuel of the propellant charge 130 is, however, distinctly higher than that of the fuel of the propellant charge 18 , so that over approximately one second gas is generated by the propellant charge 130 . After the propellant charge 130 is burnt, the propellant charge 130 ′ arranged adjacent and then the propellant charge 130 ″ is activated, so that a gradual burning of the propellant charges takes place and the gas generator 110 conveys gas into the gas bag over more than three seconds. Through the provision of still more propellant charges, the inflation time and hence the service time of the gas bag is increased to more than five or six seconds, which is sufficient to also offer protection in a rollover of the vehicle.
[0032] In the embodiment according to FIG. 3, a single propellant charge 230 to be subsequently ignited, is accommodated in a thermally insulating packing 40 . The propellant charge 230 is cylindrical in construction and has an axially through-opening 42 . The propellant charge 230 adjoins the igniter 14 , but is arranged in the combustion chamber 220 as in the embodiment according to FIG. 2. The primary propellant charge 18 adjoins the propellant charge 230 .
[0033] Through the opening 42 , the igniter 14 ignites the fuel of the propellant charge 18 . The generated gas arrives through the filter 222 into the expansion chamber 224 and from there into the filter chamber 26 . The packing 40 is constructed such that on igniting of the propellant charge 18 , no auto-ignition of the propellant charge 230 takes place. Only after the fuel of the propellant charge 18 is burnt does so much thermal energy arrive at the propellant charge 230 via the packing 40 that the propellant charge 230 ignites itself with a predeterminable time delay. Gas is generated over several seconds on burning of the fuel of the propellant charge 230 , which keeps the gas bag inflated.
[0034] In the embodiment illustrated in FIG. 4, several propellant charges 330 , 330 ′, 330 ″ are provided, spaced apart from each other by thermally insulating walls 44 . Also in the region of the opening 42 , the propellant charges 330 to 330 ″ are thermally insulated, so that they ignite themselves in succession, staggered chronologically, after the propellant charge 18 has been activated. In this embodiment, service times of six seconds and more are able to be achieved for the gas bag, and the gas generator generates gas over more than five seconds.
[0035] In the embodiment illustrated in FIG. 5, a primary propellant charge 18 and a propellant charge 430 , which is to be ignited subsequently, are each equipped with one own igniter 14 , 14 ′. The propellant charges 18 , 430 are separated from each other via a wall 50 . The propellant charge 18 serves for making the gas bag available quickly. Staggered chronologically to this, via the igniter 14 the propellant charge 430 is ignited, which consists of a very slow-burning fuel and provides for a long service time of the gas bag. In this embodiment, separate combustion chambers are provided for the individual propellant charges.
|
A vehicle occupant restraint system has a gas generator and a gas bag. A method for inflating a gas bag for restraining an occupant comprises the following steps: providing a gas generator for producing gas which is flowingly connected to the gas bag, providing at least one propellant charge within the gas generator, providing at least one igniter within the gas generator, the gas generator blowing gas into the gas bag over more than one second, preferably over more than three seconds, in order to achieve a high service time.
| 1
|
FIELD OF THE INVENTION
The present invention generally relates to magnetoresistive devices, such as magnetic tunnel junction (MTJ) devices for, e.g., disk drive read heads.
BACKGROUND OF THE INVENTION
In magnetic disk drives, data is written and read by magnetic transducers called “heads.” The magnetic disks are rotated at high speeds, producing a thin layer of air called an air bearing surface (ABS). The read and write heads are supported over the rotating disk by the ABS, where they either induce or detect flux on the magnetic disk, thereby either writing or reading data. Layered thin film structures are typically used in the manufacture of read and write heads. In write heads, thin film structures provide high areal density, which is the amount of data stored per unit of disk surface area, and in read heads they provide high resolution.
The present invention is directed generally to devices that can be used, in some implementations, as heads for disk drives, and more particularly the present invention is directed to magnetic tunnel junction (MTJ) devices. An MTJ device has at least two metallic ferromagnetic layers separated by a very thin nonmagnetic insulating tunnel barrier layer, wherein the tunneling current perpendicularly through the layers depends on the relative orientation of the magnetizations in the two ferromagnetic layers. The high magnetoresistance at room temperature and generally low magnetic switching fields of the MTJ renders it effective for use in magnetic sensors, such as a read head in a magnetic recording disk drive, and nonvolatile memory elements or cells for magnetic random access memory (MRAM).
In a MTJ device, one of the ferromagnetic layers has its magnetization fixed, such as by being pinned by exchange coupling with an adjacent antiferromagnetic layer, and the field of the other ferromagnetic layer is “free” to rotate in the presence of an applied magnetic field in the range of interest of the read head or memory cell.
To increase both sensitivity and output, the free layer, which may be composed of one or more sub-layers, may be direct coupled to an antiferromagnetic layer. To make such a device, the free layer is established on the barrier that overlays the above-mentioned pinned stack, and then is configured by protecting only the area of the free layer sought to be maintained and ion milling the remainder away, down to the barrier covering the pinned stack.
As critically recognized herein, during the above process the barrier might be unintentionally eroded because it is difficult to stop removing material exactly as the last of the free layer intended to be removed is indeed milled away. This results in a deleterious loss of tunnel magnetotresistance between the free and pinned stacks from shunting caused by a breakdown in the barrier and/or by redeposited material.
The present invention makes the additional critical observations. As understood herein, it is necessary for stabilization purposes to provide stabilization structure in MTJ devices, and one way to do this is to surround the free stack with a hard bias material. The present invention recognizes that for optimum stabilization, when so doing the hard bias layer ideally is centered around the free stack.
With these recognitions in mind, the invention herein is provided.
SUMMARY OF THE INVENTION
A magnetic tunnel junction device has a pinned ferromagnetic layer with its magnetization direction substantially prevented from rotation in the presence of an applied magnetic field. The device also includes an insulating tunnel barrier layer on the pinned layer and a free ferromagnetic stack on the tunnel barrier layer with its magnetization direction substantially free to rotate in the presence of an applied magnetic field. The free stack includes a lower free ferromagnetic sublayer on the barrier layer and an upper free ferromagnetic sublayer on the lower free ferromagnetic sublayer. The upper free sublayer can be made of a thicker and softer material than the lower free ferromagnetic sublayer. A skirt extends away from the stack against the barrier and is integral to the lower free ferromagnetic sublayer. Thus, it is of the same material as the lower free ferromagnetic sublayer, or is an oxide thereof.
A hard bias material may be deposited over the skirt and surrounding and centered on the stack. The lower free ferromagnetic sublayer may be made of CoFe and the upper free ferromagnetic sublayer can be made of NiFe and a dopant such as Mo or Rh.
In another aspect, a magnetic tunnel junction device includes a ferromagnetic layer having a magnetization pinned from rotation and upper and lower ferromagnetic sublayers against each other and not having their magnetizations pinned from rotation. The lower sublayer includes a skirt extending radially beyond the upper sublayer. A barrier layer is between the lower sublayer and ferromagnetic layer.
In yet another aspect, a method for making a MTJ device includes forming a barrier layer on a pinned stack, and forming a lower free ferromagnetic sublayer on the barrier layer. The method also includes forming an upper free ferromagnetic sublayer on the lower free ferromagnetic sublayer. According to present principles, the method contemplates etching or milling completely through the upper free ferromagnetic sublayer and but not completely through the lower free ferromagnetic sublayer, then stopping the etching or milling process to thereby establish a skirt on the lower free ferromagnetic sublayer that extends radially beyond the upper free ferromagnetic sublayer.
The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plan view of a hard disk drive, showing one non-limiting environment for the present invention;
FIG. 2 is an elevational view of a first embodiment of a non-limiting MTJ device made in accordance with the present invention;
FIG. 3 is an elevational view of a second embodiment of a non-limiting MTJ device made in accordance with the present invention; and
FIG. 4 is a flow chart of the method for making the device shown in FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1 , a magnetic disk drive 30 includes a spindle 32 that supports and rotates a magnetic disk 34 . The spindle 32 is rotated by a spindle motor that is controlled by a motor controller which may be implemented in the electronics of the drive. A slider 42 has a combined read and write magnetic head 40 and is supported by a suspension 44 and actuator arm 46 that is rotatably positioned by an actuator 47 . The head 40 may be a GMR or MR head or other magnetoresistive head. It is to be understood that a plurality of disks, sliders and suspensions may be employed. The suspension 44 and actuator arm 46 are moved by the actuator 47 to position the slider 42 so that the magnetic head 40 is in a transducing relationship with a surface of the magnetic disk 34 . When the disk 34 is rotated by the spindle motor 36 the slider is supported on a thin cushion of air known as the air bearing that exists between the surface of the disk 34 and an air bearing surface (ABS) of the head. The magnetic head 40 may then be employed for writing information to multiple circular tracks on the surface of the disk 34 , as well as for reading information therefrom. To this end, processing circuitry 50 exchanges signals, representing such information, with the head 40 , provides spindle motor drive signals for rotating the magnetic disk 34 , and provides control signals to the actuator for moving the slider to various tracks. The components described above may be mounted on a housing 55 .
Now referring to FIG. 2 , the head 40 which is manufactured using the process of the present invention includes a pinned stack 60 , it being understood that the pinned stack 60 may be formed on a substrate such as but not limited to a lower shield layer S 1 . In non-limiting implementations the pinned stack 60 may be formed on a seed layer 61 such as a bi-layer seed layer made of Ta/Ru or NiFeCr or Cu that is on the substrate and that in turn is covered by an antiferromagnetic sublayer 62 which may be made of IrMnCr, without limitation.
In the non-limiting embodiment shown, a first pinned ferromagnetic sublayer 64 that may be made of, e.g., CoFe25 is formed on the antiferromagnetic sublayer 62 . Above the first pinned ferromagnetic sublayer 64 is a template sublayer 66 and on top of that a second pinned ferromagnetic sublayer 68 , with the template sublayer 66 being made of, e.g., Ru or Cr or Ir and with the second pinned ferromagnetic sublayer 68 being made of CoFeB, in non-limiting embodiments. The ferromagnetic sublayers 64 , 68 are called “pinned” because their magnetization direction is prevented from rotation in the presence of applied magnetic fields in the desired range of interest for the MTJ device. Without limitation, the sublayers 64 , 66 , 68 respectively may be, e.g., forty Angstroms thick/4.5 Angstroms thick/forty Angstroms thick.
Other CoFe and NiFe alloys may be used for the ferromagnetic sublayers and other antiferromagnetic materials may include NiMn and IrMn. The substrate may be a silicon wafer if, for instance, the device is a memory cell, and ordinarily would be the bottom electrically conductive lead located on either the alumina gap material or the magnetic shield material on the trailing surface of the head carrier if the device is a read head.
Formed on the pinned stack 60 is a barrier layer 70 that is made of an insulating tunnel barrier material. By way of non-limiting example, the barrier layer 70 may be five to fifteen Angstroms thick and may and may be made by depositing Aluminum on the pinned stack 60 and then oxidizing it to create an Al 2 O 3 insulating tunnel barrier layer 70 . While Al 2 O 3 may be used, a wide range of other materials may be used, including MgO, AlN, aluminum oxynitride, oxides and nitrides of gallium and indium, and bilayers and trilayers of such materials.
A free ferromagnetic stack, generally designated 72 , is formed on the barrier layer 70 as shown. The free stack 72 is surrounded by an insulating layer and then a hard bias layer, collectively designated 74 . The insulating material may be, e.g., Al 2 O 3 . The free stack 72 may be covered by a protective cap 76 . The cap 76 in turn may be topped by a shield S 2 in accordance with principles known in the art.
In accordance with present principles, the free stack 72 includes, from the barrier layer 70 , a lower free ferromagnetic sublayer 78 that may be made of CoFe and an upper free ferromagnetic sublayer 80 . The sublayers 78 , 80 are stabilized by the hard bias layer. By “free” is meant that the magnetization direction of the free stack 72 is not pinned by exchange coupling, and is thus free to rotate in the presence of applied magnetic fields in the range of interest.
The upper free ferromagnetic sublayer 80 may be made of a material that can be doped to reduce its magnetization, thereby permitting use of a physically thicker free layer without a concomitant increase in magnetization. In one embodiment the upper free ferromagnetic sublayer 80 is made of NiFe, doped with, e.g., Mo or Rh. For example, the upper free ferromagnetic sublayer 80 may be {Ni 90 Fe 10 } 94 Mo 6 .
As shown in FIG. 2 , after the manufacturing process described below, a skirt portion 82 of the lower free sublayer 78 extends radially away from the free stack 72 after etching. In contrast, after etching/milling no portions of the upper free sublayer 80 extend beyond the vertical edge of the free stack 72 as shown. In any case, the skirt is integral to the lower free sublayer and is of the same material as the lower free sublayer, or, as set forth further below, may be an oxide thereof.
In one non-limiting implementation, the upper free ferromagnetic sublayer 80 maybe relatively thick (e.g., up to forty Angstroms), to render easier the stopping of the etch/mill process before completely removing the skirt 82 , because the effective magnetic thickness may be made as small as desired by appropriately doping the upper free sublayer 80 . Other thicknesses can be used. The lower free ferromagnetic layer 78 may be ten Angstroms thick.
The hard bias and insulating layers thus are deposited both around the free stack 72 and on top of the skirt 82 . Further, the hard bias material is substantially centered on the free stack 72 as shown.
FIG. 3 shows a device that is in all essential respects identical to that shown in FIG. 2 , i.e., FIG. 3 shows a free stack 72 a over a pinned stack 60 a separated from each other by a barrier, and a cap 76 a over the free stack 72 a , with the following exceptions. Between the free stack 72 a and the cap 76 a , starting from the free stack 72 a , is a spacer layer 84 , a hard bias layer 86 made of appropriate hard bias material, and an antiferromagnetic layer 88 . In one non-limiting implementation, the antiferromagnetic layer 88 is made of PtMn, as can the layer 62 . Other materials, such as NiMn, may be used.
Now referring to FIG. 4 , at block 90 the pinned stack 60 and barrier 70 are formed on a substrate in accordance with principles known in the art, e.g., by sputtering. Proceeding to block 92 , lower and upper free ferromagnetic sublayers 78 , 80 are formed, likewise by sputtering or other deposition technique. Then, at block 94 the entire portions of the upper free ferromagnetic sublayer 80 outside the free stack 72 , are removed by etching (e.g., reactive ion etching) or milling (e.g., ion milling) to leave the skirt 82 of the lower free sublayer 78 as shown. This is facilitated because the relatively thicker upper free sublayer 80 is softer and more easily removed than the lower free sublayer 78 , making it easier to stop prior to unintentionally milling or etching all the way to the barrier. Because the upper free sublayer 80 is doped, its greater physical thickness, which promotes controlled stoppage of milling or etching, does not result in undesirably high magnetization. However, because the lower free ferromagnetic sublayer 78 is retained, adequate magnetoresistance of the device is achieved.
In non-limiting embodiments a combination of 10/50 degree ion-milling may be used for the above process, essentially defining the track edge and self-cleaning process.
The skirt 82 may be oxidized at block 96 and then the insulating and hard bias materials are formed at block 98 , with the hard bias material substantially centered on the free stack 72 as shown.
While the particular TUNNEL MR HEAD FORMED WITH PARTIAL MILLED STACK as herein shown and described in detail is fully capable of attaining the above-described objects of the invention, it is to be understood that it is the presently preferred embodiment of the present invention and is thus representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more”. It is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. Absent express definitions herein, claim terms are to be given all ordinary and accustomed meanings that are not irreconcilable with the present specification and file history.
|
In a magnetic tunnel junction (MTJ) device having a pinned layer and upper and lower free sublayers, to avoid loss in tunnel magnetoresistance, etching or milling of the free sublayer materials is stopped in the lower free sublayer. The upper free sublayer may be softer and thicker than the lower free sublayer to promote this, and may be doped to reduce its magnetization while maintaining physical thickness. The lower free sublayer can be made of CoFe and the upper free sublayer can made of NiFe and a dopant such as Mo or Rh.
| 6
|
BACKGROUND OF THE INVENTION
The present invention is related to a multi-purpose stationery box set and, more particularly to a stationery box set including a lower casing coupled to an upper cover for receiving therein of an inner holder with a bottom block formed at the bottom. The inner holder includes a variety of spacings for arrangement of various different stationery accessories to provide convenient use thereof. The stationery box set is also of a design so as to serve as a decorative ornament.
The number of regular stationery accessories are innumerable. The most common include such items as: stapler, snap blade cutter, pencil, pen, eraser, scissors, glue bottle, adhesive tape, and memos. Still, there is no suitable, compact and practical container for collectively receiving the variety of stationery accessories in an efficient way. It is commonly seen in the office or elsewhere that various stationery accessories are scattered over the desk or disorderly placed in a drawer. People therefore waste a lot of time finding a specific item from the scattered stationery accessories. Therefore, it is very practical to have a compact stationery container set for arrangement of a variety of stationery accessories. The compact stationery container set may be designed to have an attractive outer appearance so as to serve as a decorative ornament. This idea comes into the scope of the present invention.
SUMMARY OF THE INVENTION
The main object of the present invention is to provide a multi-purpose stationery box set which includes an inner holder integrally formed by means of an injection molding process to provide a variety of spacings arranged in different sizes and shapes for arrangement of a variety of stationery accessories to provide convenient use and to minimize space consumption. The whole assembly of the stationery box set is designed to be very practical and to serve as a decorative ornament.
The other object of the present invention is to provide a multi-purpose stationery box set wherein the lower casing is pivotally coupled to the upper cover and revolvably connected to the bottom block for convenient adjustment of angular position.
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when considered in connection with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective structural view of a multi-purpose stationery box set embodying the present invention;
FIG. 2 is a perspective exploded view of the said preferred embodiment of the present invention;
FIG. 3 is a partly structural sectional view of the said preferred embodiment of the present invention;
FIG. 4 is a sectional view of the bottom block and the drawer of the said preferred embodiment of the present invention;
FIG. 5 is a schematic drawing illustrating an opened condition of the said preferred embodiment of the present invention during the application; and,
FIG. 6 is a schematic drawing illustrating the outer appearance of the said preferred embodiment of the present invention showing its closed condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, there is shown a multi-purpose stationery box set according to the present invention. The multi-purpose stationery box includes a semi-spherical upper cover (11), a semi-spherical lower casing (12), an inner holder (13) disposed within the semi-spherical lower casing (12), and a bottom block (14) having a drawer (15).
The inner holder (13) is integrally formed by an injection molding process. The inner holder (13) includes a notch (136) transversely formed at a central portion thereof, for positioning of a division plate (16). Division plate (16) divides the inner space of the inner holder (13) into a first inner portion and a second inner portion. The first inner portion is provided with a rectangular chamber (131) for receiving a stapler therein, a round chamber (132) for receiving a glue bottle therein, two round holes (133) made at the middle for positioning of pens, two elongated slots (134) respectively made on opposing lateral sides of the two round holes (133) for positioning of snap blade cutters, and two rectangular slots (135) respectively made on opposing lateral sides of the two elongated slots (134) for positioning of erasers. The second inner portion is provided with a circular chamber (137) for positioning of adhesive tape, and a slot (138) made on one side of the circular chamber (137) for setting a scissors therein. By means of this structural design, regular stationery accessories may be collectively received in the inner holder (13) to provide convenient storage thereof. Further, a recess (1371) is symmetrically made on opposing bilateral wall surfaces of the circular chamber (137) with a key hole (1372) respectively made on each recess (1371) for the pivotal coupling of a roll of adhesive tape, such that the roll of adhesive tape is allowed to revolve when it is set in the circular chamber (137). As a means of cutting the adhesive tape when it is drawn out for use, a toothed cutting blade (139) is disposed at the front of the circular chamber (137). There is also provided a semi-circular opening (1373) made in the circular chamber (137) at an upper front position thereof for easy access of the user's fingers to dispense the adhesive tape.
Referring to the structural sectional view of FIG. 3, the upper cover includes a key (111) formed at the front of the upper cover on the inner surface to mate with the key button (121) formed on the lower casing (12) to form a reversably lockable coupling. The upper cover also includes a protruding circular brake holder (112) formed at the back portion thereof. The brake holder (112) has a slotted opening formed therein for positioning of an arch-shaped hinge brake (113).
The hinge brake (113) includes two blades fixedly connected together at one end wherein it is formed into a solid portion, with the opposing ends of two blades having a spring (not shown) disposed therebetween. The solid portion of the two blades of the hinge brake (113) is disposed within the slotted opening of the brake holder (112) to allow the forked two ends stop against a stopper (122) formed at the inner portion of the lower casing (12) at the rear end thereof, to allow the upper cover (11) to be firmly positioned in a lifted position.
In the assembly of the hinge brake (113), the solid portion thereof, wherein the two blades of the hinge brake (113) are joined, is positioned in the groove of the brake holder (112) and the formed blades of the hinge brake (113) are supported by the stopper (122) of the lower casing (12). Then, the two tenons (123), which are formed at the rear end of the lower casing (12), are each respectively inserted into a respective one of the two holes (114), which are formed at the rear end of the upper cover (11). Such provides a pivotal coupling between the lower casing (12) and the upper cover (11), such that the upper cover (11) becomes liftable through the action of the hinge brake.
When the upper cover (11) is pressed down to a closed position, the slotted opening formed in brake holder (112) is concomitantly displaced to further squeeze the hinge brake (113) into a flat configuration, thereby tightening the connection of the hinge brake (113) with the slotted opening of the brake holder (112). Substantially simultaneously, the front key (111) of the upper cover (11) is pressed into a snap fit engagement with the key button (121) of the lower casing (12).
Opening of the upper cover (11) is accomplished by pressing down the key button (121) of the lower casing (12) to allow the key (111) of the upper cover (11) to break away from the restraint of the key button (121). Thus, the brake holder (112) as well as the upper cover (11) are pushed to open by means of the expansion force of the blades of the hinge brake (113) applied to the groove of the brake holder (112). While lifting, the top bumper (115) of the hinge brake (113) serves as a buffer to reduce the lifting speed of the upper cover (11), thereby preventing the stationery box set from falling over, due to a sudden lifting force.
The lower casing (12) which includes a circular bottom seat (124) having a positioning rod (125) coupled thereto at the bottom end of the lower casing (12). The lower casing (12) is positioned at the top of the bottom block (14) with the bottom seat (124) positioned in the top circular recess (141) of the bottom block (14) with the positioning rod (125) being movably positioned in a curved groove (142) formed on the top circular recess (141) of the bottom block (14) for position adjustment.
According to the present invention, the bottom block (14) includes an upper lid (14a) coupled to a base plate (14b) by means of screw means to define an inner space therebetween for receiving therein a movable drawer (15). The drawer (15) is preferably designed for receiving memos. Referring to FIG. 4, there is shown base plate (14b) which includes therein a reduced concave portion (143) to match with the C-shaped braking means (151) of the drawer (15), such that when the drawer (15) is withdrawn from the bottom block (14), the reduced concave portion (143) and the C-shaped braking means (151) collectively provide a braking action to prevent the drawer from breaking away from the bottom block (14).
When the drawer (15) is closed and entirely set in the bottom block (14), the braking means (151) are stopped against the back side wall of the bottom block (14). The tongue of a key button (144), which is formed at the front top portion of the bottom block (14), is disposed in a slot (152) formed at the front top surface of the drawer (15). This arrangement firmly locks the drawer (15) within the bottom block (14). When it is desired to open the drawer (15), the key button (144) is simply pressed down, letting the slot (152) to be released from the restraint of the tongue of the key button (144). The spring force from the braking means (151) which is pressed against the bottom block (14) will push the drawer (15) to move forward. Through the braking effect of the braking means (151) against the reduced concave portion (143), the forward speed of the drawer is gradually reduced to zero, thereby stopping the displacement of the drawer (15).
Referring to FIG. 5, the upper cover (11) is pivoted with respect to the lower casing (12), and the inner holder (13) is disposed in the lower casing (12), wherein the several spacings (131)-(138) are integrally formed in the inner holder (13). The spacings (131-138) are provided for locating of regular stationery accessories including a stapler, a glue bottle, a pen, a snap blade cutter, an eraser, adhesive tape, and a scissors. This arrangement minimizes space consumption and facilitates the arrangement of the stationery accessories.
Referring to FIG. 6, the upper cover (11) is closed and in mating relationship with the lower casing (12), and the drawer (15) is locked within the bottom block (14), such that all the stationery accessories arranged thereinside are protected by the upper cover. In addition to its practical application for arrangement of stationery accessories, the attractive design of the outer appearance of the stationery box set also serves as a decorative ornament.
In conclusion, the present invention provides a stationery box set having numerous features each of which tends to make the structure practical for both decoration purposes as well as for convenient arrangement of stationery accessories with space consumption being minimized.
|
A multi-purpose stationery box set including a semi-spherical lower casing, an upper cover pivotally coupled to the semi-circular lower casing, an inner holder set disposed in the lower casing, a bottom block having a drawer and being connected to the lower casing at the bottom thereof. The inner holder is integrally formed therein by an injection molding process to provide a variety of spacings having different sizes and shapes for the convenient arrangement of various stationery accessories in an efficient way with minimized space consumption. By means of the professional design of the stationery box, an attractive outer appearance is provided. Thus, in addition to its multi-purpose usage, it is also very practical and can serve as a decorative ornament.
| 1
|
BACKGROUND OF THE INVENTION
[0001] This invention relates to a light source for a vehicle or the like and more particularly to a light source that utilizes only a single light emitting device that provides the same appearance and light output as a source having a plurality of light emitting devices.
[0002] In some latest vehicles such as automobiles and motorcycles, a light device has employed one or more lamps each of which each of which employs a plurality of light emitting devices such as lamps or LEDs (light-emitting diodes) positioned in a single light source body. Such an arrangement is shown, by way of example, in published Japanese Patent Application JP-A-2004-193026. This improves not only the appearance but also the light transmission and recognition. However such an expedient is accompanied by a higher cost in relation to the number of LEDs, employed.
[0003] Therefore it is a principal an object of the present invention to provide a light source for a vehicle capable of improving appearance and visibility, without a large cost increase.
SUMMARY OF THE INVENTION
[0004] An embodiment of the invention is adapted to be embodied in a light source for a vehicle or the like and comprises a light housing defining an internal cavity between a rear reflective portion and a front light transmitting portion. A light emitting device holder is provided that is adapted to support a single emitting device source within the internal cavity. The front light transmitting portion has a plurality of highly transparent portions for transmitting light reflected from the single light emitting device by the rear reflective portion. These highly transparent portions are surrounded by less transparent portions to provide a view that emulates multiple light sources.
[0005] A further feature of the invention is comprised of a vehicle having a light source as described in the preceding paragraph.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a side elevational view of a vehicle provided with a light source embodying the invention.
[0007] FIG. 2 is a front elevational view of the vehicle.
[0008] FIG. 3 is a rear elevational view of the vehicle.
[0009] FIG. 4 is an enlarged rear elevational view looking in the same direction as FIG. 3 showing the light source embodying the invention.
[0010] FIG. 5 is a view of the structure shown in FIG. 4 with the light covers removed.
[0011] FIG. 6 is a view looking in the same direction as FIGS. 4 and 5 but showing only the light source embodying the invention.
[0012] FIG. 7 is an enlarged cross sectional view taken along the line 7 - 7 of FIG. 6 .
[0013] FIG. 8 is an enlarged cross sectional view taken along the line 8 - 8 of FIG. 6 .
DETAILED DESCRIPTION
[0014] Referring now in detail to the drawings and initially primarily to FIGS. 1-3 , a vehicle embodying the invention, as an example, a motorcycle, is indicated generally by the reference numeral 21 denotes a motorcycle. The motorcycle 21 has a front fork 22 dirigibly supported at the front end of a body frame (generally hidden in the figures). A front wheel 23 is journalled at the lower end of the front fork 22 . Steering handlebars 24 are mounted at the upper end of the front fork 22 for steering of the motorcycle 11 as is well known in the art.
[0015] The motorcycle 21 is powered by an engine transmission unit 25 suspended from and supported by the central portion of the body frame. This engine transmission unit 25 drives a rear wheel 26 journalled by a rear arm 27 that is pivotally supported by the central portion of the body frame and controlled by a suspension unit 28 .
[0016] Positioned above the rear arm 27 is a seat 30 of tandem type to accommodate a rider and if desired a passenger two persons to straddle at its front and rear and mounted on the top rear portion of the body frame.
[0017] As has been noted, the body frame is generally enclosed. To this end its front half and rear half are covered by a front cover 29 and a rear cover 31 , respectively.
[0018] The steering handlebars 24 are covered by a handlebar cover 32 . The upper rear wall of the handlebar cover 32 is provided with a meter device 33 to display information to a rider and at its front wall is provided with a headlight assembly 34 .
[0019] The headlight assembly 34 has a unitized configuration of a pair of left and right headlights 35 and a pair of left and right flasher lights 36 positioned laterally outward from the headlights 35 .
[0020] The rear wall of the rear cover 31 at its is provided with a taillight assembly 35 that incorporates an embodiment of the present invention. The taillight assembly 35 is enclosed by an upper wall portion 35 a , left and right side wall portions 35 b , and a bottom wall portion 35 c of the rear cover 35 without gaps. A rear fender 38 is provided below the taillight assembly 35 to cover the region above and rearward of the rear wheel 26 . Reference numeral 39 denotes a grab bar for the rider seated at the rear, which is provided along the rear edge of the seat 30 .
[0021] The taillight assembly 35 has a unitized configuration consisting of a taillight portion 41 positioned laterally centrally in a taillight housing 42 , and a pair of left and right rear flasher lights 43 positioned laterally outward from the taillight portion 41 .
[0022] As seen from the rear side of the vehicle, the taillight portion 41 is formed in a perfect circular shape, and the left and right rear flasher lights 43 are formed in an oval shape. The left and right flasher lights 43 each have a lamp bulb 44 . The taillight portion 41 and the left and right rear flasher lights 43 are each positioned so that their respective light axis “a” ( FIG. 1 ) is oriented slightly obliquely downward and rearward.
[0023] The taillight portion 41 has as a single light source a lamp bulb 45 , mounted in a manner to be described, between an inner reflective lens 46 for reflecting light from the lamp bulb 45 , and an outer lens 47 for covering the lamp bulb 45 and the inner reflective lens 46 . The outer lens 47 is positioned opposite the inner reflective lens 46 with respect to the lamp bulb 45 , in other words, rearwardly from the lamp bulb 45 .
[0024] The inner reflective lens 46 is made of resin and has a generally dome shape with a rearward facing opening. The inner surface of the inner reflective lens 46 is formed with a reflective coating such as chromium plating. As seen best in FIG. 7 , the inner reflective lens 46 at the center of its depression 48 is formed with a bulb fitting opening 49 , in which a socket 51 is received. The lamp bulb 45 is removably mounted in the socket 51 from the rear side of the vehicle as seen in this figure. The outer lens 47 has a generally flat-plate shape and is fitted in an opening 52 ( FIG. 4 ) of the inner reflective lens 46 .
[0025] It should be noted that in FIGS. 4 and 5 , the lamp bulb 45 appears to be displaced downward from the center of the taillight portion 41 . However this appears this way because the taillight portion 41 is inclined with its lower portion positioned forward and its upper portion positioned rearward. However and as shown in FIG. 6 , the lamp bulb 45 is positioned in the center of the taillight portion 41 , as viewed along its centerline.
[0026] The outer lens 47 is formed in a disc shape from red synthetic resin capable of transmitting light. The rear surface of the outer lens 47 is basically formed in the shape of a flat surface as best seen in FIG. 7 . As seen in this figure, the central portion of the outer lens 47 that covers the lamp bulb 45 is integrally formed with a reflecting portion 53 . The reflecting portion 53 is formed in a circular shape having a diameter approximately twice as large as a maximum diameter of the lamp bulb 45 .
[0027] The area of the reflecting portion 53 facing the lamp bulb 45 (toward the front side of the vehicle) is formed with a number of reflective elements 54 having a generally saw-tooth shape in section. The reflective elements 54 have lower light transmittance than the other portion of the outer lens and are adapted not to transmit light from the lamp bulb 45 to the outside. The reflective elements 54 also have a function of reflecting light incident from the rear side of the vehicle in the direction of the arrow b like a mirror. Thus as viewed from behind the motorcycle 21 , the lamp bulb 45 is covered by the reflecting portion 53 so that it cannot be seen.
[0028] The outer lens 47 at its outer region and around the reflective portion 53 has a plurality of lens elements formed as protrusions (light-transmitting portions) 55 formed to be positioned on the periphery of a common circle centered on the lamp bulb 45 and at equal angular intervals. As a specific example, nine such protrusions 55 are formed at intervals of 40 degrees.
[0029] The protrusions 55 are integrally formed on the outer lens 47 and project in the direction away from the lamp bulb 45 , namely, to the rear side of the vehicle. The protrusions 55 are also formed to have higher light transmittance than the surrounding peripheral region 56 . To be specific, each protrusion 55 has a generally dome shape, and its thickness t is smaller than thickness t′ of the peripheral region 56 ( FIG. 7 ).
[0030] The inner reflective lens 46 has a plurality of light-collecting portions 57 one for each protrusion 55 , for collecting light in the direction of the arrow C in FIGS. 7 and 8 from the lamp bulb 45 and directing it to its corresponding protrusion 55 . Each of the light-collecting portion 57 is made up of two lens like recesses 58 for each protrusion 55 . The recesses 58 are formed to face their corresponding protrusion 55 and extend radially outward from the lamp bulb 45 .
[0031] In this embodiment, the outer lens 47 at its outer region has the rearward protrusions 55 formed at predetermined angular intervals, and the inner reflective lens 46 is formed with the light-collecting portions 57 for collecting the light from the lamp bulb 45 and directing it to their corresponding protrusions 55 . Therefore, the light from the lamp bulb 45 is collected and reflected by the recesses 58 of the light-collecting portions 57 of the inner reflective lens 46 to the protrusions 55 . This can provide appearance as if the taillight assembly 35 had nine light sources, although it has the single lamp bulb 45 , which improves its appearance. The positional relation between the protrusions 55 and the light-collecting portion 57 and the lamp bulb 45 shown in FIG. 8 is a conceptual illustration to facilitate understanding.
[0032] Thus from the foregoing description it should be readily apparent to those skilled in the art that an improvement in appearance and light transmission is possible using a simple configuration of the protrusions 55 formed on the outer lens 47 and the light-collecting portions 57 formed on the inner reflective lens 46 and only the single lamp bulb 45 . Thus cost is reduced compared to when the device has a plurality of light sources as in the prior art. Of course those skilled in the art will readily realize that the foregoing description is only that of an exemplary embodiment and various changes may be made to practice the invention. For example, the reflecting portion 53 and the protrusions 55 are integrally formed on the outer lens in the foregoing embodiment, but these may be formed as separate components from the outer lens and attached thereto by bonding, welding or the like. Also the protrusions are made thin in thickness to configure the highly light-transmitting portions. However, to configure the protrusions as the highly light-transmitting portions, they may be formed from material of higher light transmittance than the peripheral region and attached to the outer lens by bonding, welding or the like. The highly light-transmitting portions can also be realized through change in the shape of the protrusions.
[0033] Further, in the specifically described embodiment, the protrusions 55 are positioned at equal angular intervals on the periphery of a common circle. However, positioning the protrusions is not limited to such manner but may be as appropriate according to needs in design or the like. For example, the protrusions may be positioned on the peripheries of two circles of different diameters or on the periphery of an ellipse, or in a square, polygonal or trapezoidal manner. Also although the light-transmitting portions are formed in protrusions they need not be formed in protrusions but may be configured in recesses, for example.
[0034] Further, in the foregoing embodiment, description has been made of an example in which the present invention is applied to the taillight assembly 35 for a motorcycle. However, the light device of the present invention is also applicable to a headlamp device for any other type of vehicle. Of course those skilled in the art will readily understand that the described embodiments are only exemplary of forms that the invention may take and that various changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims.
|
A vehicle and associated light source that comprises a single source of light and a surrounding housing and lens arrangement that gives the visual effect of multiple light sources.
| 1
|
This application claims benefit of Provisional Application Ser. No. 60/067,698 filed Dec. 4, 1997.
FIELD OF THE INVENTION
The present invention relates to techniques for analyzing chemicals in a sample using radiation, and more particularly to techniques for non-invasively analyzing chemicals in human blood using radiation.
BACKGROUND
The analysis of blood components is an important diagnostic tool for better understanding the physical condition of a patient. Presently, adequate noninvasive blood analysis technology is not currently available and blood samples still need to be obtained by invasive methods from a great number of patients every day for analysis. A well known example of such needs is the monitoring of glucose levels by a diabetic individual. Similarly, concentration of other physiological chemicals are important for determining the health condition of some individuals.
Research effort has been directed to non-invasive analysis of blood chemicals. Take the example of glucose. Glucose has several absorption peaks in the near infrared and the far infrared. Researchers have made progress in measuring glucose in solution by means of absorption of such radiation. Unfortunately, water, which is a major component of tissue and blood also, absorbs heavily in most of these regions. This makes it almost impossible to extract glucose information by absorption in most of these regions. However, in the near infrared some weak absorption bands of glucose overlap valleys in the water absorption bands. These bands, being weak absorption bands in the vicinity of huge water bands, are extremely difficult to analyze, particularly in complex systems such as tissue where several other analytes are also present and are themselves fluctuating. Successful glucose analysis therefore requires separating a weak signal in the midst of influences of chemical interference and temperature and flow related fluctuations.
Several techniques for processing the spectral data to eliminate these influences have been developed. Multivariate regression analysis such as PLS (partial least square) methods and PCR (principal component resolution) methods have been widely applied. More recently, Fourier filtering of the spectral data followed by multivariate regression analysis have been used to improve the prediction of glucose in biological samples. However, we have found that when the temperature of even simple aqueous samples varies over the human body temperature range, the predictive ability of these methods can be seriously reduced. Further, such prior techniques may not be robust enough to determine accurately the glucose composition when some of the interfering species such as proteins in the sample fluctuate over the normal range for human blood. Therefore, a better method of analyzing such data is required.
SUMMARY
In one aspect, the present invention involves a technique that uses wavelet analysis to determine the concentration of one or more analytes (e.g., a chemical such as glucose) in a sample. In an embodiment, the technique includes irradiating electromagnetic radiation on the sample, detecting a resulting radiation from the sample to obtain spectral data, digitally processing the data using wavelet-basis-function to increase proportionally the signal indicative of the analyte in the data, and applying a modeling algorithm to the digitally processed data to determine the quantitative characteristics of the analyte in the sample. The electromagnetic radiation irradiated on the sample interacts with the sample. The interaction results in a resultant electromagnetic radiation from the sample, such as reflected radiation, scattered radiation, or transmitted radiation. The resultant electromagnetic radiation includes signals indicative of the analyte. Therefore, by detecting and analyzing the resultant electromagnetic radiation, quantitative information on the analyte in the sample can be obtained. The resultant electromagnetic radiation spectra derived from the radiation interaction of the sample over the wavelength or frequency range or ranges include one or more bands whose magnitude or other characteristics are function of the concentration of the analyte of interest. The spectral information is then processed using wavelet analysis technique as described below. The present invention can be used, for example, to non-invasively measure the composition of one or more analytes (e.g. glucose concentration, lipid profile) of a sample, such as in-situ tissue or a blood sample, using spectral data obtained by the interaction of the radiation with the sample.
One of the steps in the implementation of this invention is the selection of a wavelet basis that is appropriate for the specific analysis. The wavelets in the basis are by definition functions that meet certain mathematical criteria (for general information about wavelets, see, Wavelets and Filter Banks, by Gilbert Strang and Truong Nguyen, Wellesley-Cambridge Press, 1996 ISBN: 0-9614088-7-1).
Although one can choose from a large collection of such functions, in analyzing the spectral information such as acquired in tissue spectroscopy, it is possible to choose a function that closely resembles the spectral signature such as absorption peak of the analyte to be measured. For example, some basis functions of Daubechies D8 are shaped substantially like the absorption peaks of pure glucose in the 4000-5000 wavenumbers range. Thus Daubechies D8 is one appropriate basis for implementing this invention.
In another embodiment of this invention a systematic optimization technique may be employed to test several sets of basis functions and choose one that best meets the chosen optimization criteria such as best correlation with the analyte signal or the least prediction error in a reference data set (a calibration set). Once the optimal set of basis functions has been determined, a mathematical prediction model is built using this set of basis functions. This prediction model can then be used to determine the concentration of the analyte of interest from a single data set such as an absorption spectrum obtained from an unknown sample.
BRIEF DESCRIPTION OF THE DRAWING
The following figures, which exemplify the embodiments of the present invention, are included to better illustrate the embodiments of the apparatus and use of the present invention. In these figures, like numerals represent like features in the several views.
FIG. 1A to FIG. 1F show examples of basis functions for a signal when using a ten-point Daubechies filter in discrete wavelet transform, DWT.
FIG. 2A to FIG. 2F show the corresponding Fourier Transform of the DWT basis functions of FIGS. 1A to FIG. 1F.
FIG. 3 shows an example of a calibration set of spectra.
FIG. 4 and FIG. 5 show two examples of matching a DWT basis function to a glucose absorbance spectrum.
FIG. 6 shows a prediction vector b in a prediction model according to the present invention.
FIG. 7 shows a set of spectra of sample the glucose concentrations of which are to be determined.
FIG. 8 shows the comparison of the predicted result and the known value of glucose solution samples, predicted according to the technique of the present invention.
FIG. 9 shows an apparatus according to the present invention.
FIG. 10 shows a more specific apparatus according to the present invention.
FIG. 11 shows an embodiment of an apparatus for radiating a part of a hand and sensing the electromagnetic radiation interaction.
FIG. 12 shows an example of an absorbance spectrum of glucose in solution.
FIG. 13 shows an example of the Fourier transform of the spectrum of FIG. 12.
DETAILED DESCRIPTION OF THE INVENTION
In one aspect, the present invention provides a technique of non-invasively measuring quantitative information about one or more analytes (e.g., a chemical such as glucose) in a sample, e.g., a physiological liquid in a patient's body, using electromagnetic radiation by applying wavelet transform. As used herein, the term "sample" includes solid, liquid, and gas, and includes one that is contained in a container or a part of a whole, e.g., a part of a human hand. The technique of the present invention uses wavelet transform to analyze one or more analytes in the sample.
Wavelet Transform
Wavelet transforms, like Fourier transforms, can be considered as rotations of data in function space to a different domain. In the new domain the information content of the data can often be extracted with fewer and/or simpler mathematical treatments. For the Fourier transform the new domain is reached by projecting signals onto basis functions that are sine and cosine functions. For the wavelet transform it can be reached by projecting onto an infinite number of possible basis function sets called wavelets. These wavelet basis functions must meet certain mathematical criteria as described in Gilbert Strang and Truong Nguyen, supra (see also, Amara Graps, "An Introduction to Wavelets," IEEE Computational Science and Engineering, Summer 1995, Vol. 2, No, 2). They can be chosen from known sets or designed by the user to suit the particular application. Thus wavelet analysis provides access to information that can be obscured by methods that use fixed basis functions such as Fourier analysis.
The functions (vectors) in discrete wavelet transform (DWT), unlike those of discrete Fourier transform (DFT), are real, aperiodic, and non-zero over only a finite portion of the signal which is projected onto them. Although one skilled in the art will know the basis functions of different DWTs employing different filters, it is difficult to describe in limited space the basis functions in concise equations. The properties of the basis functions for DWTs can be better illustrated by graphs.
As an illustration, FIG. 1 shows six of the 256 basis functions (φ i (j)), where i represent the number of the different basis functions and j refers to the data points, for a 256-point signal when performing the D10 Daubechies DWT. The name of the DWT (D10 Daubechies) describes the type of basis functions used in the DWT. The Daubechies sets of basis functions are widely used in the implementation of DWTs. Detailed descriptions of how these and other wavelet basis functions are derived are given in Gilbert Strang and Truong Nguyen, supra, and should be obvious to those familiar with the art of wavelet analysis.
The basis functions of a DWT can be divided into different groups, called resolution levels. Each one of the basis functions plotted in FIG. 1 is an example of a basis function at a certain resolution level. The resolution level of φ 1 (j) is numbered resolution level 7 since there are 2 7 =128 basis functions at this resolution level. In the lower levels of resolution levels, more data points are discarded than in the higher resolution levels. The only difference between any basis functions that are in the same resolution level is how much they are shifted. Thus, the other 127 basis functions in the same resolution level as φ 1 (j) are all described by φ 1 (j)=φ 1 (j-k), where k is the amount of shift. As a further example, in resolution level 6, there are 64 basis functions which are all shifted versions of φ.sub. 2(j), since 2 6 =64. Resolution level 3, however, the lowest of the resolution levels in this wavelet transform, is slightly different than the rest of the resolution levels. For, the lowest resolution level of a DWT always has both a set of high-frequency basis functions and a set of low frequency basis functions. The eight high-frequency basis functions of resolution level 3 are all shifted versions of φ 5 (j). The eight low-frequency basis functions of resolution level 3, on the other hand, are all shifted versions of φ 6 (j).
The magnitudes of the Fourier transforms of the wavelet basis functions shown in FIG. 1 are displayed in FIG. 2. The basis functions in a resolution level all have exactly the same magnitude Fourier transforms. Thus, the plots in FIG. 2 would look no different for different basis functions in the same resolution level. From comparing FIGS. 1 and 2, one should be able to see that the "resolution" levels do not refer to "high-resolution" or "low-resolution". For, high resolution in the time-domain corresponds to low resolution in the frequency-domain, and high resolution in the frequency-domain corresponds to low resolution in the time-domain. Thus, the different resolution levels of the DWT can best be described as representing different levels of trade-off between time and frequency resolution.
According to the present invention, knowing what wavelets look like, one can go on to describe the method by which one uses the wavelet transform in order to predict the concentration of the analyte of interest (e.g., a chemical such as glucose). As an illustration, glucose is used below as an example to show the how the wavelet technique can be used. It is to be understood that one skilled in the art will be able to apply the present technique to other chemicals individually, e.g., alcohol, or as a group, e.g., lipids. To this end, for example, one can find a linear regression model for predicting glucose concentration (y pred ) from absorbance spectra (x n ), e.g., in the form of an equation (y pred =b o +x' 1 b) where b o and b are constants, and x' i represents spectra data. The equation will be described in detail below. In the present application, matrices are represented by bold, upper case letters; vectors are represented by bold, lower case letters; and scalars are represented by non-bold, lower case letters.
Establishing a Model
To implement a model of our invention, spectra are obtained from radiation interacting with a variety of samples containing known concentrations of the analyte of interest, i.e., glucose, as an example. Often, absorption is used for this purpose. However, since the employment of wavelet transform is applicable regardless of the form of electromagnetic wave interaction used, it is contemplated that other types of radiation interaction, such as transmission, reflectance, or light scattering can be used.
As an example, in the detection of glucose concentration in blood, near infra-red (NIR) radiation can be used to irradiate a body portion (e.g., the Thenar web, i.e., the webbing fold of skin between the thumb and index finger of person) and the light transmitted therethrough can be sensed to measure the light absorption. For glucose, a set of bands of absorption is in the ranges of 4000-5000 cm -1 and 5800-6500 cm -1 . As stated earlier, an alternative is the transmittance of the light, which can be measured. Another alternative is to measure the reflectance of the irradiated light. In yet another alternative embodiment, radio frequency radiation can be used to irradiate the body portion to result in high frequency spectra (see, Fuller et al., WO 95/04496 for a description of apparatus and method for using radio frequency to estimate the concentration of a chemical in a liquid, said description is incorporated by reference herein). In each case, when the spectral signals are detected by appropriate detectors, they are converted into digital spectral data.
Since the analyte of interest has significant radiation interaction only in certain ranges, preferably, even before performing wavelet transforms to obtain wavelet basis functions, to reduce noise and reduce the amount of information to be processed, a certain amount of the spectral data in the time domain is truncated outside of these ranges before the spectral data is used to select the basis functions. Techniques for truncation of spectral data outside of a frequency range of interest are known to those skilled in the art. Thus, these spectra may be truncated so that they contain only those spectral regions known to have some correlation with analyte (e.g., glucose) concentration. For example, NIR glucose absorbance peaks would often be truncated to include only the glucose absorption ranges of 4000-5000 cm -1 or 5800-6500 cm -1 mentioned above.
In this invention, the spectral data obtained from a detector, or a truncated version thereof, is used to obtain a linear prediction model for the analyte of interest. While deriving this prediction model, we will refer to all absorbance spectra as spectra vectors (x n ). Practically, spectral data for deriving the prediction model will more conveniently be obtained from sample glucose solutions in containers. Using these spectra vectors, we will create a data matrix X, where each of the rows of X is one of the spectra vectors (x n ), as in Equation 1: ##EQU1## Thus, x' 1 , x' 2 , x' 3 , etc. are vectors, each containing data from a different episode of spectral analysis. It is helpful to center the columns of the matrix X for later prediction modeling, as shown in Equation 2: ##EQU2## where x' m is the mean value of the column, and X is the matrix containing vectors of centered values. The vector y will be made to contain the actual known glucose concentration of each spectra vector in X. It is also helpful for prediction to center this vector, as in Equation 3:
y=y-y.sub.m
At this step in the process of creating a prediction model, we need to make use of the DWT. Such DWT can be performed by a computer employing commercially available software, e.g., MATLAB (a matrix mathematics software sold by The MathWorks, Inc., 24 Prime Park Way, Natick, Mass. 01760). When performing any transform in spectral analysis, the basis functions of the chosen transform are selected to enable highlighting of the salient features of the spectra to be analyzed. In other words, at least some of the basis functions of the transform should be well matched with the important characteristics of the spectra. In the Discrete Wavelet Transform (DWT) used in this invention, there is large number of basis function sets that can be used. Thus, one of the important steps in the implementation of this invention is the selection of a wavelet basis that is appropriate for the specific analysis. The wavelets in the basis are by definition functions that meet certain mathematical criteria (see, Wavelets and Filter Banks, by Gilbert Strang and Truong Nguyen, Wellesley-Cambridge Press, 1996 ISBN: 0-9614088-7-1).
In analyzing the spectral information such as acquired in tissue spectroscopy, it is possible to choose a set of wavelet basis functions that contains some basis functions which closely resemble a spectral signature such as the absorption peak of the analyte to be measured. For example, some basis functions of the Daubechies D8 set are shaped substantially like the absorption peaks of pure glucose in the 4000-5000 wavenumbers range. Thus Daubechies D8 is one appropriate basis for implementing this invention when predicting glucose concentration. In one embodiment of this invention, a wavelet basis function set can be chosen since, to an observer, it visually appears to contain basis functions that suitably represent the important information in the spectra being studied. Thus, the wavelet basis functions are selected to correspond to the frequency and spatial characteristics of the spectral data.
In another embodiment of this invention a systematic optimization technique may be employed to test several sets of basis functions and choose one that optimizes a certain criterion, such as best correlation of one of the basis functions with the analyte signal or the least prediction error when the entire wavelet prediction method is performed in a reference data set (a calibration set). Once the optimal set of basis functions has been determined, a mathematical prediction model is built using this set of basis functions. This prediction model can then be used to determine the concentration of the analyte of interest from a single data set such as an absorption spectrum obtained from an unknown sample.
In addition to choosing the set of basis functions to be used in a DWT, the lowest resolution level of basis functions is also chosen to use in the DWT. We usually choose resolution level 2 as the lowest resolution level. A lower resolution level should be chosen, however, if the shape of the basis functions in these lower levels will match up well with the shape of the analyte of interest.
Once we have chosen a set of wavelet basis functions and the lowest resolution level, a matrix W will be created. The columns of W contain the basis vectors of the wavelet transform that is being used, as in Equation 4:
W=[φ.sub.1 φ.sub.2 . . . φ.sub.n ]
The matrix representation of the wavelet transform of the spectra in X will be called T. The rows of T are equal to the DWTs of the spectra vectors (rows) of X, as in Equation 5:
T=XW
By transforming our spectral data into this new wavelet domain, we should have concentrated information relevant to analyte concentration into as few variables as possible. At this stage a lot of the data in T would have low correlation with analyte concentration. This uncorrelated data should be eliminated from this process of building a prediction model since it represents nothing more than noise. Thus, the transformed spectra in T are truncated so that they contain only those resolution levels which are expected to contain information (characteristic frequencies of the analyte) relevant to predicting the analyte of interest. In addition, the spectra in T must often be truncated in order to perform some of the later steps of this process. Indeed, enough variables must always be eliminated from the spectra in T so that there are more rows than there are columns.
Choosing which resolution levels of T to use in the prediction process can be done in several ways. One way is to choose them based on the magnitude of the Fourier transforms. As mentioned earlier, all basis functions in a resolution level have the same magnitude of Fourier transforms. In order for a resolution level to be well suited for representing a particular analyte, the magnitude of Fourier transform of the resolution level should match up well with the magnitude of Fourier transform of the analyte's pure spectrum. In other words, the Fourier transforms of the selected basis functions of the selected resolutions levels will have peaks in the frequency ranges similar to the Fourier transform of the spectral data of the analyte of interest. This selection of resolution levels can be accomplished by inspecting the curves of the resolution levels of the basis functions and their Fourier transforms and selecting the ones with the wave number range of interest.
For example, FIG. 12 shows a 256 point absorbance spectrum obtained from 400 mg/dL glucose in an aqueous solution. FIG. 13 shows the magnitude Fourier transform of this spectra. When FIG. 13 is compared to the plots in FIG. 2, it should be apparent that some of the resolution levels of the DWT represented by FIG. 2 will contain very little information relevant to glucose concentration. For example, resolution levels seven, six, and five, represented by FIGS. 2a, 2b, and 2c, have very little in common with the plot in FIG. 13. On the other hand, resolution levels three and four, represented by FIGS. 2d, 2e, and 2f contain regions in their magnitude of Fourier transforms that overlap with the important features of the plot in FIG. 13. Thus, resolution levels three and four would likely be good resolution levels to include in the process of building a prediction model for this data.
Alternatively, an algorithm can be created to select the proper resolution levels using a quantitative optimization technique. Such optimization technique is also within the skill of one skilled in the art. Such algorithms can be run on computers. The optimization technique would use several different ranges of resolution levels in the prediction process that is presently being described. The range that optimizes a certain criterion, such as the least prediction error when cross validation is performed in a reference data set (a calibration set), could then be chosen as the best range of resolution levels.
Once the resolution levels for use in this process are chosen, the matrix T can be truncated so that it only contains spectra with these resolution levels. This new matrix will be called T a , where the "a" represents the resolution level or levels of T that are included in T a . T a can be found directly from by X using the formula T a =X W a , where W a is derived from W and contains only the basis vectors in the applicable resolution level(s). For example, T 3 represents the matrix with rows containing resolution level 3 of the DWTs of the spectra vectors in X.
The projection (q) of y onto the columns of T a is given by the following, Equation 6:
q=(T'.sub.a T.sub.a).sup.-1 T'.sub.a y
This q is the regression vector that would be used in a regression equation between the variables in T a and predicted glucose concentration. Now that q is found, the final form of the prediction model can be obtained. This prediction model will give predicted analyte concentration (y pred ) of an unknown sample from its spectrum x' p as shown here in Equation 7:
y.sub.pred =b.sub.o +x'.sub.p b
where
b=V.sub.a q; b.sub.o=y.sub.m -x'.sub.m b
with y m and x' m as defined in Equations (2) and (3).
In this application a wavelet basis function is chosen to be better matched to represent the spectral signal generated by the analyte species we are trying to analyze (for example, the absorption spectrum of glucose in solution). It is obvious that the shape of the absorption peaks of the analyte such as glucose are quite different from sine or cosine functions. Therefore, Fourier representation of this signal would be poor. However, Wavelet basis functions, due to their characteristics in resembling discontinuity and sharp peaks, are better suited to match the shape of the signal from the analyte to be analyzed and therefore will be better for analysis of the analyte.
Another advantage of wavelet transforms is that the individual wavelet basis functions are localized in space whereas Fourier sine and cosine functions are not. Thus, a very sharp signal from one analyte species can be represented by a high frequency wavelet basis function localized to the data space around the signal (e.g., absorption peak) for that species. While a wide peak generated by another species also present in the sample can be represented by a low frequency basis function over a wider data space. This property of wavelet transforms permits simpler isolation of sharp glucose peaks from a spectrum containing wide peaks generated by water and other interfering species.
Example of Modeling
The following is an illustrative example of how a model is developed for detecting quantitatively glucose concentration in aqueous solution. It is to be understood that other samples, i.e., solids, liquids in bottles, etc., can be analyzed by one skilled in the art employing a similar technique applying radiation and wavelet transform. Briefly stated, the method involves deriving a model of spectral data in relation to quantitative information (e.g., concentration) of an analyte using wavelet basis functions and matching the model with spectral data of a sample suspected to have the analyte, to find the quantitative information on the analyte in the sample.
To provide the spectra in this example, 42 aqueous solutions of glucose were irradiated and the resulting radiation interaction detected. The absorbance spectra were obtained using a BOMEM Michelson MB-155 FTIR (Bomem, Inc., 450 ave St-Jean-Baptiste, Quebec, PQ Canada G2E 5S5). Each individual spectrum contained 3,113 points of data and covered the wavenumber range 10,000 cm -1 -4000 cm -1 . These spectra were collected from sample solutions containing protein concentrations ranging from 40 g/L-60 g/L, glucose concentrations ranging from 20-400 mg/dL, and temperatures ranging from 34-40 degrees Celsius.
All forty-two (42) of the 3,113-point spectra were then transferred in their entirety into MATLAB. In MATLAB all of the spectra were truncated in the following manner. First, the index of the 3,113-point absorbance spectra corresponding to 4400 cm -1 (or the closest wavenumber to 4400 cm -1 ) was found. Then, the spectra were truncated 127 points from 4400 cm -1 in the direction of the 4000 cm -1 end, and 128 points from 4400 cm -1 in the direction of the 10,000 cm -1 end. This truncation process yields 256-point spectra (i.e., each having 256 point) covering the wavenumber range 4646 cm -1 -4100 cm -1 . The 256-point spectra, treated as vectors in MATLAB, were put into the columns of the matrix X cal . The spectra in X cal are plotted in FIG. 3.
Then, a column concentration vector, y cal , was created. As stated above, the entries of y cal corresponded to the glucose concentration of the solutions from which the columns (spectra) X cal were collected.
Next, a set of wavelet basis functions was chosen for later use in a discrete wavelet transform (DWT). In this illustrative case, the D8 (Daubechies-8) set of basis functions was chosen. The lowest resolution level of the DWT was also chosen at this point. In this example, the lowest resolutions level of the DWT was chosen to be resolution level 2.
FIGS. 4 and 5 display two different basis functions of the D8 (from resolution levels 3 and 4) basis on the same set of axes as a magnified (100×) absorbance spectrum collected from a sample containing 400 mg/dL glucose and no protein at 37 degrees Celsius. In FIG. 4, the dotted line, a, is the resolution level 3 basis function and the solid line, b, represents the spectrum. In FIG. 5, the dotted line, c, is the level 4 basis function and the solid line, d, represents the spectrum. As can clearly be seen from both figures, the primary peaks of the basis functions match up well with the primary glucose absorbance peak at 4400 cm -1 . The basis function in FIG. 4 also seems to have a small peak at about the same point as the secondary glucose absorbance peak at 4300 cm -1 . Thus, D8 appears to be a good choice of wavelet basis.
At this point, a matrix W was created from the basis functions selected. The columns of W were the 256 (two hundred and fifty six) 256-point D8 wavelet basis functions. Thus, W was a 256-by-256 matrix.
Since the full DWTs of the truncated absorbance spectra in the calibration set would only contain a few points with useful information for predicting glucose concentration, only those points that had a high chance of containing glucose information were used in the final prediction formula. In this example, resolution levels 2h-4 (the high-frequency section of resolution level 2, resolution level 3, and resolution level 4) because these resolution levels of the D8 DWT contain the frequency ranges over which protein and glucose peaks are known to occur for the given wavenumber range. By selecting the resolution levels, the size of the matrix W is reduced, yielding a matrix W 2h-4 with a size of 256×28 described above in Equations 1 to 7. This matrix is constrained to always have fewer columns than the number of spectra in the calibration set. W 2h-4 had 28 columns, which is indeed less than the 42 spectra in the calibration set.
As per the method described above in Equations 1 to 7, the calibration data matrix X cal is centered for each wave number by finding the difference of the truncated spectral data from the average, via the following operation, similar to Equation 2 above, using the transpose X'cal of X cal , as shown in the following Equation 8: ##EQU3## where the x' vector is the mean of the transpose spectral data X' cal of the 42 spectra. Further, the concentration data of the calibration samples from which the spectra were derived are put into vector form, y cal . The entries of this y cal matrix correspond to the concentrations of the analyte from the columns (i.e., spectra) of the X cal matrix. The y cal is also centered, similar to Equation 3 above, by finding the difference of the concentration data from the average, as in the following Equation 9:
y.sub.cal =y.sub.cal -y
where y is the mean of the concentration of the 42 samples.
Subsequently, X cal (or rather X' cal ) and W 2h-4 were used to produce a new matrix, the resolution matrix T, as shown in Equation 10:
T=X'.sub.cal W.sub.2h-4
T was a 42 by 28 matrix. The rows of T contained resolution levels 2h-4 of the DWTs of the columns (spectra) of X cal .
Next, the prediction coefficient vector b was found using the Equation 11:
b=W.sub.2h-4 (T' T).sup.-1 T' y.sub.cal
The scalar offset coefficient b o for the prediction model was obtained by finding the dot product of the regression coefficients b obtained above and the average spectrum vector and then subtracting this dot product from the mean concentration of the analyte in the calibration samples, as shown in the following Equation 12:
b.sub.o =y-x'b
FIG. 6 shows the prediction vector b, plotted against the corresponding wavenumbers of the signals that will later be dotted with b.
Determination of Quantitative Information Using the Model
When a sample is suspected to contain the analyte of interest, the sample can be irradiated with the radiation to obtain a spectrum as with the n calibration samples described in the above. As previously stated, a part of a human body can be considered a sample herein.
In this illustrative example, forty-two (42) NIR absorbance spectra were obtained using a BOMEM Michelson MB-155 FTIR spectrometer in the same manner as described in the above model. Each individual spectrum contained 3,113 points and covered the wavenumber range 10,000 cm -1 -4000 cm -1 . These spectra were collected from prediction sample solutions containing protein concentrations ranging from 40 g/L-60 g/L, glucose concentrations ranging from 20-400 mg/dL, and temperatures ranging from 34-40 degrees Celsius. None of these spectra in the prediction set, however, contained the same protein and glucose concentrations as any spectrum in the calibration set.
All forty-two (42) 3,113-point spectra were then transferred in their entirety into MATLAB. In MATLAB all of the spectra were truncated in the same manner as described in the above Model. Then, the forty-two 256-point spectra were put into the columns of a matrix called X pred . The spectra in X pred are plotted in FIG. 5.
Prediction was then performed using b o and b found in the model developed above and Equation 13:
y.sub.pred =b.sub.o +X'.sub.pred b
where y pred contained the predicted glucose concentration of each spectrum in X pred and X' pred is the transpose of X pred . FIG. 8 shows the plot of predicted versus actual glucose concentration. The results show that the predicted values represent the actual concentrations very well.
In this way, the model can be used to predict quantitative information of the analyte of interest in unknown samples. It is to be understood that one skilled in the art will be able to made obvious modifications, and such modification are within the scope of the present invention. For example, the mathematics can be reformulated using equivalent mathematics, curve fitting methods other than linear regression can be used, and the order or extent of the truncation steps may be modified. Further, although we use concentration as the quantitative information as the example in the above description, other quantitative information such as mass, mole, and the like, can be used, if the volume, mass, etc., of the sample is known.
The apparatus used in the present invention can be composed of standard commercial units of electromagnetic energy radiation equipment detectors, computers, monitors, amplifiers, and the like. FIG. 9 shows an embodiment of an apparatus that can be used for determining the concentration of an analyte in solution according to the present invention. The apparatus 100 includes an analyzer 110 by radiation interaction of the analyte in solution. The data of the electromagnetic wave interaction, such as absorbance, transmission, light scattering, etc. are analyzed in a processor 114 to obtain the spectra of the electromagnetic wave interaction data. The processor 114 further can determine the basis functions. Alternatively, a person can manually select the basis functions. The processor can, based on the basis functions selected, predict the concentration of the analyte according to an algorithm embodying the DWT technique described above. The result of the analysis can be communicated to the user by a user interface, such as a display, or to another analytical or computing device in remote site. In a more specific embodiment the electromagnetic wave interaction analyzer is a near infra-red (NIR) absorbance spectrometer 134. In the NIR absorbance spectrometer, light of specific wavelength is imparted on the sample and the absorbance analyzed to obtain data with the absorption peaks. The NIR absorbance spectrometer or the spectrum analyzer can analyze the spectral data. The processor can be a computer, microprocessors, etc. known in the art. The user interface for displaying the analytical results can be a CRT monitor, printer, plotter, or the like. Alternatively, the data, the algorithm, and the results can be stored separately or together in a storage medium such as a computer, hard disk, floppy disk, tape, IC, and the like, for later use. As an alternative to NIR, as described above, radio frequency interaction can be used. In this case, a radio frequency radiation generator and sensor for sensing the radio frequency interaction will be used. Devices for non-invasively irradiating a part of the body to obtain electromagnetic wave interaction for spectral analysis are known in the art. For example, NIR absorption using fiber optics for directing light to the webbing between the thumb and the forefinger is disclosed by Small et al., International Patent Application No. WO 95/22046, which description of the technique for detection of physiological chemical is incorporated by reference herein). As previously stated, devices for utilizing radio frequency for determining chemical in a human body are disclosed by Fuller, et al. (supra). In the present invention, electromagnetic radiation can be directed to, e.g., as shown in FIG. 11, the webbing between the thumb and the forefinger, the earlobe for electromagnetic interaction such as NIR, far IR absorption, and radio frequency radiation. In FIG. 11, the NIR light is generated by a NIR light source 150 such as a halogen lamp. The NIR light is transmitted through an optical cable 115 to light exit end 158 to the webbing 160. Light transmitted through the webbing 160 is carried by another optical fiber 164 to a detector 166 to be detected and later analyzed for spectral characteristics.
Although the preferred embodiment of the present invention has been described and illustrated in detail, it is to be understood that a person skilled in the art can make modifications within the scope of the invention. For example, the present technique can be used to measure chemical concentration in samples of solid, liquid, non-physiological fluids as long as electromagnetic interaction can be used to obtain spectra. Further, based on the present disclosure, the use of algorithms for wavelet analysis would be simple and obvious to one skilled in the art of wavelet analysis. For example, rather than using the basis functions of the DWT, one could also use the basis functions of a discrete wavelet packet transform. The basis functions of a wavelet packet transform are divided into resolution level detail and resolution vectors. In using wavelet packet transform, one would simply choose the sets of basis functions to use in creating the prediction equation in the same manner as described here for choosing resolution levels.
|
A technique that uses wavelet analysis to analyze the concentration of an analyte in a sample. The technique includes irradiating the sample with electromagnetic radiation and detecting a resulting radiation from the sample to obtain spectral data. The electromagnetic radiation irradiated on the sample results in radiation interaction, such as reflection, scattering, and transmission, from the sample. The radiation interaction results in a resultant electromagnetic radiation from the sample, such as reflected radiation, scattered radiation, or transmitted radiation. The resultant electromagnetic radiation includes signals indicative of the analyte. The spectral data is digitally processed using wavelet analysis to increase proportionally the signal indicative of the analyte in the data. A modeling algorithm is applied to the processed data to determine the quantitative characteristics of the analyte in the sample.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OF DEVELOPMENT
[0002] Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0003] Not applicable
BACKGROUND OF INVENTION
[0004] There is an existing product in use called the Popcorn Ceiling Scraper, U.S. Pat. No. 6,101,663, distributed by Homex Products, Incorporated. The makers of this product currently recommend the use of a plastic trash bag for use with their scraper as a collection receptacle. The bag is attached to the flexible band part of their scraper to facilitate the collection of acoustic ceiling debris removed from a ceiling by the scraper. This new invention, the Ceiling Debris Collection Bin, is designed for use with the Popcorn Ceiling Scraper and is a superior replacement of the plastic trash bag.
[0005] Prior to removing material from a ceiling, it is recommended that the ceiling be moistened to facilitate easier removal of the material. If the ceiling material is not sufficiently wet or drying occurs prior to removal, it tends to scatter upon contact with the scrapper blade. The design of the Ceiling Debris Collection Bin controls the scattering and catches and retains the removed acoustic ceiling debris, whether wet or dry. It is much more efficient than a plastic trash bag and is a preferred alternative.
BRIEF SUMMARY OF THE INVENTION
[0006] The Ceiling Debris Collection Bin is constructed of sturdy single wall corrugated cardboard. It is attached to the metal band portion of the Popcorn Ceiling Scraper by the use of four nylon cable ties. The unique design of this new invention, with flared front and rear sides, creates a much larger collection opening and surface than an ordinary plastic trash bag, and the slant wall design directs the removed acoustic ceiling material down into the lower box.
[0007] A trash bag has an opening limited to thirty-six (36) square inches (232.26 square cm) which is determined by the area encompassed by the flexible metal band part of the scraper. The Ceiling Debris Collection Bin has an opening of about ninety (90) to ninety-six (96) square inches (580.64 to 619.35 sq. cm), depending on the width of the lower box. The side front wings are collapsible when the Ceiling Debris Collection Bin is pushed against the wall and straighten when pulled away from the wall, returning the Ceiling Debris Collection Bin to its original shape. This feature accommodates the flexible metal band movement of the scraper. The foam rubber wedges on both sides of the Ceiling Debris Collection Bin have a sloped top surface that assists in the debris collection process, by directing debris into the Ceiling Debris Collection Bin. The Ceiling Debris Collection Bin is far more efficient than a common plastic trash bag and is a superior alternative. The Ceiling Debris Collection Bin is a disposable product.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] FIG. 1 shows the complete Ceiling Debris Collection Bin invention.
[0009] FIG. 2 is a view looking down into the Ceiling Debris Collection Bin.
[0010] FIG. 3 shows the inside of the right end cap, a unique design made of cardboard that transforms a certain box structure into the Ceiling Debris Collection Bin.
[0011] FIG. 4 shows the outside of the left end cap.
[0012] FIG. 5 shows the right end cap lined up to the right end flap before attachment.
[0013] FIG. 6 shows the right foam rubber wedge. There are two of these wedges, one each for the right and left wings. They are exactly alike and they facilitate the collapsing and rebounding of the wings as the Ceiling Debris Collection Bin is pushed up against the wall where the ceiling meets it.
[0014] FIG. 7 is a side view of the same right foam rubber wedge.
[0015] FIG. 8 shows the Ceiling Debris Collection Bin prior to assembly. It stores, packs and ships flat. The consumer simply folds it out and makes the appropriate connections where two sided tape is affixed to the various flaps.
[0016] FIG. 9 shows the right rear corner of the Ceiling Debris Collection Bin. It shows the right rear connector flap prior to being folded over and connected to the rear side flap.
[0017] FIG. 10 shows the Ceiling Debris Collection Bin in relation to the Popcorn Ceiling Scraper, U.S. Pat. No. 6,101,663.
[0018] FIG. 11 shows the Ceiling Debris Collection Bin connected to the Popcorn Ceiling Scraper, U.S. Pat. No. 6,101,663. This connection is facilitated by the use of cable ties.
[0019] FIG. 12 shows the Ceiling Debris Collection Bin in use. Note that the right front wing flattens as it makes contact with the wall.
DETAILED DESCRIPTION OF THE INVENTION
[0020] It is suggested that FIG. 1 be included on the front page of the patent application publication and patent.
[0021] FIG. 1 shows the Ceiling Debris Collection Bin 2 , which is designed for use with an existing product already in the marketplace known as the Popcorn Ceiling Scraper 48 , U.S. Pat. No. 6,101,663 shown in FIG. 10 . The Ceiling Debris Collection Bin 2 is constructed of sturdy single wall corrugated cardboard with a recommended minimum 200 lb. (90.72 kg) test rating. Construction begins as a box structure consisting of a lower box 1 , including two end flaps—a right end flap 5 seen in FIG. 1 and FIG. 2 and a left end flap 9 shown in FIG. 2 and two side flaps—a rear side flap 7 and a front side flap 3 seen in FIG. 1 . The right end flap 5 , shown in FIG. 1 , has two eyelets—a right end flap front eyelet 4 and a right end flap rear eyelet 6 .
[0022] FIG. 2 is a top view looking down into the Ceiling Debris Collection Bin 2 and shows the left end flap 9 and the left end flap front eyelet 10 and the left end flap rear eyelet 8 . It also shows another view of the right end flap 5 . All eyelets are positioned five-eighths (0.625) inches (1.59 cm) from the top of the end flaps 5 and 9 , measured to the top rims of the eyelets 4 and 6 , ( FIGS. 1 ), and 8 and 10 ( FIG. 2 ). It also illustrates the much expanded opening for collection of debris. The Ceiling Debris Collection Bin has an opening of about ninety (90) to ninety-six (96) square inches (580.64 to 619.35 sq. cm), depending on the width of the lower box.
[0023] In FIG. 1 the right end flap front eyelet 4 and the right end flap rear eyelet 6 are spaced three (3) inches (7.62 cm) apart measured center to center and equidistant from an imaginary vertical center line of the right end flap 5 .
[0024] In FIG. 2 the left end flap front eyelet 10 and the left end flap rear eyelet 8 are spaced three (3) inches (7.62 cm) apart measured center to center and equidistant from an imaginary vertical center line of the left end flap 9 .
[0025] The eyelets accommodate cable ties 50 , 51 , 52 , and 53 , which are an existing product shown in FIG. 11 , and which attach the Ceiling Debris Collection Bin 2 to the Popcorn Ceiling Scraper 48 shown in FIG. 11 .
[0026] The right end cap 11 is shown in FIG. 3 and the left end cap 26 is shown in FIG. 4 . These end caps, 11 and 26 , are unique in that their attachment to a proper box transforms the box into the Ceiling Debris Collection Bin 2 shown in FIG. 1 .
[0027] The right center section 13 , seen from the inside in FIG. 3 , has two eyelets—the right front eyelet 12 and the right rear eyelet 14 . Eyelets 12 and 14 are positioned five-eighths (0.625) inches (1.59 cm) from the top of the center section 13 measured to the top rims of eyelets 12 and 14 .
[0028] The right front eyelet 12 and the right rear eyelet 14 are spaced three (3) inches (7.62 cm) apart measured center to center and equidistant from an imaginary vertical center line dividing the right center section 13 .
[0029] The right rear wing 15 is shaped like an isosceles triangle with the vertical leg 16 and opposing leg 17 having a length of four (4) inches (10.16 cm) each. The vertex angle 18 is thirty degrees (30°). The shape of the right rear wing 15 allows for a wider opening and greater collection area for debris scraped off the ceiling.
[0030] The right rear connector flap 19 is rectangular in shape and measures 1″×4″ (2.54 cm×10.16 cm) and facilitates, in conjunction with the other connector flaps, the assembly of the Ceiling Debris Collection Bin 2 ( FIG. 1 ) when unfolded, by means of appropriately placed two sided tape.
[0031] The right front connector flap 20 and right front wing 21 have the mirror image configuration as the right rear connector flap 19 and right rear wing 15 , respectively. The right front connector flap 20 is rectangular in shape and measures 1″×4″ (2.54 cm×10.16 cm). The right front wing 21 is shaped like an isosceles triangle with the vertical leg 23 and opposing leg 24 having a length of four (4) inches (10.16 cm) each. The vertex angle 25 is thirty degrees) (30°). The shape of the right front wing 21 allows for a wider opening and greater collection area for debris scraped off the ceiling.
[0032] An additional part is the right foam rubber wedge 22 that is glued to the inner surface of the right front wing 21 . The right front wing 21 is creased down the middle to the center of the vertex angle 25 to allow the wing to collapse when it comes in contact with the wall where the ceiling meets the wall. The right foam rubber wedge 22 assists the right front wing 21 to rebound back into shape.
[0033] The left end cap 26 is shown in FIG. 4 . The left center section 28 has two eyelets—the left front eyelet 27 and the left rear eyelet 29 . These eyelets 27 and 29 are positioned 0.625 inches (1.59 cm) from the top of the left center section 28 measured down to the top of the eyelets. The left front eyelet 27 and the left rear eyelet 29 are spaced three inches apart center to center and are equidistant from an imaginary vertical center line dividing the left center section 28 .
[0034] The left rear wing 30 is shaped like an isosceles triangle with the vertical leg 31 and opposing leg 32 having a length of four (4) inches (10.16 cm). The vertex angle 33 is thirty degrees (30°). The shape of the left rear wing 30 allows for a wider opening and greater collection area for debris scraped off the ceiling.
[0035] The left rear connector flap is a rectangle measuring 1″×4″ (2.54 cm×10.16 cm) and helps to facilitate the connection of the left end cap 26 to the rear side flap 7 shown in FIG. 1 .
[0036] The left front connector flap 35 and left front wing 36 have the mirror image configuration as the left rear connector flap 34 and left rear wing 30 , respectively. The left front connector flap 35 is a shaped like a rectangle measuring 1″×4″ (2.54 cm×10.16 cm). The left front wing 36 is shaped like an isosceles triangle with the vertical leg 38 and opposing leg 39 having a length of four (4) inches (10.16 cm). The vertex angle 40 is thirty degrees (30°). The shape of the left front wing 36 creates a wider opening and greater collection area for debris scraped off the ceiling.
[0037] An additional part is the left foam rubber wedge 37 that is glued to the inner surface of the left front wing 36 . The left front wing 36 is creased down the middle to the center of the vertex angle 40 to allow the wing to collapse when it comes in contact with the wall where it meets the ceiling. The left foam rubber wedge 37 assists the left front wing 36 to rebound back into shape.
[0038] FIG. 5 shows the right end cap 11 being lined up for attachment to the outside of the right end flap 5 of the box. Eyelets 12 and 14 of the right center section 13 are lined up with eyelets 4 and 6 , respectively, of the right end flap 5 . The two parts are then glued together with proper adhesive for gluing cardboard. The left side is assembled in the same fashion. Once the end caps are attached to the end flaps, the eyelets may be reinforced with either metal or plastic eyelets which will accommodate the cable tie width of 0.10 inch (0.254 cm). This is simply an option.
[0039] FIG. 6 shows the right foam rubber wedge 22 prior to attachment to the right front wing 21 as seen in FIG. 3 . The right foam rubber wedge 22 is shaped like an isosceles triangle with the two legs (opposing sides) having a length of four (4) inches (10.16 cm) and a vertex angle 41 of thirty degrees (30°).
[0040] FIG. 7 is a side view of the right foam rubber wedge 22 . The top portion is cut to an angle 42 of thirty degrees (30°) resulting in a downward slope of the top surface 43 of sixty degrees (60°). This slope facilitates the collection of additional ceiling debris by directing the debris down into the Ceiling Debris Collection Bin 2 seen in FIG. 2 . The left side foam rubber wedge is the same cut.
[0041] A market ready Ceiling Debris Collection Bin 2 is seen in FIG. 8 . This packs flat and simply needs to be folded out, closure flaps 44 , 45 , 46 , and 47 ( 46 and 47 are obscured from view) folded over and secured with two sided tape already affixed at the factory. A recommended tape is 3M Double Sided Extended Liner Tape or one of similar quality.
[0042] FIG. 9 shows the right rear connector flap 19 prior to connection with the right side of the rear side flap 7 . This connection is accomplished by the use of two sided tape of the kind previously described. The right rear connector flap 19 is simply folded over onto the rear side flap 7 and connected. Another option is to have the connector flaps fold inside of the front and rear side flaps. This would increase the collection opening by about three (3) square inches (19.35 sq. cm).
[0043] FIG. 10 shows the entire Ceiling Debris Collection Bin 2 prior to connection to the Popcorn Ceiling Scraper 48 , an existing product in the marketplace—U.S. Pat. No. 6,101,663, dated Aug. 15, 2000. The joining of the two products is illustrated in FIG. 11 . This is accomplished by the use of four cable ties 50 , 51 , 52 , and 53 , another product already on the market and in wide use. It is recommended to use cable ties with a length of four (4) inches (10.16 cm) and a width of 0.10 inch (0.254 cm) with test strength of 18 lbs. (8.16 Kg). These ties run through the eyelets and are secured to the flexible metal band part 49 of the Popcorn Ceiling Scraper 48 .
[0044] FIG. 12 illustrates the entire apparatus scraping a ceiling. Note how the right front wing 22 collapses to accommodate travel of the Ceiling Popcorn Scraper 48 to the ceiling's edge where it meets the wall.
[0045] The following inside dimensions are recommended for the lower box section of the Ceiling Debris Collection Bin:
Length of lower box section: 12″ (30.48 cm) Height of lower box section: 4″-5″ (10.16-12.7 cm) Width of lower box section: 3.5″-4″ (8.89-10.16 cm) Length of front and rear side flaps: 12″ (30.48 cm) Height of front and rear side flaps: 4″ (10.16 cm) Length of left and right side flaps: 3.5″-4″ (8.89-10.16 cm) Height of left and right side flaps: 4″ (10.16 cm) Length of front and rear closure flaps: 12″ (30.48 cm)
[0054] Height of front and rear closure flaps: 3.5″-4″ (8.89-10.16 cm)
[0055] Length of right and left side closure flaps: 3.5″-4″ (8.89-10.16 cm)
[0056] Height of right and left side closure flaps: 4″ (10.16 cm) The following dimensions are recommended for the end caps:
[0057] Center section length: 3.5″-4″ (8.89-10.16 cm) Center section height: 4″ (10.16 cm)
[0058] All wings (front and rear, left and right) are shaped like isosceles triangles with the two legs 4″ (10.16 cm) each, the vertex angle 30° and the corresponding base 2.07″ (5.26 cm).
[0059] All connector flaps (front left and right and rear left and right) are shaped as rectangles with dimensions of 1″×4″ (2.54 cm×10.16 cm).
[0060] The foam rubber wedges are shaped like isosceles triangles with the two legs 4″ (10.16 cm) each, the vertex angle 30° and the corresponding base 2.07″ (5.26 cm), which dimensions conform to the left and right front wings. The recommended thickness of the foam rubber is 0.5″ (1.27 cm), but this could vary. The top of the foam rubber wedge is cut to form a 60° slope down into the bin. The suggested material for these wedges is an open cell foam such as Charcoal Firm Foam, with a density of 1.7 lb./cubic ft., or WesLastomer™ Grade 5500 Soft Open Cell Sponge, with an average density of 7.33 lb./cubic ft. or some similar product.
[0061] The eyelets are placed 0.625″ (1.59 cm) below the top of the center section measured to the top of the eyelets. They are centered and spaced 3″ (7.62 cm) apart measured center to center. The eyelets have a minimum diameter of 0.125″ (0.32 cm). A second embodiment of the Ceiling Debris Collection Bin would not have the flexible front wings and therefore no foam wedges, but would otherwise be the same in all other aspects as the first embodiment. Removal of the ceiling texture material next to the wall would then be accomplished with a putty knife, which is required for the corners anyway.
[0062] There may slight variations in the dimensions and materials due to manufacturing requirements and processes which would not alter the basic design or function of the Ceiling Debris Collection Bin. For example, the connector flaps illustrated in the drawings are shown connecting to the outside of the front and rear side flaps. A second option would be for these connector flaps to connect to the inside of the front and rear side flaps adding about three (3) square inches (19.35 sq. cm) to the collection opening.
[0063] The eyelets may also be reinforced with either metal or plastic eyelets which will accommodate the cable tie width of 0.10 inch (0.254 cm). This is an option and not a requirement.
|
The Ceiling Debris Collection Bin is a receptacle with a wide opening that facilitates the nearly complete collection of acoustic ceiling debris removed by the Popcorn Ceiling Scraper—U.S. Pat. No. 6,101,663. The makers this Scraper recommend use of a plastic trash bag for collection of debris but a trash bag is not efficient enough, being limited to an opening defined by the scraper's flexible band. The new Ceiling Debris Collection Bin is very efficient owing to the flared side design. Debris that flies all over and might escape collection by a trash bag would be captured by this uniquely designed Ceiling Debris Collection Bin with nearly three times the collection area. The collapsible wings of the bin accommodate the flexible metal band of the Popcorn Ceiling Scraper, so that the Scraper can be pushed up to where the ceiling meets the wall.
| 0
|
CROSS REFERENCE TO RELATED PATENT APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 14/480,164 filed Sep. 8, 2014 which in turn is a continuation of U.S. patent Ser. No. 8,873,215 issued Oct. 28, 2014, which in turn is a continuation-in-part of U.S. Pat. No. 8,564,924 issued Oct. 22, 2013, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/105,110 filed Oct. 14, 2008 and U.S. Provisional Patent Application Ser. No. 61/221,763 filed Jun. 30, 2009, the contents of which are incorporated in full by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of air treatment, and more particularly to the treatment of air using ionization, including bipolar ionization.
BACKGROUND OF THE INVENTION
[0003] Air and other fluids are commonly treated and delivered for a variety of applications. For example, in heating, ventilation and air-conditioning (HVAC) applications, air may be heated, cooled, humidified, dehumidified, filtered or otherwise treated for delivery into residential, commercial or other spaces.
[0004] Needs exist for improved systems and methods for mounting ion generator devices for treating and delivering air for these and other applications. It is to the provision of improved mounting devices for systems and methods meeting these needs that the present invention is primarily directed.
BRIEF SUMMARY OF THE INVENTION
[0005] According to an embodiment of the present invention, an ion generator mounting device includes a housing having base, a first and second pair of spaced-apart, opposed sidewalls projecting from the base to collectively form an interior storage compartment and to define an upper edge, a top portion, at least one opening within the housing and a retention means extending outwardly from the housing.
[0006] According to another embodiment of the present invention, an ion generator mounting device includes an ion generator disposed within the interior storage compartment.
[0007] According to yet another embodiment of the present invention, an ion generator mounting device includes an ion generator containing at least one electrode for dispersing ions from the bipolar ionization generator that is disposed within the interior storage compartment, whereby at least one electrode is disposed adjacent that at least one opening.
[0008] According to yet another embodiment of the present invention, an ion generator mounting device includes a power supply.
[0009] According to yet another embodiment of the present invention, an ion generator mounting device includes a switch.
[0010] According to yet another embodiment of the present invention, an ion generator mounting device includes a retention means disposed on one of the sidewalls and extending therefrom.
[0011] According to yet another embodiment of the present invention, an ion generator mounting device includes an LED disposed on the housing.
[0012] According to yet another embodiment of the present invention, an ion generator mounting device includes an elongate arm that includes a first side and a second side, whereby the first side contains at least one opening and an ion generator with at least one electrode that is disposed adjacent the second side of the arm, such that the at least one electrode is disposed adjacent the at least one opening.
[0013] According to yet another embodiment of the present invention, an ion generator mounting device includes an elongate arm with a top side and a bottom side.
[0014] According to yet another embodiment of the present invention, an ion generator mounting device includes mountings that engage an ion generator to the arm.
[0015] According to yet another embodiment of the present invention, an ion generator mounting device includes electrodes of the ion generator that are axially aligned with the arm.
[0016] According to yet another embodiment of the present invention, an ion generator mounting device includes electrical contacts disposed within the arm.
[0017] According to yet another embodiment of the present invention, an ion generator mounting device includes a housing that includes a base, a first and second pair of spaced-apart, opposed sidewalls projecting from the base to collectively form an interior storage compartment and to define an upper edge, a top portion, and a securing means for selectively securing the top portion to the base.
[0018] According to yet another embodiment of the present invention, an ion generator mounting device for application of ionization to an airflow within a conduit, the device includes a housing for mounting to the conduit having an internal panel within the enclosure, an arm extending from the housing for extension into the conduit and containing at least one opening, and at least one coupling for mounting an ion generator to the arm oriented with an axis extending between a pair of electrodes of the ion generator being generally perpendicular to a flow direction of the airflow within the conduit.
[0019] According to yet another embodiment of the present invention, an ion generator mounting device includes a coupling that comprises electrical contacts on the arm for delivering power to the at least one ion generator.
[0020] According to yet another embodiment of the present invention, an ion generator mounting device includes at least one terminal block for wiring connection to the ion generators via contacts on the arm.
[0021] According to yet another embodiment of the present invention, an ion generator mounting device includes a power converter for converting input power to operate the ion generators.
[0022] According to yet another embodiment of the present invention, an ion generator mounting device that includes at least one electrode that is recessed within an opening on the arm and below the horizontal plane of the external surface of the arm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The present invention is illustrated and described herein with reference to the various drawings, in which like reference numbers denote like method steps and/or system components, respectively, and in which:
[0024] FIG. 1A is a perspective view of an embodiment of the present invention;
[0025] FIG. 1B is a perspective view of an alternative embodiment of the present invention;
[0026] FIG. 2 is a perspective view of an arm of the present invention;
[0027] FIG. 3 is a perspective view of an alternative embodiment of the present invention; and
[0028] FIG. 4 is another perspective view of an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The present invention may be understood more readily by reference to the following detailed description of the invention taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.
[0030] Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.
[0031] The present invention includes a number of ion generator carrier and mounting assemblies for application and control of delivery of ionization to an airflow, including bipolar ionization.
[0032] FIGS. 1 a and 1 b show an exemplary embodiment of an assembly 200 for mounting to the exterior of a duct, housing, or other conduit for airflow. The assembly includes a housing 210 or other enclosure, such as for example a NEMA 4x enclosure or similar configuration, an internal panel 212 within the housing 210 , and an external arm 214 projecting from the back side of the housing. The external arm 214 includes mountings 248 and electrical contacts 250 for receiving one or more ion generators 240 for delivery of bipolar ionization to airflow within a conduit. Alternatively, the arm 214 may be disposed adjacent a cooling coil. Such ion generator 240 can include the Sterionizer device that may be purchased from Filt-Air, a Beth-El Group, Israel, and includes a pair of electrodes that disperse ions. The mountings 148 securely engage the ion generator 240 or ion generators 240 and maintain them in an orientation having their electrodes axially aligned with the arm 214 and generally perpendicular to the airflow. The panel 212 optionally comprises one or more pluggable terminal blocks for wiring connection to the ion generators 240 via the contacts 250 on the arm 214 , a connection for power input, and one or more indicators such as LEDs 242 to indicate the presence/absence and operational state (on/off, ion output, etc.) of the ion generators 240 . Optionally, a power converter or transformer is provided in the housing 210 for converting the input power to the power required to operate the ion generators 240 . One or more connectors are optionally provided for mounting the housing 210 to the exterior of a duct or housing, with the arm 214 extending into the duct or housing through an opening formed therein. Sealing means such as a gasket are optionally provided on the back of the housing 210 around the arm 214 for sealing around the opening.
[0033] FIGS. 2 , 3 and 4 show a device 200 according to an alternate embodiment, having a housing 210 with an arm 214 extending therefrom. The length of the arm 214 may vary depending on the size of the conduit it is to be applied to and the number of ion generators to be installed, and in example embodiments is between 2″-24″, for example about 10″ in length.
[0034] The arm 214 is generally elongate and extends outwardly from the housing 210 and has a top side, a bottom side, a first side, and a second side. The arm 214 contains at least one opening 244 contained therein in. The arm 214 includes mountings 248 and electrical contacts 250 for receiving one or more ion generators 240 for delivery of ionization to an airflow within the conduit. Such ion generator can include the Sterionizer device that may be purchased from Filt-Air, a Beth-El Group, Israel, and includes a pair of electrodes that disperse ions. The mountings 248 securely engage the ion generators 240 and maintain them in an orientation having their electrodes axially aligned with the arm 214 and generally perpendicular to the airflow. The panel 212 optionally comprises one or more pluggable terminal blocks for wiring connection to the ion generators 220 via the contacts on the arm 214 , a connection for power input, and one or more indicators such as LEDs 242 to indicate the presence/absence and operational state (on/off, ion output, etc.) of the ion generators 220 . Optionally, a power converter or transformer is provided in the housing 210 for converting the input power to the power required to operate the ion generators 240 . One or more connectors are optionally provided for mounting the housing 210 to the exterior of a duct or housing, with the arm 214 extending into the duct or housing through an opening formed therein. Sealing means such as a gasket are optionally provided on the back of the housing 210 around the arm 214 for sealing around the opening.
[0035] The electrodes of the ion generators 240 are placed in close proximity to the opening 220 on the arm 214 , thus allowing the ions to disperse through the arm 214 . As illustrated in FIG. 5 , the electrodes are recessed within the arm 214 . In other words, the electrodes of the ion generators 240 do not break the horizontal plane of the external of the top side of the arm 214 and are located equal to or beneath the horizontal plane of the arm 214 for allowing the ions to disperse through the openings 244 in the arm 214 .
[0036] As illustrated in FIGS. 2 , 3 , and 4 , the arm 214 contains two openings 244 for each ion generator 220 . In another alternative embodiment, the electrodes of the ion generator 220 may protrude through the openings 244 and extend above the horizontal plane of the arm 214 . The housing 210 includes a base 212 that extends to an outer edge. First and second pairs of opposed sidewalls 214 , 216 extend from the outer edge of the base 212 to an upper edge 218 . The sidewalls 214 , 216 each have an inner and outer sidewall surfaces 220 , 222 . As shown in FIGS. 6 and 7 , each of the second pair of sidewalls 216 interconnects the first pair of sidewalls 214 to define corners 224 and an interior storage compartment 226 . At least one retention member 228 extends from a first or second sidewall 214 , 216 or the base 212 . A top portion 230 may be selectively secured to the base 212 . As illustrated, the top portion 230 is hingedly connected to the base 212 and includes a latch 246 for selectively securing the top portion 230 to the base 212 .
[0037] Although the present invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention and are intended to be covered by the following claims.
|
The present invention provides methods and systems for an ion generator mounting device for application of bipolar ionization to airflow within a conduit, the device includes a housing for mounting to the conduit having an internal panel within the enclosure, and an arm extending from the housing for extension into the conduit and containing at least one opening. At least one coupling for mounting an ion generator to the arm oriented with an axis extending between a pair of electrodes of the ion generator being generally perpendicular to a flow direction of the airflow within the conduit.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for varying the compression ratio of an internal combustion engine and a method for using such a device and in particular relates to a device that can change the compression ratio of this engine by modifying the dead volume of the combustion chamber at the piston top dead center.
2. Description of the Prior Art
EP Patent 0,297,904 discloses a device for varying the compression ratio of an engine wherein the engine includes a crankshaft, a cylinder in which a piston slides in an alternating translational movement by means of a connecting rod connected to the piston and to the crankshaft. The piston defines with the top of the cylinder a combustion chamber including a dead volume at the top dead center (TDC). A rotary eccentric, of the pull type, is disposed between the connecting rod and the piston. The eccentric, in a first position, enables the piston to reduce the dead volume of the combustion chamber while increasing the compression ratio and increases this dead volume in the second position to achieve a lower compression ratio. The eccentric has a groove which cooperates with two locking pins each disposed symmetrically relative to the piston axis enabling the eccentric to be immobilized in one or other of the two positions.
This device, although satisfactory, nonetheless has a number of drawbacks.
One of the drawbacks of such a device resides essentially in the lack of flexibility in the options for adjusting the compression ratio, with only two options for varying the ratio.
Moreover, such a device requires a precise fit between the groove and the pin to prevent any locking of the pin in the groove.
In another type of device for varying the compression ratio, described in German Patent DE-A-42 26 361, the eccentric (which is not a pull type eccentric) is an eccentric driven by the cooperation of a toothed sector of the eccentric with an endless screw.
This device has a major drawback in that the endless screw must be driven to control the rotation of this eccentric. This drive takes up a great deal of space and requires high power levels to overcome the inertia of the moving parts and the various frictions.
SUMMARY OF THE INVENTION
The present invention overcomes the above drawbacks of the prior art by providing a device for varying the compression ratio that is simple in design, takes up little space, and increases the options for varying the compression ratio.
The present invention relates to a device for varying the compression ratio of an internal combustion engine having at least one cylinder with a combustion chamber, moving parts comprising a piston translationally movable under the action of a connecting rod that is connected by a shaft to the piston and is connected to a crankpin of a crankshaft. The piston travels between a top dead center and a bottom dead center leaving a dead volume at the top dead center of the piston. The device having a rotary pull type eccentric for varying the compression ratio and means for controlling the movement of the eccentric is utilized wherein characterized a control including a hydraulic cylinder comprising a slide placed in a recess formed in a support and defining two fluid chambers in communication with at least one closed circuit.
The fluid chambers can be in communication with each other via at least one closed circuit.
The closed circuit can include at least one valve means for controlling the flowrate of fluid from one chamber to the other.
Advantageously, the valve means can be at least a two-way valve.
Preferably, the valve means can be a piezoelectric device.
The piezoelectric device can include a needle valve and a piezoelectric actuator.
The piezoelectric device can be controlled by cooperation of contacts and electrical segments.
The circuit can include at least one metering device located downstream of the valve means.
The metering device can include a piston-cylinder assembly with a calibrating spring.
The elements of the closed circuit can be at least partly accommodated in a hydraulic cylinder.
A varying device can include means for pinpointing the position of the eccentric.
The pinpointing means can comprise a signal transmitter-receiver assembly.
The eccentric, which can include the transmitter and the receiver, can be accommodated in a fixed part of the engine.
The eccentric can include means for shape cooperation with the slide.
The cooperation means can include a toothed sector mounted on the eccentric and a toothed rack mounted on the slide.
The invention also relates to a method for varying the compression ratio of an internal combustion engine, wherein the engine includes at least one cylinder with a combustion chamber, moving parts comprising a piston translationally movable under the action of a connecting rod that is connected by a shaft to the piston and connected to a crankpin of a crankshaft, the piston travelling between a top dead center and a bottom dead center to provide a dead volume at the top dead center of the piston, comprising the method of:
determining the desired compression ratio of the engine;
determining an extent of displacement of a rotary pull type eccentric to obtain the desired compression ratio;
controlling the rotation of the eccentric to obtain the determined displacement by controlling a hydraulic cylinder to command the displacement of the eccentric.
One advantage of the present invention over the prior art devices is that the energy loss of a bearing between the connecting rod and the crankpin of the crankshaft is less. Indeed, when the compression ratio does not vary, the position of the eccentric relative to the connecting rod is fixed and the bearing between the connecting rod and the crankpin is accomplished by the relative displacement between the eccentric and the crankpin. Hence, the bearing between the connecting rod and the crankshaft is accomplished with a smaller bearing diameter, which is a non-trivial advantage since, as is known, the energy loss of a bearing, for a given load under normal operating conditions, increases as a function of its diameter.
Another advantage of the present invention is easier control of compression ratio adjustment. The present invention uses a reversible kinematic link that continuously connects the range of motion of the eccentric to translation of the slide. Hence, the angular lead of the eccentric, and hence the compression rate adjustment, is a continuous function of the translational position of the slide defined by the mechanical design of the device according to the invention. Hence, at no time can the compression ratio vary without the translational position of the slide being modified and, because of the hydraulic device of the present invention, positional control of the slide is easily achieved.
Other additional advantages of the present invention are lower energy loss, greater precision, and longer lifetime. The present invention uses a reversible kinematic link that continuously connects the range of motion of the eccentric to translation of the slide. Because of the reversibility of the kinematic link, the friction in this link can be minimized by the design. Hence, the energy loss through friction in the link, the wear in the link, and the degree of hysteresis can all be less. Moreover, the reduction in hysteresis leads to better accuracy in adjusting the compression ratio. Furthermore, due to its reversibility, the kinematic link of the present invention has no risk of jamming. This reversibility can be achieved due to a toothed segment, preferably placed in the peripheral wall of the eccentric, which, through an opening in the connecting rod head, cooperates with a toothed rack, of the rack and pinion type, provided in a slide that moves in a recess in a support connected to the connecting rod head. This slide moves tangentially to the circumference of the eccentric.
Yet another advantage of the present invention resides in the greater simplicity of integrating the device into the engine and into its environment. The present invention uses an eccentric accommodated between the crankpin and the bore of the connecting rod head. Hence, the distance between the crankshaft axis and the various peripherals of the engine—camshaft, starter, alternator, water pump, etc.—does not vary and hence does not lead to additional specific devices to offset the variations in distance between the crankshaft and the engine peripherals. Likewise, the alignment between the crankshaft and the transmission does not change. Because of the present invention, it is not necessary to use specific device to offset changes in alignment between the engine and the transmission to which it is coupled.
Moreover, the device according to the invention leads to lower weight and a smaller space requirement and greater reactivity in adjusting the compression ratio. Because the eccentric is pulled, adjustment of the compression ratio requires no eccentric drive motor and the device is hence not encumbered by the weight, space requirement, and response times of a specific motor and its kinematic links to drive the eccentric rotationally in order to adjust the compression ratio.
Moreover, the invention has still other advantages such as compatibility with a shorter distance between the crankshaft axis and the engine cylinder head, less vibration, and less construction cost. The hydraulic piston, whose function is to control the position of the eccentric located between the connecting rod head and the crankpin, is distinct from the eccentric; in particular, its slide is distinct from all the other parts and can move independently of all these other parts. Because of this, a wide choice in the orientation of the piston with respect to the connecting rod is possible, which simultaneously optimizes the distance between the crankshaft axis and the cylinder head as well as vibrations brought about by the moving parts and also the shapes to reduce manufacturing costs.
BRIEF DESCRIPTION OF THE DRAWINGS
The other features and advantages of the invention will appear from reading the description hereinbelow, provided solely for illustration and non-limiting, to which are attached:
FIG. 1 shows, in axial section, an internal combustion engine with the invention for varying the compression ratio in a first position;
FIG. 2 shows in axial section, another view of the internal combustion engine with the invention of FIG. 1 in another position and in another configuration;
FIG. 3 shows a detailed view in an end position of the invention in FIG. 1 ;
FIG. 4 shows a schematic drawing of the control circuit used for the device according to the invention;
FIG. 5 shows a detailed view of the invention showing the elements of the control circuit of the invention;
FIG. 6 a shows another detailed view of the invention showing one variant of the elements of the control circuit of the invention, while FIGS. 6 b to 6 d illustrate the various positions of the invention during the rotation of the crankshaft; and
FIGS. 7 a to 7 d show another illustration of the invention for locating the angular position of one of the elements of the device for varying the compression ratio according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made to FIGS. 1 to 3 which show an internal combustion engine with at least one cylinder 10 that includes a bore 12 inside which slides a hollow piston 14 in an alternating translational movement driven by a connecting rod 16 . This piston, at its top part, limits the side wall of the bore 12 . At the top part of this bore, which is formed by part of the cylinder head 18 , the combustion cycle takes place in a combustion chamber. The piston has two diametrically opposed radial bores 22 through which passes a cylinder shaft 24 which connects one end 26 of the connecting rod, known as the connecting rod foot, to the piston, which slides through a bore 28 provided in the connecting rod foot. The other end 30 of the connecting rod, which is the connecting rod head, is connected by a device for varying the compression ratio 32 to a crankpin 34 of a crankshaft 36 . This crankshaft is subjected to a rotary movement about an axis XX such that the crankpin 34 describes a circular path 38 around axis XX. As is known, piston 14 , connecting shaft 24 , connecting rod 16 , and crankshaft 36 with its crankpin 34 form the moving parts of the engine.
In conventional engines, during the rotary movement of the crankshaft 36 such as the intake and expansion phases, crankpin 34 passes successively into a top position, indicated as 0° in FIG. 1 , to a bottom position, indicated 180°. During this movement, piston 14 , which is connected to crankpin 34 by connecting rod 16 , undergoes an alternating translational movement between an initial top dead center (marked TDCi in FIG. 1 ) which corresponds to the top position of the crankpin and an initial bottom dead center (marked BDCi) in FIG. 2 ) corresponding to the bottom position of the crankpin. Thus, piston 14 has an initial travel between its TDCi and its BDCi.
In these engines, when the piston is at the TDCi, either at the end of the compression phase or at the end of the exhaust phase, a dead volume remains in combustion chamber 20 . This volume is necessary for operation of the engine during its compression, combustion, and exhaust phases.
As a person skilled in the art is aware, the compression ratio of an engine is a function not only of the size of the cylinder volume defined by the piston stroke but also the size of the dead volume. To modify the compression ratio, it is needed to only modify one of these volumes, particularly the size of the dead volume.
To achieve this, the device for varying the compression ratio 32 has an eccentric 42 located between crankpin 34 and bore 44 provided in the connecting rod head 30 . This eccentric has a generally circular shape with a geometric axis X 1 X 1 that corresponds to its center axis and has a bore 46 with an axis X 2 X 2 that is non-coaxial with axis X 1 X 1 but is equated with the axis of crankpin 34 . This eccentric is slidably positioned in the reception bore 44 provided in the connecting rod head and in the peripheral wall of crankpin 34 .
This eccentric is described as “pulled” because, when the engine is operating, it can be driven rotationally about axis X 2 X 2 in response to a rotational torque generated by the inertia resulting from movement of the moving parts, particularly the piston and the cylinder.
In fact, crankpin 32 travels along a semi-circular path for one phase, for example the intake phase, from 0° to 180°, then another semi-circular path (from 180° to 0°) for another phase, such as the compression phase. During these movements, the piston 14 goes from its top dead center to its bottom dead center and then from its bottom dead center to its top dead center. During this movement, the piston and connecting rod 16 undergo acceleration which increases with decreasing distance to one of its dead centers. When the inertia force resulting from this acceleration, is sufficient to overcome not only the weight of piston 14 and of connecting rod 16 and/or the resultant force of the gas pressures on the piston and connecting rod but also the frictional forces between this piston and the wall of the cylinder bore, an increase in speed is generated of the piston-connecting-rod assembly relative to the speed transmitted to the assembly by the crankpin. Hence, if the range of motion of the eccentric is not impeded, there is additional movement of the piston and connecting rod relative to that brought about by the crankpin. This movement takes place upward when the piston is on the top dead center side and downward when this piston is on the bottom dead center side. This additional drive can be made possible by rotation, around axis X 2 X 2 , of the eccentric 42 connected to connecting rod 16 . As shown for example in FIGS. 1 to 3 , the eccentric has a rotational counterclockwise movement with a decrease in the compression ratio when the piston is traveling from its top dead center to its bottom dead center and a clockwise movement for an increase in the compression ratio when the piston is passing from its bottom dead center to its top dead center.
The eccentric has, preferably on its peripheral wall, a toothed sector 48 , with an angular sweep SD, which, through an opening 50 provided in connecting rod head 30 , cooperates with a toothed rack 52 , of the rack and pinion type, provided on a slide 54 movable in straight-line translation in a recess 56 in a support 58 connected to connecting rod head 30 . Preferably, this support is built into the lower semi-bearing 60 that the connecting rod head 30 normally has and which is attached by screws 62 to the other semi-bearing 64 on the connecting rod body. Slide 54 has a peripheral wall 66 with a cylindrical section on which are placed seals 68 in the vicinity of its terminal faces 70 which preferably have axial recesses 72 . The peripheral wall is interrupted by rack and pinion 52 which is substantially rectilinear and which extends over a major part of the length of this slide. The rack and pinion has a length that corresponds at least to the length of toothed sector 48 of eccentric 42 . Recess 56 matches in shape the cross section of slide 54 and has two end walls 74 . The distance between these two walls and the pitch of the toothed sector of the eccentric relative to the toothed rack of the slide are such that the total length of the slide, to which is added the total range of motion of this slide, under the effect of the eccentric rotating, enables the geometric axis X 1 X 1 of the slide to be located to the left of the cylinder shaft, as seen in the drawings, both at the top dead center and at the bottom dead center of the piston. Preferably, the angular range of motion of the eccentric is approximately 120° C. between its two end positions. To establish the initial pitch of the toothed sector when the device is assembled, the center point M 1 of the eccentric toothed sector is located half-way to point M 2 along the length of the rack and pinion so that the axis X 1 X 1 of the eccentric is at the same height as axis X 2 X 2 of the crankpin at the top dead center and the bottom dead center of the piston. Thus, from the nominal position, the eccentric rotates counterclockwise through an angle of approximately 60° to obtain a minimum compression ratio that can be the nominal ratio and, reaching the position in FIG. 3 and for a maximum ratio, rotates, still from this initial pitch position, through an angle of approximately 60° clockwise to arrive at the position in FIG. 1 . When the maximum ratio is reached, the eccentric rotates in the counterclockwise direction through an angle of approximately 120° to reach the minimum ratio and through about 120° clockwise to obtain a maximum ratio from its minimum ratio. The space defined by the peripheral wall of the recess, its end walls, and the end faces of the slide thus form two sealed fluid chambers, called 75 a and 85 b , that allow and control the movement of the slide in the recess. This forms a hydraulic cylinder 76 comprising support 58 with its recess 56 in which slide 54 moves in a straight-line motion under the effect of the fluid present in chambers 75 a , 75 b . Thus, the variation device has a slide and a slide support that are separate from the eccentric. The relative translational position of the slide, relative to its support, is in a continuous kinematic link with the angular range of motion of the eccentric relative to the connecting rod by a kinematically reversible link.
This recess is connected to a control circuit 77 , as shown in FIG. 4 , which controls the rotation of the eccentric by controlling the movement of the slide.
The control circuit includes at least one closed circuit in which a fluid, oil for example, circulates. In the example of FIG. 4 , the control circuit has two closed circuits 78 a and 78 b and each circuit connects the two chambers 75 a and 75 b . Chamber 75 a is connected by a line 80 a to a valve means 82 a and specifically to a three-way valve having one outlet connected to line 80 a and the other of the ways is connected to a tank 84 a by a line 86 a . The valve is controlled by a means 88 a whose activation depends on the demand for varying the compression ratio. A line 90 a then connects the outlet of valve 82 a to a metering device 92 a comprising a cylinder 94 a with a sealed piston 96 a , movable inside this cylinder, which defines two metering chambers 98 a and 100 a . Chamber 98 a is connected to line 90 a while chamber 100 a , which has a spring 102 a , is connected by a line 104 a to fluid chamber 75 b . Advantageously, lines 80 a and 104 a have non-return valves 106 a and 108 a preventing fluid from flowing back into chamber 75 a and from flowing out of chamber 75 b , respectively.
Additionally, the control circuit has means for filling and draining circuits 78 a and 78 b . These means include a hydraulic pump 110 , lines 112 a , 112 b each having a non-return valve and connected to lines 104 a , 104 b , drain valves 114 a and 114 b connected to lines 80 a and 80 b , and drain devices 116 a and 116 b located on metering devices 92 a and 92 b.
Thus, considering FIG. 4 , the leftward movement of slide 54 is controlled by the opening of valve 82 a which, via lines 80 a and 90 a , places fluid chamber 75 a in communication with metering chamber 98 a . Under the effect of the pressure generated in fluid chamber 75 a by the movement of the slide driven by the eccentric, piston 96 a is urged against spring 102 a in the direction of metering chamber 100 a and the fluid present in this chamber is introduced via line 104 a into fluid chamber 75 b . Thus, any reduction in the volume of one fluid chamber results in an increase in the volume of the other chamber. This spring is calibrated such that it gradually introduces fluid into chamber 98 a , preventing the slide from jerking. As soon as this slide reaches the desired position, valve 82 a is made to close by control 88 a to keep the slide in the position it has reached. When this action takes place, the communication between chambers 75 a and 98 a is closed, and evacuation of the fluid present in metering chamber 98 a , urged by spring 102 a , is allowed through lines 90 a and 86 a to tank 84 a.
The volume of the metering chamber 98 a is designed to correspond to a given displacement value of the slide, hereinafter called “increment,” and this increment can be used partially or fully when this slide moves. To adjust the compression ratio to the desired value, the volume of fluid coming from fluid chamber 75 a , when the slide moves, can be greater than this increment. In this case, the control 88 a brings about several opening and closing sequences of valve 82 a to sequentially fill and drain chamber 98 a , keeping the slide in the position reached then causing this valve to close as soon as the eccentric reaches the desired position.
Movement of slide 54 in the opposite direction, that is rightward, is controlled in the same way, but acting on the various elements of closed circuit 87 b.
Thus, to impose a clockwise or counterclockwise direction of movement on the eccentric, one or the other of the circuits will be operated.
Regarding the filling and draining of circuits 78 a , 78 b , hydraulic pump 110 fills, through lines 112 a , 112 b , the metering chambers 100 a , 100 b and lines 104 a , 104 b . Through these lines, fluid chambers 75 a , 75 b are also filled, as are lines 80 a , 80 b , by means of which metering chambers 98 a , 98 b are also filled. During this filling procedure, the drain valves 114 a , 114 b as well as drains 116 a , 116 b are opened to evacuate any air present in the circuits. Of course, as is usual, the pump and lines 112 a , 112 b will be used to make up for any fluid losses while the device is operating.
In practice, as can be seen more clearly in FIG. 5 , the various lines, metering devices, drain valves, drains, and non-return valves are accommodated in support 58 .
Since these various elements are placed in several parallel planes transversal to the crankshaft axis, only some of these elements have been shown, to keep the drawing simple. It can thus be seen that the introduction of fluid for filling the circuits is done through axial and radial bores 120 in the crankshaft and crankpin, via a circumferential groove 122 , between the bore of the eccentric 42 and the peripheral wall of crankpin 34 , for communication with bores 120 , and via radial bores 124 providing the communication between groove 122 and line 112 (or line 112 b ) provided in support 58 . This support also has control valves 82 a and 82 b , metering devices 92 a and 92 b , non-return valves 106 and 108 (or 108 a ), drain valves 114 (or 114 a ), and lines 80 , 90 , 104 (or 104 a ) providing communication between these elements.
In operation, the device that varies the compression ratio is in a given configuration, as shown in FIG. 3 , which corresponds, for example, to a minimum compression ratio, which can be the nominal ratio, and piston 14 is at its bottom dead center (BDCv) as illustrated in FIG. 2 . In this configuration, the BDCi is the same as the BDCv and piston 14 travels from this bottom dead center to its top dead center to accomplish the compression phase of the air or air-fuel mixture present in the combustion chamber, as shown in FIG. 1 . During this travel, as illustrated in FIGS. 1 to 3 , crankpin 34 travels on a semi-circular path from its bottom point) (180°) to its top point (0°). During this movement, the piston 14 , connecting rod 16 , and eccentric 42 first undergo maximum acceleration to the bottom dead center which decreases when the piston and connecting rod move, then goes to zero. The piston and this connecting rod then undergo a deceleration which increases as piston 14 approaches its top dead center. When the resultant force of this deceleration is sufficient to overcome the resultant force of the gas pressures applied to the piston, the weight of piston 14 and of connecting rod 16 , and the various frictional forces, driving of the piston and the connecting rod is generated by this inertial force in an upward movement (as seen in the drawings). This movement is accomplished all the more easily in that the inertial and frictional forces and the resultant force of the gas pressures are all directed upward. These conjugated forces are applied to axis X 1 X 1 and create a torque which tends to rotate the eccentric around axis X 2 X 2 clockwise in the slide position illustrated in FIG. 3 .
Thus, depending on the engine operating parameters such as engine load and speed, a compression ratio is determined to respond to the demand. This compression ratio is determined by a control unit, for example the computer that the engine normally has, and this computer determines a range of motion angle for the eccentric to achieve this ratio. With reference once more to FIG. 4 , in the case the compression ratio is increased, control instructions are sent by the computer to control 88 a of three-way valve 82 a to place in communication, during a number of sequences corresponding to an increment number and/or part of an increment of slide movement, and a duration determined by the computer, the fluid chamber 75 a with the metering device 92 a to allow movement of the slide by transfer of fluid from one fluid chamber 75 a to the other fluid chamber 75 b via this metering device. Under the effect of rotation by the eccentric and cooperation of the toothed sector 48 of the eccentric with the rack and pinion 52 of the slide, this slide moves leftward to increase the compression ratio. Thus, by precisely and continuously controlling the amount of fluid leaving the fluid chamber by causing the valve to open and close, it is possible to control the movement of the slide so that the eccentric moves rotationally according to the angular range of motion determined by the computer. At the end of the activation of valve 82 a and the time for which this valve is open, the latter remains closed, isolating chamber 75 a from chamber 75 b , and the slide is immobilized in position by means of the fluid isolated in these chambers. In this configuration, the eccentric has traveled for the angular range of motion determined by the computer. Upon closure of valve 82 a , the fluid present in chamber 98 a of the metering device 92 a is evacuated to tank 84 a by lines 90 a , 86 a and piston 96 a of this metering device is back in the original state, that is close to line 90 a.
Under the influence of this angular range of motion, clockwise according to FIG. 3 , piston 14 performs an overtravel S relative to its TDCi and arrives at the position illustrated in FIG. 1 . In this position, the center to center distance between the shaft 24 of piston 14 and the shaft of the crankpin has increased, and piston 14 has prolonged its initial travel by passing beyond the TDCi and penetrating into the initial dead volume 40 . In this position, this initial dead volume is decreased and a new dead volume 118 is created in cylinder 12 . Since this new dead volume is smaller than the initial dead volume, the compression ratio of the engine is increased.
This configuration of the device is retained for as long as this modified ratio is desired.
Since the rotation of the eccentric is continuously controlled by means of controlled movement of the slide by circuits 78 a and 78 b , it is possible to vary the value of overtravel S from TDCi to TDCv, and hence the magnitude of the dead volume.
Thus, because of controlled movement of the slide, which movement is a function of the response time and number of openings and closings of valve 82 a , it is possible to increase this displacement and obtain a multitude of compression ratio options by a plurality of angular positions of the eccentric.
As soon as the computer determines a new angular range of motion of the eccentric which, for the example described below, corresponds to a new compression ratio lower than that reached (and this new ratio can be the initial compression ratio for which the initial dead volume is found or a ratio lower than that obtained in a previous phase of increasing this ratio), the computer sends instructions to control 88 b of valve 82 b of circuit 78 b so that the eccentric 42 is in the position illustrated in FIG. 3 or in a position close to that of this drawing to decrease the compression ratio obtained in a prior phase.
To accomplish this, an operating phase of the engine during which crankpin 34 passes from its 0° position to 180°, is used as the intake or expansion phase.
During this phase, the forces described above are applied to the crankpin but in the opposite direction. This has the effect of applying a force to axis X 1 X 1 that tends to rotate the eccentric around axis X 2 X 2 counterclockwise.
To allow this rotation of the eccentric one need only allow controlled movement of the slide in its recess. To do this, with reference to FIG. 4 , the opening/closing command for a specific duration of three-way valve 82 b allows the fluid chamber 75 b to be placed in communication with the metering device 92 b so as to allow this slide movement, while controlling the transfer of the amounts of fluid dispensed by metering device 92 b from one fluid chamber 75 b to the other fluid chamber 75 a . Under the effect of rotation of the eccentric generated by the inertial force and cooperation of toothed sector 48 of the eccentric with the toothed rack 52 of the slide, the slide moves rightward to arrive at the position illustrated in FIG. 3 .
Also, this movement of the slide is continuously controlled by acting on valve 82 b , allowing a plurality of angular positions of the eccentric to be obtained during its counterclockwise movement and hence a plurality of options for decreasing the overtravel of the piston, which has the effect of obtaining a plurality of options for increasing the dead volume 118 up to the initial dead volume 40 .
Thus, because of this compression ratio varying device, it is possible not only to obtain a plurality of options for increasing the compression ratio but also a plurality of options for decreasing this ratio from a ratio that has undergone an increase.
Reference will now be made to FIG. 6 a which shows an alternative embodiment of the invention.
This embodiment differs from the embodiment described above only by the fact that each three-way valve is replaced by two piezoelectric devices 126 (or 126 b ) that enable the response time to be increased and consequently the compression ratio adjustment accuracy to be enhanced. Each of the devices has a needle valve 128 subjected to the action of a piezoelectric activator 130 and constitutes a two-way valve. One of these piezoelectric devices controls the passage of fluid between line 80 (or 80 b ) and line 90 (or 90 b ) and the other of the piezoelectric devices controls the passage of fluid between line 90 (or 90 b ) and line 86 . Thus, each three-way valve 82 a , 82 b of the circuit shown in FIG. 4 is replaced by two two-way valves each formed by a piezoelectric device.
To control the piezoelectric actuator which acts on the range of motion of the needle valve, support 58 has two electrical contacts 132 connected by electrical conductors (not shown) to this actuator. Electrical segments 134 are mounted on a fixed element of the engine, such as the engine crankcase, and are disposed such that they are continuously opposite contacts 132 at least for one movement of the crankpin from its 0° point to its 180° point as illustrated in FIGS. 6 a to 6 d . Of course, and without departing from the framework of the invention, these segments can extend over the entire 360° rotation of the crankpin. These segments pass an electric current creating a magnetic field which creates an electric current in contacts 132 to actuate them. Advantageously, one electrical segment 134 is assigned to control each of the piezoelectric devices and a fifth segment controls the four piezoelectric actuators 130 in common.
The operation of the compression ratio varying device 32 and circuits 78 a , 78 b is the same as that described in relation to FIGS. 1 to 5 with the following differences: the fluid passage link between fluid chamber 75 a , 75 b and metering chamber 98 a , 98 b is provided by a first two-way valve composed of a piezoelectric device, the fluid passage link between the metering chamber 98 a , 98 b and tank 84 a , 84 b is provided by another two-way valve comprised of a piezoelectric device, and an electrical current is sent to segments 134 to control the opening of the needle valve 128 in response to a demand to vary the compression ratio.
The embodiments of the control of the variation device described thus far call for the use of two closed circuits to control the movement of the slide. However, it is also possible to use just one circuit with a line to provide a communication between chamber 75 a and a valve means such as a three-way valve, which would in this case be replaced by a two-way valve or the piezoelectric device described above, and a line connecting the valve means with the other fluid chamber 75 b . Of course, the filling means with their hydraulic pump and the lines connecting it with the line connecting the valve means to chamber 75 b , as well as the drain valves, can also be provided in this single circuit.
So that the engine compression ratio is known at all times, a means for pinpointing the angular location of the eccentric 42 is provided, as illustrated in FIGS. 7 a to 7 d.
This means includes a signal transmitter-receiver 136 with one of the elements mounted on the eccentric 42 and the other of the elements mounted on a fixed element of the engine, so that a leg 138 emerges from one wall of the crankcase. Advantageously, the eccentric has an indicator 140 which emits a signal by radiation, for example by magnetic radiation, and leg 138 carries a receiver formed by a reader 142 of the signal emitted by indicator 140 reporting the position of this indicator during the rotation of crankpin 34 . This reader is substantially arcuate with its concave side pointing toward the crankshaft, with an essentially constant radial thickness E. This reader has a first reading area 144 located at its top part to read the signal emitted by the indicator 140 when the compression ratio is at a maximum or is increased and a second area 146 in the bottom part of this reader to read the signal emitted by indicator 140 when the compression ratio is nominal or decreased.
During operation of the engine, the engine computer determines the angular lead C of the eccentric relative to the lengthwise axis of the connecting rod ( FIG. 7 a ) to obtain a given compression ratio when the piston is at the top dead center. In order to check the accuracy of the measured pitch (lead) relative to the pitch determined by the computer, the latter takes into account the intensity of the signal received by the reading area 144 . In the case of FIG. 7 a , this signal is at its highest when the emission point 148 of indicator 140 is substantially in the middle of the thickness E of this reading area and corresponds to a maximum compression ratio. Thus, the compression ratio values can be controlled taking into account the position of the emission point 148 of indicator 140 relative to the middle of the thickness E of this reading area. Hence, one of the closed circuits 78 a , 78 b will be operational so that the slide 54 moves to allow angular play of eccentric 42 enabling such a position of the emission point 148 to be obtained. As soon as this angular lead is reached, the piston leaves its top dead center and proceeds to its bottom dead center ( FIGS. 7 b and 7 c ) and indicator 140 moves away from the center zone of area 144 ( FIG. 7 b ) and eventually arrives in the vicinity of the bottom dead center, at a distance from reader 142 ( FIG. 7 c ). Likewise, this computer determines the angular lead Ci ( FIG. 7 d ) of the eccentric relative to the lengthwise axis of the compression ratio, when the piston is at the bottom dead center, to obtain a nominal compression ratio or to reduce the compression ratio obtained in a previous phase. To arrive at this determination, this computer takes into account the intensity of the signal received by the reading area 146 and, as mentioned above, this signal is at its highest value when the emission point of indicator 140 is substantially in the center of the thickness E of this region. Hence, circuits 78 a , 78 b will be actuated such that the slide can allow angular play of the eccentric enabling such an angular lead to be obtained.
According to one variant, the reader 142 has conducting wires, insulated from each other and disposed essentially radially relative to its arcuate shape over its thickness E. These conducting wires constitute a plurality of receivers of the signals emitted by indicator 140 , distributed angularly from the upper part of reader 142 to its lower part. Indicator 140 describes, for each rotation of the crankshaft, a substantially circular curve with a radius less than the radius of the substantially circular shape of the reader 142 . The substantially circular curve described by indicator 140 moves translationally as a function of the angular lead of eccentric 42 . This translational movement, the radius of reader 142 , and its position are such that the indicator 140 comes opposite the conducting wires in the thickness E of the reader 142 in an arc of a circle whose position is characteristic of the angular lead of eccentric 42 . Hence, knowledge of the identity of the conducting wires in the thickness E of the reader reported by indicator 140 during rotation of the crankshaft provides the angular position of the eccentric with an accuracy that depends on the pitch of the conducting wires.
According to another variant, the accuracy of the reading of the angular lead of eccentric 42 is improved by conjugated reading of the position and intensity of the signals received by the conducting wires informed by indicator 140 during rotation of the crankshaft. When the indicator 140 is right opposite the thickness E of the reader 142 , for example in FIGS. 7 a and 7 d , at least one of the conducting wires receives a maximum information signal from indicator 140 . When indicator 140 is partially opposite the thickness E of reader 142 , for example for FIG. 7 b , the informed wires receive a weaker signal from indicator 140 .
Advantageously, the compression ratio can be gradually and continuously decreased by increasing the angular lead from C to Ci and conversely by increasing from Ci to C, and doing so engine combustion cycle by engine combustion cycle.
Of course, the present invention is not confined to the embodiments described but encompasses all variants and equivalents.
In particular, the compression ratio varying device can be placed at the foot of connecting rod 26 with an eccentric mounted on the shaft 24 of piston 14 .
|
The invention relates to a device for varying a compression ratio in an internal combustion engine comprising at least one cylinder ( 10 ) provided with a combustion chamber ( 20 ), a movable element provided with a piston ( 14 ) which is translationally displaceable by means of a connecting rod ( 16 ) connectable thereto by an axis ( 24 ) and to the crank pin ( 34 ) of a crankshaft ( 36 ). The piston moves between a top dead center and a lower dead center allowing a dead volume ( 40, 118 ) at the top dead center of the piston. The invention also comprises a rotatable towed cam ( 42 ) which makes possible varying the compression ratio and means ( 32, 78 a , 78 b ) for controlling the cam displacement. According to the invention, the control means comprises a fluid actuator ( 76 ) provided with a sliding block ( 54 ) arranged in a receiver ( 56 ) which is formed in a support ( 58 ) and limits two fluid chambers ( 75 a , 75 b ) connected to at least one closed circuit ( 77; 78 a , 78 b ).
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation In-Part of U.S. patent application Ser. No. 12/720,973 filed on Mar. 10, 2010 and is also a Continuation In-Part of U.S. patent application Ser. No. 13/560,771 filed on Jul. 27, 2012 and of U.S. patent application Ser. No. 13/848,526.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] This invention relates to compositions of matter and methods of digesting wood chips used in paper pulping processes. The digestion is often achieved by chemical, mechanical or combined means. Chemical pulping is currently dominated in pulping industry, and among Kraft pulping is the most used pulping process. Chemical digestion is a process in which cellulosic raw materials such as wood chips are treated with chemicals including alkaline and sulfide for Kraft pulping or sulfites/bisulfites for sulfite pulping, usually at high pressure and temperature for the purpose of removing impurities and producing pulp suitable for papermaking. The mixture of chemicals is predominantly in a liquid form and is sometimes referred to as white liquor in Kraft pulping, Wood chips which consist primarily of cellulose, hemicellulose, lignin, and resins are broken down by digestion into a pulp of cellulose and hemicellulose fibers. The lignin and resins, which are undesirable in paper, are at least partially removed in the delignification stage of digestion.
[0004] The digestion process can be enhanced by the presence of one or more surfactants in the white liquor in Kraft pulping. The surfactants reduce the surface tension at the interface between the white liquor and the wood chips. This reduced surface tension allows the chemicals in the white liquor to penetrate more deeply into the wood chips and thereby better digest. Unfortunately the optimal composition of white liquor impairs the effectiveness of the surfactants. Because white liquor has a high pH, it causes most surfactants to salt out of solution especially in high temperatures and pressures. This reduces the amount of surfactant effective on the wood chips. Reducing the amount of surfactant causes wood chunks (known as rejects) to survive the digestion process which imposes additional costs and quality control issues in subsequent papermaking stages. Attempting to overcome this problem by supersaturating the white liquor with surfactant has been shown to offer little improvement and is undesirably expensive. Similarly, lowering the temperature, pressure, or pH of the white liquor, also results in more rejects surviving digestion.
[0005] Thus there is a clear need for, and utility in an improved method of digesting wood chips into paper pulp. The art described in this section is not intended to constitute an admission that any patent, publication or other information referred to herein is “prior art” with respect to this invention, unless specifically designated as such. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 C.F.R. §1.56(a) exists.
BRIEF SUMMARY OF THE INVENTION
[0006] At least one embodiment of the invention is directed towards a method for enhancing the penetration of cooking liquor into wood chips. The method comprises cooking wood chips in a cooking liquor to form a paper pulp and including at least one cross-linked glycerol-based polymer comprising additive in the cooking liquor. The method so enhances the penetration of pulping liquor into the chips that it reduces lignin such that the resulting pulp has a lower kappa number than if no polymer or if equal amounts of other glycerol based polymers were added to the liquor. The polymer may have a branched structure, the branched structure characterized as having at least three chain segments of the polymer joined at a single joining monomer of the polymer which has an alkoxylate group. At least one of the chain segments may comprise a lipophilic carbon bearing group and this chain segment is engaged to the joining monomer at a location other than the alkoxylate group of the joining monomer. The additive may be a cross-linked glycerol-based polymer having branched and cyclic structures according to the structure:
[0000]
[0000] wherein in, n, o, and p are each independently between 1 and 700 and, q and r are independently a number of 0 and integers of between 1-700, R and R′ are (CH 2 ) n and n can independently be 1 or 0, Z can be 0 or great than 0 and each R 1 is independently H, acyl, or a C1-C40 hydrocarbon group, which may be optionally substituted.
[0007] The additive may consist essentially of a cross-linked lipohydrophilic polyglycerol solution and/or may be selected from the list of crosslinked lipohydrophilic crosslinked polyglycerols, crosslinked polyglycerol derivatives, and other crosslinked glycerol-based polymers and any combinations thereof. The glycerol-based polymers may be branched, hyperbranched, dendritic, cyclic and any combinations thereof. The additive may be added to the cooking liquor in an amount of less than 1% or in an amount of 0.05 to 0.001% based on the dried weight of the chips. The additive may reduce the amount of lignin in the produced paper pulp by at least at least 0.5%.
[0008] The digestion process may be one selected from the list consisting of: Kraft digestion, sulfite pulping, oxygen pulping, semichemical pulping, mechanical pulping, thermal pulping, thermomechanical pulping, pulping designed for conversion into synthetic fibers such as dissolving grade pulps, and any combinations thereof. The cooking liquor may also comprise additional surfactant(s).
[0009] The cross-linked glycerol-based polymers may be used by combining with anthraquinone, anthraquinone derivatives, quinone derivatives, polysulfide and the like and any combinations thereof. The cross-links may be formed by reaction between a glycerol-based polymer and diisocyanates, N,N-methylenebis(meth)acrylamide, polyethyleneglycol di(meth)acrylate, glycidyl(meth)acrylate, dialdehydes such as glyoxal, di- or tri-epoxy compounds such as glycerol diglycidyl ether and glycerol triglycidyl ether, dicarboxylic acids and anhydrides such as adipic acid, maleic acid, phthalic acid, maleic anhydride and succinic anhydride, phosphorus oxychloride, trimetaphosphates, dimethoxydimethsilane, tetraalkoxysilanes, 1,2-dichloroethane, 1,2-dibromoethane, dichloroglycerols 2,4,6-trichloro-s-triazine, epichlorohydrin, and any combination thereof. The cross-linked glycerol-based polymers may comprise at least one of the structural units illustrated in FIG. 2 . The cross-linked glycerol-based polymers may comprise copolymers containing non-glycerol based structural units. The additive may consist essentially of a cross-linked polyglycerol solution. The cooking liquor may be white liquor. The crosslinked glycerol-based polymer may increase the pulping yield.
[0010] At least one embodiment of the invention is directed towards a method for enhancing the penetration of cooking liquor into wood chips, the method comprising cooking wood chips in a cooking liquor to form a paper pulp and including at least one cross-linked lipohydrophilic glycerol-based polymer additive in the white liquor, wherein the polymer has a branched structure, the branched structure characterized as having at least three chain segments of the polymer joined at a single joining monomer of the polymer which has an alkoxylate group, and in which at least one of the chain segments comprises a lipophilic carbon bearing group and this chain segment is engaged to the joining monomer at a location other than the alkoxylate group of the joining monomer, the method so enhances the penetration of pulping liquor into the chips that it reduces lignin such that the resulting pulp has a lower kappa number than if no polymer or if equal amounts of other glycerol used polymers were added to the liquor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
[0012] FIG. 1 is an illustration of a cross-linked glycerol-based polymer.
[0013] FIG. 2 is an illustration of basic structural units making up the glycerol-based polymer.
[0014] FIG. 3 is an illustration of performance data represented in terms of the kappa number of fresh wood pulp digestion in the presence of the inventive composition.
[0015] FIG. 4 is an illustration of performance data represented in terms of percentage of rejects of fresh wood pulp digestion in the presence of the inventive composition.
[0016] FIG. 5 is an illustration of performance data represented in terms of the kappa number of aged wood pulp digestion in the presence of the inventive composition.
[0017] FIG. 6 is an illustration of performance data represented in terms of percentage of rejects of aged wood pulp digestion in the presence of the inventive composition.
[0018] For the purposes of this disclosure, like reference numerals in the figures shall refer to like features unless otherwise indicated. The drawings are only an exemplification of the principles of the invention and are not intended to limit the invention to the particular embodiments illustrated.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The following definitions are provided to determine how terms used in this application, and in particular how the claims, are to be construed. The organization of the definitions is for convenience only and is not intended to limit my of the definitions to any particular category
[0020] “Acyl” means a substituent having the general formula —C(O)R, wherein R is alkyl, alkenyl, alkynyl, aryl, heteroaryl or heterocyclyl, any of which may be further substituted
[0021] “Alkyl” means a linear, branched, or cyclic saturated hydrocarbon group, such as a methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, isobutyl group, tert-butyl group, n-pentyl group, isopentyl group, n-hexyl group, isohexyl group, cyclopentyl group, cyclohexyl group, and the like. Alkyl groups may be optionally substituted.
[0022] “Alkoxylate group” means the single bonded carbon and oxygen bearing group engaged to a glycerol monomer in a glycerol-based polyoxyalkylene polymer, as described in U.S. Pat. No. 5,728,265.
[0023] “Branched” means a polymer having branch points that connect three or more chain segments. The degree of branding may be determined by 13 C NMR based on a known literature method described in Macromolecules, 1999, 32, 4240. As used herein, a branched polymer includes hyperbranched and dendritic polymers.
[0024] “Cooking liquor” means any pulp bearing fluids such as solutions or liquors used in pulping processes, consisting but not limited a list of white liquor, black liquor, blown liquor, red liquor, any other spent liquor, solvents, water or any combination thereof.
[0025] “Cyclic” means a polymer having cyclic or ring structures. The cyclic structure units can be formed by intramolecular cyclization or any other ways.
[0026] “Degree of branching” or DB means the mole fraction of monomer units at the base of a chain branching away from the main polymer chain relative to a perfectly branched dendrimer, determined by 13 C NMR based on a known literature method described in Macromolecules, 1999, 32, 4240. Cyclic units or branched alkyl chains derived from fatty alcohols or fatty acids are not included in the degree of branching. In a perfect dendrimer the DB is 1 (or 100%).
[0027] “Degree of cyclization” or DC means the mol fraction of cyclic structure units relative to the total monomer units in a polymer. The cyclic structure units can be formed by intramolecular cyclization of the polyols or any other ways to incorporate in the polyols. The cyclic structure units comprise basic structure units (V, VI and VII of FIG. 2 ) and the analogues thereof. The degree of cyclization may be determined by 13 C NMR.
[0028] “Extractives” means wood extractives consisting of resin acids, fatty acids, sterols and sterol esters.
[0029] “Glycerol-based polymers” means any polymers (including copolymers) containing repeating glycerol monomer units such as polyglycerols, polyglycerol derivatives, and a polymer consisting of glycerol monomer units and at least another monomer units to other multiple monomers units regardless of the sequence of monomers unit arrangements. In embodiments, glycerol-based polymers include alkylated, branched, cyclic polyglycerol esters.
[0030] “Hyperbranched” means a polymer, which is highly branched with three-dimensional tree-like structures or dendritic architecture.
[0031] “Interface” means the surface forming a boundary between the phase of wood chips and the phase of liquor undergoing digestion. Surfactants facilitate the delivery of digestion chemicals to the interface.
[0032] “Kappa number” means a measurement of the degree of deli .reification that occurred during digestion as determined according to the principles and methodology defined in the scientific paper: Kappa Variability. Roundtable: Kappa Measurement, 1993 Pulping Conference Proceedings, by Fuller W. S., (1993), TAPPI Technical Paper.
[0033] “Lipohydrophilic glycerol-based polymers” means glycerol-based polymers having lipophilic and hydrophilic functionalities, for example, lipohydrophilic polyglycerols resulting from lipophilic modification of polyglycerols (hydrophilic) in which at least a part of and up to all of the lipophilic character of the polymer results from a lipophilic carbon hearing group engaged to the polymer but not being an alkoxylate group, the lipophilic modification being one such as alkylation, and esterification modifications.
[0034] “Papermaking process” means a method of making paper products from pulp comprising forming an aqueous cellulosic papermaking furnish, draining the furnish to form a sheet and drying the sheet. The steps of forming the papermaking furnish, draining and drying may be carried out in any conventional manner generally known to those skilled in the art. The papermaking process may also include a pulping stage, i.e. making pulp from a lignocellulosic raw material and bleaching stage, i.e. chemical treatment of the pulp for brightness improvement.
[0035] “Substituted” means that any atom(s) such as one hydrogen on the designated atom or group is replaced with another atom(s) or group provided that the designated atom's normal valence is not exceeded.
[0036] In the event that the above definitions or a description stated elsewhere in this application is inconsistent with a meaning (explicit or implicit) which is commonly used, in a dictionary, or stated in a source incorporated by reference into this application, the application and the claim terms in particular are understood to be construed according to the definition or description in this application, and not according to the common definition, dictionary definition, or the definition that was incorporated by reference. In light of the above, in the event that a term can only be understood if it is construed by a dictionary, if the term is defined by the Kirk - Othmer Encyclopedia of Chemical Technology, 5th Edition, (2005), (Published by Wiley, John & Sons, Inc.) this definition shall control how the term is to be defined in the claims.
[0037] In at least one embodiment, an additive is added to the liquor of a wood chip digestion process, which improves the pulp yield. The liquor may be white liquor, black liquor, blown liquor, red liquor, any other spent liquor, solvents, water or any combination thereof. The additive comprises at least one cross-linked glycerol based polymer. The crosslinked glycerol-based polymers may be produced by a crosslinking reaction with or without a catalyst. The glycerol-based polymers used may be polyglycerols, lipohydrophilic polyglycerols, any other glycerol-based polymer or any combination thereof. The cross-linked polymers may be added to the cooking liquor while in a solution or in a liquid carrier. The crosslinked polymers may be added or sprayed on the woodchips.
[0038] The additive is compatible and stable both in high temperatures and when in the presence of a highly alkaline environment. The additive may be a solution and can be used in a number of digestion processes including Kraft digestion, sulfite pulping, oxygen pulping, semichemical pulping, mechanical pulping, thermal pulping, thermomechanical pulping, pulping designed for conversion into synthetic fibers (such as dissolving grade pulps), and any combination thereof. The cross-linked polymer may be at least in part cyclic and may be added to pulp slurry in the papermaking process. The pulp may comprise virgin wood cellulose fibers as well as bleached or unbleached Kraft, sulfite pulp or other chemical pulps, and groundwood (GW) or other mechanical pulps such as, for example, thermomechanical pulp (TMP).
[0039] The cross-linked polymer is made up of two or more linked polymers containing repeating glycerol (and/or glycerol based) monomer units such as polyglycerols, polyglycerol derivatives, and polymers consisting of glycerol monomer units and at least one other monomer unit, regardless of the sequence of monomers unit arrangements. Suitably, other monomers may be polyols or hydrogen active compounds such as pentaerythrital, glycols, amines, etc. capable of reacting with glycerol or any polyglycerol structures. Some examples of monomer structural units that may be present in the polymer are illustrated in FIG. 2 . The glycerol based polymers may be linear, cyclic, and/or branched.
[0040] In at least one embodiment the glycerol-based polymers are cross-linked without a crosslinking reagent, such as by a condensation reaction of expelling water between at least two polymer molecules, such as described in U.S. patent application Ser. Nos. 13/488,526 and 13/560,771. In such cases Z in FIG. 1 would be 0. The self-crosslinking reaction may be done by a thermal condensation, a catalytic condensation or any combination thereof.
[0041] In at least one embodiment the glycerol-based polymers are cross-linked by reaction with at least one crosslinking reagent, such as described in U.S. Pat. No. 7,671,098 and U.S. Pat. No. 8,298,508. The crosslinking may be done by a thermal condensation, a catalytic condensation or any combination thereof. The crosslinking may occur between at least two polymer molecules through at least one crosslinking reagent. For example, a hydroxyl group on one of the polymer molecules reacts to a crosslinking reagent such as epichlorohydrin, and the attached crosslinking reagent on the polymer reacts to a hydroxyl group on another polymer molecule, to form a crosslinked polymer. For example, Z is at least 1 in FIG. 1 . Suitable crosslinking agents may include at least two reactive groups such as double bonds, aldehydes, epoxides, halides, and the like. For example, a cross-linking agent may have at least two double bonds, a double bond and a reactive group, or two reactive groups. Non-limiting examples of such agents are diisocyanates, N,N-methylenebis(meth)acrylamide, polyethyleneglycol di(meth)acrylate, glycidyl(meth)acrylate, dialdehydes such as glyoxal, di- or tri-epoxy compounds such as glycerol diglycidyl ether and glycerol triglycidyl ether, dicarboxylic acids and anhydrides such as adipic acid, maleic acid, phthalic acid, maleic anhydride and succinic anhydride, phosphorus oxychloride, trimetaphosphates, dimethoxydimethsilane, tetraalkoxysilanes, 1,2-dichloroethane, 1,2-dibromoethane, dichloroglycerols 2,4,6-trichloro-s-triazine, epichlorohydrin, and any combination thereof.
[0042] In at least embodiment any of the hydroxyl groups on the glycerol-based polymers can participate in the crosslinking reaction to form the crosslinked polymers.
[0043] In the cross-linked polymers the ratio of cross linkages to basic repeating structural units may range from 0.000001:1 to 0.99999999:1.
[0044] The glycerol-based polymers (including lipophilic modified polymers) used to produce the corresponding cross-linked polymers may be from commercially available suppliers, from syntheses according to known prior arts such as described in U.S. Pat. Nos. 3,637,774, 5,198,532 and 6,765,082 B2, U.S. published patent applications 2008/0306211 A1,and 2011/0092743, and U.S. patent application Ser. No. 12/582,827, and/or from any combinations thereof.
[0045] In at least one embodiment, the glycerol-based polymer may be modified with a lipophilic group, e.g., alkylated or esterified. Representative examples of alkylation of polyols are described in German patent application DE 10,307,172. A1, in Canadian patent CA 2,613,704 A1, in U.S. Pat. No. 6,228,416 and in a scientific paper of Polymer International, 2003, 52, 1600-1604 and the like. Representative examples of esterificaton of glycerol-based polyols are described in U.S. Pat. No. 2,023,388, U.S. published patent application 2006/02.86052 A1 and the like. The esterification may be carried out with or without a catalyst such as acid(s) or base(s).
[0046] In at least one embodiment the (lipophilic and/or non-lipophilic) glycerol based polymers are a random/statistical collection of numerous types of gylcerol-based polymers. As a result, knowing exactly where and which R1 groups exist on the polymer chain is extremely difficult to determine precisely due to the complexity, random arrangement, and statistical distributions of the R1 groups along the polymer. Mechanistically all hydroxyl groups on the polyglycerol are reactive to esterification and alkylation though the terminal hydroxyl groups may be subject to steric based favorability.
[0047] Glycerol based polymers having both lipophilic and hydrophilic portions are not in and of themselves new. They are at least somewhat mentioned in the polyoxyalkylene polymers described in U.S. Pat. No. 5,728,265. In these prior art polymers an alkyl group is located on an alkoxylate group stemming from one of the polyglycerols monomers. In the instant invention however the lipophilic character of the polymer results from a lipophilic carbon bearing group engaged to the polymer but not being located on an alkoxylate group. Furthermore this character is further enhanced by cross-linking of the polymers. As the subsequent data shows, this results in unexpectedly superior results.
[0048] Without being limited to theory it is believed that one advantage of using lipohydrophilic glycerol based polymers that it has a particularly advantageous balance between hydrophilic and hydrophobic regions, which are especially suited to the surface region of wood chips in a white liquor environment. This balance allows the additive to occupy just the right position relative to the wood chip surface and deliver greater amounts of digestion chemicals to the wood chips than other less balanced surfactants can.
[0049] In addition, the branched nature and the resulting 3-dimensional distribution of the particular regions of the cross-linked glycerol-based polymers both allows them to better reside at the interface and to better deliver digestion chemicals to the wood chips.
[0050] In at least one embodiment, the digestion aid is cross-linked glycerol-based polymers, including one or more of: polyglycerols, lipohydrophilic polyglycerols, polyglycerol derivatives, lipohydrophilic polyglycerol derivatives, other glycerol-based polymers consisting at least one glycerol monomer unit and at least another to multiple monomers units regardless of the arrangements of monomers units, other lipohydrophilic glycerol-based polymers consisting at least one glycerol monomer unit and at least another to multiple monomers units regardless of the arrangements of monomers units, and any combination thereof.
[0051] In at least one embodiment, at least one of the glycerol-based polymers in a cross-linked network is linear, branched, hyperpbranched, dendritic, cyclic and any combinations thereof. In at least one embodiment, the network of cross-linked polymers comprises three or more glycerol-based polymers. In at least one embodiment at least one polymer chain has multiple cross-linkages to another polymer. These multiple cross linkages can join a polymer multiple times to another one polymer or to more than one other polymers.
[0052] In at least one embodiment, the additive reduces the surface tension at the wood chip-white liquor interface substantially while it is within a dosage of only 0005-0.008 weight % of additive relative to the weight of the wood chips.
[0053] In at least one embodiment, the additive lowers the surface tension of water from 71.9 Nm/g (in the absence of any additive) to 23.5-26.8 Nm/g.
[0054] In at least one embodiment the additive solution reduces the kappa number of the resulting pulp.
[0055] In at least one embodiment, the amount of additive needed is far less than of comparable surfactants as described in U.S. Pat. No. 7,081,183.
[0056] In at least one embodiment, the additive can be used with other additives including but not limited to anthraquinone, anthraquinone derivatives, quinone derivatives, polysulfide and the like.
[0057] In at least one embodiment, the additive is an effective aid for deresination and delignification in improving wood chip cooking processes.
EXAMPLES
[0058] The foregoing may be better understood by reference to the following Examples, which are presented for purposes of illustration and are not intended to limit the scope of the invention:
Example 1
Synthesis of a Glycerol-Based Polymer
[0059] 100 Units (or using different amounts) of glycerol were added to a reaction vessel followed by 3.0 to 4.0% of active NaOH relative to the reaction mixture. This mixture was agitated and then gradually heated up to 240° C. under a particular low reactivity atmospheric environment of nitrogen flow rate of 0.2 to 4 mol of nitrogen gas per hour per mol of monomer. This temperature was sustained for at least three hours to achieve the desired polyglycerol composition (Table 1), while being agitated under a particular low reactivity atmospheric environment. An in-process polyglycerol sample was drawn before next step for the molecular weight/composition analysis/performance test.
[0000]
TABLE 1
Examples of Glycerol-Based Polymers
Molecular
Lactic acid
weight
weight by
Degree of
Sample ID
(Daltons)*
NMR**
branching**
PGI
6,100
15%
0.32
PGII
7,800
14%
0.34
Note:
*Determined by borate aqueous SEC (size exclusion chromatography) method and calibrated with PEO/PEG standards;
**determined by 13 C NMR which is consistent with HPLC results.
Example 2
Synthesis of a Crosslinked Glycerol-Based Polymer
[0060] Polyglycerol from the example 1 (PGI) was dissolved in water as 30-60% solution. To the polyglycerol solution was added 50% NaOH solution (1-15% relative to PGI) at room temperature. After mixing, epichlorohydrin (1-15% relative to PGI) was added, and the resulting reaction mixture was agitated at room temperature for hours until the desired crosslinked glycerol-based polymer formed. The molecular weight of the product was analyzed by SEC (Table 2, CLPG—crosslinked polyglycerol).
[0000]
TABLE 2
Examples of Crosslinked Glycerol-Based Polymers
Polyglycerol
Molecular weight
Lactic acid weight
Sample ID
used
(Daltons)
by HPLC***
CLPG
PGI
55,000*
NA
CLHPG
PGII
18,000**
0.56%
Note:
*Determined by borate aqueous SEC (size exclusion chromatography) method and calibrated with PEO/PEG standards.
**Weight average molecular weight determined by SEC method using PLgel Guard Mixed-D column and DMSO as mobile phase, and calibrated with polysaccharide standards.
***Determined by HPLC external standard quantification.
Example 3
Synthesis of a Crosslinked Lipohydrophilic Glycerol-Based Polymer
[0061] To the polyglycerol from the example 1 (PGII) was added H 2 SO 4 (10-22% relative to PGII) at 100-125° C., while agitation under a low reactivity atmospheric environment. The mixture was gradually heated up to 130° C.-150° C. and kept there for at least 30 minutes under a particular low reactivity atmospheric environment, to achieve the desired esterification, C10-C16 alcohols (1-15% relative to PGII) were added. The mixture was heated up to 150° C. and kept there under a particular low reactivity atmospheric environment for at least 30 minutes to achieve the desired alkylation. The resulting reaction mixture was stirred at 150° C. under a particular low reactivity atmospheric environment for at least 30 minutes to achieve the crosslinking to produce the desired end product. The product was dissolved in water (50%) (Table 2, CLHPG—crosslinked lipohydrophilic polyglycerol). During the whole process in-process samples were drawn every 30 minutes to 2 hours as needed to monitor the reaction progress and determine the composition as needed.
Example 4
Kappa Number and Rejects
[0062] Aged or fresh softwood chips from a midwestern mill were used. Cooking experiments were performed on 20 g of wood at 4:1 liquor to wood ratio, with 15% alkali and 25% sulfidity charge. The alkali was sourced from sodium hydroxide (70%) and sodium sulfide (30%). Weak black liquor (˜20% solids) was used to makeup liquid. Digester additives were added to the black liquor, which was mixed well and then combined with the white liquor. All cooks began at 55° C. and the temperature was quickly ramped to 170° C. for a total cooking time of 3 hours. After that, the cooking capsules were placed under cold running water for approximately 10 minutes. The contents were then transferred to cheesecloth and squeezed under warm water to remove the majority of cooking liquor. The pulp was then diluted with warm tap water to 800 mL and disintegrated in Waring blender for 30 seconds. The resulting slurry was transferred to cheesecloth and washed three times with 800 mL of warm tap water. The pulp was broken down by hand into small pieces and all rejects were removed manually. The resulting pulp was oven dried overnight and weighted. The pulp was allowed to dry in the CTH room for 4 days to an average consistency of 92%. Kappa numbers were determined using TAPPI test method T 236.
[0063] The performance of crosslinked glycerol-based polymers was compared with a prior art alkyl polyalkylene glycol surfactant (DVP6O002) described in U.S. Pat. No. 7,081,183B2 (Tables 3 and 4, and FIGS. 3-6 ).
[0000]
TABLE 3
Digestion Performance with Aged Wood Chips
Surfactant
Rejects
Sample ID
wt %
Kappa #
wt %
DVP6O002
0.025%
44.63
1.40%
PGI
0.008%
47.63
1.50%
CLPG
0.008%
39.61
0.20%
[0000]
TABLE 4
Digestion Performance with Fresh Wood Chips
Surfactant
Rejects
Sample ID
wt %
Kappa #
wt %
DVP6O002
0.025%
37.98
0.57%
CLHPG
0.008%
34.89
0.06%
[0064] While this invention may be embodied in many different forms, there are shown in the drawings and described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. All patents, patent applications, scientific papers, and any other referenced materials mentioned herein are incorporated by reference in their entirety. Furthermore, the invention encompasses any possible combination of some or all of the various embodiments described herein and incorporated herein.
[0065] Any ranges given either in absolute terms or in approximate terms are intended to encompass both, and any definitions used herein are intended to be clarifying and not limiting. All ranges and parameters disclosed herein are understood to encompass any and all subranges (including all fractional and whole values) subsumed therein, and every number between the endpoints. For example, a stated range 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 beginning with a minimum value of 1 or more, (e.g. 1 to 6.1), end ending with a maximum value of 10 or less, (e.g. 2.3 to 9.4, 3 to 8, 4 to 7), and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the range. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0066] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
[0067] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
|
The invention provides a method of improving the digestion of wood chips into pulp. The method involves: adding a cross-linked glycerol-based polymer additive to a solution used in the digestion process. This additive is unexpectedly effective at facilitating digestion. The branched and ether structure of the additive allows it to withstand the harsh nature of a high stress environment. In addition, it is more soluble in the harsh condition than other surfactants. The structure, resistance, and particular balance between hydrophobic and hydrophilic regions, causes the additive to increases the interaction between the wood chips and the digestion chemicals. This in turn reduces the costs, the amount of additive needed, and the amount of reject wood chunks that result from the digestion process.
| 3
|
FIELD OF THE INVENTION
[0001] This invention relates to the art of modeling manufacturing systems and more particularly to the art of developing analytical models for optimizing manufacturing systems in order to optimize process variables within the system. The present invention also relates to a method of operation, control, and system integration of a plant for producing, conveying, and packaging articles.
BACKGROUND OF THE INVENTION
[0002] In serial manufacturing systems, manufacturing stages are generally separated by storage spaces used for temporary storage and transport, for example conveyors or other queueing techniques. Each manufacturing stage can comprise one or more manufacturing operations for the assembly of, or for the manufacture of, components or products.
[0003] For example, plants for producing and packaging rolls of materials that are convolutely wound upon a support core may comprise a plurality of individual manufacturing operations. These operations then produce rolls, packages, bundles, cases, or pallets of consumer-ready finally wound products. For instance, rolls of materials, such as rolls of paper material or the like, can be wound on a support core, such as a cardboard core tube. Such rolls of consumer-ready finally wound products are preferably rolls of toilet paper, paper toweling, aluminum foiling, and other such materials suitable for personal, domestic, industrial use, or the like. Other examples of serial manufacturing systems can include plants for producing and packaging bags, bottles, and cartons of consumer-ready products such as food, cosmetics, parts, toys, or medicaments.
[0004] Machinery suitable for forming rolls of materials can generally comprise a series of operative sections that produce coils or logs of rolled material where the individual consumer-ready finally wound products are generated. Typically, the starting materials for such consumer-ready finally wound products are provided from a paper mill in the form of large sized rolls of convolutely wound web materials. The machinery used for the production of such consumer-ready finally wound products may have an initial unwind section that unwinds the starting material from the large roll and transfers it to successive sections in which the product can be embossed in order to increase the apparent thickness, or change the appearance, of the web material and the resulting consumer-ready finally wound product. Downstream of such an embossing section, several layers of the starting material (processed or otherwise) may be cooperatively coupled in a face-to-face relationship and presented to a recoiling section that receives elongate support cores upon which the material produced by the upstream sections is convolutely disposed about to a desired diameter corresponding to that of the rolls of consumer-ready finally wound products to be produced. The elongate cores having material convolutely wound thereabout can then be introduced to a successive section for either storing the resulting wound web material as elongate rolls of convolutely wound material or sent directly to another manufacturing system that cuts the elongate roll of convolutely wound material into shorter rolls of consumer-ready finally wound product.
[0005] Machinery that provides for the transverse cutting of the elongate convolutely wound material into shorter pieces of convolutely wound material (known to those of skill in the art as a log saw) may then be followed by an endless variety of packaging machines that can collect the individual rolls of convolutely wound web material and, either individually or in packaged groups, encapsulate the roll or group of rolls with a film of plastic or paper material. The packs can contain a preselected number of the resulting consumer-ready finally wound product ordered in rows which can be arranged in multiple layers or in any other desired arrangement. The packaged groups or individual rolls of convolutely wound web material can then be collected and contained in still larger groups by cartoning processes or in still larger groups by an ensuing palletizing processes.
[0006] Manufacturing operations where the consumer-ready finally wound product sold to consumers is produced and packaged generally use machinery produced by different manufacturers. This may occur because the machinery is acquired at different times or the specific machinery was selected to provide certain advantageous characteristics that relate to the entire manufacturing process and/or to the desired consumer-ready finally wound product.
[0007] In such operations, there can be problems associated with coordinating the operation between different machines for different processes. This can include coordinating the operation between roll forming machines and packaging machines as well as between the packaging machine and the various and extensive conveyor belts connecting them. These issues can cause the actual yield of the manufacturing process to be diminished and may not allow sufficient exploitation of the high working rate potential of the individual components of an entire manufacturing process.
[0008] Also, the various components of a manufacturing process can be subject to equipment malfunction or the requirement of down time in order to facilitate maintenance. In such systems, it is not uncommon to have one unit operation process sufficient product in order to satisfy the in-feed requirements of a plurality of machines connected to its output. Thus, when an operating event occurs, such as a planned intervention of a particular unit operation of a manufacturing system or a failure of such a unit operation, the production rate of a unit operation providing product to a plurality of unit operations must necessarily be adjusted. Exemplary planned interventions can include preventative maintenance, cleaning, changeover, and curtailment. Unit operation failures may be of a mechanical, electrical, process, or operational nature.
[0009] For the sake of comparison, most manufacturing systems operate as a group of unit operations that operate independently of adjacent unit operations. For example, a unit operation may monitor its in-feed status in order to maintain a pre-determined target level or range. Without knowledge of the state and/or speed of any adjacent upstream unit operation(s), the unit operation is unable to determine the best speed to run. Because of this, the unit operation can make unnecessary process speed adjustments. This can result in the unit operation starving itself in one instance or blocking upstream unit operation(s) in another. At times, this can lead to significant, or even perpetual, cycling between the various unit operations comprising the manufacturing system. These non-steady-state conditions have been found to both reduce the speed of the unit operation as well as its reliability thereby greatly impacting throughput of the entire manufacturing system. Traditionally, what has been done to alleviate these non steady-state problems is to increase the amount of conveyor or the size of the queue between the various unit operations. This solution is expensive and reduces operability, introduces greater variability in in-feed conditions (level, backpressure, product distortion), and does not always solve the problem of cycling or unnecessary speed adjustments. This is especially true if the conveyor or queue between the unit operations is not controlled properly.
[0010] Another downfall of today's systems is that they do not readily adapt to new products or configurations. Typically, control attributes such as unit operation rates, conveyor speeds, so-called photoeye blocked/cleared timer delays, and path/routing logic must be consistently and constantly added or updated. This can require a significant amount of programming, and at times it requires a complete overhaul of a manufacturing system's control logic. As a result, a significant amount of throughput is lost during the startup and debug of the process on the new product/configuration. Many times this process yields sub-optimal integration of the manufacturing system, and often, the changes have adverse effects on other existing products and manufacturing system configurations. This can cause lost throughput on all future production. Eventually, the manufacturing system and its corresponding control strategy can become too complex and the manufacturing operation is forced to reduce complexity by reducing flexibility, and therefore system capability, in order to achieve some minimum level of system reliability.
[0011] What is clear is that the prior art is remarkably silent in providing solutions that facilitate an in situ change in a manufacturing process, coordinating a simultaneous speed change of the effected unit operations, maximizing product throughput, as well as accommodating the interruption of production capacity caused by the shutdown or malfunction of a particular unit operation, while utilizing an algorithm that can be applied consistently to a broad range of system configurations and interconnectivities. It is believed that providing such a unique process can result in a standard solution that can be applied to both like and unlike systems by providing improved flexibility to run various products and paths, maximize throughput by ensuring the system constraint or constraints are running at or most near their maximum speed(s), maximize reliability by reducing or eliminating unnecessary unit operation speed changes, and reducing conveyor lengths by providing more consistent product flow through the system. The reduction of conveyor length can further lead to the reduction of the manufacturing system capital costs, the reduction of the manufacturing system footprint, and improved manufacturing system productivity. What will be realized is that the invention disclosed herein can provide all of the aforementioned benefits while reasonably accommodating various situations in a manufacturing process that can cause an interruption in production.
SUMMARY OF THE INVENTION
[0012] The present invention provides a process to control the product throughput in a multi-station manufacturing system. The process comprises the steps of first, providing the multi-station manufacturing system as a plurality of discrete operating stations. Each of the plurality of discrete operating stations has a known rate capacity and is interconnected to form a plurality of pathways for an object of manufacture to pass through the multi-station manufacturing system from a first operating station to a distal operating station. Next, the plurality of pathways are separated into a plurality of independent pathways. Third, a first constraining throughput capacity corresponding to each of the plurality of independent pathways is identified. Fourth, a target rate of each of the discrete operating stations in each of the plurality of independent pathways is adjusted according to the corresponding first constraining throughput capacity. Next, the plurality of independent pathways is reconstituted into an interconnected pathway comprising the discrete operating stations and the plurality of pathways for the object of manufacture to pass through the multi-station manufacturing system from the first operating station to the distal operating station are reformed. Next, the target rate of each of the discrete operating stations of the interconnected pathway is combined. Finally, the product throughput is adjusted according to the combined target rates.
[0013] The present invention also provides a process to control product throughput in a multi-station manufacturing system. The process comprises the steps of first providing the multi-station manufacturing system as a plurality of discrete operating stations where each of the plurality of discrete operating stations has a known rate capacity and is interconnected to form a plurality of pathways for an object of manufacture to pass through the multi-station manufacturing system from a first operating station to a distal operating station. Second, the plurality of pathways is separated into a plurality of independent pathways. Third, a first constraining throughput capacity corresponding to each of the plurality of independent pathways is identified. Fourth, a target rate of each of the discrete operating stations in each of the plurality of independent pathways is adjusted according to the corresponding first constraining throughput capacity. Fifth, a second constraining throughput capacity for discrete operating stations common to each of the independent pathways is identified. Next, the target rate of each of the discrete operating stations in the multi-station manufacturing system is adjusted according to the second constraining throughput capacity. Then, the plurality of independent pathways is reconstituted into the interconnected pathway comprising the discrete operating stations and the plurality of pathways for the object of manufacture to pass through the multi-station manufacturing system from the first operating station to the distal operating station is reformed. Finally, the product throughput is adjusted according to the combined target rate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a block diagram of an exemplary manufacturing system;
[0015] FIGS. 2-8 are block diagrams representing the steps of the instant invention that can maximize production throughput of the exemplary manufacturing system of FIG. 1 as well as accommodate for the interruption of service due to a planned or unplanned intervention or failure of equipment used to manufacture the consumer-ready finally wound product contemplated herein;
[0016] FIG. 9 is a block diagram of another exemplary manufacturing system; and,
[0017] FIGS. 10-17 are block diagrams representing the steps of the instant invention that can maximize production throughput of the exemplary manufacturing system of FIG. 9 as well as accommodate for the interruption of service due to a planned or unplanned intervention or failure of equipment used to manufacture the consumer-ready finally wound product contemplated herein.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention provides a method for maximizing product throughput and determining the optimal operating speeds for a plurality of interconnected machines operating within a manufacturing system. The individual machines of the manufacturing system are typically provided as a plurality of discrete operating stations and may be arranged in any number of configurations and be provided in any desired quantity. In a preferred embodiment, each machine within a manufacturing system has its own local control unit and variable speed control that communicates with a master control unit where the processes described herein are executed, and the user enters certain process variables required by the master control unit via a master operator interface.
[0019] In short, the connectivity of a manufacturing system is defined in the inventive process as the set of independent paths that a consumer-ready finally wound product of manufacture would travel. Referring to FIG. 1 , an exemplary process 10 could utilize a manufacturing system 12 (also used interchangeably with the term “system 12 ” herein) that is suitable for the manufacture of convolutely wound paper products, for example. Such a system 12 could comprise in an exemplary, but non-limiting, embodiment a log saw 14 , at least one wrapper 16 , a bundler 18 , and a case packer 20 . In principle, an elongate convolutely wound material disposed about a core would be processed first by a log saw 14 . The log saw 14 , in principle, transversely cuts the elongate convolutely wound web material into a plurality of shorter, consumer-ready finally wound lengths of convolutely wound material. An exemplary wrapper 16 could envelop each individual consumer-ready finally wound length of convolutely wound web material with an overwrap. Typically, a polymeric film is used in order to encapsulate each consumer-ready finally wound convolutely wound web material. Next, an exemplary bundler 18 could effectively bundle a plurality of consumer-ready finally wound convolutely wound web materials into an array of products that could be eventually encapsulated in yet another thicker and more durable polymeric film. Such an encapsulated array of products would be suitable for sale at a warehouse or other merchandising operation for the consumer to buy the consumer-ready finally wound convolutely wound product in bulk. Further, an exemplary case packer 20 could be capable of taking a plurality of consumer-ready finally wound convolutely wound products and place them within a carton for containing the individual finally wound consumer-ready products for the eventual transport of individual products to merchandising outlets and the ultimate sale of the individual consumer-ready finally wound products to consumers.
[0020] As can be seen from FIG. 1 , the output of log saw 14 can feed the input of a plurality of manufacturing unit operations. In the example provided herein, the output of log saw 14 is directed in two streams toward the input of a plurality of wrappers 16 , although it should be realized and readily apparent to one of skill in the art that virtually any number or type of machines (also referred to herein as “unit operations”) and any manner of connecting inputs and outputs of such a unit operations are suitable for use with the present invention.
[0021] Turning now to FIG. 2 , the process 10 of the instant invention provides that the system 12 be displayed as a plurality of independent paths 24 in which a consumer-ready convolutely wound product may progress through system 12 . By way of example, it was noted with reference to FIG. 1 above that the output of log saw 14 provided product to the input of a plurality of wrappers 16 . Thus, since one unit operation of system 12 provides for relative distribution of the output therefrom to a plurality of devices, the system 12 can be represented as a plurality of independent paths 24 where each unit operation of the system 12 is represented within each independent path 24 through which the consumer-ready final product may progress through system 12 . In other words, a consumer-ready product may successively progress from the output of log saw 14 to a first wrapper 16 and then to a bundler 18 or the consumer-ready product may successively progress from the output of log saw 14 to a second wrapper 16 and then a case packer 20 .
[0022] Referring to FIG. 3 , the rate capacity (also used interchangeably herein with “maximum rate” or “capacity”) of each unit operation of system 12 in each independent path 24 is then determined. This information can be provided by the manufacturer of the specific equipment or may be realized through use and experience as an evaluative known output of the specific equipment. By way of non-limiting example, the known output of a log saw 14 (represented as M 1 ) may be 200 units/minute, the throughput of a first wrapper (represented as M 2 ) may be 50 units/minute, and the output of the second wrapper 16 (here represented as M 3 ) may be 150 units/minute. Similarly, the capacity of exemplary bundler shown may be 200 units/minute and the exemplary case packer shown as 200 units/minute. In any regard, the rate capacity at each unit operation of the system 12 is likely the maximum rate for the specific equipment for the given format of consumer-ready product as well as any applicable system conditions. Preferably, the maximum rate is provided by the unit operation automatically and takes into account both mechanical and process limitations, therefore eliminating the possibility of erroneous data entry by an operator or any control scheme utilized to control the unit operation.
[0023] If a specific piece of manufacturing equipment (or unit operation) appears in a plurality of independent pathways 24 (in this example log saw 14 (M 1 )), the maximum capacity of the machinery should be divided according to the number of appearances of that specific equipment per number of independent paths 24 in which that specific machinery appears. Thus, if the capacity of log saw 14 (M 1 ) is 200 units/minute, by way of the example provided herein, the maximum speed per path of the log saw is 100 units/minute. By way of convention, the capacity of each piece of equipment is generally reflected with common units. For example, for a manufacturing system such as that contemplated herein, the common units may be rolls per minute, pieces per minute, articles per hour, and the like.
[0024] Referring again to FIG. 3 , next the constraining throughput capacity of each independent path 24 is identified. Typically, the constraint is determined by identifying the manufacturing equipment having the lowest rate capacity. By way of example and as shown in FIG. 3 , the constraint of the upper independent path 26 would be identified as the wrapper 16 (M 2 ). This is because the capacity of the wrapper 16 (M 2 ) has the lowest capacity of all equipment present in the upper independent path 26 . Likewise, the constraint in the lower independent path 28 shown in FIG. 3 is log saw 14 (M 1 ). This is because the log saw 14 has the lowest capacity of all the equipment present in the lower independent path 28 represented therein.
[0025] Referring to FIG. 4 , next the target rate of each piece of equipment in each independent path 24 is determined. In other words, at this point in the process, each independent path 24 transitions from understanding the rate capacity of each piece of equipment located in that independent path 24 to determine the target rate to command each piece of equipment in that associated independent path 24 to operate. By way of example, in the upper independent path 26 of FIG. 4 , since the constraint is wrapper 16 (M 2 ) having a capacity of 50 units/minute, all other equipment located in the independent path 26 should have a target rate that is adjusted to be commensurate in scope with that constraining piece of equipment (here, wrapper 16 (M 2 )). Thus, the target rate of the log saw 14 (M 1 ) is adjusted downward from its initial capacity of 100 units/minute to 50 units/minute. Similarly, since the constraint in the lower independent path 28 of FIG. 4 is the log saw 14 (M 1 ), the target rates of the wrapper 16 (M 3 ) and case packer 20 (M 5 ) are adjusted accordingly to be commensurate with the constraining capacity of log saw 14 (M 1 ).
[0026] Referring to FIG. 5 , one next identifies the specific machinery common to more than one independent path 24 . As shown in the figure, the log saw 14 (M 1 ) is common to both the upper independent path 26 and the lower independent path 28 .
[0027] Referring to FIG. 6 , for machines that are common to more than one independent path 24 , the lowest target rate for the respective independent path 24 to which that machine appears is identified. By way of example and as shown in FIG. 5 , it can be seen that one portion of the log saw 14 (M 1 ) has a lower target rate in the upper independent path 26 compared to the higher target rate shown in the lower independent path 28 . For each independent path 24 that the common machine occupies, the independent paths where the target rate exceeds the lowest target rate identified previously is scaled so that the output of the common machine provides an even distribution of the consumer-ready finally wound product produced therefore between the independent paths 24 in common. One of skill in the art would recognize that such a step may be required because production machines are often required to distribute such consumer-ready finally wound product in even proportions. Thus, for example, since the lowest target rate was identified as the target rate for the upper independent path 26 comprising log saw 14 (M 1 ), the target rate of the log saw 14 (M 1 ) in the lower independent path 28 is adjusted commensurate in scope with the target rate provided in the upper independent path 26 comprising log saw 14 (M 1 ). As shown in FIG. 6 , the target rate of log saw 14 (M 1 ) to the lower independent path 28 comprising log saw 14 (M 1 ), wrapper 16 (M 3 ), and case packer 20 (M 5 ) is adjusted to the same rate ( 50 ) as the upper independent path 26 comprising log saw 14 (M 1 ), wrapper 16 (M 2 ), and bundler 18 (M 4 ). In short, the throughput of all machines in system 12 comprising process 10 is adjusted to be the same as the lowest rate of the available components comprising system 12 . It should be realized by one of skill in the art that the preceding steps can be repeated as required to accommodate machinery that may be common to more than independent path 24 and can be utilized in systems 12 that may distribute consumer-ready final product in even proportions. In the non-limiting, but exemplary circumstance that a machine must distribute or receive consumer-ready final product in uneven proportions, these percentages should be defined and are initially applied when distributing the component's maximum rate among each independent path 24 in which it appears. Subsequently, the process utilized in systems 12 utilizing such uneven proportion distributions should be reconfirmed in this step using a similar process to that described for a system 12 utilizing even proportion distribution. In a second non-limiting, but exemplary circumstance that a machine is able to distribute or receive consumer-ready finally wound product in variable proportions, the maximum rate initially distributed among each independent path 24 in which it appears may be as high as the machine's throughput capacity in each instance. This is because at any given instance the machine may be able to accept or distribute its full capacity from/to a single independent path.
[0028] Next, referring to FIG. 7 , the state of each independent path 24 is identified. If any machine on an independent path 24 is stopped, the respective independent path 24 would be considered in a “down” state. As shown in FIG. 7 , upper independent path 26 comprising log saw 14 (M 1 ), wrapper 16 (M 2 ), and bundler 18 (M 4 ) is down due to some situation affecting the upper independent path 24 . This may include, for example, preventive maintenance occurring on bundler 18 (M 1 ) or an equipment malfunction related to the operation of bundler 18 (M 4 ). In the example shown in FIG. 7 , the lower independent path 28 comprising log saw 14 (M 1 ), wrapper 16 (M 3 ), and case packer 20 (M 5 ) remains in operation.
[0029] Referring to FIG. 8 , all of the independent paths 24 are reconstituted or resolved into their pre-process configuration. For a machine common to multiple independent paths 24 , the target rate for that machine is the sum of all target rates for each machine instance among the independent paths, provided the particular independent path 24 is in an operating state. Thus, the target rates for the instantaneous operating capacity of each machine comprising system 12 are then implemented in order to provide for maximum throughput through system 12 . Referring back to FIG. 7 , if the upper independent path 26 comprising log saw 14 (M 1 ), wrapper 16 (M 2 ), and bundler 18 (M 4 ) is in a down state, the reconstituted machine target rates are then taken into account to adjust the throughput of system 12 . Thus, since the upper independent path 26 comprising log saw 14 (M 1 ), wrapper 16 (M 2 ), and bundler 18 (M 4 ) is not in operation, all output from log saw 14 (M 1 ) is directed toward wrapper 16 (M 3 ), and case packer 20 (M 5 ). This situation requires the output of log saw 14 (M 1 ) to be reduced to a level that is only required to support the equipment present in lower independent path 28 . Thus, even though the capacity of log saw 14 (M 1 ) is far in excess of the realized output according to the process 10 described herein, the output of the log saw 14 (M 1 ) is reduced and the output of all other equipment in system 12 is maintained, thus maintaining the throughput of the lower independent path 28 , to accommodate an instantaneous interruption in production due to a malfunction of one of the components of system 12 . By maintaining the throughput of the lower independent path 28 , the lower independent path 28 is not exposed to a rate-change condition, which could otherwise increase the probability of a failure. Similarly, if the upper independent path 26 having log saw 14 (M 1 ), wrapper 16 (M 2 ), and bundler 18 (M 4 ) is in operation, the reconstituted machine target rates would provide for the log saw 14 (M 1 ) to provide for an equal distribution of consumer-ready finally wound product to the respective wrapper 16 (M 2 ) disposed in each independent path 24 . Thus, using the example shown in FIG. 8 , the target rate of log saw 14 (M 1 ) could be adjusted to a value of 50 units/minute in order to satisfy the throughput of just the lower independent path 28 as shown in FIG. 6 since it is the only independent path 24 remaining in operation.
[0030] If a given independent path 28 is to be in a “down” state for an extended time period, or if other process conditions dictate, such as an accumulation or queue level of consumer-ready finally wound product, it may be advantageous to increase the speed of the remaining independent paths 24 to compensate for this situation. This operational mode is referred to herein as “speed-compensating.” In this operational mode it may be deemed necessary to accept the increased risk in reliability to speeding up the operations associated with the remaining independent paths 24 in order to achieve higher throughput. In order to cause this change, it could be necessary to ignore the independent path 28 currently in the “down” state by excluding independent path 28 from the initial distribution of each operating stations's maximum rate among each independent path 24 in which the operating station occurs. The system 10 may go into a speed-compensating mode either automatically, in which case it is typically triggered by a certain accumulation or queue level, or manually by the operator through the operator interface.
[0031] As shown in FIG. 9 , exemplary system 12 A suitable for use with process 10 A of the present invention to produce consumer-ready finally wound product provides for a log saw 14 (M 1 ) to feed the input of a plurality of wrappers 16 (M 2 ). The output of two wrappers 16 (M 2 ) feed the input of a bundler 18 (M 3 ). The output of a third wrapper 16 (M 2 ) feeds the input of a case packer 20 (M 4 ). The resulting outputs of both the bundler 18 (M 3 ) and case packer 20 (M 4 ) feed the input of a palletizer 22 (M 5 ).
[0032] Consistent with the process described herein, in this more complex system as shown in FIG. 10 , the process 10 A of the instant invention provides that the system 12 A be displayed as a plurality of independent paths 24 A in which a consumer-ready finally wound product may progress through system 12 A. As shown, since more than one unit operation comprising system 12 A provides for relative distribution of the output therefrom to a plurality of devices, the system 12 A can be represented as a plurality of independent paths 24 A. In other words, each unit operation comprising system 12 A is represented by each independent path 24 A through which the consumer-ready finally wound product may progress through system 12 A. Thus, upper independent path 26 A can be represented by a consumer-ready finally wound product that can progress from the output of log saw 14 (M 1 ), to a first wrapper 16 (M 2 ), then a bundler 18 (M 3 ), and subsequently a palletizer 22 (M 5 ). Alternatively, the consumer ready finally wound product may progress through system 12 A in middle independent path 30 A from the output of log saw 14 (M 1 ) to a second wrapper 16 (M 2 ), then to bundler 18 (M 3 ), and subsequently palletizer 22 (M 5 ). Yet further still, the consumer-ready finally wound product may progress through system 12 A in lower independent path 28 A from the output of log saw 14 (M 1 ) to a third wrapper 16 (M 2 ) to a case packer 20 (M 4 ) and a subsequent palletizer 22 (M 5 ).
[0033] Referring to FIG. 11 , the throughput capacity of each unit operation of system 12 A is then determined. As discussed supra, this information can be provided by the manufacturer of the specific piece of equipment or may be realized through use and experience as an evaluative known output of the unit operation. By way of example, the known capacity of log saw 14 (M 1 ) may be 90 units per minute. Similarly, it may be determined that the capacities of each wrapper 16 (M 2 ), the bundler 18 (M 3 ), and the case packer 20 (M 4 ) may be 40 units per minute, respectively. Further, the capacity of palletizer 22 (M 5 ) may be known to be 75 units per minute. As stated above, the throughput capacities at each position of the system 12 A is likely to be maximum rate for the specific equipment for the given format of consumer-ready finally wound product, as well as any system 12 A conditions that may be present.
[0034] Referring to FIG. 12 , the constraining capacity of each independent path 24 A is identified. As shown, the constraint of the upper independent path 26 A would be identified as the bundler 18 (M 3 ). This is because the throughput capacity of the bundler 18 (M 3 ) is the lowest throughput capacity of all equipment present in the upper independent path 26 A. The constraint in the middle independent path 30 A is likewise the bundler 18 (M 3 ). The observed constraint in the lower independent path 28 A is the palletizer 22 (M 5 ).
[0035] Referring to FIG. 13 , in the instance where a common operating station is shared over a plurality of independent paths 24 A, it may be useful to shift the constraining capacity from one unit operation in a given independent path 24 A to another unit operation in that same independent path 24 . As shown in FIG. 13 , since the lower independent path 28 A shares a common operating station (log saw 14 (M 1 )) with both the upper independent path 26 A and the middle independent path 30 A, the constraint is shifted to the log saw 14 (M 1 ). This is because the upper independent path 26 A and middle independent path 30 A have lower constraint values as compared with the constraint value presented by palletizer 22 (M 5 ) shown in the lower independent path 28 A, and assuming the logsaw 14 (M 1 ) is required to split its output proportionally. Thus, for purposes of this example, the constraining rate for the lower independent path 28 A effectively becomes the log saw 14 (M 1 ). Thus, the independent paths 24 A shown in FIG. 13 can be represented as three independent paths 24 A with the constraining rates displayed as shown in FIG. 14 .
[0036] Next, a speed trimming percentage is applied to each independent path 24 A because, as would be known to one of skill in the art, many unit operations (e.g., the wrappers 16 (M 2 )) monitor their in-feed level in order to adjust their speed to maintain a consistent throughput level. “Speed trimming” or “speed compensation” as used herein refers to these small speed compensations required to maintain a consistent in-feed level in any given unit operation. The term “high trim” as used herein refers to a state in which any given unit operation has excess product at its in-feed and therefore runs at a speed incrementally higher than a cooperatively associated upstream unit operation. Likewise, the term “low trim” as used herein refers to the state in which a given unit operation has a deficiency of product at its in-feed and therefore runs at a speed incrementally higher than a cooperatively associated upstream unit operation.
[0037] One aspect of the system of the present invention provides for speed trimming to be applied for each independent path 24 A from the constraining unit operation outward. For example, a unit operation positioned downstream of the constraining unit operation on a given independent path 24 A and it detects a high trim or low trim condition, the speed trimming percentage can be applied to that unit operation and then propagate downstream. However, if the unit operation is the constraint, or is upstream of the constraint, and a high or low trim condition is detected, the speed trimming percentage can be applied to the upstream unit operation and then propagate further upstream. In this way, and without desiring to be bound by theory, the speed of the constraint can be maximized. It was found that traditional approaches typically apply speed trimming locally to the downstream detecting unit operation, regardless of the location relative to the constraint, and typically do not propagate downstream, thus requiring the constraint to run below its maximum speed unless the constraint happens to be the upstream-most unit operation.
[0038] Thus, it should be realized that nearly all transfer of consumer-ready finally wound product between each component of the system 12 A would behave as a constant density transport conveyor. In other words, the conveyor starts, stops, and changes speed in conjunction with the upstream machine in order to maintain a constant product density. It should also be realized that this strategy also allows all machines within the system 12 A to change speed simultaneously. It is believed that a key benefit of this approach is that all conveyor states and speeds within system 12 A are calculated based on product density, unit operation speed, and the individualized consumer ready product recipe. In this way, the identical, standard logic is used for every conveyor in the system, enabling a variety of configurations and avoiding custom logic for each conveyor motor. This standard logic allows flexibility and scalability; for example, a conveyor may be added or removed to/from the system 12 A without impacting the logic. The traditional approach of custom logic for each motor requires a significant amount of programming, is prone to errors, and difficult to troubleshoot.
[0039] Without desiring to be bound by theory, it is believed that the following equation is used to calculate the speed for a transport conveyor:
[0000] S TC =R US ×(1 ÷X )/( L×D ); where: S TC =transport conveyor speed (in distance/minute); R US =upstream machine rate (in units/minute); I=product length (in distance/product) in the direction of travel; X=product roll count (in units/product); L=number of simultaneous lanes of product (#); and D=target product density (%).
[0047] In addition to any transport conveyors used in system 12 A, a process constraint may require additional conveyor types, for example accumulating and fixed speed. Accumulating conveyors behave like transport conveyors except that they follow the downstream machine. Fixed speed conveyors always run a fixed speed. Also, a given unit operation may require a certain amount of clean-out when shutting down. If this is the case, the conveyor(s) immediately downstream of the unit operation should continue to run for a certain amount of time after the respective unit operation shuts down.
[0048] In order to account for any variations in rates and product properties, and in order to be certain that a conveyor is operating within an acceptable speed range, the target product density in the equation above may need to be adjusted on a case-by-case basis. Preferably, this adjustment occurs automatically in the algorithm in order to ensure the calculated speed does not fall outside the acceptable range for the motor or drive. If so, the constant density of product on the conveyor will be jeopardized and unnecessary speed changes on the unit operations may occur.
[0049] When restarting the system 12 A, if any active unit operation is starved (i.e. lacking adequate quantity of product at its in-feed or in queue in order to run) for consumer-ready finally wound product, the target speeds for the associated independent paths 24 A are reduced to a low speed as defined in the master operator interface for each consumer-ready finally wound product recipe. The low speed start-up value is typically about half the steady state speed and is defined as a percentage of full speed. As is known to those of skill in the art, low speed start-up is critical in a close-coupled system 12 A because it allows the downstream starved operating station to ramp up to a matched speed with the upstream machine cooperatively coupled and associated thereto without blocking it (i.e., filling the downstream conveyor or queue such that the machine must stop). This “throughput reduction factor” is preferably applied to all discrete operating stations within each associated independent path 24 A in order to facilitate system 12 A trouble-shooting, re-starting, or other conditions consistent with a reduced operation and resulting output of system 12 A.
[0050] Once all the unit operations associated with system 12 A are satisfied and at rate, the machine target rates will increase to full speed after a pre-set time delay as defined in the master operator interface for each consumer-ready finally wound product recipe. Preferably the target rates and acceleration/deceleration rates for all unit operations and conveyors associated with system 12 A are provided from a single master control unit in order to best maintain product density on the conveyors. Note that a unit operation that is starved should use the maximum possible acceleration rate in order to minimize any accumulation at the in-feed as the unit operation ramps up. If any machine in system 12 A starves while in the steady state full speed running condition, the target rates will revert back to the low speed start-up values. This can occur, for example, when off-quality consumer-ready finally wound product is being generated and removed from a conveyor within system 12 A. Depending on process behavior, namely the variation in speeds, rates, and product density upon restart and unit operation reliability during acceleration, it may be desirable to apply low speed startup when recovering from all “down” states.
[0051] In a dual pack system 12 A with a shared unit operation downstream, it may not be possible to have one independent path 24 A at a steady state full speed condition and another independent path 12 A in a low speed start-up mode. This is typically due to the downstream unit operation not being able to merge incoming streams of dramatically different rates. An excellent example of this is two wrappers 16 (M 2 ) feeding a single bundler 18 (M 3 ), as shown in the instant example. If the bundler 18 (M 3 ) is running a format that requires two in-feed lanes, it may not be able to handle dramatically different in-feed rates. On the other hand, for one or three in-feed lanes, the rate variation may be acceptable. For this reason, an operator of system 12 A can select which operational mode, either low speed startup by path or for the entire system 12 A, is desired in the master operator interface.
[0052] Speed trimming occurs in the master control unit and not the individual machinery comprising system 12 A. In order to allow the system 12 A constraint to run at full rate and maximize throughput of consumer-ready finally wound product, the constraint unit operation speed is never trimmed. Rather, when a low trim condition occurs at the constraint, the corresponding upstream module goes into high trim. Likewise, for high trim condition at the constraint or upstream of the constraint, the corresponding upstream module goes into low trim.
[0053] Thus, if a module associated with an independent path 24 A of system 12 A is downstream of the constraint in a particular independent path 24 A, the independent path 24 A uses its local in-feed level to determine its speed trimming mode. If an operating station is upstream of the constraint, it uses the in-feed level of the corresponding downstream unit operation to determine its speed trimming mode. Recall that speed trimming modes are high trim and low trim, where high trim indicates the downstream machine should run faster than the upstream machine, and low trim indicates the upstream should run faster.
[0054] To minimize cycling between the trim modes, a particular unit operation should remain in a high or low trim for a minimum amount of time. The “minimum time in high trim” and “minimum time in low trim” parameters can be set in the master operator interface and are not necessarily specific to the consumer-ready finally wound product. High trim is preferably disabled while in low speed start-up mode, since the in-feed level usually increases after a stop as upstream conveyors run longer to clean-out the unit operation and/or clear back-up or blocked photoeyes.
[0055] Thus, referring to FIG. 15 , speed trimming is applied working outward from the constraint for each independent path 24 A. By way of example, a proportional consumer-ready product split is applied to the log saw 14 (M 1 ) and the constraint is satisfied on the bundler 18 (M 3 ). This effectively reduces the throughput of the lower independent path 28 A such that the target rate for the log saw 14 (M 1 ) on the lower independent path 28 A is 20 units/min.
[0056] Next, referring to FIG. 16 , the state of each independent path 24 A is identified. If any machine on an independent path 24 A is stopped, or any conveyor or queue between unit operations on that path is jammed or faulted, that particular independent path 24 A is considered to be in a “down” state. By way of non-limiting example, if the upper independent path 26 A shown in FIG. 16 comprising log saw 14 (M 1 ), wrapper 16 (M 2 ), bundler 18 (M 3 ), palletizer 22 (M 5 ) is in a “down” state, the reconstituted machine target rates are then taken into account to adjust the throughput of system 12 A. It then follows that the independent paths 24 A are then reconstituted or resolved into their pre-process configuration. For a machine common to multiple independent paths, the target rate for the machine is the sum of all target rates for each machine instance among the independent paths, provided the path is in an operating state. Thus, the target rates for the instantaneous operating capacity of each machine comprising system 12 A are then implemented in order to provide for maximum throughput through system 12 A. Thus, if the upper independent path 26 A comprising log saw 14 (M 1 ), wrapper 16 (M 2 ), bundler 18 (M 3 ), and palletizer 22 (M 5 ) is in a “down” state, the reconstituted machine target rates are then taken into account to adjust the output of system 12 A. Thus, since the upper independent path 26 A comprising log saw 14 (M 1 ), wrapper 16 (M 2 ), bundler 18 (M 3 ), and palletizer 22 (M 5 ) is not in operation, all output from log saw 14 (M 1 ) is directed toward the second wrapper 16 (M 2 ) and the third wrapper 16 (M 2 ) and eventually to bundler 18 (M 3 ), case packer 20 (M 4 ), and palletizer 22 (M 5 ), comprising, respectively, middle independent path 30 A and lower independent path 28 A. Thus, even though the capacity of log saw 14 (M 1 ) is far in excess of the realized output according to the process 10 A described herein, the output of log saw 14 (M 1 ) is reduced and the output of the remaining equipment comprising system 12 A is maintained as possible to accommodate an instantaneous interruption in production due to a malfunction of one of the components of system 12 A. Thus, using the example exhibited in FIGS. 9 through 17 , the target rate of log saw 14 (M 1 ) could be adjusted to a value of 40 units/minute in order to satisfy the capacity of both independent paths remaining operational as shown in FIG. 17 . As discussed previously, if the system 12 A were in speed-compensating mode, the outcome could be different in order to maximize throughput instead of maintaining rate on the running, and unaffected, unit operations.
[0057] In a preferred embodiment, special cases can exist where part of an independent path 24 A may be considered “down” and another part of independent path 24 A “operating” for purposes of reconstituting the unit operation target speeds. Exemplary and non-limiting cases can include: (Note: Low Speed Startup should be Applied in these Cases)
1) Unit operations upstream of a “blocked” unit operation are “down.” Those unit operations downstream are considered “running.” This way the downstream unit operations can attempt to clear the blocked condition. 2) Unit operations downstream of a “starved” unit operation are “down.” Those unit operations upstream are considered “running.” This way the upstream unit operations can provide product to the starved machine. Note that a true starved condition is not part of the normal machine process. For example, some case packers may have a short “waiting” period at the beginning of every cycle as it waits for product to enter the lifting chamber. In this instance, this should not be reported as a “starved” event. 3) A unit operation that is in jog mode is considered to be “down,” therefore causing any independent paths 24 A on which it resides to be “down.” However, if the unit operation is in jog mode and requires additional product at its in-feed (as determined from its in-feed monitoring sensors, typically photoeyes), the unit operations upstream of the jogging machine are considered “running.” 4) For purposes of multiple special cases, “down” takes precedence over “running.” For example, if there was a blocked unit operation on a path and further downstream a starved unit operation, only the unit operations in between would be in the special “running” state.
[0062] The dimensions and/or values disclosed herein are not to be understood as being strictly limited to the exact dimension and/or numerical values recited. Instead, unless otherwise specified, each such dimension and/or value is intended to mean both the recited dimension and/or value and a functionally equivalent range surrounding that recited dimension and/or value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
[0063] Every document cited herein, including any cross referenced, related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0064] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
|
A process to control product throughput in a multi-station manufacturing system is disclosed. The process comprises the steps of: providing the manufacturing system as a plurality of discrete operating stations; separating the plurality of pathways into a plurality of independent pathways; identifying a first constraining throughput capacity corresponding to each of the plurality of independent pathways; adjusting a target rate of each of the discrete operating stations in each of the plurality of independent pathways according to the corresponding first constraining throughput capacity; reconstituting the plurality of independent pathways into an interconnected pathway comprising the discrete operating stations; reforming the plurality of pathways for the object of manufacture to pass from the first operating station to the distal operating station; combining the target rate of each of the discrete operating stations of the interconnected pathways; and, adjusting product throughput according to the combined target rates.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of Korean Patent Application No. 10-2017-0037747, filed on Mar. 24, 2017, which claims the benefit of Korean Patent Application No. 10-2016-0062409, filed on May 20, 2016, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND
1. Field of the Invention
[0002] The present invention relates to a plant for expressing a target protein, a method of preparing the same, and a method of producing a target protein using the same, and more particularly, to a technique of fusing a target protein to a ribulose bisphosphate carboxylase/oxygenase small subunit (RbcS), which is a protein present in a chloroplast, and introducing the fusion product to a plant body for mass production, and preparation of a composition for oral administration of a biopharmaceutical using the same.
2. Discussion of Related Art
[0003] Biopharmaceuticals are medical substances present in living organisms, and in a broad sense, may be defined as medical products produced on the basis of bioengineering techniques including genetic recombination, cell fusion, cell culture, etc., which are high-end biotechnology. Such biopharmaceuticals are classified into protein drugs, therapeutic antibodies, vaccines, gene therapeutics and cell therapeutics.
[0004] These days, most recombinant proteins use higher cells such as animal cells and insect cells as hosts or are produced using microorganisms such as yeasts or bacteria. However, recombinant protein production through animal cell culture needs an expensive medium, has a high probability to contaminate viruses that can be infected to humans, and needs a separate purification process to remove the contaminated viruses due to a probability of the uptake of bovine serum-derived proteins. In addition, bacteria or yeasts facilitate the mass production of recombinant proteins, but never have post-synthetic modification of proteins or are not suitable for producing glycoproteins because they are very different from humans.
[0005] For this reason, in recent years, as an alternative production system for recombinant proteins, plant cell culture has attracted much attention. Plant cells are not only infected by animal-derived viruses or pathogenic bacteria but also have no risk of being mixed with animal-derived substances, and therefore the plant cell culture is considered as a safe production system.
[0006] However, the plant cell culture exhibits a relatively lower protein expression level and a lower growth rate than different hosts including animal cells. When recombinant proteins are produced in plant bodies to commercialize plant-derived biopharmaceuticals, it is urgent to develop a technique for increasing expression efficiency of an introduced gene.
[0007] Meanwhile, protein drugs are most widely used to be administered into a human body in an injectable form and can be the most effective method that can be applied, but they can cause pain in patients. Particularly, in the case of metabolic diseases such as diabetes, it is necessary to administer protein drugs regularly for a long time by injection, and therefore patients with such a disease endure much pain. For this reason, it is urgent to develop a technique for oral administration of protein drugs. Since biopharmaceuticals produced in plant bodies can be orally administered without protein isolation and purification, they can be a dramatic method. However, when protein drugs are orally administered, they can be degraded by pepsin secreted from the stomach and trypsin secreted from the intestines.
SUMMARY OF THE INVENTION
[0008] Therefore, the inventors completed the present invention by confirming that an RbcS gene known to be stably present in the form of a protein complex in a chloroplast increases expression of a target protein in plant cells, and a fusion protein between the target protein and RbcS was linked with RbcL to make a macromolecule, thereby highly increasing a resistance to the protein degradation by the existing pepsin described above.
[0009] Accordingly, the present invention is directed to providing an RbcS gene fragment and a gene construct for high expression of a target protein.
[0010] The present invention is also directed to providing a recombinant expression vector for high expression of a target protein.
[0011] The present invention is also directed to providing a transformed plant body that highly expresses target proteins.
[0012] The present invention is also directed to providing a method of preparing a transformed plant body that highly expresses target proteins.
[0013] The present invention is also directed to providing a method of constructing an expression vector for high expression of target proteins in plant cells to produce a large quantity of target proteins from a plant body by utilizing the vector.
[0014] The present invention is also directed to providing a fusion protein in which a target protein is bound with an RbcS peptide fragment.
[0015] The present invention is also directed to providing a method of forming a 500 to 800-kD large complex when a target protein is bound with an RbcS peptide fragment to have a resistance to a protease present in a digestive organ.
[0016] The present invention is also directed to providing a pharmaceutical composition for oral administration, which includes a fusion protein in which a target protein is bound with an RbcS peptide fragment as an active ingredient.
[0017] In one aspect, the present invention provides an RbcS gene fragment, which improves the expression level of a target protein located downstream in plant cells.
[0018] In another aspect, the present invention provides a gene construct for high expression of a target protein in which (a) RbcS gene and (b) a gene encoding a target protein are operably linked in order.
[0019] According to an exemplary embodiment of the present invention, the RbcS gene may be a polynucleotide sequence represented as SEQ ID NO: 1.
[0020] According to another exemplary embodiment of the present invention, the target protein may be, but is not limited to, any one or more selected from the group consisting of an antigen, an antibody, an antibody fragment, a structural protein, a regulatory protein, a transcription factor, a toxin protein, a hormone, a hormone analogue, a cytokine, an enzyme, an enzyme inhibitor, a transport protein, a receptor, a fragment of a receptor, a defense inducer, a storage protein, a movement protein, an exploitive protein and a reporter protein.
[0021] According to an exemplary embodiment of the present invention, the gene construct may further include a promoter gene at the 5′ end of the RbcS gene, and the promoter may be, but is not limited to, a 35S promoter derived from cauliflower mosaic virus, a 19S RNA promoter derived from cauliflower mosaic virus, a plant actin promoter and a ubiquitin promoter.
[0022] According to another exemplary embodiment of the present invention, a protein tag gene may be further included at the 3′ end of a gene encoding a target protein, and may be, but is not limited to, any one selected from the group consisting of an Avi tag, a Calmodulin tag, a polyglutamate tag, an E tag, a FLAG tag, a HA tag, a His tag, an Myc tag, a S tag, a SBP tag, an IgG-Fc tag, a CTB tag, a Softag 1 tag, a Softag 3 tag, a Strep tag, a TC tag, a V5 tag, a VSV tag and an Xpress tag.
[0023] The present invention also provides a recombinant expression vector including the gene construct.
[0024] In still another aspect, the present invention provides a transformed plant body which is transformed with the recombinant expression vector and highly expresses a target protein.
[0025] According to an exemplary embodiment of the present invention, the plant may be selected from food crops including rice, wheat, barley, corn, bean, potato, red bean, oat and sorghum; vegetable crops including Arabidopsis thaliana, Chinese cabbage, white radish, pepper, strawberry, tomato, watermelon, cucumber, cabbage, oriental melon, pumpkin, spring onion, onion, and carrot; industrial crops including ginseng, tobacco, cotton, sesame, sugarcane, sugar beet, perilla, peanut, and rape; fruit crops including apple tree, pear tree, jujube tree, peach, grape, tangerine, persimmon, plum, apricot, and banana; and flower crops including rose, carnation, chrysanthemum, lily, and tulip, but the present invention is not limited thereto.
[0026] In yet another aspect, the present invention provides a method of preparing a transformed plant body for highly expressing a target protein, which includes constructing a recombinant expression vector and introducing the recombinant expression vector into a plant body.
[0027] According to an exemplary embodiment of the present invention, the introduction of the recombinant expression vector into a plant body may be selected from, but not limited to, an Agrobacterium sp.-mediated method, particle gun bombardment, silicon carbide whiskers, sonication, electroporation and polyethylene glycol (PEG)-mediated transformation.
[0028] In yet another aspect, the present invention provides a method of producing a target protein, which includes (a) constructing the recombinant expression vector, (b) preparing a transformed plant body by introducing the recombinant expression vector to a plant, (c) culturing the transformed plant body and (d) isolating and purifying a target protein from the transformed plant body or a culture solution.
[0029] According to an exemplary embodiment of the present invention, a transformed plant body may be prepared by introducing the recombinant expression vector into a plant from which an RbcS gene present in a genome is deficient, and thereby a target protein may be effectively produced.
[0030] In yet another aspect, the present invention provides a fusion protein which includes a target protein and an RbcS peptide fragment linked to the 5′ end of the target protein.
[0031] According to an exemplary embodiment of the present invention, the RbcS peptide fragment may be an amino acid sequence represented by SEQ ID NO: 2.
[0032] According to an exemplary embodiment of the present invention, the fusion protein may be a 500 to 800-kD large complex. The size of the fusion protein may depend on the size of a target protein linked to the RbcS peptide fragment.
[0033] According to an exemplary embodiment of the present invention, the fusion protein has a resistance to a digestive enzyme.
[0034] In yet another aspect, the present invention provides a pharmaceutical composition for oral administration, which includes a fusion protein to which an RbcS peptide fragment is linked at the 5′ end of a target protein.
[0035] In yet another aspect, the present invention provides a pharmaceutical composition for oral administration, which includes a transformed plant body for expressing a fusion protein to which an RbcS peptide fragment is linked at the 5′ end of a target protein as an active ingredient.
[0036] According to an exemplary embodiment of the present invention, the RbcS peptide fragment may be an amino acid sequence represented by SEQ ID NO: 2.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The above and other objects, features and advantages of the present invention will become more apparent to those of ordinary skill in the art by describing exemplary embodiments thereof in detail with reference to the accompanying drawings, in which:
[0038] FIG. 1 is a schematic diagram of an RbcS-fusion construct prepared according to an exemplary embodiment of the present invention;
[0039] FIG. 2 is an image of western blots confirming that a target protein is highly expressed in plant cells due to RbcS fusion prepared according to an exemplary embodiment of the present invention;
[0040] FIG. 3 shows an image of western blots confirming that an RbcS-fusion protein prepared according to an exemplary embodiment of the present invention is more highly expressed in RbcS deletion mutants than normal plants;
[0041] FIG. 4 is an image of western blots confirming that expression of an RbcS-fusion protein in a transformed plant body prepared according to an exemplary embodiment of the present invention;
[0042] FIG. 5 is a result of an experiment on a pepsin resistance effect per concentration of an RbcS protein-fused target protein (RbcS-FL:leptin:HA) according to an exemplary embodiment of the present invention;
[0043] FIG. 6 is a result of an experiment for a pepsin resistance effect per reaction time of an RbcS protein-fused target protein (RbcS-FL:leptin:HA) according to an exemplary embodiment of the present invention;
[0044] FIG. 7 is a Blue-Native PAGE result confirming that an RbcS protein-fused target protein complex is formed according to an exemplary embodiment of the present invention;
[0045] FIG. 8 is a result confirming stability of RbcS-FL:leptin:HA in a digestive tract according to an exemplary embodiment of the present invention;
[0046] FIG. 9 is a result confirming high expression of a fusion protein RFeEx4fG15 according to an exemplary embodiment of the present invention; and
[0047] FIG. 10 is a result confirming the formation of a complex between rubisco and a fusion protein RFeEx4fG15 according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0048] Hereinafter, the present invention will be described in detail.
[0049] As described above, to design a method capable of producing a large quantity of target proteins in plant cells, the inventors focused on protein domain fusion capable of stabilizing target proteins in cells, isolated an RbcS gene known to be stably present in the form of a protein complex in the chloroplast of Arabidopsis thaliana , and confirmed the fact that when the RbcS gene is fused, expression of target proteins in plant cells is increased (refer to Example 2).
[0050] Therefore, the present invention provides an RbcS gene fragment which is characterized by improving the expression level of target proteins located downstream in plant cells.
[0051] The RbcS gene may consist of an amino acid sequence of SEQ ID NO: 1. In addition, a variant of the base sequence is included in the scope of the present invention. Specifically, the gene may include a base sequence having 70% or more, preferably 80% or more, more preferably 90% or more, and most preferably 95% or more sequence homology with respect to the base sequence of SEQ ID NO: 1. The “% sequence homology” with respect to a polynucleotide is determined by comparing two optimally-arranged sequences with a comparative region, and a part of the polynucleotide sequence in the comparative region may include addition or deletion (that is, a gap) compared to a reference sequence (without addition or deletion) with respect to the optimal arrangement of two sequences.
[0052] In addition, the present invention provides a gene construct for high expression of a target protein, in which (a) an RbcS gene; and (b) a target protein-encoding gene are operably linked in order.
[0053] The gene construct of the present invention may further include a promoter gene at the 5′ end of the RbcS gene.
[0054] The gene construct of the present invention may further include a protein tag gene at the 3′ end of a gene encoding a target protein.
[0055] In the gene construct of the present invention, (a) a promoter gene; (b) an RbcS gene; (c) a gene encoding a target protein; and (d) a protein tag gene are operably linked in order.
[0056] In this case, a promoter may be any one that can express a gene inserted in a plant body without a particular limitation, and is preferably selected from a 35S promoter derived from cauliflower mosaic virus, a 19S RNA promoter derived from cauliflower mosaic virus, a plant actin promoter and a ubiquitin promoter.
[0057] The RbcS gene may be a gene encoding RbcS, and most preferably an RbcS gene represented by SEQ ID NO: 1, derived from Arabidopsis thaliana.
[0058] Here, the target protein is a term referring to a protein to be produced, and is not limited to a specific protein. Specifically, the target protein may be any one or more selected from the group consisting of an antigen, an antibody, an antibody fragment, a structural protein, a regulatory protein, a transcription factor, a toxin protein, a hormone, a hormone analogue, a cytokine, an enzyme, an enzyme inhibitor, a transport protein, a receptor, a fragment of a receptor, a defense inducer, a storage protein, a movement protein, an exploitive protein and a reporter protein.
[0059] In one exemplary embodiment of the present invention, as the target protein, parathyroid hormone (PTH) or leptin was used. However, the target protein of the present invention is not limited to leptin or PTH. The present invention may also be used in mass expression of various small peptide-like hormones such as human growth hormone, GLP1, Exendin-4, etc. The expressed protein may be isolated and purified from RbcS by introducing a specific protein degradation site into a fusion part with RbcS.
[0060] In addition, the protein tag gene of the present invention may be any distinguishable tag without limitation in order to isolate and purify a protein. Specifically, the protein tag may be any one or more selected from the group consisting of an Avi tag, a Calmodulin tag, a polyglutamate tag, an E tag, a FLAG tag, a HA tag, a His tag, a Myc tag, a S tag, a SBP tag, an IgG-Fc tag, a CTB tag, a Softag 1 tag, a Softag 3 tag, a Strep tag, a TC tag, a V5 tag, a VSV tag and an Xpress tag.
[0061] The present invention also provides a recombinant expression vector including the gene construct.
[0062] The term “recombinant” is used to refer to cells that replicate heterologous nucleic acids, express the nucleic acids, or express a protein encoded by peptides, heterologous peptides or heterologous nucleic acids. Such recombinant cells may express one of sense and antisense genes or gene fragments, which have not been found in natural cells. In addition, while the recombinant cells may express a gene that is found in natural cells, the gene is modified, and reintroduced to cells by an artificial means.
[0063] In the present invention, the RbcS gene sequence may be inserted into a recombinant expression vector. The term “recombinant expression vector” refers to a bacterial plasmid, a phage, a yeast plasmid, a plant cell virus, a mammalian cell virus or a different vector. Generally, any plasmid and vector may be used as long as they can be replicated and stabilized in hosts. The key feature of the expression vector is having a replication origin, a promoter, a marker gene and a translation control element.
[0064] An expression vector including the RbcS gene sequence and suitable transcription/translation control signals may be constructed by a method known in the art. The method includes an in vitro recombinant DNA technique, a DNA synthesis technique and an in vivo recombination technique.
[0065] The DNA sequence may be effectively linked to a suitable promoter in the expression vector to elicit mRNA synthesis. A vector suitable for expressing the DNA fragment according to the present invention and a gene encoding a target protein in plant cells is a pUC19-based plasmid or Ti plasmid vector.
[0066] Exemplary examples of the recombinant vector of the present invention include a part of the vector when the vector is present in suitable hosts such as Agrobacterium tumefaciens , and a Ti-plasmid vector which can transfer the so-called T region to plant cells. A different type of Ti-plasmid vector is a protoplast capable of producing a new plant which suitably inserts current plant cells or hybrid DNA into a plant genome to transfer a hybrid DNA sequence. A particularly exemplary form of the Ti-plasmid vector is a so-called binary vector, which has been disclosed in European Patent (EP) No. 0120 516 B1 and U.S. Pat. No. 4,940,838. Another suitable vector that can be used to introduce the DNA according to the present invention into a plant host may be selected from viral vectors derived from a double-stranded plant virus (e.g., CaMV) and a single-stranded virus, for example, a non-competent plant virus vector. The use of such a vector may be particularly advantageous when it is difficult to properly transform a plant host.
[0067] Examples of the suitable vectors may include, but are not limited to, a binary vector such as a 326 GFP or pCAMBIA-derived vector, and thus one of ordinary skill in the art can select any vector capable of expressing the DNA fragment according to the present invention and a gene encoding a target protein in plant cells.
[0068] More specifically, the recombinant vector is a recombinant expression vector in which a promoter, the DNA fragment according to the present invention to improve an expression level of a target protein, and a gene encoding a target protein are operably linked in order to a conventional vector used in protein expression as a basic backbone.
[0069] In addition, the expression vector may include a ribosome-binding site as a translation initiation site and a transcription terminator.
[0070] The expression vector may include one or more selectable markers. The marker is a nucleic acid sequence conventionally having a characteristic selected by a conventional chemical method, and includes any gene capable of discriminating transformed cells from untransformed cells. Examples of such genes include, but are not limited to, genes having a resistance to herbicides such as glyphosate and phosphinothricin, genes having a resistance to antibiotics such as kanamycin, G418, bleomycin, hygromycin, and chloramphenicol, and aadA gene.
[0071] In the recombinant vector of the present invention, the promoter may be a CaMV 35S, actin, ubiquitin, pEMU, MAS, histone promoter, or Clp promoter, but the present invention is not limited thereto. The “promoter” refers to a DNA region upstream from a structural gene, and a DNA molecule to which an RNA polymerase is bound to initiate transcription. The “plant promoter” is a promoter capable of initiating transcription in plant cells. The “constitutive promoter” is a promoter that is active under most of environmental conditions and developing stage or cell differentiation. Since the selection of transformants can be achieved by various types of tissue in various stages, in the present invention, a constitutive promoter is preferably used. Therefore, a constitutive promoter is not limited in selectability.
[0072] In the recombinant vector of the present invention, a conventional terminator may be used, and may be, for example, nopaline synthase (NOS), rice amylase RAmy1 A terminator, phaseolin terminator, Octopine gene terminator of Agrobacterium tumefaciens , or E. coli rrnB 1/B2 terminator, but the present invention is not limited thereto. In terms of the necessity of a terminator, such a region is generally known to increase certainty and efficiency of transcription in plant cells. Therefore, the use of a terminator is very preferable for the scope of the present invention.
[0073] Host cells which can stably and sequentially clone and express the vector of the present invention in prokaryotic cells may be any host cells known in the art, and include, for example, E. coli JM109, E. coli BL21, E. coli RR1, E. coli LE392, E. coli B, E. coli X 1776, E. coli W3110, Bacillus strains such as Bacillus subtilis and Bacillus thuringiensis , and Enterobacteriaceae strains such as Salmonella typhimurium, Serratia marcescens and various Pseudomonas sp.
[0074] In addition, when the vector of the present invention is transformed in eukaryotic cells, as host cells, yeast cells ( Saccharomyce cerevisiae ), insect cells, human cells (e.g., a Chinese hamster ovary (CHO) cell line, W138, BHK, COS-7, 293, HepG2, 3T3, RIN and MDCK cell lines) or plant cells may be used. The host cells are preferably plant cells, and the plant may be selected from rice, wheat, barley, corn, bean, potato, red bean, oat and sorghum; vegetable crops including Arabidopsis thaliana, Chinese cabbage, white radish, pepper, strawberry, tomato, watermelon, cucumber, cabbage, oriental melon, pumpkin, spring onion, onion, and carrot; industrial crops including ginseng, tobacco, cotton, sesame, sugarcane, sugar beet, perilla, peanut, and rape; fruit crops including apple tree, pear tree, jujube tree, peach, grape, tangerine, persimmon, plum, apricot, and banana; and flower crops including rose, carnation, chrysanthemum, lily, and tulip.
[0075] A method of delivering the vector of the present invention into host cells may be performed by, when host cells are prokaryotic cells, a CaCl 2 method, a Hanahan method (Hanahan, D., J. Mol. Biol., 166:557-580(1983)) or electroporation. In addition, when host cells are eukaryotic cells, the vector may be injected into the host cells by microinjection, calcium phosphate precipitation, electroporation, liposome-mediated transfection, DEAE-dextran treatment, or gene bombardment.
[0076] The present invention also provides a transformed plant body which is transformed with the recombinant expression vector and highly expresses a target protein.
[0077] According to another exemplary embodiment of the present invention, the plant may be selected from rice, wheat, barley, corn, bean, potato, red bean, oat and sorghum; vegetable crops including Arabidopsis thaliana , Chinese cabbage, white radish, pepper, strawberry, tomato, watermelon, cucumber, cabbage, oriental melon, pumpkin, spring onion, onion, and carrot; industrial crops including ginseng, tobacco, cotton, sesame, sugarcane, sugar beet, perilla, peanut, and rape; fruit crops including apple tree, pear tree, jujube tree, peach, grape, tangerine, persimmon, plum, apricot, and banana; and flower crops including rose, carnation, chrysanthemum, lily, and tulip.
[0078] The present invention also provides a method of preparing a transformed plant body for highly expressing a target protein, which includes constructing a recombinant expression vector; and introducing the recombinant expression vector into a plant body.
[0079] For the introduction of the plant expression vector into plant cells or a plant body, any one method selected from the group consisting of an Agrobacterium sp.-mediated method, particle gun bombardment, sonication, electroporation and polyethylene glycol (PEG)-mediated transformation may be used. In one exemplary embodiment of the present invention, for transformation of an Arabidopsis thaliana protoplast, PEG-mediated transformation, and for construction of an Arabidopsis thaliana transformant, an Agrobacterium sp.-mediated method were used.
[0080] The present invention also provides a method of producing a large quantity of target proteins using a plant transformed with the recombinant vector of the present invention.
[0081] Specifically, the method of producing a target protein of the present invention includes (a) constructing the recombinant expression vector; (b) preparing a transformed plant body by introducing the recombinant expression vector into a plant; (c) culturing the transformed plant body; and (d) isolating and purifying a target protein from the transformed plant body or a culture solution.
[0082] In the method of producing a target protein of the present invention, the plant may be a plant from which an RbcS gene present in the genome is deficient.
[0083] The method of producing a target protein from the transformed plant cells may obtain a target protein from transformed cells after plant cells are transformed with the recombinant vector according to the present invention and culturing the cells for a suitable time to express the target protein. Here, a method of expressing the target protein is any method known in the art.
[0084] In this method, a transformant was constructed with Arabidopsis thaliana , but the present invention is not limited thereto, and the method of the present invention can employ all of protoplasts isolated from dicotyledones or monocotyledones.
[0085] The present invention provides a fusion protein including a target protein and an RbcS peptide fragment binding at the 5′ end of the target protein.
[0086] The fusion protein of the present invention forms a 500 to 800-kD large complex to have a resistance to a protease in a digestive organ.
[0087] The present invention also provides a pharmaceutical composition for oral administration, which includes a fusion protein in which an RbcS peptide fragment is bound at the 5′ end of a target protein as an active ingredient.
[0088] The present invention also provides a pharmaceutical composition for oral administration, which includes a transformed plant body expressing a fusion protein in which an RbcS peptide fragment is bound at the 5′ end of a target protein as an active ingredient.
[0089] According to an exemplary embodiment of the present invention, the RbcS peptide fragment may be an amino acid sequence represented by SEQ ID NO: 2.
[0090] Hereinafter, the present invention will be described in further detail with reference to examples. These examples are merely provided to exemplify the present invention, and it would be obvious to those of ordinary skill in the art as long as the scope of the present invention is not limited by these examples.
Example 1
Construction of Recombinant Expression Vector
[0091] The inventors used a gene construct to which [35S promoter]-[RbcS gene]-[target protein gene]-[HA tag] was operably linked as an expression vector ( FIG. 1 ). When a gene encoding a target protein was cloned in an expression vector and then expressed in plant cells, RbcS was expressed in a fused state, transferred to a chloroplast and thus accumulated.
[0092] In one example of the present invention, parathyroid hormone (PTH) was used as a target protein, and a method of constructing an expression vector is as follows. PCR was performed with the genomic DNA of Arabidopsis thaliana as a template using a forward primer consisting of a “XbaI-RbcS N-terminal sequence” (SEQ ID NO: 6) and a reverse primer consisting of a “BamHI-RbcS C-terminal sequence” (SEQ ID NO: 7) to amplify an RbcS gene. In addition, PCR was performed with PTH-contained plasmid DNA as a template using a forward primer consisting of a “BamHI-PTH N-terminal sequence” (SEQ ID NO: 8) and a reverse primer consisting of a “XhoI-stop codon-HA C-terminal sequence” (SEQ ID NO: 9) to amplify a HA-tag-fused PTH gene. The amplified PCR products were cleaved with XbaI/BamHI (the first PCR product) and BamHI/XhoI (the second PCR product) and purified, respectively. These two PCR products were cloned between a 35S promoter of cauliflower mosaic virus (SEQ ID NO: 3) and a NOS terminator in a 326 GFP (Arabidopsis Biological Resource Center, Ohio State University, Ohio, USA) plasmid cleaved with XbaI/XhoI, thereby constructing an expression vector RbcS:PTH:HA.
Example 2
Comparison of Protein Expression Effects of RbcS Fusion Vectors
[0093] A transformant was prepared by introducing the expression vector prepared in Example 1 into the protoplast separated from a leaf of Arabidopsis thaliana , and amounts of RbcS-fusion proteins expressed from the transformant were compared by western blotting analysis.
[0094] Specifically, 30 μg of a cell lysate was mixed with an SDS sample buffer, heated, and then subjected to electrophoresis using a 10% SDS-PAGE gel. A separated protein was transferred to a PVDF membrane, and the reaction was blocked with 5% skim milk. Subsequently, the resulting product was reacted with anti-HA antibodies (1:1,000 dilution), and then reacted with horseradish peroxidase (HRP)-labeled secondary antibodies. Afterward, an ECL solution was treated according to a manufacturer's instruction manual.
Example 3
Analysis of Protein Expression Levels Due to RbcS Fusion in Plant Cells
[0095] To confirm protein expression levels due to RbcS fusion, a plasmid gene in which an RbcS full length gene (SEQ ID NO: 1) was installed upstream PTH:HA, and as a control, a plasmid gene in which an RbcS transit peptide (SEQ ID NO: 10), instead of the RbcS full length gene, was installed upstream PTH:HA was used. These genes were introduced to protoplasts separated from leaves of Arabidopsis thaliana by PEG-mediated transformation and cultured for 24 hours, the protoplasts were collected, lysed and quantified, followed by western blotting analysis.
[0096] Consequently, referring to FIG. 2 , it was shown that the expression of PTH:HA fused with the RbcS full-length gene in the Arabidopsis thaliana protoplast was higher than that of PTH:HA fused with the RbcS transit peptide, which was the control. Accordingly, it can be seen that when the RbcS gene is used as a fusion partner, the expression level of a target protein is improved.
Example 4
Comparative Analysis of Protein Expression Levels Due to RbcS Fusion in Wild-Type Plants and RbcS Gene-Deleted Plants
[0097] To analyze the expression level of the RbcS-fusion protein in RbcS gene-deficient plants, RbcS gene-deficient mutants of Arabidopsis thaliana were used as host cells.
[0098] Specifically, after protoplasts were separated from leaves of wild-type Arabidopsis thaliana and RbcS gene-deficient mutant of Arabidopsis thaliana , respectively, the PTH:HA gene fused with the RbcS full length gene (SEQ ID NO: 1) was introduced to each protoplast by PEG-mediated transformation, and cultured for 24 hours to collect, lyse and quantify protoplasts, followed by western blotting analysis.
[0099] As a result, referring to FIG. 3 , it was shown that the expression of the PTH:HA fused with the RbcS full length gene is higher in the RbcS gene-deficient mutant of Arabidopsis thaliana than in the wild-type Arabidopsis thaliana . Accordingly, it can be seen that the expression level of a target protein can be effectively improved using a method of expressing the RbcS-fusion protein in the RbcS gene-deficient mutant.
Example 5
Construction of Transformed Plant Body Expressing RbcS Fusion Protein
[0100] A transformed plant body which is improved in target protein expression due to RbcS fusion was constructed. A plasmid for transforming a plant body was constructed as follows. First, PCR was performed with plasmid DNA containing leptin as a template using a forward primer consisting of “BamHI-leptin N-terminal sequence” (SEQ ID NO: 12 GGATCCATGTGCTGGAGACCCCTG) and a reverse primer consisting of “XhoI-stop codon-HA C-terminal sequence” (SEQ ID NO: 13 ctcgagtcaggaagcgtaatctggaacatcgtatgggtaagcccgggggcattcagggctaacatccaac) to amplify a HA-tag-fused leptin gene. The amplified PCR product was cleaved with BamHI/XhoI, purified and then cloned in RbcS:PTH:HA plasmid DNA cleaved with BamHI/XhoI, thereby constructing RbcS:leptin:HA.
[0101] A recombinant transformation vector was prepared by cloning a 35S promoter-RbcS:leptin:HA:NOS terminator-formed gene construct in a multi-cloning site of a pCAMBIA1300 vector by cleaving an RbcS:leptin:HA-contained region in the prepared recombinant vector using XbaI and EcoRI restriction enzymes. Subsequently, a transformed plant body was manufactured by Agrobacterium sp.-mediated transformation using the prepared recombinant transformation vector. Here, the plant body transformed with pCABIA1300, which is a basic vector of the prepared transformation vector was selected by the method of the present invention through a hygromycin resistance test. In addition, the plant body selected by the resistance test was subjected to western blotting to identify a line highly expressing a protein, thereby ensuring first generation transformants ( FIG. 4 ), from second generation transformants, lines clearly exhibiting “dead individuals:live individuals” at a ratio of 1:3 were selected using a hygromycin resistance test, and among these lines, all live individuals from third generation transformants were selected as homo to maintain a line, thereby ensuring a transformed plant body line. Referring to FIG. 4 , various bands were observed in transformants 1 to 5, 8 and 11, confirming that a target protein (RbcS:leptin:HA) was highly expressed.
Example 6
Pepsin-Resistant Effect of RbcS-Fused Protein
[0102] A transformed plant body of the RbcS-FL:leptin:HA as shown in Example 5 was manufactured and then a resistance against pepsin was investigated in vitro using the plant body.
[0103] Specifically, after the corresponding transformed plant body was grown for approximately 4 weeks in a green house, leaves were harvested, freeze-dried and then grinded to manufacture a fine powder. A 10 mg aliquot of such a powder-type transformed plant body was mixed with a buffer with pH 2.0, and treated with 0, 200 or 400 ng/μL of pepsin to perform a reaction at 37° C. for 30 minutes. Afterward, the sample was cooled on ice for approximately 10 minutes to reduce the activity of pepsin, and treated with a 1.5 M Tris buffer with pH 8.8 to raise pH and then reduce the activity of pepsin again. Subsequently, cells were disrupted by sonication, mixed with a buffer and boiled for 10 minutes to remove a debris by centrifugation at 14,000 rpm. After then, the sample corresponding to 100 μg was quantified and subjected to SDS-PAGE and then western blotting. As controls to compare a resistance of the fusion protein according to pepsin treatment, an ER protein, which was a chaperone-binding protein (BiP), and a chloroplast protein for forming a complex protein, which was a chlorophyll a-b binding protein (Lhcb4), were used. As a result, referring to FIG. 5 , a leptin protein (RFL-leptin) fused with an RbcS full length gene exhibited a higher degradation resistance than Bip in a reaction with a high concentration of pepsin, and exhibited a similar degradation resistance to Lhcb4 for forming another complex.
[0104] Here, it was confirmed that the RbcS-fusion protein exhibited a degradation resistance according to pepsin treatment per concentration, and subsequently, the degradation was examined with a reaction time variation of 30 minutes, 1 hour and 2 hours with respect to 400 ng/μL pepsin. Consequently, referring to FIG. 6 , although the reaction time was increased, the RbcS-fusion protein still exhibited degradation resistance, unlike other proteins.
Example 7
Confirmation of Stability of RbcS-Leptin in Digestive Tract
[0105] To measure the stability of RbcS-FL:leptin:HA protein in a digestive tract, the protein was given to a mouse by a forced diet, and food was obtained from the stomach and the small intestine, followed by western blotting.
[0106] Subsequently, leaves of an RbcS-FL:leptin:HA-transformed plant body were freeze-dried under liquid nitrogen, and grinded to manufacture a fine powder. The powder was suspended in PBS, and to exactly control a time in the digestive tract, 80 mg (based on leaf dry weight) of the suspension per individual was directly administered to the stomach of each C57BL/6 mouse (n=5) using zoned. 30 minutes after the administration, food was obtained from the stomach and the small intestine, added to an RIPA lysis buffer, and disrupted by sonication. Cell debris was removed by centrifugation (14,000 xg). Following Bradford protein quantification, 20 μg of a protein was loaded in an SDS-PAGE gel to perform western blotting. HA antibodies were used to identify the presence of the RbcS-FL:leptin:HA.
[0107] Consequently, referring to FIG. 7 , when the food was harvested from the stomach, the original molecular weight of the RbcS-FL:leptin:HA was detected in most individuals. At the same time, compared to the stomach, while it seems that digestion further progressed in the small intestine, the original molecular weight of RbcS-FL:leptin:HA was detected. This showed that when the RbcS-fusion target protein was orally administered, the protein was not degraded by a digestive enzyme but stably present in the digestive tract.
Example 8
Confirmation of Rubisco Complex of RbcS-Fused Protein
[0108] To confirm whether the RbcS-FL:leptin:HA prepared in the above-described example still forms a rubisco complex regardless of the fusion of a leptin gene, Blue-Native polyacrylamide gel electrophoresis (PAGE) was performed.
[0109] The Blue-Native PAGE analysis is a method of confirming a polymer-form protein, and specifically included the following process. After the transformed plant body was grown in a green house for approximately 4 weeks, leaves were collected therefrom, freeze-dried, and grinded to manufacture a fine powder. 10 mg aliquot of the powder-type transformed plant body was mixed with a Bis-Tris buffer, the cells were disrupted by sonication, quantified and then lysed with a non-ionic detergent, which was n-dodecyl β-D-maltoside. Afterward, following mixing with Coomassie brilliant blue-G250 (CBB-G), electrophoresis was performed in a Blue-Native gel in a 4 to 16% concentration gradient, and then western blotting was performed by the same method as described in the above-described example.
[0110] Consequently, referring to FIG. 8 , it was confirmed that the fusion protein forms a rubisco complex.
Example 9
Confirmation of Formation of Rubisco Complex of RbcS-fused Protein with Different Target Protein
[0111] As confirmed in Example 8, to further clarify that an RbcS-fusion target protein forms a rubisco complex, an experiment was performed on a different target protein, except leptin.
[0112] Specifically, the leptin:HA part was removed from the RbcS-leptin:HA recombinant vector, and a DNA fragment in which exendin-4 (SEQ ID NO: 14) and a GM1-binding peptide (G15) (SEQ ID NO: 16) were fused was recombined with the resulting vector (RFeEx4fG15). The prepared recombinant vector was introduced to a protoplast separated from a leaf of Arabidopsis thaliana by PEG-mediated transformation, and an amount of the RbcS-fusion protein expressed after 24 hours was detected by western blotting analysis. Consequently, referring to FIG. 9 , it was confirmed that a target fusion protein (RFeEx4fG15) was overexpressed in an expected size (29 kD).
[0113] In addition, to confirm whether the target fusion protein (RFeEx4fG15) forms a rubisco complex, a recombinant vector was introduced to a protoplast by the above-described method, and Blue native-PAGE was performed. As a result, referring to FIG. 10 , it was confirmed that a fusion protein that had an original size of 29 kD was identified as a larger protein complex than a band observed at approximately 480 kD with Coomassie brilliant blue (CBB) staining, compared to a band (rubisco complex) observed at approximately 480 kD, which indicates that the target fusion protein normally formed the rubisco complex. Therefore, it can be confirmed that, when the RbcS fragment of the present invention was used as a fusion partner regardless of the type of a target protein, the rubisco complex can be stably formed.
[0114] Therefore, the present invention provides a plant for expressing a target protein, a method of preparing the same, and a method of producing a target protein using the same. According to the present invention, a target protein can be highly expressed at high efficiency from a plant body and thus can be applied to mass production of an industrial or medical protein using a plant body. Particularly, the plant can be applied to produce a protein drug for oral administration and prepare a pharmaceutical composition for oral administration without isolation and purification of the produced protein.
[0115] Above, the present invention has been described with reference to exemplary examples, but it can be understood by those of ordinary skill in the art that the present invention may be changed and modified in various forms without departing from the spirit and scope of the present invention which are described in the accompanying claims.
|
The present invention provides a plant expressing a target protein, a method of preparing the same and a method of preparing a composition for oral administration of a biopharmaceutical using the same. A target protein expression system using plant cells according to the present invention solves conventional problems in plant cell culture, provides a method of producing a large quantity of target proteins including a biopharmaceutical protein and allowing a target protein to have a resistance to a protease present in a digestive organ, and therefore is very effective to enable commercialization of plant-derived biopharmaceuticals.
| 2
|
BACKGROUND OF THE INVENTION
A variety of adjustable measuring spoons or cups are known. Examples include those described in U.S. Pat. No. 2,165,642, U.S. Pat. No. 2,630,014, U.S. Pat. No. 5,182,948, US 2005/0160807. Such devices provide a cook or baker with a single device for measuring solid particulate substances as salt, flour, sugar, spices and the like, with reasonable accuracy, but are much less suited to liquid measure, such as water, oil, vinegar, etc. This is because liquid often can get behind the movable dam or wall of the device.
The known devices also include complex shapes which makes cleaning difficult and/or which requires that relatively thin plastic parts be unsnapped for disassembly and cleaning, stressing relatively thin plastic parts which can easily break or become loose as a result.
SUMMARY OF THE INVENTION
The present invention in some aspects provides an adjustable measuring device which provides a simpler construction and easier cleaning. In some further aspects the present invention provides an adjustable measuring device which provides a sealing engagement of the movable parts sufficient to allow use with low viscosity liquids.
In some aspects the invention is an adjustable measuring device comprising:
an open container defining a volume and including a channel having an elongated wall of a length L 1 comprising at least a portion of the volume of the container; and
a slider mating with the shape of the channel and having a length L 2 shorter than L 1 so that the slider can be positioned at multiple locations in the channel to define at least one measuring chamber of variable volume depending on the positioning of the slider in the channel,
the slider and container channel being magnetically attractive to each other so that the slider attaches to the container to form a measuring assembly when the slider is fitted into the channel at one of said multiple locations, and the measuring assembly being separable for cleaning by pulling the slider from the container channel.
In some embodiments measurement markings may be provided of an overmolded elastomeric material that sealingly engages the slider, for instance an elastomeric silicone.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of an embodiment of adjustable measuring device of the invention.
FIG. 2 is an exploded parts view of the device of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides several significant advantages over prior adjustable measuring devices. It utilizes a simple two part device comprising a container channel and a mating slider that fits closely in the channel. The container channel and slider attach magnetically, so there is no need for snap fit. The magnetic attachment allows for very close mating, easy separation and adaptability to a wide variety of ornamental configurations. The magnetic attachment also simplifies the disassembly for cleaning and reassembly for use or storage. In storage the magnetic attraction reliably holds the parts together so they do not become separated in a drawer or the like, but it also allows very easy repositioning at the desired volume.
Referring to FIG. 1 there is shown an assembled measuring device 10 of the invention. Device 10 comprises two parts, container 14 and slider 12 . The two parts are magnetically attracted to each other and separable simply by pulling the slider out of the container channel.
Container 14 is has a fixed volume and includes an elongated channel 13 having a length L 1 . The slider 12 matingly fits in channel 13 and has a length L 2 , shorter than L 1 , which allows the slider to be positioned at multiple locations in the channel.
Marker lines 16 provide the gradations of volume measurement. This may be for instance be single or multiple system volumes such as fractional teaspoon, and teaspoon, fraction tablespoon and tablespoon, ounces, fractional cups and cup(s), pints or quarts and the like, or Metric system units such as volume in milliliter, deciliter, or liter units. Several different systems may be combined such as tablespoon and teaspoon. Other size indicia, not shown, may be provided in the chamber wall, for instance by print or molding, to indicate the specific volume marked by each line 16 .
In the device 10 , the location of the slider 10 defines two possible measuring chambers, 15 and 17 . The device can be manufactured so that the markings are the same or different between the two chambers.
Alternatively the device may be configured so only one chamber is used for measurement. The measurement chamber may be indicated for instance by the reading orientation of the size indicia. In another embodiment, not shown, the slider may include a cover on the top of one of the chambers 15 or 17 when it is in minimum volume location so that only the uncovered chamber is used for measurement.
In at least one embodiment, one of the chambers 15 or 17 may be provided with indicia marking a different volume system from the other. For instance teaspoon, ½ teaspoon, and ¼ teaspoon may be provided on one side and tablespoon, ½ tablespoon provided on the other. In another embodiment English system volumes may be provided on one side and the Metric system volumes on the other. The marker lines for the two systems may be distinguished for instance by different colors if they overlap at any point along the length of the container 14 .
Referring to FIG. 2 there is shown an exploded view of the elements combined to form the respective parts 12 and 14 of the device 10 . Container 14 is formed with inner and outer walls 18 and 20 , and a ferromagnetic rod 22 which is assembled in a fixed position between the inner and outer wall.
Rod 22 may be a magnet but preferably is non-magnetized metal that is attracted to magnets. Many grades of stainless steel may be suitable as is or after cold working. Steel, iron, nickel or the like may also be used.
In some embodiments the marker lines 16 may be flush or recessed in the inner wall 18 . In the embodiment shown in FIGS. 1 and 2 , however, the marker lines are overmolded onto the inner wall 18 , suitably of elastomeric polymer such as a curable silicone that cures to a soft elastomer when molded. The overmolded lines 16 may be raised slightly from the inner wall 18 , for instance about 0.01 mm-1 mm. This allows the slider 12 to engage the marker lines in a sealing manner effective to hold even low viscosity liquids such as water, milk, oils and the like.
For assembly, the rod 18 is fitted between the outer wall 10 and the inner wall 18 which already is provided with the lines 16 overmolded therein. The inner and outer walls are then fixedly joined, for instance by fusion welding or with an adhesive, to form the container 14 as a single part of device 10 .
The slider 12 may have a three-piece construction comprising slider bottom 24 , slider lid 26 , and magnet 28 . The magnet 28 is fitted into an internal chamber 30 of the slider bottom 24 and then the lid is fixedly joined, for instance by fusion welding or with an adhesive, to form the slider 12 as a single part of device 10 .
In the embodiment of FIGS. 1 and 2 , the measuring chambers have a minimum volume which is defined by the portion of the interior volume that extends beyond the ends of the channel 13 . This is an optional feature. In other embodiments the 14 , so that when the slider is advanced to the end of a channel, one of the measuring chambers 15 or 17 is effectively channel 13 defines the entire volume of the container closed. In still other embodiments the slider ends may have curvature that adds or subtracts to the minimum volume of the embodiment shown in the Figures.
In some embodiments the slider can be located at any desired volume at, or between, predetermined marked volumes. In other embodiments the device may be provided with slot and protrusions that limit the slider to mating with the chamber at predetermined locations.
The device is suited to manufacture from thermoplastic or thermoset plastics together with at least one magnet, embedded or assembled within one or both of the parts, and either a second magnet or ferromagnetic material embedded or assembled within the other.
Exemplary thermoplastic materials include polyolefins, such as polyethylene (e.g. high density polyethylene, medium density polyethylene or low density polyethylene), polypropylene or copolymers of either of these with each other or with other monomers having olefinic unsaturation; polysulfone; poly(meth)acrylates; thermoplastic polyurethanes; aliphatic or aromatic polyesters and copolymers thereof, for instance PET, PBT, Hytrel® polyester-block-polyether copolymers and the like; polyamides and polyamide copolymers, for instance nylons such as nylon 6, nylon 6/6, nylon 12, Pebax® polyamide-block-polyethers, and the like. Preferred thermoplastic materials are nylon polymers, which have good durability in kitchen devices and can be overmolded with silicones.
Exemplary thermoset plastic materials include curable acrylic, epoxy, melamine, silicone and urethane materials. Cure systems may be initiated by heat, light (e.g. UV curing), mixing of two parts or by moisture.
In the case that one uses magnets for both the element 28 and the rod 18 it may be advantageous to use a rod 18 that has a similar or shorter length than the element 28 and provide room between the inner and outer walls of container 14 to allow the magnetic rod 18 to slide longitudinally therein. The opposite poles of the two magnets will attract strongly and then the magnetic rod 18 can side within the walls of container 14 as the slider 10 is slid in the channel 13 to a desired position.
In some embodiments magnetic stainless steel, for instance a cold worked 300 series stainless steel, may be used for one or both of the parts 12 or 14 . In such case one of the stainless steel parts may be magnetized into a permanent magnet as is known in the art.
In another embodiment the slider 12 or the container 14 may be formed of ceramic type permanent magnet, suitably one sealed by impregnation and/or polymeric coating, such as a cured acrylic, epoxy, or silicone impregnant or sealant.
In still other embodiments the slider or the container or both can be molded or extruded of a polymer mixed with magnetic particles which are magnetically aligned at the time of molding or extrusion.
Of course these various alternatives may be combined. For instance a slider 12 of ceramic or extruded magnetic material may be combined with a container 14 of a suitable stainless steel or container, or vice versa, without departing from the invention hereof.
For devices intended for measuring foodstuffs, food grade materials should be used on at least all external surfaces.
The magnet should be a permanent magnet that has a Curie temperature well above the boiling point of water so that it does not become demagnetized in the course of normal cleaning operations. In embodiments where the magnet is sealing enclosed within either the container body or the slider, any magnetic material having a suitable magnetic strength, Curie temperature and stability may be used. In embodiments where the slider or the container are themselves magnetic, the material is suitably selected for these same properties and also for acceptable food contact properties.
All published documents, including all US patent documents, mentioned anywhere in this application are hereby expressly incorporated herein by reference in their entirety. Any copending patent applications, mentioned anywhere in this application are also hereby expressly incorporated herein by reference in their entirety.
The above examples and disclosure are intended to be illustrative and not exhaustive. These examples and description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims, where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims. Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of written description, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all claims which possess all antecedents referenced in such dependent claim.
|
An adjustable measuring device that includes a container with a channel and a mating slider in the container. The slider is magnetically attached. Portion(s) not filled by the slider provide define at least one measuring chamber of variable volume depending on the positioning of the slider in the channel. Also, in an adjustable measuring device using a mating slider, measurement lines can be formed of elastomeric polymer to facilitate sealing.
| 6
|
RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application No. 60/665,779, filed on Mar. 28, 2005.
FIELD OF THE INVENTION
The present invention relates to a virus harboring DNA encoding a subunit of factor G derived from a horseshoe crab (hereinafter may be referred to as limulus-derived factor G), to a cell harboring the virus, and to a method of producing factor G by use of the cell.
BACKGROUND ART
Abbreviations used in the present specification are as follows.
AcNPV: nuclear polyhedrosis virus of Autographa californica
BG: (1→3)-β-D-glucan
Et: endotoxin (also referred to as lipopolysaccharide)
HEPES: 2-[4-(2-hydroxyethyl)-1-piperazinyl]ethanesulfonic acid
HRP: horseradish peroxidase
MOI: multiplicity of infection
NPV: nuclear polyhedrosis virus
PBS: phosphate buffered saline
PCR: polymerase chain reaction
pNA: p-nitroaniline
PVDF: polyvinylidene difluoride
SDS: sodium dodecyl sulfate
SDS-PAGE: sodium dodecyl sulfate-polyacrylamide gel electrophoresis
Japanese Patent Application laid-Open (kokai) No. 08-122334 and a non-patent document (J. Protein Chem., 5, p. 255-268 (1986)) disclose methods for determining Et or BG by use of an amebocyte lysate of a horseshoe crab (hereinafter referred to simply as a lysate). These methods are based on coagulation of the lysate by Et or BG. The coagulation reaction occurs through cascade reaction of coagulation factors.
For example, when BG is brought into contact with the lysate, factor G contained in the lysate is activated, to thereby form activated factor G. The activated factor G activates a pro-clotting enzyme present in the lysate, to thereby form a clotting enzyme. The clotting enzyme hydrolyzes a specific site of a coagulogen molecule present in the lysate, thereby forming coagulin gel, leading to coagulation of the lysate. The coagulogen also acts on a synthetic substrate (e.g., t-butoxycarbonyl-leucyl-glycyl-arginine-pNA (Boc-Leu-Gly-Arg-pNA)), to thereby hydrolyze the amide bonds, whereby pNA is released. Thus, BG can be determined through measuring absorbance of the formed coloring substance (pNA) (disclosed in Japanese Patent Application laid-Open (kokai) No. 08-122334).
Factor G is a protein formed of subunits α and β, and cloning of each subunit has already been performed (disclosed in J. Biol. Chem., 269(2), p. 1370-1374 (1994)). However, an active protein (factor G) has been difficult to express through employment of cloned DNAs encoding the subunits.
SUMMARY OF THE INVENTION
Thus, an object of the present invention is provide an virus harboring a DNA encoding a subunit of limulus-derived factor G, the virus being capable of mass-producing a BG assay reagent of satisfactory quality, steadily and at low cost. Another object is to provide a cell harboring the virus. Still another object is to provide a method of producing factor G by use of the cell.
The present inventors have conducted extensive studies in order to attain the aforementioned objects, and have found that a protein having factor G activity can be produced by use of a cell harboring a virus containing a DNA encoding a subunit of factor G, whereby a BG assay reagent of satisfactory quality can be mass-produced steadily and at low cost. The present invention has been accomplished on the basis of this finding.
Accordingly, the present invention provides a virus harboring a DNA encoding subunit α of limulus-derived factor G (hereinafter the virus may be referred to as “virus 1 of the present invention”). The horseshoe crab (limulus) is preferably selected from among Tachypleus tridentatus, Limulus polyphemus, Tachypleus gigas, and Carcinoscorpius rotundicauda.
The DNA encoding subunit α of limulus-derived factor G is preferably a DNA (A) or a DNA (B) as described below:
(A) a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 2,
(B) a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 2 in which one or more amino acid residues are deleted, substituted, inserted, or transposed and having activity of subunit α of limulus-derived factor G.
The DNA encoding subunit α of limulus-derived factor G herein is also preferably a DNA (a) or a DNA (b) as described below:
(a) a DNA having a nucleotide sequence defined by nucleotides 1 to 2022 in SEQ ID NO: 1,
(b) a DNA having a nucleotide mutation in a nucleotide sequence defined by nucleotides 1 to 2022 in SEQ ID NO: 1, the mutation causing deletion, substitution, insertion, or transposition of one or more amino acid residues in the amino acid sequence of a protein encoded by the mutation-containing nucleotide sequence, and the expressed protein having activity of subunit α of limulus-derived factor G.
The virus is preferably baculovirus. The baculovirus is preferably NPV. The NPV is preferably AcNPV.
The present invention also provides a virus harboring a DNA encoding subunit β of limulus-derived factor G (hereinafter the virus may be referred to as “virus 2 of the present invention”).
The horseshoe crab (limulus) is preferably selected from among Tachypleus tridentatus, Limulus polyphemus, Tachypleus gigas, and Carcinoscorpius rotundicauda.
The DNA encoding subunit β of limulus-derived factor G herein is also preferably a DNA (A) or a DNA (B) as described below:
(A) a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 4,
(B) a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 4 in which one or more amino acid residues are deleted, substituted, inserted, or transposed and having activity of subunit β of limulus-derived factor G.
The DNA encoding subunit β of limulus-derived factor G herein is also preferably a DNA (a) or a DNA (b) as described below:
(a) a DNA having a nucleotide sequence defined by nucleotides 1 to 930 in SEQ ID NO: 3,
(b) a DNA having a nucleotide mutation in a nucleotide sequence defined by nucleotides 1 to 930 in SEQ ID NO: 3, the mutation causing deletion, substitution, insertion, or transposition of one or more amino acid residues in the amino acid sequence of a protein encoded by the mutation-containing nucleotide sequence, and the expressed protein having activity of subunit β of limulus-derived factor G.
The virus is preferably baculovirus. The baculovirus is preferably NPV. The NPV is preferably AcNPV.
Hereinafter, virus 1 of the present invention and virus 2 of the present invention may be collectively or individually referred to as “the virus of the present invention”.
The present invention also provides a cell harboring the virus of the present invention (hereinafter the cell may be referred to as “the cell of the present invention”).
The cell of the present invention preferably harbors viruses 1 and 2 of the present invention. Preferably, the cell is obtained through infection with virus 1 and virus 2 such that MOI of virus 1 exceeds MOI of virus 2. In this case, the ratio of MOI of virus 1 to MOI of virus 2 is preferably controlled to 1.5:1 to 64:1.
The cell of the present invention is preferably a cell of insect origin.
The present invention also provides a method of producing subunit α and/or subunit β of limulus-derived factor G, the method comprising growing the cell of the present invention and collecting subunit α and/or subunit β of limulus-derived factor G from the growth product (hereinafter the method may be referred to as “the method of the present invention”). The subunit α and/or subunit β of limulus-derived factor G is preferably a protein which is formed of subunit α and subunit β and which maintains limulus-derived factor G activity.
The method of the present invention includes a concept of “a method of producing factor G, the method comprising growing a cell which harbors a DNA encoding subunit α of factor G derived from a horseshoe crab and a DNA encoding subunit β of factor G derived from a horseshoe crab, and collecting, from the growth product, a protein having activity of factor G derived from a horseshoe crab”.
The virus of the present invention is very useful, since the cell of the present invention, which is useful for mass-producing factor G of satisfactory quality, steadily, at high efficiency and low cost, can be attained by using the virus.
Employment of the cell is remarkably useful, since a protein which maintains factor G activity and which has satisfactory quality can be mass-produced steadily at high efficiency and low cost, whereby the method of the present invention can be attained. Furthermore, through employment of the method of the present invention, a protein which maintains factor G activity and which has satisfactory quality can be mass-produced steadily, at high efficiency and low cost.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Best modes for carrying out the present invention will next be described in detail.
<1>-1 Virus 1 of the Present Invention
Virus 1 of the present invention is a virus harboring a DNA encoding subunit α of limulus-derived factor G.
No particular limitation is imposed on the type of the DNA encoding subunit α of limulus-derived factor G harbored by virus 1 of the present invention, so long as the DNA encodes subunit α of limulus-derived factor G.
Examples of the DNA include those encoding subunit α of factor G derived from the following horseshoe crabs: Tachypleus tridentatus, Limulus polyphemus, Tachypleus gigas, and Carcinoscorpius rotundicauda.
Of these, DNAs encoding subunit α of factor G derived from Tachypleus tridentatus and Limulus polyphemus are preferred, more preferably a DNA encoding subunit α of factor G derived from Tachypleus tridentatus.
Particularly, the DNA harbored by virus 1 of the present invention is preferably the following DNA (A) or (B):
(A) a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 2,
(B) a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 2 in which one or more amino acid residues are deleted, substituted, inserted, or transposed and having activity of subunit α of limulus-derived factor G.
The DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 2 herein is a DNA encoding subunit α of factor G derived from Tachypleus tridentatus.
The DNA coding for a naturally occurring protein may include polymorphism and mutations, and the formed protein may include mutations in the amino acid sequence due to intracellular alteration or modification incurred during purification; such as deletion, substitution, insertion, and transposition in amino acid residues. Although having such a mutation, some proteins are known to exhibit physiological and biological effects virtually the same as those of the protein having none of the above mutations. Thus, the protein encoded by DNA (B), which slightly differs from the protein encoded by DNA (A) in structure and which has no significant difference in function can be regarded as substantially equivalent to the protein encoded by DNA (A). A similar logic is also applied to the case where the aforementioned mutations are intentionally introduced into an amino acid sequence of protein. In this case, a wider range of variants can be fabricated. For example, a polypeptide engineered from human interleukin 2 (IL-2) so that a certain cysteine residue in the amino acid sequence of IL-2 is substituted by serine is known to maintain human interleukin 2 (IL-2) activity (Science, 224, 1431 (1984)). Also, a certain protein is known to have a peptide region that is not essential in terms of activity. Examples of such a protein include a signal peptide present in a protein secreted from a cell and a pro-sequence observed in a protease precursor or a similar substance. Most of these peptide regions are removed after translation or during conversion to the corresponding activated proteins. Although having different primary structures, the above-mentioned variants are virtually equivalent in terms of the function to the protein encoded by DNA (A). Therefore, the protein encoded by DNA (B) represents these proteins.
In the present specification, the term “one or more amino acid residues” refers to amino acid residues which are allowed to have mutations without impairing the protein activity. For example, when a protein contains 600 amino acid residues, the number of such amino acid residues is about 1 to 30, preferably 1 to 15, more preferably 1 to 8.
The protein encoded by DNA (B) has activity of subunit α of limulus-derived factor G. Since subunit α of factor G has BG-binding activity, subunit α activity can be detected by checking the presence of BG-binding activity.
The state “harboring a DNA” in virus 1 of the present invention does not exclude the state in which the virus harbors other nucleotides and DNAs, so long as the relevant DNA is harbored. Thus, in addition to the DNA, other DNAs encoding a marker peptide etc. may be harbored.
For example, a vector harboring a linked DNA between the aforementioned DNA (A) or (B) and a DNA encoding a marker peptide etc. also falls within the scope of virus 1 of the present invention. When the DNA to be harbored is designed in the above manner, a protein fused with a marker peptide etc. may be expressed. The thus-expressed protein is advantageous for facilitating purification, detection, analysis, etc. Examples of the marker peptide include protein A, an insulin signal sequence, His-tag, FLAG, CBP (calmodulin-binding protein), and GST (glutathione S-transferase). For example, a protein fused with protein A may be purified in a simple manner through affinity chromatography employing an IgG-immobilized solid phase. Similarly, a His-tag-fused protein may be purified with a magnetic nickel-immobilized solid phase, whereas a FLAG-fused protein may be purified with an anti-FLAG antibody-immobilized solid phase. A protein fused with an insulin signal sequence is secreted from a cell to the outside (e.g., culture medium). Therefore, an extraction step including crushing of cells may be eliminated.
No particular limitation is imposed on the production method of virus 1 of the present invention. One exemplary method of producing virus 1 of the present invention will be described as follows. More specific procedure thereof will be described in the Examples.
Firstly, a DNA encoding subunit α of limulus-derived factor G is provided. In the case where the aforementioned DNA (A) is employed as the DNA, a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 2 is provided. In the case where the aforementioned DNA (B) is employed as the DNA, provided is a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 2 in which one or more amino acid residues are deleted, substituted, inserted, or transposed and having activity of subunit α of limulus-derived factor G. No particular limitation is imposed on the type of the DNA, so long as the DNA encodes the relevant protein. The DNA includes those having a variety of nucleotide sequences due to degeneracy of genetic codes. However, any of these DNAs having a specific nucleotide sequence may be employed.
The DNA (A) serving as a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 2 may be, among others, a DNA having a nucleotide sequence defined by nucleotides 1 to 2022 in SEQ ID NO: 1. Alternatively, a DNA deposited in GenBank with an accession No. D16622 may also be employed. Furthermore, a DNA having a nucleotide sequence defined by nucleotides 1 to 2058 in SEQ ID NO: 1 may also be employed.
The DNA (B) serving as a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 2 in which one or more amino acid residues are deleted, substituted, inserted, or transposed and having activity of subunit α of limulus-derived factor G, may be the aforementioned DNA (A), a complementary DNA thereof, or a DNA which hybridizes with any of the DNAs under stringent conditions.
As used herein, the term “stringent conditions” refers to conditions which allow formation of a so-called specific hybrid but do not allow formation of a non-specific hybrid (see, for example, Sambrook, J. et al., Molecular Cloning A Laboratory Manual, second Edition, Cold Spring Harbor Laboratory Press (1989)). Specific examples of the stringent conditions include performing hybridization in a solution containing 50% formamide, 4×SSC, 50 mM HEPES (pH 7.0), 10× Denhardt's solution, and 100 μg/mL salmon sperm DNA at 42° C., and washing at room temperature with 2×SSC and a 0.1% SDS solution and at 50° C. with 0.1×SSC and a 0.1% SDS solution.
Through introduction of such a DNA into virus, virus 1 of the present invention can be produced.
No particular limitation is imposed on the species of the virus into which such a DNA is introduced, so long as the virus is available for transfection. The virus is preferably baculovirus. The baculovirus is preferably NPV. No particular limitation is imposed on the species of the NPV, so long as the NPV is a virus belonging to NPVs. For example, AcNPV or Bombyx mori NPV (BmNPV) may be employed. Of these, AcNPV is preferred.
Introduction of a DNA into virus may be performed through homologous recombination by use of a transfer vector. No particular limitation is imposed on the type of the transfer vector. For example, pPSC8 (Protein Science), pFastBac (Invitrogen), or pVL1393 (Pharmingen) may be employed. Of these, pPSC8 is preferred. These transfer vectors may be commercial products.
No particular limitation is imposed on the method of homologous recombination by use of a transfer vector. A specific example thereof will be described later in the Examples.
Whether or not the produced virus harbors the aforementioned DNA (A) or DNA (B) may be confirmed by any of the following procedures: checking that the produced virus harbors a DNA encoding subunit α of limulus-derived factor G through nucleotide sequence analysis; checking that a protein expressed by the produced virus has an amino acid sequence of subunit α of limulus-derived factor G; and checking that a protein expressed by the produced virus has activity of subunit α of limulus-derived factor G.
Virus 1 of the present invention may be used in the production of “the cell of the present invention” described later, and in “the method of the present invention.”
<1>-2 Virus 2 of the Present Invention
Virus 2 of the present invention is a virus harboring a DNA encoding subunit β of limulus-derived factor G.
Examples of the horseshoe crab and preferred embodiments are the same as described in <1>-1.
Particularly, the DNA harbored by virus 2 of the present invention is preferably the following DNA (A) or (B):
(A) a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 4,
(B) a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 4 in which one or more amino acid residues are deleted, substituted, inserted, or transposed and having activity of subunit β of limulus-derived factor G.
The DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 4 herein is a DNA encoding subunit β of factor G derived from Tachypleus tridentatus.
The definition of the protein encoded by DNA (B) is the same as described in <1>-1. The protein encoded by DNA (B) has activity of subunit β of limulus-derived factor G. Since subunit β of factor G has serine protease activity, subunit β activity can be confirmed by the presence of serine protease activity.
Notably, the term “one or more amino acid residues” and the state “harboring a DNA” are the same as described in <1>-1. The method of producing virus 2 of the present invention is identical to that described in <1>-1, except that SEQ ID NO: 2 is changed to SEQ ID NO: 4.
The DNA (A) serving as a DNA encoding a protein having an amino acid sequence defined by SEQ ID NO: 4 may be, among others, a DNA having a nucleotide sequence defined by nucleotides 1 to 930 in SEQ ID NO: 3. Alternatively, a DNA deposited in GenBank with an accession No. D16623 may also be employed.
The aforementioned DNA (B) encoding a protein having an amino acid sequence defined by SEQ ID NO: 4 in which one or more amino acid residues are deleted, substituted, inserted, or transposed and having activity of subunit β of limulus-derived factor G is the same as described in <1>-1.
Through introduction of such a DNA into virus, virus 2 of the present invention can be produced. Examples of the virus into which the DNA is introduced, preferred embodiments, and the DNA introduction method are the same as described in <1>-1.
Whether or not the produced virus harbors the aforementioned DNA (A) or DNA (B) may be confirmed through the same method as described in <1>-1.
Virus 2 of the present invention may be used in the production of “the cell of the present invention” described later, and in “the method of the present invention.”
<2> The Cell of the Present Invention
The cell of the present invention harbors the virus of the present invention.
The virus of the present invention is the same as mentioned above.
No particular limitation is imposed on the cell to be employed, so long as the cell allows infection with the virus of the present invention, and can express, by the mediation of the virus of the present invention, subunits α and/or β of limulus-derived factor G. Examples of the cell include cells derived from insects, and specific examples include an Sf9 cell.
No particular limitation is imposed on the method for causing the virus of the present invention to harbor the cell. For example, contact between the virus of the present invention and the cell readily causes infection of the cell with the virus of the present invention, whereby the cell can harbor the virus of the present invention. A specific method thereof will be described later in the Examples.
The cell of present invention may harbor sole virus 1 of the present invention, sole virus 2 of the present invention, or both viruses 1 and 2 of the present invention. The cell may further harbor a virus other than viruses 1 and 2.
In the case where the cell of the present invention harbors viruses 1 and 2 of the present invention, the cell is preferably produced by infecting with the viruses 1 and 2 such that MOI of virus 1 exceeds MOI of virus 2. For example, the cell of the present invention may be infected with viruses 1 and 2 at a ratio of MOI of virus 1 to MOI of virus 2 of 1.5:1 to 64:1. The ratio of MOI of virus 1 to MOI of virus 2 is more preferably controlled to 1.5:1 to 32:1, 2:1 to 32:1, 2:1 to 16:1, 2:1 to 8:1, 2:1 to 6:1, 2:1 to 4:1 or 3:1 to 5:1, 4:1, in this order.
Since the cell of the present invention can produce subunits α and/or β of limulus-derived factor G, the cell of the present invention may be selected on the basis of the production performance as an index.
The cell of the present invention may be employed in, for example, the below-mentioned method of the present invention.
<3> The Method of the Present Invention
The method of the present invention for producing subunit α and/or subunit β of limulus-derived factor G includes growing the cell of the present invention and collecting subunit α and/or subunit β of limulus-derived factor G from the growth product.
The cell of the present invention is the same as mentioned above.
In the present invention, the term “grow” refers to a concept including proliferation of cells which are transformants and growing organisms such as animals and insects into which transformant cells have been incorporated. The term “growth product” is a concept including a culture medium (supernatant of the culture) after completion of growth of transformants, cultured cells themselves, and matter secreted or excreted from organisms such as animals and insects into which the cells have been incorporated.
No particular limitation is imposed on the growth conditions (e.g., medium and culture conditions), so long as the cell of the present invention can grow and produce subunit α and/or subunit β of limulus-derived factor G. The conditions are appropriately selected in accordance with the type of the vectors, cells, etc. employed. For example, culturing temperature may be about 20 to 40° C.
The growth period of the cell of the present invention may also be appropriately tuned in accordance with the amount of the cell used in the present invention, a desired production amount of the subunit(s), and other growth conditions.
The person skilled in the art may select the method for collecting subunit α and/or subunit β of limulus-derived factor G from the growth product from generally employed methods in accordance with the type of the growth product.
For example, in the case where these subunits are produced in the soluble form which are secreted into a culture medium (culture supernatant), the culture medium is collected and may be employed without performing further treatment. In the case where these subunits are produced in the soluble form which are secreted in the cytoplasm, or produced in the insoluble form (membrane-binding), these subunits may be extracted through extraction with cell crushing such as the nitrogen cavitation apparatus method, homogenizing, glass beads milling, sonication treatment, the permeation shock method, or freeze-thawing; extraction with a surfactant; or a combination thereof. The extract itself may be used as subunit α and/or subunit β without performing further treatment.
The method of the present invention may further include other steps, so long as the method includes growing the cell of the present invention and collecting subunit α and/or subunit β of limulus-derived factor G from the growth product. For example, the method may include a step of purifying the collected subunit(s). The purification may be incomplete (partial) purification or complete purification, and may be appropriately selected in accordance with the use purpose of the subunit(s).
Specific examples of the purification method include salting out by the mediation of a salt such as ammonium sulfate or sodium sulfate; centrifugation; dialysis; ultrafiltration; chromatographic methods such as adsorption chromatography, ion-exchange chromatography, hydrophobic chromatography, reverse-phase chromatography, gel filtration, gel permeation chromatography, and affinity chromatography; electrophoresis; and combinations thereof.
The method of the present invention may be employed for producing sole subunit α, sole subunit β, or both subunits α and β. The method may also produce a subunit other than subunits α and β.
In the production of subunit α, a cell harboring virus 1 of the present invention is employed. In the production of subunit β, a cell harboring virus 2 of the present invention is employed. In the production of subunits α and β, a cell harboring both viruses 1 and 2 of the present invention is employed.
In the case where both subunits α and β are produced, a protein which is formed of subunits α and β and which maintains activity of limulus-derived factor G can be produced.
Whether or not the produced protein is subunit α and/or subunit β, is formed of subunits α and β, or maintains activity of limulus-derived factor G may be confirmed through analysis of the collected protein such as amino acid sequence, molecular weight, electrophoresis features, Western blotting employing an antibody reacting specifically to the relevant subunit, BG binding performance, or presence of serine protease activity.
The method of the present invention realizes remarkably effective production of a protein which is formed of subunit α, subunit β, or subunits α and β and which maintains activity of limulus-derived factor G.
The method of the present invention includes a concept of “a method of producing factor G, the method comprising growing a cell which harbors a DNA encoding subunit α of factor G derived from a horseshoe crab and a DNA encoding subunit β of factor G derived from a horseshoe crab, and collecting, from the growth product, a protein having activity of factor G derived from a horseshoe crab”.
EXAMPLES
The present invention will next be described in detail by way of examples.
<1> Expression of Subunit α of Factor G
A cDNA encoding factor G subunit α was kindly offered by Dr. Tatsushi MUTA (Department of Molecular and Cellular Biochemistry, Graduate School of Medical Sciences, Kyushu University). The cDNA had been prepared through a method disclosed in J. Biol. Chem., 269(2), p. 1370-1374 (1994). The cDNA was introduced into a transfer vector (pPSC8), and a clone having a predetermined nucleotide sequence was selected. The thus-selected expression vector (Factor G-α/pPSC8) DNA and a baculovirus (AcNPV) DNA were co-transfected into Sf9 cells. The virus fluid obtained from the culture supernatant was purified and amplified. The viral DNA was extracted from the cells infected with the baculovirus, and sequenced. Cells (expresSF+, trade name) were infected with the thus-obtained virus fluid, and the expression product was analyzed through Western blotting. Details of these steps will next be described.
1. Construction of Expression Vector
A cDNA encoding factor G subunit α (Factor G-α/pFastbac1) was treated with BamHI/Hind III, and fragments (about 2,100 bp) having a target gene were collected. The sample was blunt-ended, and subsequently, ligated through mixing with Nru I-treated pPSC8 (product of Protein Science). E. coli JM109 was transformed with the ligation product, to thereby form a transformant. Plasmids in which fragments of the target size had been determined were purified, and sequenced. The sequencing was performed by use of the below-described primers and ABI Prism Big Dye Terminator Cycle Sequencing Kit Ver.3 (Applied Biosystems). Electrophoresis was performed by means of an automated sequencer ABI Prism 310 Genetic Analyzer (Applied Biosystems), and analysis was performed by means of Genetyx (Genetyx). Sequences of the primers are shown in the following sequence list by SEQ ID NOs: 5 to 13.
SEQ ID NO: 5: PSC F
SEQ ID NO: 6: PSC R
SEQ ID NO: 7: Factor G α 441/460-F
SEQ ID NO: 8: Factor G α 941/960-F
SEQ ID NO: 9: Factor G α 1601/1620-F
SEQ ID NO: 10: Factor G α 582/563-R
SEQ ID NO: 11: Factor G α 1082/1063-R
SEQ ID NO: 12: Factor G α 1582/1563-R
SEQ ID NO: 13: Factor G α 1700/1681-R
A clone in which insertion of a target gene had been confirmed was inoculated to an LB medium (100 mL) containing 50 μg/mL ampicillin, and cultivated at 30° C. for one night. Proliferated cells were collected, and plasmids were purified in accordance with the manual of Plasmid Midi Kit (QIAGEN).
2. Co-transfection
To Sf9 cells (1.0×106) plated in a 25-cm2 flask was added a serum-free SF-900 II medium (product of Invitrogen) (200 μL) containing an expression vector harboring a cDNA encoding factor G subunit α (4.6 μg), a linear AcNPV DNA (85 ng), and LIPOFECTIN Reagent (product of Invitrogen) (5 μL). After the culture had been allowed to stand at 28° C. for six hours, a serum-free SF-900 II medium was further added so as to adjust the volume of the culture liquid to 5 mL. The culture was further cultivated at 28° C. for nine days, and the culture supernatant was collected. The thus-obtained solution through co-transfection referred to as a co-transfection solution.
3. Purification of Recombinant Virus
The recombinant virus was purified through the plaque assay method. The specific procedure is as follows.
Sf9 cells (2.0×106) were plated onto a plate (diameter: 60 mm) and allowed to stand at 28° C. for one hour, whereby the cells were adhered to the bottom surface. The aforementioned co-transfection solution was diluted with a serum-free Sf-900 II medium at dilution factors of 104, 105, 106, and 107. An aliquot (1 mL) of each of these diluted solutions was added to the cells, followed by gentle shaking at room temperature for one hour. After removal of the plate supernatant (virus fluid), a serum-free Sf-900 II medium (4 mL) containing 0.5% SeaKemGTG agarose (product of BMA) was added to the plate, and stationary culture was performed at 28° C. for seven days. From each culture medium, six plaques of infected insect cells including no polyhedra were collected. The plaques of each medium were suspended in a serum-free Sf-900 II medium (1 mL), to thereby serve as a virus fluid.
4. Amplification of Recombinant Virus
Next, amplification of the recombinant virus (preparation of recombinant virus fluid) was performed. The specific procedure is as follows.
To Sf9 cells (2.0×106) plated in a 25-cm2 flask was added each (0.5 mL) of the aforementioned virus fluids, followed by stationary cultivation at 28° C. for one hour. A serum-free SF-900 II medium was added to the culture so as to adjust the volume of the culture liquid to 5 mL, and the culture was further stationary-cultivated for three days, to thereby yield a first-generation virus fluid.
To Sf9 cells (6.0×106) plated in a 75-cm2 flask was added the entirety of the aforementioned first-generation virus fluid, followed by stationary cultivation at 28° C. for one hour. Subsequently, a serum-free SF-900 II medium (10 mL) was added to the culture, followed by stationary cultivation for four days. After completion of cultivation, cells were scraped out from the bottom of the flask by use of a cell scraper. The thus-collected cells were centrifuged at 3,000×g and 4° C. for 15 minutes, to thereby fractionate into the supernatant and the precipitate. The culture supernatant was collected and employed as a second-generation virus fluid.
5. Confirmation of Gene Insertion
Subsequently, insertion of a DNA into a cell was confirmed through the following procedure.
The precipitate obtained at the collection of the second-generation virus fluid was suspended in TE (200 μL), and a viral DNA was extracted in accordance with a manual of QIAamp DNA Mini Kit (QIAGEN). PCR was performed by use of the thus-extracted viral DNA as a template and the following primers.
SEQ ID NO: 14: PSC F2
SEQ ID NO: 15: PSC R2
To a 0.2-mL sample tube, the aforementioned viral DNA (1 μL), 2.5 mM dNTP (8 μL), KOD buffer (5 μL), 25 mM magnesium chloride solution (4 μL), primers PSC F2 and PSC R2 (4 pmol/mL each, 2.5 μL each), KOD DNA polymerase (product of TOYOBO) (1 μL), and sterilized pure water (26 μL) were added, and the mixture was sufficiently stirred. The mixture was subjected to PCR for 30 cycles, each cycle consisting of 94° C. for 30 seconds, 50° C. for 30 seconds, and 74° C. for 60 seconds.
The PCR product (5 μL) was subjected to electrophoresis on agarose gel, and the length of the amplified fragments was determined. A PCR product of a fragment having a target length was purified, and the sequences of the N-terminus side and the C-terminus side were determined, through use of the same reagents, apparatuses, and primers PSC F and PSC R as employed in the aforementioned “1. Construction of expression vector.”
6. Production of Recombinant Virus Fluid
Insect cells (expresSF+, trade name, Protein Science) which were in the logarithmic growth phase during cultivation were diluted with a serum-free Sf-900 II medium so as to adjust the concentration to 1.5×106 cells/mL, and the diluted product (100 mL) was placed in a 250-mL Erlenmeyer flask. The aforementioned second-generation virus fluid (1 mL) was added thereto, and the mixture was subjected to shake cultivation at 130 rpm and 28° C. for three days. After completion of cultivation, the culture liquid was centrifuged at 3,000×g and 4° C. for 15 minutes, to thereby fractionate into the supernatant and the precipitate. The culture supernatant was collected and employed as a third-generation virus fluid.
7. Titer Determination
Sf9 cells (2.0×106) were plated onto a plate (diameter: 60 mm) and allowed to stand at 28° C. for one hour, whereby the cells were adhered to the bottom surface. Subsequently, the culture liquid was removed. Separately, the third-generation virus fluid was diluted with a serum-free Sf-900 II medium at dilution factors of 105, 106, 107, and 108. An aliquot (1 mL) of each of these solutions was added to the plate, followed by gentle shaking at room temperature for one hour. After removal of the plate supernatant (virus fluid), a serum-free Sf-900 II medium (4 mL) containing 0.5% SeaKemGTG agarose (product of BMA) was added to the plate, and stationary culture was performed at 28° C. for nine days. In each culture medium, the number of observed plaques was counted, thereby determining the titer.
8. Expression Test
Insect cells (expresSF+) were diluted with a serum-free Sf-900 II medium so as to adjust the concentration to 1.5×106 cells/mL, and the diluted product (100 mL/per flask) was placed in three 250-mL Erlenmeyer flasks. The aforementioned third-generation virus fluid was added thereto so as to attain MOIs of 0.5, 2, and 8, respectively. Each mixture was subjected to shake cultivation at 130 rpm and 28° C. for three days. After completion of cultivation, the culture liquid was centrifuged at 3,000×g and 4° C. for 15 minutes, to thereby fractionate into the supernatant and the precipitate.
9. Detection of Expression Product
Each of the samples collected in “8. Expression test” above was subjected to SDS-PAGE through a routine method. A protein was transferred to a blotting membrane through the semi-dry blotting method, and the expression product was detected by Western blotting under the below-mentioned conditions. Note that the DNA encoding factor G subunit α incorporated into the virus had been designed so as to express a His-tag-bound protein. Sample treatment: The supernatant was mixed with Laemmli Sample Buffer (product of BIO-RAD), and the mixture was heated at 99° C. for three minutes. The precipitate (200 μL) was mixed with PBS (200 μL), to thereby form a suspension. Laemmli Sample Buffer was added to the suspension, and the mixture was heated at 99° C. for three minutes.
Amount of applied sample: 20 μL/lane SDS-PAGE gel: 12.5% gel (product of BIO-RAD) Voltage application in SDS-PAGE: 150V, CV Blotting membrane: PVDF Voltage application in blotting: 15V, CV, 30 minutes Antibody: Penta His HRP Conjugate (product of QIAGEN) Detection: ECL Detection Reagent (product of Amersham Biosciences)
10. Results
Analysis of the total nucleotide sequence after insertion to pPSC8 indicates that the obtained nucleotide sequence completely coincides with that of the DNA encoding factor G subunit α. Therefore, no mutation was found to be introduced through PCR. The nucleotide sequence analysis of the N-terminal portion and C-terminal portion of the target sequence in the recombinant virus has revealed that the nucleotide sequences of the two portions completely coincide with those of the DNA encoding factor G subunit α. Thus, the recombinant virus was found to have a nucleotide sequence of the DNA encoding factor G subunit α.
The titer was determined to be 3×108 pfu/mL.
In the results of “9. Detection of expressed product” above, a band attributed to reaction with an anti-His-Tag antibody was observed at a target position (about 75 kDa). Thus, expression of factor G subunit α was confirmed.
<2> Expression of Subunit β of Factor G
A cDNA encoding factor G subunit β was kindly offered by Dr. Tatsushi MUTA (Department of Molecular and Cellular Biochemistry, Graduate School of Medical Sciences, Kyushu University). The cDNA had been as prepared through a method disclosed in J. Biol. Chem., 269(2), p. 1370-1374 (1994). Factor G subunit β was expressed through the same procedure as employed in <1> above, and the expression product was analyzed. Details of these steps will next be described.
1. Construction of Expression Vector
A cDNA encoding factor G subunit β (Factor G-β/pFastbac1) was treated with BamHI/Hind III, and fragments (about 1,000 bp) having a target gene were collected. The sample was blunt-ended, and subsequently, ligated through mixing with Nru I-treated pPSC8. E. coli JM109 was transformed with the ligation product, to thereby form a transformant. A clone in which insertion of a target gene had been confirmed was inoculated to an LB medium (100 mL) containing 50 μg/mL ampicillin, and cultivated at 37° C. for one night. Proliferated cells were collected, and plasmids were purified in accordance with the manual of Plasmid Midi Kit (QIAGEN).
2. Co-transfection
To Sf9 cells (1.0×106) plated in a 25-cm2 flask was added a serum-free SF-900 II medium (200 μL) containing an expression vector harboring a cDNA encoding factor G subunit β (4.6 μg), a linear AcNPV DNA (85 ng), and LIPOFECTIN Reagent (5 μL). After the culture had been allowed to stand at 28° C. for six hours, a serum-free SF-900 II medium was further added so as to adjust the volume of the culture liquid to 5 mL. The culture was further cultivated at 28° C. for seven days, and the culture supernatant was collected, to thereby serve as a co-transfection solution.
3. Purification of Recombinant Virus
The recombinant virus was purified through the plaque assay method. The specific procedure is as follows.
Sf9 cells (2.0×106) were plated onto a plate (diameter: 60 mm) and allowed to stand at 28° C. for one hour, whereby the cells were adhered to the bottom surface. The aforementioned co-transfection solution was diluted with a serum-free Sf-900 II medium at dilution factors of 104, 105, 106, and 107. An aliquot (1 mL) of each of these solutions was added to the cells, followed by gentle shaking at room temperature for one hour. After removal of the plate supernatant (virus fluid), a serum-free Sf-900 II medium (4 mL) containing 0.5% SeaKemGTG agarose (product of BMA) was added to the plate, and stationary culture was performed at 28° C. for six days. From each culture medium, six plaques of infected insect cells including no polyhedra were collected. The plaques of each medium were suspended in a serum-free Sf-900 II medium (1 mL), to thereby serve as a virus fluid.
4. Amplification of Recombinant Virus
Next, amplification of the recombinant virus (preparation of recombinant virus fluid) was performed. The specific procedure was as follows.
To Sf9 cells (2.0×106) plated in a 25-cm2 flask was added each (0.5 mL) of the aforementioned virus fluids, followed by stationary cultivation at 28° C. for one hour. A serum-free SF-900 II medium was added to the culture so as to adjust the volume of the culture liquid to 5 mL, and the culture was further stationary-cultivated for three days, to thereby yield a first-generation virus fluid.
To Sf9 cells (6.0×106) plated in a 75-cm2 flask was added the entirety of the aforementioned first-generation virus fluid, followed by stationary cultivation at 28° C. for one hour. Subsequently, a serum-free SF-900 II medium (10 mL) was added to the culture, followed by stationary cultivation for four days. After completion of cultivation, cells were scraped out from the bottom of the flask by use of a cell scraper. The thus-collected cells were centrifuged at 3,000×g and 4° C. for 15 minutes, to thereby fractionate into the supernatant and the precipitate. The culture supernatant was collected and employed as a second-generation virus fluid.
5. Confirmation of Gene Insertion
Subsequently, insertion of a DNA into a cell was confirmed through the following procedure.
The precipitate obtained at the collection of the second-generation virus fluid was suspended in TE (200 μL), and a viral DNA was extracted in accordance with a manual of QIAamp DNA Mini Kit (QIAGEN). PCR was performed by use of the thus-extracted viral DNA as a template and the following primers.
SEQ ID NO: 16: PSC F2
SEQ ID NO: 17: PSC R2
To a 0.2-mL sample tube, the aforementioned viral DNA (1 μL), 2.5 mM dNTP (8 μL), KOD buffer (5 μL), 25 mM magnesium chloride solution (4 μL), primers PSC F2 and PSC R2 (4 pmol/mL each, 2.5 μL each), KOD DNA polymerase (product of TOYOBO) (1 μL), and sterilized pure water (26 μL) were added, and the mixture was sufficiently stirred. The mixture was subjected to PCR for 30 cycles, each cycle consisting of 94° C. for 30 seconds, 50° C. for 30 seconds, and 74° C. for 60 seconds.
The PCR product (5 μL) was subjected to electrophoresis on agarose gel, and the length of amplified fragments was determined. A PCR product of a fragment having a target length was purified, and the sequences of the N-terminus side and the C-terminus side were determined, through use of the same reagents and apparatuses as employed in the aforementioned “<1>-1. Construction of expression vector.” The following primers were employed.
SEQ ID NO: 18: PSC F
SEQ ID NO: 19: PSC R
6. Production of Recombinant Virus Fluid
Insect cells (expresSF+, trade name, Protein Science) which were in the logarithmic growth phase during cultivation were diluted with a serum-free Sf-900 II medium so as to adjust the concentration to 1.5×106 cells/mL, and the diluted product (100 mL) was placed in a 250-mL Erlenmeyer flask. The aforementioned second-generation virus fluid (1 mL) was added thereto, and the mixture was subjected to shake cultivation at 130 rpm and 28° C. for three days. After completion of cultivation, the culture liquid was centrifuged at 3,000×g and 4° C. for 15 minutes, to thereby fractionate into the supernatant and the precipitate. The culture supernatant was collected and employed as a third-generation virus fluid.
7. Titer Determination
Sf9 cells (2.0×106) were plated onto a plate (diameter: 60 mm) and allowed to stand at 28° C. for one hour, whereby the cells were adhered to the bottom surface. Subsequently, the culture liquid was removed. Separately, the third-generation virus fluid was diluted with a serum-free Sf-900 II medium at dilution factors of 105, 106, 107, and 108. An aliquot (1 mL) of each of these solutions was added to the plate, followed by gentle shaking at room temperature for one hour. After removal of the plate supernatant (virus fluid), a serum-free Sf-900 II medium (4 mL) containing 0.5% SeaKemGTG agarose (product of BMA) was added to the plate, and stationary culture was performed at 28° C. for nine days. In each culture medium, the number of observed plaques was counted, thereby determining the titer.
8. Expression Test
Insect cells (expresSF+) were diluted with a serum-free Sf-900 II medium so as to adjust the concentration to 1.5×106 cells/mL, and the diluted product (100 mL/per flask) was placed in three 250-mL Erlenmeyer flasks. The aforementioned third-generation virus fluid was added thereto so as to attain MOIs of 0.5, 2, and 8, respectively. Each mixture was subjected to shake cultivation at 130 rpm and 28° C. for three days. After completion of cultivation, the culture liquid was centrifuged at 3,000×g and 4° C. for 15 minutes, to thereby fractionate into the supernatant and the precipitate.
9. Detection of Expression Product
Each of the samples collected in “8. Expression test” above was subjected to SDS-PAGE and Western blotting through the same method as employed in “<1>-9. Detection of expression product. Note that the DNA encoding factor G subunit β incorporated into the virus had been designed so as to express a His-tag-bound protein.
10. Results
The nucleotide sequence analysis of the N-terminal portion and C-terminal portion of the target sequence in the recombinant virus has revealed that the nucleotide sequences of the two portions completely coincide with those of the DNA encoding factor G subunit β. Thus, the recombinant virus was found to have a nucleotide sequence of the DNA encoding factor G subunit β.
The titer was determined to be 1.7×108 pfu/mL.
In the results of “9. Detection of expressed product” above, a band attributed to reaction with an anti-His-Tag antibody was observed at a target position (about 37 kDa). Thus, expression of factor G subunit β was confirmed.
<3> Co-Expression of Subunits α and β of Factor G
The third-generation virus fluids prepared in <1> and <2> above for producing factor G subunits α and β, respectively, were employed so as to co-express both subunits.
Insect cells (expresSF+) were diluted with a serum-free Sf-900 II medium so as to adjust the concentration to 1.5×106 cells/mL, and the diluted product (50 mL/per flask) was placed in three 125-mL Erlenmeyer flasks. The aforementioned third-generation virus fluids, which had been prepared for producing factor G subunits α and β, were added thereto at the following proportions. Each mixture was subjected to shake cultivation at 130 rpm and 28° C. for three days. After completion of cultivation, the culture liquid was centrifuged at 3,000×g and 4° C. for 15 minutes, to thereby fractionate into the supernatant and the precipitate. The supernatant was frozen for preservation.
Sample 1:
subunit α:subunit β=1:0 (by MOI)
subunit α:subunit β=57.7:0 (by virus amount (μL))
Sample 2:
subunit α:subunit β=0:1 (by MOI)
subunit α:subunit β=0:187.5 (by virus amount (μL))
Sample 3:
subunit α:subunit β=1:1 (by MOI)
subunit α:subunit β=57.7:187.5 (by virus amount (μL))
Sample 4:
subunit α:subunit β=1:2 (by MOI)
subunit α:subunit β=57.7:375 (by virus amount (μL))
Sample 5:
subunit α:subunit β=1:4 (by MOI)
subunit α:subunit β=57.7:750 (by virus amount (μL))
Sample 6:
subunit α:subunit β=2:1 (by MOI)
subunit α:subunit β=115.4:187.5 (by virus amount (μL))
Sample 7:
subunit α:subunit β=4:1 (by MOI)
subunit α:subunit β=230.8:187.5 (by virus amount (μL))
The procedure as employed in <1>-9 above was repeated, except that 10% gel (product of BIO-RAD) was employed as the SDS-PAGE gel and an anti-GST-HRP Conjugate (product of Amersham Biosciences) was employed as an antibody for detection, to thereby perform SDS-PAGE and Western blotting of the supernatants. Note that the DNA encoding factor G subunit α and that encoding factor G subunit β incorporated into the virus had been designed so as to express GST-bound proteins.
As a result, bands attributed to reaction with an anti-GST antibody were observed at target positions (about 75 kDa and 37 kDa). Thus, expression of factor G subunits α and β was confirmed.
Separately, the supernatant was purified by using Ni Sepharose 6 Fast Flow (product of Amersham Biosciences). After desalting and concentration of the eluate, the procedure as employed in <1>-9 above was repeated, except that 5-20% gradient gel (product of ATTO) was employed as the SDS-PAGE gel, mixture of an anti-Factor G subunit α serum and an anti-Factor G subunit β serum (kindly offered by Dr. Tatsushi MUTA (Department of Molecular and Cellular Biochemistry, Graduate School of Medical Sciences, Kyushu University)) was employed as a first antibody, HRP-conjugated anti-rabbit IgG antibody was employed as a second antibody and Konica Immunostain HRP-100 (product of Konica Minolta) was employed as a reagent for detection, to thereby perform SDS-PAGE and Western blotting of the eluate. Note that the DNA encoding factor G subunit α and that encoding factor G subunit β incorporated into the virus had been designed so as to express His-tag-bound proteins.
As a result, bands attributed to reaction with the mixture of an anti-Factor G subunit α serum and an anti-Factor G subunit β serum were observed at target positions (about 75 kDa and 37 kDa). Thus, expression of factor G subunits α and β was confirmed.
After cultivation, the supernatant was collected from each of the aforementioned seven samples, and whether or not the expressed protein maintains factor G activity was checked.
Specifically, the supernatant fraction after completion of cultivation was diluted at a factor of 11 times with an ice-cooled 50 mM Tris-HCl buffer (pH: 7.5) containing 150 mM NaCl. To the diluted product (25 μL), there were added a pro-clotting enzyme derived from a lysate (25 μL), dextran (final concentration: 2.4%), Tris-HCl buffer (pH: 8.0) (final concentration: 0.08 M), MgSO4 (final concentration: 0.08 M), CaCl2 (final concentration: 0.16 mM), distilled water for injection (10 μL), Boc-Leu-Gly-Arg-pNA substrate (see Japanese Patent Application laid-Open (kokai) No. 08-122334) (final concentration: 0.53 mM), and BG (0.25 ng), followed by adjusting the total volume to 125.1 μL. The mixture was allowed to react at 37° C. for 24 hours. After completion of reaction, absorbance of the sample was measured at 405 nm (blank) and 492 nm. Factor G derived from a lysate was employed as a positive control. The experiment was performed twice, and absorbance measures were averaged. The results are as follows.
Results:
Sample 1 (α:β=1:0): 0.166
Sample 2 (α:β=0:1): 0.167
Sample 3 (α:β=1:1): 0.278
Sample 4 (α:β=1:2): 0.190
Sample 5 (α:β=1:4): 0.169
Sample 6 (α:β=2:1): 0.730
Sample 7 (α:β=4:1): 1.078
factor G: 1.328
As is clear from the results, Samples 6 and 7, which had been prepared with controlling a MOI of virus harboring a DNA encoding subunit α to be higher than a MOI of virus harboring a DNA encoding subunit β during infection of cells with the virus, were found to have factor G activity. The analysis also indicated that intrinsic functions of the thus-expressed subunits α and β were not impaired.
The thus-produced factor G can be reacted with BG. Therefore, as-produced factor G may be employed for assaying BG or diagnosing mycosis.
As described hereinabove, the present invention provides a tool and a method for mass-expressing factor G derived from a horseshoe crab or a subunit forming the factor. Factor G and subunit(s) forming the factor produced according to the present invention may be employed as assay/diagnosis tools for BG assay, mycosis diagnosis, and other purposes, as well as laboratory reagents.
|
The invention provides a virus harboring a DNA encoding a subunit of limulus-derived factor G, the virus being capable of mass-producing a (1→3)-β-D-glucan assay reagent of satisfactory quality, steadily and at low cost, a cell harboring the virus, and a method of producing factor G by use of the cell.
| 2
|
This application is a continuation of application Ser. No. 07/863,874 noe abandoned, filed Apr. 6, 1992, which is a continuation of application Ser. No. 07/422,022, filed Oct. 16, 1989, now U.S. Pat. No. 5,103,499, which is a division of application Ser. No. 06/886,796, filed Jul. 18, 1986, now U.S. Pat. No. 4,874,164.
BACKGROUND OF THE INVENTION
This invention relates to the field of microprocessor powered computers for video games and personal computers, incorporating DMA techniques, especially such systems which are implemented in MOS (metal oxide semiconductor) LSI (large scale integrated) circuitry where circuit area is a consideration. The invention further relates to enhanced systems where auxiliary circuitry has been added to the host system; where a televisiontype display device is used; and where bit map mode (at least one bit of video information is stored in memory for every element location (pixel) of the picture displayed) is likewise incorporated.
The invention also relates to video display drives for color video display monitors where color sprites (which are sometimes called background) are operated in unison.
Bit mapping, while space and time implementation consuming, has proven to be a straightforward and an accurate method for video display generation. Complex displays provided by video games and personal computers require overlay presentations of movable and/or changeable information and of fixed information; and of collisions between movable objects. Bit map implementation has been the focus of various prior circuits.
Prior video game circuits have provided a complex display format to a television receiver display unit (a cathode ray tube), which display unit generates the presentation with a plurality of horizontal scans or raster lines. A video game circuit which is capable of displaying fixed objects as background, as well as, moving objects, is shown by Rosenthal, U.S. Pat No. 4,053,470.
Rosenthal has built a special purpose digital computer to generate video game information from a plurality of selected, on a mutually exclusive basis, software defined programs. Operator commands are separated into an independent computational section and an independent display section of the circuit for processing. Rosenthal, U.S. Pat. No. 4,053,740, utilized arithmetic logic units to drive accumulators to control x and y registers and associated horizontal and vertical beam direction drive circuits for cathode ray tube displays.
Personal computers, such as the Apple Computer, have utilized a main microprocessor to perform computational operations and to process (retrieve) video display information to generate displays to a television-type receiver.
The Apple Computer has incorporated a general purpose microprocessor, the MOS Technology Inc. Model 6502, to perform both computational operations and video display information retrieval. Such a single microprocessor driven system has speed limitations, as most microprocessors, including the Model 6502, have significant processing dead time used for refreshing registers and resetting and initializing operations. As a result, information processing in such systems can be slow.
In order to enhance processing speeds these small microprocessor driven computers have sacrificed display quality, i.e., "definition", "character" and "detail."
One approach to increasing the speed of such a personal computer has been to utilize two processors; a Motorola Inc. 68000 and a 6502. In this system, the first processor is dedicated to computational operations and the second microprocessor is dedicated to video display information retrieval.
Other early game circuits, such as Dash et al., U.S. Pat. No. 4,034,983 utilized special purpose control circuits to generate signals to the antenna connection of a commercial color television receiver. Such a special purpose control circuit could include analog interface circuits for processing gamepaddle signals and a decoding functions, and sync pulse generation could be used to generate horizontal sync and raster scan information.
Personal computer and microprocessor driven systems, such as Chunq U.S. Pat. No. 4,177,462, have used display generator circuitry driven off of an address bus data bus and control bus, including raster line generation and vertical position counters.
Likewise, Sukonick et al., U.S. Pat. No. 4,070,710 incorporates video control circuits and raster memory access into a system with data and address bus architecture. Sukonick et al. uses video control circuit which relies upon a plurality of vertical and horizontal position registers, a skip pattern memory and modulo comparison circuitry for "FIFO" processing of video information.
Sukonick, U.S. Pat. No. 4,070,710, shows a two processor system. Sukonick has added a display system 16 to programmed host computer 10. This video display system 16 contains an Intel Corporation 8088 microprocessor 76 within the micro-control unit 22 of the video display system
Along this line Burson, U.S. Pat. No. 4,180,805, has provided a video display circuit which incorporates a general purpose microprocessor 15, the TMS 1100 microcomputer. A character memory is provided separable from a display memory and character generator memory. Each display memory word is partitioned into two bytes, with the first byte being a character memory address and the second being a sub-address to locate a character-word within a set of character words in memory. Each character memory word is likewise partitioned into two bytes with the first byte determining color and the second byte selecting a particular character from a prestored set.
The use of a second general purpose commercially available microcomputer to process video display information, while increasing the system speed, also increases the cost of manufacture for the system, as well as the size of the system, i.e., chip "real estate."
A micro-control unit is also used and is necessary to the circuitry. The micro-control unit decodes instructions from a host computer for use by the raster memory unit and generates (encodes) control information to cause the raster memory to write display information, as well as, to control the video control circuit to read information from the raster memory and to translate it into video signals usable by a CRT drive circuit. Ackley et al., U.S. Pat. No. 4,243,984, shows a video display processor including general circuit components for overlay control, priority selection, sequence control, and memory control of sprite position and color.
Rahman, U.S. Pat. No. 4,420,770, shows a video background generation system including field correction logic, priority encoder circuitry and horizontal and vertical bit map memory.
Others have developed display circuits which have included an address bus,, data bus, and control signal lines for interfacing with a microprocessor based computer system. Some display circuits have included DMA control and playfield and spritegenerator components utilizing a plurality of control registers connected to operate with a plurality of memories, including collision detection and display priority logic.
Dual commercial microprocessor systems have increased off-chip wire connections as each commercial circuit comes as a separate dual-in-line package (DIP). In LSI (large scale integration) circuit design, this increases backplane and circuit card costs and increases the likelihood of noise pickup, often necessitating additional filtering and increased signal levels, which usually leads to more power consumption. Except in the very expensive dual microprocessor systems--priced above the personal computer market--display quality is not greatly enhanced with these second microprocessors as noise pickup and filtering costs often dictate a lesser display output quality.
Others have taken a divergent and different approach, such as using a display generator circuit designed as a raster scan line buffer structure. In such an approach, a general microprocessor can be used to address display object storage random access memory (RAM). The circuitry divides the display into moving objects (sprites) and into stationary objects (playfields).
This approach while cheaper to implement than the dual microprocessor approaches discussed above, and using less chip geometry and inter-chip wiring, does provide degraded system performance and display capabilities compared with the dual microprocessor systems.
One specific display generator enhanced microprocessor based system is shown by Hogan et al., U.S. Pat. No. 3,996,585, where a display generator is implemented with a plurality of buffer registers. He uses this display generator to process bit map information obtained from random access memory (RAM). A pattern generator is used to decode data for each raster scan line. Decoded rastor line data is stored in a buffer register for display. The pattern generator also decodes control data to determine collisions. The decoded collision control data is stored in a buffer register. Hogan et al.'s circuit is intended to relieve the system microprocessor from simple video display data retrieval and manipulation.
In keeping with the display generator circuit approach of Hogan et al., others have built a decoder based video display generators. Such a circuit would not utilize a second general purpose microprocessor to drive a video generator, but may use display instruction decoder circuits to provide movable object and stationary playfield object information to the video display, thereby reducing the work on the only (general purpose) microprocessor present Any of these circuits, as with Hoqan et al., require an increase in memory or storage space which is satisfied by a large number of registers. Some video display generators have their circuitry divided into a decoder(s), RAM(S) and register(s) for handling playfield fixed-object data; and into a decoder-selector(s) and register(s) for handling moving object data.
It is desirable to provide an auxiliary circuit which is intended to be incorporated into a microprocessor based personal computer system, which auxiliary circuit has true microprocessor capabilities, including bit-map data manipulation capabilities, but does not use the space and power of a second microprocessor or the increase in memory needed by the decoder approach, which can be implemented where inter-chip and backplane wiring is minimized.
SUMMARY OF THE INVENTION
The Amiga personal computer is a low-cost high performance computer with advanced graphics features. It is an object of the invention to provide a high resolution color display, fast graphics for simulation and animation, and substantial processing power at low cost.
High resolution color displays are becoming increasingly common because of the continued dramatic decreases in the cost of memory. However, the resulting huge display buffer memory can be painfully slow to draw or move display images around in, especially when using only a single conventional microprocessor. This situation is worsened by other large memory transfer channels, such as multi-channel stereo sound, high speed line buffer objects (such as sprites), and full track floppy disk buffers, which compete with the display for memory bus time. The conflicting design goals of high resolution color, fast moving displays, and low production cost have been largely resolved by the features of the invention. The hardware solutions are made less costly by designing them on custom silicon chips.
Extensive use is made of Direct Memory Access channels, to relieve the main microprocessor of most of the data transfers and beam position checking peculiar to windowed, real time, dynamic displays. The Motorola 68000 is used as the main microprocessor. The performance of the 68000 is enhanced by a system design that gives it every alternate bus cycle, allowing it to run at full rated speed most of the time. The special functions described below are produced using two custom-designed VLSI circuits, which work in concert with the 68000 to use the shared memory on a fully interleaved basis. Since the 68000 only needs to access the memory bus during each alternate clock cycle in order to run full-speed, the rest of the time the memory bus is free for other activities. A coprocessor and a data-moving DMA channel called the blitter can each steal time from the 68000 for jobs they can do faster than the 68000. Thus, the system DMA channels are designed with maximum performance in mind: the task is performed by the most efficient hardware element available.
A custom display coprocessor allows for changes to most of the special-purpose registers in synchronization with the position of the video beam. This allows such special effects as mid-screen changes to the color palette, splitting the screen into multiple horizontal slices, each having different video resilutions and color depths, and beam-synchronized interrupt generation for the 68000. The coprocessor can trigger many times per screen, in the middle of lines as well as during blanking intervals. The coprocessor itself can directly affect most of the registers of the special-purpose hardware, freeing the 68000 for general-purpose computing tasks.
Thirty-two system color registers are provided, each of which contains a 12-bit number as four bits of red, four bits of green, and four bits of blue intensity information. This allows a system color palette of 4,096 different choices of color for each register. A bitmap display memory organization called bitplane addressing is used. This method groups bitplanes (instead of pixels) together in memory, allows variability in the number and grouping of biplanes into separate images, and allows increased speed when using reduced numbers of bitplanes.
Eight reusable 16-bit-wide sprites are incorporated into the hardware with up to 15 color choices per sprite pixel (when sprites are paired). A sprite is an easily movable graphics object whose display is entirely independent of the background (called a playfield). Sprites can be displayed "over" or "under" this background. After producing the last line of a sprite on the screen, a sprite DMA (direct memory access) channel may be reused to produce yet another sprite image elsewhere on-screen (with at least one horizontal line between each reuse of a sprite processor).
Additional logic allows for dynamically-controllable inter-object priority, with collision detection. The system can dynamically control the video priority between the sprite objects and the bit-plane backgrounds (playfields), and system hardware can be used to detect collisions between objects so that a program can react to such collisions.
The Blitter is used for high speed data movement, adaptable to bitplane animation. The Blitter efficiently retrieves data from up to three sources, combines the data in one of 256 different possible ways, and optionally stores the combined data in a destination area. The blitter can draw patterned lines into rectangularly organized memory regions at a speed of about 1 million dots per second; and it can efficiently handle area fill.
Additional objects and advantages of the invention will be apparent to those skilled in the art from a reading of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from a reading of the following detailed description of the preferred embodiment in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram of the address generator (Agnus) chip;
FIG. 2 is an operational block diagram of a bitmap image manipulator (blitter) portion of the circuit;
FIG. 3 is a block diagram of the light pen registers and synch counters portion of the circuit;
FIG. 4 is a block diagram of the RAM (random access memory) address generator portion of the circuitry;
FIG. 5 is a block diagram of the bitplane DMA control logic;
FIG. 6 is a block diagram of the sprite vertical comparator and position registers portion of the circuitry;
FIG. 7 is a block diagram of the coprocessor (copper);
FIG. 8 is a block diagram of the Amiga system;
FIG. 9 is a block diagram of the display encoder (Denise) chip;
FIG. 10 is a block diagram of the bitplane data registers and serializers;
FIG. 11 is a block diagram of the sprite data registers and serializers;
FIG. 12 is a diagram of the collision detection logic; and
FIG. 13 is a diagram of the display priority control logic.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The Amiga personal computer is a low cost, high performance graphics and sound system for state of the art video game and personal computer applications. The system includes three custom IC's controlled by a Motorola 68000 16/32 bit microprocessor. These chips provide extraordinary color graphics on a standard TV or on an RGB color monitor, with arcade quality resolution and depth to display video games, cartoons, low resolution photographs, or up to 80 characters of text on the screen. The sound circuits can duplicate complex waveforms on each of four channels, matching commercial synthesizers in quality. Chip costs were kept low by using conservative design rules, process specifications, and logic density. The process selected is a common silicon gate NMOS one that is supported by almost all MOS manufacturers.
The Amiga system block diagram in FIG. 8 shows the three custom chips, designated Agnus, Denise, and Paula, and how they are connected to the address and data bus of the Amiga system. The block diagram shows the system data bus connecting the RAM 401 to all three custom chips, and to the 68000 microprocessor 402 through the bidirectional tristate buffer 403. The system data bus 404 is 16 bit and is bidirectional. The register address bus 405, or RGA bus, is bidirectional only with respect to the Agnus chip. The addresses to RAM 401 are input from either the Motorola 68000 processor 402, or from the Agnus chip through the DRA bus 406, with selection of either source under the control of multiplexer 407. The register address bus 405, or RGA bus, is driven when no DMA is occurring by the low address bits on output lines 408 of the 68000 through tristate buffer 409. This allows the microprocessor 402 to read or write the custom chips as if they were random access memory. When a DMA cycle is needed, the Agnus chip 410 informs the microprocessor 402 by asserting the data bus request (DBR) line 411. The bus control logic 412 then outputs signal DTACK on line 413, which suspends operation of the 68000 microprocessor 402, and switches both tristate buffers 403 and 409 so that processor 402 no longer has access to system data bus 404 or RGA bus 405. When in this DMA mode, Agnus chip 410 addresses the RAM 401 with its own RAM address bus, the DRA bus 406, which is selected by the multiplexer 407 for input to RAM 401 under the control of the bus control logic 412, while simultaneously placing a destination address for the data on the register address (RGA) bus 405. The register address on the RGA bus 405 selects one of a plurality of registers on any of the three custom chips, including Agnus chip 410, as the destination of the data from the RAM 401.
Operation of the Amiga computer system as a whole with a more detailed description of the interaction between the microprocessor 402 and the custom chips, Agnus chip 410, Denise chip 420, and Paula chip 430, is described in the copending application filed Jul. 19, 1985, entitled "Video Game and Personal Computer", Ser. No. 756,910, which is hereby incorporated by reference. The present application is principally concerned with the hardware and features associated with the Agnus chip 410 and the Denise chip 420. Block diagrams of the Agnus chip and the Denise chip are shown in FIGS. 1 and 9, respectively. A description of the hardware and features associated with the Paula chip 430 is described in the copending application filed Jul. 18, 1986, entitled "Peripheral Control Circuitry for Personal Computer", Ser. No 886,614, which is hereby incorporated by reference.
The Agnus chip 410 is the address generator chip (FIG. 1). It is 238×281 mils, and contains about 21,000 transistors. Its main function (in chip area) is the RAM address generator 45 and register address encoder 43 that produce all register and RAM addresses during DMA cycles. DMA (direct memory access) is a method for transferring data between memory and one of the custom chips without requiring execution of an "interrupt" routine by the microprocessor 402. The Agnus chip contains all of the DMA channel controllers for the Amiga system. It also contains a hardware bit map image manipulator 67, called the Blitter, and a display synchronized coprocessor 47, referred to as the Copper. The Agnus block diagram shows the DMA control logic and the drivers for the register address bus 405 and RAM address bus 406. The output of each one of the DMA controller circuits is labeled with two numbered arrows. These arrows indicate the number of DMA channels from each of these controllers that are driving the register address encoder 43 and the RAM address generator 45.
The Agnus chip 410 generates two addresses, for the source and destination, for all DMA data transfers involving any of the three chips, including data transfers utilizing registers on the Agnus chip 410 itself. The source of DMA data transfers is almost always the dynamic RAM, which is addressed by the RAM address generator 45. The chip registers are almost always the destination of the DMA data transfers, and are addressed by the register address encoder 43.
The priority control logic 73 outputs a bus demand signal DBR on line 411 to the bus control logic 412 shown on FIG. 8 whenever a DMA operation is needed in order to prevent the 68000 microprocessor 402 from accessing the RAM 401 during a DMA operation. Each of the DMA controllers 41, 47, 53, 57, 61, and 65 sends out a priority request signal and receives a priority enable signal from the priority control logic 73. The actual logic is similar to a daisy chain connecting the DMA controllers and giving different priority to different types of DMA requests. The logic 73 receives the video beam count from video beam counter 117, which is contained within synch counter circuits 31, and which can affect the priority given certain DMA channels. Memory access cycles are allocated among the DMA controllers and the processor 402, as will be described subsequently. Thus, for example, if the video beam count indicates that the beam is scanning the display and is not being blanked, the DMA controller for the bitplane display will be given priority and a bus demand signal will be output by logic 73 whenever the bitplane DMA controller requests access to the data bus 404.
In order to select a register on any of the three custom chips as the destination or source for data to/from the RAM 401 on the data bus 404, the register address encoder 43 places a prewired address on the RGA bus 405 whenever one of the 25 DMA channels on the Amiga computer is activated. All addresses on the register address bus 405 are input to the register address decoder 27 on the Agnus chip 410, which has a plurality of output lines 29 to the Blitter, the Copper, and all the other registers contained on the Agnus chip. If one of the registers on the Agnus chip 410 is being addressed, the decoder 27 places an output on a single one of its output lines 29, which will enable the data bus 404 to be accessed only by the specific register selected by the address on register address bus 405. The register address encoder 43 is driven by the DMA channel controllers and drives the register address bus 405 with a unique code selected by the control logic for each DMA channel. The 8 bits of the RGA bus 405 provide enough address information so that each register on the three chips can have its own unique address, and sometimes separate ones for read/write, without separate chip select lines or register read/write lines. Whenever the Agnus chip 410 is not performing a DMA operation, the encoder 43 will put eight 1's on the RGA bus 405, which signifies the default or "no address" address.
While a destination for data from RAM 401 is placed on the register address bus 405 by the register address encoder 43, the RAM address generator 45 generates an address for accessing a memory word in the RAM 401 and places it on the DRA bus 406. Thus, when a DMA operation occurs, the Agnus chip 410 asserts the data bus demand line 411 and addresses a word in the RAM with RAM address bus 406. The RAM address generator 45 is shown in greater detail in FIG. 4.
The Amiga personal computer system provides a total of 25 DMA channels. As shown in FIG. 1, control signals for all 25 DMA channels are input into the RAM address generator 45. The RAM address generator 45 contains a set of 25 pointer registers 138 (FIG. 4). Each of the pointer registers contains an 18-bit address, which points to the location in memory of data to be fetched next for the particular DMA channel. The pointer registers 138 are loaded with data (an address) from data bus 404 by the processor 402 or coprocessor 47 under program control. The DMA channels are associated with the sprite DMA control logic 41 (eight channels), the Copper 47 (one channel), the audio DMA control logic 53 (four channels), the bitplane DMA control logic 57 (six channels), the disk and refresh DMA control logic 61 (2 channels), and the Blitter DMA control logic 67 (four channels). For each of the 25 DMA channels, an 18 bit RAM address pointer is stored in a designated pointer register 138 and is subsequently output on the DRA bus 406 when that channel is active in order to select the memory address of the data in RAM 401 to be accessed by DMA. The DRA address lines from the Agnus chip 410 are already pre-multiplexed within the chip into high and low order bytes by multiplexer 69, so that 9 rather than 18 lines are output from the Agnus chip 410 onto the RAM address bus 406 at one time, thereby saving nine pins for other purposes. The multiplexer 69 in FIGS. 1 and 4 includes an output buffer register 141 that is directly connected to the DRA bus 406.
The RAM address bus 406 is a nine pin bus that carries 18 bits of multiplexed address data to address one of 256K words (512K bytes) stored in the RAM 401. The bus 406 is always driven by chip 410, and will drive the address pins on the RAM 401 when externally selected and demultiplexed. Addresses on the bus are generated one-half memory cycle early in order to be latched into the RAM 401 before data is actually transferred. The least significant nine bits of the RAM address are output on bus 406 during the last half of the preceding memory cycle. The most significant nine bits of the RAM address are output on bus 406 during the first half of the present DMA cycle. During the second half of the present DMA cycle, data contained in the RAM is transferred to the selected register in one of the three custom chips, and simultaneously the least significant nine bits of the RAM address for the next (if required) DMA cycle are placed on the RAM address bus.
If the RAM is the destination during a data transfer, data will be transferred to the RAM from a register during the first half of the present. DMA cycle as well, which is called an early read. Although many registers act as sources of data when read by the microprocessor 402, only two chip registers are sources of data for DMA data transfers into RAM 401. These are the Blitter destination register 113 and a disk data read register (not shown). These types of DMA operations use early read cycles because data must be read very early from the chip register in order to have the data available at the RAM 401 before the end of the first half of the DMA cycle. As a result, there is no time for a register address to be placed by the Agnus chip 410 on the register address bus 405. Therefore, the early read addresses put on the RGA bus 405 are only dummy addresses for cycle identification. The chip register data is automatically output by the Agnus chip 410 at the beginning of the present DMA cycle because the chip can determine in advance when either of the these two DMA cycles is about to occur.
The RAM address generator 45 of FIG. 4 is composed of a RAM address bus 406, a group of 25 pointer registers 138, a group of six modulo registers 131, and a group of six backup (or location) registers 129. The 25 DMA channels described above each use an address pointer to address dynamic RAM 401 when access to the data bus is obtained. The registers 138 are 18 bit registers that are loaded with a starting value by the microprocessor 402 or the Copper 47. Each pointer is used as an address on the DRA bus 406 and is typically incremented by one to point to the next address in memory the next time it is utilized. When a DMA channel must be quickly restarted over and over again at the same address, the address pointer is reloaded from a hardware register automatically. This is done using the backup, or location, registers 129. There are six backup registers 129, four for the four audio channels, and two location registers for the two copper indirect jump registers. In the case of audio DMA, the backup value is reloaded into the pointer register whenever the audio waveform being output is finished. In the case of the coprocessor or Copper 47, the backup value is reloaded (strobed) into the pointer register 138 (program counter) whenever the (strobe) address which corresponds to either of the two copper location registers 129 is written.
The bitplane DMA control logic 57 and Blitter 67 are utilized in the display of bit-mapped video images. When the window, i.e., the video image to be displayed on the screen, is a portion of a larger image stored in RAM 401, it is necessary to increase the value of the data address stored in the bitplane pointer registers 138 from an address corresponding to the end of one horizontal line of pixels to the address corresponding to the beginning of the next line of pixels to be scanned for that image. In order to accomplish this, modulo registers 131 are utilized. There are six modulo registers 131, four for the four Blitter channels, and two that are used separately by the three even and three odd bitplane channels. The modulo registers are preloaded with an address jump value that equals the number of words in memory between the last word being displayed on the screen on one horizontal line and the beginning of the first word on the next line. Whenever the end of a video scan line is reached instead of merely incrementing the address contained in the corresponding pointer registers 138 by one, the address jump value stored in the modulo register 131 is added to the address pointer in order to access the data in RAM 401 corresponding to the beginning of the data to be used in displaying the next video scan line. The six bitplanes have only two modulo registers, so that one register is reserved for even and one for odd numbered bitplanes. Thus, for each of two playfields, a larger image can be stored in memory than is displayed on the screen. Each Blitter channel has its own modulo register. Therefore, each of three "source" images and one "destination" image handled by the Blitter can have images of different sizes stored in memory, although the screen, of course, can only display a window of a single size.
There is an 18 bit adder 137 in the RAM address generator 45 that performs any incrementing and decrementing of the pointers in the pointer registers, and which also adds or subtracts the modules stored in the modulo registers 131 for the bitplane and Blitter DMA channels when the beam scanning the screen has reached the end of a horizontal scan line (as defined by comparing the video beam count with the value in a data fetch stop register). The adder 137 also can be switched to "add" (substitute) the values in the six backup registers 129 in place of the values in the corresponding pointer registers 138 upon occurrence of the audio DMA or Copper DMA events described above. The backup registers 129 and modulo registers 131 have their outputs to the adder 137 under the control of enable lines 29 from the register address decoder 27 of FIGS. 1 and 4, so that only one modulo or backup value is input to adder 137 at a time. As shown in FIG. 4, a gate inhibit signal on line 133, responsive to the Copper 47 and audio DMA controller 53, controls a gate 135. This gate 135 controls the backup reloading operation during which the gate 135 drives all inputs to adder 137 from the registers 138 to zero, and the adder 137 is operating in the add mode, so that the value in the backup registers 129 is substituted for the previous value in the register 138. An invert instruction and a carry instruction is also provided to the adder 137 from the DMA controllers. Four operations are performed by the adder 137 in response to the two bit input provided by the carry and invert instruction. The invert instructions causes the adder to operate in descending mode, as required, for example, during certain blitter operations involving overlapping memory. Thus, subtract or decrement by one operations are chosen instead of add or increment operations. The carry instruction causes the adder to add or subtract two inputs, instead of merely incrementing/decrementing the pointer, as is required in order to use the modulo and backup values. The adder 137 provides the pointer return value, which is output into multiplexer 139, in order to place the address to be used during the next memory cycle into the pointer register 138. The multiplexer 139 also receives an input from the data bus 404. More than 16 bits are provided from the 16 bit system data bus by repeating several of the bits on the bus as inputs to the multiplexer 139. Either the data on the data bus 404 or the pointer return value from the adder 137 will be selected by multiplexer 139 and be loaded into the particular pointer register 138 selected by the register address decoder 27.
The bitplane control registers 55 and bitplane DMA controller 57 are shown in FIG. 5. There are several bitplane control registers, shown as registers 143, which receive data from the data bus 404. The control registers 143 include bits for enabling each bitplane and are loaded under the control of an enable signal from the register address decoder 27. The outputs from the registers 143 are input in parallel to a state sequencer 145 along with timing inputs and a bitplane run signal. The sequencer 145 pulses one of six output lines for each of the six bitplane DMA channels. Each output line is sent to both the RAM address generator 45 and the register address encoder 43. The outputs to the RAM address generator 45 of FIG. 4 are used to select a particular pointer for output on the RAM address bus 406 in order to access bitplane data stored at that address in RAM. Identical outputs to the register address encoder 43 cause the encoder to select the 8 bit code that must be output on the register address bus 405 in order to select a destination for the bitplane data from memory. The bitplane run signal on line 149 is from bitplane start/stop control logic in the priority control logic 73 and gives priority to the bitplane DMA controller when it requests memory access. The run signal is output only when the video beam count indicates the display is on and must therefore be given priority. This occurs when bitplane start/stop control logic indicates the video beam count is between the limits set in display window start and stop and data fetch start and stop registers included among the bitplane control registers 55. The circuitry shown in FIG. 5 for generating outputs on lines to the encoder 43 and pointer registers 138 is similar to that used for all the DMA controllers.
The synch counters and light pen registers 31 are shown in FIG. 3. The circuitry has access to the data bus 404 when enabled by one of the lines 29 from the register address decoder 27. A light pen input signal 33 is fed into the light pen register circuitry 119, and a television synch signal 35 is output by the synch video beam counter 117 to the display to synchronize its operation with that of the processor. The light pen signal 33 is received from a light pen port connected to the circuit and can cause the beam count when the beam passed the light pen to be loaded onto the data bus 404 under the control of the register address decoder 27. The output of the synch video beam counter 117 is input into the copper 47, the sprite vertical position comparator 39, and into the priority control logic 73. The beam count is important in determining what DMA controllers can demand the next memory cycle, in displaying sprites, and in changing the contents of registers by the Copper 47 during a blanking interval or in the middle of a display.
The vertical position and comparison logic for the sprites is shown in greater detail in FIG. 6. Vertical start location registers 153 and vertical stop location registers 155 are loaded with data from the data bus 404 for up to eight possible sprites under the control of the register address decoder 27. Each sprite channel sends two output lines 120 to a state sequencer in the sprite DMA controller 41 in order to start and stop display of the sprite. The synch video beam counter 117 outputs the vertical portion of the count to a sprite vertical position comparator 39. The other inputs to comparator 39 are provided by both the vertical start and stop location registers for each sprite. When the vertical count exceeds or equals the value in either of the registers 153 and 155, output is sent on the corresponding line 120 to the sprite DMA controller 41. The sprite DMA controller has a state sequencer that receives the vertical position comparator outputs for each of the eight sprites and, in turn, drives the register address encoder 43 and pointer registers 138 in RAM address generator 45 with output lines for each of the eight sprites.
The Copper 47 is a coprocessor that utilizes one DMA channel to fetch its instructions. The pointer stored in the pointer register 138 corresponding to the Copper 47 is the instruction or program counter, and must be preloaded with the starting address in memory of the program instructions for the Copper. The Copper can control nearly the entire graphics system, freeing the processor 402 to execute program logic. The Copper can also directly affect the contents of most of the registers on the chips. The Copper serves as a powerful tool for directing midscreen modifications in graphics displays and for directing changes in register values that must occur during the vertical blanking period between displays. Among other things, the Copper can control register updates, reposition sprites, change the color palette, update the audio channels, and control the Blotter. The Copper 47 is a coprocessor and has its own instruction set consisting of only three instructions. The Copper can: WAIT for the beam scanning the screen to reach a specific screen position specified as X and Y coordinates; MOVE an immediate data value from RAM into one of the special purpose registers; and SKIP the next instruction if the video beam has already reached a specified screen position. All of these instructions consist of two 16 bit words in sequential memory locations. The Copper fetches both words each time it fetches an instruction. The MOVE and SKIP instructions require two memory cycles and two instruction words, and the WAIT instruction requires three memory cycles. In accordance with the DMA time slot allocation set up for the Amiga system, only the odd memory cycles are requested by the Copper 47, so four memory cycles are required for execution of MOVE and SKIP instructions and six memory cycles are required for the WAIT instruction.
The MOVE instruction transfers data from the RAM 401 to a register destination. The first word in the MOVE instruction contains the address of the destination register, while the second word of the MOVE instruction is irrelevant (it contains the data to be transferred). The WAIT instruction causes the Copper 47 to wait until the beam position count equals or is greater than the coordinates specified in the instruction. While waiting, the Copper is off the system data bus 404 and is not using any memory cycles. The first instruction word contains the vertical and horizontal coordinates of the beam position. The second word contains enable bits that are used to form a mask that indicates which bits of the beam position count to use in making the comparison. The SKIP instruction causes the Copper to skip the next instruction if the video beam position count as equal to or greater than the value given in the instruction.
The Copper 47 is shown in greater detail in FIG. 7. A first instruction register 173 stores the contents of a first instruction word received from the data bus 404, while a second instruction register receives the contents of a second instruction word received from the data bus 404. The loading of data from the bus 404 to registers 173 and 175 is controlled by enable signals sent on lines 29 from the register address decoder 27. The least significant bit in the first instruction word and in the second instruction word are used to determine which of the three possible instructions is to be executed. Thus, single bit control lines 177 and 181 input the least significant bit of the first and second instruction words, respectively, into an instruction operational code decoder 179. The operational code decoder 179 uses the two bits of input to determine the instruction to be executed, and will enable either the MOVE instruction line 183, the SKIP instruction line 185, or the WAIT instruction line 187. These three output lines identifying the requested instruction are input into a state sequencer 199.
The least significant eight bits (not including bit 0) loaded into the first instruction register are output to delay latches 191. If and only if a MOVE instruction is being executed by the Copper 47, these eight bits specify the address of the register that is the destination of the data that is on the data bus during fetch of the second word instruction. If a MOVE instruction is being executed by the Copper, the eight bits from the delay latches 191 will be output at a later time from the register address encoder 43 to the register address bus 405 and the buffer circuitry 21. The placement of the eight bits on the RGA bus 405 enables the particular register being addressed to receive data that is output to the data bus 404 from the RAM 401 address specified in the pointer register 138 corresponding to the Copper.
The video beam position counter 117 contained within the synch counter circuitry 31 outputs 15 bits of data to a comparator 193 within the Copper 47. The contents of the video beam position counter 117 indicate the specific position that the electron beam scanning the display has reached on the screen. Bits 1-15 in the first instruction word register during a WAIT or a SKIP instruction specify the horizontal (bits 1-7) and vertical (bits 8-15) beam position, and form one set of inputs to an AND gate 195. The value input from the beam counter is compared within the comparator 193 with a value input from the AND gate 195. The other set of inputs to the AND gate 195 is provided by the least significant bits (not including bits) contained in the second instruction word register 175. These bits are enable bits that are used to form a mask, so that the comparator 193 will ignore certain bits in making the comparison during a WAIT or a SKIP instruction. In the comparator 193, the beam position bits specified by the first instruction word that are not masked by the enable bits in the second instruction word are tested against the count of the video beam position counter 117 before any further action is taken. The comparator 193 output is sent to the state sequencer 199.
The state sequencer 199 provides three outputs in response to jump address strobes and to input of the result of the beam count comparison and the inputs identifying the instruction being executed. The fetch output on line 219 is sent to both the register address encoder 43 and the pointer register (program counter) in the RAM address generator 45, so that the Copper 47 can access memory if the priority control logic 73 so allows. Output lines 221 and 223 are sent to the RAM address generator 45 shown in FIG. 4. The gate inhibit signal on line 133 in FIG. 4 results from output lines 221 and 223 being wired-or together, so that either output causes the adder 137 to substitute a value in the backup (location) registers 129 into the program counter 138. The two outputs, Jump 1 and Jump 2, are also sent to two respective location registers 129 containing the address in RAM 401 of the next instruction to be executed by the Copper 47. A first location register 129 and a second location register 129 contain the two indirect jump addresses used by the Copper 47. The Copper 47 fetches its instructions from RAM 401 using its program counter (pointer register 138), incrementing the program counter after each data fetch. When a jump strobe address is written, the address stored in the corresponding location register is loaded into the Copper 47 program counter. This causes the Copper 47 to "lump" to a new location in memory, from which its next program instruction will be fetched. The program instruction fetch then continues sequentially until another jump address strobe from register address decoder 27 occurs. At the start of each vertical blanking interval, the address in first location register 129 is automatically used to start the program counter and the Jump 1 output is activated. Thus, when the end of a vertical blanking interval occurs, the Copper 47 will automatically restart its operations with the instruction in RAM 401 at the address specified in the first location register 129.
The Blitter DMA controller 65 operation is sufficiently described by reference to FIGS. 4 and 5. The Blitter control registers are each enabled by a line 29 from the register address decoder 27 in order to transfer data from the bus 404 into one of the registers 63. The Blitter control registers 63 have outputs sent to a state sequencer, which is similar in structure to the state sequencer 145 described with respect to the bitplane controller 57. The state sequencer outputs, four in all for the four Blitter DMA channels, are input to the register address encoder 43, which provides the priority control logic 73 with a priority request signal in order to generate a data bus demand on line 411 to the bus control logic 412, and which also outputs the code selecting a particular register on the register address bus 405. The four outputs are also sent to the RAM address generator 45, where one of the pointer registers is selected and where additional adder control circuitry exists to generate an invert instruction and a carry instruction as inputs to the adder 137.
The implementation of the audio DMA controller 53 shown on FIG. 1 is very similar to the circuitry shown for FIGS. 4 and 5 for bitplane DMA control. There is a single set of registers 51 for holding left and right,audio control information, and these registers have outputs connected to a state sequencer with four outputs similar to the state sequencer 145 shown for the bitplane DMA channels in FIG. 5. Additional outputs are provided, however, to the backup registers by the audio DMA controller rather than to the modulo registers as in the case of the bitplane and Blitter DMA controllers. These outputs, like the Copper 47 jump outputs, are wired-OR together and feed the line 133 providing the gate inhibit signal to gate 135 in order to cause substitution rather than addition by adder 137. In contrast, for the bitplane and Blitter control registers 55 and 63, certain registers (such as the display window start and stop registers or the Blitter size register) are loaded with display position count data in order to enable the sending of outputs to the modulo registers 131 at the proper time.
The hardware for the Blitter 67 is shown in an operational block diagram in FIG. 2. Data on the data bus 404 is input into the A and B source data registers 77 and 79 under the control of the register address decoder 27. The A and B source data registers 77 and 79 each comprise two 16 bit registers, with A and B old source data registers 77a and 79a each respectively storing the data word that was previously input to registers 77 and 79. The A and B source data registers each output two 16 bit words into the 16 bit barrel shifter 81. Data on the data bus 404 is also input to first word and second word A mask registers 83 and 85. The output from these mask registers is input for loading into the A source mask logic 90. The A mask logic 90 receives control signals which also enable the modulo registers 131 from the Blitter DMA controller 65 of FIG. 1 when the word in register 77 is the first and/or last in the Blitter window for a horizontal line.
Data bus 404 also provides an input into the C source data register 89, which is also loaded under control of the register address decoder 27. The C source data register 89 sends data to a logic unit 91, which is a logic unit that can be controlled to perform any one of 256 possible logic operations on the three inputs it receives from the A, B, and C registers. An A shift count register 93 and a B shift count register 95 among the Blitter control registers 63 are each loaded with four bits of data from the data bus 404. The 4 bit outputs are provided by shift count registers 93 and 95 to the barrel shifter 81. The barrel shifter 81 can perform up to 15 bits of shifting separately for the A and B source data registers 77 and 79, with the shifter containing 32 bits from each source. A 16 bit output from the barrel shifter 81 for each source is provided to the A and B holding registers 101 and 102. The holding registers 101 and 102 have 16 bit outputs. One of the Blitter control registers 63 receives a data word from the data bus 404. Eight bits in this Blitter control word contain multi-minterm select bits that are input to the logic unit 91 and select which of the eight available minterms to combine to select one of 256 possible logic operations that can be performed on the A, B, and C source inputs.
The logic unit 91 also includes fill logic circuitry. The fill logic circuitry operates to "fill in" bits between the horizontal outlines of an object that is being displayed on the screen. It generates the data if one of the Blitter control registers 63 has been loaded with bits enabling the fill operation. The fill logic for each bit and each word has a fill carry out signal on line 107 which is input to the logic for the next bit, or for the first bit of the next word if the Blitter operations on the present word are complete. The exclusive OR circuitry 108, once a "1" is found for the first time on a horizontal line, will change all subsequent zeros on the line to "1"'s, until another "1" is found on the line. The logic unit 91 output is input to a D holding register 113. The output from the D holding register can be sent out on the data bus 404 and stored in the RAM 401.
Data is conveyed with the display encoder (Denise) chip 420 via the data bus 404 (FIG. 9). A bidirectional buffer 313 is connected to the data bus, and a continuation 315 of this data bus continues throughout the circuits on the Denise chip 420. This data bus 315 is 16 bits wide. Various registers receive or send data onto the data bus 315. These registers are controlled by load enable signals 317 from a register address decoder 319, which utilizes destination "instructions" placed into the address decoder 319 via the register address bus 405 and through a buffer circuit 323 connected to a register address bus continuation portion 325, which is 8 bits wide. The register address decoder 319 decodes a destination "instruction" and provides an output on one of the lines 317 to enable a data transfer into or out of a particular destination register.
Among the registers connected to the data bus 315 are bitplane control registers 327. These registers 327 send control signals to the bitplane select serializer circuitry 329. Bitplane select serializer 329 acts as a serializer for bitplane data received from the bitplane data registers 331, of which there are six. Each register 331 is connected to send data to the serializer circuitry 329 when selected by the register address decoder 319. The output of the bitplane select serializer 329 are six bits corresponding to each of the six bitplanes and constituting the bitplane bus 333. Bitplane bus 333 is connected to output color register selection data to both collision detection logic 335 and display priority control logic 337.
A horizontal synch beam counter 339 exists on the Denise chip, and is synchronized with the beam counter 117 on the Agnus chip 410. The output is connected to the bitplane control registers 327 and to sprite horizontal position comparator logic 341.
Sprite horizontal position registers 343 receive data from each of eight data bus 315. The output from the sprite horizontal position registers 343 is input as a second input to the sprite horizontal position comparator logic 341. This sprite horizontal position comparator logic 341 compares an 8-bit word from the horizontal synch beam counter 339 with a word from each of the sprite horizontal position registers 343.
There are two 8-bit sprite data registers 345 receiving data from data bus 315 for each of eight sprites. These sprite data registers 345 output color register selection data to sprite select serializer circuitry 347, which acts as a serializer and outputs eight pairs of signal lines corresponding to each of eight sprites to form a sprite bus 349. The sprite bus 349 is therefore 16 bits wide. The output from the sprite horizontal position comparator logic 341 is input to the sprite select serializer 347. Sprite bus 349 is connected to output color register selection data to both the collision detection logic 335 and the display priority control logic 337.
A collision control register 351 receives data from data bus 315. The output from the collision control register 351 is input to the collision detection logic 335. A 16-bit output from the collision detection logic 335 is input to a collision storage register 353, which is connected to send the data out on data bus 315.
Bitplane priority and control registers 355 receive data from the data bus 315. The output is connected to the display priority control logic 337. Display priority control logic 337 sends 5-bit color register selection data to a color select decoder 357.
The color select decoder 357 has 32 lines of output which are exclusively selected to enable one of 32 color registers 359, which operate to provide the video to the display using 12-bit codes that control the red, green and blue guns used to generate images on a display. The 32 color registers 359 are loaded with data from the data bus 315.
The video output is sent to hold and modify logic 360, which also receives inputs from the bitplane bus. The logic 360 is enbled by an output from one of the bitplate control registers 355.
Auxiliary peripheral controllers such as mouse counters 361 can also be connected to data bus 315. Such mouse counters 361 are used with commercial cursor positioning devices. Such mouse counter circuits 361 receive and dump data onto the data bus 315.
The bitplane data registers 331, of which there are six, are each 16 bits wide (FIG. 10). Each of the six bitplane data registers 331 passes 16-bit information into a corresponding one of six bitplane parallel-to-serial registers 363 in bitplane serializer 329. The transfer of the data in each bitplane data register 331 to a corresponding the parallel-to-serial register 363 occurs after data for all active bitplanes has been transferred to the bitplane data registers 331 under DMA control. Each bitplane parallel-to-serial register 363 passes bitplane information in serial form on a corresponding one of six output lines comprising the bitplane bus 333. This occurs after line 317 to bitplane data register 1 has caused this register to be loaded, triggering the simultaneous dump of data by each of the bitplane registers into the corresponding serializers in response to bitplane control register enable signal on lines 365 from the bitplane control registers 327.
The sprite select serializer portion 347 of the Denise chip, FIG. 11, uses parallel-to-serial conversion and serialization, as does the bitplane select serializer 329 described above. The sprite data registers 345 are comprised of two 16-bit sprite data registers 367 for each of the eight sprites. A total of eight pairs of 16-bit registers 367 receive data from the data bus 315. Each individual sprite data register 367 is connected to a corresponding sprite parallel-to-serial register 369, of which there also are a total of eight pairs. Each of the 16 sprite parallel-to-serial registers 369 feeds sprite data serially onto a corresponding one of the 16 output lines comprising the sprite bus 333. Output from each pair of registers 369 for each sprite is under the control of signals on 8 pairs of output lines 371 from the sprite horizontal position comparator logic 341 to each of the registers 369.
The collision detection logic 335 is shown in greater detail in FIG. 12. Collisions can be detected when two or more objects, as defined by any non-zero bits used to display any of eight sprites or two playfields, overlap in the same pixel position. A logic array network consisting of two stages of NAND gates 373 and 375 (gates 373 being the first stage and gates 375 being the second stage) forms the collision detection logic. The first stage of NAND gates 373 receive inverted data (using inverters 372) or non-inverted data from each line of the bitplane bus 333 and the sprite bus 349, and from each line output from the collision control register 351. Each of the second stage NAND gates 375 has connected as inputs thereto a selected number of the outputs from the first stage NAND gates 373 for certain sprites or playfields to form a MINTERM. The bits loaded in the collision control register 351 determine whether odd-numbered sprites and specific bitplanes will be utilized by the detection logic 335 in setting the bits in collision storage register 353. Depending on the implementation selected by the bits in control register 351, the polarity of the bits used to detect a collision can also be specified.
The bitplane and display priority portion of the circuit is shown in FIG. 13. The display priority control logic 337 is implemented by a logic array network consisting of two stages of NAND gates 377 and 378. The first stage of NAND gates 377 receives inverted data (through inverters 376) or non-inverted data from each of six lines of the bitplane bus 333 and 16 lines from the sprite bus 349, and also receives inputs from the bitplane priority register 355, to generate an array of MINTERMS. A selected combination of the first stage NAND gate 377 outputs are used to generate the 5 bit output sent to the color select decoder 357. The sprites have fixed priorities with respect to each other, but the priority of the even and odd bitplanes with respect to sprites and each other can be controlled with the bitplane priority register 355.
The color select decoder 357 provides 32 control lines corresponding to the 32 color registers 359 for selecting the three 4-bit color code words for red, green, and blue video color intensity. Each color register is loaded with the bits defining its color from the data bus 315.
THEORY OF OPERATION
There are two basic parts to any display which can be seen on the display screen when using the Amiga personal computer. First, are objects which are easily movable, called sprites. Second, are things which do not move or can only move slowly, called playfields or playfield objects. The playfield is the background against which the sprites and objects may be displayed or with which the sprites and objects can interact. A playfield object is simply a smaller subsection of the playfield, but it is considered by the software in the Amiga system to be an object of some kind. Even though playfield objects are classified as non-moving objects, these objects can appear to move by using a technique called playfield animation. Thus, the Blitter allows playfield objects to be rapidly redrawn on the screen, while saving and restoring the background or playfield onto which they are drawn, to give the illusion of motion.
There are two different operating modes for the playfield display: normal resolution and high resolution. In normal resolution mode, there are 320 picture elements or pixels which form each horizontal line of the screen. This is the resolution generally used for standard home television. High resolution pictures are normally only available on a high resolution monochrome or RGB monitor. In high resolution mode, there are 640 pixels which form each horizontal line of the screen display. There are normally approximately 200 lines per display screen in a vertical direction. In interlace mode, however, there are approximately 400 lines per display screen in the vertical direction. In interlace mode, the video scanning circuitry displays a set of 200 lines during one frame (which occurs 60 times per second), but on the very next display frame, the video scanning circuitry interlaces a different 200 lines on the screen by placing the 200 lines of each frame in between each other. This provides double the vertical resolution. The count from video beam counter 117 includes a long-frame bit used for interlaced mode to distinguish the two frames. A bitplane control registers 55 and 327 contain the bits which define both the horizontal bit resolution and the interlace mode for vertical resolution. One bit selects the high resolution mode, and another bit enables the interlace mode.
In the Amiga system, the user can define a color "palette" containing 32 out of a possible 4096 available colors. In normal resolution mode, any one of the 32 colors in the palette can be selected and matched with any one of the pixel elements that make up the overall picture being displayed. A pixel is the smallest picture element in the video display. In high resolution mode, each pixel can be any one of 16 colors contained in the color palette. In the special hold and modify operating mode, up to 3616 colors can be written on the screen at the same time for a standard television, or up to 4096 colors can be drawn on the screen of an RGB monitor.
Each pixel displayed on the screen is represented by one or more bits in the Amiga random access memory 401. Thus, for each individual pixel element, there is a corresponding set of bits in the computer memory which determines which of the 32 color registers 359 contains the color information for that pixel. Because the pixels are organized in a two-dimensional (horizontal and vertical) array, the playfield is referred to as a color plane. The corresponding sections in RAM 401 that contain bits that determine the color of each of the playfield pixels are called bitplanes. The value of the color to be used for each pixel is not stored directly as part of the bitplanes in memory, but is rather stored in a color table, previously referred to as the color palette. Thirty-two color registers 359 are contained on the display encoder chip 420, and consist of a set of 12-bit registers, each of which is selectable by one of 32 lines from the color select decoder 357. Thus, any particular pixel on the display can have any one of 32 different colors. The contents of each of the 32 registers are selected by the user. The 12 bits contained in each register allow selection from a total of 4096 possible colors for each color register. The COLORO register is always reserved for the background color of the screen. The background color is the color which shows in any area on the display when no other objects are present, since all other objects have a higher priority than the background.
In order to select the color of a particular pixel from a palette of more than two colors, there must be more than a single bit in RAM 401 corresponding to each pixel displayed on the screen so that one of several color registers can be selected. If only one bitplane is used to specify the colors of a playfield, each pixel in that playfield can only have the color specified in color registers COLOR0 and COLOR1. Additional color choices for the pixels become available when several bitplanes are combined in order to specify the color register for each individual pixel. When several bitplanes are combined in order to specify the color of the onscreen pixel elements, the bits from each are combined into a longer binary number which can select additional color registers. Normally, for a single playfield, only five bitplanes can be active in the Amiga system. The combination of five binary bits for each pixel element allows a choice among 32 different color registers 359 each of which specifies a color. Each bitplane forms a separate block of bits stored in RAM 401. However, the display interprets the bitplanes as if they were stacked, so that bits in corresponding positions in different bitplanes are combined by the display hardware to form a binary number which corresponds to a particular color register used to provide the color for that pixel element. A bitplane control register contains three bits which allow the user to designate from 0 to 6 bitplanes for the display.
The bitplane control registers 355 also contain a dual playfield enable bit. In the dual playfield mode of operation, all odd numbered bitplanes are grouped together as playfield 1 and all even numbered bitplanes are grouped together as playfield 2. For example, if six bitplanes are specified and the dual playfield mode is selected, eight different color registers can be designated for any particular pixel by three bits combined for each playfield, and the set of eight color registers is completely separate for each playfield.
A special case exists when the bitplanes contain all zeros for a particular pixel in either playfield 1 or playfield 2. The designation of all zeros for a pixel means that the playfield is in transparent mode. (The COLORO register contains the background color.) Wherever the bit combination in either playfield is set for transparent mode the display will show the color of whatever is "behind" (has lower priority than) the particular playfield (e.g., the other playfield, a sprite, or the background color). The user can designate whether certain objects are to be placed in front of or behind each other by controlling the relative visual priority of the playfields and sprites, using the bitplane priority register 355. In dual playfield mode, the two playfields are combined on the screen to form a dual playfield display. If playfield 1 has a higher priority than playfield 2, the color for each pixel element is selected in display priority control logic 337 by utilizing the color registers designated by the odd bitplanes of playfield 1. However, if any pixels on the screen are placed in the transparent mode (all bits are zero) by the odd bitplanes for playfield 1, then the pixels will be colored using the color register designated by the even bitplanes associated with playfield 2. If the bitplanes for both playfields select the COLORO register for the same pixel, that pixel element will be colored with the background color contained in the COLORO register.
In order to simultaneously display more colors than the 32 possible choices stored in the color registers 359, there is a special hold-and-modify mode. The mode is selected using a bit within the bitplane control registers 355; In this mode, the system interprets the bitplane data in a different manner. As described previously, each color register 359 contains 12 bits that designate a particular color. An RGB color monitor is driven directly by an RGB (red, green, blue) color input signal. An RGB color signal is virtually three monochrome signals, separately driving the red, green, and blue guns of a raster display. When using normal resolution, the 12 bits of the color registers are interpreted such that bits 0 through 3 designate the intensity level for the blue electron gun, bits 4 through 7 correspond to the green electron gun, and bits 8 through 11 correspond to the red electron gun. In hold-and-modify mode, the value in the color output circuitry for the previously displayed pixel is held, and one of the three 4-bit parts of that value is then modified by the data in the first four bitplanes for that pixel. In hold and modify mode, the bit combinations for a pixel from bitplanes 5 and 6 are used to modify the way in which the bits from bitplanes 1 through 4 are interpreted. The bitplane bus 333 and the 12 video outputs from the color registers 359 are input to the hold and modify circuitry 360, which has 12 video outputs. If the bits in bitplanes 5 and 6 for a pixel element are set to zero, the first four bitplanes will be used to choose one of 16 color registers 359. For the three other possible combinations of the two bits from bitplanes 5 and 6, the color of the previous pixel displayed (to the left of the current pixel) will be duplicated, except for a 4-bit modification. The bits contained in bitplanes 5 and 6 determine whether the red, green, or blue portion of the display will be modified. The four bits in bitplanes 1 through 4 will then be used to replace the four (out of 12) bits used in driving either the red, green, or blue gun of the display. Thus, in this mode, two parts (e.g., green and red) of the output from the color registers are held over from the previous pixel, and one part (e.g., blue) is modified by the data contained in the bitplanes.
Each line of pixels that is displayed on a television screen is formed from the overlap of one or more bitplanes containing bits associated with each particular pixel. Each bitplane, in turn, is formed from blocks of 16 bit data words in consecutive locations in random access memory 401. Each line of a bitplane consists of a sequence of data words, with the most significant bit of each data word relating to the leftmost pixel to appear on the display of pixel elements. Each memory word is at a sequentially increasing memory address as one moves from left to right across the display. If the entire bitplane corresponds to pixels that will all be displayed, then the leftmost pixel displayed on any horizontal line corresponds to a bit contained in a memory word at an address one greater than the address of the word containing the bit corresponding to the last pixel on the right of the horizontal line displayed immediately above. Within each data word, each bit represents a single pixel on the screen. The sequence of bits stored in memory defines a two-dimensional plane of bits having one bit for each x and y position defined on the display, referred to as a bitplane. Each bitplane as a whole provides one bit for each possible x-y coordinate on the screen.
In order to display the background color and one or two playfields on the screen, the Amiga system must be given the starting address during the vertical blanking time for the data block for each of the bitplanes to be used. The start of the bitplane data is specified using pointers contained in the pointer registers 138 of FIG. 4, with one register existing for each of the six possible bitplanes. The bitplane pointers are address pointers which point to the starting address within RAM 401 at which the data for a specific bitplane actually starts. The pointers in the registers 138 are 19 bits wide and are dynamic. Once the fetch of bitplane data begins during DMA cycles, the pointers in registers 138 are continuously incremented using adder 137 to point to the address of the next word in RAM 401 to be fetched. The address of the data being accessed is then placed on the DRA bus 406 by the RAM address generator 45 of the Agnus chip 410. When the electron beam for the television screen reaches the last pixel to be displayed on a horizontal line (as determined by the beam count) it will have fetched the last data word for that line. Each pointer for each of the bitplanes is then adjusted by the modulo amount contained in the modulo registers 131, which is added to the pointer value stored in registers 138 using the adder 137. The addition of the modulo amount ensures that the next data word fetched will be the word in memory corresponding to the leftmost pixel to be displayed on the next line of the screen. Separate modulo amounts can be used for the even and odd bitplanes and stored in two modulo registers 131.
As described previously, there are 320 pixels in each horizontal line in normal resolution mode. Each data word consists of 16 bits, so that 20 data words containing 320 bits are sufficient for each bitplane to contain all the data corresponding to one horizontal line of pixels being displayed. If the size of the bitplane is exactly the same as the size of the display window, then zero is loaded into the modulo register 131. In this case, the number of bits stored in RAM 401 is exactly the same as the number of pixels which will appear on the screen. As each data word for the bitplane is fetched as the electron beam travels horizontally along the screen, the pointer for that bitplane is incremented by one by adder 137. Thus, after each horizontal line is scanned by the beam, the value (in words) stored in the pointer register 138 when the data fetch for the next line is begun will exceed the pointer value when the previous line was begun by 20. However, if, for example, the bitplane has exactly twice the number of bits per horizontal line as the number of pixels to be displayed, a modulo of 20 words must be used to assure that the data used to generate the colors for the next line of pixels are the bits relating to the next horizontal line. After displaying the last pixel on a horizontal line, the pointer corresponding to that bitplane in one of the six bitplane pointer registers 138 contains a value corresponding to the starting memory address for that line plus 20. A modulo of 20 words must be added to this pointer using modulo register 131 and adder 137, so that when the data fetch for the next horizontal line begins, the next 20 words in memory (corresponding to the part of the playfield picture that is to the right or left of what can be displayed on the 320 available pixels at that particular instant) will be skipped. In this manner, the address of the data,not used in the current display is not placed by the generator 45 on the RAM address bus 406. When the high resolution mode is being used to display the playfields, 40 words of data must be fetched for each line instead of 20, and the modulo is 40 when the bitplane is double the window size.
The system can be directed to display another portion (e.g., the right half) of the picture defined by a bitplane that is larger than (e.g., twice) the size of the allowable display window. In such a case, a different pointer value is loaded into the pointer register 138 for that bitplane when the first bit is fetched for display of the upper left pixel on the screen (during vertical blanking). To display only the right half of a picture defined by bitplanes with 640-bit wide horizontal lines, the value of the pointer must be 20 words (320 bits) higher than the starting address when only the left half of the picture is displayed. In this case, the modulo would remain at 20 to prevent the addressing of data related to the left half of the picture after each line is scanned.
The modulo stored in the bitplane modulo registers 131 is also used in producing an interlaced picture. A frame bit generated by the video beam counter 117 can be loaded into a control register and read during the vertical blanking routines of the operating system. Depending on the state of this bit, the system will produce either an odd frame or an even frame. Based on the value of this bit, for odd frames the vertical blanking routines will load the bitplane pointer register 138 with an address corresponding to line one, whereas for even frames an address corresponding to data related to line two is loaded. The copper 47 skip instruction can be utilized to achieve this. The display of alternate lines of a complete picture contained in memory during alternate frames of the display requires setting the modulo number in registers 131 equal to the total number of words in memory relating to a single horizontal line plus the normal value associated with the modulo (the number of words by which the data in memory defining a particular horizontal line exceeds the number of pixels that are displayed on the screen at any one time.) If the "picture" stored in memory is defined as 400 lines long, the 200 odd numbered lines are shown during one frame, and the other 200 even numbered lines are shown during the next frame to form the complete picture. The scanning circuitry vertically offsets the start of every other field by half a scan line in interlaced mode. For odd frames, the pointer loaded in the pointer register 138 for a bitplane during the vertical blanking interval is set at some starting memory address. Then, for even frames, the value of the pointer loaded in the pointer register 138 at the beginning of the scan of an even frame corresponds to the original starting memory address plus the total number of words in memory containing bits relating to a single horizontal line.
To create a playfield that is the same size as the television screen, a width of either 320 pixels or 640 pixels (high resolution) is chosen. The height can be either 200 lines or 400 lines (interlaced mode). The actual size of the on screen display, however, can be further adjusted by defining a window size. Nothing will be displayed outside of the defined display window, including playfields and sprites. The display window size is defined by specifying the horizontal and vertical positions at which the display window starts and stops. The resolution of vertical start and stop is one scan line; the resolution of horizontal start and stop is one low resolution mode pixel. The display window start register controls the display window starting position. Both the horizontal and vertical components of the display window starting positions are loaded into this register, which is located among the bitplane control registers 55 on the Agnus chip 410, by either the processor 402 or the Copper 47. Similarly, a display window stop register exists on the Agnus chip 410 and is loaded with the horizontal and vertical components of the display window stopping position. The stopping position, like the starting position, is interpreted in low resolution non-interlaced mode, even if the high resolution or interlaced modes are selected.
After the size and position of the display window is defined using the display window start and stop registers, the onscreen location for the data fetched from memory must be identified. This is done by loading the horizontal positions where each line starts and stops to a data fetch start register and a data fetch stop register located among the bitplane control registers 55. Unlike the display window registers, which have a one pixel resolution (low resolution mode), the data fetch registers have only a 4 pixel resolution because only five bits are used in either register to specify the beginning and ending position for the data fetch. The hardware requires some time after the first data fetch before it can actually display the data. As a result, there is a difference between the value of window start and data fetch start, and the registers control the horizontal timing of the bitplane DMA data fetch. In low resolution mode, the difference is 8.5 clock cycles; the difference is 4.5 clock cycles in high resolution mode. As described previously, the bitplane address pointers stored in pointer registers 138 are used to fetch the data to the screen. Once the data fetch begins, the pointers are continuously incremented to point to the next word. The data fetch stop register defines when the end of a horizontal line is reached, at which point the bitplane run signal is off and the modulo contained in the modulo register 131 for that bitplane is added to the pointer for that bitplane. Thus, the pointer is adjusted to contain the address of the first word of data to be fetched for the next horizontal line. There are two modulo registers, the bitplanel modulo register for the odd numbered bitplanes (or for playfield 1 when operating in the dual playfield mode) and bitplane2 modulo register for the even numbered bitplanes (or for playfield 2 when operating in the dual playfield mode).
To start the display of the playfields, the pointers for the bitplanes must be set and the bitplane DMA is turned on. The bitplane DMA is turned on by setting a bit in a DMA control register. Each time the playfield is redisplayed after the vertical blanking interval, the bitplane pointers must be reset. Resetting is necessary because the values in the pointer registers have been incremented to point to each successive word in memory for each set of bitplanes and must now be repointed to the first word for the next display. Program instructions for the Copper 47 are used to perform this operation as part of a vertical blanking task.
One of the features of the Copper 47 is its ability to wait for a specific video beam position, then move data into a system register. During the wait period, the Copper 47 examines the contents of the video beam position counter 117 directly. Thus, while the Copper 47 is waiting for the beam to reach a specific position, it does not use the data bus 404 at all. Therefore, the data bus 404 is freed for use by other DMA channels or by the microprocessor 402. When the wait condition has been satisfied, the Copper 47 steals memory cycles from either the Blitter 67 or the processor 402 to move the specified data into the selected special purpose registers. The copper 47 is a two cycle processor that requests the bus only during odd numbered memory cycles. This prevents collision with audio, disk, refresh, sprites, and most low resolution display DMA access, all of which use only the even numbered memory cycles. The Copper 47 therefore needs priority over only the processor 402 and the Blitter 67.
The Copper 47 instruction list is sufficient to accomplish all the register resetting done during the vertical blanking interval and the register modifications necessary for making midscreen alterations. For example, the pointers for the odd and even bitplanes used in playfield displays and the sprite pointers must be rewritten during the vertical blanking interval so that the data relating to the top left of the screen will be retrieved when the display starts again. This can be done with a copper instruction list that does the following: (1) wait until the video beam reaches the first line of the display; (2) MOVE starting address in RAM 401 for odd bitplane data to the first bitplane pointer register; (3) MOVE starting address for even bitplane data to second bitplane pointer register; (4) MOVE data to first sprite pointer register; etc. As another example, the color registers can be reloaded with bits specifying the display of different colors in the middle of the display of a screen. Thus, the program instruction list for the Copper 47 would wait for the first line of the display, then move a series of 12 bit codes into several of the color registers, wait for a subsequent line of the display (such as the first line corresponding to a reuse of a particular sprite processor), and then move 12 bits of data specifying a new set of colors into some of the color registers previously loaded during the first line of display.
The Copper 47 fetches its instructions by using its program counter and increments the program counter after each fetch. The Copper 47, however, has two jump strobe addresses, jump 1 and jump 2. When an attempt is made to write to either the jump 1 or jump 2 strobe addresses, the program counter of the Copper 47 is loaded with a new address. The Copper 47 has a first and a second location register 129 which contain RAM addresses Whenever a jump strobe address is written, the address contained in the corresponding location register is loaded into the copper program counter (pointer register) using adder 137 and the gate inhibit signal. This causes the Copper to jump to the address specified in either the first or second location register 129, and to execute the instruction contained at that RAM address. The instruction fetch then continues sequentially until the Copper 47 is interrupted by another jump address strobe. At the start of each vertical blanking interval, no matter what the Copper is doing, the Copper is automatically forced to restart its operations at the address contained in the first location register. The Copper can also write to its own location registers and then to its strobe addresses to perform programmed jumps. Thus, the Copper can move a new address into the second location register. Then, a subsequent move instruction executed by the Copper that addresses the jump 2 address causes the new address in the second location register to be strobed into the copper's program counter. At power on or reset time, the first and second location registers of the copper must be initialized and the jump strobe address must be written to so that a known start address and known state is ensured before the copper DMA is first turned on. Then, if the contents of the first location register are not changed, the copper will restart at the same location every time vertical blanking occurs for each subsequent video screen. One bit in a DMA control register is set in order to enable coprocessor DMA operations.
In order to obtain a background display that moves, a playfield larger than the display window is stored in memory and scrolled. When using dual playfields, each playfield can be scrolled separately. In horizontal scrolling, one additional word of data must be fetched for the display of each horizontal line, and the display of this data must be delayed. In vertical scrolling, the starting address loaded into the bitplane pointers is increased or decreased by an integer multiple of the amount of words taken up by a horizontal line in memory. This causes a lower or higher part of the picture to be displayed after each vertical blanking interval. To accomplish vertical scrolling, during each vertical blanking interval, the Copper must increase or decrease the value of the pointer stored in the bitplane pointer register 138 by an amount large enough to ensure that the display begins at least one horizontal line later or earlier each time. For either type of scrolling, the Copper 47 can be used during the vertical blanking interval to reset pointers and data fetch registers. For a low resolution display in which only 20 words of data is used for each horizontal line, the starting address loaded into the pointer register 138 by the Copper 47 would be changed by a multiple of 20 words during each vertical blanking interval.
The playfields can be scrolled horizontally from left to right or vice versa on the screen. Horizontal scrolling is controlled by specifying the amount of delay prior to display of the pixels. The delay occurs when an extra word of data for a horizontal line is fetched but is not immediately displayed. The additional data word is located to the left of the left edge of the display window and is retrieved before normal data fetch begins. As the beam scans to the right, however, the bits in this additional data word are used to define the color of the pixels appearing on screen at the left hand side of the window, and data formerly used to color pixels appearing on the right hand side of the screen no longer appears during the display. For each pixel of delay specified, the onscreen data shifts one pixel to the right after each vertical blanking interval. The greater the delay utilized, the greater the speed of scrolling of the display. Up to 15 pixels of delay can be specified by loading a bitplane control register 327 with four bits of data specifying the delay for playfield 1 and four bits of data specifying the delay for playfield 2. Thus, in horizontal scrolling, the data fetch start register must be loaded with a beginning position for the data fetch that is 16 pixels (one extra word) before the unscrolled beginning position for data fetch, the modulo for the playfield must be increased by one word, and the number of bits of delay must be loaded into a bitplane control register 327.
The term Blitter stands for block image transferer. The primary purpose of the Blitter 67 is to copy (transfer) data in large blocks from one memory location to another, with or without further processing. The operations it performs after its registers are set up are considerably faster than those performed by the microprocessor 402. The Blitter 67 is very efficient at copying blocks of data because it needs to be told only the starting address in RAM 401, the destination address in RAM 401, and the size of the block. It will then automatically move the data block, one word at a time, whenever the data bus 404 is available. The Blitter will signal the processor 402 with a flag and an interrupt when the transfer has been completed.
The Blitter performs its various data fetch, modify, and store operations through DMA sequences, and it shares memory access with the other devices in the Amiga system. Disk DMA, audio DMA, bitplane DMA, and sprite DMA all have the highest priority level. Each of these four devices is allocated a group of time slots during each horizontal scan of the video beam. If a device does not request one of its allocated time slots, the slot is open for other uses. First priority is given to these devices because missed DMA cycles can cause lost data, noise in the sound output, or interruptions in the display on the screen. The Copper 47 has the next priority because it must perform its operations at the same time during each display frame to remain synchronized with the video beam sweeping the screen. The lowest priorities are assigned to the Blitter 67 and the microprocessor 402, in that order. The Blitter 67 is given the higher priority because it performs data copying, modifying, and line drawing operations much faster than the microprocessor 402. During scan of a horizontal line, there are typically 227.5 memory access cycles, each of which is approximately 280 nanoseconds in duration. Of this time, 226 cycles are available to be allocated to the various devices needing memory access The memory cycles are allocated as follows: four cycles for memory refresh (assigned only to odd numbered cycles); three cycles for disk DMA (assigned only to odd numbered cycles); four cycles for audio DMA (assigned only to odd numbered cycles, one word per channel); 16 cycles for sprite DMA (assigned only to odd numbered cycles, two words per channel); and 80 cycles for bitplane DMA (can be assigned only to odd numbered cycles if display is low resolution and contains four or fewer bitplanes). The microprocessor 402 uses only the even numbered memory access cycles. Normally, during a complete processor instruction time, the processor 402 spends about half of the time doing internal operations and the other half accessing memory. Therefore, by allocating every other memory cycle to the 68000 processor, the processor 402 can run at full speed because it appears to the processor that it has memory access all of the time. Thus, the 68000 runs at full speed most of the time if there is no Blitter DMA interference. If cycles are missed by the 68000, it waits until its next available memory cycle before continuing. However, if there are more than four bitplanes being displayed, or a high resolution display is used, bitplane DMA will begin to steal cycles from the 68000 during the display. If, for example, four high resolution bitplanes are specified, bitplane DMA needs all of the available memory time slots during the display time (bitplane run signal is on) in order to fetch the 40 data words needed for each line for each of the four bitplanes. This effectively locks out the processor 42 as well as the Blitter 67 and Copper 47 from any memory access during the display. During the display time for a four bitplane low resolution display, 80 odd numbered time slots are reserved for the bitplane DMA and the 80 even numbered time slots are all available for the processor 402. For a display of a six bitplane low resolution display, bitplane DMA steals half of the 80 even numbered slots during the display because 120 time slots are needed to fetch 20 data words for six bitplanes. No memory time slots are available during display of a four bitplane high resolution display because all 160 time slots are needed to fetch the 40 data words for each of the four bitplanes.
The Blitter 67 normally has a higher priority than the processor 402 for DMA cycles. If given the chance, the Blitter would steal every available memory cycle, blocking the processor 402 from bus access. By setting a bit in a DMA control register, the Blitter will be given priority over the processor 402 for every available memory cycle. However, if the bit is not set, the Blitter 67 will be forced to release the data bus 404 to the processor 402 for one cycle if the processor 402 is unsatisfied for three consecutive memory cycles.
The Blitter uses up to four DMA channels. Three DMA channels are dedicated to retrieving data from RAM 401 to the Blitter 67, and are designated as source A, source B, and source C. The one destination DMA channel is designated as destination D. A Blitter control register 63 is loaded with data from data bus 404 to indicate which of the four DMA channels are to be used, with four bits needed in all to independently enable each of the four channels. Each of the Blitter source and destination channels has its own memory pointer register 138 and its own modulo register 131. This allows the Blitter to move data to and from identical rectangular windows within larger playfield images that can be of different sizes for each of the sources and for the destination block in memory. The pointer registers 138 for the Blitter channels are used to point to the address in RAM 401 where the next word of source or destination data is located. Similar to the bitplane operations described previously, the Blitter 67 uses modules to allow manipulation of smaller windows within larger images stored in memory. When the modulo amount stored in the corresponding modulo register 131 is added to the value in the appropriate pointer register 138, the address pointer will identify the start of the next horizontal line after the last word in the window on the previous line has been processed. When operating on data words contained on the same horizontal line of a window of selected size, the address contained in the pointer register 138 will be incremented by one word each time. It is possible to specify blocks of data for the sources and destination that overlap. In such a case, it is possible that the Blitter will write to a particular memory address within the destination block before the data at that same address was read by the Blitter as the source. To prevent such data destruction, it is possible to either increment or decrement the pointer values as the data is being processed using an invert instruction signal. For example, the value in the pointer registers should be decremented and the Blitter should operate in descending mode if there is an overlap between the source and destination blocks of data and it is desired to move data toward a higher address in RAM 401. The descending or ascending mode of operation is selected by loading a bit contained within the Blitter control registers 63.
A Blitter size register among control registers 63 is loaded with the width and height of the window being operated on by the Blitter. Ten bits in this register define the height of the Blitter operation, up to a maximum of 1024 lines. Six bits in this register define the width of the Blitter operation, up to a maximum of 64 words or 1024 pixels. Loading data into the Blitter size register starts operation of the Blitter, and is done last after all pointers and control registers have been initialized.
Instead of simply retrieving data from a single source, the Blitter can retrieve data from up to three sources as it generates a result for a possible destination area. These sources are usually one bitplane from each of three separate graphic images. The Blitter logic operation is defined by describing what occurs for all of the possible combinations of one bit from each of the three sources. The eight possible data combinations of three bits are referred to as MINTERMS. For each of the eight input possibilities, the value of the bit output to the corresponding destination in RAM 401 must be specified. One of the Blitter control register 63 is loaded with eight bits used, as logic function MINTERM select lines. The setting of these eight bits specifies one of 256 possible logic operations to be performed on the data from three sources during the Blitter operation.
The Blitter 67 is extremely efficient in performing bitplane animation because it can logically combine data bits from separate image sources during a data move. For example, it may be desired to move a predrawn image of a car in front of a predrawn image of a building. To animate (move) the car, the first step is to save a window containing the background image where the car will be placed. Data containing the complete outline (mask) of the car is created somewhere in memory and can be designated as source A, the data containing one of the bitplanes defining the color for the car object itself can be designated as source B, and the data containing the background (or building) can be referred to as source C. Next, a temporary location T in RAM 401 is designated the destination for the background of source C where the car is going to be placed. The AC logic operation is selected, which will save the background by copying it to a new destination at all points where the outline mask of the car (A) and the background (C) exist at the same location. The next step is to copy the car in its first location. The destination selected this time is the same as the block of data containing the background (C). The AB+AC operation is used to indicate that the window will now contain the car data (B) wherever the car outline mask (A) exists, but will keep the previous background data (C) wherever the car outline mask does not exist (A). If the car was already present somewhere on the display, the old background image which the car covered prior to moving must be restored at the location from which the car was moved before copying the background that will be covered next. The background (C) is the destination and the operation AT is used, where the source T is the temporary destination at which the background where the car was previously placed was stored using the AC operation. This AT logic operation replaces the background (C) with the saved background at all places where the car outline mask (A) existed. If the data and the mask is shifted to a new location and the logic operations above are repeated continuously by the Blitter, the car will appear to move across the background. The logic operation in which the new image is created using the logic operation AB+AC is referred to as the "cookie cut" operation.
In the example just described, the car image (B) and the car outline mask (A) must be shifted to a new position each time before the background is saved (AC) and the car is placed (AB+AC). The movement of an image (B) across a background (C) can cause the edge of the image to land on any bit position within a 16 bit word. This creates a need for a high speed shift capability within the Blitter 67. Accordingly, the Blitter contains a barrel shifter 81 that is used with both the A and B data source registers 77 and 79. The shifter 81 can shift sources A and B from zero to 15 bits. It is a true barrel shifter in that bigger shifts do not take more time than smaller shifts, as they would if performed by the microprocessor 402 Thus, even though 16 pixels must be addressed at a time as each word in a bitplane is fetched, the shifter 81 allows movement of images on pixel boundaries. The amount of the shift for each of the sources is set by loading four bits into the Blitter control registers 63 for the A source and four bits for the B source.
The Blitter 67 can mask the left most and right most data word in the selected window from each horizontal line. Mask registers 83 and 85 are provided for the first and last words on every horizontal line of Blitter data for source A. This allows logic operations on bit boundaries from both the left and the right edge of a rectangular region. Only when there is a 1 bit loaded in the first word mask will that bit from the first word of source A be utilized in the logic operations performed by the Blitter. In a similar way, the last word mask 85 masks the right most word of the source A data. Thus, it is possible to perform operations on a rectangular block of data with left and right edges occurring between word boundaries. If the window is only one word wide, the first and last word masks overlap and bits from the source A word will be utilized only at bit positions where both masks contain ones.
The Blitter can sense whether any "1" bits are present as a result of a logic operation on source data. This feature can be used for hardware assisted detection of a collision between two images. The operation AB can be performed, and if the images A and B do not overlap, a zero flag will be set in a Blitter DMA status register. When the Blitter is doing only zero detection and not being used to generate a destination image, time and bus cycles can be saved by disabling the destination channel by not setting the appropriate bit in the Blitter control registers 63.
In addition to copying data, the Blitter 67 can simultaneously perform a fill operation during the copy. A restriction on the fill operation requires that the fill area be defined by first drawing untextured lines that contain only one pixel per horizontal line to set the boundaries for the fill. A special line draw mode executed by the Blitter can accomplish this line drawing operation. The Blitter can draw ordinary lines of any angle and can also apply a pattern to the lines it draws. A bit is set in the Blitter control registers 63 in order to indicate the Blitter is to operate in line draw mode. In order to ensure that the lines being drawn are one pixel wide, as required for a subsequent area fill, another bit must be set in the Blitter control register 63 to designate a single bit per horizontal line. The source A and source C are utilized in conjunction with the destination D Blitter DMA channels. The Blitter source A register 77 during line draw mode iS preloaded with a 16 bit word containing 15 zeros and a single "1" as the most significant bit. This is the single bit which will be shifted into the correct position by the value in the A shift register 93 initially, then by the line drawing hardware later in the process. The 16 bits in the B data register 77 are used to indicate the texture of the line and are preloaded with all ones to create the solid lines required if the fill mode will be executed subsequently. Four bits in a Blitter control register 63 are loaded with the bit position within the word at which the starting bit of the line occurs. Three bits in a Blitter control register 63 are loaded with a value that selects one of eight octants used for line drawing. The eight octants are used to divide a two dimensional Cartesian plane into eight regions to define the direction of the line for purposes of line drawing. The Blitter size register is used to control the line length and starts the line draw when data is written into it. Ten bits designate the height and allow for lines extending up to 1024 pixels, while six bits indicating the number of words in the width must always be set equal to two. The slope of the line is defined by loading the difference in bit position between the starting and ending points of the line in the A modulo register (horizontal change) and B modulo register (vertical change). The Blitter pointer register 138 for source A is used as an accumulator when in line mode. The pointer registers for the source C and destination D must be preloaded with the starting address of the first horizontal line. The module registers for the C source and D destination are both preloaded with the width of the screen into which the line is being drawn.
The Blitter control register 63 during a line draw mode is always loaded with the same logic function minterm select bits. The logic function selected Blitter operation during line draw mode is the moving into the destination of AC+ABC. The A source data register 77, as described above, is loaded with only a single bit in the data word, a one. Therefore, this operation on the display field (C) will leave most bits in the bitplanes unchanged, because for at least 15 of the 16 bits in each word, the destination will be loaded with the existing bit values in the C source data register 89 (AC). If the line draw is to be followed by an area fill, untextured lines are required, so that the B source data register 79 contains only ones. Therefore, for the one bit per word in the A source register 77 that is a one, the bit value contained in the C source data register 89 will be inverted (ABC). For each subsequent horizontal line, the Blitter hardware automatically moves the "1" to the correct position in the data words being stored in the A source data register 77. As a result, special lines with one pixel on each horizontal scan line can be drawn by the Blitter 67.
A fill operation can be performed during other Blitter data copy operations. Prior to the area fill, a Blitter line draw is first performed to provide two vertical lines, each one bit wide, on the display. The fill operation operates correctly only in the descending mode (from higher memory addresses to lower memory addresses). Only one source and the destination D is required. The pointers for the source and the destination in pointer registers 138 should be set to the same value, which will be the address of the last word of the enclosing rectangle of the window in RAM 401 since the operation is performed in a descending direction. The modulo registers for the source and destination are loaded with the difference between the number of words in a horizontal line of the rectangle to be filled and the number of words per horizontal line taken up in memory by the bitplanes. The Blitter size register is then loaded with 10 bits setting the number of vertical lines in the display window and 6 bits specifying the number of words in each horizontal line. Writing to the Blitter size register will start the operation of the Blitter. A Fill Carry In control bit is loaded into a Blitter control register 63 to indicate the starting fill state beginning at the right most edge (descending mode) of each line. If the Fill Carry In bit is set to a one, the area in the source area outside the lines is filled with ones and the area inside the lines is left with zeros. If the Fill Carry In bit is a zero, the area between the lines is filled with ones. The Blitter control register 63 also is loaded with bits indicating whether an inclusive fill or an exclusive fill is to be utilized. When the exclusive fill is enabled, the outline on the trailing edge of the fill (left side) is excluded from the resulting filled area. Enabling the exclusive fill mode is used to produce sharp, single pixel vertices.
Sprite objects are graphic objects that can be moved quickly on the screen, without moving their image location in memory. In contrast, bitmapped objects have a position on the display screen that is directly related to their location in RAM 401, and in order to move them, the object image stored in memory must be erased and rewritten in a different location. This can be very time consuming. The sprites used in the Amiga system are moved with extra hardware, such as horizontal position registers 343, vertical position registers 37, a horizontal position comparator 341, a vertical position comparator 39, and sprite data buffer registers 345. To move a sprite, the values stored in the position registers are simply changed. The vertical position circuits are located on the Agnus chip 410. The data buffers and the horizontal position circuits are located on the Denise chip 420.
The location of a sprite is defined by specifying the coordinates of its upper lefthand pixel. In the Amiga system, each sprite forms a rectangle on the display with a fixed width of 16 pixels (one data word) and a variable height. A sprite therefore consists of a series of 16 bit words in a contiguous memory area. To create a sprite data structure, the bits in the position register 153 and 343 for that particular sprite (there are eight sprites available in all) are loaded with eight bits that specify the vertical start position and eight bits that specify the horizontal start position of the pixel at the upper left hand corner of the sprite. Next, eight bits in the vertical stop location register 155 for that particular sprite are loaded with the vertical stop position for the particular sprite (also referred to as a sprite control register). There is one position and one control register for each sprite, or a total of eight of each for the entire Amiga system. Each sprite also is associated with two data registers containing the bits defining the color registers utilized for each of 16 pixels on a particular horizontal line of the sprite. The two data registers for each sprite allow two bits to be used in defining the color register associated with any particular pixel in the sprite. Therefore, four possible registers are available. When both bits are set at zero for a particular pixel, this is interpreted as "transparent" and the color defined by the data associated with a playfield or sprite having a lower priority can be displayed. Any other binary number points to one of the three color registers assigned to that particular sprite DMA channel. The eight sprites use system color registers 17-19, 21-23, 25-27, and 29-31. For purposes of color selection, the eight sprites are organized into pairs and each pair uses one of three color registers or else selects the transparent mode. For each of the odd numbered sprites, the associated control register 37 contains a bit that can be set in order to attach an odd and an even numbered sprite to pair the data for both sprites in color interpretation. The two sprites will remain capable of independent motion. However, if their edges overlay one another at any particular pixel location, a greater selection of colors is possible because all four bits are then utilized in selecting one of 16 color registers.
The memory address for the data defining each sprite must be written into the proper pointer registers 138 during the vertical blanking interval before the first display of the sprite. Normally, the sprite pointer registers are loaded during the vertical blanking interval by the Copper 47. The values in the sprite pointer registers are dynamic and are incremented using the adder 137 and point first to the memory address containing the start data to be loaded into the position register, then the next address containing vertical stop data to be loaded into the sprite (vertical stop) control register 155, then the following addresses containing pairs of data words specifying the color selection information needed for each horizontal line of the sprite. After the data words describing the color selection in the last horizontal line in the sprite, two data words indicate the next usage of this sprite and comprise the start and stop data for reuse of the sprite. This last word pair contains all zeros if the particular sprite processor is to be used only once vertically in the display frame. During the vertical blanking interval, the sprite pointers must be rewritten into the pointer registers. The video beam counter 117 contains a count indicating the current location of the video beam that is producing the picture. The sprite vertical position comparator 39 and horizontal position comparator 341 compare the value of the beam counter to the value of the start position in the sprite position registers 153 and 343. Writing to the sprite position and control registers disables the horizontal comparator circuitry 341. This prevents the data registers 345 from sending any output to the serializers 347 and to the sprite bus 349. If the beam has reached the horizontal line on which the uppermost pixel of the sprite is to appear, the vertical position comparator 39 causes the sprite DMA controller 41 to have data registers 345 for that sprite loaded, which enables the horizontal comparator 341. This enables output by the serializers 369 for that sprite to the sprite bus when comparator 341 indicates the horizontal start position has been reached. Each of the 16 bits of a sprite data word is individually sent to the color select circuitry at the time that the pixel associated with that bit is being displayed on screen. Each parallel to serial converter 369 begins shifting the bits out of the converter, with the most significant bit first. The shift occurs once during each low resolution pixel time and continues until all 16 bits have been transferred to the sprite bus 349. The sprite bus goes to the priority circuitry 337 to establish the priority between sprites and playfields in selecting a color register. The sprite DMA channel examines the contents of the sprite position and control registers to determine how many lines of sprite data are to be fetched, with two data words fetched per each horizontal scan line occurs during a horizontal blanking interval. The fetch and store for each horizontal scan line occurs during a horizontal blanking interval. When the data words are fetched and written into the data registers, this arms the sprite horizontal comparators 341 and allows them to start the output of the sprite data to the screen as soon as the horizontal beam count value matches the value stored in the sprite horizontal position register 343. When the vertical position of the beam counter is equal to the vertical stop value contained in the sprite control register, the next two words addressed by the sprite pointer registers and fetched from memory will be written into the sprite position and control registers instead of being sent to the data registers 345. These words are interpreted by the hardware in exactly the same manner as the original words first loaded into the position and control registers. By loading the position register with a vertical starting position that is higher than the current beam position, the sprite can be reused during the same display field.
A sprite generated in the manner described above can be moved by simply changing the vertical and horizontal starting position and vertical stopping position loaded into the sprite position and control registers. If this position data is changed before the sprite is redrawn, the sprite will appear in a new position and will appear to be moving. Usually, the vertical blanking period is the best time to change the position of the sprite. Each sprite DMA channel can be reused several times within the same display field. The only restriction on reuse of a sprite at a lower vertical position on the display screen is that the last line of the prior usage of a sprite must be separated by at least one horizontal scan line from the top line of the next usage of the sprite. This restriction is necessary because the time during this horizontal scan line is needed to fetch the position and control words defining the next usage of the sprite. As sprites move on the display screen, they can collide with each other or with either of the two playfields. The Amiga system contains special collision detection logic 335 to create special effects or to keep a moving object within specific onscreen boundaries. Built in sprite video priority ensures that one sprite appears to be behind the other when sprites are overlapped. The priority circuitry 337 gives the lowest numbered sprite the highest priority and the highest numbered sprite the lowest priority. Therefore, when two sprites overlap, the image defined by the data for the lower numbered sprite will be displayed except for pixel positions that are designated as being transparent, in which case the lower priority sprite data can be used to generate an image.
The priorities of various objects on the display can be controlled to give the illusion of three dimensions. For playfield priority and collision purposes only, sprites are treated as four groups of two sprites each. The relative priority of the sprites to each other cannot be changed. They will always appear on the screen with the lower numbered sprites appearing in front of (having higher screen priority than) the higher numbered sprites. This priority is wired into the display priority control logic 337. In the bitplane priority registers 355, seven bits can be loaded that will control the relative video priorities of playfield 1, playfield 2, and the four pairs of sprites. Three bits are utilized to determine the relative priority of playfield 1 with respect to the four pairs of sprites. Similarly, three more bits are utilized to establish the priority between playfield 2 and four pairs of sprites. However, one more bit is utilized to determine which of the two playfields has higher priority than the other. This allows for unusual visual affects on the screen. Thus, it is possible to have sprites appear in front of playfield 1 but disappear behind playfield 2 while playfield 2, in turn, has lower priority than playfield 1 and is not visible behind it.
The collision control register 351 contains the bits that define certain characteristics of collision detection. Collisions are detected when two or more objects attempt to overlap in the same pixel position. This will set a bit in the collision data storage register 353 if the collision control register indicates that particular overlap will cause a collision. Fifteen bits in the collision storage register are utilized to indicate whether any of several types of overlaps has occurred: e.g., one sprite to another sprite, even bitplanes to odd bitplanes, even bitplanes to a certain sprite, or odd bitplanes to a certain sprite. The collision control register contains bits that specify whether to include or exclude the odd-numbered sprites or specific bitplanes from collision detection. Furthermore, other bits specify the true-false condition of the bits in each bitplane that will cause a collision. Thus, it is possible to register collisions only when an object collides with something of a particular color.
The above description of the invention is intended to be illustrative of a single preferred embodiment. Changes can be made to the structures described herein without departing from the features and scope of the invention.
|
A computer that provides data to a video display using a bitmap display memory organization and bitplane addressing. Separate control is provided for two bitplane backgrounds and for eight reusable and easily movable sprites. Additional logic allows for dynamically-controllable interobject priority and collision detection among data in each of the bitplane backgrounds and sprites. A coprocessor provides for video beam-synchronized changes to data in registers, freeing the main processor for general purpose computing tasks. A block image transferer is provided to rapidly copy data in large blocks from one memory location to another. In hold-and-modify mode, color output circuitry holds the values for a previously displayed pixel while bitplane data modifies those values, allowing for simultaneous display of a greatly increased number of colors.
| 6
|
TECHNICAL FIELD
[0001] The present disclosure relates to a tool commonly known as a sucker rod tong used for assembling and disassembling threaded sucker rods of oil wells, and more specifically pertains to a linear drive mechanism for the second stage tightening to a circumferential displacement of the sucker rods to a rod coupling.
BACKGROUND
[0002] Oilfield wells include the use of sucker rods consisting of 25 to 30 foot lengths of solid rods with male threads at each end, threaded together into a rod string that connect the downhole oilwell pump to the surface reciprocating drive that in its entirety brings liquid hydrocarbons from deep within the ground to the surface.
[0003] Each sucker rod threaded male end is screwed into a rod coupling or collar or box so that the shoulder of each rod end is tightened against the shoulder of the rod coupling. The connected and tightened assembly of sucker rod connected to a rod coupling which is connected to the next sucker rod forms the rod string.
[0004] The tightening of each sucker rod threaded connection to a specific circumferential displacement from a hand tight shouldered circumferential position is the method determined by the sucker rod manufacturers to achieve the correct tightness between the sucker rod and the sucker rod collar. Inaccurate tightness of a connection can cause failure of the sucker rod string within the well bore.
[0005] Hundreds of sucker rod connections typically comprise a rod string in oilwells. Sucker rod connections are critical to the operational life of a sucker rod string.
[0006] Currently hydraulically powered sucker rod tongs are commonly used to assemble and disassemble a string of sucker rods. Current practices involve screwing the sucker rod connections together manually or with hydraulic powered sucker rod tongs to the shoulder of the connection and then without stopping the sucker rod tongs, they apply rotational torque between the upper and lower sucker rod connections using the hydraulically powered sucker rod tong and engage the upper and lower sucker rod segments on their respective mating rod flats to the rod coupling. The rod coupling provides the connection between sucker rods. Activating the hydraulically powered sucker rod tongs rotates one sucker rod thread relative to the other sucker rod thread to achieve a tight connection. As the connection tightens, the tong ultimately stalls at the hydraulic pressure preset by the operator assuming the achievement of a corresponding torque and circumferential displacement movement of the sucker rod connections relative to each other. When the tong rotationally stalls, the operator assumes that the connection has achieved the predetermined circumferential displacement position and is properly torqued.
[0007] The position at which the rod connections displace from the hand tightened shouldered circumferential position is not predictable. Frequently, the operator tests the position at which the force of the hydraulically powered sucker rod tongs tightens the connection to and the operator measures that distance in comparison to a known circumferential displacement scale or CD Card. The hydraulic pressure setting of the hydraulic circuit is adjusted to approach the displacement result desired. This is an inaccurate, unreliable and unpredictable method of achieving a circumferential displacement from a known position. Repeatability of hydraulic relief valves is dependent on oil flow, viscosity and fluid pressure drops. Variations within the relief valves ability to repeat this setting can exceed 10%. The hydraulic motor that delivers the torque to the hydraulically powered tong assembly within its design can vary its output torque given the same input hydraulic pressure throughout 1 revolution of the motor. The motor can have as few as 5 power strokes per revolution and output torque can exceed ±20% specifically due to the rotational position that the motor is in as torque is being applied to the sucker rod connections. The force which is required to rotate different sucker rods and couplings can vary significantly resulting in significant differences in final circumferential displacement. The result of the current sucker rod hydraulic powered tongs design is that circumferential displacement of the sucker rod connection from a hand tightened shoulder circumferential position is not predictable or reliable.
[0008] It is, therefore, desirable to provide a sucker rod tong that can tighten sucker rod connections to an accurate, repeatable and reliable circumferential displacement from a shoulder position.
SUMMARY
[0009] In some embodiments, a sucker rod tong can be provided that can consistently achieve a shoulder point of a sucker rod connection by the mechanical and hydraulic force limitations of the first stage of the CD tong drive. In some embodiments, a sucker rod tong can be provided with the ability to circumferentially displace the sucker rod connection to a position that can be a physical, mechanical and adjustable stop achieved by a linear actuator in one continuous movement.
[0010] In some embodiments, a hydraulically powered sucker rod tong can be provided (hereinafter referred to as a CD tong) that can, in its first stage of movement, limit the tightening of the sucker rod connection positively in its achievement to a hand-tight, shouldered circumferential position.
[0011] In some embodiments, the CD tong can comprise a linear-geared rack and pinion to provide the second stage of movement drive integrated with the first stage main drive gear of the CD tong that can, following achievement of a shouldered connection sequentially, move the main gear of the CD tong to a preset distance to a mechanical stop of the linear geared rack that is the circumferential displacement from the shouldered position of the sucker rod connection.
[0012] In some embodiments, the linear gear drive can circumferentially displace a sucker rod connection from a hydraulically generated hand tightened position to a specific set distance from that hand tightened position in one continuous movement. The mechanical set point for each size and grade of sucker rod connection can be manually adjusted, set and locked for a complete run of one size of sucker rods.
[0013] In some embodiments, a method can be provided to tighten two sucker rods into a sucker rod connector after reaching the point of hand tightness, said method can comprise the step of actuating a linear gear drive to move to a predetermined position, wherein the linear drive gear can be in operational connection with sucker rod tongs, and wherein the movement of the linear drive gear can actuate a circumferential rotational movement of the sucker rod tongs to a pre-determined position.
[0014] In some embodiments a use of a linear gear drive in a sucker rod tong assembly used in oil wells can be provided, wherein the linear gear drive can be operatively connected to a sucker rod tong adapted to tighten two sucker rods into a sucker rod connector from a hand-tight first position to a predetermined second position by rotating a first sucker rod. In some embodiments, the linear gear drive can comprise a rack and pinion. In other embodiments, several linear displacement drives can be adapted for use in the CD tong assembly.
[0015] In some embodiments, a sucker rod tong assembly can be provided comprising a linear drive mechanism adapted to tighten a sucker rod to a rod connector from a first hand-tight position to a second predetermined position, wherein the linear drive mechanism can be operatively connected to the sucker rod tong such that positive movement of the linear drive mechanism can actuate rotational movement of the sucker rod tong to tighten a sucker rod into a sucker rod connector.
[0016] In some embodiments, a device for use in the tightening of two sucker rods into a rod coupling can be provided, wherein the device can comprise a first stage tightening mechanism and a second stage tightening mechanism, where the second stage tightening mechanism can be a linear drive mechanism operatively connected to a sucker rod tong and adapted to move the sucker rod tong from a first position circumferential position to a second predetermined circumferential position.
[0017] In some embodiments, the sucker rod tong assembly does not require the use of electrical instrumentation; rather, it can effect a positive displacement using mechanical circumferential displacement movement only.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is an exploded side elevation view depicting two sucker rods and a rod coupling, the rod coupling shown in cross section.
[0019] FIG. 2 is a side elevation view depicting one embodiment of a CD tong assembly and a lower sucker rod ( 9 ) with rod coupling engaged with the lower back up wrench of the CD tong assembly.
[0020] FIG. 3 is a front elevation view depicting the CD tong assembly of FIG. 2 .
[0021] FIG. 4 is a bottom plan view depicting the CD tong assembly of FIG. 2 in cross-section view and the hydraulic cylinder rack gear disengaged from the pinion gear.
[0022] FIG. 5 is a bottom plan view depicting the CD tong assembly of FIG. 2 with the backup wrench engaged with the lower sucker rod shown in cross section.
[0023] FIG. 6 is a top cross-sectional place view depicting the CD tong of FIG. 2 engaged with upper sucker rod connection in relation to the lower sucker rod connection.
[0024] FIG. 7 is a top cross-sectional plan view depicting the CD tong assembly of FIG. 2 , wherein the tong is engaged and rotating the upper sucker rod connection in relation to the lower sucker rod connection to shoulder without the hydraulic cylinder rack gear engaged with the CD tong pinion gear.
[0025] FIG. 8 is a top cross-sectional plan view depicting the CD tong assembly of FIG. 2 , wherein the tong is engaged and in rotational movement driven by the hydraulic cylinder rack gear as it is engaged with the pinion gear to a mechanical stop set and locked with a hand wheel or other mechanical adjustment.
[0026] FIG. 9 is a top perspective transparent view depicting the CD tong assembly of FIG. 2 showing the inner workings of the assembly.
[0027] FIG. 10 is a bottom perspective view depicting the CD tong assembly of FIG. 2 .
DETAILED DESCRIPTION OF EMBODIMENTS
[0028] Referring to FIG. 1 , upper sucker rod ( 8 ) and lower sucker rod ( 9 ) can each include threaded pin ( 10 ) that screws into coupling ( 11 ). Shoulder ( 12 ) of upper sucker rod ( 8 ) and lower sucker rod ( 9 ) can be machined to bear against axial face ( 13 ) of coupling ( 11 ). Upper sucker rod ( 8 ) and lower sucker rod ( 9 ) can be provided with a set of wrench flats ( 15 ) suitable to be engaged by sucker rod CD tong assembly ( 14 ) used for screwing together and tightening the sucker rods.
[0029] Referring to FIG. 2 , CD tong assembly ( 14 ) and lower sucker rod ( 9 ) with rod coupling ( 11 ) is shown engaged with lower back up wrench ( 17 ) of the CD tong assembly ( 14 ). To tighten the threaded connection between upper sucker rod ( 8 ) and lower sucker rod ( 9 ) to a required circumferential displacement, CD tong assembly ( 14 ) can first be maneuvered to engage with mating rod flats ( 15 ) of upper sucker rod ( 8 ) and lower sucker rod ( 9 ) on either side of rod coupling ( 11 ). Then, CD tong assembly ( 14 ) can be activated to rotate the connecting threads of upper sucker rod ( 8 ) and lower sucker rod ( 9 ) into rod coupling ( 11 ) to a hand tight, shoulder circumferential start position. In some embodiments, CD tong assembly's ( 14 ) first gear hydraulic motor drive stage ( 25 ) does not have the mechanical ability to exceed the rotational forces required to exceed a hand tight connection between upper sucker rod ( 8 ) and lower sucker rod ( 9 ) and the rod coupling. Once the rotational force is achieved to a hand tight shouldered position of the sucker rod connection, a hydraulic sequence valve can automatically shift and engage second gear hydraulic cylinder linear drive stage ( 30 ) of CD tong assembly ( 14 ), which can comprise linear hydraulic cylinder ( 31 ) driven rack ( 32 ) and pinion gear assembly ( 33 ). Hydraulic cylinder driven rack ( 32 ) can then extend, rotating pinion gear assembly ( 33 ) until hydraulic cylinder driven rack ( 32 ) stops against mechanical stop ( 34 ) that can be adjusted to an exact position that is the circumferential displacement from the hand tight shouldered position for the size and grade of sucker rod of the assembly.
[0030] Referring to FIGS. 5 to 10 , in some embodiments, CD tong assembly ( 14 ) can comprise rotational upper jaw ( 1 ) to engage flats ( 15 ) of upper sucker rod ( 8 ) and backup wrench ( 17 ) for engaging flats ( 15 ) of lower sucker rod ( 9 ). In some embodiments, upper jaw ( 1 ) can comprise one gripper ( 19 ) pivotally attached to gear segment ( 20 ) and outer geared ring assembly ( 22 ) by way of pins ( 21 ). Pins ( 21 ) can allow gripper ( 19 ) to pivot in and out of engagement with flats ( 15 ) of upper sucker rod ( 8 ), while gear segment ( 22 ) can render upper jaw assembly ( 1 ) rotationally relative to CD tong housing ( 23 ).
[0031] FIG. 2 shows backup wrench ( 17 ) of CD tong assembly ( 14 ) engaged from lower sucker rod ( 9 ). FIG. 3 shows CD tong assembly ( 14 ) disengaged from the sucker rods.
[0032] FIG. 4 shows a cross sectional view of CD tong assembly ( 14 ) and illustrates gear drive train ( 24 ) that can couple hydraulic motor ( 25 ) to upper jaw ( 1 ). In some embodiments, gear drive train ( 24 ) can comprise two drive gears ( 26 ) so that at least one of them remains in driving contact with gear segment ( 22 ) at all times, as gear segment ( 22 ) has a discontinuity or opening ( 27 ) for receiving and releasing upper sucker rod ( 8 ). In some embodiments, two drive gears ( 26 ) can reduce drive speed from input pinion gear ( 28 ) to input segment gear ( 22 ). In some embodiments, hydraulic motor ( 25 ) can be coupled to and turn input pinion gear ( 28 ) and rotate drive gear train ( 24 ) at a reduced speed to provide upper jaw ( 1 ) with sufficient torque to be able to screw sucker rods ( 8 ) and ( 9 ) into coupling ( 11 ) to a hand tighten shoulder torque. To disassemble or unscrew at least one sucker rod ( 8 ) or ( 9 ) from coupling ( 11 ), the rotational direction of motor ( 25 ) can be reversed.
[0033] In some embodiments, when the hydraulic pressure within the hydraulic system powering hydraulic motor ( 25 ) achieves a set fixed hydraulic pressure, a hydraulic pressure sequence valve can be activated directing hydraulic oil to hydraulic cylinder ( 31 ) activating that hydraulic cylinder ( 31 ) to move geared rack ( 32 ) to mechanical threaded stop ( 34 ) ensuring that the rod connection has achieved circumferential displacement from the hand tightened shoulder position of the connection.
[0034] CD tong assembly ( 14 ) geared rack ( 32 ) driven hydraulically by hydraulic cylinder ( 31 ) can engage with pinion gear ( 28 ) to displace the connection between upper sucker rod ( 8 ) and lower sucker rod ( 9 ) from a hand tight shouldered torque to a circumferential displacement from the shoulder tight position of the connection. The distance that the geared rack moves can correspond to an accurate circumferential displacement of the connection from the hand tight shouldered torque and can be determined by mechanical threaded stop ( 34 ) that can be adjusted manually and set by hand wheel ( 35 ). It is unique that the circumferential displacement of the connection can be determined by a fixed distance traveled to a mechanical stop by hydraulic cylinder ( 31 ) powered geared rack ( 32 ).
[0035] In some embodiments, once the connection between upper sucker rod ( 8 ) is circumferentially displaced by a predetermined distance relative to lower sucker rod ( 9 ), the linear gear drive can stop moving.
[0036] Although a few embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications can be made to these embodiments without changing or departing from their scope, intent or functionality. The terms and expressions used in the preceding specification have been used herein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the invention is defined and limited only by the claims that follow.
|
A sucker rod tong assembly for fastening together sucker rods to a rod coupling, where the assembly can include a two-stage mechanical drive mechanism. The first stage can connect an upper sucker rod to a lower sucker rod via a rod coupling. The first stage can be limited in mechanical ability to tighten the connection to a pre-set shoulder torque value. The second stage can then be hydraulically and mechanically sequenced, using a linear gear drive mechanism, to rotate a main tong pinion gear that can further rotate the sucker rod connection through a fixed circumferential displacement to a mechanical stop.
| 4
|
This is a continuation of application Ser. No. 06/673,694, filed Nov. 21, 1984, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a microprocessor and specifically to a microprocessor architecture designed to asynchronously execute assembly instructions, one instruction per clock cycle. The microprocessor architecture and assembly instructions are specifically designed to facilitate use of the language known as FORTH.
SUMMARY OF THE PRIOR ART
Computer architecture, including integrated circuit microprocessors, have heretofore been designed with little reference to the programming languages that are ultimately used to operate and control them. To the contrary, prior microprocessor or design goals have been to make the architecture of the microprocessor capable of running practically any type of programming language.
The interface between what might be termed a high level programming language, such as COBOL, BASIC, PASCAL, and FORTH, to name a few, and machine code (the "ones" and "zeros" which are actually applied to the microprocessor) is often the assembly language. Programs written in assembly language have the advantage of often being very fast, efficient, and compact (i.e., the number of machine language instructions used to perform a specific operation is much less than other types of programming). However, programming in assembly language is a tedious, exact, and demanding chore--even for those skilled in such a language. The programmer must often have intimate knowledge of the architecture of the device being programmed--be it computer or microprocessor.
Further, as indicated earlier, the architecture of prior microprocessors has been developed with an eye toward performing as many different tasks or operations as possible; that is, it is often a design goal in microprocessor development to make the microprocessor as "general purpose" as possible. This design goal is usually implemented by incorporating in the design a variety of registers, latches, and other memory elements whose content is often used to qualify, direct, or cause, present or subsequent microprocessor operation.
Such a design approach tends to dictate synchronous operation, requiring multiple (clocked) steps per instruction execution, and some form of internal micro-code. Once the micro-code design is fixed into the microprocessor architecture, it usually cannot be changed without a great deal of difficulty. In addition, this complexity of design places a burden on the programmer: The assembly language programming dictated by the design now requires, in addition to knowledge of the architecture itself, a continuing awareness of the content of such registers, etc., when certain instructions are to be executed. One must also have knowledge of what certain registers, latches, etc., contain before other instructions are to be executed to obtain the results desired.
Moreover, the assembly language used with such integrated microprocessors can be extremely arbitrary, and as such does not provide a relatively easy to learn logical connection that higher-level programming languages typically provide programmers. Further, where mistakes are present in an assembly language program, they are extremely difficult to locate and correct. This difficulty arises from the lack of any logical relation of the assembly language to any computer language. Logical connections between successive assembly language steps are not apparent.
The FORTH implementations on most computers have an additional difficulty. The memory of the computers must be used in three discrete sections. These discrete sections are at least the return stack, the parameter stack, and the main memory. While efforts are made to restrict the specific memory areas, it is common in the FORTH language to cause loops and other overflows to any of the three discrete sections. Overflow to any one section typically writes over the remaining sections of the computer memory. Such overwrites cause memory to be obliterated and the entirety of the computer to "crash". This latter phenomenon causes the information in the computer to be largely useless and usually requires reloading of the entire operating system. Furthermore, it is only with difficulty that the causes of such "crashes" can be precisely located. Typically, the overflow to main memory obliterates or renders inaccessible the programming error which caused the overflow in the first place.
SUMMARY OF THE INVENTION
Accordingly, the present invention discloses a microprocessor architecture specifically designed and constructed to operate in response to an assembly language that is substantially identical to the higher-level FORTH programming language.
Generally, the microprocessor architecture of the present invention is provided with at least three separate, independent input/output ports for communicating data words between the microprocessor and external data elements, one of which can be a memory element for storing instruction words as well as data. A first of the three input/output ports is adapted to be connected to receive instructions. The other two input/output ports are coupled to one another by a two-way data path that includes an arithmetic-logic unit (ALU) for performing a variety of arithmetic and logic operations on data that passes therethrough. The two-way data path allows one of the input/output ports to receive unprocessed data synchronously with receipt of instructions (received at the first port), and pass that data through the ALU to present it, as processed data, at the other input/output port coupled to the ALU.
In the preferred embodiment of the invention a pair of data registers each respectively coupled one of the input/output ports to the ALU in a manner that establishes that aforementioned two-way communication, and each of the input/output ports is coupled to an independent, external memory element, forming a pair of Last In, First Out (LIFO) data stacks for storing a number of sequentially ordered data words. A program counter generates address information that is supplied to a third (main) memory in which are stored microprocessor instructions and data; an address multiplexer selectively communicates the content of the program counter, or the content of certain internal registers of the microprocessor, to an address bus that interconnects the address bus and the main memory. An instruction decode unit receives and decodes instructions accessed from the main memory to provide therefrom the necessary control signals that, via a variety of multiplexing schemes, "pipe" information to desired registers and latches and effect loading of those registers and latches, as dictated by the decoded instruction.
The preferred embodiment of the present invention further includes logic that interconnects the registers and the ALU in a manner that permits one-cycle information "swaps" between any one of the registers and an internal register of the ALU. This feature, together with the two-way data path through the ALU between a pair of input/output data ports, provide a microprocessor architecture uniquely adapted to the design of an assembly language containing the structure and operating characteristics of the FORTH programming language.
Finally, the preferred embodiment of the invention includes addressing circuitry coupled to the external memory elements forming the LIFO stacks of the system in which the microprocessor is used. This addressing circuitry maintain the addresses ("pointers") of (1) the memory locations at which the last data element written to the memory element and (2) the next available memory location at which the next memory element is written. These pointers are automatically incremented or decremented when data is written to (i.e., "pushed into") or read from ("popped") the stacks, thereby maintaining stack structure without direct intervention of the microprocessor itself.
The stack structure, a concept basic to the structure and operation of FORTH, is utilized extensively by FORTH programming to store "return" from subroutine addresses. FORTH is often referred to as a "building-block" language; using standard FORTH vocabulary words ("primitives"), metawords, meta-metawords, and so on, can be built. Implementation of this (as well as other) concepts require the formation of extensive subroutine programs, many of which are often deeply nested within other subroutines which, in turn, are nested in yet other subroutines. Further, some of these subroutines may even be recursive. In order to be able to return to a point of initiation of a subroutine or subroutines, a return address, usually the address of the memory location containing the next instruction following in succession that which called the subroutine, must be stored. Often, therefore, and particularly in the case of deeply nested subroutines, a successive list of return addresses must be maintained in order to provide a return path. This list is uniquely fitted for storage in one of the LIFO stacks of the system capable of being implemented by the microprocessor of the present invention and an external memory element. Subroutine calls effect an automatic push onto a return stack of the necessary return address.
To complement the aforementioned feature of automatically maintaining a list of return addresses in a "return stack" is the reservation of a specific bit position of the machine language instruction designed for the present invention for use in effecting a return operation without specific memory (or other) manipulation. According to this aspect of the invention, setting this specific bit of the microprocessor instruction to a predetermined state automatically causes the last stored return address to be used to address the main memory (in which instructions are stored) and to "pop" the stack for the next sequential instruction. This feature provides an additional advantage: the last instructions of every subroutine can be an operation (e.g., an arithmetic-logic operation, data transfer, or the like) combined with a subroutine return, merely by setting the "return bit" of any such last instruction to the return or predetermined state.
A number of advantages are obtained from the present invention. First and foremost is the fact that the disclosed architecture is structured so that the assembly language developed therefore implements many of the "primitives" (standard words) of the FORTH programming language. Execution of each primitive (in some cases multiple primitives) requires only one machine cycle; an exception is certain data transfer instructions (fetch and store) which operate in two machine cycles. This allows for compact object code for a given application, and also provides extremely fast execution of that code. These advantages are realized, in part, from the stack constructions and their interconnection with the ALU. The FORTH programming language typically operates from two stacks: A first stack stores parameters which are to be arithmetically and/or logically combined or otherwise manipulated, and a second stack typically used for storing the return addresses--described above. The microprocessor architecture permits use of the stacks by the ALU, permitting greater flexibility by permitting data manipulations to be performed and stored with incredible speed. The requirement of accessing main memory for data storage is reduced automatically.
The ALU includes a register that is used as an output buffer (and, in some cases, also function as an accumulator). The microprocessor of the present invention utilizes this register as the top of one of the aforementioned LIFO stacks (the "parameter" stack). The next location of the stack is also implemented via a register, and the following locations of the stack are found in one of the external memories. The two registers are interconnected so that "SWAPS" can be performed between them; that is, the content of each register is transferred to the other register simultaneous with a reverse transfer, thereby implementing the FORTH "SWAP" primitive. The other stack also has an internal register of the microprocessor coupled to the accumulator of the ALU in a manner that provides this same swap capability.
In addition to receiving a corresponding one of the two aforementioned stacks, the ALU operand inputs are also structured to selectively receive many of the other internal registers of the microprocessor, and thereby perform arithmetic-logic operations on the content.
OTHER OBJECTS, FEATURES AND ADVANTAGES
An object of this invention is to disclose a microprocessor architecture designed specifically to accommodate the FORTH computer language. Accordingly, a microprocessor with four main registers, three main addressing multiplexers, and four input/output ports is disclosed. The registers are each designed to hold a parameter and include a decode register L for operating the microprocessor and a central register T with an appended arithmetic logic unit. The arithmetic logic unit (ALU) connects to a parameter stack through a next parameter register circuit N, and connects to a return stack through an index register circuit I. These connections are made along paths permitting simultaneous swaps of parameters between the T register and the I and N register circuits, for stack pushes and pops to the respective LIFO return memory stacks and LIFO next parameter memory stacks. These latter stacks have simplified counters permitting automatic decrementing and data writing incrementing with appropriate data discharge from the stacks. Addressing of main memory is permitted through a multiplexer which accepts data from the instruction latch L (for absolute jumps); data from the arithmetic logic unit in register T (for fetches and stores of data to memory); data from the index register I (for returns from subroutines); and data from a program counter. These results a microprocessor whose assembly language instructions are performed in one machine cycle with the exception of certain fetches and stores which require two cycles for execution.
A further object of the disclosed microprocessor architecture is to provide a service of at least three isolated, separate and discrete memory islands: a main program emory (typically 32K data and program instructions, and 32K additional data) and the return stack and parameter stack (each typically containing 256 addressable memory locations). These discrete memory islands are fast, are served and can be used simultaneously without sequential cycles.
A further advantage of discrete memory spaces is that problems due to overflow can be at least isolated to that discrete portion of memory where the error has been caused to occur. Stack overflow will not invade and overflow main memory. Moreover, where any stack does overflow, there remains the last overflows to provide a programming clue for debugging. Consequently, the programmer can list the main memory and identify bugs causing stack and/or memory overflow, a principle cause of FORTH crashes.
Yet another advantage of this invention is that both the parameter stack and the return stack are available for pop or push and the main memory accessible on a simultaneous basis. Typically, only the speed of the main memory is limiting--the parameter stack and the return stacks are fast and typically do not limit memory access.
Yet an additional advantage of the discrete memory with this microprocessor is that a 48-bit wide path to commonly accessible memory is provided, which path to memory can be three separate 16 bit wide paths, all accessible simultaneously with microprocessor operation.
Yet another advantage of this invention is that the ALU contained within the T register is effectively decoupled from main memory. This arithmetic logic unit runs from parameters on the nearby I and N registers, thereby assuring high speed asynchronous operation.
Yet another advantage of the microprocessor architecture is the memory paths to main memory and the stacks are always active. Shifts in sequential cycles to differing portions of the main memory, return stack, and parameter stack in sequence are not required.
A further object of this invention is to disclose a microprocessor in which so-called "swapping" paths permit the exchange of data between registers. The index register I, the ALU register T and the next parameter register N are interconnected to permit swapping of data from the T register to either the I or N registers. Execution of the FORTH primitives is expedited and in most cases, confined to a single cycle.
An advantage of the registers and their swap path is that the execution of instructions on the microprocessor is essentially asynchronous. Operations can go on between discrete registers on the microprocessor simultaneously and are not required to be cycled sequentially in discrete cycles.
The further advantage is that the architecture positioning of the microprocessor permits a single cycle entry into subroutines, using a single bit (the most significant bit or MSB of the instruction) to define the jump instruction. In addition, all jump instructions include the address to which the jump is made within the instruction itself. Further, the microprocessor architecture permits the jump to be made simultaneous with saving of a return address. An end of cycle instruction is all that is required to do a return from subroutine. A discrete cycle of the microprocessor is not required for a subroutine return.
A further advantage of this invention is to disclose an addressing multiplexer to a main memory which is readily capable of input from a number of internal registers of the microprocessor. According to this aspect, the addressing multiplexer A includes a direct path from instruction latch L for absolute jump, a write and read path to a programming counter P for storing or reading the next program or subroutine step to be executed, a direct path from the indexing register I for placing the next return to the addressing multiplexer, and a direct path from the T register to the addressing multiplexer for two cycle fetches and stores of data from main memory. There results a microprocessor which in a single cycle can set-up the memory location for a future step, latch a memory instruction from main memory for the next step while executing instructions of a current step on an asynchronous basis. Consequently overlap in the execution of microprocessor operation is provided to increase speed.
A further object of this invention is to provide a single cycle jump to subroutine with an accompanying push of the return stack. Accordingly, the program counter P writes its incremented count directly to the return stack in a push. Simultaneously, the address multiplexer receives the next instructed routine direct from the instruction latch L. Since cycle subroutine entry is achieved.
Yet another advantage of the disclosed I or indexing register with the T register is that looping, an extremely common technique in the FORTH and other languages, can occur under control of this register to approximately 65,536 times. Instructions may be repeated. Moreover, stores and fetches to memory can be streamed using a count in the I register and sequences of data, for example a stream of data stored in the next parameter LIFO memory stack; discrete addressing of each data entry is not required.
Yet another object of this invention is to include a microprocessor whose assembler language is directly analogous to and understandable in terms of FORTH.
An advantage of an assembler directly analogous to FORTH is that more than 1,000 man years of programs in FORTH for the public domain are readily available for adaptation to this microprocessor. In short, the microprocessor may be readily programmed with extant programs.
A further advantage of this invention is that many other existent program languages can be implemented in terms of the FORTH program language.
Yet another advantage of the architecture is that the computer language FORTH has been designed first and the architecture of the disclosed microprocessor designed second and conformed to the language known as FORTH. Consequently, the architecture flowing from software design results in a vastly simplified rapidly cycling microprocessor.
Yet another advantage of the assembler being analogous to the FORTH language is that programming in assembler is vastly simplified. This simplification occurs with respect to the level of programming skill required, the time required for programming, and the amount of complexity of the program itself. Consequently providing the microprocessor with an "operating system" can be done with about 1/10 of the time and effort required with traditional assemblers. Moreover, since the assembler language carries with it the words of FORTH, a programmer in reading the listings can follow the logic of the FORTH language to debug or locate errors in the operating system. Consequently debugging time and effort is vastly reduced.
A further advantage of this microprocessor is an operation code which includes a 5-bit short literal at the end of the FORTH primitive instructions. Such short literals can be used for adjustable incrementing and decrementing of registers, especially the T register within the microprocessor. For example, incrementing and decrementing is adjustable with each cycle in a range of 0 to 31. Moreover, the bottom 32 positions of memory can provide faster fetches and stores of commonly used data.
Yet another object of this microprocessor is to disclose a microprocessor architecture in cooperation with the return stack that permits a FORTH dictionary to be lodged having subroutine threaded code. Specifically, a dictionary design is set forth having the word, a link to the next word, and thereafter the series of subroutines to be run to execute the word. No longer is indirect address threading required where the indirect address of the address of a word or subroutine is utilized. This function directly cooperates with the return stack and provides increased speed of execution.
An advantage of the dictionary structure is that it is faster by at least a full cycle in executing each word contained within a FORTH word definition.
Yet another advantage of this invention is to disclose loops and jumps contained wholly within a single instruction. According to this aspect of the invention, jumps include a 12 bit address capable of jumping within an 4K memory "page". A single machine cycle is all that is required for such loop and jump addressing.
Other objects, features, and advantages of this invention will become more apparent after referring to the following specification and attached drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified block diagram of the microprocessor of the present invention, illustrating generally the overall information flow of this invention;
FIG. 2 is a map of main memory used within this invention;
FIG. 3 is a block diagram of the instruction decode unit of FIG. 1, illustrating that unit in greater detail;
FIG. 4 is a block diagram of the address multiplexer and program counter of microprocessor of FIG. 1;
FIG. 5 is a block diagram of the I (Return/Index) register circuit of the microprocessor of FIG. 1;
FIG. 6 is a block diagram of the N (Next Parameter) register of the microprocessor of FIG. 1;
FIG. 7 illustrates, in block diagram form, the main memory port of microprocessor FIG. 1;
FIG. 8 is a block diagram of one (J) of the stack pointers (J/K) that provide addressing for the external memory units that are used to form the return (R) and parameter (S) stacks used by the microprocessor of FIG. 1;
FIG. 9 illustrates, in block diagram, the arithmetic logic unit (ALU) of the microprocessor of FIG. 1;
FIGS. 10A and 10B illustrate in greater detail, and in block diagram form, multiplexer output portions of the ALU shown in FIGS. 1 and 9;
FIGS. 11A and 11B are timing diagrams of the CLOCK pulse used to operate the microprocessor of FIG. 1; and
FIG. 12 is an illustration of additional internal registers of the microprocessor of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
General Description
Turning now to the Figures, and specifically FIG. 1, there is illustrated in block diagram form, and designated with the reference numeral 10, the microprocessor of the present invention. As shown, the microprocessor includes a program counter P for generating addresses that are communicated, via an address multiplexer A, output terminals 15, and an address bus A-BUS, to a main memory 12. AS addresses are generated and applied to the main memory 12, instructions, and data words as the case may be, are accessed and coupled to a main memory port M of the microprocessor 10 by a DATA BUS that interconnects the microprocessor 10 with the main memory 12 at I/O terminals 13. Instructions are passed by the main memory port M to an instruction latch L (FIG. 3) contained in an instruction decode unit 14 of the microprocessor 10, and held for decoding.
Instructions that are decoded by the instruction decode unit 14 cause activation of one or more of a number of internal gating and command signals that are dispersed throughout the internal circuitry of the microprocessor 10 to direct information flow and information manipulation within and by the microprocessor.
The microprocessor 10 also receives an externally generated CLOCK signal, illustrated in FIGS. 11A and 11B. From this CLOCK signal is generated an internal clock (CLK) signal that is used to perform various coding and latching operations that will be more fully explained below. It is important at this point to recognize certain overlap operations performed by the instruction decode unit. Instructions are latched in the instruction decode unit 14 on each rising edge 18 (FIG. 11A) of the CLOCK signal, and the latched instruction is decoded during each HIGH state of that signal; instruction decoding is preferably complete by each falling edge 20 of the CLOCK signal. Accordingly, prior to each successive rising edge 18 of the CLOCK signal a determination has been made as to the memory location in the main memory 12 of the next sequential instruction or data word (which, as will be seen, can be obtained from several sources). After instruction decode time is complete, the instruction is executed prior to the next successive rising edge 18 of the CLOCK signal. This allows an overlap of two basic microprocessor operations: Address formation and instruction execution.
These two independent operations take place during each of the periods of the CLOCK signal: the address for the next sequential instruction (or, in the case of data fetches, the data) is formed, and the operation dictated by the instruction is executed. Thus, at latch time T.0. (FIG. 12A) an instruction is latched in the instruction decode unit, the location of which has been determined by a previous instruction determination made concomitant with other instruction execution. Similarly, during the time between latch time T.0. and latch T1 another address is formed, and applied to the A-BUS while the instruction received at latch time T.0. is being executed.
In addition to receiving and passing on to the instruction decode unit 14 instructions words (and, in some cases, addresses), the main memory port M selectively communicates data words to the next parameter register N on a two-way data path 37, structured to permit a simultaneous two-way transfer of data between the main memory port M and the N register circuit. The data received by the main memory port M from the N register circuit, as well as from an arithmetic logic unit (ALU), can be selectively communicated to the main memory 12 for storage.
The N register circuit, in addition to being connected to the main memory port M, is also connected to the ALU by a two-way data path 36, and to an input/output (I/O) port 22. In turn, port 22 is preferably connected to an external parameter memory 24 by a 16-bit S-BUS. The N register circuit, together with the parameter memory 24, form a LAST-IN-FIRST-OUT (LIFO) parameter stack S for storing a one dimensional array of sequential ordered data words. A similar LIFO stack, termed the return stack R, is formed by a return/index (I) register in conjunction with an external return memory 26. The return memory 26 connects to (16) input-output (I/O) terminals 28 of the microprocessor 10 (to which the I register also is connected) by a sixteen line R-BUS. The return memory 26, like the parameter memory 24, is operated, with the I register, to store data words in a sequentially ordered, one-dimensional array or stack. Entry to the return stack R is via the I register. Entry to the parameter stack S can be through a "top parameter" register T (FIG. 9) via the N register circuit, or through the N register circuit itself as will be described more particularly below. Stack operation is maintained by stack pointers, J/K, that each (the J pointer and the K pointer) respectively produce address signals to the parameter memory 24 and return memory 26. Operation of the parameter and return stacks S and R will be more fully described when the operation of the stack pointers are discussed with respect to FIG. 8.
Finally, the microprocessor 10 includes an input-output PORT 30 comprising twenty-one individual input/output (I/O) terminals. Five of those terminals connect to an X-BUS, and the remaining sixteen connect to a B-BUS. These twenty-one I/O terminals are associated with, and connected to, associated 5-bit and 16-bit registers, to provide an additional input/output capability.
Before continuing to a more detailed description of the individual elements that make up the microprocessor 10, a number of important features of the invention can be noted. First is the fact that the microprocessor 10 is capable of communicating with and using four distinct, independent data paths to corresponding I/O terminals 13, 22, 28, and the I/O port 30. While, in the present invention, the main memory 12, parameter memory 24 and return memory 26 are connected to the microprocessor 10 in order to implement an architecture uniquely adapted to a specific programming language, i.e., FORTH, other connections to these terminals can be made to advantageously utilize the microprocessor 10 in different implementations. For example, the microprocessor 10 can be used for digital signal processing under command of a FORTH language program, wherein the I/O terminals 22 and 28 are adapted to receive data streams indicative of the signals to be processed.
Another important feature of the present invention, particularly when viewed from the FORTH programming language, is the fact that the communicating paths 36, 37, 38, and the G-BUS that respectively connect the ALU to the N and I register circuits, the main memory port M, and the I/O port 30 all provide simultaneous, two-way data transfer, more commonly termed "swaps."
INSTRUCTION DECODE UNIT
Turning now to the circuit implementation of the various elements of microprocessor 10 shown in FIG. 1, FIG. 3 shows the instruction decode unit 14 in greater detail. As illustrated, the instruction decode 14 includes a 16-bit latch 50, an instruction decode circuit 52 and two input AND gates 54, 56, and 58. The 16-bit latch 50 receives at its data input a data word (M) from the main memory port M. The received data word (M) is latched along the rising edge of a CLK signal (derived from and essentially identical to the CLOCK signal received at input terminals 16 of the microprocessor 10) when the enabled clock EN-CLK signal from the instruction decode circuit 52 is HIGH. The EN-CLK signal is usually in its HIGH state except when an instruction dictating iterative operation is being executed. In that case, depending upon the instruction (which will be discussed more fully below), the EN-CLK signal may be LOW for a number of CLOCK signals (and, therefore, CLK signals) to make it appear to the microprocessor 10 as if an equal number (plus 2 as will be described) of identical instructions have been sequentially received, latched, and decoded.
Instructions that are received and latched by the 16-bit latch 50 are applied to the instruction decode circuit 52, where they are decoded. The decoding performed by the instruction decode circuit 52 generates the necessary internal gating and command signals, such as, for example, those listed in FIG. 3 (among others), to direct operation of the microprocessor 10.
The instruction decode unit 14 also receives an INT signal, derived from the INTERRUPT signal received at the input terminal 18 of the microprocessor 10, and an RST signal derived from the RESET signal received at the input terminal 20. The INT signal, when HIGH causes the 16-bit latch 50 to be set to a predetermined 16-bit instruction that, in turn, and after decoding, causes an immediate jump to a memory location of the main memory 12 wherein is stored the coding for handling interrupt sequences. The RST signal forces the content of the 16-bit latch 50 to, when decoded, cause another jump to a memory location in the main memory 12 wherein is stored the coding for a reset routine.
In addition to the 16-bit instruction from the latch 50, the instruction decode circuit 52 also receives an I=.0. signal from the I register. As will be seen, the I register at times will operate an index register to keep track of the number of iterations performed in response to certain instructions. The I=.0. signal notifies the instruction decode circuit 52 when the appropriate number of iterations has been reached so that the next instruction can be accessed from the main memory 12.
The carry out (Co) T=.0. signals are developed by the ALU. The Co signal is indicative of overflow conditions or a negative result, while the T=.0. signal is useful to test for the completion of certain arithmetic operations, as will be discussed below.
ADDRESS MULTIPLEXER AND PROGRAM COUNTER
Turning now to FIG. 4, there is illustrated in greater detail the address multiplexer A and program counter P, shown in combined form to illustrate their interrelation. As shown, the address multiplexer A comprises a multiplex circuit 60. The program counter P of FIG. 1 comprises a program register 62, a 16-bit adder circuit 64 and a two input AND gate 66.
The multiplex circuit 60 has four, 16-bit, inputs, three of which, 1, 2 and 3, respectively receive the latch 50 output, [L], and output [T] of a T register contained in the ALU (FIG. 9), and the output [I] of the I register (FIG. 5). In addition, the 16-bit input 4 of the multiplexer 16 receives the output [P] of the program register 62. Selection between which of the 16-bit inputs is multiplexed to the output of the multiplexer 60 is determined by an A-CTL signal generated by the instruction decode circuit 52 (FIG. 3) and received at the selection SEL input of the multiplexer 60.
The selected input is passed by the multiplexer 60 to operand input 64 of a 16-bit adder 64, as well as being communicated to the A-BUS that connects the microprocessor 10 to the appropriate addressing circuitry of the main memory 12 (FIG. 1). A second operand input 70 receives a hard-wired "+1". This arrangement allows the program register to always be loaded with a value, incremented by 1. Thus, for sequential operation, the multiplexer 60 will select the output [P] of the program register 62, reloading the program register 62 with its prior content plus 1.
The program register 62 receives the output of the AND and GATE 66 upon coincidence between the CLK and P-EN signals. The latter signal is generated by the instruction decode circuit 52.
I REGISTER
In addition to the multiplexer circuit 60, the output [P] of the program register 62 is also applied to the I register, which is illustrated in greater detail in FIG. 5. As shown, the I register includes a four input (each 16-bit) multiplex circuit 78, the output of which is applied to the data inputs of a register 80. Selection of which of the inputs 1-4 of the multiplex circuit 68 is coupled to the register 80 is made by the I-CTL signal received at the selection l(SEL) input of the multiplexer.
The 16-bit output [I] of the register 80 is coupled, via a zero test circuit 82 to one (16-bit) operand input of a 16l-bit adder 84. The other operand input of the adder 84 receives a "-1". The combination of the register 80, zero test circuit 82, and adder 84, together with the feedback path provided by the multiplexer circuit 78, provide a technique whereby the content of the register 80 can be incrementally decreased (decremented), testing each decrement for zero. This allows the I register circuit (i.e., register 80) to be used as an index register to count a number of iterative steps of microprocessor operation (such as, for example, during execution of multiply instructions), and provides a means for testing for an end to those iterative steps.
The output [I] of the register 80 is coupled to a tri-state buffer, and from there to the I/O terminals 28 that connect the microprocessor 10 to the R-BUS. An R-ENABLE signal selectively communicates the register 80 output [I] to the I/O terminals 28 when in one state, i.e., HIGH; and disconnects the register from the I/O terminals 28 by placing the output of the tri-state buffer 86 in a high impedance state when LOW.
The I/O terminals 28 are also connected to a receiver circuit 88 that couple the I/O terminals 28 to an input of the multiplexer circuit 78. The combination of the tri-state buffer 86 and receiver circuit 188 provide two-way communication between the I register circuit and the return memory 26 (FIG. 1) via the R-BUS.
The content of the register 80 is determined by various instructions. Accordingly, it is the I-CTL and I-LD that determine what is placed in the register 80 and when.
N-REGISTER CIRCUIT
The detail of the N (next parameter) register circuit is illustrated in FIG. 6. As shown, the N register circuit includes a five (16-bit) input multiplex circuit 96, a register 98, and a AND gate 100. The multiplex circuit 96 receives at its (16-bit) inputs 1 and 2 the output [T] from the T register of the ALU (FIG. 9), the output [M] from the main memory port M (FIG. 7) at the (16-bit) inputs 3 and of the multiplexer 96 and receive the output of the register 98--but in special fashion. As will be seen, the register 98 can be configured by certain of the arithmetic instructions as the lower sixteen bits of a 32-bit register formed by register 98 and the T register of the ALU. When so configured, the register combination is capable of being shifted either left or right. When shifted left, the lower sixteen bits receive, at the LSB position, the CARRY signal generated by the ALU (FIG. 9); when being shifted right the MSB of the register 98 receives the LSB of the T register (T 518 ). The feedback path through the multiplexer 96 performs this shift operation. Input 4 of the multiplexer 96, when selected, multiplexes the low-order fifteen bits (i.e., LSB.sub..0. -MSB -1 ) of the register 98 to the input of that register so that, when loaded, the effect is a 1-bit shift left. At the same time, the CARRY signal is combined with the fifteen output lines from register 98 at the input 4 of the multiplexer 96 so that the LSB receives the CARRY signal. In similar fashion, the high-order fifteen bits (MSB-LSB +1 ) are combined with the LSB (T.sub..0.) of the output [T] at the input 3 of the multiplexer 96 to effect a 1-bit right shift of the content of the register 98, with the LSB of the output [T] shifted into the MSB position.
Loading is effected by coincidence, at the two inputs of the AND gate 100, between the CLK signal and the control original N-LD signal produced by the instruction decode circuit 52 (FIG. 3). Selection of which of the multiplexer inputs 1-5 will be applied to the register 98 is effected by the control signal N-CTL also produced by the instruction decode circuit 52.
The 16-bit output [N] of the N register circuit from register 98 is coupled to the S-BUS by a tri-state device 99 when the control signal S-ENABLE is active. Data may be coupled to the register 98 from the S-BUS via the receiver 101 and the multiplexer 96.
MAIN MEMORY PORT M
As indicated during the discussion of FIG. 1, instructions and data are received or transmitted by the microprocessor 10 via the main memory port M. Illustrated in FIG. 7, in greater detail, is the main memory port M, which is shown as including a two (16-bit) input multiplexer 110, a (16-bit) tri-state device 112, and a receiver-buffer 114. The multiplexer circuit 110 receives two (16-bit) outputs: [N] from the N register circuit (FIG. 6) and [T] from the T register of the ALU (FIG. 9). The multiplexed quantity (i.e., [N] or [T]), selected by the control signal M-CTL is passed by the multiplexer 110 to the tri-state device 112 and from there to the I/O terminals 13 for communication via the DATA BUS to main memory 12. In addition, the output of the tri-state 12 (as well as the I/O terminals 13) is made available to the internal circuitry of the microprocessor 10 as the output [M] of the main memory port M by the buffer circuitry 114. Thus, the output [M] of the main memory port M represents either (1) the selected one of the N register circuit output [N] or T register [T] or (2) data from the main memory 12, depending on whether or not the tri-state device is in its transmitting or high impedance state, respectively. Control of the tri-state device 112 is effected by a selection signal M-SEL generated by the instruction decode unit 14.
STACK POINTERS J AND K
As previously indicated, maintenance of the parameter and return stacks S and R is conducted, in part, by the stack pointers J and K--under at least partial control of control signals from the instruction decode unit 14. The stack pointers J and K function to generate the address signals that are applied to the parameter memory 24 and return memory 26 for reading and writing from or to the stacks as necessary. They keep track of the last memory location written (and, therefore, is the location of the data that is accessed if the stack is read or "popped"), and have ready the address of the next empty memory location to which data will be written when a "push" is implemented. Each stack pointer J and K generates two 8-bit addresses, and the structure of each is essentially identical. Accordingly, only the stack pointer J will be described in detail, it being understood that the discussion applies with equal force to the stack pointer K unless otherwise noted.
Referring, therefore, to FIG. 8, there is illustrated in greater detail the stack pointer J used for addressing the return memory 26. As shown, the stack pointer J includes three two input, 8-bit multiplexers 120, 122, and 124, two 8-bit latches 126 and 128, and an output multiplexer 130. The latches 126 and 128 are each respectively caused to be loaded by signals generated by the AND gates 132 and 134. Loading of the 8-bit latch 126 is enabled by the J1-EN signal produced by the instruction decode unit 14, together with the CLK signal, while the 8-bit latch 128 is loaded by presence of the J2-EN enable signal and the CLK signal.
A feedback path for the output 8-bit latch 126 to the input 2 of the multiplexer 120 is provided by a decrement circuit 136, which receives the output of the 8-bit latch 126, subtracts "1" from that output, and supplies the decremented value to the input 2 of the multiplexer 120. In similar fashion, an increment circuit 138 receives the output of the 8-bit latch 128, increases it by 1, and provides the increased value to the input 1 of the multiplexer 122. The outputs of the 8-bit latches 126 and 128 are also communicated to the JA bus (which connects the stack pointer J to the return memory 26) by a multiplexer 130.
As previously indicated, the stack pointer J is responsible for generating two addresses: The first "points" to the memory location of the return memory 26 at which the last quantity has been stored; the second points to the memory location at which the next value will be written. It is the function of the 8-bit latches 126 and 128 to always retain these respective pointers. As constructed, the content of the 8-bit latches will always be one address apart; that is, the content of the 8-bit latch 128 will be one greater than that of the 8-bit latch 126; the content of the 8-bit latch 126 points to the "last written" memory location and the 8-bit latch 128 points to the next available location.
The 8-bit latch 126 is presettable with the low-order eight bits from the output [T] of the T register (FIG. 9). The high-order eight bits of [T] preset the 8-bit latch (not shown) of the stack pointer K corresponding to latch 126. The 8-bit latch 128 (and its counterpart in the stack pointer K) are not preset and are, therefore, indeterminate until a data read. When such a read operation occurs, the content of latch 128 is loaded with the read address, and the latch 126 is loaded with the read address minus one.
The parameter and return stacks S and R, respectively, are operated in conventional fashion; that is, data is either "pushed" (written) onto or "popped" (read) from the stacks. A push is implemented by writing into the next available memory location the desired data and incrementing the 8-bit latches 126, 128; a pop is effected by reading the last value written and decrementing the 8-bit latches 126, 128. In actual operation of the parameter and return stacks S and R, the pop and push operation utilize the N register circuit or the I register circuit, which respectively form the top of the stacks. The following discussion concerns operation of the return memory 26 by the stack pointer J.
Consider first a "push" operation in which the output of the I register circuit [I] is to be added the remaining portion of the return stack R, (i.e., that portion of the return stacks implemented by the return memory 26. The memory location at which the content of the I register is to be placed can be found by the content of the 8-bit latch 128. Accordingly, the instruction decode unit 14 brings HIGH a WRITE signal which causes the multiplexer 130 to select the output of the 8-bit latch 128, which output is applied to the address circuitry via the JA bus, of the return memory 26. At the same time, the WRITE signal causes the multiplexer 122 to select its input 1 for application to the data input of the 8-bit latch 128, and causes the multiplexer 120 to select its input 1 for application to the input 2 of the multiplexer 124. During this time, the READ signal is low, causing the multiplexer 124 to communicate its input 2 to the 8-bit latch 126. Thus, it can be seen from the FIG. 8 when the WRITE signal is high, the multiplexers 120, 122, and 124 cause (1) the content of the 8-bit latch 128 plus 1 to be applied to the data inputs of that latch; (2l) the content of the 8-bit latch 128 to be applied to the data inputs of the 8-bit latch 126; and (3) the content of the 8-bit latch 128 to be applied to the memory circuits of the return memory 26. The J1-En and J2-EN signals are brought HIGH by the instruction decode unit 14 so that the pointers contained by the 8-bit latches 126, 128 are incremented by 1, while the desired value is written to the memory, at CLK time.
The data is "popped" from the return memory into the I register in the following manner: the READ signal is brought HIGH, and the WRITE signal is kept LOW, by the instruction decode unit 14. With WRITE HIGH and READ LOW, the multiplexers 120 and 124 each have selected their inputs too, thereby returning the content of the 8-bit latch 126, -1, to its data inputs; and the multiplexer 122 selects its input to communicate the content of the 8-bit latch 126 to the 8-bit latch 128. The multiplexer 130 selects its input and applies the content of the 8-bit latch 126 to the memory circuits (not shown) of the return memory 26. Upon appearance of the next successive CLK pulse (assuming appropriate command signals from the instruction decode unit, i.e., J1-EN, J2-EN HIGH, the address pointers contained in the 8-bit latches 126 and 128 are decremented. Note that this pop operation will be accompanied by the necessary control signals, generated by the instruction decode unit 14, to cause the register 80 (FIG. 5) to receive and retain the data sitting on the R-BUS from the return memory 26; that is, the I-CTL signal selects the input 3 of multiplexer 78, the I-LD signal is HIGH and the R-ENABLE signal places the tri-state device 86 in its high impedance state so that upon arrival of the CLK signal that decrements the J stack pointer, the register 80 will also be loaded with the "popped" quantity.
ALU AND T REGISTER
Shown in FIG. 9, in greater detail, is the ALU of the microprocessor 10. FIGS. 10A and 10B show, in greater detail, portions of the heart of the ALU, the arithmetic logic circuit 144. Referring first to FIG. 9, the ALU is shown as including a four-input multiplexer 142, the arithmetic logic circuit 144, the previously mentioned T (top of parameter) register, a zero detect circuit 146, an AND gate 148, which produces (from a T-EN signal from the instruction decode unit 14 and the CLK signal) a load signal for the T REGISTER, and a carry flip-flop 150. The arithmetic logic circuit 144 is, in essence, a 16-bit design that is provided with two operand inputs 144a and 144b that respectively receive the outputs [T] and [U] from the T register (via the zero detect circuit 146) and the multiplexer 142, providing the sum of [T] and [U], the difference of [T] and [U], the difference of [U] and [T], [T] itself, [U] itself, the logical [T] OR [ U], the logical [T] AND [U], or the logical [T] EXCLUSIVE-OR [U].
The output of the arithmetic logic circuit is coupled to the inputs of the T register by a bus line 154, which communicates the result of the arithmetic or logic operation performed on the values received at the operand inputs 114a, 144b of the arithmetic logic circuit 144.
The arithmetic logic circuit 144 also receives OP-SELECT, which determines which arithmetic result (identified above) is to be communicated to the bus 154 and L-SHIFT and R-SHIFT which function to perform left and right 1-bit shifts of the results for reasons that will be made clearer below.
In general, therefore, the ALU receives four quantities: [SL] from the instruction decode unit 14 (FIG. 3), the output [MD] from the register multiply/divide 202 (FIG. 12), the output [N] from the N register circuit (FIG. 6), and output [G] from a variety of internal registers (FIG. 12), which will be described more fully below. Note that it is the multiplexer 142 that establishes, via the arithmetic logic circuit 144 a 16-bit wide communication path from either the I register or the N register circuit to the T register. Note also that the output [T] of the T register is communicated to both the I register and the N register. On appropriate signals from the instruction decode unit 14, information from the parameter stack S, including the N register circuit, can be sequentially supplied to the T register, or alternatively, information from the return stack R, via the I register can be communicated to the T register. Note particularly the fact that this data path allows information stored in the parameter memory 24 to be transferred to the return memory 26 and vice versa, as needed. Note further still that the swap paths designated as 36 and 38 in FIG. 1 are established by multiplexers 142 and multiplexer 96 (for the swap path 36) and multiplexer 78 (for the swap path 38).
As will be seen, certain of the instructions test the content of the T register for "zero" to determine whether to continue operation or select another instruction option. Accordingly, the (16-bit) data path from the T register to the arithmetic logic circuit 144 of the ALU includes a zero detect circuit 146 that issues a "T=.0." when the output [T] is a .0.. As illustrated in FIG. 3, the T=.0. is an input to the instruction decode circuit 52 o the instruction decode unit 14.
The arithmetic logic circuit 144 is illustrated in greater detail in FIG. 10A. As illustrated, the arithmetic logic unit includes sixteen interconnected stages, each stage structured in a manner known to those skilled in the art to produce the necessary arithmetic and/or logical signals indicative of an arithmetic logic circuit. Thus, for example, as illustrated in FIG. 10B, the individual arithmetic-logic stage Y n produces, from its operand inputs [U n ] and [T n ] (together with any carry from the immediately lower stage, Y n-1 ) the terms U n , T n , (T n +U n ), (T n -U n ), (U n -T n ), (T n OR U n ), (T n AND U n ), and (T n EXCLUSIVE-OR U n ). These outputs of each of the stages Y.sub..0. . . . Y 15 are applied to corresponding multiplexers 160(Y.sub..0.) . . . 160(Y 15 ), respectively. Each of the output multiplexers 160(Y.sub..0.) . . . 160(Y 15 ) receive a 3-bit bus that carries a selection signal OP-SELECT. The OP-SELECT signal is generated by the instruction decode unit 14 in response to a decoded instruction that dictates which of the terms are going to be selected.
Referring again to FIG. 10A, the output of each of the multiplexers 160(Y.sub..0.)-160(Y 15 ) are each supplied to yet another corresponding multiplexer 162(Y.sub..0.)-162(Y 15 ). In addition, the output lines of each of the multiplexers 160(Y 1 )-160(Y 14 ) are connected to the multiplexers of the bit positions immediately below and above. Thus, for example, the output line from the multiplexer 160(Y n ), in addition to being applied to the input 2 of its associated multiplexer 162(Y n ), is also applied to input 1 of multiplexer 162(Y n-1 ) and input 3 of multiplexer 162(Y n+1 l). The multiplexers for the arithmetic-logic stages Y.sub..0. and Y 15 are different only in that the multiplexer 162(Y.sub..0.) receives at input 3 the carry-in (C i ), and the multiplexer 162(Y 15 ) receives at input 1 the output of a multiplexer 164, which selects one of four available signals: the output of the multiplexer 160(Y 15 ), CARRY, LSB from the N register, N.sub..0., or a "zero sign". Selection of which signal is coupled to the input 1 of the multiplexer 162(Y 15 ) is made by the CTL ONE signal generated by the instruction decode unit 14 (FIG. 3).
The multiplexers 162(Y.sub..0. -162(Y 15 l) function to perform 1l-bit left shifts, 1-bit right shifts, or no shift upon the result from the arithmetic-logic stages Y.sub..0. -Y 15 . In addition, multiplexers function to propagate the sign bit (i.e., the MSB) throughout the T register. A 1-bit left shift operation is performed when the signal L-SHIFT, generated by the instruction decode unit 14, is HIGH (the R-SHIFT signal being kept LOW), with a carry (C i ) being shifted into the LSB position; a right shift operation is performed when the R-SHIFT is HIGH (and the L-SHIFT signal is LOW), with either the output of the multiplexer 160(Y 15 ), the CARRY signal from the flip-flop 150 (FIG. 9), the LSB of the N-register, N.sub..0., or a "zero" being the putative output of the stage Y 15 ; or, when both of the L-SHIFT and R-SHIFT signals are LOW, the outputs of the multiplexers 160(Y.sub..0.)-160(Y 15 ) are passed by the corresponding multiplexers 162(Y.sub..0.)-162(Y 15 ). The selected results are received by the bus line 154 and communicated to the T register (FIG. 9).
Sign bit propagation is affected by being HIGH the .0.< signal. This causes the multiplexers 162(Y.sub..0.)-162(Y 15 ) to communicate their input 2 to the bus line 154. The input 2 of each multiplexer 162(Y.sub..0.)-162(Y 15 ) receives the MSB bit passed by the multiplexer 160(Y 15 ).
OTHER INTERNAL REGISTERS
The microprocessor 10 incorporates other registers, together with a two-way communication "swap" path (via the multiplexer 142) to the ALU. These registers are shown in FIG. 12, and include the multiply/divide (MD) register 214, the square root (SR) register 204, the B register 206, and the X register 208--all presettable from the output [T] of the T register. The outputs of these registers are selectively communicated to the ALU via the G multiplexer 210.
FIG. 12 also discloses a square root logic circuit 220 which receives the outputs of the MD and SR registers to provide (as the 16-bit signal [M/S]) the logical OR of the content of the SR register 204 content, shifted by 2, with the content of the MD register 202.
INSTRUCTION SET
Having now described the circuitry of the microprocessor 10, the instruction set will be explained and discussed with respect to Tables I-XIV.
The instructions can be, generally, grouped in four categories: (1l) the Arithmetic group includes those instructions of groups I and II include those instructions that performed arithmetic operations; (2) the Jump group includes those instructions which provide for conditional or absolute program jumps; (3) the Indexing instructions are basically "set up" instructions or instructions that effect iterative operations; and (4) the Data Fetch/Store instructions which transfer information between various memory spaces, registers, and the like.
As will be seen, the mnemonics used for each instruction, as well as its operation, utilizes the FORTH programming language and concepts as much as possible.
ARITHMETIC INSTRUCTION
Tables I and II set forth those instructions used to cause the microprocessor 10 (FIG. 1), and in particular its ALU (FIGS. 9, 10A and 10B) to perform arithmetic operations.
TABLE I______________________________________ARITHMETIC INSTRUCTIONSOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________100000 NO OP No Operation107020 DROP Pop N into T107000 DROP DUP Copy N into T107120 DUP Push T into N107120 OVER Copy N into T while pushing T into N107100 SWAP Exchange N and T104020 + Add N to T and pop N102420 +c Add N to T with carry and pop N106020 - Subtract T from N and pop N106420 -c Subtract T from N with carry and pop N102020 SWAP - Subtract N from T and pop N102420 SWAP -c Subtract N from T with carry and pop N103020 OR Logically OR N into T and pop N105020 XOR Logically XOR N into T and pop N101020 AND Logically AND N into T and pop N100001 2/ Shift T right one bit with N.sub..0. into T.sub.15100002 2* Shift T left one bit with N.sub. 15 into T.sub..0.100003 0< Propagate sign of T through T100011 D2/ Shift the combination of N and T left one bit100012 D2* Shift the combination of N and T right one bit104211 *' Multiply step102211 *- Signed multiply step102212 *F Fractional multiply step102216 /' Divide step102214 /" Last divide step102616 S' Square root step______________________________________
Referring first to Table I, illustrated there are the operation code, mnemonic, and a brief description of the operation or action for each of the basic arithmetic instructions; the more complex arithmetic instructions, i.e., those instructions that can perform multiple operations in one machine cycle.
The first few instructions will be described in terms of the circuitry illustrated in FIGS. 1-13 in order to provide a clear understanding of not only the execution of an instruction, but the operation of the circuitries itself and, in effect, the coding necessary to be set into the instruction decode circuit 52 (FIG. 3) to activate the necessary control signals (such as those shown in connection with FIG. 3) in response to the op code bit structure of the instruction.
Thus, now referring to FIG. 1, the no operation (NO OP) instruction does just that: it performs no operation whatsoever; it is a "null" instruction. The DROP instruction causes the content of the N register, i.e., the register 98 (FIG. 6) to be transferred via the multiplexer 142, arithmetic-logic circuit 144 (via the multiplexers 160 and 162) to the T register. The instruction decode circuit 52, therefore, sets up the appropriate data path via the control signals ALU-CTL, OP-SELECT, L-SHIFT, R-SHIFT, and T-ENABLE. AS an illustration of the timing of this (and any other) instruction, assume that the instruction was latched in the instruction latch 50 at time T.sub..0. (FIG. 11A). During the DECODE time indicated in FIG. 11A .0., the instruction decode 52 perceives the instruction from the instruction latch 50, decodes that instruction, and sets up the appropriate data path to the T register by activating the necessary aforementioned gating and command signals. At time T 1 , when the next instruction is to be latched into the instruction latch 50, the CLK signal (together with R-EN via the AND gate 48) causes the transferred information to be set in the T register.
The DROP instruction also "pops" the parameter stack S. Accordingly, the internal gating and command signals issued from the instruction decode circuit 52 cause the memory location designated (at the time of execution of the DROP instruction) by the gate bit latch of the stack pointer K (not shown) that corresponds to the 8-bit latch 128 of the stack pointer J (FIG. 8) to be conducted via the multiplexer 196 to the register 98 and loaded therein at the next rising edge of the CLK signal, i.e., at time T 1 of the above described example.
DROP DUP instruction is essentially the same as the DROP instruction except that the parameter stack is not popped. Thus, at the completion of the DROP DUP instruction, the content of the N register is identical to that of the T register.
The DUP instruction "pushes" the content of the T register onto the parameter stack S. Thus, execution of this instruction requires the input 1 of the multiplexer 96 (FIG. 6) to select the output [T] of the T register for communication to the register 98. The output [N] since on the I/O terminals 22 and, therefore, is communicated to the parameter memory 24 (FIG. 1) of the S-BUS. At the next CLOCK signal (and the CLK signal derived therefrom) the content of the T register is loaded into the N register, at the same time the (prior) content of the N register is loaded into the parameter memory 24 at the memory location designated by the K stack pointer counterpart of the 8-bit latch 128, and the 8-bit latches (not shown) of the stack pointer K incremented by 1.
The OVER instruction utilizes the two-way communication 36 illustrated in FIG. 1 between the T register of the ALU and the N register. Assume, for the purposes of illustrating this instruction, that just after time T.sub..0. (FIG. 11A) the content of the T register is T(.0.), and the content of the N register is N(.0.). Just after the time R 1 (FIG. 11A) the content of the T register will be N(.0.), the content of the N register will be T(.0.) and the memory location of the top of that portion of the parameter stack S contained in the parameter memory 24 will contain N(.0.). This instruction requires the necessary internal gating and command signals to be issued by the instruction decode circuit 52 to cause the multiplexer 96 (FIG. 6) to select the output [T] from the T register, the multiplexer 142 (and arithmetic-logic circuit 144) to select and communicate the output [N] of the N register to be communicated to the T register, and to cause an appropriate read command (not shown) to be communicated to the parameter stack memory 24 to load the necessary registers and memory.
The SWAP instruction also utilizes the simultaneous two-way data path 36, and causes the multiplexer 142 and arithmetic-logic circuit 14 to communicate the output [N] of the N register to the T register at the same time that the output [T] of the T register is communicated via the multiplexer 96 to the register 98 of the N register. The effect is to "swap" or exchange the respective contents of the N and T registers.
The + instruction adds the content of the N and T registers, leaving the result in the T register, and "pops" the parameter stack S into the N register; the 8-bit registers (not shown) of the stack pointer K, corresponding to those of the stack pointer J (FIG. 8) are each decremented by 1.
The +c instruction utilizes the CARRY signal from the flip-flop 150 of the ALU (FIG. 9). The CARRY signal is gated to the C i input of the ALU so that the operation of adding the content of the N register to the content of the T register together with any carry from a previous instruction is performed, and the parameter stack S popped.
The - instruction is the same at the + instruction except that it is a subtraction operation that is performed, and the content of the T register is subtracted from the N register. It may be appropriate at time to point out again that each individual stage Y.sub..0. -Y 15 performs all necessary arithmetic (i.e., add and subtract) operations so that at the output of each stage are the operations as indicated previously and in FIG. 10B. A particular operation is selected by the OP-SELECT signal generated by the instruction decode circuit 52 of the instruction decode unit 14. Thus, for the arithmetic-logic stage Y n outputs illustrated in FIG. 10B, the + instruction would cause the OP-SELECT signal to be of a predetermined state to cause the multiplexer 160(Y n ) to select the term (T n +U n ) for passage to the second multiplexer 162 (Y n ) (FIG. 10A). Of course, the U operand is, in fact, the output [N] from the N register circuit via the multiplexer 142 (FIG. 9). In similar fashion, the - sign instruction would select, via generation of the OP-SELECT signal the (U n -T n ).
The -c is, as indicated in TABLE I, an operation that subtracts the content of the T register from the N register circuit (i.e., register 98) and any carry, the result being left in the T register. The parameter stack S is popped.
The SWAP- and SWAP-c are, in effect, the same as the - and -c instructions, described above, except that the result is obtained by subtracting the [U] operand from the content of the T register. Referring to FIG. 10B, the OP-SELECT signal will cause the multiplexer 160 (Y n ), as well as the other multiplexers 160.
The OR, XOR, and AND perform the logical operations indicated, causing the necessary multiplexer selections to be made through the internal gating and command signals generated by the instruction decode unit 14.
The 2/ and 2* performs right and left shift operations, utilizing the multiplexers 162 (FIG. 10A). The 2/ instruction activates the R-SHIFT and CTL1 signals so that each of the multiplexers 162(Y 14 )-162(Y.sub..0.) to select its corresponding input 1. The MSB multiplexer, 162(Y 15 ), receives at its input 1 the N.sub..0. from the multiplexer 163. The 2* instruction activates the L-SHIFT and C-CTL signals to operate the multiplexers 162(Y.sub..0.)-162(Y 15 ) and 165 to effectively shift the content of the T register one bit to the left, with the MSB, N 15 of the N register being shifted into the LSB position of the N register.
The .0.< instruction functions to propagate the sign (i.e., the MSB) through the T register.
The D2/ and D2* instructions perform left and right 1-bit shifts of both the N and T registers as if there were combined 32-bit register with the T register forming the upper-most-significant sixteen bits. The left and right shifts of the T register are performed as described above with respect to the 2/ and 2* instructions. The shift of the N register is performed using the multiplexer 96 and feedback path from register 98. If a left shift is performed, the input 4 of the multiplexer 96 is selected by the N-CTL signal, effecting a 1-bit left shift of the content of the register 98, the CARRY being shifted into the LSB position. If a right shift is effected, the N-CTL signal affects selection of input 3 (at which the low-order fifteen bit positions of register 98 are communicated to the register 98 as the high-order fifteen bit positions combined with the T.sub..0. as the LSB).
The *!, *-, and *F multiply instructions utilize the T and N registers (FIGS. 6 and 9) together with the multiply/divide (MD) register 202 (FIG. 13). Before these instructions are used, however, data transfer instructions (discussed below) put the multiplier in the MD register 202, the multiplicand in the N register, and the T register is cleared. Execution of the multiply instruction, *!, causes the MD register 202 to be communicated, via the multiplexer 142 of the ALU 14 (where it appears as the input [MD]), and is applied to the arithmetic-logic circuitry 144 as the operand input [U] and added to the content of the T, if the LSB, N.sub..0., of the N register is a "1". Simultaneous with the prior described set up, the T and N registers are loaded with their content shifted one bit left.
The operation for the signed multiply step, *-, is identical, except that the content of the MD register 202 is subtracted from that of the T register if N.sub..0. is a "1". The fractional multiply step, *F, is identical to the signed multiply step, except that a left shift is performed.
The divide step, /', subtracts the content of the MD register from that of the T register. If the result of that subtraction is negative (which would be indicated by a carry from the arithmetic-logic circuit), the result is discarded, and the 32-bit combination formed by the T and N registers is shifted left one bit, with the CARRY signal being shifted into the LSB position of the N register. If the result is not negative, it is loaded, shifted one bit left, into the T register (along with the shift of the N register).
The multiply and divide steps are performed only once when encountered. Iterative operations utilize the TIMES indexing instruction (TABLE-IV) in a manner that will be described below, and in conjunction with the I register. The divide operation, however, requires special handling for the last step of the process and, therefore, there is provided the last divide step instruction, /". This instruction is essentially identical to the divide step instruction, /', except that execution does not terminate with any shift of the T register; only the N register is shifted one bit.
TABLE II______________________________________ARITHMETIC INSTRUCTIONS (COMBINED)OP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________104000 OVER + N + T; result in T; no stack operation104400 OVER +.sub.c N + T + carry; result in T; no stack operation102000 OVER - N - T; result in T102400 OVER -.sub.c N - T - carry; result in T106000 OVER SWAP - T - N106400 OVER SWAP -.sub.c T - N - carry103000 OVER OR T OR N105000 OVER XOR T XOR N101000 OVER AND T AND N______________________________________
The combined arithmetics instructions of TABLE II, above, are essentially identical to those discussed with respect to TABLE I except that, due to the design, certain instructions can be combined to be performed in one block cycle. Thus, for example, the OVER + combines the OVER and + instructions of TABLE I to cause the content of the registers N and T to be added and loaded into T. The content of the N register and remainder of the parameter stack S remain unchanged. Similarly, the OVER and +c adds the content of the N register to that of the T register with any carry, the result being retained by the T register. Again, the parameter stack S, including the content of the N register, are left undisturbed.
JUMP INSTRUCTIONS
Jumps from one memory location to another, primarily from subroutine calls and returns, which can often be deeply nested, are indigenous to the FORTH language. The microprocessor 10 of the present invention, together with the return stack R provides an optimized device for executing such memory jumps. TABLE III, below, lists the operation codes, mnemonics, and action taken for each of the five jump instructions.
TABLE III______________________________________JUMPSOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________0aaaaa :word Absolute Jump To Subroutine11aaaa IF Jump if T=.0.13aaaa ELSE Unconditional jump12aaaa - LOOP Jump if I≠.0.; decrement I0xxx4x ; Return______________________________________
The first four instructions, the :word, IF, ELSE, and -LOOP, all have the address of the memory location of main memory 12 to which the jump will occur embedded in the instruction itself (indicated, in the op code as aa . . . a).
Referring first to the :word instruction, two operations are required to be performed since this is a jump to a subroutine. First, the return path must be established; and, second, the jump address must be placed on the A-BUS to address the main memory 12 (FIG. 1). Thus, during the decoding and set up process of the clock cycle, the program counter P (or more specifically, the program register 62 contained therein) contains the address of the next sequential instruction that would be executed if no jump were performed. This address must be stored. Accordingly, the output [P] of the program register 62 is selected by the multiplexer 78 (FIG. 5) for application to the register 80 of the I register circuit. In turn, the output [L] of the latch 50 (FIG. 3) is selected by the multiplexer 60 (FIG. 4) for application to the A-BUS and to the program register 62, incremented by 1 by the adder 64. Thereby, a jump is made to the address of the subroutine, the next sequential address of the subroutine set in the program register 62, and the return address "pushed" onto the return stack R at the I register circuit, the 8-bit latches 126, 128 incrementing by 1 to automatically perform the push operation o the stack.
The return is executed by use of the ; instruction, which is bit six of the instruction word (the LSB being the first bit, the LSB+1 being the second bit, and so on), may be "embedded" in any other instruction to effect the return. Thus, every subroutine can end in any instruction, together with its sixth bit (which would normally be a ".0.") set to a "1" to simultaneously execute the last instruction and perform the return necessary.
The return is effected by communicating the output [I] of the register 80 of the I register circuit (which should contain the return address) to the A-BUS via the multiplexer 60 so that at the end of the decode/set up time, the parameter stack R is "popped" and the content of the memory location indicated by the output [I] is passed by the main memory port M to the instruction decode unit 14 and loaded in the latch 50.
The IF instruction perform a jump (to an address formed from the low-order twelve bits of [L] and the high-order four bits of the program register 62) after testing the T register for a .0.. Accordingly, the output T=.0. is coupled from the zero detect circuit 146 of the ALU (FIG. 9) to the instruction decode circuit 52 (FIG. 3) and utilized, in connection with the content of the latch 50 to determine whether or not a jump is to be effected. If the content of the T register is, in fact, .0., the jump is performed in the same manner as described with respect to the :word instruction. If not, the content of the program register 62 is coupled to the A-BUS.
The LOOP instruction utilizes the I=.0. generated by the zero test circuit 82 of the I register circuit (FIG. 5) in much the same manner as the IF instruction uses the T=.0. signal. If the I=.0. is not true, the jump is taken, and the register 80 is loaded with its prior content -1; that is, the content of the register 80 is decremented by 1 via the adder 84 and input 4 of the multiplexer 78.
The ELSE instruction is an unconditional jump. This instruction always causes the multiplexer 60 (4) to select the output [L] from the instruction decode unit 14 to be communicated to the A-BUS.
INDEXING INSTRUCTIONS
Certain iterative operations capable of being performed by the microprocessor and are set up by the four indexing instructions, which are listed below in TABLE IV. These instructions set an index into the register 80 of the I register circuit, which is ultimately used for keeping track of the number of iterations performed by repeatedly (each clock cycle) decrementing the register 80 until its content becomes .0..
TABLE IV______________________________________INDEXINGOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________147302 I I located in T, T pushed onto parameter stack147321 R> Pop return stack, push I onto parameter stack157201 >R Pop parameter stack, push T onto return stack157221 TIMES Repeat______________________________________
The I instruction pushes the content of the I register (i.e., the register 80 - FIG. 5) onto the parameter stack S. during decode and set up time of this instruction, the output [I] is coupled to the T register via the multiplexer 142 and arithmetic-logic circuit 144. It should be evident that in order to pass the output [I] to the T register, the multiplexers 160(Y.sub..0.)-160(Y 15 ) are set by the OP-SELECT signal to select only the U operand for communication to the bus line 154. In addition, the output [N] of the N register is pushed onto the parameter stack S, while the register 98 of the N register receives the output [T] of the T register.
The R> and >R instructions function to move data, through the ALU, between the return and parameter stacks R and S. The R> instruction moves data from the return memory 26, through the I register circuit, the ALU, and the N register circuit to the parameter memory 24. Its execution sees the following simultaneous operations: the content of the top memory location of return memory 26, as indicated by the content of the 8-bit latch 128 of the stack pointer J (FIG. 8) is read into the register 80 of the I register circuit (FIG. 5); the output [I] of the I register circuit is passed, via the multiplexer 142 and arithmetic-logic circuit 144, to and loaded into the T register; the output of the [T] of the T register is passed, via the multiplexer 96 (FIG. 6) to the register 98 of the N register, and loaded therein; and the output [N] of the N register is loaded into the next available memory location of parameter memory 24, as indicated by the 8-bit latch (not shown) of the stack pointer K corresponding to the 8-bit latch 126 of the stack pointer J.
The instruction >R performs essentially the same parameter move, except that data is moved from the parameter stack S through the ALU to the return memory 26.
The TIMES instruction causes the microprocessor 10 to begin iterative operation. At least one precondition must be met before the TIMES instruction can be used: the I register circuit must contain the index, i.e., the number (-2) indicative of the number of iterative steps desired. Following the TIMES instruction must be the instruction that is to be repetitively performed such as, for example, one of the multiply, divide, or square root instructions described above with reference to TABLE I (remember, these instructions are single-step only unless used with the TIMES instruction), or one of the data fetch or store instructions described below.
The index that is to be contained in the I register circuit is two less than the actual desired number of iterative steps. The reason for this will be seen in the following discussion of the iterative operation.
When the TIMES instruction is received and decoded by the instruction decode unit 14, a repeat flag or flip-flop (not shown) contained in the instruction decode circuit 52 is set, and one further access of main memory 12 is made to retrieve the next sequential instruction, which will be the one repetitively executed. Thus, the instruction following the TIMES instruction is loaded in the latch 50 of the instruction decode unit 14, and decoded; and execution begins. Each execution of the instruction terminates in a test of the I=.0. signal by the instruction decode circuit 52. If this signal is not true, the register 80 of the I register circuit is decremented in the manner described above and the instruction held in the latch 50 is executed again. When the I=.0. from the zero test circuit 82 of the I register circuit is finally true, the instruction has been executed the number of times indicated by the content of the register 80 when the iterative process began, plus 1 (this latter execution results from the fact that the test of I=.0. is performed after instruction execution). When the next CLOCK (and the CLK signal derived therefrom) is received, the repeat flag (not shown) contained in the instruction decode circuit 52 of the instruction decode unit 14 is reset, but the instruction is executed one additional time.
DATA TRANSFER INSTRUCTIONS
The data transfer instructions concern data transfers between the microprocessor 10 and the main memory 12, the I/O port 30 and any external element connected thereto, and between various internal registers of the microprocessor. To a certain extent, the indexing instructions may be considered data transfer instructions, since they also concern transfers between the parameter and return stacks. However, their main focus is the content of the I register circuit (for subsequent iterative instruction execution using the TIMES instruction) and, to a lesser extent, the T register of the ALU.
The category of data transfer instructions include instructions that contain the data to be transferred; instructions that contain the address of the main memory location 12 at which the data to be transferred resides; instructions that infer a memory location address; and instructions capable of utilizing the 5-bit X-BUS in an extended address operation.
TABLE V______________________________________SHORT LITERAL FETCHOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________1575nn nn nn located in T; T pushed onto parameter stack1544nn nn + nn + T loaded in T1546nn nn +.sub.c nn + T + carry loaded in T1524nn nn - T - nn loaded in T1526nn nn -.sub.c T - nn + carry loaded in T1564nn nn SWAP - N - nn loaded in T1566nn nn SWAP -.sub.c N - nn + carry load in T1534nn nn OR T OR nn loaded in T1554nn nn XOR T XOR nn loaded in T1514nn nn AND T AND nn loaded in T______________________________________
TABLE VI______________________________________FULL LITERAL FETCHOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________147500 n Data from memory loaded in T; T pushed onto parameter stack144400 n+ Data from memory + T loaded in144600 n+.sub.c Data from memory + T + carry loaded in T142400 n- T - data from memory located in T142600 n-.sub.c T - data from memory + carry loaded in T146400 n SWAP - N - data from memory loaded in146600 n SWAP -.sub.c N - data from memory + carry loaded in T143400 n OR T OR data from memory loaded in T145400 n XOR T XOR data from memory loaded in T141400 n AND T AND data from memory loaded in T______________________________________
Set forth above, in TABLES V and VI are those instructions involving data transfers to a location within the microprocessor 10. The Short Literal Fetch instructions load or leave a result in the T register and either push the previous content of the register onto the parameter stack or pop the stack. Thus, the nn instruction causes the instruction decode circuit 52 to output the five bits embedded in the instruction as [SL] which are applied to the input 1 of the multiplexer 142 of the ALU. The ALU-CTL signal transfers the [SL] to the operand input 144b of the arithmetic-logic circuit 144 as a 16-bit data word: the lower five bits being nn (i.e., [SL]), and eleven high-order bits of zeros. At the same time, the content of the T register is pushed onto the parameter stack (i.e., the content of the T register is loaded in the register 80 of the I register circuit, and the content of register 80 is stored in the next available memory location, as indicated by the 8-bit latch of the K stack pointer corresponding to the 8-bit latch 128 of the J stack pointer, and the K stack pointer incremented 1).
The nn + instruction causes the sum of [SL] (i.e., the five bits of nn) and the content of the T register are loaded in the T register.
The nn + c , nn-, and nn- c are similar to nn instruction except that where the c is shown, it is summed with either the sum or difference of the content of the T register and the 5-bit [SL].
The nn OR, nn XOR, and nn AND instructions perform the logical operations indicated between [SL] and T, loading the result in the T register.
The Full Literal Fetch instructions (TABLE VI, above) involve a data transfer directly from the main memory 12 to the microprocessor 10. Thus, for example, the n instruction will cause the content of the accessed memory location to be pushed onto the parameter stack S at the N register circuit (i.e., the register 80 (FIG. 5)). The second cycle of the execution of this instruction "swaps" the content of the T register and register 98 so that the end of the execution of this two-cycle operation finds the T register containing the accessed data and the register 98 containing the prior 98 content of the T register, and the prior content of the register 98 has been pushed onto the parameter stack S.
To amplify execution of this instruction: Referring to FIG. 12A, assume that the instruction is latched in the latch 50 at the time indicated as T 3 of the CLOCK (i.e., CLK) signal. During the decode time T 4 the instruction is decoded, the program counter P (FIG. 1) incremented, and the address of the next sequential memory location, which contains the data desired, is communicated via the multiplexer A and the A-BUS to the main memory 12. In response, the data contained in the memory location designated by the applied address will be put on the data bus 13, passed by the main memory port M, and applied, as [M] to the N register, and communicated via the multiplexer 96 to the register 98. At the next clock pulse, i.e., at the time T 5 (FIG. 12A), the desired parameter is loaded in the register 98. Also, at time T 5 , the CLK signal to the latch 50 is inhibited by the EN-CLK signal; the latch 50, therefore, retains the n instruction. The instruction decode circuit 52 continues the decode cycle, issuing those internal gating and command signals necessary to cause the output [N] of the N register to be conducted to the operand input 144b of the arithmetic-logic circuit 144 via the multiplexer 142 to be added with the content of the T register. At the time indicated as T 6 , the output [N] of the N register circuit is loaded into T.
The remaining instructions are similar, and self-explanatory to a certain extent, except that they do not involve, in effect, a push of the parameter stack S. For example, the n+ c instruction adds the data fetched from memory to the T register with the carry. The n- instruction subtracts the data fetched from memory from the content of the T register and loads the content in the T register; and the n- c instruction is the same with the addition of a carry. The SWAP-Full Literal Fetch instructions logically swap the content of the n and T registers before the memory access is performed so that the parameter is then subtracted from the T register. The logical functions OR, XOR, and AND logically combine the data fetched from memory with the content of the T register and store the result in the T register.
Listed below are the Data Fetch (TABLE VII) fetch data from the main memory 12 using, as a memory location address, the content of the T register. Thus, for example, the 7/8 instruction causes the output [T] of the T register to be communicated to the A-BUS via the multiplexer 60 (FIG. 4) during the first clock cycle of this two-cycle instruction. The addressed memory location of the main memory 12 is communicated via the DATA BUS 13, the main memory port M, applied to the multiplexer 96 of the N register (FIG. 6) as the output [M] of the main memory port M and, at the end of the first cycle, loaded in the register 98--simultaneous with a push of the prior content of the register 98 onto the parameter stack S. T and N are swapped during the second cycle.
TABLE VII______________________________________DATA FETCHOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________167100 @ Data fetched from memory and stored in N164000 @ + Data fetched, stored in N, data + T stored in T164200 @ +.sub.c Data fetched, stored in N, data + T + carry stored in T162000 @ - Data fetched, stored in N, T - data stored in T162200 @ -.sub.c Data fetched, stored in N, T - data + carry stored in T166000 @ SWAP - Data fetched, stored in N, data - T stored in T166200 @ SWAP -.sub.c Data fetched, stored in N, data - T + carry stored in T163000 @ OR Data OR T stored in T165000 @ XOR Data XOR T stored in T161000 @ AND Data AND T stored in T1647nn DUP @ SWAP nn +1627nn DUP @ SWAP nn-______________________________________
The @+, @+ c , @-, @- c , @ SWAP -, @ SWAP - c , @ OR, @ XOR, and @ AND instructions operate essentially the same as the @ instruction insofar as memory fetches are concerned (i.e., the address being derived from the content of the T register), and their execution is as indicated in TABLE VII, above. The DUP @ SWAP nn + and DUP @ SWAP nn - require further discussion.
The DUP @ SWAP nn + instruction: the end result of this instruction is to push the content of the memory location addressed by the content of the T register onto the parameter stack S at the N register circuit, and increment the content of the T register by nn. The DUP @ SWAP nn - results in the identical operation, except that the content of the T register is decremented by nn. These two instructions, when used in combination with the TIMES instruction, permits block moment of data from one memory space to another.
TABLE VIII______________________________________EXTENDED ADDRESS DATA FETCHOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________1675nn nn X@ Data fetch from memory and stored in N1644nn nn X@ + Data fetched, stored in N, data + T stored in T1646nn nn X@ +.sub.c Data fetched, stored in N, data + T + carry stored in T1624nn nn X@ - Data fetched, stored in N, T - data stored in T1626nn nn X@ -.sub.c Data fetched, stored in N, T - data + carry stored in T1664nn nn X@ SWAP - Data fetched, stored in N, data - T stored in T1666nn nn X@ SWAP -.sub.c Data fetched, stored in N, data - T + carry stored in T1634nn nn X@ OR Data OR T stored in T1654nn nn X@ XOR Data XOR T stored in T1614nn nn X@ AND Data XOR T stored in T______________________________________
The extended address data fetch instruction (TABLE VIII, above) perform the same as their counterparts in the Data Fetch instruction set, except that there is an extended addressing capability. Embedded in the instruction is the parameter nn. This (5-bit) parameter, when the instruction is decoded, issues from the instruction decode circuit 52 as the output [SL] and conducted to the X-BUS of the I/O port 30 (FIG. 1) via the OR gate 230. At the same time, the instruction decode circuit 52 ensures that the X-EN signal is disabled (i.e., a logic LOW, to disable the AND gate 238). Thus, the Extended Address Data Fetches function to override the content of the X-REGISTER 208. Although not specifically shown, the X-BUS is capable of being connected to the main memory 12 and used to access one of a possible thirty-two, 64 KiloByte word memory. The accessed data is, in the case of the nn X@ instruction, loaded in the T register or, in the case of the instructions combine arithmetic/logic operations, the result is loaded in the T register.
TABLE IX______________________________________LOCAL DATA FETCHOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________1411nn nn @ Data fetched from memory location nn, stored in N1420nn nn @ + Data in N, data + T stored in1422nn nn @ +.sub.c Data stored in N, data + T + carry stored in T1440nn nn @ - Data stored in N, T - data stored in T1442nn nn @ -.sub.c Data stored in N, T - data + carry stored in T1460nn nn @ SWAP - Data stored in N, data - T stored in T1462nn nn @ SWAP -.sub.c Data stored in N, data - T + carry stored in T1430nn nn @ OR Data OR T stored in T1450nn nn @ XOR Data XOR T stored in T1470nn nn @ AND Data AND T stored in T______________________________________
Local Data Fetch instructions are identical to their counterparts of the Data Fetch and Extended Addressed Data Fetch instructions, insofar as the fetch and operation are concerned. The difference being that the Local Data Fetch instruction each carry with them a 5l-bit address that designates the memory location from which the data will be obtained. Thus, execution of each Local Data Fetch instruction will cause the instruction decode circuit 52 to issue the nn portion of the instruction as the [SL] output and apply to the input of the multiplexer 60 (FIG. 4). The A-CTL signal is activated to select input 1 of the multiplexer 60, communicating [SL] to the A-BUS. The remainder of the operation of the instruction is the same as the @ and nn X@ instructions.
TABLE X______________________________________INTERNAL DATA FETCHOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________1413nn nn I@ Content of internal register nn, [nn], pushed onto stack at1427nn nn I@ + [nn] + T loaded in T1447nn nn I@ - T - [nn] loaded in T1467nn nn I@ SWAP - [nn] -T loaded in T1437nn nn I@ OR [nn] OR T loaded in T1457nn nn I@ XOR [nn] XOR T loaded in T1477nn nn I@ AND [nn]AND T loaded in T1423nn DUP nn I@ + [nn] pushed onto parameter stacks; [nn] + T loaded in T1443nn DUP nn I@ -1463nn DUP nn I@ SWAP -1433nn DUP nn I@ OR1453nn DUP nn I@ XOR1473nn DUP nn I@ AND______________________________________
STORE INSTRUCTIONS
The instructions that transfer data to the main memory 12 are listed in TABLE XI and XII. These instructions form a memory address from the content of the T register (TABLE XI) or from the instruction itself (TABLE X). In the latter case, the 32 pages of 64K words of memory are available.
TABLE XI______________________________________DATA STOREOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________171000 ! N stored at address from T; S popped twice171100 DUP ! N stored at address from T; S popped once1727nn SWAP OVER ! nn + N stored at address from T; nn + T stored in T; S popped1747nn SWAP OVER ! nn - N stored at address from T; T - nn stored in T; S popped______________________________________
TABLE XII______________________________________EXTENDED ADDRESS DATA STOREOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________1714nn nn X! N stored at address from T; nn applied to X-BUS; S popped twice1715nn DUP nn X! N stored at address from T; nn applied to X-BUS; S popped once______________________________________
TABLE XIII, below, lists those instructions that transfer the data to the lower 32 memory locations of the current gate of memory (that page indicated by the content of the X register). TABLE XIV lists instructions that transfer data from the T register to the other internal registers of the microprocessor 10. In TABLE X nn (in octal) refers to:
______________________________________nn (octal) Destination______________________________________00 J/K stack pointers01 I Register Circuit02 Program Counter P04 MD Register06 SR Register10 B Register14 X Register______________________________________
TABLE XIII______________________________________LOCAL DATA STOREOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________1570nn nn ! Store T at memory location nn1571nn DUP nn ! Non-destructive store to memory location nn1540nn DUP nn ! + Store T at nn; store T + N in T and pop S1560nn DUP nn ! - Store T at nn; store N - T in T; pop S1520nn DUP nn ! SWAP - Store T at nn; store T - N in T; pop S1530nn DUP nn ! OR Store T at nn; store T OR N in T; pop S1550nn DUP nn ! XOR Store T at nn; store T XOR N in T; pop S1510nn DUP nn ! AND Store T at nn; store T AND N in T; pop S______________________________________
TABLE XIV______________________________________INTERNAL DATA STOREOP CODE INSTRUCTION(OCTAL) MNEMONIC ACTION______________________________________1512nn nn I! T stored at register nn; stack S popped into T1503nn DUP nn I! T stored at register nn1522nn DUP nn I! + T stored at register nn; N + T stored in T; stack S popped into N1562nn DUP nn I! - T stored at register nn; N - T stored in T; stack S popped into N1542nn DUP nn I! SWAP - T stored at register nn; T - N stored in T; stack S popped into N1532nn DUP nn I! OR T stored at register nn; N OR T stored in T; stack S popped into N1552nn DUP nn I! XOR T stored at register nn; N XOR T stored in T; stack S popped into N1572nn DUP nn I! AND T stored at register nn; N AND T stored in T; stack S popped into N1577nn nn I@! Swap content of T and content of register nn with one another______________________________________
Attached hereto as Appendix A is a FORTH program listing of an emulation of the microprocessor 10, prepared for DEC PDP/11 computer. This listing or source code was used to validate the design and, in particular, includes the instruction unit decodes of the instruction set of the microprocessor. The listing includes 24 program blocks numbered 128 to 143 (the first nine blocks of code are for testing). Attached as Appendix B are comment blocks 159-173, each respectively corresponding to the program blocks 129-143, each describing, in a line-by-line basis, the intent of the program. ##SPC1##
|
A language specific microprocessor for the computer language known as FORTH is disclosed. The microprocessor includes four main registers each for holding a parameter; a L or instruction latch register for decoding instructions and activating microprocessor operation; an I or return index register for tracking returns; an N or next parameter register for operation with an arithmetic logic unit (ALU); and a T or top of parameter stack register with an appended ALU. A return stack port is connected to the I register and a parameter stack port is connected to the N register circuit, each have last in/first out (LIFO) memory stacks for reads and writes to isolated independent memory islands that are external to the microprocessor. The respective I, T and N registers are connected in respective series by paired bus connections for swapping parameters between adjacent registers. A first split 16 bit multiplexer J/K controls the LIFO stack for the I and N registers on paired 8 bit address stacks; a second 16 bit multiplexer designates the pointer to main memory with 65K addresses and an adjoining 65K for data. This addressing multiplexer receives selective input from a program counter P, the return index register I, the top of the parameter stack T and/or the instruction latch L. Movement to subroutine is handled in a single cycle with returns being handled at the end of any designated cycle. Asynchronous microprocessor operation is provided with the address multiplexer being simultaneously set up with an address to a future machine step, unloading from memory of appropriate data or instruction for the next machine step and asynchronously executing the current machine step. A two-phase clock latches data as valid on a rising edge and moves to a new memory location on a falling edge. This two phase clock is given a pulse width sufficient for all asynchronous cycles of microprocessor operations to settle. The microprocessor's assembler language is FORTH and the stack and main memory port architecture uniquely complements FORTH to produce a small (17,000 gates) fast (40 mips) microprocess or operable on extant FORTH programs. Provision is made for an additional G port which enables the current operating state of the microprocesor to be mapped, addressing of up to 21 bits as well as the ability to operate the microprocessor in tandem with similar microprocessors.
| 6
|
FIELD OF THE INVENTION
The field of the invention relates to devices for disconnection downhole, more specifically oriented toward wireline applications.
BACKGROUND OF THE INVENTION
During oilfield operations, tubing or wireline or electric line can be used to place a wide variety of downhole tools in a wellbore. A disconnect mechanism is necessary should the equipment being run into the well become stuck. While a tubing string can withstand substantially higher extraction forces than wireline or electric line, many times operators prefer to run wireline because it saves substantial rig time in getting the downhole tools positioned properly in the wellbore. In the past, disconnect mechanisms have been provided which primarily rely on shear pins. Since wireline or electric line has fairly low tensile capabilities with respect to a tubing string, the shear screw or screws used in the prior art had to be set at a fairly low shear rating. The low shear rating was necessary to prevent damage to the wireline or electric line from excessive tensile stress should the downhole tool become stuck in the wellbore.
However, problems have been encountered using a shear screw or screws that have a low failure point. During normal operation, the shear screws are exposed to various cyclical forces which tend to affect their ultimate shear rating. The shear screws are also exposed to the fluids in the wellbore which also over time can affect the inherent strength of the shear screws or pins, making them susceptible to failure at stresses below their rated failure point. Unexpected release can significantly delay operations, thereby costing the well operator significant sums due to the delays incurred. Unexpected release of a release mechanism can also result in loss of the downhole tool in the wellbore and in extreme cases can cause severe damage to the wellbore, which requires substantial time and money to repair.
It has long been desired in wireline or slickline applications to have a release mechanism that will predictably release with a known preset force. Such a release mechanism would ideally be able to provide numerous cycles of operation, with reliability of performance so that premature release would not occur. One of the objects of the present invention is to provide a simple, easy-to-construct release mechanism which will operate reliably at a desired release force. Another object of the present invention is to provide a simply constructed release mechanism which is so configured as to be substantially unaffected by the wellbore conditions or prior cycles of loading. Another object of the invention is to provide a simply constructed release mechanism which can be easily reused without significant disassembly and reassembly.
SUMMARY OF THE INVENTION
A wireline pull disconnect is enclosed which operates using a system of trapped collets. The collets are releasable by a pulling force which is resisted by one or more Belleville washers. Upon the exertion of a predetermined force which will flatten the Belleville washers, sufficient movement of the components of the pull disconnect occurs so that the collets become liberated and disconnection is effected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional elevational view of one of the embodiments of the present invention, showing the collets in the trap position.
FIG. 2 is the view of FIG. 1, showing the wireline pull disconnect assembly with a pulling force applied and the collets about to be released.
FIG. 3 is the view of FIGS. 1 and 2, with the collets fully released.
FIG. 4 is a sectional elevational view of an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus A is shown in FIG. 1 in the run-in position. The apparatus A has a mandrel 10, with a connection 12 to accommodate a wireline or electric line in a known manner. The mandrel 10 extends longitudinally into an inner sleeve segment 14. Inner sleeve 14 forms a shoulder 16. Attached to mandrel 10, preferably by a threaded connection, is outer sleeve 18. Outer sleeve 18 has a raised surface 20. Located between inner sleeve 14 and outer sleeve 18 is collet ring 22, which has a plurality of collet heads 24. In the run-in position shown in FIG. 1, collet heads 24 are trapped in recess 26 of lower housing 28 by virtue of raised surface 20 abutting collet heads 24.
Inner sleeve 14 is movable with respect to lower housing 28. The interface between inner sleeve 14 and lower housing 28 is sealed off by seal 30. Also connected to inner sleeve 14 is ring 32, which is preferably threaded to inner sleeve 14, with set screw 34 holding the threaded connection. Above ring 32 is a plurality of Belleville washers 36. The Belleville washers 36 are disposed between ring 32 and collet ring 22. The Belleville washers 36 bear on surface 38 of collet ring 22. In the preferred embodiment, a plurality of Belleville washers 36 are stacked up. The washers can be preselected so that a predetermined applied force will be necessary in order to initiate movement of mandrel 10 and, in conjunction with it, outer sleeve 18. Preferably, washers that require a force of about 1400 lbs. applied at the surface to the wireline can be selected. The washers can be arranged in series, opposing each other or in parallel, arranged in the same direction. When in series, the force to deform them all is unaffected by the number in the stack. When in parallel, the force required to flatten the washers increases with the addition of each washer. The number of washers 36 in the stack can be predetermined on the basis of the amount of travel desired for raised surface 20. The initial position of raised surface 20 with respect to collet heads 24 can be adjusted since there is a threaded connection between outer sleeve 18 and mandrel 10. Depending on the degree that the threaded joint between outer sleeve 18 and mandrel 10 is made up, the initial position of raised surface 20 will vary. Those skilled in the art will appreciate that the necessary distance that raised surface 20 must be moved to release the collet heads 24 will also vary, depending upon the final make-up of the threaded joint between outer sleeve 18 and mandrel 10. While a threaded joint is illustrated for the connection between outer sleeve 18 and mandrel 10, other types of connections that allow for variability of placement of the components connected is within the scope of the invention. Since in the preferred embodiment the Belleville washers 36 are in a vertical stack, the number of washers does not alter the required force to get mandrel 10 moving. Those skilled in the art will appreciate that when lower housing 28 becomes stuck in the wellbore by virtue of its attachment to a stuck downhole tool, the procedure as illustrated allows disconnection of the mandrel 10 from lower housing 28.
The disconnection is illustrated by comparing FIG. 1 to FIGS. 2 and 3. In FIG. 2, the raised surface 20 has been elevated and the Belleville washers 36 have begun to be compressed. The collet heads 24 are no longer trapped by raised surface 20 and can be ramped radially outwardly on tapered surface 40. As can be seen by comparing FIG. 1 to FIG. 2, the Belleville washers 36 have been compressed to allow mandrel 10 to move upwardly. The compression actually occurs when ring 32 shifts upwardly while collet ring 22 is held in position until the collet heads 24 are disengaged from groove or recess 26. Once the collet heads 24 are released, the force compressing Belleville washers 36 is released, and the stack of Belleville washers 36 relaxes to the position shown in FIG. 3. At that time, the collet heads 24 have cleared recess 26, and mandrel 10 can be lifted away from lower housing 28.
FIG. 4 illustrates an alternative embodiment which operates similarly in principle but has a different layout of the components. The embodiment shown in FIG. 4 does not have the adjustability feature for its outer sleeve, as will be described below. The apparatus A shown in FIG. 4 has mandrel 42 to which a wireline or electric line can be attached (not shown). The mandrel 42 has an extension segment which forms an inner sleeve 44. Ring 46 is threadedly connected to sleeve 44. Ring 46 has a longitudinal extension segment 48. Outer sleeve 50 is threadedly connected to ring 66 at thread 52. Lower housing 54 is at the bottom of the assembly and, when it comes time for the assembly A to operate, is the component that is stuck in the wellbore by virtue of its attachment to a stuck downhole tool. Mounted to lower housing 54 is collet ring 56, which has a plurality of collet heads 58. The collet heads 58 are trapped in recess 60 in the run-in position shown in FIG. 4. Extension segment 48 holds collet heads 58 trapped in recess 60. A plurality of Belleville washers 62 are stacked between inner sleeve 44 and outer sleeve 50. The quantity of washers used can be varied without departing from the spirit of the invention. Different ranges of motion of extension segment 48 will necessitate varying amounts of washers 62 in the stack. The washers preferably are selected to have a force requirement on the wireline (not shown) of approximately 1400 lbs. to flatten them. Other force ranges or settings can be used. Therefore, a 1400-lb. force applied to washers 62 through ring 46 will result in compaction of the washer stack 62 to allow mandrel 42 to come up and with it bring up extension segment 48. Once extension segment 48 moves up sufficiently to be clear of collet heads 58, the collet heads 58 become liberated from recess 60. The upward force exerted on mandrel 42 is transmitted to the washer stack 62 through ring 46. When collet heads 58 are no longer trapped in recess 60, the mandrel 42 is clear to separate from lower housing 54, and bring with it outer sleeve 50 with collet ring 56. It should be noted that collet ring 56 is threadedly connected to outer sleeve 50 at thread 64. Thread 52 connects outer sleeve 50 to ring 66.
To make the apparatus A shown in FIG. 4 release, an upward force is put on mandrel 42. The upward force on mandrel 42 translates into upward motion of ring 46, which tends to compress the Belleville washers 62 against ring 66. Ring 66 can't move until extension segment 48 liberates collet heads 58. As ring 46 comes up, extension segment 48 comes up as well. Ring 66 is then liberated and, by virtue of ring 46 and washers 62, comes up with mandrel 42. This lifts the collet heads 58 clear of recess 60.
The apparatus A of the present invention has numerous advantages over the prior designs which use shear pins. It can be reused without component replacement or complete disassembly. The performance of the washers 62 is predictable and reliable through many cycles. Exposure to downhole fluids does not significantly vary the force required to flatten the washers 62 and, hence, accomplish the release. The doubts and uncertainties of the prior designs' releasing prematurely are substantially eliminated with the apparatus of the present invention. Shear pins have proven to be less than reliable when the set force for release is at or near 1400 lbs. or less. The apparatus is simple to construct and does not require significant time in disassembly as was required in prior shear pin designs. The washers absorb shock and are, therefore, less affected by such loading as shear pins. Shear pins tend to fail at lower stress when subjected to cyclic loading.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention.
|
A wireline pull disconnect is enclosed which operates using a system of trapped collets. The collets are releasable by a pulling force which is resisted by one or more Belleville washers. Upon the exertion of a predetermined force which will flatten the Belleville washers, sufficient movement of the components of the pull disconnect occurs so that the collets become liberated and disconnection is effected.
| 4
|
FIELD OF THE INVENTION
[0001] The present invention relates to thermoplastic vulcanizates (also referred to as thermoplastic elastomers) including thermoplastic vulcanizates derived from diene or diene/vinylaromatic rubbers and elastomer blends comprising diene or diene/vinylaromatic rubbers.
BACKGROUND OF THE INVENTION
[0002] Thermoplastic vulcanizates (“TPVs”) are a fine dispersion of highly vulcanized rubber in a continuous phase of a polyolefin. TPVs are traditionally made by blending a rubber with a semi-crystalline polyolefin under conditions that allow for the dynamic vulcanization of the rubber. The result is a material comprised of a continuous plastic phase formed by the polyolefin and interspersed with discrete, crosslinked rubber particles, which form a rubber phase. TPVs have the benefit of the elastomeric properties provided by the rubber phase, with the thermoreversible processability of thermoplastics.
[0003] Products manufactured from TPVs are used in a variety of exterior applications. Such products may include weather-stripping, pipe seals, couplings, O-rings, mats, grips, gaskets, and a variety of building and vehicle seals and gaskets, including but not limited to hood-to-radiator seals, rocker panels, hood-to-cowl seals, cowl seals, windshield seals, sunroof seals, roof line seals, window seals, trunk and tailgate seals, quarterlight seals, cutline seals, door seals, glass channels, vehicle moldings, belt line seals, and mirror gaskets. In exterior applications, exposure to the weather, including ozone, ultraviolet (LV) radiation, and temperature and humidity variations, can materially alter the physical properties of the TPVs resulting in both aesthetic degradation and physical degradation of the product. Aesthetic degradation may materialize as discoloration; for example, the graying of a black article. Physical degradation may emerge as brittleness and increased hardness. Physical degradation can have a materially negative impact on the ability of a product to perform satisfactorily.
[0004] In many exterior applications, selection of a suitable TPV may depend less on its absolute physical properties; namely its compression set, tensile strength, color, hardness, elongation, and the like, and more on TPV's ability to retain its physical properties upon exposure to weather, including Uw radiation. For example, it may be preferable to select a TPV that better retains its tensile strength upon weathering over a TPV that has a better absolute tensile strength, but retains less of its tensile strength, proportionately, upon exposure to UV radiation. Retention of physical properties through weathering cycles is, therefore, a valuable characteristic in TPV selection, even apart from the values of the underlying physical properties.
[0005] One characteristic that is known to be related to rubber's susceptibility to weathering, and particularly UV degradation, is the degree of saturation in the rubber. Highly saturated rubbers, such as ethylene propylene diene monomer (EPDM) rubber, demonstrate better resistance to both UV degradation and ozone as measured by the retention of physical properties following exposure, than more unsaturated rubbers such as styrene butadiene (SB) rubber. See, R UBBER T ECHNOLOGY H ANDBOOK 164 (Hafrnann, W., Hanser/Gardner Publications, Inc., Cincinnati, Ohio, 1994). This effect is seen in both thermoset rubbers as well as TPVs. As a result, it is generally believed preferable to use highly saturated rubbers, such as EPDM rubber in exterior applications where exposure to UV radiation creates a risk of adversely affecting material properties. Thus, the seals and gaskets described above are known to be manufactured using TPVs having EPDM rubber as the primary rubber. Despite its increased susceptibility to UV degradation, SB rubber is traditionally more inexpensive than EPDM rubber and demonstrates better processability (reduced viscosity and melt pressure). For these reasons, it would be preferable in many instances to use SB rubber as the rubber component in TPVs in order to reduce material cost and increase processability.
[0006] In manufacturing TPV based articles for exterior applications, compounders must select between rubbers having such variations in weatherability, processability, and cost, amongst other factors. Given the lower cost and generally better inherent processability of SB rubber, it would be beneficial to find ways to improve the UV resistance of SB rubber, over EPDM rubber, so that SB rubber could be incorporated into TPVs for exterior applications, in place of EPDM rubber, thus resulting in lower cost articles.
[0007] In traditional thermoset rubber compounding, it is known to add carbon black as a way of improving rubber weatherability and adding bulk. See, 2 E NCYCLOPEDIA OF P OLYMER S CIENCE AND E NGINEERING 633 (Kroschwitz, J. I., John Wiley and Sons, New York, N.Y., 1985). When present, carbon black absorbs UV radiation and disperses the radiation as heat, resulting in less damage to the rubber. The addition of carbon black, however, reduces processability by increasing viscosity. In TPVs, it is expected that carbon black would impart similar UV resistance to comparable thermoset rubber counterparts. It would also be expected, however, that the addition of carbon black would impart at least comparable improvement in UV resistance in EPDM rubber over SB rubber and that the overall combination of EPDM rubber with carbon black would still exhibit better overall UV resistance than SB rubber with carbon black, given the initial lower initial susceptibility of EPDM rubber to UV radiation as compared to SB rubber. Thus, the wide relative difference in UV resistance between SB rubber and EPDM rubber, in the absence of carbon black, would be expected to remain upon the addition of carbon black. UV resistance may be quantified, for purposes of comparison between TPVs, by measuring the retention of selected physical properties in TPVs after a period of exposure to UV radiation. Those physical properties may include hardness, elongation, tensile strength and color.
[0008] The present invention demonstrates that the addition of carbon black to SB rubber imparts to SB rubber based TPV's a relatively higher improvement in UV resistance, as evidenced by measuring the retention of physical properties; including tensile strength and elongation after exposure to UV radiation. As a result, the UV resistance of SB rubber based TPVs with carbon black is made comparable to the level of UV resistance found in EPDM based TPVs comprising comparable amounts of carbon black, and additionally, carbon black affords superior color-fastness to the SB rubber based TPV. As a result, by the addition of carbon black, lower cost, better processing SB rubber may be more suitable than EPDM rubber for use in TPVs for exterior applications where retention of physical properties is desirable.
[0009] The use of processing agents, most notably paraffinic oil, naphthenic oil, and aromatic process oils, to aid in the processability of TPV compositions is well documented (for example in U.S. Pat. No. 6,667,364). Such processing oils reduce viscosity during blending of the plastic and rubber TPV constituents, thus aiding the dispersion of the rubber phase in the continuous plastic phase. Further, the processing oils may be absorbed in the rubber phase of the TPV, thereby increasing the volume of material. By increasing the volume of material using relatively low cost processing oils, overall cost can be reduced. In many instances, it may be preferable to substantially saturate the TPV with processing oil in order to maximize volume and processability. However, over-saturation of the TPV with processing oil can result in oil bleed and reduction in physical properties of the rubber. It would be advantageous, therefore, to be able to determine the amount of processing oil to add in order to achieve substantial saturation of the TPV without oil bleed. Determining the optimal maximum amount of processing oil to add can prove problematic since many TPV components, particularly the elastomer components contain processing agents. The present invention discloses means for maximizing the volume of processing agents in diene and diene/vinylaromatic rubber based TPVs, including SB rubber based TPVs.
SUMMARY OF THE INVENTION
[0010] According to one aspect of the invention, there is taught a method of producing a low cost, highly weatherable TPV; namely a TPV having good colorfastness (ΔE<3.0) and UV resistance as measured by the retention of selected physical properties following an amount of UV radiation exposure. The method may include selecting from 80% by weight to 20% by weight of the total amount of plastic plus elastomer in the TPV of a conjugated diene elastomer or unsaturated styrenic triblock copolymer having a conjugated diene rubber midblock. These are collectively referred to herein as conjugated diene rubbers. Exemplary conjugated diene rubbers may include styrene butadiene rubber, polybutadiene rubber, polyisoprene rubber, styrene/butadiene/styrene (SBS) rubber, styrene/isoprene/styrene (SIS) rubber, and blends thereof. The method may further include selecting from 20% by weight to 80% by weight of a polyolefin of the total amount of plastic plus elastomer in the TPV. Exemplary suitable polyolefins may include polyethylene, isotactic poly(1-butene), or polypropylene. The polypropylene may be isotactic or syndiotactic polypropylene. The method may additionally include selecting an amount of carbon black from 1 parts per hundred rubber (phr) to 50 phr, preferably from 5 to 50 phr, and most preferably from 20 to 50 phr, and still more preferably 40 to 50 phr, blending the elastomer and the polyolefin and blending the carbon black into at least the elastomer. The carbon black is selected and blended into at least the elastomer to improve a physical property of the thermoplastic vulcanizate, which may be colorfastness or UV resistance. The suitable amount of carbon black may be added to generate a level of UV resistance that is comparable to a TPV comprising the same amount of the polyolefin and carbon black, with EPDM rubber as the elastomer.
[0011] According to another aspect of the invention, the elastomer of the low cost, highly weatherable TPV may include at least 50% by weight, and preferably from 55% to 95% by weight, and most preferably from 60% to 75% by weight of the total elastomer a conjugated diene rubber. In another embodiment, the conjugated diene rubber may comprise as high as 99.9% by weight of the total elastomer. Exemplary conjugated diene rubbers may include styrene butadiene rubber, polybutadiene rubber, polyisoprene rubber, SIS rubber, SBS rubber and blends thereof.
[0012] According to still another aspect of the invention, the elastomer of the low cost, highly weatherable TPV may include from 0.1% to less than 50% by weight, and preferably from 5% to 45% by weight and most preferably from 25% to 40% by weight of a saturated carbon backbone rubber. Exemplary saturated carbon backbone rubbers may include EPM rubber, EPDM rubber, and rubbers selected from the class of styrenic triblock copolymers having substantially saturated backbones (defined below as SBC rubbers and explicitly distinct from unsaturated styrenic triblock copolymer rubbers such as SIS and SBS rubber). An exemplary SBC rubber is styrene/ethylene-butene/styrene triblock copolymer rubber (SEBS rubber).
[0013] According to another aspect of the invention, the polyolefin of the low cost, highly weatherable TPV may be polyethylene, isotactic poly(1-butene), or polypropylene. The polypropylene may be isotactic or syndiotactic polypropylene.
[0014] According to another embodiment of the invention, the elastomer of the low cost, highly weatherable TPV may comprise from at least 50% to 99%, and preferably from 55% to 95% and still more preferably from 60% to 75% by weight of styrene butadiene rubber and from 1% to 50% and preferably from 25% to 45% and still more preferably from 25% to 40% of EPDM rubber.
[0015] According to still another embodiment of the invention, the elastomer of the low cost, highly weatherable TPV may consist essentially of styrene butadiene rubber.
[0016] According to another aspect of the invention, the amount of the carbon black selected for use in the low cost, highly weatherable TPV may be selected to improve retention of a physical characteristics of the TPV following exposure of the TPV to UV radiation. Physical characteristics may include colorfastness, hardness, elongation, and tensile strength. In a preferred embodiment, the colorfastness of the TPVs according to the present invention (ΔE based on the Hunter Lab scale after 2500 kJ of UV exposure (“the Exposure”)) is less than 2.0 and preferably less than 1.7 and in still a more preferred embodiment, less than 1.0. In one embodiment, the tensile strength (psi) of the TPV following the Exposure is preferably at least 100% and more preferably at least 103% and most preferably at least 105% of the tensile strength of the TPV before the Exposure. Still further, in one embodiment, the elongation of the TPV following the Exposure is preferably at least 85% and more preferably at least 88% and most preferably at least 95% of the elongation of the TPV following the Exposure.
[0017] In accordance with other aspects of the invention, there are taught methods and formulations of low cost, highly weatherable thermoplastic vulcanizates that include from 20% by weight to 80% by weight, and in other embodiments, ranges described elsewhere herein, of the total amount of the plastic plus elastomer in the TPV, of an elastomer. The elastomer may be a conjugated diene rubber. The elastomer may be styrene butadiene rubber, polybutadiene rubber, SIS rubber, polyisoprene rubber, SBS rubber, or blends thereof. The thermoplastic vulcanizate may further include from 80% by weight to 20% by weight, and in other embodiments, ranges described elsewhere herein of the total amount of the plastic plus elastomer in the TPV of a suitable polyolefin; from between 1 phr to 50 phr, and preferably from 5 to 50 phr, and most preferably from 20 to 50 phr, and still more preferably 40 to 50 phr, of carbon black; and an amount of a processing agent selected to substantially saturate the thermoplastic vulcanizate without causing bleed. According to this aspect of the invention, suitable processing agents include naphthenic oil and paraffinic oil and the amount of paraffinic or naphthenic oil may be based on a vinyl weight fraction of the copolymerized butadiene in the conjugated diene rubber and a copolymerized butadiene weight fraction of the conjugated diene rubber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein:
[0019] FIGS. 1-18 depict various articles that may be constructed with the TPVs and methods of the present invention.
[0020] FIG. 19 depicts a partial two lobe twin extruder formation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] As described herein and demonstrated in the Examples below, the addition of carbon black to TPVs consisting essentially of SB rubber as the elastomeric phase produces TPVs having comparable weatherability, defined with respect to UV resistance (as further defined with respect to retention of tensile strength and elongation following an amount of exposure to UV radiation, described herein as the Exposure) and color-fastness, to TPVs provided with the same amount of carbon black, and the same plastic, but consisting essentially of EPDM rubber as the elastomer (the “benchmark TPV”).
[0022] Accordingly, in one embodiment of the invention, low cost, highly weatherable TPVs may be formed by the method that includes the steps of selecting from 80% by weight to 20% by weight of the total amount of the plastic plus elastomer in the TPV, and preferably from 30% to 70% by weight, and most preferably from 40% to 60% by weight of one or a blend of more than one elastomer for the rubber phase of the TPV, selecting from 20% by weight to 80% by weight, and preferably from 30% to 70% by weight, and most preferably from 40% to 60% by weight of the total amount of the plastic plus elastomer in the TPV of a polyolefin or blend of polyolefins for the plastic phase of the TPV, selecting an amount of carbon black from 1 phr to 50 phr, and preferably from 5 to 50 phr and most preferably from 20 to 50 phr, and still more preferably 40 to 50 phr, and blending the elastomer, the polyolefin, and the carbon black. Amounts of carbon black greater than 50 phr up to 100 phr may be selected in accordance with the present invention.
[0023] In this and other embodiments herein, the amount of carbon black may be selected to improve a physical characteristic of the thermoplastic vulcanizate. The physical characteristic may be one or more of colorfastness following an amount of UV exposure and UV resistance and preferably colorfastness. In a preferred embodiment, the colorfastness of the TPVs according to the present invention (ΔE based on the Hunter Lab scale) is less than 3.0 and preferably less than 2.0 and in still a more preferred embodiment, less than 1.0. The amount of the Exposure is preferably 2500 kJ of UV radiation at 30 kJ per day in a weatherometer. In another embodiment, the amount of the exposure may be 1300 kJ.
[0024] The Hunter Lab scale is organized in a cube, having an L axis that runs from top to bottom, an a axis and a b axis. The maximum value of L is 100, representing a perfect reflecting diffuser. The minimum value of L is zero, representing black. Moving in a positive direction on the a axis indicates red. Moving in the negative direction on the a axis indicates green. Moving in the positive direction on the b axis indicates yellow and the negative direction indicates blue. Changes in each of these axis points, (ΔL, Δa, and Δb) are variables in determining the total color difference (ΔE). SQRT (ΔL 2 +Δa 2 +Δb 2 ). See 8(9) H UNTER L AB A PPLICATION'S N OTE August 1-15 (1996).
[0025] In one embodiment, the tensile strength (psi) of the TPV following the Exposure is preferably at least 100%, and more preferably at least 103%, and most preferably at least 105% of the tensile strength of the TPV before the Exposure. Still further, in one embodiment, the elongation of the TPV following the Exposure is preferably at least 85%, and more preferably at least 88%, and most preferably at least 95% of the elongation of the TPV before the Exposure.
[0026] In a preferred embodiment, the elastomet may comprise at least 50% by weight, and preferably from 55% to 95% by weight, and most preferably from 60% to 75% by weight of the elastomer of a conjugated diene rubber. Conjugated diene rubber may be less than 99.9% by weight of the total elastomer. Suitable conjugated diene rubbers may include diene or diene/vinylaromatic rubbers, which may include styrene butadiene (“SB”) rubber, which is preferred, polybutadiene (“PB”) rubber, polyisoprene rubber, SIS rubber, and SBS rubber. In one embodiment, the elastomer may comprise from at least 50% to 99%, and preferably from 55% to 95% and still more preferably from 60% to 75% by weight of the elastomer of styrene butadiene rubber. The elastomer may consist substantially of a single conjugated diene rubber. In a most preferred embodiment, the elastomer may consist essentially of SB rubber. The elastomer may also comprise blends of conjugated diene rubbers and/or SBC rubbers or saturated carbon backbone rubbers; however, conjugated diene rubbers preferably comprise at least 50% by weight of the elastomer.
[0027] SB rubber refers to random block copolymers of styrene and butadiene. The SB rubber may have a styrene content of between 1% to 50% by weight of the SB rubber. Styrene content of between 15% and 45%, and preferably between 20% and 40%, and still more preferably between 20% and 30% are also contemplated in accordance with the present invention. Suitable butadiene micro structures may include 1,2-butadiene, and cis and trans 1,4-butadiene. The copolymer may be prepared in any of the well known conventional cis and trans processes, such as through solution or emulsion polymerization. The weight percent of the butadiene in the SB rubber may range from 50% by weight to 99% by weight. Weight percents of butadiene in the SB rubber of between 85% and 55%, and preferably between 80% and 60%, and still more preferably between 80% and 70% are contemplated in accordance with the present invention. Larger or smaller amounts of butadiene may be employed. The butadiene portion may contain from 10% to 90% of 1,2-polybutadiene, with the remainder consisting essentially of cis and trans 1,4-polybutadiene. The ratio of cis to trans isomers in the 1,4-polybutadiene may be between 0.2 and 0.65. The molecular weight, on a number average value, may be from 30,000 to greater than one million. The exemplary solution SB rubber used in the compositions set forth in the examples is VSL 5025-0HM, manufactured by Lanxess Corp.
[0028] PB rubber refers to homopolymers of butadiene having a cis-1,4 butadiene content as low as 5% to as high as 98% by weight. PB rubber also refers to homopolymers of butadiene having a vinyl-1,2 butadiene content as low as 2% and as high as 90% by weight. As discussed above, and described in further detail below, it has been discovered that the capacity of PB rubber and SB rubbers to hold processing agents is determined by the vinyl content of the polybutadiene. The molecular weight, on a number average value, may be from 30,000 and greater than one million.
[0029] Polyisoprene rubber refers to homopolymers of isoprene, including natural rubber. Polyisoprene rubber may have a cis-content as low as 5% to as high as 98% by weight. The molecular weight, on a number average value, may be from 30,000 and greater than one million.
[0030] As indicated above, the elastomer of the present invention may comprise a blend of two or more rubbers. Preferably, in such an embodiment, the blend comprises at least 50% of a conjugated diene, including unsaturated styrenic triblock copolymer rubber, or diene vinylaromatic rubber and most preferably, at least 50% of SB rubber, though it is recognized above that in other embodiments, the conjugated diene rubber in the blend may comprise greater than 55% or 60% by weight of the total elastomer in the TPV. Other suitable rubbers, which may be used in the elastomer as part of the rubber blend, in amounts from 0.1% to less than 50%, and preferably from 25% to 45% and still more preferably from 25% to 40% by weight may include EPM rubber, EPDM rubber, and SBC rubber, with EPDM rubber being preferred
[0031] EPM rubber refers to an ethylene-propylene copolymer rubber which can be cross-linked by radiation curing or peroxide curing.
[0032] EPDM rubber refers to a terpolymer of ethylene, propylene and a non-conjugated diene. Illustrative non-limiting examples of suitable non-conjugated dienes are 5-ethylidene-2-norbornene (ENB); 1,4-hexadiene; 5-methylene-2-norbomene (MNB); 1,6-octadiene; 5-methyl-1,4-hexadiene; 3,7-dimethyl-1,6-octadiene; 1,4-cyclohexadiene; tetrahydroindene; methyltetrahydroindene; dicyclopentadiene; 5-isopropylidene-2-norbomene; 5-vinyl- norbomene; etc. The ethylene content of the EPDM rubber may be from 25% to 80% by weight. Weight percents of the ethylene in the EPDM rubber of between 30% and 70%, and preferably 45% and 65%, and still more preferably 50% and 60% are contemplated in accordance with the present invention. The non-conjugated diene content may be from 2% to 10% by weight, with the remaining content being substantially polypropylene. The molecular weight, on a number average value, may be from 30,000 and greater than one million. The exemplary EPDM rubber used in the compositions set forth in the examples is V3666 (EP(ENB)DM) manufactured by ExxonMobil.
[0033] SBC rubber refers to hydrogenated styrenic triblock copolymer elastomers, exemplified by SEBS (styrene/ethylene-butene/styrene), SEPS (styrene/ethylene-propylene/styrene), SEEPS (styrene/ethylene-ethylene-propylene/styrene) are widely commercially available and are described in further detail in U.S. Patent Application Pub. No. 2004/0132907. As noted in the aforementioned reference, hydrogenated styrenic triblock copolymers may include crosslinkable styrenic blocks, which, in combination with the crosslinkable midblocks, may afford greater overall crosslinking of the cured elastomer within the TPV. These elastomers may have a styrene content as low as 10% by weight to as high as 50% by weight, preferably 20% and 40% by weight, and most preferably from 25% to 35% by weight. The molecular weight of the styrene component may be from 7,000 to 50,000 and the molecular weight of the elastomeric component may be from 30,000 to greater than 150,000. Methods of forming suitable hydrogenated styrenic triblock copolymer elastomers are well known in the art. See, Styrenic Thermoplastic Elastomers, in T HERMOPLASTIC E LASTOMERS Ch. 3 (G. Holden, N. R. Legge, R. Quirk, and H. E. Schroeder eds., Hauser/Gardner Publications, Inc., Cincinnati, Ohio, 1996). It is noted that styrene isoprene styrene (SIS) rubber and styrene butadiene styrene (SBS) rubber are not within the scope of SBC rubbers for purposes of this application, but are referred to collectively as unsaturated styrenic triblock copolymer rubbers having a conjugated diene rubber midblock.
[0034] In another embodiment of the invention, the elastomer may be a blend including conjugated diene rubbers and saturated carbon backbone rubbers. The amount of saturated carbon backbone rubbers in the blend may be from 0.1% by weight, and preferably 5% by weight to less than 50% by weight, though in other embodiments, the amount of saturated carbon backbone rubbers may be from 5% to 45% by weight, and preferably 25% to 40% by weight. In a preferred embodiment, the saturated carbon backbone rubber is EPDM, which may be added to improve ozone resistance in the resultant thermoplastic vulcanizate. In another embodiment, the amount of EPDM may be from 5% to 45%. In still another embodiment, the amount of EPDM may be 25% to 40%. The EPDM rubber may be incorporated into the elastomer blend to improve ozone resistance. In still other embodiments, EPM rubber may be used in place of all or a portion of the EPDM rubber in the selected elastomer. In still other embodiments, styrenic triblock copolymer elastomers may be used in a blend with SB rubber. In this embodiment, the styrenic triblock copolymer elastomer may comprise from 0.1% by weight to 50% by weight of the elastomer though it will be appreciated that ranges of 5% to 45% and 25% to 40% by weight may be used in accordance with the invention. In other embodiments, the selected elastomer may be PB rubber, polyisoprene rubber, SIS rubber, SBS rubber or blends of these rubbers rubber with one or more of EP, EPDM, SEBS, SEPS, or SEEPS rubber. It is noted that the possible blends of elastomers that may be used according to the present invention are numerous and not all are specifically recorded herein.
[0035] Suitable polyolefins include isotactic polypropylene (“iPP”), homopolymers of ethylene, including high density polyethylene, low density polyethylene, very low density polyethylene, ethylene/propylene copolymer, ethylene/1-butene copolymer, ethylene/i-hexene copolymer, ethylene/1-octene copolymer (collectively, the polyethylene homopolymers and copolymers are referred to as “polyethylene” unless otherwise stated); isotactic poly(1-butene) and copolymers of 1-butene with ethylene, propylene, 1-hexene, or 1-octene (collectively, the isotactic poly(1-butene) homopolymers and copolymers are referred to as “isotactic poly(1-butene” unless otherwise stated); and syndiotactic polypropylene and copolymers of syndiotactic propylene with ethylene, 1-butene, 1-hexene, or 1-octene (collectively, the syndiotactic propylene homopolymers and copolymers are referred to as “syndiotactic propylene” unless otherwise stated), ands blends of the aforementioned. In a preferred embodiment, the polyolefin is iPP.
[0036] Suitable carbon blacks include carbon blacks of all ASTM designations.
[0037] A selected amount of a processing agent may be added to the TPV, before or during the blending stage. Suitable processing agents may include naphthenic oil and paraffinic oil. In one embodiment, from 0 to 200 phr of processing agent may be added to the TPV, which may be above the amounts present in the constituent rubber component. In another embodiment, an amount of processing agent selected to substantially saturate the TPV without resulting oil bleed may be added.
[0038] Where the elastomer selected for the TPV is a diene/vinylaromatic rubber, such as SB rubber, it has been discovered that the amount of paraffinic or naphthenic oil that can be held by the resultant TPV without oil bleed (the “oil holding capacity”) bears a relation to the vinyl weight fraction of the diene and the diene weight fraction in the rubber. The vinyl weight fraction refers to the weight fraction of the vinyl isomer in the diene to the total weight of the diene, which may be the sum of the cis, trans, and vinyl isomers.
[0039] In accordance with this discovery, the oil holding capacity (parts per hundred rubber) of TPVs having iPP, isotactic poly (1-butene) or syndiotactic polypropylene as the plastic and SB rubber as the elastomer may be determined by the formula:
BD°[66+(V−0.15)°68]
[0040] Wherein BD is the weight fraction of copolymerized butadiene in the SB rubber and V is the vinyl weight fraction of the copolymerized butadiene.
[0041] In TPVs having polyethylene as the plastic and SB rubber as the elastomer, the oil holding capacity may be determined by the formula:
BD°[46.7+(V−0.15)°68]
[0042] When a TPV contains a blend of PE and iPP (or iPB or sPP) as the plastic and SB rubber as the elastomer, the oil holding capacity may be determined by interpolating between the above referenced formulas.
[0043] In addition to an amount of processing agent, various fillers, such as carbon black and clay, antioxidants, antiozonants, stabilizers, lubricants (e.g., oleamide), antiblocking agents, antistatic agents, waxes, coupling agents for the fillers, foaming agents, pigments, fire retardants, titanium dioxide, talc, and other similar materials may be selected and blended into the TPV, in amounts that are well known in the art of compounding.
[0044] The method of forming low cost, highly weatherable TPVs may further include the step of dynamically vulcanizing the elastomer. Suitable curing methods may include peroxide cure, sulfur cure, resin cure, and hydrosilylation cure. The curing method selected may depend on the TPV formulation as it is known that certain elastomers will respond more efficiently to specific curing methods. Suitable curing agents and co-agents may be used in amounts that are well known in the art.
[0045] In a preferred embodiment, the elastomer may be fully cured. The term “fully cured” or “fully vulcanized” relative to the dynamically vulcanized rubber component of this invention denotes that the rubber component to be vulcanized has been cured to a state in which the physical properties of the rubber are developed to impart elastomeric properties to the rubber generally associated with the rubber in its conventional vulcanized state. The degree of cure of the vulcanized rubber can be described in terms of extractable components. Using this measure of the degree of cure, the improved thermoplastic elastomeric compositions may be produced by vulcanizing the curable rubber component of the blends to the extent that the composition contains no more than 6 percent by weight of the cured rubber component extractable at room temperature by a solvent which dissolves the rubber which is intended to be vulcanized, and preferably to the extent that the composition contains less than three percent by weight extractable.
[0046] The structure of products formulated from EPDM rubber based TPVs and used in applications where exposure to UV radiation is likely are well described in the literature, such as, for example, in product brochures entitled “Residential Glazing and Weather Seals”, “Automotive Molded Seals Solutions”, and “Drive Innovation,” available from Advanced Elastomer Systems, Inc. (published 2000 to 2005). Such products may include weather-stripping, pipe seals, couplings, O-rings, mats, grips, such as handle grips, and gaskets and seals for automotive and building applications. FIGS. 1-18 depict a wide variety of gaskets and seals used in automotive applications. It should be understood that the depictions in the FIGURES are 2-dimensional profiles of 3-dimensional objects. The FIGURES are intended to be representative of some of the types of seals and gaskets that are presently manufactured using benchmark TPVs. The 3-dimensional structures depicted in the FIGURES are well known in the art and it is not within the scope of this invention to be limited to any particular structure, though it will be readily understood that each of these articles may be constructed either wholly or in-part from the TPVs described herein.
[0047] As indicated above, the article may be weather-stripping, pipe seal, couplings, O-rings, mats, grips, or gaskets. In still another embodiment, the article may be an automotive seal or gasket.
[0048] In support of the discovery disclosed herein relating to the selective effect of carbon black on UV resistant and weatherability in diene and diene vinylaromatic based TPVs, the following Examples are offered.
[0049] For purposes of the Examples, the following materials were used:
Rubbers SBR VSL Bayer Solution SBR, 25 wt % bound styrene, 5025-0 HM 75 wt % bound butadiene. Butadiene microstructure: 65.5% vinyl, 14.1% cis, 20.4% trans. V3666 ExxonMobil EP(ENB)DM: 64 wt % ethylene, 3.9 wt % ethylidenenorbornene, 75 phr paraffinic oil. VSL N330/105 Rubber Masterbatch: 100 phr VSL 5025-0 Pellet HM, 10 phr N330 black, 5 phr Sunpar 150M paraffinic oil. VSL N330/505 Rubber materbatch: Pellet 100 phr VSL 5025-0 HM, 50 phr N330 black, 5 phr Sunpar 150M paraffinic oil. V3666 MB Rubber masterbatch: 175 phr V3666, 50 phr N330 black. P597 DSM EP(ENB)DM: 63 wt % ethylene, 4.4 wt % ethylidenenorbornene, 0.2 wt % vinylnorbornene, 100 phr paraffinic oil. Plastic Materials PP51S07A Sunoco 0.8 MFR iPP homopolymer HD 6706:19 ExxonMobil 7.0 MI HDPE Rubber Curatives SP 1045 Schenectady “resole” type phenolic resin SMD 31214 Schenectady: 30 wt % solution of a “resole” type phenolic resin in paraffinic oil. Catalyst for Rubber Curative SnCl 2 , SnCl 2 •2H 2 0 Cure promoter ZnO Scorch retarder and heat stabilizer Other Materials Sunpar 150, Sunoco paraffinic oil Sunpar 150M Icecap K Clay Burgess calcined clay. N330 black Degussa
EXAMPLE 1
[0050] In Example 1, carbon black (N330) was blended into Bayer oil free SBR 5025-0 HM at 10 and 50 phr levels (Sample 1 and Sample 2 respectively in Table 1) in a Banbury. In both cases, 5 phr of paraffinic oil was added during rubber masterbatch preparation in order to facilitate black dispersion. The rubber masterbatches were then pelletized. A rubber masterbatch of V3666 EPDM containing 50 phr of N330 carbon black was also prepared in a similar manner (Control). Due to the oil extended EPDM rubber used (75 phr of paraffinic oil), no additional oil was necessary in blend preparation.
[0051] TPVs were then prepared in a Berstorff 43 mm two lobe twin screw extruder with eight barrel sections such as is depicted in FIG. 19 , (which shows one half of the twin screw design) using the rubber masterbatches with iPP as plastic phase, and phenolic resin as curative as per the formulations in Table 1. Sample 1 was prepared at 200 revolutions per minute (rpm) at 50 kg/hr. Samples 2 and 3 were prepared at 400 rpm at 50 kg/hr. The final oil extension in all the SB rubber based TPVs was 75 phr (60.20 phr was added during the process, 9.8 phr came from the solution of the phenolic resin curative in paraffinic oil, and 5 phr from rubber masterbatch preparation). The TPVs produced with EPDM rubber contained 84.8 phr of paraffinic oil (75 phr from the oil extended rubber and 9.8 phr from the phenolic resin curative solution).
TABLE 1 TPV Formulations For Example 1 Example Sample 1 Sample 2 Control VSL N330/105(SBR) 1 115 VSL N330/505(SBR) 2 155 V3666 BMB 3 225 Sunpar 150M 60.2 60.2 PP51S07A 40.0 40.0 40.0 SnCl 2 1.50 1.50 1.50 ZnO 2.00 2.00 2.00 SMD31214 14.0 14.0 14.0 1 Blend of 100 parts SB rubber; 10 parts carbon black; 5 parts oil. 2 Blend of 100 parts SB rubber; 50 parts carbon black; 5 parts oil. 3 Blend of 100 parts EPDM rubber; 50 parts carbon black; 75 parts oil.
[0052] Injection molded plaques obtained from the Sample and Control formulations of Table 1 were subjected to 2500 kJ of UV exposure in a weatherometer that simulated night, day, and rainy conditions (30 kJ/day). As demonstrated from the data in Table 2, the physical property retention for the SB rubber based TPV products were comparable to that of the EPDM based TPV after weathering (% retention of tensile strength of 105% versus 104%); (% retention of elongation of 88% versus 103%; % retention of modulus of 120% versus 108%). The color stability of the SB rubber TPVs was superior to that of the EPDM TPV (ΔE of 0.97 versus 3.64). Color measurements (ΔE) are derived according to the Hunter Lab color scale.
TABLE 2 Weathering Test Data for Example 1 Example Sample 1 Sample 2 Control Hardness (Shore A) 65 64 69 UTS (psi) 745 828 1464 UE (%) 217 194 357 M100 (psi) 463 501 536 Change in Hardness +6 +5 +1 % Retention UTS 103 105 104 UE 96 88 103 M100 108 120 108 Color Change (ΔE) 1.69 0.97 3.64
EXAMPLE 2
[0053] To test the effect on weathering when SB rubber is partially replaced with EPDM rubber, a masterbatch (MB) was prepared according to the formulation in Table 3 to include 70 parts of SB rubber and 30 parts of EPDM—representing a 30% replacement of SB rubber with EPDM. Masterbatch preparation was carried out under nitrogen in a laboratory Brabender-Plasticorder, model EPL - V5502. The mixing bowls had a capacity of 85 ml with the cam-type rotors employed. The SB rubber and EPDM rubber were melt blended in the mixing bowl that was heated to 180° C. and at 100 rpm rotor speed. After blending for 2.5 minutes, 50 parts of carbon black was blended into the rubber for 2.25 minutes. An amount of paraffinic oil was packed into the mixer over a period of 1.25 minutes. Following addition of the oil, the masterbatch was blended an additional 2.25 minutes.
[0054] Preparation of the TPV labeled Sample 3 in Table 3 involved melting in Brabender 24 parts of iPP and 16 parts of PE at 180° C. and at 100 rpm rotor speed over a period of 1 minute. Thereafter the amounts of masterbatch MB, described above, and tin chloride, were added to the plastic and mixed for 3 minutes. Thereafter, the curative agent (phenolic resin) was added and mixing continued for 3 minutes. The molten TPV was removed from the mixer, and pressed when hot between Teflon plates into a sheet that was cooled, cut-up, and compression molded at 400° F. A Wabash press, model 12-1212-2 TMB was used for compression molding, with 4.5″×4.5″×0.06″ mold cavity dimensions in a 4-cavity Teflon-coated mold. Material in the mold was initially preheated at 400° F. for 2-2.5 min. at a 2-ton pressure on a 4″ ram, after which the pressure was increased to 10-tons, and heating was continued for 2-2.5 min. more. The mold platens were then cooled with water, and the mold pressure was released after cooling (140° F.).
[0055] Dog-bones were cut out of the molded (aged at room temperature for 24 hr.) plaque for tensile testing (0.16″ width, 1.1″ test length (not including tabs at end)).
TABLE 3 TPV Formulations For Example 2 MB Sample 3 VSL 5025-0 70.00 P597 60.00 N 330 50.00 Sunpar 150M 52.50 MB 232.50 PP51S07A 24.00 HD 6706.19 16.00 SnCl2•2H2O 1.80 SP1045P 8.00 Total 232.50 282.30
[0056] As demonstrated in Table 4, the retention of physical properties following UV exposure (1300 kJ) is observed when 30% by weight of the SB rubber in the total elastomer is replaced with EPDM as per the formulation of Table 3. Color measurements (L, a, b, and ΔE) are derived according to the Hunter Lab color scale. After exposure to 1300 kJ of UV radiation, the tensile strength was 99% retained, the elongation was 98% retained, the modulus was 102% retained and ΔE (unwashed and washed) were 2.2 and 1.2 respectively.
[0057] For comparative purposes, the retention of physical properties of a commercially available 64 shore A hardness iPP/EPDM TPV sold under the tradename Santoprene 101-64 by Advanced Elastomer Systems, LP similarly exposed to 1300 kJ of UV radiation are presented in Table 4.
TABLE 4 Weathering Test Data for Example 2 Santoprene Sample 3 101-64 Original Hardness (Shore A) 67 63 UTS (psi) 912 908 Elong % 170 337 M 100 (psi) 586 436 WEATHEROMETER 1300 KJ Change in Hardness +1 0 Retention % UTS 99 78 Elongation 98 78 M 100 102 101 COLOR CHANGE Original L 13.35 14.78 a −0.02 −0.01 b −0.80 −0.75 Aged 1300 KJ (Unwashed) L 15.59 22.07 a −0.04 −0.09 b −0.57 −0.47 ΔE 2.2 7.3 Aged 1300 KJ (Washed) L 14.57 20.64 a −0.03 −0.09 b −0.62 −0.63 ΔE 1.2 5.9
EXAMPLE 3
[0058] To demonstrate the effect of carbon black on processability, TPVs according to the formulations in Table 1 were prepared in a Berstorff 43 mm two lobe twin screw extruder with eight barrel sections, excluding a feed barrel at the head of the extruder (L/D=5 per barrel) as shown in FIG. 19 . The twin screw tip was followed by a diverter valve and die (not shown in the barrel and screw design schematic representation of FIG. 1 ). The extrudate from the die was fed to an underwater pelletizer. Melt temperature probes were attached to barrels B, (T 1 ), B 4 (T 2 ), B 5 (T 3 ), and B 8 (T 4 ). A melt pressure probe was attached to barrel B 6 . The externally added oil was split between B1 (15.2 phr before cure) and B6 (45.0 phr after cure) for SB rubber TPV preparation.
[0059] As shown in Table 5, all the SB rubber based black filled TPV formulations of Table 1, were much more readily processable (i.e., had a lower melt viscosity) than the EPDM based black filled TPV. Specifically, the melt temperatures and pressure of comparable formulations Sample 2 and Control (Table 1) were better for the SB rubber based Sample 2 than the EPDM based Control. On increasing the carbon black level in SB rubber formulations from 10 phr to 50 phr (Sample 1 and Sample 2 respectively), the TPV melt pressure changed from 1535 to only 1615 psi, where as in the EPDM rubber TPV, at 50 phr carbon black loading, the melt pressure was 2840 psi. All the TPV compositions containing SBR could be blow molded. The EPDM containing composition (Control) yielded a torn part with a rough surface on attempted blow molding, presumably due to one or a combination of the high TPV melt viscosity or poor materials dispersion in the molten TPV.
TABLE 3 Processability Data Sample 1 Sample 2 Control T 3 (° C.) 233 263 236 T 4 (° C.) 202 221 278 Melt Pressure (psi) 1535 1615 2840
[0060] The Examples demonstrate that despite the generally higher initial UV resistance of EPDM rubber to SB rubber, the addition of carbon black improves the UV resistance of SB rubber based TPVs as compared to EPDM rubber based TPVS in a manner that renders SB rubber based TPVs with carbon black comparable to EPDM rubber based TPVs with similar amounts of carbon black. SB rubber based TPVs with carbon black demonstrate superior color-fastness as compared to comparable EPDM rubber based TPVs. The processability advantages of TPVs based on SB rubber remain. Accordingly, low cost, highly weatherable TPVs may be developed for use in applications where exposure to UV radiation may prove detrimental to the physical properties of the article.
[0061] The preferred embodiments have been described, hereinabove. It will be apparent to those skilled in the art that the above methods may incorporate changes and modifications without departing from the general scope of this invention. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.
1. One aspect of the invention can be described as a thermoplastic vulcanizate comprising:
from 80% by weight to 20% by weight of an elastomer, wherein the elastomer comprises at least 50% by weight of a conjugated diene rubber, selected from the group consisting of styrene butadiene rubber, polybutadiene rubber, styrene/isoprene/styrene rubber, polyisoprene rubber, and styrene/butene/styrene rubber, and blends thereof, from 20% by weight to 80% by weight of a polyolefin; from 1 phr to 50 phr of carbon black; and an amount of a processing agent based on a vinyl weight fraction of the copolymerized butadiene in the styrene butadiene rubber and a copolymerized butadiene weight fraction of the styrene butadiene rubber.
2. The weatherable thermoplastic vulcanizate of numbered embodiment 1, wherein the conjugated diene rubber consists essentially of styrene butadiene rubber;
wherein the polyolefin is selected from the group consisting of isotactic polypropylene, syndiotactic polypropylene, and isotactic poly(1-butene); wherein the processing agent is selected from the group consisting of naphthenic oil and paraffinic oil; and wherein the amount of the processing agent is selected according to the formula BD [66+(V-0.15) 68], wherein BD is the weight fraction of copolymerized butadiene in the styrene butadiene rubber and V is the vinyl weight fraction of the copolymerized butadiene.
3. The weatherable thermoplastic vulcanizate of either of embodiments 1 and 2, characterized in possessing a ΔE of less than 1.0, wherein the ΔE is calculated based on an exposure to 2500 kJ of ultraviolet radiation at a rate of 30 kJ per day. 4. The weatherable thermoplastic vulcanizate of any of the preceding numbered embodiments, wherein the conjugated diene rubber consists essentially of styrene butadiene rubber;
wherein the polyolefin consists essentially of polyethylene; wherein the processing agent is selected from the group consisting of napthenic oil and paraffinic oil; and wherein the amount of the processing agent is selected according to the formula BD°[46.7+(V-0.15)°68], wherein BD is the weight fraction of copolymerized butadiene in the styrene butadiene rubber and V is the vinyl weight fraction of the copolymerized butadiene.
5. The thermoplastic vulcanizate of any of the preceding numbered embodiments, wherein the elastomer comprises from 0.1% to less than 50% by weight of a saturated backbone rubber selected from the group consisting of EPM rubber, EPDM rubber, and SBC rubber. 6. The thermoplastic vulcanizate of any of the preceding numbered embodiments, wherein the thermoplastic vulcanizate retains at least 100% of its tensile strength following the exposure to 2500 kJ of ultraviolet radiation at a rate of 30 kJ per day 7. Another aspect of the invention can be described an article comprising the thermoplastic vulcanizate of any of the preceding numbered embodiments, wherein the article is selected from the group consisting of hood-to-radiator seals, rocker panels, hood-to-cowl seals, cowl seals, windshield seals, sunroof seals, roof line seals, window seals, trunk and tailgate seals, quarterlight seals, cutline seals, door seals, glass channels, vehicle moldings, belt line seals, and mirror gaskets. 8. Another aspect includes a method of preparing a thermoplastic vulcanizate, the method comprising:
selecting from 80% by weight to 20% by weight of an elastomer, wherein the elastomer comprises at least 50% by weight of a conjugated diene rubber, selected from the group consisting of styrene butadiene rubber, polybutadiene rubber, styrene/isoprene/styrene rubber, polyisoprene rubber, and styrene/butene/styrene rubber, and blends thereof; selecting from 20% by weight to 80% by weight of a polyolefin selected from the group consisting of polyethylene, isotactic poly(1-butene), and polypropylene; selecting an amount of carbon black from 1 phr to 50 phr; blending the carbon black into at least the elastomer; and forming the thermoplastic vulcanizate.
9. Yet another aspect of the invention is to the use of a thermoplastic vulcanizate comprising:
from 80% by weight to 20% by weight of an elastomer, wherein the elastomer comprises at least 50% by weight of a conjugated diene rubber, selected from the group consisting of styrene butadiene rubber, polybutadiene rubber, styrene/isoprene/styrene rubber, polyisoprene rubber, and styrene/butene/styrene rubber, and blends thereof; from 20% by weight to 80% by weight of a polyolefin; from 1 phr to 50 phr of carbon black; and an amount of a processing agent based on a vinyl weight fraction of the copolymerized butadiene in the styrene butadiene rubber and a copolymerized butadiene weight fraction of the styrene butadiene rubber.
|
Low cost, highly weatherable thermoplastic vulcanizates comprising diene or diene/vinylaromatic, and preferably styrene-butadiene rubber, are taught. Weatherability; namely, UV resistance and color-fastness, is improved by the addition of carbon black. It is demonstrated that the addition of carbon black increases the UV resistance of SB rubber based TPVs to a level comparable to EPDM rubber based TPVs, while providing superior color fastness. As a result, lower cost SB rubber may be a preferable rubber for use in TPVs for exterior applications despite a lower inherent UV resistance.
| 2
|
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of application Ser. No. 133,321, filed Dec. 16, 1987, and now abandoned.
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a method of intensifying the washing of a fiber suspension. In particular, the present invention relates to decreasing the lignin content of a fiber suspension by extracting the substance whereby the suspension to be treated has a higher consistency than usually and the viscosity of the fibers is kept unchanged. In other words, the strength properties of the fibers are preserved and are the same as before the washing.
In pulp production processes, chips and digesting chemicals are dosed to the reaction vessel. The chemical reacts with the wood and these digestion reactions dissolve the lignin. The products of the reaction remain partly in the chips and partly in the surrounding liquid solution.
The reaction products of the digestion, the so-called dry substance, are to be washed off from the pulp in a washing process after digestion. The pulp which was before the washing or during the washing in the form of chips has the washing or during the washing in the form of chips has been dispersed to a fiber suspension. The fraction which has not been spread into fiber suspension, separated from the pulp before, during or after the washing, is treated and returned to the process or is removed from it as the case may be. Washing liquid is introduced to the washing process of pulp in a direction opposite the flow direction of the pulp. From the beginning of the washing plant the sludge containing solid material is guided to a chemical regeneration section and to combustion.
After digestion, washing and screening, pulp is often delignified with oxygen and bleached by using different bleaching chemicals and sequences. These treatments involve reactions between the fiber material and chemicals and reaction products are produced which should be removed in the following washing phase.
The structure of the wood fiber is known to be layered. The innermost layer is hollow lumen which is surrounded by walls containing cellulose, hemicellulose and lignin. The fiber wall has different pores depending on the fiber species and type. When chemicals contact the fibers, in particular, in digestion where the fibers are in a noncompressed state, they are absorbed by penetration and diffusion even to the lumen. Thus, reactions between the wood and the chemicals take place through the whole fiber. The dissolved and soluble reaction products remain partly in the fibers. The washing phase following the reaction phase and the conditions in the washing phase in washing plants applying modern technology are such that all the soluble reaction products cannot be removed from the fibers or there is insufficient time to remove all the soluble reaction products.
It is a well known fact that by treating pulp at an increased temperature and pressure, the reaction product contained in a soluble form in the fiber can be removed. A treatment of this type provides remarkable advantages compared with conventional treatments. For example, the kappa number of the pulp to be bleached, in other words, its lignin content, is lower which saves bleaching chemicals and decreases the impact of the process on the environment. After bleaching and oxygen treatment, the same advantages are to be achieved with a treatment of the same type. However, the prior art methods have their drawbacks. Usually, lignin is removed at a consistency of less than 3%, at which consistency pulp warms up slowly and the heating requires energy many times as much as heating of pulp of, for instance, the consistency of 10%. The following example clarifies the difference. In a fiber suspension having a consistency of 3%, there is about 32 kg's liquid per one kg of fibers and in a suspension having a consistency of 10%, there is 9 kg's liquid per one kg of fibers. Thus, to heat one kg of fibers in a consistency of 3%, one needs to heat 23 kg's more liquid than in the case of heating pulp in a consistency of 10%. A more serious problem in particular in the paper manufacture is the decrease of the viscosity of the fiber suspension as illustrated in FIGS. 6 and 7. This indicates that the strength properties of the fibers decrease considerably when lignin is removed at a low consistency. For example, at the consistency of 10%, the strength properties do not change substantially.
SUMMARY OF THE INVENTION
The method of the present invention is characterized . in that the fiber suspension of a consistency of over 3-30% is prewashed, fiberized after the prewashing and dry-substance, and chemicals contained in the fibers are extracted from the produced concentrated fiber suspension at an increased temperature and pressure without any chemical reaction. The consistency of prewashing and extraction is maintained at 3-30%.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the drawings and descriptive matter in which there is illustrated and described the preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a schematic illustration of a preferred embodiment of the invention;
FIG. 2 illustrates an apparatus arrangement of another preferred embodiment of the invention;
FIG. 3 illustrates a third preferred embodiment of the invention;
FIG. 4 illustrates a fourth preferred embodiment of the invention;
FIG. 5 illustrates a fifth preferred embodiment of the invention;
FIGS. 6 and 7 illustrate the viscosity of pulp as a function of the treatment time in extraction; and
FIGS. 8-10 illustrate the results of tests performed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment illustrated in FIG. 1 comprises two pressure washers 1 and 2 which may be, for example, pressure diffusers. An extraction vessel 3, preferably provided with a mixer 4, is placed between these washers. A heat exchanger 5 is provided for recovering heat from the washing liquid from the second phase washer 2. Further, it may be necessary in some cases to provide an apparatus for recovering heat between the extraction vessel and the washer 2 to cool the pulp supplied from the extraction step to the washing step.
The method of this embodiment operates in the following way. The lignin-containing pulp suspension to be washed is supplied to the pressure washer 1 at a temperature below 100° C. in which its temperature is raised to over 100 ° C. and a pressure of 0.01-1.0 MPa by feeding it to heated fresh water and hot washing liquid displaced in the pressure washer 2. Said washing liquid in turn displaces the cool liquid used in preceding washing phases and flowing in with the pulp suspension.
From the pressure washer 1, the pulp suspension is fed to the extraction vessel in which the lignin contained in the pulp fibers is extracted to the surrounding liquid at an increased temperature of 90°-170° C. and for a period of time of 1-120 min. Tests performed have proven that lignin is separated from the fibers much more efficiently with the method of the present invention than with conventional methods even though the liquid volume in the suspension in the test had been decreased by 90%, the lignin content was tenfold, and the consistency of the pulp was 10% instead of 1%. As already mentioned above, a mixer may be provided in the extraction vessel to intensify the extraction, but the tests indicate that it is not indispensable.
From the extraction vessel, the hot suspension is supplied either directly or via a heat exchanger to the pressure washer 2 in which the hot solution containing extraction products is displaced by cool cooling water after which the extracted solution is partly supplied straight to the pressure washer 1 and partly to a heat exchanger 5 in which the heat is transferred to the fresh water supplied to the process. The heat exchanger 5 makes possible heating of fresh water and supplying heat to where it is needed, for example, to some extraction vessels. The heat exchanger 5 may be provided with an apparatus for supplying additional heat to the fresh water to be fed to the process.
The consistency of the pulp used in the test was 10%, the temperature of the pulp when it was supplied to the pressure washer 1 was 100° C., the temperature of the pulp when it was supplied to the extraction vessel was approximately 150° C. and the duration of the extraction 1 hour. In the pressure washer 2, the temperature of the pulp was decreased to approximately 50° C.
In the embodiment illustrated in FIG. 2, the apparatus consists of a pressure thickener 12, a cooler 13 and a heat exchanger 14. The principle applied to this embodiment is extraction of lignin from high consistency pulp at a raised temperature and pressure. The difference compared to the previous embodiment is that extraction is carried out at a higher consistency whereby the pulp warms up in a shorter time than before and less energy is required for the heating. As indicated by the figure, a filtrate separated in a pressure thickener 10 is recycled to previous phases of the process. The filtrate separated in the thickener 12 is partly recirculated straight to the extraction vessel 11 and partly to the heat exchanger 14 in which the heat contained in the filtrate is transferred to the fresh water supplied further to the extraction vessel. Proceeding of the extraction process can be controlled by regulating the ratio of the volume of the filtrate recycled straight to the extraction vessel and the volume of the fresh water. It is also an essential feature of the method of this embodiment that the heating liquid supplied to the extraction vessel decreases the consistency of the pulp suspension. In this case, hot lignin-containing liquid is separated in the pressure thickener from the pulp discharged from the extraction vessel 11, in which thickener the consistency is raised to its initial percentage. It is, of course, possible to use a pressure washer in connection with heat recovery, in which case the cooler 13 and the pressure thickener 12 of this embodiment would be omitted. The cooler 13 in the embodiment illustrated in FIG. 2 is employed to cool the fiber suspension, but also to decrease the consistency of the suspension to 10% from the initial 30%; thus, no heat is recovered in this phase. A mixer 15 can be used to intensify the equalizing of the temperature of the pulp suspension.
The apparatus according to the embodiment illustrated in FIG. 3 comprises a pressure washer 20 which can be, for example, a pressure diffuser, a pressure extraction washer 21, a second pressure washer 22 and a heater 23.
In the method according to this embodiment, the pulp suspension containing lignin is supplied to the pressure washer 20 in which its temperature and pressure are raised towards the readings required by the extraction by washing liquid supplied from the second washer 22 via the heater 23 and the extraction vessel 21 against the flow direction of the pulp. From the washer 20, the pulp suspension is supplied to the pressure extraction washer 21 in which the temperature of the suspension is raised with the washing liquid supplied from the heater 23 to a value which is advantageous for extraction. Part of the lignin-containing liquid produced in the extraction is displaced to the washer 20 and another part with the pulp suspension to the second washer 22 into which also cooling liquid is supplied which displaces the hot liquid and returns part of the heat via the heater to the extraction vessel 21. Through the whole process the consistency of the pulp suspension is meant to be kept constant, for example, 10%.
The apparatus according to the embodiment illustrated in FIG. 4 comprises washing filters 25 of suction, pressure or compression type. It is typical for a washing apparatus of the filter type that the pulp suspension has to be diluted to 1 to 3% before it is supplied to the washer. Filter washing plants have several washers 25 connected in series. The consistency of the pulp discharged from a filter washing plate is usually 10-30% if the pulp is not diluted. Extraction phase 26 of a filter washing plant can be installed after a washing phase or all the washing phases. It is advantageous to carry out the extraction at the discharge consistency of the filter in order to avoid the use of large tanks and stores.
The apparatus according to the embodiment illustrated in FIG. 5 comprises a digester 26, a washing compartment 30 connected to it and a discharge device 27. The pulp is supplied from the digester in the form of fiber pulp via pipe 28 to a washer 29 which can be, for instance, a pressure diffuser. The extraction process is carried out as follows: when the wood chips have been digested, the cellulose still in the form of chips is prewashed in the washing compartment 30 of the digester. After prewashing, the cellulose is fiberized to fiber pulp in the discharge device 27 or in the pipe 28 and is supplied to the washer 29 in which the fiber pulp is washed at a raised temperature and pressure.
It is to be noted that after the chips have been cooked so that lignin has dissolved from the chips loosening the fiber bonding, the pulp is still in the form of chips as there has been no force that could have separated the fibers from each other. The pulp stands still in the cooking vessel. Thus, without any fiberizing action, the pulp looks like chips, that is, pulp is in chip form. Now if the pressure in the cooking vessel is rapidly lowered, the liquid between the fibers in the "chips" boils and evaporates and the steam pushes the fibers apart, whereby the fibers are separated and the pulp is converted into fiber form. At the same time, the formation of steam requires plenty of energy, whereby the temperature is being lowered. It is also possible to lower the temperature rapidly, whereby the pressure is also lowered so that both phenomena, lowering of pressure and/or temperature, belong together.
FIGS. 6 and 7 illustrate the results of laboratory tests. The left vertical axis in the figures illustrates the kappa number of the pulp and the right vertical axis the viscosity of the pulp. The horizontal axis illustrates treatment time. In the treatment illustrated in FIG. 6, the consistency of the pulp was 10% and the temperature 155° C. In the treatment of FIG. 7, the consistency of the pulp was 1% and the temperature 155° C. In both cases, the pulp sample had been washed pine sulphate pulp from a mill.
The curves in FIGS. 6 and 7 indicate that the viscosity of the pulp does not decrease at the consistency of 10% (FIG. 6), whereas at the consistency of 1%, the viscosity decreases very sharply. As the viscosity of the pulp is proportional to the stiffness of the fibers, in other words, to their strength, their strength properties can be seen to deteriorate remarkably during washing at a low consistency. The kappa number of the pulp decreases almost as much in both cases, in the treatment at 10% from 41 to 30 (FIG. 6) and in the treatment at 1% from 26 to 19 (FIG. 7).
It is to be noted that the alkali mentioned in the following examples is a residue from the cooking process, said alkali not having been totally washed away in the prewashing stage. An ordinary amount of residual alkali after the cooking stage is about 10 g/l and after the prewashing stage suspension contains 0.5-5 g/l alkali so that by the prewashing stage, we have removed about 9.5-5 g/l alkali from the suspension. The alkali, however, is a vital factor for achieving the results explained, the alkali practically does not react chemically, but makes the fibers swell physically, whereby the dry substances and chemicals are able to extract from inside the fibers. The chemicals and dry substances mentioned in the claims are the residues from chemical reactions during the digesting process. Thus, the alkali is present in the suspension during the extraction, but does not take an active chemically reactive part in the extraction process.
It is also to be noted that when applying the method in accordance with the present invention, no additional chemicals are needed in the washing stage.
EXAMPLE 1
The pulp was digested in a laboratory to a kappa number of 30. The pulp was prewashed at a temperature of 150 ° C. under pressure while still in the chip form (i.e., with the lignin dissolved, but the chips not yet separated into fibers). It was found out that the kappa number began to decrease rapidly at the residual alkali content of 1-2 g/l as illustrated in FIG. 8 by curve 41 (horizontal axis: residual alkali content in extraction, vertical axis: change of kappa number). After prewashing, the pressure in the laboratory digester was suddenly dropped which resulted in the cellulose still in the form of chips being changed to fiber suspension (the pulp in chip form was fiberized). The digester was again pressurized and washing was carried out at a raised temperature of 150° C. The kappa number decreased further by five units (curve 42). The consistency was all the time 10%.
This example showed that extraction is most successful when the digested pulp is fiberized to fiber suspension and the extraction is carried out at a raised temperature.
EXAMPLE 2
Pulp was digested, prewashed and fiberized in the same way as in Example 1. Extraction was carried out at the consistency of 10% at a raised temperature.
Curve 51 in FIG. 9 (horizontal axis: volume of residual NaOH, vertical axis: change of kappa number) indicates that it is advantageous to wash the pulp in alkaline conditions at least when digestion has been carried out by the sulfate method as in this example. With pine sulfate pulp, a decrease of 8 kappa units was achieved by an extraction temperature of 150° C. and an extraction time of 30 minutes. In the example, the initial kappa number was approximately 30. Thus, washing can well be done with ordinary alkaline washing waters otherwise also used in a sulfate pulp mill.
EXAMPLE 3
FIG. 10 (horizontal axis: dry-substance content of the extraction solution, %; vertical axis: change of kappa number) illustrates the results of a third test. Pine sulfate pulp was at first digested under laboratory conditions and prewashed in the chip form at a raised temperature. Extraction was carried out at 150° C., extraction time 30 minutes. The extraction in the chip form decreased the kappa number as illustrated by curve 61. When the pulp was fiberized before the extraction (curve 62), the kappa number decreased rapidly (not illustrated in the figure) and the decrease was more intense. The difference was approximately two units. The test series showed that a low dry-substance content in the extraction is advantageous.
The share of bleaching on the effluent load of the whole sulfate process is directly proportional to the kappa number. A decrease of the kappa number from 30.5 to 24 decreases the effluent load by 20%. Also, consumption of bleaching chemicals is proportional to the kappa number and also decreases by 20%.
As the five embodiments described above show, there are quite a number of apparatus combinations for carrying out the method of the present invention which is extraction of lignin from a fiber suspension at a raised temperature and pressure without adding any washing chemicals and substantially without any chemical reactions during washing of a pulp suspension having a consistency higher than 3%. In addition to the economic point of view mentioned at the beginning, the volume of water used in the process also decreases as the high consistency technology available decreases the need for water to a fraction as compared with the amount required by previous methods. Further, considerable savings in the apparatus are to be gained as the consistency of the pulp need not alternatingly be increased or decreased, but pulp of medium consistency can be treated the whole time. Also, as the volume of water per pulp unit decreases the side of the apparatus can be smaller while the volume of the treated pulp increases.
While specific embodiments of the invention have been shown and described in detail to illustrate the application or the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.
|
The present invention relates to a method of intensifying the washing of a fiber suspension. In particular, the present invention relates to decreasing the lignin content of a fiber suspension by extracting. Lignin removal is usually carried out at a consistency of less than 3% whereby heating consumes much energy. The method of the invention allows a considerable increase in the consistency of the suspension which results in that the energy consumption is decreased to a fraction of the one required by prior art methods. A characteristic feature of the method of the invention is that dry substance and chemicals contained in the fibers are extracted at a raised pressure and temperature.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present patent application refers to a special equipment used to cut and model sheets of leather or other modellable materials, in order to produce semi-finished products with desired profile and shape, designed to be incorporated in a more complex product obtained from moulding.
2. Description of Related Art
In particular, the process and equipment of the invention have been devised to solve a problem that is frequently encountered in the footwear sector, which refers to the fabrication of moulded outer soles and bottoms with built-in decorative inserts or constructive components made of natural or synthetic leather or other modellable materials.
According to the technique that is currently used to produce the said bottoms, leather inserts are cut out from a leather sheet, using special socket punches/cutters that cut a flat piece with predefined dimensions and profile and punch holes or slots in the piece, as well as seams or decorative cuts on the piece surface.
These semi-finished products are then loaded in the mould used to obtain the bottom, in such a way that the insert can be applied and fixed to the bottom during moulding, applying adhesive substances on the insert surface to guarantee strong uniform adherence between moulding material and insert.
This technique, which has been used for a long time, is advantageous in case of inserts with flat profile loaded in the mould in horizontal position, such as against the bottom wall of the mould impression.
However, problems arise when inserts are given a three-dimensional shape before being loaded in the mould, such as for example a cup shape with profile perfectly matching the profile of the walls where inserts are to be positioned.
In this case, after punching, the flat leather piece is modelled by special moulds.
In spite of the techniques used during modeling to guarantee stability of shape, no rapid, inexpensive and safe process has been devised so far to prevent the flat punched piece from springing out of shape.
BRIEF SUMMARY OF THE INVENTION
The purpose of the present invention is to provide a process used to cut and model a flat sheet of leather or other materials that can be cut and modelled like leather in a stable way, during the same productive cycle.
Another purpose of the invention is to provide an equipment used to implement the said process, which is composed of a single tool used to cut and model the flat leather sheet in a stable way.
According to the process of the invention, the first punching operation is carried out by means of a socket punch that compresses the sheet against a die, which is suitably shaped to provide pre-modeling of the sheet, in cooperation with the said punch.
In order to give the pre-modelled sheet the desired accurate shape and prevent it from springing out of shape, according to the process of the invention a thin layer of plastic material, such as thermoplastic polyurethane, is injected in one of the two sides of the sheet, which compresses the sheet against the walls of the die or punch, based on the side of the sheet that has been injected.
In any case, the pre-modelled sheet is forced to perfectly adhere to the wall of the die or punch under the pressure of the injection material, thus exactly copying the surface profile.
Obviously, the side of the sheet that is injected is not the visible face on the bottom in which the modelled insert is to be applied.
Once it solidifies and cools down, the layer of plastic material forms a surface indeformable film that obstacles spring-back of the modelled leather sheet.
Now, the modelled insert is loaded in the bottom forming die (the moulding operation is carried out with conventional techniques that do not fall within the scope of the present invention), it being evident that the coating film is designed to be covered and hidden by the material used to mould the bottom.
With reference to the equipment used to implement the process of the invention, it basically consists in an ordinary injection mould, of the type used to mould plastic outer soles, in which the lid and die are used to cut the piece of leather that is positioned between them.
Another characteristic of this mould consists in that the internal profiles of lid and die are designed to cooperate to pre-model the leather sheet tightened between them, it being provided that the exact final modelling of the sheet is carried out at a later stage by injecting the plastic material.
Finally, it must be said that the mould die or lid are provided with one or more channels used to inject the plastic material that creates the thin indeformable coating film that acts as a stiffening surface crust on the leather sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
For purposes of clarity, the description of the process and equipment of the invention continues with reference to the enclosed drawings, which are intended for purposes of illustration only and not in a limiting sense, whereby:
FIGS. 1 to 5 are transversal cross-sections of the equipment of the invention shown in different positions that correspond to different operations of the process of the invention;
FIG. 6 is a perspective view of a bottom for shoes provided with a leather insert shaped and modelled with the process and equipment of the invention.
FIG. 7 is the cross-section of the bottom shown in FIG. 6 with transversal plane VII-VII.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIGS. 1 to 5 , the process of the invention is implemented by means of a special equipment (A) used to cut a flat leather sheet to measure and model it in a stable way during the same production cycle.
The said equipment (A) basically consists in an ordinary mould, of the type normally used to mould injection moulded bottoms made of plastic material, which comprises a die ( 1 ) with internal impression ( 2 ) that cooperates with a lid-punch ( 3 ) with protuberances ( 3 a ) on the internal side, provided with shaped cross-section and cutting corners ( 3 b ), that perfectly match with corresponding cavities ( 2 a ) located on the impression ( 2 ) and provided with cutting counter-corners ( 2 b ).
When the flat leather sheet (F) is positioned and tightened between the die ( 1 ) and lid-punch ( 3 ), as shown in FIG. 2 , the edges of the impression ( 2 ) cooperate with the edges of the lid-punch ( 3 ) to cut the sheet (F) along a closed perimeter line (L), forming perimeter off-cuts (S).
The protuberances ( 3 a ) cut the sheet (F) with their cutting corners, thus forming leather off-cuts (S 1 ) that are pushed to the bottom of the cavities ( 2 a ) by the protuberances ( 3 a ) during penetration in corresponding housings.
Because of the male-female coupling between lid-punch ( 3 ) and die ( 1 ), the sheet (F) positioned between the lid-punch ( 3 ) and die ( 1 ) is cut and modelled, being forced to assume the same profile as the internal sides of the lid-punch ( 3 ) and impression ( 2 ), between which the sheet (F) is tightened, as shown in FIG. 2 .
The lid-punch ( 3 ) is provided with one or more channels ( 4 ) used to inject plastic material (M) inside the impression ( 2 a ).
According to the process of the invention, plastic material is injected until the sheet (F) is positioned inside the impression ( 2 ) and tightened under the lid-punch ( 3 ), whose protuberances ( 3 a ) are momentarily positioned on the bottom of corresponding cavities ( 2 a ), so that the injection material (M) is applied over the sheet (F), and not drawn inside the cavities ( 2 a ), thus filling the lowered open spaces ( 3 c ) provided on the internal side of the lid-punch ( 3 ).
Under the pressure of the injection material (M), the sheet (F), after cutting and pre-modelling, is forced to perfectly adhere to the walls of the impression ( 2 ), exactly copying the surface profile; once it solidifies and cools down, the plastic material (M) forms a thin film ( 5 ) basically having the same surface area and shape as the sheet (F), as shown in FIG. 5 that illustrates the equipment (A) in open position with the semi-finished product (SL) extracted from the equipment.
The semi-finished product (SL) is obtained from the leather sheet (F) after cutting and modelling according to the shape of the impression ( 2 ) of the die ( 1 ), provided with holes ( 6 ) in the same positions as the protuberances ( 3 a ) of the lid-punch ( 3 ).
The sheet (F), after cutting and modelling, is coated by a thin coating film ( 5 ) moulded from plastic material on one side, i.e. the side facing the lid-punch ( 3 ), which basically acts as a stiffening surface crust on the leather sheet (F).
The process of the invention comprises the following operations:
positioning of a flat leather sheet (F) between the die ( 1 ) and the lid-punch ( 3 ) closing of the lid-punch ( 3 ) until the protuberances ( 3 a ) completely penetrate the cavities ( 2 a ) located on the impression ( 2 ) of the die ( 1 ) injection of plastic material (M) through injection channels ( 4 ) in order to finally model the sheet (F) and form a thin coating film ( 5 ) on one of the two sides of the sheet (F), as long as the sheet (F) is tightened between the die ( 1 ) and the lid-punch ( 3 ) opening of lid-punch ( 3 ); extraction of semi-finished product (SL) obtained from the sheet (F) after cutting and modelling, coated with the said thin film ( 5 ), of plastic material.
FIG. 6 illustrates a bottom ( 7 ) for shoes obtained from injection moulding, which incorporates the semi-finished product (SL), in which the holes ( 6 ) are penetrated and filled with the injection material (MA) used to mould the bottom ( 7 ), whose tread ( 8 ) is formed by a series of protuberances (P) coming out of the leather sheet (F) after cutting and modelling.
|
A process used to cut and model sheets of leather or other modellable materials, according to which cutting and modeling are carried out by means of a die and a lid-punch that cooperate to cut a leather sheet positioned and tightened between the die and the lid-punch according to predefined cutting lines and at the same time model the sheet in a stable way by a plastic film injected on one of the two sides of the sheet.
| 0
|
BACKGROUND OF THE INVENTION
The present invention relates to the production of synthetic yarns in which subsequent to melt spinning the yarn is drawn and twisted on an apparatus sometimes hereinafter referred to as a drawtwister. In particular, the invention is directed to a string-up and cut-down device on a drawtwister.
The production of synthetic yarns often involves a two step process, that is, first, unoriented filaments are melt spun and wound onto bobbins; second, a creel of these bobbins is used to supply a drawtwister which draws or orients the filaments, twists them together and winds the resultant yarn onto pirns.
A method of producing synthetic yarns in which the filaments are melt spun, drawn, twisted and wound onto pirns without the intermediate step of bobbin winding has been shown to be possible and to have the advantages of reducing labor requirements and of improving yarn quality. However, conventional drawtwisters are designed to operate with a creel of passive bobbins and are not designed to handle a continuously flowing supply during periods when the yarn is not being wound onto the pirn.
It is an object of this invention to provide a means with which a conventional drawtwister, employing a conventional ring twisting technique, may be adapted to accommodate a continuous supply of yarn.
It is also an object of this invention to provide a string-up apparatus which may be operated manually on an individual position of a drawtwister or automatically and simultaneously over all the drawtwister positions while the drawtwister is running with a continuous supply of yarn.
It is a further object of this invention to provide a means by which a drawtwister may be left strung up and running during doffing.
It is yet another object of this invention to provide an automatic cut-down means which may be operated manually on individual positions or automatically and simultaneously over all positions of the drawtwister being adapted to stop the yarn from winding onto the pirn without interrupting continuous supply which remains running through the drawtwister.
SUMMARY OF THE INVENTION
In a ring twister for winding yarn on the surface of a pirn carried by a rotating spindle including a ring positioned concentric with and mounted for traversing said spindle, said ring having a freely rotatable traveller through which yarn passes in a path past a yarn disposal means to the spindle, means for traversing said ring, and means for snagging the yarn mounted at the base of the spindle, the improvement comprising: a rotatable pulley mounted adjacent said yarn snagging means, said pulley being concentric with said spindle and having a diameter less than said ring; means for rotating said pulley; cutting means attached to said yarn disposal means; and a guide attached to said pulley for engaging said yarn as said pulley is rotated and moving said yarn into engagement with said cutter and said snagging means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a preferred embodiment of this invention on one position of a drawtwister.
FIG. 2A is a plan view of this preferred embodiment just prior to string up (one position only).
FIG. 2B is a front elevation of the apparatus shown in FIG. 2A.
FIG. 3A is a plan view showing the initial step in string up (one position only).
FIG. 3B is a front elevation of the apparatus in the position shown in FIG. 3A.
FIG. 4 is a schematic diagram of manifolds used to provide compressed air.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the embodiment of the invention shown in FIG. 1, a pirn 10 is seated on a snag means 11 while mounted on the drawtwister's driving spindle (10a, FIGS. 2B and 3B). Concentrically surrounding the snag means 11 is a pulley 12 and a ring twister means 13. A string-up guide 14 is attached to the upper face of the pulley 12. The string-up guide 14 resembles a shark fin in that one edge 15 is perpendicular to the pulley face while the other edge 16 is sloped away from the said face in a smooth curve to meet the perpendicular edge. The ring twisting means 13 consists of a traveller ring 17 and a traveller 18 which is free to slide around said traveller ring 17. Traveller ring 17 is adapted to move vertically up and down the length of the pirn 10 as indicated by the reversing arrow in the conventional manner by means not shown.
A cord 19 is wrapped around the pulley 12. One end of said cord 19 is attached to a counterweight 20 while the other is attached to and wound about a gang roller 21. Direction changes in the cord 19 in its respective courses to the counterweight 20 and the gang roller 21 are achieved by appropriately positioned guides 22. The pulley 12 is positioned slightly lower than the traveller ring 17 when the traveller ring 17 is at its lowest position to allow the cord 19 to pass below said traveller ring 17 without obstructing the traveller 18.
A disposal means 23, powered by compressed air, is positioned so that its intake opening 24 is located below the top of the snag means 11 and about the top of the traveller ring 17, when said traveller ring 17 is in its lowest position. In another plane the intake opening 24 lies between the pulley 12 and the snag means 11 along a diameter of said pulley 12 that if extended would pass through the centers of the pirns on adjacent positions of the drawtwister. The intake opening 24 may lie to the left or right of the pirn 10 when viewed by one facing the drawtwister in this embodiment. This last location is determined by the relationship of the driving belts to the spindle on the particular position of the drawtwister. Both left and right hand locations were used to avoid the belts. It will be appreciated that on other drawtwisters of different design, the positioning would be suitably adapted.
A cut-down guide 25 and a cutting blade 26 are mounted above the disposal means 23, on the side 27 of said disposal means 23 closest to the snag means 11.
The cut-down guide 25 has a slanting edge 28 which terminates at the intersection of the said edge 28 and the top of disposal means 23. The slanting edge 28 is sharpened near the intersection to form a cutting blade 26 which lightly presses against the top of the disposal means 23.
Each position on the drawtwister is similarly fitted. The gang roller 21 therefore runs the full length of the drawtwister having attached to it the cords 19 from all the positions of said drawtwister.
The disposal means 23 at each position are connected by valves 34 to an individual operation manifold 29 and a gang operation manifold 30 shown in FIG. 4 which allows individual or simultaneous control of the air supply to the disposal means.
The interaction of these components during string-up may now be described with the air of FIGS. 1, 2A, 3A and 3B. The description will be of a drawtwister position which puts Z twist in the yarn. For S twist, the spindle will rotate in the opposite direction and the apparatus will be appropriately reversed.
In preparation for string-up, the yarn 31 (FIG. 1) is led through the traveller 18 over the pulley 12 and into the intake opening 24 of the disposal means 23. The traveller ring 17 is in its lowest position. A new pirn 10 is seated on a spindle 10a fitted with a snag means 11 which is not turning. The string-up guide 14 is positioned so that its perpendicular edge 15 will be adjacent to the horizontal section 32 of yarn now running continuously between the traveller 18 and the disposal means 23. The spindle is now started so that the pirn 10 and the snag means 11 rotate clockwise.
The pulley 12 may be rotated with cord 19 by rolling up said cord 19 on the gang roller 21. To reverse the rotation of the pulley 12, the gang roller 21 is unrolled and the cord 19 is pulled in the other direction by the counterweight 20.
The string-up guide 14 is attached to the pulley 12 which is connected by cord 19 to gang roller 21 so that movement of the said string-up guide 14 may be controlled by the gang roller 21.
To commence string-up, the perpendicular edge 15 of the string-up guide 14 is now moved against the horizontal section 32 of yarn 31 (FIGS. 2A and 2B) so that it pushes said horizontal section 32 radially around the disposal means 23 so that said horizontal section 32 is thereby brought into contact with the rotating snag means 11 (FIGS. 3A and 3B).
At this time, the traveller ring 17 is raised to its regular winding traverse. As the ring rises, the yarn passes into a crack 33 formed between the bottom of the pirn 10 and the top of snag means 11. Within the crack 33 lies a disk of sandpaper (not shown) slightly recessed into the top of said snag means, which causes the yarn to snag. Once snagged, the yarn breaks between the disposal means 23 and the pirn 10 and starts to wind on the pirn as the traveller ring 17 continues to rise.
In this preferred embodiment, the snag means 11 has the shape of a truncated cone having its base affixed to the spindle. This shape causes the horizontal section 32 of yarn to meet the crack 33 of the snag means and pirn joint at a preferred angle so as to facilitate entry into said crack 33.
It will be appreciated that in other embodiments the snag means 11 may employ means to cause snagging other than a crack lined with sandpaper.
The interaction of the components during cut-down may be described with the aid of FIG. 1.
The yarn is winding on the pirn 10 in normal fashion when the traveller ring 17 is lowered to its lowest position for doffing. As said traveller ring 17 is lowered, the yarn between the traveller 18 and the pirn 10 is caught by the cut-down guide 25 which is mounted above the disposal means 23. The horizontal section 32 of yarn 31 is guided down to the disposal means 23 and across the cutting edge of cutter blade 26. Thus trapped, the tension in the yarn between said cutter blade 26 and the pirn 10 causes the yarn to break at the cutter blade 26 whereupon the free end of the horizontal section 32 of yarn 31 is drawn into the intake opening 24 of the disposal means 23 and carried to waste. At this point, the spindle may be stopped for doffing pirn 10.
During the cut down, the string-up guide 14 is positioned just ahead of cut-down guide 25 so that the sloping edge 16 of string-up guide 14 is presented to the yarn and the yarn rises up and over guide 14 avoiding guide 25 until traveller ring 17 is low enough for the yarn to be pulled down the perpendicular edge 15 of guide 14 and into guide 25. This delay caused by guide 14 ensures that the traveller ring 17 is low enough so that the yarn is immediately pressed to the disposal means 23 once caught by guide 25.
Although the string-up and cut-down action described has been for one position, the action may be made to occur simultaneously on all positions of the drawtwister.
Drawtwister spindles are usually driven from a central gang shaft called the cylinder shaft which runs the length of the drawtwister. Thus, by starting or stopping the cylinder shaft, all the spindles start or stop simultaneously. The cylinder shaft may be driven by its own motor or from a main drawtwister motor through a clutch. Individual positions may be stopped independently of others by using an individual spindle brake usually supplied on drawtwisters.
The traveller rings may be connected to a layrail by a quick release catch. By lowering the layrail to its lowest position, all traveller rings are lowered. With the quick release catch individual rings may be lowered when the layrail is in the winding position.
As mentioned previously, the rotating string up guides 14 are each controlled by a cord 19 which may be connected to a gang roller 21 running the length of the drawtwister which may control them for all positions of the drawtwister simultaneously.
The string-up guide 14 may be operated on an individual position by manually pulling cord 19 towards the gang roller 21 so that guide 14 is reset for string up. Upon releasing cord 19 to the force of counterweight 20, cord 19 will cause guide 14 to drag the horizontal section 32 of yarn around to the bottom of the snag means 11. Thereafter the traveller ring 17 may be manually raised to connect to the layrail thereby engaging the horizontal section 32 of yarn with the upper portion of the snag means 11 which causes string up to occur as previously described.
The disposal means may be controlled by a three-way valve 34 on the air supply and the two manifolds 29 and 30 will permit either individual or simultaneous operation. A two-way valve 35 permits the air supply to gang operation manifold 30 to be turned off when the aspirators 23 are not required such as during winding.
|
An apparatus for stringing up a rotating package holder on a ring twister with a yarn being fed to a waste jet. A rotatable pulley with a yarn guide attached is used to intercept the yarn and move it into engagement with a cutter attached to the waste jet and a yarn snagging means adjacent the package holder. The waste jet-cutter combination is also designed to cut down a full package at the completion of a winding cycle.
| 3
|
FIELD OF THE INVENTION
The present invention relates in general to methods and apparatuses for processing chip-like or wafer-like materials, and relates in particular to methods and apparatuses for processing jumbo wood chips or wafers.
BACKGROUND OF THE INVENTION
Wood is a naturally occurring composite material being made of wood fibers embedded in a matrix of lignin. Thus lumber made from harvested wood has strength properties which are dependent on the orientation of the fibers or wood grain. Recently the convergence of two trends in the development of wood products has led to the development of new engineered wood-based structural members. The first trend is the increasing costs of wood due to increased demand and decreased supply due to environmental restrictions on logging. In the past, wood unsuitable for forming dimensional timber was often discarded or burnt as waste fuel. Now, however, scrap wood is reduced to wood chips for use in papermaking, particle board or engineered structural members. The second trend is the result of an insight from the structural composites industry marking the realization that composite materials may be engineered to suit particular applications. The result has been products such as wafer board or chip board which have randomly oriented chips or wafers of wood which are laminated together to form a plywood replacement product which is not only cheaper but stronger than plywood in many applications.
Structural timbers are composed of wood chips in which the chip fibers are oriented in the direction of the principle stresses. The wood chips are laminated under heat and pressure to form large laminated loaves which are in turn milled into structural members. The process allows the fabrication of wood structural members which do not require large or uniform logs as starting materials. Further, because the structural properties of the member may be designed, the beam may be stronger and lighter than one constructed of wood boards.
The wood chips or wafers utilized in the construction of these new wood products are fabricated from a wide range of raw logs and wood scraps. Typically the wafers are forty to sixty thousandths of an inch thick, four to twelve inches long, and one-half to three inches wide. In the production of strand board in particular, and structurally engineered wood products in general, it is desirable that the strands not be too wide. This allows better control of the orientation of the strands to achieve the structural properties desired, particularly the random orientation of the strand layers in strand board.
Wafers of uniform width also improve the overall appearance of the product by yielding a uniform surface and by facilitating improved uniformity of the glue coating on the wafers. Slicing the wafers into wafers of proper width presents several problems. The wafers must be precisely oriented as they are fed into the knives to prevent the knives from cutting across the grain and so cutting the fibers in the wafers. It is also desireable to minimize the fines produced by cutting the wafers, as small particles are unacceptable for use in the formation of wafer board.
What is needed is a process and apparatus for splitting strand boards into narrow, uniform lengths without the destruction of useful fiber.
SUMMARY OF THE INVENTION
The strand splitter of this invention employs a pair of opposed rolls. The surface of each roll is formed of uniformly spaced, circumferential triangular grooves with triangular ridges defined between adjacent grooves. The ridges of one roll are closely spaced, about an eight of an inch, from the grooves of the opposed roll, thereby forming a sinuous nip between the rolls. The rolls are mounted on a frame and driven to rotate about spaced parallel axes by electric motors operating through speed reducers. Wood chips strands or wafers are fed to the nip from a vibrating conveyor which orients the strands so they enter the rolls with the grain of the strands parallel to the ridges and grooves on the rolls. The infed wood chips, which are forty to sixty thousandths of an inch thick, have low strength transverse to the direction of the grain and, thus, when forced to flex by the interdigitating ridges and grooves of the opposed rolls, are split into strands which have a width less than or equal to the length of a groove side plus the width of the gap between rolls.
It is a feature of the present invention to provide a wood chip strand splitter which retains fiber integrity.
It is another feature of the present invention to provide a wood chip strand splitter which reduces the generation of fines.
It is a further feature of the present invention to provide a wood chip strand splitter which cracks an infed wafer along the fiber length.
It is a still further feature of the present invention to facilitate the production of strand board by reducing the cost of the strands comprising it.
Further objects, features and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of the wood chip strand splitter of this invention.
FIG. 2 is a cross-sectional view of the wood chip strand splitter of FIG. 1 taken along section line 2--2.
FIG. 3 is an cross-sectional view of the strand splitter of FIG. 1 taken along section line 3--3.
FIG. 4 is an enlarged fragmentary plan view of the intermeshing rolls of the strand splitter of FIG. 1.
FIG. 5 is an enlarged fragmentary plan view of the intermeshed rolls of an alternative embodiment strand splitter of this invention which run tip to tip.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to FIGS. 1-5, wherein like numbers refer to similar parts, a wood chip strand splitter 20 is shown in FIGS. 1-3. As shown in FIG. 1, wooden strands 22 are introduced to the splitter 20 by a vibrating conveyor 23. The strands 22, also known as wafers or jumbo wood chips, have their largest dimension, their length, along the grain of the wood chip 22. The chip length typically varies between four and twelve inches. The wood chips 22 are typically forty to sixty thousandths of an inch thick and one to three inches wide.
As shown in FIGS. 1 and 2, the vibrating conveyor 23 has upstanding vertical ribs 24. The ribs 24 are spaced apart to form troughs 28 approximately three inches wide. The vibration of the conveyor 23 not only progresses the chips 22 toward the conveyor discharge edge 26 but also causes the chips to align and fall within the troughs 28 between the ribs 24. The overall effect of the vibrating conveyor 23 is to spread out and feed the wood chips 24 with the grain aligned along the direction of movement. A scraper or brush (not shown) can be positioned over the vibrating conveyor to prevent any wood chips which have not fallen into a trough 28 from progressing to the conveyor discharge edge 26. The conveyor 23 is mounted above the frame 30 of the strand splitter 20. The chips 22 discharged from the conveyor 23 are fed into a sinuous nip 32 formed between a first roll 34 and a second roll 36 which are mounted to the frame 30 for rotation on bearings 38.
The rolls 34, 36 are generally cylindrical. An exemplary roll is ten feet long and approximately eleven inches in diameter. The surfaces 40, 42 of the rolls 34, 36 are contoured with parallel spaced circumferential grooves 44. Circumferential ridges 46 are defined between adjacent grooves 44. Each groove 44 is defined as the intersection of two frustoconical side surfaces 55. As shown in FIG. 4, the grooves 44 of the first roll 34 interdigitate with the ridges 46 of the second roll 36. The nip 32, shown in FIGS. 1 and 4, is sinuous and snakes back and forth between the opposed ridges and grooves of the first and second rolls 34, 36. The wood strands 22 leave the vibrating conveyor 23 and free fall into the nip 32 between the rolls 34, 36 as shown in FIGS. 2 and 3. The wood strands 22 enter the nip 32 with their grain oriented in the direction of travel and thus the grain of the strands 22 is substantially tangent to the rolls 34, 36.
As the wood strands 22 pass through the nip 32, they are forced to conform to the sinuous saw-toothed shaped gap 48 of the nip 32. This causes the strands 22 to bend sharply parallel to the grain which fractures the chips into narrow strands 50. The width of the resulting processed strands 50 is dependent on the size of the grooves 44 and the ridges 46. It has been found that a strand splitter having rolls with grooves which are three-quarters of an inch deep and three-quarters of an inch wide will produce processed strands which have a maximum width of approximately one inch. Because the infed wood strands 22 vary in width and because the edges 51 of the infed strands 22 are not precisely aligned with a ridge 46, the groove spacing controls the maximum width of the chip with a size distribution below that maximum width.
In some strand board products it is desirable that the wood strands all have widths less than one inch. A particular configuration of the rolls 34, 36, as shown in FIG.4, has grooves which are three quarters of an inch wide and three quarters of an inch deep, and advantageously achieves this desired size distribution.
The size of the processed strands 50 is generally governed by the length of the groove sides 55 together and by the width of the gap between rolls which is preferably approximately one-eighth of an inch flat to flat.
The rolls are driven by motors 56 through speed reducers 58. The speed reducers 58 are mounted on the roll shafts 60 which define axes 62 about which the shafts rotate. The motors are connected by V-belts 64 to the speed reducers 58 which drive the shafts to cause the rolls to counter-rotate and draw the infed wood strands 22 through the nip 32. The wood chips 22 have dimensions of length, width and thickness. The wood fibers are rod-like structures which extend along the length. The strands 22 are resistant to breaking if bent across the length because the fibers traverse the length. On the other hand, because few or no fibers traverse the width, if bent across the width, the wood strands 22 readily break. The wood chips 22 are composites of wood fibers in a matrix of lignin and if broken crosswise, the fracture takes place in the lignin and thus the individual fibers are not damaged.
Conventionally, wood strands are sliced by blades to the proper width. Slicing presents several problems which are overcome by the strand splitter 20. Blades wear and must be sharpened and further can be subject to rapid wear by grit or dirt carried along by the wood strands. Another disadvantage of slicing blades is that because wood grain is not perfectly straight, and because the strands are not perfectly aligned with a slicer's blades, wood fibers are cut in the slicing operation. The slicing operation can produce fines which become waste. The overall strength of a strand is decreased by the slicer cutting across the strand grain.
The strand splitter 20 of this invention, on the other hand, by breaking the chips along the grain, allows the break line to follow the grain of the wood. Thus, the strands 22 are broken along the grain into smaller strands, not cut, thus avoiding the breaking of any fibers. This breaking along the grain maximizes the utilization of the fibers and the strength of the strands. The grooves and ridges formed on the roll have rounded edges, for example a radius of 0.032 for the tops of the ridges and bottom of the grooves. Thus the strand splitter 20 has no sharp edges and so significantly less maintenance is required than in a slicer.
Although in the preferred embodiment, the ridges of the rolls 34, 36 interdigitate, as shown in FIG. 5, alternative rolls 72, 74 may run with the ridges peak to peak. When the ridges are run opposed, the tips of the ridges engage so that the fracturing takes place between the tips of the ridges which induce a compressive fracture in the strands 22. The maximum width of the strands formed by the grooved rolls of FIG. 5 is governed by the tip spacing of the ridges, in contrast to the rolls in FIG. 4 where the maximum length is governed by the length of the side of the groove between the ridge tip and groove bottom.
It should be understood that wherein grooves of varying widths could be employed, grooves having widths of one-half to three-quarters of an inch have particular utility in forming chips of a preferred size distribution for strand board construction.
It should be further understood that in place of a vibrating conveyor for aligning and feeding the chips, orientation rolls which use discs, or other similar devices could be used.
It should also be understood that the, grooved rolls may be formed of nickel-plated cast iron. Rolls also may be formed with an outer layer of high durometer plastic so that tramp materials will not damage them as they transit the nip 32.
It is understood that the invention is not limited to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims.
|
Two rolls are mounted to a frame and rotated about spaced parallel axes by electric motors operating through speed reducers. Each roll has a surface formed of uniformly spaced, circumferential extending triangular grooves and ridges defined between grooves. The ridges of one roll are closely spaced from the grooves of the other roll to define a sinuous nip therebetween. A vibrating conveyor orients wood strands and feeds the strands to the nip with the grain of the strands parallel to the roll ridges and grooves. Wood chips have low strength transverse to the direction of the grain and, thus, when forced to flex by the interdigitating ridges and grooves of the opposed rolls, split into narrower strands.
| 3
|
This application is a continuation of Ser. No. 08/552,938 filed Nov. 3, 1995 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a novel electrolytic cell and bipolar electrodes for producing peroxydisulfuric acid and peroxydisulfates and a closed loop process for the production of hydrogen peroxide by hydrolysis of said peroxydisulfuric acid and peroxydisulfates.
2. Description of Related Prior Art
Inorganic persulfate compounds are very strong oxidants used mainly in textile bleaching, metal cleaning, and etching solutions as well as emulsion polymerization initiators. The only commercial method of preparation for a persulfate compound such as peroxydisulfuric acid (persulfuric acid) and salts thereof (persulfates) is an electrochemical process with platinum being commonly used as the anode material. The state of the art with respect to the commercial production of peroxydisulfates has been reviewed in an article entitled Electrochemical Reactors by Balej et al. appearing in Fortschritte Der Verfahrenstechnik (Progress in Chemical Engineering) section D, 22 (1984) pages 361-389. This article also reviews the state of the art with respect to the commercial production of hydrogen peroxide by the hydrolysis of peroxydisulfate. Hydrogen peroxide can be produced from ammonium bisulfate by electrolysis with 80 to 90 percent current efficiency in accordance with the following reaction.
(NH 4 ) 2 S 2 O 8 +2H 2 O2NH 4 HSO 4 +H 2 O 2 (II)
Hydrogen peroxides can also be produced by the electrolysis of a sulfuric acid solution in a series of electrolytic cells, preferably arranged so that the electrolyte solution cascades from one cell to the next by gravity. The persulfuric acid or ammonium persulfate derived from the electrolysis can be hydrolyzed by passing it continuously through a steam jacketed coil in which the liquid is evaporated to about ½ its original volume and the peroxydisulfuric acid and persulfate are hydrolyzed to produce hydrogen peroxide as vapor. The evaporation of water increases the acid concentration of the electrolyte containing peroxydisulfuric acid thereby accelerating the rate of hydrolysis to produce hydrogen peroxide. The overall reaction for producing persulfuric acid by electrolysis from sulfuric acid and the subsequent reaction outside the cell of the persulfuric acid to produce hydrogen peroxide in the hydrolyzer are:
In the cell:
2H 2 SO 4 H 2 S 2 O 8 +H 2 (III)
and in the hydrolyzer:
H 2 S 2 O 8 +H 2 O 2 H 2 SO 4 +H 2 O 2 (IV)
Other processes for the production of hydrogen peroxide are disclosed in:
U.S. 2,745,719
U.S. 2,178,496
U.S. 2,163,898
U.S. 2,169,128
U.S. 2,278,605
U.S. 2,091,218
U.S. 2,243,810
Most of the hydrogen peroxide produced on an industrial scale is prepared by the oxidation of alkylhydroanthraquinones in view of the very high energy consumption of electrolytic processes for the production of persulfuric acid or salts thereof and the concentration and hydrolysis of the product of the electrolytic process to produce hydrogen peroxide. More recent work to improve the efficiency of producing persulfuric acid or persulfate salts by electrolysis and the subsequent concentration and hydrolysis to produce hydrogen peroxide are disclosed in the following patents:
U.S. 2,282,184
U.S. 4,802,959
U.S. 3,884,778
U.S. 3,694,154
In U.S. Pat. No. 4,802,959, a glassy carbon anode is disclosed as a low cost alternative to platinum for use in an electrolytic cell for the production of peroxydisulfuric acid and its salts. In U.S. Pat. No. 3,884,778, an electrolytic cell having three compartments is utilized to prepare peroxydisulfuric acids and sulfuric acid in one compartment of the cell and an alkali metal hydroxide in another compartment of the cell. Hydrolysis of the peroxydisulfuric acid outside the cell is used to produce hydrogen peroxide.
In U.S. Pat. No. 5,082,543, an electrolysis cell of the filter press type is disclosed for the production of peroxy and perhalogenate compounds including peroxydisulfates and peroxydisulfuric acid. Platinum coated valve metal substrates are disclosed as anodes, the platinum layer being applied to the substrates by hot isostatic pressing, or diffusion welding, of a platinum foil onto the valve metal substrate. Preferably, the platinum foil has a thickness of about 20 to about 100 microns. The cathode used in the electrolytic cell is a perforated, liquid and gas permeable cathode of stainless steel which is further identified as tool steel number 1.4539. Electrolysis cell separators are cation exchange membranes such as Nafion® 423. These are clamped between the frames of the cell and the frames are sealed by gaskets of a vinylidene fluoride-hexafluoropropylene copolymer.
SUMMARY OF THE INVENTION
In accordance with the invention, an electrolytic cell is disclosed for the production of peroxydisulfuric acid or salts thereof utilizing a high overvoltage anode comprising a valve metal substrate and a discontinuous coating of a platinum group metal. A stainless steel cathode is used having substantially higher concentrations of nickel, chromium, and molybdenum in comparison with 316 stainless steel. The novel electrolytic cell is of the filter press type having frames of polyvinyl chloride bonded with a vinyl ester polymer. Where the electrolytic cell is utilized in a bipolar electrode configuration, the anode and cathode current collectors are bonded utilizing a vinyl ester polymer containing a substantial proportion of graphite to render the mixture electrically conductive. The electrolytic cell can be operated utilizing a permselective membrane between the anode and cathode but, preferably, a microporous polyvinyl chloride diaphragm is utilized.
For the production of peroxysulfuric acid or salts thereof and for the production of hydrogen peroxide by the subsequent concentration and hydrolysis outside the cell of peroxydisulfuric acid and salts thereof, the filter press cells can be arranged in a series of cascading cells in which the electrolyte is led by gravity from one cell to the next and the catholyte from the last cell in the series is recycled to the anolyte compartment of the first cell of the series so as to constitute a closed loop system. A feature of the novel electrolytic filter press cells disclosed is the use of a metal impurity removal step in which ion exchange resins or other means are used as a means of removing from the electrolyte the metal impurities which accumulate during operation of the cells. If allowed to remain in the peroxydisulfuric acid or salt thereof anolyte product withdrawn for further processing to concentrate and to hydrolyze the product to produce hydrogen peroxide, these metals would act as catalysts for the decomposition of the hydrogen peroxide produced by hydrolysis.
When the novel electrolytic cell is utilized to produce peroxydisulfuric acid and salts thereof for use as reactants in the production of hydrogen peroxide, the use of a metal purification step allows the process to be a closed loop process. The process is environmentally desirable over prior art processes which require periodic purging and disposal to the environment of process streams to remove metal impurities. When the reactants fed to the anode compartment of the electrolytic cells are sulfuric acid and ammonium sulfate, a closed loop process is permitted with the bottoms from the hydrolyzer consisting of sulfuric acid being recycled to the anode compartment of the electrolytic cells as the hydrogen peroxide is removed in the overheads from the hydrolyzer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the filter press type electrolysis cell described in U.S. Pat. No. 5,082,543, hollow cathodes and anodes are disclosed wherein the cathode hollow bodies are liquid and gas permeable and the anode hollow bodies have, above and below a platinum layer, openings for the introduction and removal of the anolyte. The effective anode surface is formed by the platinum layer of a composite anode comprising a valve metal substrate and a platinum layer present thereon which is obtainable by the hot isostatic pressing of a platinum foil onto a valve metal substrate. The cells of this reference are disclosed as useful for the production of peroxy and compounds, specifically, the anodic production of peroxydisulfate, peroxomono sulfates, peroxydiphosphates. By providing circulation of cooling water in the anode, the electrolysis operation is disclosed as being able to proceed with current densities of up to 15 kA/m 2 by reducing ohmic voltage losses caused by heating of the anode surface.
As noted above, the '543 patent discloses an electrolysis cell having an anode hollow body and a cathode hollow body through which cooling water circulates in order to dissipate heat formed, particularly, in the anodic production of peroxydisulfates and salts thereof. Because such a cell design in which hollow electrodes are used is fraught with the danger of leakage of the cooling water into the cell electrolyte and, accordingly, requires effective, dependable sealing so as to avoid such leakage, with the possibility of precipitation of one or more electrolysis products within the cell, such a cell design has been intentionally avoided in favor of the use of external heat exchangers in the process of the invention.
The Applicants have found it unnecessary to provide the complexity of electrodes disclosed in '543 in order to operate the electrolytic cell at a high current density on the anode in the production of peroxydisulfuric acid and salts thereof. Accordingly, the possibility of cooling water leakage into the electrolyte is avoided in the electrolytic cells disclosed by the Applicants in which the electrodes are arranged in a planar configuration in a filter press type electrolytic cell with the anode being formed of a valve metal substrate such as titanium, niobium, or zirconium, preferably, titanium, coated with strips of a platinum group metal, preferably, a platinum foil wherein the width of the foil strips is about two times the distance between the strips. The platinum strips are cold rolled onto the valve metal substrate so as to produce a durable anode material which is capable of operating at the high overvoltage conditions necessary to the production of peroxydisulfuric acid and salts thereof. The use of titanium as an anode substrate in the inventive electrolytic cell in the presence of sulfuric acid, which has a reducing effect on the titanium, is made possible by the application of an anodic cell potential which makes the anode environment oxidizing.
The novel cathode utilized in the electrolytic cell of the invention is a mesh or expanded metal planar sheet of a stainless steel having higher concentrations of nickel, chromium, and molybdenum than the 316 stainless steel which has been used as a cathode in electrolytic cells for production of peroxydisulfuric acids and salts thereof. Specifically, the stainless steel cathode comprises in parts by weight about 20 to about 30 parts of nickel, about 15 to about 25 parts of chromium, and about 5 to about 7 parts of molybdenum. A typical composition in weight percent of stainless steels which are suitable as cathodes in the electrolytic cell of the invention is given in Table I in comparison with 316 stainless steel.
TABLE I
Stainless Steel components, weight percent.
Metal
Stainless Steel A
Stainless Steel B
ANSI 316
Nickel
24.0
25.0
12.0
Chromium
20.5
20.0
17.0
Molybdenum
6.3
6.5
2.5
Silicon
0.4
0.5
1.0
Manganese
0.4
1.0
2.0
Iron
48.0
47.0
67.0
The electrolytic cells of the invention can have electrodes arranged in either monopolar or bipolar configuration. Preferably, the electrolytic cells have a bipolar electrode configuration since, given the relatively high cost of the electrode materials, the use of thin planar sheets of electrode material allow the economical use of such high cost electrode materials. In addition, with a bipolar electrode configuration, the multiple electrical connections and multiple seals required at the monopolar electrode leads through a cell wall are avoided. In addition, since electrolytic cells for the production of peroxydisulfate and salts thereof require a relatively high current density at the anode of the cell, even a slightly higher electrode material resistivity can lead to severe heat generation at a monopolar connection. In contrast, with a bipolar electrode, such current distribution problems are avoided which result from the resistivity of the electrode. While the bipolar electrode configuration is less desirable from a current leakage point of view as compared with a monopolar electrode configuration, the use of small inter-cellular flow channels for electrolyte so as to reduce the current leakage and the use of larger electrolyte flow channels to aide in the distribution of electrolyte and for heat removal must be balanced. In a bipolar electrode configuration having a valve metal anode substrate coated with a discontinuous coating of a platinum group metal, preferably platinum, the valve metal anode substrate is subject to exposure to hydrogen produced at the cathode of the cell. The hydrogen can migrate as atomic hydrogen through the bipolar cathode toward the valve metal anode substrate. Prior art bipolar cell configurations have suffered from the formation of a metal hydride at the junction of a valve metal anode and cathode of a bipolar electrode. While the hydride thus formed is a conductive material, the resistance of the hydride is greater than the resistance of the anode and cathode electrodes but, most importantly, because the hydride has a lower density than that of the pure metal from which the anode substrate and the cathode are formed, mechanical stresses can build up large enough to cause failure of the bipolar connection.
In the electrolytic cell of the invention, the possibility of hydride formation and the likelihood of failure of the junction of the anode and cathode in the bipolar electrode configuration has been avoided by the use of a conductive vinyl ester polymer adhesive, which resists hydrogen migration, to join the anode and cathode to form the bipolar electrode.
The vinyl ester polymer utilized is an elastomer modified vinyl ester polymer which is superior to the polyesters utilized in most conventional polyester resin applications. The vinyl ester polymer selected as a component of the conductive adhesive used to join the anode and the cathode of the bipolar electrode configuration is made more flexible and ductile by reacting an elastomer onto the vinyl polymer backbone of the resin. This provides increased adhesive strength, superior resistance to abrasion and mechanical stress and double or triple the toughness performance of standard vinyl ester polymers. As with more conventional vinyl ester polymers the elastomer modified vinyl ester polymer can be reacted with peroxides such as methyl ethyl ketone peroxide and benzoyl peroxide to cure the resin so that it becomes resistant to the highly acid electrolyte. In order to provide the necessary conductivity, the vinyl ester polymer is mixed with a graphite powder in the proportion of about 20 to about 60 percent by weight of the total composition. Preferably, about 30 to about 50 percent of a graphite powder having a particle size of about 10 microns is mixed with about 70 to about 50 percent by weight of the vinyl ester polymer to form the electrically conductive adhesive composition used to bond the anode and cathode of the bipolar electrode. More specifically, it is the anode and cathode current collectors of the electrolytic cell which are bonded together while the anode and cathode are spot welded by spacer posts to the respective current collectors. This allows the adjustment of the anode and cathode gap between the cell separator by selection of spacer post length.
While the sealing of the cells of the filter press configuration assembly of electrolytic cells can be accomplished by O-rings or flat gaskets between the cells and between the multiple frame components making up each individual cell, it has been found advantageous to assemble the cell utilizing the vinyl ester polymer described above in which the adherent toughness of conventional vinyl esters have been enhanced by reacting an elastomer onto the backbone of the vinyl resin. Improved bond strength can be obtained by mechanical or chemical abrasion or etching of the cell frame surfaces to be joined. Sandblasting or organic solvent etching have proven effective to prepare the surface for bonding. It has been found that this vinyl ester resin is superior to the use of an epoxy resin which has been conventionally used in filter press type electrolytic cell construction as a sealing material. This adhesive can also be used to bond individual cell units together to make up the assembled filter press configuration. Alternatively, individual cells can have gaskets joining other cells in the series utilizing conventional gasketing material such as O-rings or flat gaskets of an elastomeric material such as a silicone or fluorine rubber.
The filter press type electrolytic cell configuration of the invention can be used for the production of peroxydisulfates and salts thereof in a closed loop system. The electrolyte of each cell is led to the adjacent cell by arranging the cells in a cascading series so as to utilize gravitational force to move the electrolyte between cells. The catholyte in the last cell of the series is recycled to the anode compartment of the first cell in the series and the peroxydisulfate or salt thereof is removed from the anode compartment of the last cell in the series. Additional reactants are provided to the anolyte compartment of the first cell of the series to make up for the removal of the desired product in the last cell in the series.
When a filter press type electrolysis cell series is utilized in the production of peroxydisulfates and salts thereof which are concentrated and hydrolyzed to produce hydrogen peroxide, a closed loop process can also be provided. In the hydrolysis of the peroxydisulfuric acid or peroxydisulfates to produce hydrogen peroxide, which is removed from the process, the bottoms from the distillation column comprising sulfuric acid can be passed back to the cathode compartment of the electrolysis cell. Such a closed loop process is possible because the process stream leaving the last cell in the series of filter press type electrolysis cells arranged in a cascading series is passed to a metal impurity removal stage of the process in which the process stream is treated to remove impurity metals. Preferably, the process stream exiting the last cell in the cell series is passed through at least one ion exchange resin prior to passing the process stream back to the anode compartment of the first cell in the series. It is essential to remove the impurity metals which accumulate in the process stream of the electrolysis cells in view of the fact that such metals which accumulate can act as decomposition catalysts for hydrogen peroxide which is produced in the hydrolysis stage of the process.
While this invention has been described with reference to certain specific embodiments, it will be recognized by those skilled in this art that many variations are possible without departing from the scope and spirit of the invention, and it will be understood that it is intended to cover all changes and modifications of the invention disclosed herein for the purpose of illustration which do not constitute departures from the spirit and scope of the invention.
|
Peroxydisulfuric acid and salts thereof are produced electrochemically from an aqueous acid sulfate solution in a cascading series of bipolar electrolytic cells having a cell body frames of polyvinyl chloride which are bonded with a vinyl ester polymer. An aqueous solution of peroxydisulfuric acid and salts thereof are withdrawn from the anode compartment of the last cell in the series, and metal impurities are removed by treatment with an ion exchange resin. Hydrogen peroxide is produced by hydrolyzing persulfuric acid and salts thereof. The sulfuric acid produced is recycled to the first cell in the series of cascading electrolytic cells.
| 2
|
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to illuminators and, particularly, to a light emitting diode (LED) illuminator and a heat-dissipating method thereof.
[0003] 2. Description of related art
[0004] With the continuing development of scientific technology, light emitting diodes (LEDs) have been widely used in the field of illumination due to its high brightness, long lifespan, wide color gamut and so on. LEDs generally emit visible light at specific wavelengths and generate a significant amount of heat. Generally, approximately 80-90% of the electric energy consumed by the LEDs is converted to heat, with the remainder of the electric energy converted to light. If the generated heat cannot be timely dissipated, the LEDs may overheat, and thus the performance and lifespan maybe significantly reduced.
[0005] Therefore, heat-dissipating apparatuses are applied in the illuminators to timely dissipate heat generated by the LEDs. The heat-dissipating apparatus includes a fan to induce an airflow for the purpose of cooling the LEDs and a number of fins. However, during the working process of the heat-dissipating apparatus, dust and suspending particles may exist in the surroundings of the illuminators. These dust and suspending particles may negatively impact and affect the working efficiency and lifespan of the fin of the heat-dissipating apparatus, thereby shortening the lifespan of the illuminators.
[0006] What is needed, therefore, is a LED illuminator and a heat-dissipating method thereof which can overcome the above-described problems.
SUMMARY OF THE INVENTION
[0007] An exemplary embodiment of a heat-dissipating method of a light emitting diode illuminator includes the following steps. First, the light emitting diode illuminator is provided and includes a light emitting diode, a fan apparatus, a temperature sensor and a controller. The controller is electrically connected with the fan and the temperature sensor. The fan is controlled by the controller to work at various speeds. Second, a predetermined working temperature of the light emitting diode is defined in the controller. Third, a working temperature of the light emitting diode is sensed using the temperature sensor, and a signal of the working temperature is transmitted to the controller. Fourth, the working temperature sensed by the temperature sensor is compared with the predetermined working temperature in the controller, and the fan is controlled by the controller to work at a suitable speed according to the comparison result between the working temperature and the predetermined working temperature.
[0008] Advantages and novel features will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Many aspects of the present embodiment can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present embodiment. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0010] FIG. 1 is a schematic, isometric view of a light emitting diode illuminator according to an exemplary embodiment.
[0011] FIG. 2 is a flowchart of a heat-dissipating method of the light emitting diode illuminator of FIG. 1 .
[0012] FIG. 3 is a logical view of a heat-dissipating process of the light emitting diode illuminator of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0013] An embodiment will now be described in detail below and with reference to the drawings.
[0014] Referring to FIG. 1 , a LED illuminator 100 according to an exemplary embodiment is illustrated. The LED illuminator 100 includes at least a LED 110 , a heat-dissipating apparatus 120 , a temperature sensor 130 , and a controller 140 .
[0015] The heat-dissipating apparatus 120 includes a heat-dissipating base 121 , a heat sink 122 and a fan 123 . The heat-dissipating base 121 includes a first surface 121 a and a second surface 121 b on an opposite side of the first surface 121 a . The LED 110 is defined on the first surface 121 a of the heat-dissipating base 121 . The heat sink 122 is thermally connected to the second surface 121 b of the heat-dissipating base 121 . The fan 123 is coupled with the heat sink 122 , and cooperates with the heat sink 122 to dissipate heat generated from the LED 110 .
[0016] The temperature sensor 130 can be thermally connected to the heat-dissipating base 121 or the heat sink 122 to detect their temperatures, thereby evaluating or measuring a working temperature of the LED 110 . In the present embodiment, the temperature sensor 130 is thermally connected to the heat-dissipating base 121 to detect a temperature of the heat-dissipating base 121 , thereby evaluating or measuring the working temperature of the LED 110 .
[0017] The controller 140 is electrically connected to the fan 123 and the temperature sensor 130 , respectively. The controller 140 includes a predetermined temperature and various speeds. At the predetermined temperature, the LED 110 cannot overheat and works normally. The temperature sensor 130 senses the working temperature of the LED 110 and transmits signals of the working temperature to the controller 140 . The controller 140 compares the working temperature with the predetermined working temperature, and adjusts the speed of the fan 123 according to the comparison result of the working temperature and the predetermined working temperature. Therefore, the controller 140 has functions of activating the fan 123 , stopping the fan 123 and adjusting the fan 123 to work at a suitable speed. For example, the fan 123 can be controlled by the controller 140 to work at various speeds. In the present embodiment, the fan 123 has two speeds, that is, a first speed (V 1 ) and a second speed (V 2 ) faster than the first speed. According to the requirement of heat to be dissipated in the working process of the LED 110 , the fan 123 can be controlled by the controller 140 to work in any of the first and second speeds.
[0018] Referring to FIG. 2 , an exemplary embodiment of a heat-dissipating method of the LED illuminator 100 includes: step 210 , defining a predetermined working temperature of the LEDs 110 in the controller; step 220 , sensing a working temperature of the LEDs 110 using the temperature sensor 130 and transmitting a signal of the working temperature to the controller 140 ; step 230 , comparing the working temperature sensed by the temperature sensor 130 with the predetermined working temperature and adjusting the fan 123 to work at a suitable speed using the controller 140 according to the comparison result of the working temperature and the predetermined working temperature.
[0019] An detailed heat-dissipating process of the LED illuminator 100 is described below and with reference to FIG. 3 .
[0020] In a general step 210 , a predetermined working temperature (or a temperature range) of the LED 110 is defined in the controller 140 according to a working status of the LED illuminator 100 . In the present embodiment, the LEDs 110 are blue LEDs. About 40% of the electric energy of the LED 110 is converted to light, that is, about 60% electric energy is converted into heat energy. Thus, when the LEDs 110 work nonstop for a long period of time, the temperature of the environment surrounding the LEDs 110 (i.e., the working temperature) rises. The LEDs 110 normally works at a temperature below 120 degrees Celsius. In the present embodiment, the predetermined working temperature is set to be 70 degrees Celsius. However, the working temperature of the LEDs 110 is difficult to be measured directly, so the predetermined working temperature and the working temperature below are acquired by measuring the temperature of the heat-dissipating base 121 . That is, the predetermined working temperature and the working temperature below of the heat-dissipating base 121 are employed as the predetermined working temperature and the working temperature of the LEDs 110 .
[0021] In a general step 220 , the temperature sensor 130 senses the working temperature of the LED 110 , and transmits a signal of the working temperature to the controller 140 . Specifically, during the working process of the LED illuminator 100 , the temperature sensor 130 continues to periodically sense the working temperature of the heat-dissipating base 121 , and transmits the signal of the working temperature to the controller 140 .
[0022] In a general step 230 , the working temperature sensed by the temperature sensor 130 is compared with the predetermined working temperature using the controller 140 , and the fan 123 is adjusted by the controller 140 to work at a suitable speed according to the comparison result of the working temperature and the predetermined working temperature. At the beginning of the working of the LED illuminator 100 , the LEDs 110 generate a small amount of heat and the working temperature (T) of the LEDs 110 has not reach the predetermined working temperature value, i.e., 70 degrees Celsius. Under this condition, the fan 123 is in an “off” state.
[0023] When the working temperature value of the heat-dissipating base 121 sensed by the temperature sensor 130 is higher than 70 degrees Celsius, the fan 123 activates and the controller 140 adjusts the fan 123 to work at the first speed (V 1 ). After a first period of time (t 1 ), the working temperature of the heat-dissipating base 121 is sensed again by the temperature sensor 130 , if the working temperature of the heat-dissipating base 121 is lower than 70 degrees Celsius, the fan 123 is controlled by the controller 140 to be stopped working, i.e., the fan 123 is in the “off” state. However, if the working temperature of the heat-dissipating base 121 is still higher than 70 degrees Celsius, the controller 140 adjusts the fan 123 to work at the second speed (V 2 ). Because the second speed is faster than the first speed, the airflow of the fan 123 flows more quickly than the first speed. After a second period of time (t 2 ), the working temperature of the heat-dissipating base 121 is sensed again by the temperature sensor 120 , if the working temperature of the heat-dissipating base 121 is lower than 70 degrees Celsius, the fan 123 is controlled by the controller 140 to stop working or to work at the first speed. If the working temperature of the heat-dissipating base 121 is higher than 70 degrees Celsius, the fan 123 continuously works at the second speed until the working temperature is lower than 70 degrees Celsius. It is understood that three or more speeds can be defined in the controller 140 to adjust the fan 123 to works at three or more speeds, thereby accommodating the heat-dissipating requirement of the LEDs 110 .
[0024] In the heat-dissipating method of the LED illuminator 100 , the working temperature of the LEDs 110 is sensed periodically by the temperature sensor 130 , and is compared with the predetermined working temperature of the LEDs 110 by the controller 1 40 . According to the comparison result, the fan 123 is adjusted by the controller 140 to work at a suitable speed, for example, stops working, works at the first speed, works at the second speed. That is, the working speed of the fan 123 can be adjusted according to the quantity of the heat to be dissipated of the LEDs 110 , thereby avoiding the fan 123 continuously working at a high speed. Therefore, the present heat-dissipating method prevents the LEDs 110 from overheating, simultaneously saves the energy of the fan 123 and extends the service lifetime of the fan 123 . Accordingly, the service lifetime of the illuminator is extended.
[0025] It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the invention.
|
A heat-dissipating method of a light emitting diode illuminator includes the following steps. First, the light emitting diode illuminator is provided and includes a light emitting diode, a fan apparatus, a temperature sensor and a controller. The controller is electrically connected with the fan and the temperature sensor. Second, a predetermined working temperature of the light emitting diode is defined in the controller. Third, a working temperature of the light emitting diode is sensed using the temperature sensor, and a signal of the working temperature is transmitted to the controller. Fourth, the working temperature sensed by the temperature sensor is compared with the predetermined working temperature in the controller, and the fan is adjusted by the controller to work at a suitable speed.
| 5
|
FIELD OF THE INVENTION
[0001] The application relates to the field of clinical testing and in particular to an immunological test element having at least one test chamber and covered by a pierceable foil layer. Clinical testing includes immunohematology, immunodiagnostic and other clinical testing. The foil layer is defined by at least one portion that permits puncture in order to facilitate access to the contents of the test chamber.
BACKGROUND OF THE INVENTION
[0002] Predispensed reagents, in particular for immunohematology (“IH”) testing, are often provided in sealed chambers that are accessed when needed in a testing environment. For instance, BIOVUE™ cassettes and MTS Gel Cards™ utilize a foil seal over the Reaction Chamber to maintain the integrity of the pre-dispensed reagent within each column. Other comparable systems use similar test elements for IH testing. It's possible through mishandling of the card/cassette that the inside of the foil seal can come into contact with the pre-dispensed reagent.
[0003] Immunological agglutination reactions are typically used for identifying various kinds of blood types as well as for detecting various kinds of antibodies and antigens in blood samples and other aqueous solutions. In such procedures, a sample of red blood cells is mixed with serum or plasma in either test tubes or microplates, wherein the mixture is incubated and then centrifuged. Various reactions then occur or do not occur depending on, for example, the blood types of the red blood cells or whether certain antibodies are present within the blood sample. These reactions manifest themselves as clumps of cells or as particles with antigens or antibodies on their surfaces, referred to as agglutinates. The failure of any agglutinates to appear indicates no reaction has occurred, while the presence of agglutinates, depending on the size and amount of the clumps formed, indicates the presence of a reaction and the level of concentration of cells and antibodies in the sample and reaction strength.
[0004] Many such reactions are included in the slate of reactions run on clinical diagnostic analyzers and other analyzers. A clinical laboratory testing and diagnostic system typically includes a Scheduler, which controls and specifies operations in the analyzer by allocating resources at various time points to ensure the desired tests are carried out in a timely and orderly manner. A system clock determines which of the steps are carried out in various parts of the analyzer. Thus, the position of samples, dispensing of reagents, signal detection and the like by various part of the analyzer are specified relative to the common clock to ensure they march to the same beat. The Scheduler ensures that samples are accepted from an input queue as resources are reserved for the various expected tests relevant to a particular sample. Unless the required resources are available, a sample continues to be in the input queue. Samples are further batched into trays (or slots). In a preferred analyzer, the sample is aspirated and then sub-samples are taken from this aspirated volume for various tests. The operation of the Scheduler together with the types of tests supported by the analyzer provides a reasonably accurate description of exemplary analyzers.
[0005] Reagents for various tests are preferably provided in sterile packs. Examples of such packs are BioVue Cassettes and MTS Gel Cards, which utilize a foil seal to maintain the integrity of the pre-dispensed reagent within. Further, using very small aliquots of sealed reagents increases the cost and potential bio-hazardous waste while larger quantities of reagents packaged for use in multiple reactions invites cross contamination risk since it is possible through mishandling of the card/cassette that the inside of the foil seal can come into contact with the pre-dispensed reagent. Transfer of the reagent from one well to the next resulting in a false positive response for either a blood type or a screen is a problem that is not addressed well by current systems.
[0006] Some components that help run a clinical analyzer as directed and expected by the Scheduler include stepper motors. Control of stepper motors, and hence probe and mechanism movement, is accomplished by techniques well known in the art such as those described in U.S. Pat. No. 5,646,049 which is incorporated herein by reference.
[0007] As described, for example, in U.S. Pat. No. 5,512,432 to LaPierre et al., and rather than using microplates or test tubes, another form of agglutination test method has been developed and successfully commercialized. According to this method, gel or glass bead microparticles are contained within a small column, referred to as a microcolumn or a microtube. A reagent, such as anti-A, is dispensed in a diluent in the microcolumn and test red blood cells are placed in the reaction chamber above the column. The column, which is typically one of a plurality of columns formed in a transparent card or cassette, is then centrifuged. The centrifugation accelerates the reaction, if any, between the red blood cells and the reagent, and also urges any cells toward the bottom of the column. In the meantime, the glass beads or the gel material acts as a filter, and resists or impedes downward movement of the particles in the column. As a result, the nature and distribution of the particles in the micro-column provides a visual indication of whether any agglutination reaction has occurred, and if such a reaction has occurred, the strength of the reaction based on the relative position of the agglutinates in the column. If no agglutination reaction has occurred, then all or virtually all of the red blood cells in the micro-tube will pass downward during the centrifugation procedure, to the bottom of the column in the form of a pellet. Conversely and if there is a strong reaction between the reagent and the red blood cells, then virtually all of the red blood cells will agglutinate, and large groupings will form at the top of the microtube above the gel or bead matrix in that the matrix is sized not to let these clumps pass through. Reactions falling between these latter two extremes are possible in which some but not all of the red blood cells will have agglutinated. The percentage of red blood cells that agglutinate and the size of the agglutinated particles each have a relationship with the strength of the reaction. Following the centrifugation process and after all processing steps have been completed, the microtube is visually examined by either a human operator or by machine vision and the reaction between the red blood cells and the reagent is then classified. The reaction is classified as being either positive or negative, and if positive, the reaction is further classified into one of four classes depending on the strength of the reaction.
[0008] Gel cards and/or bead cassettes are test elements that employ a plurality of microtubes for purposes of creating agglutination reactions as described above for purposes of blood grouping, blood typing, antigen or antibody detection and other related applications and uses. These test elements commonly include a planar substrate that supports a plurality of transparent columns or microtubes, each of the columns containing a quantity of an inert material, such as a gel material or a plurality of glass beads, respectively, that is coated with an antigen or antibody or material or is provided with a carrier-bound antibody or antigen, each of the foregoing being provided by the manufacturer. A pierceable wrap completes the assembly of the test element, the wrap, which may be, for example, in the form of an adhesively or otherwise-attached foil wrap, covering the top side of the test element, in order to cover the contents of each column. Once pierced, aliquots of patient sample and possibly reagents (e.g., if reagents are not first added by the manufacturer or additional reagents, depending on the test) can be added to the columns, either manually or using automated apparatus. The test element thus containing patient sample (e.g., red blood cells and sera) is then incubated and following incubation, the test element is spun down by centrifugation, as noted above, in order to accelerate an agglutination reaction that can be graded either based on the position of agglutinates within each transparent column of the test element or cassette or due to a lack of agglutination based on the cells settling at the bottom of the test column.
[0009] As noted, each of these test elements typically include a foil wrap disposed at the top of the card or cassette covering the columns wherein the wrap can be pierced prior to the dispensing of the patient sample, reagents, or other material into at least one microtube of the test element. The foil wrap forms a seal relative to the contents of the columns to prevent contamination and also prevents the contents of the columns from drying out or degrading.
[0010] A number of automated or semi-automated apparatus, such as those manufactured by Ortho-Clinical Diagnostics, Inc., DiaMed A. G., and Grifols, are known that utilize plurality of gel cards or bead cassettes, such as those manufactured and sold by Micro Typing Systems™, Inc., DiaMed™ A. G., and Bio-Rad™, among others. Typically, these apparatus employ separate assemblies to accomplish the piercing function. In one known version, a pipette assembly probe is used to directly puncture the foil wrap. Using the metering probe for puncture wherein contact is made with the contents of the test columns means that this probe must undergo a separate washing operation following the piercing step before use thereof can be resumed to avoid contamination. In addition to potential contamination issues, there are also related issues dealing with spillage as well as fluidic carryover. In addition, washing operations add levels of complexity to the size and manufacture of the apparatus as well as hinder potential throughput time. In another known apparatus, AUTOVUE™, a piercing assembly is provided having a plurality of dedicated punches (gang punch) for puncturing the seals for each of the test chambers of a test element. This dedicated apparatus also adds a level of complexity, including an increase to the size of the overall footprint of the apparatus. The latter assembly also requires washing operations of the punches themselves, albeit on a limited basis, during re-use thereof and includes a large number of punches to accommodate the needs of many different tests.
[0011] Thus, the extent systems and supplies require either a tolerance for false positive results, which may result in retesting or erroneous tests, or packaging of reagents in single use packs, which results in increased generation of waste as well as inefficiency.
SUMMARY OF THE INVENTION
[0012] For each test intended to be performed on a clinical analyzer, there would be available one or more disposable punches compatible with the reagents to be used in tests implemented on the clinical analyzer. Preferably such a clinical analyzer is an immunohematology analyzer, but other uses, such as in a immunodiagnostic analyzer are also within the scope of this disclosure. By way of an example duration, all of the disposable punches may be replaced once every six months unless an earlier replacement is warranted. According to one aspect, an exemplary embodiment of an immunodiagnostic test analyzer has a disposable punch in a repositionable punch holder, at least one set of sealed elements, each sealed element sealed with a puncturable seal, for holding at least one member of the group consisting of a reagent, a sample and a reaction mix. Preferably, the puncturable seal is a foil seal. Further, the foil seal may be pre-stressed, although this is not a requirement. Each element may comprise a substrate, at least one test column supported by said substrate, each said test column containing a test material, and a wrap adhesively or otherwise-attached wrap covering the top of said at least one element to form the sealed element. A disposable punch is defined to have any suitable shape for punching an opening in an element provided it is not used for aspirating fluids into or out of the element. It is noteworthy that through even chance mishandling of the card/cassette the inside of the foil seal can come into contact with the pre-dispensed reagent or a tip. Then, transfer of the reagent from one well to the next can result in a false positive response for either a blood type or a screen in an immunodiagnostic analyzer or immunohematology testing.
[0013] According to one aspect, an exemplary method for reducing cross contamination in an immunodiagnostic testing apparatus comprises multiple steps. In one such step, a time, say T, for using an element having a puncturable seal in the performance of a specified test is estimated, typically by a scheduler. A disposable punch may take any suitable shape, but it is not used for aspirating fluids from one element to another. The disposable punch may be held singly or, more preferably, in an array or collection of disposable punches. The prior use of each disposable punch is tracked by the system to ensure its future use does not compromise testing by introducing the possibility of unacceptable cross-contamination or otherwise compromising test results. To this end it is expected that replacing the disposable punches is desirable if one or more of the conditions selected from exceeding a specified number of uses of a punch, exceeding a time duration for which a punch is expected to be in use, and an increase in variability of control test results above a threshold is met. A disposable punch is used to punch an opening in a seal on the element to enable a fluid carrying tip to aspirate fluids therefrom or to dispense fluids therein. An element may be a particular chamber in an MTS Gel-Card, a reagent holding vessel, a patient sample holding tube, bead cassette, a microtube, a test tube and the like.
[0014] If a disposable punch could be used for more than one assay then it would reduce the number of punches for all of the assays on the system. According to one aspect, the exemplary method for reducing cross contamination in an immunodiagnostic testing apparatus includes determining whether a previous use of the disposable punch provisionally assigned/available for a specified test is compatible with the specified test. Such a disposable punch may be provisionally marked as the ‘current’ disposable punch. In a preferred embodiment the ‘current’ disposable punch is associated with an actuator. If the current disposable punch is not compatible, i.e., it has been used with a test or reagent that will introduce unacceptable risk of cross-contamination, then another disposable punch is made the ‘current’ disposable punch and evaluated in a like manner. It should be noted that there may be multiple actuators in other implementations. In a preferred embodiment, one or a few actuators operate a greater number of punches. Further, while there are multiple punches, the number of punches is less than the distinct type of elements that need to be accessed with the help of a punch. The use of multiple punches allows for more efficient use of punches with replacement of punches becoming relatively infrequent without the requirement that each type of element have its own dedicated punch. Returning to the exemplary method, if there are no disposable punches that pass the evaluation, then a new disposable punch is loaded. This may require scheduling and/or executing a routine to load a new punch. In a related aspect, a disposable punch may be replaced by a new disposable punch for reasons other than compatibility such as time for which it has been in use, or the number of seals it has been used to punch. When a new punch is introduced, its use with different types of elements is tracked to ensure it is only used with other compatible elements.
[0015] A preferred immunohematology analyzer includes means for aligning the specified element, which may be a chamber a cassettes with a disposable punch in the repositionable punch holder. Means for aligning are implemented by programming a processor to determine the suitable punch for the specified element followed by aligning the punch in question with an actuator and the element such that upon command the actuator moves the punch to pierce the seal on the element. Means for aligning generate instructions for moving the disposable punch or the specified element adjacent to each other prior to the time for the next use of the specified element. This ensures that at the time for the next use, the disposable punch is positioned correctly relative to the specified element for operating the disposable punch, if needed. In a preferred embodiment, the element is moved to a different location for aspiration of fluids from it or for dispensing of fluids into it. Preferably, a fluid-carrying tip is selected from a disposable metering tip, a washable metering tip, and a reusable metering tip.
[0016] According to one aspect there is provided a linear path suitable for the repositionable punch holder to move a disposable punch along it. In another aspect, in another preferred embodiment, the repositionable punch holder may move the disposable punch along a closed path, an exemplary closed path being a circular path.
[0017] According to one aspect, there is provided a means for compatibility testing to determine if the disposable punch is compatible with the next planned use of the disposable punch. Means for compatibility testing are implemented by programming a processor to determine whether the disposable punch in question, the current disposable punch, is compatible with the element in need of having its seal pierced, and if there is no other compatible disposable punch available, then the disposable punch is replaced with a new punch. Further, the number of times the disposable punch has been used is evaluated to decide whether to replace the disposable punch. In a preferred exemplary embodiment, a lookup table is used to identify a disposable punch corresponding to a test or a reagent. Then, the means for compatibility testing further determine if a new disposable punch is needed—such as due to the time for which the disposable punch has been in use, or the number of times the disposable punch has been used. Other possible criteria include incidence of suspected cross-contamination. When disposable punches are replaced, in the interest of efficiency, preferably all or most of the punches in the punch nest are replaced.
[0018] In another preferred embodiment, an immunodiagnostic testing apparatus includes an incubator or a card/cassette preparation station holding a cassette or a card with a plurality of chambers and at least one disposable punch held in a manipulable configuration of disposable punches; software for estimating or assigning a time for using a particular element sealed with a wrap in a test to be performed by the immunodiagnostic testing apparatus; a means for aligning the at least one disposable punch element with the particular element; and an actuator for punching a sufficiently large opening using at least one disposable punch in the wrap on the particular element to enable a fluid-carrying tip to aspirate or dispense fluids without touching the wrap.
[0019] Without loss of generality, in the immunodiagnostic testing apparatus the fluid-carrying tip is selected from a disposable metering tip, a washable metering tip, and a reusable metering tip. The wrap may be a foil seal. In an embodiment, the foil seal may even be pre-stressed.
[0020] According to one aspect, there is provided an immunodiagnostic test element comprising a substrate, at least one test column supported by said substrate, each said test column containing a test material, and a wrap adhesively or otherwise-attached wrap covering the top of said at least one test element, such as, for example, an adhesively-attached foil wrap wherein said foil wrap includes a weakened portion directly above each said at least one test column, each said weakened portion being formed by pre-stressing said portion, but not to the point of puncturing the foil wrap. Further details for such elements are found in US Patent Publication No. 20090246877.
[0021] By providing at least one pre-stressed portion, the foil wrap is drastically weakened locally, thereby enabling each pre-stressed portion to be easily punctured, for example, using a disposable fluid aspirating dispensing member, such as a metering tip. Moreover, the pre-stressed portions are also locally deformed and assume a bowl-like concave shape. Alternatively, the pre-stressing can be performed on the wrap prior to covering of the test element with the wrap.
[0022] The pre-stressing of the foil wrap results in local deformation of the foil wrap, creating an indentation that is inwardly curved, forming a substantially bowl-like appearance. This portion can then be easily punctured in a distinct operation.
[0023] These and other features and advantages will become readily apparent from the following Detailed Description, which should be read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 Shows an exemplary listing of reagents in a table showing compatible and incompatible reagents for the use of a common disposable punch.
[0025] FIG. 2 shows part of an immunodiagnostic testing apparatus illustrating disposable punches arranged in a circular pattern for punching seals on elements in linear holders below.
[0026] FIG. 3 shows is a simplified view of an MTS GelCard;
[0027] FIG. 4 shows a column in an MTS GelCard aligned with a disposable punch;
[0028] FIG. 5 shows a column in an MTS GelCard aligned with a disposable punch and a linear actuator;
[0029] FIG. 6 depicts an implementation of the means for compatibility testing and the means for alignment in the context of the operation of an immunodiagnostic analyzer with disposable punches;
[0030] FIG. 7 depicts a different aspect of an implementation of means for compatibility testing; and
[0031] FIG. 8 depicts the operation of means for compatibility testing and means for alignment in the context of the operation of an immunodiagnostic analyzer with disposable punches to effect alignment of the disposable punch with an actuator and the sealed element.
[0032] FIG. 9 depicts the exemplary operation of immunodiagnostic analyzer in allocating resources and scheduling events involving the use of disposable punches for accessing a sealed element.
[0033] FIG. 10 depicts another exemplary logic flow for the operation of immunodiagnostic analyzer with scheduling of events involving the use of disposable punches for accessing a sealed element.
DETAILED DESCRIPTION
[0034] The following discussion relates to certain exemplary embodiments of an immunodiagnostic analyzer (also referred to as an immunohematology analyzer depending on the context) using disposable punches and sealed elements pierced thereby. In a preferred embodiment, the analyzer uses a gel card or bead cassette. It will be readily apparent to those of skill in the field that the inventive concepts described herein also relate to literally any other form of immunodiagnostic analyzers that include at least one test chamber and a wrap/seal, such as, for example, a foil wrap, which covers the at least one test chamber, which is also referred to as an element or sealed element. In addition, certain terms are used throughout this discussion in an effort to provide a frame of reference with regard to the accompanying drawings. These terms should not be regarded as limiting, except where specifically indicated.
[0035] Typically prior to use of a reaction chamber, the foil must be either physically removed or perforated to create an opening that can be accessed by the pipetter. For manual testing, a technician will peel the foil off the reaction chambers that are needed to run a test. Automated Immunohematology systems typically gain access to the reaction chambers by piercing the foil with either the pipetter probe itself or by a sharp metal punch. In the case of AutoVue™, a series of punches are arranged in gangs for opening specific card types. Each punch is dedicated to a specific Reaction Chamber type to mitigate carry-over from one well to the next. Over time these punches become dirty or contaminated and must be cleaned by service person. In the case of ProVue™, the pipetter is cut at an angle on the dispense end and the resulting sharp point is used to perforate the foil before each metering event. This approach requires that the outside of the probe be washed after every fluid dispense into a reaction chamber to avoid carry-over to the next reaction chamber.
[0036] For VISION™, the design uses a disposable tip pipetter or a washable probe system. For each fluid dispense into a reaction cell, the foil seal has to be opened in such a way that when the tip enters a reaction cell, there is no contact with foil seal. A large opening in the foil above the test column needs to be created to allow access by the disposable tip. The AutoVue™ “gang punch” approach is large and requires cleaning by service every 6 months. A new smaller foil punch mechanism that addresses carry-over is desirable as a result. It is also desired that the foil opening mechanism open only those test columns scheduled for use and can be serviced by the operator instead of a service person. The prevention of touching the seal is especially important when the same tip is used to pipette fluids/suspensions such as patient red blood cells into multiple column types such as A, B, and D. Table in FIG. 1 for ProVue™ indicates there are approximate 13 pre-dispensed reagents that if carried over could affect the result of the next column fluid is dispensed into. AutoVue™ has 20 such pre-dispensed reagents.
[0037] The disclosed embodiment uses disposable foil punches that can be replaced by the operator on a periodic basis. The number of such punches required would be dictated by the number of different column types run on the instrument. The Piercing Punch would preferably be an injection molded plastic part, but other materials and manufacturing methods can be use. Each punch can preferably be replaced by an operator on a periodic basis. Approximately 20 punches would be needed to avoid any Cell to Cell Carry-over for most applications.
[0038] FIG. 1 provides an exemplary listing of reagents in a table showing which reagent/test combinations are compatible with the use of a common disposable punch. For purposes of background, not all cross contamination may result in compromising tests to such an extent that the results are unacceptably suspect or may be compromised. For instance, carryover of sample from one element to another is not acceptable unless mixing of different samples is intended. On the other hand, as shown in FIG. 1 , reagent carryover may not affect the results for certain combinations.
[0039] FIG. 2 illustrates an exemplary implementation of multiple punches held in a circular configuration where each punch is rotated into a position for piercing the foil seal on a card or cassette. The cards, containing elements with seals to be pierced, are staged below the punch assembly in a buffer that rotates to software align the correct column with the correct punch. FIG. 2 illustrates part of such an exemplary immunodiagnostic analyzer 200 showing disposable punches 205 placed in a circular punch holder 210 . Also shown is the operation of activator 215 on a particular disposable punch 220 . Below the punch holder 210 is element holder 225 with a seal 230 covering a plurality of elements of which element 235 is below the lower end 240 of disposable punch 220 being pushed by operation of activator 215 . The alignment of operation of activator 215 , disposable punch 220 and element 235 in this exemplary example is accomplished by means for aligning. The choice of a particular disposable punch, such as disposable punch 235 , is also subject to means for compatibility testing. Also shown in FIG. 2 is a linear Punch Nest 245 for holding disposable punches 250 . Such alternative geometries and designs may be implemented instead of Punch Nest 210 shown as part of instrument 200 . The illustrated Punch Nest 245 has a linear configuration where the punches can be positioned over a stationary card/cassette/sample/element. The actuator preferably moves on a separate stage with alignment and positioning under software control. The linear arrangement can be compared to the circular arrangement 255 corresponding to that of punch nest 210 of instrument 200 . In the circular arrangement, the smaller arrangement is the punch nest positioned over the larger arrangement holding the card/cassette/sample/element 260 . Such variations in implementing the teachings are included within the scope of the disclosure.
[0040] FIG. 3 shows a gelcard 300 having a seal 305 and chambers/columns/microtubes 310 . Such a gelcard 300 could be used in manner illustrated for element holder 225 in FIG. 2 . A gel card, or a bead cassette, commonly includes a support member, such as a planar substrate supporting a plurality of microtubes or test columns. An exemplary microtube 310 is made from a transparent material and is further defined by an upper portion 315 having an open top opening, an inwardly tapering transitional portion 320 and a lower portion 325 . A predetermined quantity of an inert material 330 is contained within the lower portion 325 of each test column 310 , as typically provided by a manufacturer. The inert material 330 is a gel material, such as Sephacryl™ or other suitable material, while in the instance of the bead cassette, the inert material is defined by a matrix of glass or other beads. The inert material typically comprises a plurality of particles having a diameter of between about 10 and 100 microns.
[0041] Further, the inert material is further coated with an antibody or provided with a carrier-bound antigen or antibody, such as anti-A, also typically provided by the manufacturer. A pierceable foil wrap 305 provided at the top side of each test element 310 covers that seals the microtubes in order to protect the contents and also to prevent dehydration or degrading thereof.
[0042] The foregoing immunodiagnostic test elements or element holder 225 can be used in an automated testing apparatus 200 , such as that shown in FIG. 2 . In brief, the testing apparatus 200 retains a number of components including a reagent and sample supply, an incubator station, a centrifuge, an analysis station, and a drawer assembly. More particularly, the sample and reagent supply of this apparatus 200 includes a gel card 225 , FIG. 2 , 300 , FIG. 3 , 400 , FIG. 4 .
[0043] In the testing apparatus 200 shown, for example, a plurality of test elements 310 , such as those previously described according to either FIG. 3 , are initially read by a bar code reader (not shown). Assuming the read is successful, the element holder 225 is loaded using the transport assembly. Actuator 435 , FIG. 4 , is deployed to open the seal on a desired element 410 in element holder 225 . The pipette of a pipette assembly is used to aspirate sample while actuator 435 , FIG. 4 , is used to puncture each of the microtubes. Once the puncturing step has been completed, the pipette can then be used to dispense a predetermined quantity of patient sample (and possibly additional reagents) from the sample and reagent supply into each of the test columns 410 , FIG. 4 , wherein the mixture can be suitably incubated.
[0044] FIG. 5 shows further details such as the linear actuator for making the disposable punch puncture the seal. Linear actuator 500 acts on foil punch 510 as depicted, which disposable punch 510 is seated in a Punch Nest 515 with Washer 520 providing for shock absorption and spring retention. Spring 525 is compressed by the action of linear actuator 500 when punching an opening in seal 530 in element 540 in Gel Card 535 with the disposable punch 510 rebounding to its position due to spring 525 after the punching operation.
[0045] Following incubation, for carrying out an agglutination reaction, the element holder 225 , 300 , 400 is removed from the incubator and then spun down, thereby accelerating an agglutination reaction as red blood cells are clumped together in the presence of coated reagents. The plurality of beads disposed in each element/column 310 includes particles having diameters ranging between about 10 and 100 microns, providing a matrix to let the red blood cells, but not the heavier formed agglutinates to pass through by filtering. The resulting reaction can be imaged within the analysis station (not shown) of the immunodiagnostic analyzer 200 by the illumination assembly and imaging subsystem. Machine vision for grading of the reaction may provide automated data generation. Additional details are provided in the commonly-assigned U.S. Pat. No. 5,578,269 to Yaremko et al., the entire contents of which are incorporated herein by reference.
[0046] In a typical analyzer, as shown in FIG. 6 , during step 600 the scheduler determines the resources required for testing the next sample being considered by the scheduler. The scheduler, as shown, during step 605 determines the time point when the required resources will be available. The scheduler directly or by invoking a routine determines the position of an element required for the test being considered by the scheduler, as is depicted by step 610 . A suitable disposable punch from a collection of disposable punches is determined during step 615 . This determination is preferably made with the aid of a lookup table indexed by either the type of sealed element or the type of test to be carried out. A determination of whether the disposable punch so identified to punch an opening in the element required for the test is compatible with the element is made during steps 615 through 625 . During step 615 a lookup table is used to determine a suitable disposable punch for the particular element or the test to be carried. A lookup table is useful, for instance when there are many disposable punches in the punch nest and each is compatible, based on cross contamination considerations, with a few reagents/tests. Then instead of maintaining a large data structure like the table in FIG. 1 , it is advantageous to exploit the sparseness of the data structure by using a lookup table. This may be done based on the data such as the illustrative data provided in FIG. 1 to generate a mapping between a test/reagent/element and the corresponding disposable punch position in the punch nest to form the lookup table. If no compatible disposable punch is available control flows to step 620 , in accordance with which a disposable punch is added to an empty slot in the punch nest to provide a punch compatible with the element required for the test. Then control flows from step 620 to step 625 , during which instructions for aligning a compatible disposable punch with the element required for the test are generated. Control can flow directly to step 625 from step 615 if the disposable punch is determined to be compatible with the element during step 615 . Following step 625 the illustrative logic of FIG. 6 ends.
[0047] FIG. 7 provides a more detailed view of the operation of an immunodiagnostic analyzer with disposable punches. During step 700 the scheduler assigns a time ‘T’ for using an element having a puncturable seal—that is an element requiring the use of the disposable punch. Control flows to decision step 705 , during which compatibility of the disposable punch, preferably initially identified using a lookup table, with the specified test or element is evaluated. If incompatibility is detected, control flows to decision step 710 , during which a determination is made as to whether another disposable punch, for instance in punch nest 515 , FIG. 5 , that is compatible with the element in question is available. This step can also benefit from data structures related to a lookup table in that if multiple punches are compatible, based on cross-contamination considerations, with an element/test/reagent then such disposable punches be listed in a chain or tree that can be systematically traversed. A variation that instead examines an alternative element that is compatible with the disposable punch is possible in some instances and is intended to be covered by the step 710 . If not compatible disposable punches are available, then control flows to step 715 , during which a new punch is obtained, preferably by loading it in punch nest 515 , FIG. 5 . It should be noted that the described means for compatibility testing broadly comprise an implementation of steps 705 through 710 , and more preferably also including step 715 and step 720 , by way of programming an exemplary central processing unit of the immunodiagnostic analyzer to direct other mechanical and sensory parts of the analyzer to perform them based on the stored data about past usage of the current disposable punch. As is well known to one having ordinary skill in the art, such programming, for instance, with the aid of programming tools such as assembly languages, machine languages, JAVA, C or variations thereof, and other higher languages coverts a general purpose central processing unit into a customized machine with a defined performance for controlling the analyzer. Upon detecting a usable and compatible disposable punch, it is made the current disposable punch for the logic to flow to step 725 . If the current disposable punch is determined to be compatible during step 705 , then control directly flows to step 725 . During step 725 , the scheduler invokes routine(s) for aligning the current disposable punch to be operational with the expected position of the sealed element at time ‘T’. This alignment may be immediately before time ‘T’ or well before the appointed time. The operations during step 725 , by way of programming an exemplary central processing unit of the immunodiagnostic analyzer to direct other mechanical and sensory parts of the analyzer to perform them based on the stored position data and feedback controls are included in the means for aligning. Control then flows from step 725 to step 730 , during which an opening is made in the seal on the element. In some embodiment, the disposable punch may merely be reopening an opening or more securely opening a previously opened seal. Control flows to step 735 from step 730 . During step 735 the type of element whose seal was opened by the disposable punch, and the number of uses made of the punch, and other data relevant to determining whether the disposable punch needs to be replaced based on frequency of use or the type of use (see exemplary compatibility table in FIG. 1 ) are updated and recorded.
[0048] FIG. 8 provides further exemplary details for the compatibility testing, including means for compatibility testing and means for aligning, which are implementable by way of programming an exemplary central processing unit of the immunodiagnostic analyzer to direct other mechanical and sensory parts of the analyzer to perform them based on the stored data about past usage of the current disposable punch. During step 800 it is determined whether the current disposable punch is compatible with the specified element—including by considerations such as number of times a punch has been used, the time duration over which it has been used, the failures or variability of test results in which the punch was used and the like. If the disposable punch is compatible, then control directly flows to step 810 . Else, control flows to step 805 during which the current disposable punch is replaced by another disposable punch that becomes the current disposable punch. The replacement may be by way of an entirely new punch being introduced into the Punch Nest 515 , FIG. 5 , or by examining another punch already loaded in Punch Nest 515 for compatibility. As previously described, such identification of disposable punches in Punch Nest 515 is readily made using data structures and constructs like lookup tables, trees and chains. Once a new disposable punch has been identified, control flows back to step 800 from step 805 . This loop ensures a compatible disposable punch is in place before control flows to step 810 to ensure means for compatibility testing results in a compatible disposable punch. If no compatible disposable punch is possible, then during step 805 an error message is generated to indicate as much (this detail is not illustrated expressly in FIG. 8 ). During step 810 a determination is made as to whether the Current Disposable Punch is aligned with the actuator, as is expected from means for aligning. If not then control flows to step 815 during which such alignment is carried out. In alternative exemplary embodiments, an actuator, linear or of another type, may be prealigned with a current disposable punch. Control flows to step 820 upon satisfactory alignment of the current disposable punch with the actuator. During step 820 a determination is made as to whether the Current Disposable Punch is aligned with the Specified Element, the element whose seal is to be opened, as is expected in another aspect of the means for aligning. If not then control flows to step 825 during which such alignment is carried out or instructions generated or placed into an execution for execution on the exemplary central processing unit at the appropriate time. Upon successful alignment of the Current Disposable Punch with the Specified Element control flows from steps 820 or 825 and this part of the logic terminates.
[0049] FIG. 9 provides another exemplary aspect of the use of disposable punches in an immunodiagnostic analyzer. During step 900 a determination is made as to whether required resources are available at the time for testing the current sample, the current sample typically being the sample being evaluated by the scheduler. If the resources are not available, control flows to step 905 , during which the time for testing is advanced and control flows back to step 900 . In this manner a suitable time for testing of the current sample is identified. Alternative exemplary embodiments may decide whether resources are available depending on whether the sample is a STAT sample, in which case it is prioritized over non-STAT samples. If resources are determined to be available during step 900 , control flows to step 910 . During step 910 resources are reserved and the control flows to step 915 . During step 915 a determination is made as to whether the test is the last test on the current sample. This step is useful when aspirating samples from a sealed sample since it typically is preferable to provide resources to complete all testing on the sample. If the test is not the last test, control flows from step 915 to 920 to update information for another test. Control then flows to step 900 to evaluate the resource and scheduling needs of the additional test identified in step 920 along with the use of disposable punches. If the test is the last test, with the possibility that sample may be dispensed for more than one test, control flows to step 925 , during which instructions for means for compatibility testing are implemented to ensure a compatible disposable punch is deployed. Many of the details for compatibility testing have been discussed above. The exemplary logic then terminates.
[0050] In another aspect, as shown in the exemplary logic of FIG. 10 for an exemplary embodiment, during step 1000 whether an element requires use of a disposable punch at the next time point is determined. If there is no need, control flows to step 1005 , during which the next time point is updated and control returns to step 1000 . In this manner, time points at which disposable punch is needed are identified. Upon identifying such a time point, control flows to step 1010 during which means for compatibility testing assist in determining if a compatible disposable punch is available. Compatibility testing details have been discussed previously, in particular, in the context of FIGS. 6 through 8 . If such a punch is available, control flows to step 1020 during which means for aligning are employed to generate instructions for aligning the punch with the reagent and the like. Else, in the absence of such a punch, control flows to step 1015 during which a compatible punch is identified, for instance as described previously, and control flows to step 1020 described above. Following step 1020 the logic terminates.
[0051] It will be understood that numerous variations and modifications are possible in this disclosure. Such variations are should be considered as being within the scope of the following claims.
|
Disclosed is a device and method of using the device to reduce false positives when using sealed packs in an immunodiagnostic analyzer while allowing use of the reagents in multiple tests as well as reuse of disposable punches employed for piercing foil covering the reagent aliquots. The disclosed devices and methods are useful in carrying out tests in immunohematology such as for a blood type or a screen.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] Referring to the application data sheet filed herewith, this application claims a benefit of priority under 35 U.S.C. 119(e) from copending provisional patent application U.S. Ser. No. 62/066,717, filed Oct. 21, 2104, the entire contents of which are hereby expressly incorporated herein by reference for all purposes.
BACKGROUND
[0002] Plastic parts have been sealed by spraying and dipping in liquids, such as acetone for ABS parts. Unfortunately, this results in loss of details, particularly in corners where the liquid acetone accumulates. Because of the porousness of the parts, the liquid penetrates the parts and uncontrolled melting continues inside, even after removal of surface acetone. This results in unacceptable dimensional distortions. Another effect is a discoloration that usually appears like a white frost.
SUMMARY
[0003] There is a need for the following embodiments of the present disclosure. Of course, the present disclosure is not limited to these embodiments.
[0004] According to an embodiment of the present disclosure, a process comprises: finishing 3-D prints with potentially explosive vapors safely contained in a vapor chamber including at least one side and at least one lid coupled to the at least one side; and reducing arbitrary condensation dripping from the lid with a vapor condenser located on an inside surface of the lid. According to another embodiment of the present disclosure, a machine comprises: a vapor containment chamber for finishing 3-D prints with potentially explosive vapors safely contained, the vapor chamber including at least one side and at least one lid coupled to the at least one side and a vapor condenser located on an inside surface of the compression lid reducing arbitrary condensation dripping from the lid.
[0005] These, and other, embodiments of the present disclosure will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating various embodiments of the present disclosure and numerous specific details thereof, is given for the purpose of illustration and does not imply limitation. Many substitutions, modifications, additions and/or rearrangements may be made within the scope of embodiments of the present disclosure, and embodiments of the present disclosure include all such substitutions, modifications, additions and/or rearrangements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The drawings accompanying and forming part of this specification are included to depict certain embodiments of the present disclosure. A clearer concept of the embodiments described in this application will be readily apparent by referring to the exemplary, and therefore nonlimiting, embodiments illustrated in the drawings (wherein identical reference numerals (if they occur in more than one view) designate the same elements). The described embodiments may be better understood by reference to one or more of these drawings in combination with the following description presented herein. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale.
[0007] FIG. 1 is a front perspective view of a vapor tank.
[0008] FIG. 2 is a rear perspective view of a vapor tank.
[0009] FIG. 3 is a side perspective view of a vapor tank opened.
[0010] FIG. 4 is a top perspective view of a vapor tank with part tray removed.
[0011] FIG. 5 is a perspective view of a part tray with part hanger tray removed.
[0012] FIG. 6 is an exploded perspective view of a control module.
[0013] FIG. 7 is an exploded perspective view of a vapor tank.
[0014] FIG. 8 is an exploded perspective view of a vapor condenser assembly.
[0015] FIG. 9 is a perspective view of an alternate vapor tank embodiment coupled to a drying chamber.
[0016] FIG. 10 is a flow diagram of an operation process that can be implemented by a computer program.
[0017] FIG. 11 is a flow diagram of a smoothing interrupt process that can be implemented by a computer program.
[0018] FIG. 12 is a view of exemplary control algorithms.
[0019] FIG. 13 is view of an operational fan RPM chart.
DETAILED DESCRIPTION
[0020] Embodiments presented in the present disclosure and the various features and advantageous details thereof are explained more fully with reference to the nonlimiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well known materials, techniques, components and equipment are omitted so as not to unnecessarily obscure the embodiments of the present disclosure in detail. It should be understood, however, that the detailed description and the specific examples are given by way of illustration only and not by way of limitation. Various substitutions, modifications, additions and/or rearrangements within the scope of the underlying inventive concept will become apparent to those skilled in the art from this disclosure.
[0021] In general, the embodiments of the disclosure relate to features associated with vapor phase etching that are advantageous to smoothing and sealing 3-D printed parts (work-pieces) especially when those work-pieces are mesoporous. For instance, useful stable vapor solvent classes (e.g. ketones like acetone) can be used to smooth work-piece materials (e.g. styrenics like ABS). Acrylonitrile butadiene styrene (ABS) can be sealed with 1,2 Dichloroethane vapor, Acetone vapor, Cyclohexanone vapor and/or MEK vapor. Polyacetal (Delrin-POM) can be sealed with MEK vapor and/or Methyl benzene vapor.
[0022] FIG. 1 shows the tank front view with a parts tray inside. The tank is 4 sheets of glass with blast contaminant film applied, and has an aluminum bottom. Silicone rubber or other solvent resistant adhesive is used in the edges and corners to secure the glass and bottom aluminum. Extruded aluminum edge pieces are glued to secure the film and strengthen the box. A hinged aluminum top with an elastomer seal contains the acetone solvent vapor in normal operations. A controller box 1 is coupled to vapor tank lid 9 .
[0023] FIG. 2 shows the tank rear view with the parts tray inside. This invention uses a closed clear glass tank with an external blast film applied to allow safe viewing of the progress of parts being treated. A light-weight cover keeps the vapor contained but allows any possible vapor ignition to open the lid, thus reducing pressure to prevent possible explosion. Optionally a magnetic latch may be included to prevent easy opening of the tank in a way that exposes the user to excessive vapors. A heating pad under the tank controls the tank temperature. Instead of using direct liquid contact, this invention uses only vapor for treating parts. A fan provides homogeneous saturation of solvent vapors that prevents layering of air and solvent vapor for uniform part treatment. A computer module on the lid controls the process and helps calculate the proper time for the desired smoothing, controls the fan motor, lamp and tank temperature, and sounds an alarm to notify the user to remove the parts upon completion of the process. If the delay is too long, the alarm becomes loud and insistent.
[0024] FIG. 3 shows the open tank, Condenser Assembly 6 , LED Lamp, and stirring fan 4 that speeds processing and prevents the vapors from layering. An electronic cooling device in the top prevents liquid solvent from dripping on the parts by concentrating condensation to one location. Dripping condensate is measured in a graduated cup that gives a visual indicator of proper tank operation. The cumulative condensate level in the cup is proportional to the smoothing effect on the parts. Upon opening the lid, the graduated cup is automatically emptied.
[0025] High-intensity LED light(s) are provided for viewing the smoothing process and are mounted to the aluminum lid which serves as a heat sink The LED light(s) enhance observation of the smoothing process without the need for external lighting.
[0026] FIG. 4 shows the tank with the parts tray removed. The inside-bottom of the tank may be covered with a disposable sheet of paper to capture contaminants for easy removal. FIG. 5 shows parts tray 27 with the top hanger tray 28 removed.
[0027] FIG. 6 shows control module and associated parts. The control module includes a controller box 1 that is coupled to a control board 2 . A wire protector for condenser and LED lamp 3 is coupled to the control board 2 . An aluminum fan blade 4 is coupled to the control board 2 . A speaker 5 is coupled to the control board 2 . A condenser assembly 6 is coupled to the control board 2 . A high intensity LED Lamp 7 is coupled to the control board 2 .
[0028] The Fan assembly includes a low-voltage brushless motor to eliminate any electric arcing as a possible source of ignition. The fan motor is variable speed to adapt to different parts and requirements. The Fan is composed of metal, wood or other solvent resistant material. The shaft driving the fan is sealed with a greased elastomer washer to create a vapor tight seal.
[0029] The controller allows the user to select the amount of smoothing desired (Sheen value), alarm music, fan speed, lamp intensity, and other parameters as desired. These settings are remembered in internal flash memory and need setting only once.
[0030] FIG. 7 shows exploded vapor tank parts. A control module assembly 8 is coupled to a vapor tank lid 9 . A vapor seal 10 and a hinge 11 are coupled to the vapor tank lid 9 . A vapor tank top rim 12 is coupled to the vapor seal 10 . A clear blast film 13 is coupled to a glass tank 14 . Aluminum side molding 15 is coupled to the clear blast film 13 . A power module 16 controls vapor tank heater 18 and provides 12V to control computer module assembly 8 . Aluminum Bottom Molding 17 is coupled to the clear blast film 13 . Rubber base mat 19 is located within glass tank 14 . Aluminum vapor tank bottom 20 is coupled to vapor tank heater 18 .
[0031] FIG. 8 shows the vapor condenser assembly 6 including solid state refrigerator 21 and concentrating cone 22 . The apex of concentrating cone 22 is an example of a cool spot. A housing 23 is coupled to a graduated cup 24 . A drain pipe 25 is coupled to housing 23 . Mounting screws 26 connect solid state refrigerator 21 to housing 23 .
[0032] FIGS. 10 and 11 show computer operational flowcharts. FIG. 10 is a General Computer Operation Flowchart. FIG. 11 is a Smoothing Interrupt Flowchart.
[0033] FIG. 12 shows program control algorithms. Those program control algorithms are also recited below to ensure completeness.
[0000]
// Ref_time comes from a table according to temperature between 0 and 49 degrees C
const int time_temp_secs[ ] = {
1378, 1286, 1200, 1119, 1044, 974, 909, 848, 791, 738,
689, 643, 600, 559, 522, 487, 454, 424, 395, 369,
344, 321, 300, 279, 261, 243, 227, 212, 197, 184,
172, 160, 150, 139, 130, 121, 113, 106, 98, 92,
86, 80, 75, 69, 65, 60, 56, 53, 49, 46};
// calculate initial exposure time in seconds
DegC = IntDegC;
if (DegC < min_tempC) DegC=min_tempC; // insure it is within range
if (DegC > max_tempC) DegC=max_tempC;
// DegC is an integer between 0 and 49
ref_time = (float)time_temp_secs[DegC]; // table lookup according to degrees
C pointer
// calculate seconds remaining
ref_exposure = (int)(ref_time * (((float)sheen − 1) / 5 + 1));
During acetoning, monitor temperature and modify remaining seconds as follows:
// every 10 seconds check temperature
// if last check is different than current ...
// get percentage of last full time to remaining time
// C routine for division
t_calc = div_int_float(time_sec, (float)last_full_exposure_time);
// get new full time for new temp
z = calculate_exposure_time(IntDegC);
// total time in seconds at current
temperature
// calc same remaining percentage
t_calc = mul_int_float(z, t_calc);
// C routine for multiplication
// set new time
time_sec = (int)t_calc;
// save new values
last_full_exposure_time = z;
// saved last full time_sec for running
time change
last_time_sec = time_sec;
// saved last time for running time change
last_IntDegC = IntDegC;
// saved last temp for running time change
[0034] FIG. 13 shows an Operational Fan RPM Chart. Experimentally the inventors observed an optimum mixing energy. Changing (varying) the mixing energy between: (from) 1) enough to prevent stratification of the vapor and coincidence non uniform part treatment and (to) 2) the maximum mixing energy our system can provide shows a distinct optimum, with decreased part treatment rates below and above that optimum level. Pressure loss increases as the square of the velocity. The flow rate caused by the mixing fan has multiple effects. It speeds the evaporation of the solvent, homogenizes the vapor density, and transfers the vapor saturated air through the parts to be treated. As the mixing energy is increased, parts will start to move around, bang into each other, and low pressure areas will be created that will actually reduce smoothing in “shadowed” areas. Thus, there is an optimum mixing energy, and an optimum fan RPM to achieve that as depicted in the chart.
[0035] Exposure times are calculated by formula. Arrhenius temperature dependence, the effect of temperature on the reaction rate k, is found to be exponential as the following formula describes:
[0000] k=k 0* e ̂(− E/RT )
[0000] where: k0 a pre-exponential (Arrhenius) factor.
E is the activation energy, R is the universal gas constant. T is Temperature in K.
[0039] Thus, this invention automatically controls the tank temperature, plus measures it and corrects the exposure time to achieve a repeatable level of smoothing. Alternatively, a mode may be selected that allows the user to select a fixed time duration manually.
[0040] The user enters the sheen (smoothing factor) desired and the controller calculates the time. The user places the parts in the tank and starts the treatment by activating the controller. During the smoothing process, the controller adjusts the time remaining to compensate for temperature changes. When the time is up, a musical alert is sounded which progressively provides louder and more attention getting sound sequences while flashing the light. The User stops the process by pressing the button on the controller, and the music and fan stops. Then the user removes the parts and sets them aside to dry. Because the tank offers unparalleled visibility of the progress and is internally lighted, the user may elect to watch the treatment and stop it at any time they choose. There is some minor continuation of the melting after removal from the tank, but it is far less than with liquid based systems. Multiple treatments may be used to alter smoothing effects. The first treatment will treat all the way through porous parts, and will seal them so that future treatments affect the surface rather than the part interior.
[0041] The controller is built with a user replaceable computer chip to allow for future updates and possible alternate part types and solvents.
[0042] Description of an Alternate Embodiment:
[0043] FIG. 9 shows alternate embodiment of industrial use Vapor Tank. A vapor tank exposure section 110 is shown containing a rolling parts tray 120 . A control module 130 is located above the vapor tank exposure section 110 . A vapor exhaust and parts removal tank 140 is coupled to the vapor tank exposure section 110 . The vapor exhaust and parts removal tank 140 is coupled to an exhaust vent 150 . The vapor exhaust and parts removal tank 140 has vapor sealing doors 160 .
[0044] The main tank section is similar to the preferred embodiment with a flow-through assembly line for continuous part processing. Parts are introduced to the tank on a rolling parts tray and exposed. Upon process completion, vapor lock doors open and the parts tray is shifted into the Vapor exhaust and Parts Removal tank, at which time a new parts tray is introduced into the main tank section for the next load of parts to be processed. Once the vapors are exhausted, the processed parts are removed.
[0045] List of Solvent Cross Materials:
[0046] Nearly any plastic can be smoothed with some solvent or combination of solvents. Patent U.S. Pat. No. 4,529,563A for instance explores the various plastics and effective smoothing agents for use with each, plus lays out a strategy for finding appropriate solvents for a given plastic. The entire contents of U.S. Pat. No. 4,529,563 are hereby expressly incorporated by reference herein for all purposes.
[0047] As noted above, acrylonitrile butadiene styrene (ABS) can be sealed with 1,2 Dichloroethane vapor, Acetone vapor, Cyclohexanone vapor and/or MEK vapor. Polyacetal (Delrin-POM) can be sealed with MEK vapor and/or Methyl benzene vapor. Polycarbonate can be smoothed with minimal loss of strength using Azeotropic (vapor) mixtures of meta xylene and iso-amyl acetate that are formed by a mixture that is 46% xylene and 54% amyl acetate at 136° C. A vapor mixture of 44.87% butyl alcohol and 55.2% butyl acetate at 113° C. also works on polycarbonate.
[0048] List of Independent Process Variables That Can be Controlled to Improve Performance and Repeatability:
1. Temperature 2. Humidity 3. Partial pressure of solvents 4. Illumination intensity and wavelength 5. Mixing energy
[0054] User Operational Sequence:
1. Turn on unit, put acetone or other liquid or gas in the tank. 2. Adjust processing exposure values as desired. 3. Place the parts in the tank using the parts tray or optionally using a user-supplied holder. 4. Close the lid, push start. 5. Upon alarm sounding, push stop and remove the parts.
[0060] Controller Operational Sequence:
[0061] During system operation, the computer controls the smoothing process automatically:
1. Turns on the fan, light, and heater, starts the timer 2. Monitors the temperature, optionally measure saturation, and computes when the proper level of treatment has been achieved. 3. Upon completion, turns off the heat for about a minute before the predicted finishing time and keeps the fan going to condense out and cool the vapor in the tank 4. Upon total completion time:
a. turns off the fan b. flashes the lamp c. sounds the alarm music d. as time progresses without user interaction, the alarm changes to an attention-getting series of musical sequences, getting louder.
In the above embodiment, the user turns off the controller and removes the parts tray for drying.
[0071] An embodiment can include a clear tank for treating parts with potentially explosive vapors safely contained using blast film and a low compression lid. An embodiment can include a vapor treatment system with a controller that continually adjusts for changing environment parameters such as temperature, or humidity. An embodiment can include a spot cooling system to control and measure top condensation that is automatically cleared each time the unit is opened. An embodiment can include an electronic measurement of the cumulative condensation used by the computer to optimize treatment time. Sensing liquid levels may be achieved by but is not limited to the following methods: ultrasonic, optical, float, mass, capacitive and/or inductive. An embodiment can include localized controlled condensation that prevents arbitrary condensation dripping from the lid onto the parts. In a preferred embodiment use is made of pettier (Peltier) cooling chips. Alternative condenser configurations: water cooled or use the whole lid condenser hemisphere with collector around the rim, chiller based with coils, evaporator based cooling, air impingement and vortex tube cooling, ice or dry ice cooling and/or ambient heat sink attached to collection spot. Alternate tank versions include automatic insertion and removal from vapors to an exhaust drying area. Alarm when process is done, that increases in intensity and speed with time. Vapor sensors can be added as needed to improve accuracy of computer controlled exposure.
[0072] An embodiment can include lowering the temperature and changing other parameters such as fan speed and partial pressure alters vapor penetration deeper into the parts, variations in smoothing, and treating part internal structures. An embodiments can include a fan the prevents layering of vapors and resulting uneven exposure. Use of Brushless low voltage motor removes possible ignition source. All of the electronics are also low voltage for the same reasons. Lowering the temperature, allows vapor penetrating deeper into the parts and smoothing, and treating the internals.
[0073] The two chamber embodiment, allows automation of the entire sequence, form insertion, to multiple exposures, to final drying. The two chamber embodiment allows integrating into an assembly line and automation. The two chamber embodiment eliminates vapor exposure for users.
Definitions
[0074] The term vapor is intended to mean a solid and/or liquid in equilibrium with a gas phase; and this is intended to preclude just a gas in the absence of a solid and/or liquid as well as also precluding a solid and/or liquid in the absence of a gas. The terms program and software and/or the phrases program elements, computer program and computer software are intended to mean a sequence of instructions designed for execution on a computer system (e.g., a program and/or computer program, may include a subroutine, a function, a procedure, an object method, an object implementation, an executable application, an applet, a servlet, a source code, an object code, a shared library/dynamic load library and/or other sequence of instructions designed for execution on a computer or computer system).
[0075] The term uniformly is intended to mean unvarying or deviate very little from a given and/or expected value (e.g. within 10% of). The term substantially is intended to mean largely but not necessarily wholly that which is specified. The term approximately is intended to mean at least close to a given value (e.g., within 10% of). The term generally is intended to mean at least approaching a given state. The term coupled is intended to mean connected, although not necessarily directly, and not necessarily mechanically. The term proximate, as used herein, is intended to mean close, near adjacent and/or coincident; and includes spatial situations where specified functions and/or results (if any) can be carried out and/or achieved. The term distal, as used herein, is intended to mean far, away, spaced apart from and/or non-coincident, and includes spatial situation where specified functions and/or results (if any) can be carried out and/or achieved. The term deploying is intended to mean designing, building, shipping, installing and/or operating.
[0076] The terms first or one, and the phrases at least a first or at least one, are intended to mean the singular or the plural unless it is clear from the intrinsic text of this document that it is meant otherwise. The terms second or another, and the phrases at least a second or at least another, are intended to mean the singular or the plural unless it is clear from the intrinsic text of this document that it is meant otherwise. Unless expressly stated to the contrary in the intrinsic text of this document, the term or is intended to mean an inclusive or and not an exclusive or. Specifically, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present). The terms a and/or an are employed for grammatical style and merely for convenience.
[0077] The term plurality is intended to mean two or more than two. The term any is intended to mean all applicable members of a set or at least a subset of all applicable members of the set. The phrase any integer derivable therein is intended to mean an integer between the corresponding numbers recited in the specification. The phrase any range derivable therein is intended to mean any range within such corresponding numbers. The term means, when followed by the term “for” is intended to mean hardware, firmware and/or software for achieving a result. The term step, when followed by the term “for” is intended to mean a (sub)method, (sub)process and/or (sub)routine for achieving the recited result. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this present disclosure belongs. In case of conflict, the present specification, including definitions, will control.
[0078] The described embodiments and examples are illustrative only and not intended to be limiting. Although embodiments of the present disclosure can be implemented separately, embodiments of the present disclosure may be integrated into the system(s) with which they are associated. All the embodiments of the present disclosure disclosed herein can be made and used without undue experimentation in light of the disclosure. Embodiments of the present disclosure are not limited by theoretical statements (if any) recited herein. The individual steps of embodiments of the present disclosure need not be performed in the disclosed manner, or combined in the disclosed sequences, but may be performed in any and all manner and/or combined in any and all sequences. The individual components of embodiments of the present disclosure need not be formed in the disclosed shapes, or combined in the disclosed configurations, but could be provided in any and all shapes, and/or combined in any and all configurations. The individual components need not be fabricated from the disclosed materials, but could be fabricated from any and all suitable materials.
[0079] Various substitutions, modifications, additions and/or rearrangements of the features of embodiments of the present disclosure may be made without deviating from the scope of the underlying inventive concept. All the disclosed elements and features of each disclosed embodiment can be combined with, or substituted for, the disclosed elements and features of every other disclosed embodiment except where such elements or features are mutually exclusive. The scope of the underlying inventive concept as defined by the appended claims and their equivalents cover all such substitutions, modifications, additions and/or rearrangements.
[0080] The appended claims are not to be interpreted as including means-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “mechanism for” or “step for”. Sub-generic embodiments of this disclosure are delineated by the appended independent claims and their equivalents. Specific embodiments of this disclosure are differentiated by the appended dependent claims and their equivalents.
|
This invention is an improved treatment process and apparatus for smoothing and strengthening plastic parts, and particularly parts made by rapid prototyping machines.
| 1
|
This application claims the benefit of U.S. Provisional Patent Application 61/424,071 filed on 17 Dec. 2010, the specification of which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the invention relate to a permanently or temporarily implantable device having a longitudinally extended electrical conductor.
2. Description of the Related Art
Such devices, for example, electrode conductors for electrical stimulation or catheters with electrodes, have the disadvantage that the electrical leads thereof can heat up in an MRI machine because the alternating magnetic fields in an MRI machine induce electrical currents in the electrical conductor which are not insignificant. For this reason, patients with heart pacemakers usually cannot be examined in an MRI machine using today's technology or can be examined only to a limited extent.
Implantable heart pacemakers or defibrillators typically have at least one stimulation electrode lead attached to said pacemaker, wherein said electrode lead has a standardized electrical connection at its proximal end, said end being provided for connection to the heart pacemaker or defibrillator and said electrode lead having one or more electrode poles on its distal end, said distal end being provided for locating the same in the heart. Such an electrode pole serves to deliver electrical pulses to the (myocardial) tissue of the heart or to sense electrical fields, in order to be able to sense an activity of the heart as part of so-called sensing. To this end, electrode poles typically form electrically conductive surface sections of an electrode lead. Electrode poles are typically provided as ring electrodes in the form of a ring around the electrode lead or in the form of a point or tip electrode at the distal end of the electrode lead. The electrode poles are electrically connected to contacts of the electrical connection of the electrode lead at its proximal end via one or more electrical conductors. Thus, one or more electrical conductors run between the contacts of the electrical connection of the electrode leads at their proximal end and the electrode poles at the distal end of the electrode lead, electrically connecting one or more of the electrode poles to one or more of the contacts. These electrical conductors may in turn be used for transmitting stimulation pulses to the electrode poles and to transmit electrical signals picked up by the electrode poles to the proximal end of the electrode lead and are also referred to as functional leads in the course of the further description. Such functional leads are electrical conductors, which are necessary for the function of the respective electrode lead and as such are exposed to the risk that electrical currents are induced in them due to external alternating magnetic fields. This electrical current may, for instance, result in unwanted heating of the functional leads or of the electrode poles connected to them or may result in a discharge of corresponding currents via the electrode poles into the surrounding tissue, thereby heating the surrounding tissue.
BRIEF SUMMARY OF THE INVENTION
The problem addressed by one or more embodiments of the invention is that of creating a device, which solves the problem described above.
According to one or more embodiments of the invention, this problem is solved by a device having at least two longitudinally extended electrical functional conductors for transmitting therapeutic signals or diagnostic signals or both, and having an electrode pole connected to one of the functional conductors, by which electrical current is delivered to the surrounding bodily tissue in the case of use or with which electrical potentials in the surrounding tissue can be sensed in the event of use, or both. The two electrical functional conductors are inductively coupled for defined resonant frequencies, so that RF energy of a first functional conductor is diverted to a second functional conductor, and the energy is delivered via this functional conductor and an electrode pole connected to this functional conductor to surrounding tissue in the event of use. It is possible in this way to divert RF energy induced in the event of use to an electrode pole suitable for distributing this energy.
According to a preferred embodiment variant, the medical device is a bipolar or multipolar catheter for temporary use or a permanently implantable electrode lead or some other longitudinally extended, electrically conductive implant having partial insulation, so that local heating due to MRI-induced currents is to be expected on defined electrode surfaces, such that the RF energy of a first lead, as the first functional conductor, is diverted by means of an inductive coupling for defined resonant frequencies, i.e., it is diverted to a second or additional lead as the respective second functional conductor, which then delivers the energy to the surrounding tissue via an electrode pole.
The electrode pole, which is connected to the respective second functional conductor, is preferably formed by at least one ring electrode. This ring electrode may be a functional ring electrode, which also serves to deliver stimulation pulses or to detect potentials. Alternatively, the ring electrode may also be provided only for diverting induced energy, that is, it may not have any other function, so that it is also referred to below as being nonfunctional. In the latter sense, a preferred embodiment variant is one in which the second functional conductor is electrically connected to at least one additional ring electrode as an electrode pole, which is provided specifically for diverting induced RF energy.
The medical device is preferably a stimulation electrode lead for connection to a permanently implantable stimulator, for example, a heart pacemaker or defibrillator, to enable the users of such implants to be examined in an MRI machine.
For inductive coupling of the two functional conductors, a transformer is preferably connected between the first and second functional conductors. In addition, a capacitor connected in parallel or in series with a winding of the transformer is preferably provided for tuning the resonant frequency of the inductive coupling circuit, comprised of a transformer and a capacitor. The capacitor is preferably connected to the secondary winding of the transformer, which is in turn connected to the second functional conductor.
The transformer and a capacitor, which is optionally present, are preferably tuned to one another in such a way that a desired resonant frequency is obtained, taking into account a parasitic capacitance to be expected in the event of use, to the surrounding body tissue and surrounding body fluid.
It is especially preferred if the transformer has no core. Alternatively, the transformer may have a core of ferromagnetic core material. In this case, the core preferably utilizes a ferromagnetic core material, whose saturation begins only at an MRI magnetic field strength higher than that expected.
In addition to the embodiments described herein other alternative embodiments may include some or all of the disclosed features.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be explained in greater detail on the basis of embodiments with reference to the figures. The figures show the following:
FIG. 1 shows an implantable heart stimulator and an implantable electrode lead connected thereto as the implantable medical device.
FIG. 2 shows an example of a temperature characteristic at the electrode tip.
FIGS. 3A and 3B show examples of an MRI resonator suitable for inductive coupling of two functional conductors.
FIG. 4 shows an MRI resonator variant 2 .
FIG. 5 shows an MRI resonator having two diverting leads.
FIG. 6 shows an MRI resonator having two diverting leads in variant 2 .
FIG. 7 shows an MRI resonator having multiple non-therapeutic rings for diverting energy.
FIG. 8 shows an MRI resonator having a non-therapeutic ring electrode.
DETAILED DESCRIPTION OF THE INVENTION
The implantable heart stimulator 10 may be a heart pacemaker or a cardioverter/defibrillator (ICD). In the embodiment shown here, the heart stimulator 10 is a ventricular heart pacemaker and defibrillator. Other known heart stimulators are two-chamber heart pacemakers for stimulation of the right atrium and the right ventricle or biventricular heart pacemakers, which are additionally able to stimulate the right ventricle as well as the left ventricle.
Such stimulators typically have a housing 12 , which is usually made of metal and is therefore electrically conductive and may serve as a large-surface-area electrode pole. Typically a terminal housing 14 is attached to the outside of the housing 12 and is also referred to as a header. Such a header typically has female contacts to receive plug contacts. The female contacts have electrical contacts 16 , which are connected via corresponding conductors to electronics provided in the housing 12 of the heart stimulator 10 .
The electrode lead 20 also constitutes an implantable medical device in the sense of this invention. Electrode poles in the form of a point electrode or tip electrode 22 and a ring electrode 24 arranged nearby are arranged on the distal end of the electrode lead 20 in a known manner. The electrode poles 22 and 24 are designed so that they serve to sense electric potentials of the (myocardial) heart tissue depending on the function of the heart stimulator to which the electrode lead 20 is connected, or they are designed to deliver electrical signals, for example, for delivering stimulation pulses to the surrounding heart tissue. FIG. 1 shows how the electrode poles, i.e., the tip electrode 22 and the ring electrode 24 , the electrode lead 20 in the application case, are situated at the apex of a right ventricle of a heart.
The tip electrode 22 and the ring electrode 24 are each electrically connected to a plug contact 28 on the proximal end of the electrode lead 20 via at least one electrical conductor 22 each. The plug contact 28 has electrical contacts, which correspond to the electrical contacts 16 of the contact busing in the terminal housing 14 of the implantable heart stimulator. The electrical conductors 26 in the electrode lead 20 may be designed as approximately elongated cable conductors or as helically coiled conductors. Such conductors, which electrically connect the functional electrode poles to electrical contacts of the plug contact on the proximal end of the electrode lead 20 , are referred to in the context of this text as functional conductors because they transmit electrical signals, which are used therapeutically, from a plug contact to the respective electrode pole, or they transmit signals representing electrical potentials that are sensed from the respective electrode pole to the plug contact and thus serve the elementary function of the medical device.
The electrical conductors 26 , which connect the electrode poles 22 and/or 24 to the electrical contacts of the plug 28 of the electrode lead 20 , are surrounded by an insulating sheath over most of their length, so that an electrical contact with the tissue of the heart is achieved in a targeted manner via the electrode poles.
In addition to the electrode poles 22 and 24 , which typically serve to stimulate the heart tissue (ventricular in this case), the electrode lead 20 also has two large-surface-area electrode poles 30 and 32 , which serve as defibrillation electrodes and are formed by at least one helically coiled, uninsulated wire.
It should be pointed out that the invention is explained below as part of this exemplary embodiment on the basis of a right ventricular heart pacemaker and defibrillator. Essentially, however, an ablation electrode lead may also serve as the medical device in the sense of this invention. In the application case, this ablation electrode lead also extends into the patient's heart and is controlled by a device located outside of the patient and is connected to this device for this purpose.
FIG. 2 illustrates a typical temperature characteristic 100 of a conventional pacemaker/ICD electrode in an MRI machine. When the high-frequency alternating field is turned on in the MRI machine at time 110 , the temperature rises rapidly, such that the steepness of the rise and the maximum achievable temperature depend greatly on the electrode position, based on the high-frequency alternating fields of the MRI. If the high-frequency alternating field is deactivated (at time 120 ), then the electrode tip cools again relatively rapidly due to its comparatively low thermal capacity.
FIGS. 3 to 8 show, in schematically simplified diagrams, two functional conductors each on the distal end of an electrode lead. The functional conductors are each identified as ZL 1 (for the first electrode lead) and ZL 2 (for the second electrode lead). The first lead ZL 1 is connected as the electrode pole to a respective tip electrode 210 , 310 , 410 , 510 , 610 and/or 710 , while the respective second functional conductor ZL 2 is connected to a ring electrode 220 , 320 , 420 , 520 and/or 720 as the electrode pole. Additional typical components of electrode leads such as an insulating sheath or terminal contacts on the respective proximal end have been omitted here for the sake of simplicity.
FIG. 3A shows the diverting lead according to the invention for the MRI-induced currents on the ring electrode 220 on the second functional conductor ZL 2 . The principle is to short-circuit the tip electrode 210 and ring electrode 220 with the oscillating circuit shown in the resonant case. To do so, a transformer 230 is connected between the first and second functional conductors ZL 1 and ZL 2 . A capacitor 240 , which is connected in parallel with the secondary winding L of the transformer 230 , serves to tune the resonant frequency. This arrangement allows small component sizes, in particular coils having a very low inductance, and is thus easily compatible with the electrode design.
The resonant frequency is calculated according to the equation:
f
0
=
1
2
π
LC
Thus, at a capacitance C=1 pF, an inductance of “only” approximately 6.5 μH is required in the resonant circuit for a 1.5 T MRI. Such an arrangement may optionally be accommodated behind a ring electrode.
In another preferred implementation, C>10 pF is selected because otherwise the core-free implementation (because of saturation in the static magnetic field of the MRI) would require too many windings/a large geometry.
In the embodiment variant shown in FIG. 3A , the transformer is without a core. In another preferred implementation, a core is used, but only at field strengths greater than those of the anticipated MRI (for example, materials which become saturated only at approximately 1.7 T). Electrodes having a very effective core transformer may thus be constructed for use with 1 T and 1.5 T MRI machines.
The contact point K is provided on lead ZL 2 in FIG. 3A as an example, that is, it is provided on the second functional conductor. The invention also relates to all implementation variants in which a contact point K on the first functional conductor ZL 1 is contacted. In this case, the result is a series resonant circuit LC of the secondary winding L of the transformer 230 and of the capacitor 240 .
All the implementations are thus also the subject of the invention, when the transformer 230 ′ is coupled in the reverse manner from that show in FIG. 3B .
FIG. 3A shows the following:
210 : tip electrode 220 : ring electrode 230 : transformer (with or without a core) 240 : capacitor ZL 1 : lead for tip electrode ZL 2 : lead for ring electrode
FIG. 4 shows an alternative embodiment, in which the resonator 330 with the transformer and the capacitor is attached proximally from the ring electrode 320 . This embodiment offers the structural advantage that no reinforcement of the electrode is required in the area of the electrode tip.
FIG. 4 shows the following:
310 : tip electrode 320 : ring electrode 330 : transformer and capacitor (resonator) ZL 1 : lead for tip electrode ZL 2 : lead for ring electrode
FIG. 5 shows an expanded embodiment, in which an additional non-functional ring electrode 450 , which is connected to the second functional conductor ZL 2 , is provided. The diverting lead of the MRI-induced RF energy is additionally diverted here to a non-functional ring electrode 450 .
In this configuration, the parasitic body RC network 460 is taken into account and/or utilized in the dimensioning. The parasitic body RC network 460 is obtained in the use case—after implantation—from the electrical properties of the surrounding body fluids and the surrounding body tissue.
The advantage of this variant is the possibility of being able to divert higher energies and at the same time not having to optimize the dimensioning of the functional ring electrode 420 to the requirements of heat dissipation.
FIG. 5 shows the following:
410 : tip electrode 420 : functional ring electrode 430 : transformer and capacitor (resonator) 450 : additional ring electrode for dissipating heat 460 : parasitic body network ZL 1 : lead for tip electrode ZL 2 : lead for ring electrode
FIG. 6 shows a simplified embodiment in comparison with that in FIG. 5 . This embodiment also has an additional non-functional second ring electrode 540 on the second functional conductor ZL 2 . The MRI-induced RF energy here is additionally diverted to the non-functional ring electrode 540 .
However, the capacitor in the resonator circuit 530 is omitted in this configuration. The capacitance required for the resonance is replaced in the dimensioning by the parasitic body capacitance 550 to be expected in the use case.
FIG. 6 shows the following:
510 : tip electrode 520 : functional ring electrode 530 : transformer 540 : additional ring electrode for dissipating heat 550 : parasitic body capacitance ZL 1 : lead for tip electrode ZL 2 : lead for ring electrode
FIG. 7 shows an embodiment having several non-functional ring electrodes 640 , 640 ′ for dissipation of heat. The basic principle here corresponds to the embodiment variant according to FIG. 6 but offers the advantage that larger quantities of heat can be dissipated.
The functional ring electrode 620 is also not affected by the additional wiring. The embodiment variant according to FIG. 7 thus also makes do essentially without second functional conductors, so that the lead segments between the secondary winding LL of the transformer 530 and the respective ring electrode 640 and/or 640 ′ act as the second functional conductor in the sense of this embodiment of the invention.
FIG. 7 shows the following:
610 : tip electrode 620 : functional ring electrode 630 : transformer 640 , 640 ′: additional ring electrodes for dissipating heat 650 : parasitic body capacitance 660 : optional capacitor for adapting to the resonant case Zl 1 : lead for tip electrode Zl 2 : lead for ring electrode
In the embodiment variant shown in FIG. 8 , the principle of the embodiment variant according to FIG. 7 is simplified. The energy is dissipated here to a non-functional ring electrode 740 . However, the functional ring electrode 720 is not influenced by the additional wiring.
FIG. 8 shows the following:
710 : tip electrode 720 : functional ring electrode 730 : transformer 740 : additional ring electrode for dissipating heat 750 : parasitic body capacitance 760 : optional capacitor for adapting to the resonant case ZL 1 : lead for tip electrode ZL 2 : lead for ring electrode
It will be apparent to those skilled in the art that numerous modifications and variations of the described examples and embodiments are possible in light of the above teaching. The disclosed examples and embodiments are presented for purposes of illustration only. Therefore, it is the intent to cover all such modifications and alternate embodiments as may come within the true scope of this invention.
|
An implantable medical device having at least one first and one second longitudinally extended electrical functional conductor to transmit therapeutic signals or diagnostic signals or both. The implantable medical device includes one electrode pole connected to the functional conductor, wherein electrical current is delivered to the surrounded bodily tissue using the electrode pole. Electrical potentials may be sensed in the surrounding tissue using the electrode pole, such that the two electrical functional conductors are inductively coupled for defined resonant frequencies and such that RF energy of a first functional conductor is diverted to the second functional conductor. The RF energy is delivered to the surrounding tissue via the second functional conductor and via an electrode pole connected to the second functional conductor.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to fluid handling. More particularly, it relates to valves with explosive actuation and with fluid control by a destructible or deformable element which retains pressure.
2. Description of the Prior Art
Certain devices for a one-shot function, such as missile fin extension or automobile air bag inflation, use a source of stored, cold gas, typically at 4000 to 5000 psi. The device is pressurized from the source through a valve which is actuated at an appropriate time after a storage period which is, typically, long and indefinite so that the valve must have substantially no leakage before actuation in order that sufficient pressure remains in the source at such time. When the valve is actuated, typically by a pyrotechnic squib, leakage from the valve must be minimal so that the device remains pressurized during its operation, and the valve must remain in its actuated configuration despite large acceleration forces often associated with such one-shot functions.
Prior art valves using O-rings are not suited for such a function since they leak excessively. Certain other prior art valves of normally open construction achieve "zero-leakage" prior to actuation by using a tube extending through the valve to contain the pressurized gas, the tube being severed to close the valve on actuation thereof. After severing the tube, one portion thereof may be pinched off to prevent leakage from the one portion. Alternatively, leakage from both portions may be prevented by wedging the severing element therebetween. Similarly, certain prior art, zero-leakage, normally-closed valves retain pressurized gas by a closed tube end which is severed to open the valve. These prior art zero-leakage valves thus effectively eliminate leakage before they are actuated. However, they are they are deficient in one or more ways, as by excessive leakage after actuation, by not being positively retained in their actuated configuration, or by being inconvenient and expensive to reuse. A particular deficiency is that a single such prior art zero-leakage valve is not adapted to three-way operation. This last deficiency may be avoided by the use of several valves; however, the additional bulk, weight, and expense of several valves is highly disadvantageous in many applications of one-shot valves for high pressure, zero-leakage operation.
SUMMARY OF THE INVENTION
A one-shot, three-way valve having an internal tube, which extends across a cylinder and forms a zero-leakage fluid path prior to actuation of the valve, and having a ram sliding in the cylinder and, typically, motivated by gas from a pyrotechnic squib to move to an actuated position and cut the tube in two. The ram has a passageway which, inthis actuated position, mates with one portion of the cut tube to establish another fluid path. The ram is configured so that, as it moves to the actuated position, the other tube portion is pinched between the ram and the cylinder to both close off such other portion and wedge the ram in its actuated position. The valve has fittings replaceably connecting the opposite ends of the tube to the cylinder.
It is an object of the present invention to provide a three-way one shot valve having substantially zero leakage before actuation.
Another object is to provide such a valve which, after actuation, has minimal leakage and has its moveable valving elements positively retained in their actuated positions.
A further object is to provide such a valve which may be inexpensively and conveniently reused, is adapted to actuation by a pyrotechnic squib, and is of economical and rugged construction.
BRIEF DESCRIPTION OF THE DRAWINGS
Other, objects, advantages, and novel features of the present invention will be apparent from the following detailed description when considered with the accompanying drawings wherein:
FIG. 1 is an axial section of a one-shot, three way valve which embodies the principles of the invention and has its elements in an unactuated position;
FIG. 2 is a section similar to FIG. 1 with the elements in an actuated position;
FIG. 3 is a transverse section of the valve on line 3--3 of FIG. 2;
FIG. 4 is fragmentary axial section of the valve showing certain elements thereof as they initially move from the unactuated position; and
FIG. 5 is a section similar to that of FIG. 4 showing the valve with certain elements removed for installation of a tube.
DETAILED DESCRIPTION
The Figures show a one-shot, three way valve embodying the principles of the present invention. The valve includes a housing 10 having a cylindrically tubular wall 12 defining a cylindrical valve chamber 14. Housing 10 includes a disk-like wall 16 generally closing one end of chamber 14 and having a central opening or first port 18 of the valve. Port 18 opens through wall 16 into chamber 14 and has internal screw-threads 19 for connecting this port to a pressurized fluid conduit, not shown but sometimes referred to in the claims as a "third conduit, for pressurized fluid." The other end of chamber 16 is generally closed by a plug 22 which, typically, is screw-threadably engaged with wall 12 and has a port 23 for admission of hot gas from a pyrotechnic squib, not shown. Housing 10 is depicted in a representative configuration in which chamber 16 is of stepped configuration with a larger diameter portion adjacent plug 22 and a smaller diameter portion adjacent to wall 16, the housing having an annular, O-ring receiving groove 25 in the latter portion near its junction with the larger portion.
Housing 10 has pair of bosses 30 extended outwardly of wall 12 at locations thereon diametrically opposite of chamber 14 toward the end thereof at wall 16. Housing 10 has an opening, bore, or second port 31 of the valve at one boss 30, the upper boss in the Figures, and has another opening, bore, or third port 32 of the valve at the other boss. Ports 31 and 32 are coaxial and open through their respective bosses 30 and through wall 12. Each port 31 or 32 has a smaller diameter cylindrical section or conduit opening 35 adjacent to chamber 14 and has a larger diameter, internally screw-threaded section 36 at the end of the corresponding boss 30. As indicated for port 31 in FIG. 1, each port 31 or 32 is adapted for use in a well-known flared tubing sealing arrangement by having a concave frustoconical section 37 interconnecting portions 35 and 36.
The valve has a ram 40 which is externally cylindrical and is slidably fitted in chamber 14 for movement of the ram axially therein, in a direction from plug 22 to disk-like wall 16, from a first or unactuated position 41 of the ram, shown in FIG. 1, to a second or actuated position 42 in which the ram is depicted in FIG. 2. As identified in FIG. 1, ram 40 has first side 43 facing second port 31, has a second side 44 facing third port 32, has a first or operating end 45 disposed toward wall 16 and first port 18, and has a second or piston end 46 disposed toward plug 22. Piston end 46 is fitted in the larger diameter portion of chamber 14 and is circumscribed by an O-ring so that pressurized gas introduced through port 23 into chamber 14 acts on piston end 44 to motivate ram 40 from its position 41 toward its position 42. The valve has a shear pin 48 extending radially of wall 12 and ram 40 through bores individual thereto and aligned in the unactuated position 41. Pin 48 retains ram 40 in position 41 with sides 43 and 44 disposed as just described until gas pressure against end 46 is sufficient to shear the pin 48 and drive ram 40 to its position 42.
Ram 40 defines an L-shaped fluid passage 50 having a first opening 51, which opens through ram end 45 into the chamber 14 portion at wall 16, and having a port or second opening 52 through first ram side 43. Opening 52 is disposed axially of ram 40 so as to be aligned transversely thereof with second port 31 in housing 10 when ram 40 is in its actuated position 42. Ram 40 has on its end 45 a unitary cutting portion or cutter 55 which extends along tubular wall 12 axially of the ram from its side 43 and terminates in an edge 56. Edge 56 is juxtapositioned to section 35 of port 31 at the side thereof opposite wall 16 when the ram is in its unactuated position 41. Ram 40 bears on its side 44 a planar collapsing, crimping, and wedging surface 58 extending axially of chamber 14 from ram end 45 in a direction opposite to chamber end wall 16. Surface 58 is inclined to the axis of chamber 14 so that the end of surface 58 at ram end 45 is spaced from wall 16 a predetermined distance which is greater than the distance surface 58 is spaced from wall 16 remotely from ram end 45. Surface 58 thus diverges from wall 12 in the direction of movement of ram 40 from position 41 to position 42.
As best shown in FIG. 1, the subject valve has a conduit or tube 60 extending through ports 31 and 32 and extending transversely across chamber 14 coaxially of these ports when ram 40 is in its unactuated position 41. Tube 60 is cylindrical and has a first end portion 61 and an opposite second end portion 62 disposed oppositely of chamber 14. Tube 60 is constructed of any suitable material resulting in the tube being sufficiently severable, flexible, and collapsible to permit certain deformations of the tube from an initial tubular configuration shown in FIG. 1 to another and subsequently described configuration shown in FIG. 2. Tube portions 61 and 62 are received, respectively, in ports 31 and 32 at sections 35 thereof, sections 35 being slightly larger in diameter than tube 60 so that the tube is slidably extendable through wall 12 at each port section 35. Each tube end portion 61 or 62 terminates outwardly of wall 12 in a flared, frustoconical region 65 conforming to and disposed in mating relation with the corresponding frustoconical section 37 of housing 10. It is apparent that each surface 37 is radially outward of tube 60 and that each screwthreaded section 36 of housing 10 is axially outward of the tube. It is also apparent that flared regions 65 are individual to tube portions 61 and 62 and may be considered to be annular compression elements externally larger in diameter than port sections 35 and disposed thereat about the corresponding tube end portion 61 or 62.,
The valve is provided with a pair of well-known flared tubing fittings 70 individually received in ports 31 and 32. As indicated in FIGS. 2 and 3, each fitting 70 has a central hexagonal region 71 from which extend oppositely a pair of male flared fitting elements 72 each terminating in a convex frustoconical end 73, which conforms toa flared region 65 of tube 60 and to frustoconical housing sections 37, and having external screw-threads 74 which extend between region 71 and end 73 and are constructed to engage a screw-threaded section 36 of a port 31 or 32. At each fitting 70, one element 72 has its screw-threads 74 so engaged so that turning the fitting urges the end 73 into compressive sealing relation with the corresponding flared region 65 and urges this region into compressive sealing relation with the corresponding housing section 37. Each fitting 70 thus serves to fix the corresponding tube end portion 61 or 62 to wall 12 in pressure sealed relation thereto, this relation being established at the corresponding port 31 or 32. The other element 72 of each fitting 70 projects from the corresponding boss 30 and serves to connect in communicating relation to the corresponding tube end portion 65 any suitable conduit, not shown, for pressurized fluid, a first such conduit being attached to port 31 and a second such conduit being attached to port 32.
OPERATION
The operation of the described valve embodying the present invention is believed clearly apparent and will now be briefly described beginning with reference to FIG. 1 in which ram 40 is in its unactuated position 41. In this position, ram 40 is disposed between tube 60 and plug 22 with ram end 45 adjacent to the tube, and the tube is intact so that a first conduit attached to the fitting 70 at port 31 communicates, as indicated by arrows 80, through the tube with a second conduit attached to the fitting 70 at port 32.
In FIG. 4, ram 40 is depicted in a position relative to housing 10 in which the ram has moved somewhat toward its position 42 from its position 41 and cutter 55 has severed tube 60 at wall 12 and adjacent to port 31 leaving a portion 85 of tube 60 extending toward port 31 from port 32 and still connected at port 32 by the corresponding fitting 70 to any pressurized fluid conduit, hot shown, connected to element 72 and projecting from the corresponding boss 30.
In the position of ram 40 shown in FIG. 4 ram end 41 and crimping surface 58 are about to engage tube portion 85 as the ram continues to move toward its position 42 shown in FIG. 2 wherein end 51 of passage 50 aligns in communicating relation with port 31 since tube 60 has been previously severed at port 31 as shown in FIG. 4. Referring now to FIG. 3, it is seen that, in position 41, ram end 45 is disposed axially of chamber 14 between both of the ports 31 and 32 and the disk-like wall 16 with passage end 51 aligned with port 31 as just stated so that port 32 communicates with port 18 through passage 50 and end 52 thereof as indicated by arrows 90.
As ram 40 moves from its position shown in FIG. 4 and engages tube portion 85 after its severing by cutter 55, portion 85 is bent by ram end 45 in the direction of ram movement and crimped by ram surface 58 into a collapsed configuration 95, shown in FIGS. 2 and 3, against wall 12 in the region thereof adjacent to port 32. When tube 60 is collapsed into its configuration 95, it effectively seals port 32 from chamber 14 and prevents flow into the subject valve from any conduit attached to the fitting 70 of this port. Also, as ram 40 is motivated by gas pressure on its piston end 46 to move from its FIG. 4 position relative to housing 10 to its position 42, surface 58 overrides tube portion 85 and, as this portion approaches its collapsed configuration 95, wedges the tube portion between surface 58 and wall 12 so as to retain ram 40 in its actuated position 42.
If it is desired to reuse the subject valve for another one-shot operation, this may be done with relative convenience by unscrewing fittings 70 and driving ram 40 from its position 42 back to its position 41 in any suitable manner, as by a tool inserted through port 18. The severed portions of tube 60 may then be removed from ports 31 and 32. An unsevered tube 60, on which only one flanged region 65 is formed, may then be inserted through port 31 and into port 32 as shown in FIG. 5. It will be apparent that another flanged region may then be formed on the tube portion in port 32; the fittings 70 reinstalled; and a new shear pin 48 provided to restore the valve to its condition shown in FIG. 1.
Obviously many modifications and variations of the present invention are possible in view of the above teachings. It is, therefore, to be understood that, within the scope of the appended claims, the present invention may be practiced other than as specifically described above.
|
A one-shot, three-way valve having an internal tube forming a zero-leakage fluid path prior to actuation of the valve and having a ram moveable to an actuated position where the tube is cut in two. The ram has a passageway mating in the actuated position with one portion of the cut tube to establish another fluid path. The ram is configured so that, in its actuated position, the other tube portion is pinched by the ram to both close off this other portion and wedge the ram in the actuated position. The valve is adapted for actuation by a pyrotechnic squib and for reuse by convenient replacement of the tube.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 14/059,020, filed Oct. 21, 2013, now U.S. Pat. No. 8,816,002, which is a continuation of U.S. application Ser. No. 13/664,021, filed Oct. 30, 2012, now U.S. Pat. No. 8,563,651, which is a continuation of U.S. application Ser. No. 13/154,917, filed Jun. 7, 2011, now U.S. Pat. No. 8,299,173, which is a continuation of U.S. application Ser. No. 12/756,905, filed April 8, 2010, now U.S. Pat. No. 7,977,427, which is a continuation of U.S. application Ser. No. 12/433,874, filed April 30, 2009, now U.S. Pat. No. 7,723,432, which is a continuation of U.S. application Ser. No. 12/150,136, filed April 25, 2008, now U.S. Pat. No. 7,544,738, which is a continuation of U.S. application Ser. No. 11/492,133, filed Jul. 24, 2006, now U.S. Pat. No. 7,378,469, which is a continuation of U.S. application Ser. No. 10/727,337, filed Dec. 2, 2003, now U.S. Pat. No. 7,101,932, which is a continuation of U.S. application Ser. No. 10/068,371, filed Feb. 6, 2002, now U.S. Pat. No. 6,710,125, which is a divisional of U.S. application Ser. No. 09/740,556, filed Dec. 18, 2000, now U.S. Pat. No. 6,376,604, and claims the benefit of priority of U.S. Provisional Application No. 60/171,834, filed Dec. 22, 1999, each of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
This invention relates to activated poly(ethylene glycol) derivatives and methods of preparing such derivatives.
BACKGROUND OF THE INVENTION
Covalent attachment of the hydrophilic polymer, poly(ethylene glycol), abbreviated PEG, also known as poly(ethylene oxide), abbreviated PEO, to molecules and surfaces is of considerable utility in biotechnology and medicine. In its most common form, PEG is a linear polymer terminated at each end with hydroxyl groups:
HO—CH 2 CH 2 O—(CH 2 CH 2 O) n —CH 2 CH 2 —OH
The above polymer, alpha-,omega-dihydroxylpoly(ethylene glycol), can be represented in brief form as “HO-PEG-OH” where it is understood that the “PEG” symbol represents the following structural unit:
—CH 2 CH 2 O—(CH 2 CH 2 O) n —CH 2 CH 2 —
where n typically ranges from about 3 to about 4000.
PEG is commonly used as methoxy-PEG-OH, or mPEG in brief, in which one terminus is the relatively inert methoxy group, while the other terminus is a hydroxyl group that is subject to ready chemical modification. The structure of mPEG is given below.
CH 3 O—(CH 2 CH 2 O) n —CH 2 CH 2 —OH
mPEG
Random or block copolymers of ethylene oxide and propylene oxide, shown below, are closely related to PEG in their chemistry, and they can be substituted for PEG in many of its applications:
HO—CH 2 CHRO(CH 2 CHRO) n CH 2 CHR—OH
wherein each R is independently H or CH 3 .
PEG is a polymer having the properties of solubility in water and in many organic solvents, lack of toxicity, and lack of immunogenicity. One use of PEG is to covalently attach the polymer to insoluble molecules to make the resulting PEG-molecule “conjugate” soluble. For example, it has been shown that the water-insoluble drug paclitaxel, when coupled to PEG, becomes water-soluble. Greenwald, et al., J. Org. Chem., 60:331-336 (1995).
To couple PEG to a molecule, such as a protein, it is often necessary to “activate” the PEG by preparing a derivative of the PEG having a functional group at a terminus thereof. The functional group can react with certain moieties on the protein, such as an amino group, thus forming a PEG-protein conjugate.
In U.S. Pat. No. 5,650,234, which is incorporated by reference herein in its entirety, a 1-benzotriazolylcarbonate ester of poly(ethylene glycol) is described. The multi-step process described in the '234 patent for forming the 1-benzotriazolylcarbonate ester of PEG includes reaction of a PEG molecule with the volatile and hazardous compound, phosgene, in order to form a PEG chloroformate intermediate. The use of phosgene in the process results in the formation of HCl, which can cause degradation of the PEG backbone. Due to the volatile nature of phosgene, and the resulting safety and quality problems associated with its use, there is a need in the art for a method for preparing 1-benzotriazolylcarbonate esters of PEG without using phosgene.
SUMMARY OF THE INVENTION
The invention provides a method for the preparation of a 1-benzotriazolyl-carbonate ester of a water-soluble and non-peptidic polymer by reacting the polymer with di(1-benzotriazolyl)carbonate (“di-BTC”). Using the invention, the 1-benzotriazolylcarbonate ester can be formed in a single step and without using phosgene, thereby avoiding the safety and quality problems associated with that compound.
The method of the invention includes providing a water-soluble and non-peptidic polymer having at least one terminal hydroxyl group and reacting the terminal hydroxyl group of the water-soluble and non-peptidic polymer with di(1-benzotriazolyl)carbonate to form the 1-benzotriazolylcarbonate ester of the water-soluble and non-peptidic polymer. Examples of suitable water-soluble and non-peptidic polymers include poly(alkylene glycol), poly(oxyethylated polyol), poly(olefinic alcohol), poly(vinylpyrrolidone), poly(hydroxypropylmethacrylamide), poly(α-hydroxy acid), poly(vinyl alcohol), polyphosphazene, polyoxazoline, poly(N-acryloylmorpholine), and copolymers, terpolymers, and mixtures thereof. In one embodiment, the polymer is poly(ethylene glycol) having an average molecular weight from about 200 Da to about 100,000 Da.
The reaction step can be conducted in the presence of an organic solvent and a base. Examples of suitable organic solvents include methylene chloride, chloroform, acetonitrile, tetrahydrofuran, dimethylformamide, dimethyl sulfoxide, and mixtures thereof. The base can be, for example, pyridine, dimethylaminopyridine, quinoline, trialkylamines, and mixtures thereof.
The method of the invention can further include reacting the 1-benzotriazolylcarbonate ester of the water-soluble and non-peptidic polymer with the amino groups of a second polymer having a plurality of primary amino groups, such as a protein, poly(ethylene glycol), aminocarbohydrates, or poly(vinylamine), to form a cross-linked polymer. Additionally, the 1-benzotriazolylcarbonate ester can be reacted with either an amino acid, such as lysine, to form a polymeric amino acid derivative, or a biologically active agent to form a biologically active polymer conjugate.
DETAILED DESCRIPTION OF THE INVENTION
The terms “functional group”, “active moiety”, “activating group”, “reactive site”, “chemically reactive group” and “chemically reactive moiety” are used in the art and herein to refer to distinct, definable portions or units of a molecule. The terms are somewhat synonymous in the chemical arts and are used herein to indicate portions of molecules that perform some function or activity and are reactive with other molecules. The term “active,” when used in conjunction with “functional groups”, is intended to include those functional groups that react readily with electrophilic or nucleophilic groups on other molecules, in contrast to those groups that require strong catalysts or highly impractical reaction conditions in order to react. For example, as would be understood in the art, the term “active ester” would include those esters that react readily with nucleophilic groups such as amines. Typically, an active ester will react with an amine in aqueous media in a matter of minutes, whereas certain esters, such as methyl or ethyl esters, require a strong catalyst in order to react with a nucleophilic group.
The term “linkage” or “linker” is used herein to refer to groups or bonds that normally are formed as the result of a chemical reaction and typically are covalent linkages. “Hydrolytically stable linkages” means that the linkages are substantially stable in water and do not react with water at useful pHs, e.g., under physiological conditions for an extended period of time, perhaps even indefinitely. “Hydrolytically unstable” or “hydrolytically degradable” linkages means that the linkages are degradable in water or in aqueous solutions, including for example, blood. “Enzymatically unstable” or “enzmatically degradable” linkages means that the linkage can be degraded by one or more enzymes. As understood in the art, PEG and related polymers may include degradable linkages in the polymer backbone or in the linker group between the polymer backbone and one or more of the terminal functional groups of the polymer molecule.
The term “biologically active molecule”, “biologically active moiety” or “biologically active agent” when used herein means any substance which can affect any physical or biochemical properties of a biological organism, including but not limited to viruses, bacteria, fungi, plants, animals, and humans. In particular, as used herein, biologically active molecules include any substance intended for diagnosis, cure mitigation, treatment, or prevention of disease in humans or other animals, or to otherwise enhance physical or mental well-being of humans or animals. Examples of biologically active molecules include, but are not limited to, peptides, proteins, enzymes, small molecule drugs, dyes, lipids, nucleosides, oligonucleotides, cells, viruses, liposomes, microparticles and micelles. Classes of biologically active agents that are suitable for use with the invention include, but are not limited to, antibiotics, fungicides, anti-viral agents, anti-inflammatory agents, anti-tumor agents, cardiovascular agents, anti-anxiety agents, hormones, growth factors, steroidal agents, and the like.
The invention provides a method for the preparation of a 1-benzotriazolylcarbonate ester (also referred to as a BTC ester) of a water-soluble and non-peptidic polymer, wherein a terminal hydroxyl group of a water-soluble and non-peptidic polymer is reacted with di(1-benzotriazolyl)carbonate, the structure of which is shown below, to form the 1-benzotriazolylcarbonate ester.
Di(1-benzotriazolyl)carbonate, which should not pose significant safety or handling problems as a reagent and should not cause degradation of the polymer backbone, can be purchased as a 70% (w/w) mixture with 1,1,2-trichloroethane from Fluka Chemical Corporation of Milwaukee, Wis.
The polymer backbone of the water-soluble and non-peptidic polymer can be poly(ethylene glycol) (i.e. PEG). However, it should be understood that other related polymers are also suitable for use in the practice of this invention and that the use of the term “PEG” or “poly(ethylene glycol)” is intended to be inclusive and not exclusive in this respect. The term, “PEG”, includes poly(ethylene glycol) in any of its forms, including alkoxy PEG, difunctional PEG, multi-armed PEG, forked PEG, branched PEG, pendent PEG (i.e. PEG or related polymers having one or more functional groups pendent to the polymer backbone), or PEG with degradable linkages therein.
PEG is typically clear, colorless, odorless, soluble in water, stable to heat, inert to many chemical agents, does not hydrolyze or deteriorate, and is generally non-toxic. Poly(ethylene glycol) is considered to be biocompatible, which is to say that PEG is capable of coexistence with living tissues or organisms without causing harm. More specifically, PEG is substantially non-immunogenic, which is to say that PEG does not tend to produce an immune response in the body. When attached to a molecule having some desirable function in the body, such as a biologically active agent, the PEG tends to mask the agent and can reduce or eliminate an immune response so that an organism can tolerate the presence of the agent. PEG conjugates tend not to produce a substantial immune response or cause clotting or other undesirable effects. PEG, having the formula —CH 2 CH 2 O—(CH 2 CH 2 O) n —CH 2 CH 2 —, where n is from about 3 to about 4000, typically from about 3 to about 2000, is one useful polymer in the practice of the invention. PEGs having a molecular weight of from about 200 Da to about 100,000 Da are particularly useful as the polymer backbone.
The polymer backbone can be linear or branched. Branched polymer backbones are generally known in the art. Typically, a branched polymer has a central branch core moiety and a plurality of linear polymer chains linked to the central branch core. PEG is commonly used in branched forms that can be prepared by addition of ethylene oxide to various polyols, such as glycerol, pentaerythritol and sorbitol. The central branch moiety can also be derived from several amino acids, such as lysine. The branched poly(ethylene glycol) can be represented in general form as R(-PEG-OH) m in which R represents the core moiety, such as glycerol or pentaerythritol, and m represents the number of arms. Multi-armed PEG molecules, such as those described in U.S. Pat. No. 5,932,462, which is incorporated by reference herein in its entirety, can also be used as the polymer backbone.
Many other polymers are also suitable for the invention. Polymer backbones that are non-peptidic and water-soluble, with from 2 to about 300 termini, are particularly useful in the invention. Examples of suitable polymers include, but are not limited to, other poly(alkylene glycols), such as poly(propylene glycol) (“PPG”), copolymers of ethylene glycol and propylene glycol and the like, poly(oxyethylated polyol), poly(olefinic alcohol), poly(vinylpyrrolidone), poly(hydroxypropylmethacrylamide), poly(α-hydroxy acid), poly(vinyl alcohol), polyphosphazene, polyoxazoline, poly(N-acryloylmorpholine), such as described in U.S. Pat. No. 5,629,384, which is incorporated by reference herein in its entirety, and copolymers, terpolymers, and mixtures thereof. Although the molecular weight of each chain of the polymer backbone can vary, it is typically in the range of from about 100 Da to about 100,000 Da, often from about 6,000 Da to about 80,000 Da.
Those of ordinary skill in the art will recognize that the foregoing list of substantially water soluble and non-peptidic polymer backbones is by no means exhaustive and is merely illustrative, and that all polymeric materials having the qualities described above are contemplated.
For purposes of illustration, a simplified reaction scheme for the method of the invention is shown below.
wherein BT is
L being the point of bonding to the oxygen atom.
In one embodiment, the reaction between the polymer and diBTC takes place in an organic solvent and in the presence of a base. Examples of suitable organic solvents include methylene chloride, chloroform, acetonitrile, tetrahydrofuran, dimethylformamide, dimethyl sulfoxide, and mixtures thereof. Amine bases, such as pyridine, dimethylaminopyridine, quinoline, trialkylamines, including triethylamine, and mixtures thereof, are examples of suitable bases. In one aspect of the invention, the molar ratio of di(1-benzotriazolyl)carbonate to the water-soluble and non-peptidic polymer is about 30:1 or less.
In one embodiment, the water-soluble and non-peptidic polymer has the structure R′-POLY-OH and the 1-benzotriazolylcarbonate ester of the water-soluble and non-peptidic polymer has the structure:
wherein POLY is a water-soluble and non-peptidic polymer backbone, such as PEG, and R′ is a capping group. R′ can be any suitable capping group known in the art for polymers of this type. For example, R′ can be a relatively inert capping group, such as an alkoxy group (e.g. methoxy). Alternatively, R′ can be a functional group. Examples of suitable functional groups include hydroxyl, protected hydroxyl, active ester, such as N-hydroxysuccinimidyl esters and 1-benzotriazolyl esters, active carbonate, such as N-hydroxysuccinimidyl carbonates and 1-benzotriazolyl carbonates, acetal, aldehyde, aldehyde hydrates, alkenyl, acrylate, methacrylate, acrylamide, active sulfone, protected amine, protected hydrazide, thiol, protected thiol, carboxylic acid, protected carboxylic acid, isocyanate, isothiocyanate, maleimide, vinylsulfone, dithiopyridine, vinylpyridine, iodoacetamide, epoxide, glyoxals, diones, mesylates, tosylates, and tresylate. The functional group is typically chosen for attachment to a functional group on a biologically active agent.
As would be understood in the art, the term “protected” refers to the presence of a protecting group or moiety that prevents reaction of the chemically reactive functional group under certain reaction conditions. The protecting group will vary depending on the type of chemically reactive group being protected. For example, if the chemically reactive group is an amine or a hydrazide, the protecting group can be selected from the group of tert-butyloxycarbonyl (t-Boc) and 9-fluorenylmethoxycarbonyl (Fmoc). If the chemically reactive group is a thiol, the protecting group can be orthopyridyldisulfide. If the chemically reactive group is a carboxylic acid, such as butanoic or propionic acid, or a hydroxyl group, the protecting group can be benzyl or an alkyl group such as methyl or ethyl. Other protecting groups known in the art may also be used in the invention.
In another embodiment, the water-soluble and non-peptidic polymer has the structure HO-POLY a -R(POLY b -X) q and the 1-benzotriazolylcarbonate ester of the water-soluble and non-peptidic polymer has the structure
wherein POLY a and POLY b are water-soluble and non-peptidic polymer backbones, such as PEG, that may be the same or different; R is a central core molecule, such as glycerol or pentaerythritol; q is an integer from 2 to about 300; and each X is a capping group. The X capping groups may be the same as discussed above for R′.
In another aspect, a difunctional or higher functional BTC ester of the water-soluble and non-peptidic polymer is reacted with at least two amino groups of a second polymer having a plurality of primary amino groups, such as amino PEGs or other multifunctional amine polymers, such as proteins, aminocarbohydrates, or poly(vinylamine), to form cross-linked polymers. The amine polymer will generally have three or more available amino groups. Such polymers form hydrogels; that is, they become highly hydrated in aqueous media, but do not dissolve. Since these hydrogels are commonly biocompatable and may be degradable, many biomedical applications are possible in the areas of drug delivery, wound covering, and adhesion prevention.
A further embodiment of the invention involves the reaction of BTC esters of water-soluble and non-peptidic polymers with amino acids to form amino acid derivatives. In one embodiment, a PEG-BTC ester is reacted with lysine to form a polymeric lysine derivative. For example, one such lysine derivative is a doubly PEGylated lysine, wherein the two PEGs are linked to the lysine amines by carbamate bonds, as shown below.
wherein PEG is poly(ethylene glycol) and Z is selected from the group consisting of H, N-succinimidyl, or 1-benzotriazolyl.
Such PEG derivatives of lysine are useful as reagents for preparation of PEG derivatives of proteins. These PEG derivatives often offer advantages over non-PEGylated proteins, such as longer circulating life-times in vivo, reduced rates of proteolysis, and lowered immunogenicity. In another aspect, PEG BTC derivatives are used directly in attaching PEG to proteins through carbamate linkages and may offer advantages similar to those described for the lysine PEG derivatives.
BTC esters of water-soluble and non-peptidic polymers can also be reacted with biologically active agents to form biologically active polymer conjugates. Examples of biologically active agents include peptides, proteins, enzymes, small molecule drugs, dyes, lipids, nucleosides, oligonucleotides, cells, viruses, liposomes, microparticles and micelles.
The invention also includes 1-benzotriazolylcarbonate esters of water-soluble and non-peptidic polymers prepared according to the above-described process. As noted above, it is believed that polymer derivatives prepared according to the invention exhibit higher quality because degradation of the polymer backbone caused by phosgene is avoided. Further, since the method of the invention requires only one step and fewer reactants, process efficiency is enhanced and cost is reduced.
The following examples are given to illustrate the invention, but should not be considered in limitation of the invention.
EXAMPLES
Example 1
Preparation of mPEG 5000 BTC
A solution of mPEG 5000 -OH (MW 5000, 15 g, 0.003 moles), di(1-benzotriazolyl)carbonate (4.0 g of 70% mixture, 0.000945 moles), and pyridine (2.2 ml) in acetonitrile (30 ml) was stirred at room temperature under nitrogen overnight. The solvent was removed by distillation, the residue was dissolved in 80 ml of methylene chloride, and the resulting solution was added to 850 ml of ethyl ether. The mixture was cooled to 0-5° C. and the precipitate was collected by filtration. The precipitation process was then repeated to obtain a white solid which was dried under vacuum at room temperature to yield 13.5 g of product which was shown by 1 H NMR to be 100% substituted. 1 H NMR (dmso d-6): 3.23 ppm, CH 3 O; 3.51 ppm, O—C H 2 C H 2 —O; 4.62 ppm, m, mPEG-O—C H 2 —OCO 2 —; 7.41-8.21, complex mult., benzotriazole protons.
Example 2
Preparation of mPEG 20,000 BTC
A solution of mPEG 20,000 -OH (MW 20,000, 20 g, 0.001 moles), di(1-benzotriazolyl)carbonate (3.4 g of 70% mixture, 0.00803 moles), and pyridine (3.0 ml) in acetonitrile (40 ml) was stirred at room temperature under nitrogen overnight. The solvent was removed by distillation and the residue was dissolved in 80 ml of methylene chloride and the resulting solution was added to 800 ml of ethyl ether. The precipitate was collected by filtration and was dried under vacuum at room temperature to yield 16.8 g of product which was shown by 1 H NMR to be 100% substituted. 1 H NMR (dmso d-6): 3.23 ppm, CH 3 O; 3.51 ppm, O—C H 2 C H 2 —O; 4.62 ppm, m, mPEG-O—C H 2 —OCO 2 —; 7.41-8.21, complex mult., benzotriazole protons.
Example 3
Derivatization of Lysine with mPEG 20,000 BTC
Lysine.HCl (0.0275 g, 0.000151 moles) was dissolved in 26 ml of 0.1 M borate buffer and the pH was adjusted to 8.0 with 0.1 M NaOH. To the resulting solution was added mPEG 20,000 BTC (7.0 g, 0.00350 moles) over 15 minutes and the pH was kept at 8 by addition of 0.1 M NaOH. After stirring the resulting solution for 3 h, 15 g of H 2 O and 4 g of NaCl were added and the pH was adjusted to 3.0 with 10% phosphoric acid. The product was extracted with methylene chloride and the extract dried over MgSO 4 . After concentrating the solution to 30 ml, the solution was poured into 300 ml of ethyl ether and the product collected by filtration and dried under vacuum at room temperature to yield 5.9 g of product as a white solid. Analysis by gel permeation chromatography (Ultrahydrogel 250, column temperature 75° C., aqueous buffer pH 7.2) showed the product to be a mixture of di-N-PEGylated lysine (MW˜40 KDa, 63.05%), mono-N-PEGylated lysine (MW˜20 KDa, 36.95%), and mPEG 20,000 .
Example 4
Derivatization of Lysozyme with mPEG 5000 BTC
To 4 ml of lysozyme solution (3 mg/ml in 50 mM sodium phosphate buffer, pH 7.2) was added 20.3 mg of mPEG 5000 BTC (5-fold excess of mPEG5000 BTC) and the mixture was continually mixed at room temperature. Analysis by capillary electrophoresis (57 cm×76 um column; 30 mM phosphate buffer; operating voltage 25 kV) after 4 hours showed that 6.94% of unreacted lysozyme remained, while 33.99% of mono-PEGylated lysozyme, 43.11% di-PEGylated lysozyme, 13.03% tri-PEGylated lysozyme, and 2.92% of tetra-PEGylated lysozyme had formed.
Example 5
PEG 2KDa -α-hydroxy-ω-propionic Acid, Benzyl Ester
To a solution of PEG 2KDa -α-hydroxy-ω-propionic acid (10 g, 0.0050 moles) (Shearwater Corp.) in anhydrous methylene chloride (100 ml), 1-hydroxybenzotriazole (0.30 g), 4-(dimethylamino)pyridine (1.0 g), benzyl alcohol (10.8 g, 0.100 moles) and 1,3-dicyclohexylcarbodiimide (1.0 M solution in methylene chloride, 7.5 ml, 0.0075 moles) were added. The reaction mixture was stirred overnight at room temperature under argon. The mixture was then concentrated to about 50 ml, filtered and added to 800 ml cold diethyl ether. The precipitated product was filtered off and dried under reduced pressure. Yield 8.2 g. NMR (d6-DMSO): 2.60 ppm (t, —CH 2 —COO—), 3.51 ppm (s, PEG backbone), 4.57 ppm (t, —OH—), 5.11 ppm (s, —CH 2 — (benzyl)), 7.36 ppm (m, —C 6 H 5 (benzyl)).
Example 6
PEG 2KDa -α-benzotriazole Carbonate-ω-propionic Acid, Benzyl Ester
To a solution of PEG 2KDa -α-hydroxy-ω-propionic acid, benzyl ester (8.2 g, 0.0025 moles) in acetonitrile (82 ml), pyridine (0.98 ml) and di(1-benzotriazolyl)carbonate (1.48 g) were added and the reaction mixture was stirred overnight at room temperature under argon atmosphere. The mixture was then filtered and solvent was evaporated to dryness. The crude product was dissolved in methylene chloride and precipitated with isopropyl alcohol. The wet product was dried under reduced pressure. Yield 6.8 g. NMR (d6-DMSO): 2.60 ppm (t, —CH 2 —COO—), 3.51 ppm (s, PEG backbone), 4.62 ppm (m, —CH 2 —O(C═O)—), 5.11 ppm (s, —CH 2 -(benzyl)), 7.36 ppm (m, —C 6 H 5 (benzyl)), 7.60-8.50 ppm (4 m, aromatic protons of benzotriazole).
|
The invention provides for preparing a polymer-active agent conjugate, the method comprising the steps of reacting an amino acid derivative with a biologically active agent under conditions to form a polymer-active agent conjugate.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 60/536,024, filed Jan. 13, 2004, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the present invention generally relate to completion of a well. More specifically, embodiments of the present invention pertain to analysis of different drilling methods used for completing a well.
2. Description of the Related Art
Historically, wells have been drilled with a column of fluid in the wellbore designed to overcome any formation pressure encountered as the wellbore is formed. This “overbalanced condition” restricts the influx of formation fluids such as oil, gas or water into the wellbore. Typically, well control is maintained by using a drilling fluid with a predetermined density to keep the hydrostatic pressure of the drilling fluid higher than the formation pressure. As the wellbore is formed, drill cuttings and small particles or “fines” are created by the drilling operation. Formation damage may occur when the hydrostatic pressure forces the drilling fluid, drill cuttings and fines into the reservoir. Further, drilling fluid may flow into the formation at a rate where little or no fluid returns to the surface. This flow of fluid into the formation can cause the “fines” to line the walls of the wellbore. Eventually, the cuttings or other solids form a wellbore “skin” along the interface between the wellbore and the formation. The wellbore skin restricts the flow of the formation fluid and thereby damages the well.
In conventional (overbalanced) drilling conditions, the drilling fluid penetrates the reservoir, damaging the near-bore formation and obstructing the flow of oil and gas into the wellbore. This formation damage limits the productivity of the well. The less oil and gas an operator recovers from a well, the less money returned on their investment. Several years ago, one major operator estimated the net potential cost of formation damage over the remaining life of all of their fields at $1.5 billion before taxes.
Underbalanced drilling operations lighten the hydrostatic pressure of the drilling fluid column so that the pressure in the wellbore is less than the formation pressure at all times. The lower pressure in the wellbore encourages the oil/gas to flow from the formation and virtually eliminates the flow of drilling fluids into the formation. This increases the reservoir's rate of production and maximizes the recovery of available reserves.
The industry uses a dimensionless number called the skin factor to measure the amount of formation damage. The skin factor represents the degree which a wellbore is lined with particulate matter. The skin factor is proportional to the steady state pressure difference around the wellbore. The skin factor is calculated to determine the production efficiency of a wellbore by comparing actual conditions with theoretical or ideal conditions. Over three years, the production value of a well with a skin factor of ten might be $60 million. If the same well were drilled underbalanced-leaving it with a skin factor of two—the production value would typically be 75 percent higher or $105 million over the same three-year period.
The costs for underbalanced drilling (UBD) are higher than the costs for overbalanced drilling. Taken alone however, when benefits directly attributable to underbalanced drilling are considered, such as increased rates of penetration (ROP) and more trouble-free rig time, underbalanced drilling proves to be the more cost-effective drilling method. Lighter drilling fluids mean faster drilling time. Faster drilling time means lower drilling costs. Underbalanced drilling has been proven to increase the ROP by 100-500 percent. For example, an operator in Venezuela estimated drilling time for a conventionally drilled well at 43 days. The well was later drilled underbalanced in 17 days.
A lost circulation zone can drive up the cost of any well. It results in lost fluid, the addition of lost circulation materials, slower drilling time, and the reconditioning of the drilling mud when the zone is passed through—all additional costs. If the lost circulation zone causes the pipe to stick, then the costs of the equipment lost in the hole, fishing operations, sidetracking, and rig downtime will also be incurred. Underbalanced drilling provides insurance against such drilling problems because the pressure in the annulus is never greater than the formation pressure, and therefore, the pressure differential neither pushes the drilling fluid into the reservoir nor draws the pipe to the formation.
For example, a conventionally drilled well in Wyoming suffered fluid losses of 40,000 barrels as well as differential sticking (the well was sidetracked three times). The budget overrun was $6 million. By comparison, an underbalanced well was drilled in the pay section, experiencing total fluid losses of only 200 barrels and no differential sticking. The well was drilled under budget.
Underbalanced drilling can also curtail expensive stimulation costs. Stimulations are usually conducted to get beyond formation damage or to create artificial permeability in low-permeability zones. Since underbalanced techniques decrease the amount of formation damage and encourage the oil and gas to flow from the reservoir, underbalanced drilling can reduce or eliminate the need of stimulation.
Formulas for calculating skin factor based on geological data, experience, core samples, etc., are well known in the art. Companies have also modified these formulas or formulated new ones based on experience which they most certainly regard as proprietary. Once the skin factor is calculated, a production curve can then be calculated. Combining the production curve with cost data will yield the net present value (NPV) of the well. Compounding this, though, is the fact that a lot of the factors that go into calculating the skin factor and the costs are fraught with substantial uncertainty. Thus, the uncertainty associated with the skin factor and costs calculations must be statistically analyzed or “risked”, calculating skin factor and cost while varying the “riskable” parameters. Further, all of these calculations must be performed with all of the available completion methods, i.e., underbalanced and overbalanced completion, to enable selection of the best method.
Computer programs for performing at least some of these functions are also known in the art. However, performing all of these functions together involves splicing together numerous different computer programs and/or manual calculations, wasting valuable manpower. Thus, there is a need for a comprehensive computer program that allows a user to input all of the necessary data to perform rigorous skin factor calculations, cost analysis, flow projections, NPV analysis, and risking of all values associated with substantial uncertainty. Further, due to the uncertainty associated with many of the calculations, calibration of the software using data from existing wells would be very beneficial.
SUMMARY OF THE INVENTION
The present invention provides a method and software for evaluating different completion methods for a reservoir. More specifically, the invention is useful in selecting the most viable method to complete a wellbore.
Embodiments of the present invention may be implemented as a set of one or more (e.g., a suite of) application programs for use with a computer system. The application program(s) generally include sets of instructions defining operations of methods described herein and can be contained on any suitable type computer-readable medium. Examples of suitable type computer-readable media include, but are not limited to: read-only storage media (e.g., a CD-ROM or DVD), writable storage media (e.g., floppy disks, hard drives, CD-R/RWs), as well as information conveyed to a computer by a communications medium, such as through a computer network, including wireless networks and the Internet.
In an exemplary arrangement, an interface is provided allowing a user to enter reservoir data. The method further comprises providing an interface allowing a user to enter parameters related to a first drilling technique. A first skin factor is then generated based on the reservoir data and the drilling parameters. Preferably, a first set of production data is then calculated from the first skin factor. Optionally, an interface is provided allowing the user to enter cost data related to the first drilling technique and a first total cost is generated. The production and the total cost related to the first technique can be combined and a report indicating the economic impact of drilling the reservoir using the first completion technique can then be generated.
Preferably, the user can enter ranges of the reservoir and/or cost data, referred to as “riskable” parameters, that are subject to considerable uncertainty and multiple total costs and/or skin factors can be calculated through multiple iterations. Risked production data can be calculated from the multiple skin factors and combined with the multiple total costs to yield risked net revenue data and a risked net present value. The entire process may be completed with alternate completion methods. The economic data resulting from each completion method can then be combined for comparison by the user. The user can then select the most feasible option and complete the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIGS. 1A and 1B are cross sections of a well completed with overbalanced and underbalanced techniques, respectively.
FIG. 2 is a flow diagram of exemplary operations of methods employed in the current invention.
FIG. 3 is a detailed flow diagram of exemplary operations of methods employed in the current invention.
FIG. 4 illustrates an exemplary GUI screen of a historical database.
FIG. 5 displays an exemplary GUI screen of a formation data input module.
FIG. 6 displays an exemplary GUI screen of a skin factor calculation and a production curve.
FIG. 7 displays an exemplary GUI screen of a skin factor calculation and a production curve.
FIG. 8 is a flow diagram of exemplary operations for skin factor risk analysis.
FIG. 9 is an exemplary skin distribution curve generated using the operations of FIG. 8 .
FIG. 10 is an exemplary skin sensitivity curve.
FIG. 11 is an exemplary risked net revenue curve for completion using both overbalanced and underbalanced completion techniques.
FIG. 12 is an exemplary risked NPV curve for completion using both overbalanced and underbalanced completion techniques
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides an improved method and software for evaluating completion of a wellbore. The invention employs extensive input and calculation modules as a means for efficiently comparing alternative methods of completion.
FIGS. 1A and 1B depict a wellbore completed using overbalanced and underbalanced techniques, respectively. As discussed above, overbalanced completion results in more skin damage to the producing formation than does a well completed using underbalanced techniques. Thus, the flow rate, Q, for a given well, will be lower for the well completed by overbalanced drilling compared to the same well completed with underbalanced techniques.
For sake of convenience, the software of the preferred embodiment discussed below shall be referenced in modules. These modules are the input, calculation, and risk modules.
FIG. 2 is a flow diagram of exemplary operations 200 for selecting a completion method (i.e., underbalanced or overbalanced) according to aspects of the present invention. A reservoir is shown ready for completion. At step 202 , the reservoir data, such as formation depth, formation type, and fracture or vug data, is entered into the input module of the present embodiment. At step 204 , necessary cost and completion data for one type of drilling method for completion (e.g., overbalanced). The software then calculates the skin factor, at step 206 , and total completion cost, at step 209 , that would result from using the selected completion method. From the skin factor, the software then generates production data at step 208 , such as initial flow rate, flow decline, and cumulative production. The software combines the total completion cost data and the production data at step 210 to generate a net present value (NPV) for the well completed with the selected completion method.
At step 212 , the process is then repeated for any/all alternate completion methods (i.e., underbalanced). The NPVs of the two completion methods can be compared at step 214 to select the better method of completion. At step 216 , the well is then completed with the better method.
FIG. 3 is a flow diagram of exemplary operations 300 for completion analysis according to the present invention. Once a wellbore is ready to be completed, the software is first run on past-completed wells at step 302 , similar to the wellbore at hand, to see if the total completion cost and skin factor calculations are accurate. For example, the data for past-completed wells may be stored in a historical database module of the software. If the predictions are not accurate, the cost estimation and/or skin factor calculation modules can be configured until they conform to actual results.
FIG. 4 is an exemplary screen of a historical database illustrating some of the information that may be stored. In the screen shot, reservoir and production data is shown for a past-completed well. First seen in the screen shot is a list of wells for which data is contained providing the well name and record number. There is also a section of the screen for individual data for a particular well. This section comprises four subsections: general well data, production zone data, pressure data, and production data. The general well data subsection comprises data for country, province/state, county/parish, and well name. The production zone subsection comprises data for latitude, longitude, TV depth, KB elevation, sub sea depth, R/R date, license date, and on production date of a selected production zone for the particular well. This subsection also comprises a scroll bar for selecting through the various production zones. This subsection also comprises data (not shown) for the drilling approach used (i.e., underbalanced or overbalanced), the orientation (i.e., vertical or horizontal), and the name of the selected production zone. This data is also reproduced (shown) above the pressure data and production data subsections. The pressure data subsection comprises data for test identification, date, type, shut in time, well head pressure, and run depth for the selected production zone. This subsection also comprises a scroll bar for selecting through multiple sets of pressure data for a selected production zone. The production data subsection comprises data for year, month, production time, oil production, gas production, and water production of the selected production zone. The historical database may also store other data collected from the past-completed well, such as completion cost and/or skin factor(s).
At step 304 the reservoir, completion, and cost parameters are entered into graphical user interface (GUI) screens of the input module for the set completion method (i.e., overbalanced) of the well being analyzed.
Calculation Module
The calculation module is comprised of skin factor and cost estimation sub-modules. The skin factor calculation and cost estimation sub-modules at step 306 then calculate the skin factor and total cost, respectively, for the set completion method (i.e., overbalanced) of the well being analyzed. From the skin factor and other parameters, the program at step 308 then calculates an initial flow rate, flow decline data, and cumulative production data for completion of the well using the set completion method. The program can calculate and generate a gross revenue curve from the cumulative production results.
FIG. 6 is an exemplary skin factor output screen. Preferably, the software calculates skin factor by combining several different forms of skin damage. These different forms may include, but are not limited to solids invasion, glazing, mashing, phase trap (invasion), phase trap (inhibition), fines migration, clay sensitivity, wettability alteration, asphaltene precipitation, scale precipitation, and emulsion creation. Also calculated and displayed is the radius of damage into the wellbore wall for each form of damage and for the overall skin factor.
The weight each form of damage contributes to the overall skin factor can be changed by altering the weighing factor, displayed in the Figure. A form of damage can be entirely excluded by setting the weighing factor to zero. The program also calculates and displays both permeability and radius of damage for average near wellbore, average deep damage, average total damage, and undamaged zone. This screen also contains a production curve calculated from the skin factor. As discussed above, the different forms of skin damage can be calculated from formulas known in the art or proprietary ones. Also, more or less forms of damage can be used to calculate the skin factor without deriving from the scope of the invention.
Risk Module
At step 310 , the estimated ranges for well data and cost variables associated with substantial uncertainty (“risked variables”) are then entered into a GUI screen. Preferably, the ranges are actually entered when the well and cost parameters are entered in the input module. For some embodiments, these ranges may be entered via a tabbed Risked Reservoir Variables sub-module GUI screen of the input module, such as that illustrated in FIG. 7 , and the Time Estimates, Cost Estimates, and Correlations sub-portions of the Cost sub-module of the input module (not shown).
The Risked Reservoir Variables, contained in FIG. 7 , sub-module provides three sub-portions for skin, NPV, and correlations. The skin sub-portion comprises min., mode, and max. inputs for reservoir pressure, largest aperture of fracture, type of vugs (i.e., pinpoint, medium, or large), in-situ horizontal permeability, vertical to horizontal permeability ratio, dynamic drilling period in pay section, number of tripping operations, number of OB pulse incidents during drilling, amount of OB pressure incidents, duration of OB pressure pulse incidents, circulating OB pressure, mud API fluid loss—base solution only, water saturation fraction, and formation porosity fraction. For each variable, the program calculates and displays an estimation from the inputs. The program also calculates and displays a min., mode, max., and estimated skin from the inputs. The NPV sub-portion (not shown) comprises inputs for unit price and discount rate. The correlations sub-portion (not shown) comprises inputs for correlating factors that correlate each of the variables inputted in the skin sub-portion to one another.
The Time Estimates sub-portion of the Cost sub-module (not shown) comprises min., mode, and max. time inputs; probability, maximum incidents, and additional cost inputs; and estimated time and estimated cost outputs for drilling casing exit/curve (time only), time to drill reservoir section (time only), rig crew efficiency fraction (time only), slide, stuck in hole, lost circulation, surface equipment failure, drillstring problems, BHA failure (outputs time, no inputs), completion, and equipment logistics time. The sub-portion also outputs times and costs for dynamic drilling period, total estimated drilling, and total estimated drilling and completion calculated from the data inputted into the sub-portion. The Cost Estimates sub-portion (not shown) comprises min., mode, and max. drilling cost inputs; min., mode, and max. completion cost inputs; and estimated drilling cost and estimated completion cost outputs for daily drilling cost, location, bits, casing and liners, cement, mob/de mob, formation evaluation, other costs, additional personnel, top hole cost, casing, wellhead equipment, and other equipment. The program also calculates and displays total estimated drilling cost and total estimated completion cost from data entered into the sub-portion. The correlations sub-portion comprises inputs for correlating factors that correlate each of the variables inputted in the time estimates sub-portion to one another (time and probability, if applicable).
At step 312 , the program then runs through multiple iterations, varying one or more variable(s) by a set increment and calculating a skin factor, total cost, and production curves for each iteration of each variable until all possible combinations have been exhausted. FIG. 8 is a flow diagram of exemplary operations 800 for a skin factor risk analysis. Once the user has entered the ranges for selected inputs at step 802 affecting the skin factor, the software begins iterating through the ranges of the input variables at step 804 , calculating a skin factor during each iteration at step 806 . Production data may also be calculated during this step. The results of each iteration are stored at step 808 for later analysis. Then one or more of the variable(s) are modified at step 810 according to known statistical techniques, such as a Monte Carlo technique. When the loop is completed at step 812 , the software can then calculate and generate skin distribution, skin sensitivity, and risked production curves. The software can also perform a similar process to calculate a risked total cost.
At steps 314 , 316 , and 318 , the program then assembles the risked skin and total completion cost data and generates a skin distribution and sensitivity chart, a total cost distribution and sensitivity chart, and a risked production curve (and/or gross revenue curve). FIG. 9 is an exemplary skin distribution graph generated by the software from the results of the skin factor risk analysis. From the graph, the user can gauge the variance in the skin factor resulting from the ranges of the riskable input factors. A similar curve can be calculated and generated with total cost. FIG. 10 is an exemplary skin correlation graph generated by the software from the results of the skin factor risk analysis. From the graph, the user can see the relative effect of each of the riskable input variables on the skin factor. Thus, investment in one area may be warranted to control a parameter that has a great impact on the skin factor. A similar graph can be calculated and generated with total cost.
At step 320 , the program then combines the risked production and total completion cost results and calculates a risked NPV and/or calculates and generates a net revenue curve. FIG. 11 contains two sets of exemplary risked net revenue curves, one for overbalanced completion and one for underbalanced completion. From these curves, the user can compare the two different techniques for completing the well. FIG. 12 contains two exemplary NPV distribution curves, one for overbalanced completion and one for underbalanced completion. From these curves, the user can compare the two different techniques for completing the well, gauge the variance in the NPV resulting from risking the input variables, and select the most advantageous completion method.
At step 322 , the entire process is then repeated for any/all alternate completion methods (i.e., underbalanced). At step 324 , the software then combines the results for comparison by the user.
Input Module
Preferably, the input module comprises several sub-modules. These include, but are not limited to, formation, well data, drilling fluid, reservoir, formation damage, flow module, risked reservoir variables, and cost modules. Preferably, each sub-module can be accessed on the GUI screen by clicking on a tab. Each sub-module may further comprise multiple sub-portions and sub-parts also accessible by tabs or check-boxes. The input blanks may be configured to allow data to be typed in, comprise a pull-down box, or comprise a fill-dot selection.
FIG. 5 is an exemplary GUI screen of the Formation sub-module of the input module. The screen displays a typical Formation sub-module further comprising a basic core data, X-ray data, fracture data, and vug data sub-part. The Basic Core Data sub-part is selected in the screen shot. Seen FIG. 5 are inputs for formation name, top depth, base depth, net to gross pay, net pay, current reservoir pressure, current reservoir temperature, formation O-W contact angle, and formation type (sandstone, limestone, dolomite, granite, or evaporate). The “Formation is” check-box activates the fracture data and/or vugs data sub-parts depending on the selection. The Fracture Data sub-part contains inputs for smallest aperture of fracture, largest aperture of fracture, most frequently occurring fracture size, fracture density, and fracture orientation. The Vugs Data sub-part provides inputs for type of vugs and frequency vugs. The tabbed Basic Core Data sub-part provides inputs for sample number, interval, K h , K v , and Phi. The tabbed X-ray Data (not shown) sub-part allows inputs for a bulk x-ray data analysis comprising percentages of quartz, calcite, dolomite, anhydrite, pyrobitumen, and total clay; a clay fraction analysis comprising percentages of kalonite, illite, chlorite, smectite, and mixed layer clay; cement type; and degree of cementation.
The tabbed Well Data sub-module (not shown) provides inputs for well name, well location, type of well (horizontal, vertical, etc.), well orientation, well size, completion type, perforation charge size, shot density, completion method (overbalanced, underbalanced, etc.) planned stimulation type, depth of stimulation, completion fluid, completion overbalanced pressure, fracture gradient, surface casing size, surface casing top depth, surface casing base depth, intermediate casing size, intermediate casing top depth, intermediate casing base depth, open hole size, open hole top depth, open hole base depth, primary producing phase, aquifer in contact with pay zone, gas cap in contact with oil leg, total length of well in contact with gross pay, well overall drainage area, length to width ratio of drainage area, length of drainage area, width of drainage area, X-coordinate of horizontal well, Z-coordinate of horizontal well, Y1-coordinate of horizontal well, and Y2-coordinate of horizontal well.
The tabbed Drilling Parameter sub-module (not shown) provides inputs for desire drilling approach (conventional overbalanced, low head overbalanced, flow drilling, or induced underbalanced), solids control type (double centrifuge, centrifuge, shaker, or none), expected average ROP while drilling, bit type proposed for use, duration of dynamic drilling period in pay section, duration of shut in period after drilling, hole cleaning effectiveness, number of tripping operations, estimated friction pressure component, calculated static BH pressure, calculated static OB pressure, calculated circulating BH pressure, calculated circulating OB pressure, number of OB pulse incidents during drilling, duration of OB pressure pulse incidents, average value of OB pressure incidents, BH pressure during drilling operation, surface back pressure to be maintained, and desired amount of UB pressure.
The tabbed Drilling Fluid sub-module (not shown) provides inputs for drilling fluid (water based clear fluid, water based polymer, water based polymer and starch, water based gel chemical, aphron, water based foam, pure oil based, invert emulsion oil based, oil based foam, oil-gas energized system, water-gas energized system, water based mutual solvent, mist drilling water, mist drilling oil, pure air, pure nitrogen, pure natural gas, or pure flue gas. The sub-module contains three tabbed sub-portions for Basic Drilling Fluid Data, Additives and Solids, and Filtrate Analysis. The Basic Drilling Fluid Data sub-portion contains inputs for nominal density of the circulating mud at average TVD, including entrained gas, if present; mud API fluid loss of base solution only; gas phase type; base fluid injection rate; base gas injection rate; mud name; mud supplier; mud PV for base solution only; mud YP for foaming base solution only; mud HPHT fluid loss for base solution only; and mud filtrate oil-water contact angle. The Additives and Solids sub-portion contains inputs for additive name, additive concentration, concentration units, artificial bridging agent type, artificial bridging agent concentration, artificial bridging agent concentration units, amount of hydrophobic additives, particle size of median size mud solids, particle size of median size bridging agent, particle size of D10 size mud solids, particle size of D10 size bridging agent, particle size D50 size mud solids, particle size of D50 size bridging agent, particle size of D90 size mud solids, particle size of D90 size bridging agent, and mass percentage of total mud solids content. The Additives and Solids sub-portion comprises inputs for N 2 , CO 2 , H 2 S, C 1 , C 2 , C 3 , C 4 , IC 4 , NC 4 , IC 5 , NC 5 , and C 6 + components of pure gas mud filtrate and oil base mud filtrate. For water base mud filtrate, the inputs provided are for cations Na, K, Ca, Mg, Ba, Sr, Fe, and Mn; anions Cl, I, HCO 3 , SC 4 , OH, CO 3 , and H 2 S; PH; total dissolved solids; viscosity; and density.
The tabbed Reservoir sub-module (not shown) provides five tabbed sub-portions for Reservoir Fluids, In-Situ Permeability, Capillary Pressure, Relative Permeability, and Reservoir Problems. The Reservoir Fluids sub-portion comprises inputs for N 2 , CO 2 , H 2 S, C 1 , C 2 , C 3 , C 4 , IC 4 , NC 4 , IC 5 , NC 5 , and C 6 + components of gas, dead oil, and recombined phases of the reservoir fluid. The sub-portion further provides three tabbed sub-parts for Oil, Gas, and Formation Water. The Oil sub-part comprises inputs for oil API gravity, specific gravity of solution gas, separator GOR, separator pressure, separator temperature, dead oil viscosity at reservoir temperature, date of PVT study, PVT study conducted by, PVT study report number, formation sampled, well location sampled, bubble point pressure, sample analyzed (i.e., recombined), and paraffinic oil (cloud point greater than water freezing temperature). Also, the sub-part comprises inputs for P, Do, Vo, Bo, GOR, Z, Sg, and Bg components of differential liberation data. The Gas sub-part comprises inputs for condensate gas ratio, dew point pressure, and max. liquid dropout. The Formation Water sub-part comprises inputs for cations Na, K, Ca, Mg, Ba, Sr, Fe, and Mn; anions Cl, I, HCO 3 , SC 4 , OH, CO 3 , H 2 S, and F; PH; total dissolved solids; viscosity; and density. Also, the sub-part comprises inputs for P, Do, Vo, Bo, GOR, Z, Sg, and Bg components of differential liberation data. The In-Situ Permeability sub-portion comprises inputs for in-situ permeability options (i.e., user input), average in-situ horizontal permeability of producing zone, estimated vertical to horizontal permeability ratio, average formation porosity, and desired net overburden pressure. From these inputs, the program can calculate and display calculated reservoir net overburden pressure in this sub-portion. The capillary pressure sub-portion comprises an option to import raw air-mercury pressure data (Pc and Sair) for the target formation or the user can use library data from a database contained in the software. The sub-portion also provides inputs for is reservoir in capillary equilibrium with a free water contact, distance of the mapped water oil or gas oil contact to the midpoint of the oil or gas production interval, estimated swi from capillary pressure data, estimated swi from log data or traced core analysis, correlation of measured log sw with porosity, oil-water interfacial tension, gas-water interfacial tension, and formation wettability. From these inputs, the program can calculate and display estimated formation wettability, calculated <1 micron percent micorpores, calculated 1-3 micron percent micorpores, and calculated >3 micron percent micorpores. The Reservoir Permeability sub-portion comprises an option to enter relative permeability data (Sw, Knw, and Kro), have the program calculate relative permeability from provided inputs for shape exponents, or use library data from a database contained in the software. The provided inputs for shape exponents are water shape factor (1-10), oil shape factor (1-10), desired initial water saturation at Kro=1, critical water saturation, maximum water saturation, and endpoint water relative permeability. The sub-portion also contains an option to have the software normalize the relative permeability data to average initial water saturation. The Reservoir Problems sub-portion comprises location (i.e., at surface, in tubing, or downhole), severity (i.e., moderate, mild, or severe), and type (i.e., oil in water, water in oil, or gas in oil) inputs for wax and paraffin problems, emulsion problems, asphaltene deposition issues, scale problems, and bacterial induced damage.
The tabbed Formation Damage sub-module (not shown) provides five tabbed sub-portions for Drilling Fluid Leakoff Data, Phase Trap Test Data, Fines Migration, Water Sensitivity, and Fluid Compatibility. The Drilling Fluid Leakoff Data sub-portion provides an option to enter drilling mud leakoff testing on formation core data or to use analog data contained in the software. If testing data is used, the sub-module provides inputs for a leakoff test validity check further providing inputs for wettability restored or preserved state core, corrected initial saturations, reservoir temperature used, correct overbalanced pressure used, drilling mud used same as evaluated here, mud fluid loss and solids content compatible, and mud contained drilling solids. Also, the sub-module comprises inputs for core sample number, core length, core diameter, base mud name and type, underbalanced pressure used, and overbalanced pressure used. Further, the sub-module provides pressure and permeability inputs for initial undamaged permeability at max. drawdown pressure, threshold permeability post UB mud flow initiation, permeability at max. drawdown regain pressure post UB, threshold permeability post OB mud pulse, and permeability post max OB pulse drawdown regain pressure. Even further, the sub-module provides cumulative fluid loss inputs for measurements taken at 30, 120, 180, 210, and 240 minutes. The Phase Trap Test Data sub-portion provides a phase trap test validity check further comprising inputs for phase trapping fluid is water, wettability restored or preserved state core, corrected initial saturations, reservoir temperature used, and core permeability representative of formation of interest. Further, the sub-portion comprises pressure, permeability, gas saturation fraction, oil saturation fraction, and water saturation fraction inputs for initial undamaged core and test conditions, at phase trap fluid mobilization threshold (pressure and permeability only), post phase trap maximum pressure, and core sample length (pressure only). The Fines Migration Data sub-portion provides inputs for displacing fluid for fines migration test, was a fines migration problem present, critical interstitial velocity when fines migration occurred, and percent maximum reduction in base permeability. The Water Sensitivity sub-portion provides salinity, divalent ions, total cat ions, PH, and percent reduction in permeability inputs for formation water and mud filtrate. The Fluid Compatibility sub-portion comprises available fluid compatibility data for the drilling filtrate and formation fluids inputs for type(s) of data available (i.e., filtrate water-formation), incompatibility (i.e., mild), and emulsion problem (i.e., severe).
The tabbed Flow Module sub-module (not shown) provides four sub-portions for Boundary Conditions, Simulation Time, Relative Permeability Data of Reservoir Fluid, and Optional Data. The Boundary Conditions sub-portion comprises inputs for maximum flow rate, initial reservoir pressure, and flowing bottom-hole pressure. The Simulation Time sub-portion comprises inputs for start year, stop year, and time step. The relative permeability data of reservoir fluids sub-portion comprises inputs for critical gas saturation, residual oil saturation, oil end point relative permeability, and gas end point relative permeability. The Optional Data sub-portion comprises inputs for comparable skin factor.
The tabbed Risked Reservoir sub-module is discussed above with the Risk module.
The tabbed Cost sub-module (not shown) provides four tabbed sub-portions for Drilling Reservoir Section, Time Estimates, Cost Estimates, and Correlations. The Drilling Reservoir Section sub-portion comprises 5 sub-parts for lateral section, tripping data, lateral time, tripping time distribution, and trip counter. The lateral section sub-part provides inputs for expected average ROP and lateral length. The Tripping Data provides inputs for initial trip length (no snubbing), length of trip #1, length of trip #2, length of trip #3, average tripping speed, average tripping speed using snubbing, and start depth for snubbing. The program calculates and displays final trip length from the inputs. The Lateral Time sub-part provides inputs for time spent on build-up test and time spent on flow test. From the inputs, the program calculates and displays expected drilling time and time spent tripping. The Tripping Time Distribution sub-part provides outputs for min., mean, and max. calculated from data inputted into the sub-portion. The Trip Counter sub-portion provides inputs for completion trips and formation evaluation trips and outputs for planned trips, unscheduled trips, and total trips calculated by the program from data inputted into the sub-portion. The Time Estimates, Cost Estimates, and Correlations sub-portions are discussed above with the Risk module.
The input module, described above, is only for a preferred embodiment of the present invention. Depending on formulations used to calculate skin factor, individual well conditions, and individual user preference, some sub-modules, sub-portions, sub-parts, and/or individual inputs may be increased, reduced, or entirely eliminated.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
|
A method and a computer program for economic evaluation of completion methods for drilling a well. An extensive user interface is provided for inputting of reservoir data and parameters relating to a first completion method. A rigorous first skin factor is generated based on the reservoir data and first drilling parameters. An interface is preferably provided for entering cost data related to the first completion technique and a first total cost can be generated. Production data is optionally generated from the first skin factor. The production and cost data can then be combined to generate an economic analysis of the first completion technique. The process can be repeated for alternate completion techniques. Preferably, ranges can be entered for certain reservoir and/or cost variables. Multiple iterations can be performed on the ranges resulting in total cost and production ranges which can be combined to yield ranges of economic data for statistical analysis. This results in a user being able to choose the most advantageous completion method.
| 4
|
FIELD OF THE INVENTION
The present invention relates to a method for preserving food products using an antimicrobial system. More particularly, the invention relates to the use of an antimicrobial system containing acetic acid and/or salt of acetic acid effective for controlling growth of spoilage and/or pathogenic bacteria in chilled foods and beverages.
BACKGROUND OF THE INVENTION
Food can be unsafe to eat or drink, for many reasons. It can contain toxins or viruses, and even parasitic protozoa and worms. More frequently in Western countries, food is subjected to pathogenic bacteria poisoning.
For instance, Escherichia coli has been known for years to cause diarrhoea in infants, and gastro-enteritis in humans, associated with abdominal cramps, low-grade fever, nausea and malaise. Escherichia coli can be found in water, leading to food contamination. It is frequently isolated from dairy products, such as Semi-soft cheeses, for example.
Salmonella spp. are Gram-negative bacteria widespread in poultry and swine, but the environmental sources of these organisms also include water, soil, insects, factory or kitchen surfaces, raw meats and seafoods, etc. They are responsible for acute symptoms, but are also frequently associated with chronic consequences such as arthritic symptoms.
Bacillus cereus is a Gram-positive bacterium incriminated in a wide variety of foods including meats, milk, vegetables, fish, and starchy foods. It causes diarrhoea, abdominal cramps, pain and nausea.
Listeria monocytogenes is particularly dangerous to pregnant women and elderly people. The manifestations of this Gram-positive bacterium include septicaemia, meningitis, encephalitis, or intrauterine or cervical infections it pregnant women. This bacterium may be found in foods such as raw milk, cheeses, ice cream, raw vegetables, raw meats, fermented raw-meat sausages, etc. Its ability to grow at temperatures as low as 3° C. permits multiplication in refrigerated foods.
Commercial acetic acid, acetates, and more specifically sodium acetate, as produced from gas or oil, are known as having antimicrobial properties against many foodborne pathogens, especially against Salmonella spp and Escherichia coli , particularly when used in combination with primary hurdles such as temperature and/or high acidity. However, these compounds are less effective when they are used as a primary hurdle against microorganisms such as Listeria monocytogenes , lactic acid bacteria, yeast and molds.
The preservative properties of acetic acid and salts of acetic acid in foods are described in the literature. In particular, U.S. Pat. No. 5,811,147 relates to a food and beverage preservative comprising a calcium component dissolved in a fermented solution of vinegar, alcohol, and a fermenting agent. The calcium component, coming mostly from shells or bones, is present in an amount of 3000 to 4000 mg, in 100 to 200 cc of the preservative solution. The preservative contains a relatively high concentration of alcohol (5 to 95%) as resulting from the process of producing the preservative, which has a positive effect on reduction of bacteria but may render the use of the preservative unsuitable for some food or beverage categories and, more specifically, as it may adversely affect the taste and flavor of the food product. Furthermore, the preservative composition contains calcium in amounts which increases the final cost of the food product. Furthermore, in certain circumstances, calcium-containing food may be not allowed for people having specific diseases such as hyperparathyroidies, kidney lithiasis, hypersensitivity to vitamin D or others.
U.S. Pat. No. 5,431,940 relates to a process for preparing noncarbonated beverage products with improved microbial stability which comprises mixing of a preservative (chosen from the group consisting of sorbic acid, benzoic acid, alkali metal salts thereof and mixtures thereof, fruit juice, polyphosphates and water. The process aims to control microbial growth in noncarbonated diluted juice beverages.
The methods of preservation of food of the prior art have restricted applications in the food and beverage domain, in particular, in the conditions of preservation of chilled products. Furthermore, none of the methods have proved to give a satisfactory inhibitory effect on pathogenic bacteria, in particular on Listeria monocytogenes , at chilled or abuse temperatures. The present invention proposes to overcome these problems, with the aim of obtaining a method of preservation usable for food and beverage, while controlling the growth of microorganisms capable of causing spoilage and/or pathogenic infection of the product.
SUMMARY OF THE INVENTION
The present invention provides an efficient and cost effective method for preserving food products from spoilage of microorganisms, for shelf life extension or pathogenic microorganisms, in particular, even if non-exclusively, Listeria monocytogenes , at chilled and chilled abuse temperatures. This method comprises adding to a food product an alcohol-free fermentate comprising of acetic acid and/or its salts resulting from the fermentation by acetic acid producing bacteria, and wherein the food is maintained at pH below 5.8.
It has been found that a fermentate of acetic acid or its salts used as a preservative system, by itself, as opposed to commercial or pure acetic acid or salt of acetic acid, had an improved inhibitory effect on Gram- negative and Gram-positive bacteria in food products during storage at chilled and chilled abuse conditions during the storage of the food product provided the acidity of the food product can be maintained at a sufficient level.
It has also been found that the inhibitory effect was even more remarkable at pH of about 5.6 or below, of the food product. The pH of the product has proved to be important for the fermentate to be fully effective. In particular, it is theorized that at lower pH, as defined, a sufficient amount of undissociated acetic acid compounds is formed in the food product which effects inhibition on the pathogenic microorganisms.
An inhibitory effect is also noticed particularly when the fermentate is added to the food product in an amount corresponding to a concentration of about 0.2 to 1% by weight of acetic acid and/or its salts, upon the weight of the food product. Preferably, the fermentate is added to the food product in an amount of from about 0.25 to 0.6 % by weight of acetic acid or its salts based upon the weight of the food product. A superior inhibitory effect is noticed at 0.5 (+/−0.01) % by weight.
The method of the invention includes the step of producing a fermentate of acetic acid and/or salt of acetic acid from a bacterial growth medium inoculated with an acetic acid producing bacterium and sodium hydroxide so as to produce said acetic acid and/or salt of acetic acid at a controlled pH. A preferred pH of the medium is of from about 3.8 to 5.2, preferably of about 5. At such a pH level, the resulting fermentate, when transformed into a powder, has improved flowing properties. The medium preferably comprises at least one carbohydrate, alcohol, yeast extract, peptone and water.
Fermentation is preferably carried out for at least 2 days, preferably for about 5 to 10 days, even more preferably for 7 days, so as to reach an effective amount of growth of the acetic acid producing bacterium and of a suitable concentration of acetic acid and acetate in the fermentate. A suitable concentration of acetic acid and salt of acetic acid in the fermentate is about 3 to 6 g/L.
In a preferred aspect of the invention, the method further comprises the step of drying of the fermentate prior to its addition to the food product so as to produce a powdered preservative. Drying of the fermentate enables the reduction of the alcoholic compounds to infinitesimal and negligible concentrations, favors the stability of the preservative over time and facilitates the proper dosage of the preservative in the food product.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, “food” means a food or a beverage, and “food product” means a food product or a beverage product.
As used herein, “chilled” temperature means a temperature in the range of about 0 to 10° C. and “chilled abuse” temperature means a temperature range of about 10 to 30° C.
In the present specification, the abbreviation “GRAS” will be written instead of the full expression “Generally Recognized As Safe”.
The invention provides a broad spectrum GRAS anti-microbial system based on acetate that is effective against both Gram-negative and Gram-positive bacteria at chilled and chilled abuse temperatures.
The method of the invention produces an antimicrobial agent, which comprises mainly salts of acetic acid and/or acetic acid, and other fermentation end-products such as free fatty acids, hydrogen peroxide, and organic acids.
The fermentating agent can be any producers of acetic acid in presence of sodium hydroxide in the medium of culture. Sodium hydroxide is added to the medium as a proper source of sodium. For example, the fermenting agent can be chosen in the Acetobacter genus. In a preferred embodiment, the organism used is an Acetobacter aceti . The bacteria can also be, for example, Gluconacetobacter liquefaciens, Gluconacetobacter xylinus, Gluconacetobacter hansenii, Gluconacetobacter diazotrophicus, Brachyspira pilosicoli or Gluconacetobacter europaeus .
Acetate, in particular sodium acetate, is recognised as GRAS by the Food and Drug Administration (FDA), which means they are chemicals designated by the FDA as safe when used under good manufacturing conditions (Code of Practic, Chapter 21, Section 182-186). Acetobacter aceti is also a GRAS micro-organism.
An example of medium of culture for the acetic acid producing bacteria comprises between about 0.05 to 2% of carbohydrate(s), about 0.05 to 2% peptone, about 0.1 to 1% yeast extract, about 1 to 8 % alcohol, about 5 to 15% of fermenting agent or inoculum and water (all percentages given by weight). A preferred medium is about 0.08-1.2% of carbohydrate(s), about 0.08-1.2% of peptone, about 0.3-0.7% yeast extract, about 2-5% ethanol, about 8-12% inoculum and water.
Suitable carbohydrates are monosaccharides such as glucose, fructose or galactose, di-sachaccharides such as sucrose naturally found in sugar cane or sugar beet or oligosaccharides such as those resulting from the partial hydrolysis of starch. A preferred carbohydrate is glucose at an amount of between about 0.08 to 1.2 % by weight of the medium.
During the fermentation step, the pH of the fermentate is controlled and modified accordingly to remain preferably below 6. Preferably, the pH is below about 5.2, and preferably is between about 4.5 to 5.2. The pH is controlled by addition of NaOH, or any other bases, such as calcium hydroxide, known to be used in ingredients entering in food compositions. The incubation is processed at a temperature of from about 25 to 35° C. for at least 2 days, preferably for at least about 4 to 10 days, to allow a sufficient level of acetic acid and/or salts of acetic acid to be produced.
During the fermentation, acetate, more particularly sodium acetate, is produced. Other organic acids, organic phosphates and polysaccharides, are also present in the fermentate medium. The mechanism by which the enhanced inhibition occurs with the fermentate remains unknown. However, these compounds as well as other metabolites are likely to produce a synergetic influence with the acetate on the antimicrobial effect.
After fermentation, the fermentate is pasteurized in order to inactivate the bacteria developed during he fermentation process. Pasteurization is carried out at temperatures sufficient to inactivate the acetic acid producing bacteria but lower enough to prevent acetate from volatilizing. Therefore, pasteurization temperatures are about 85-100° C. for about 5 to 25 min. It is also possible to use any other process allowing to kill the bacteria and while preserving the properties of the acetic acid or the acetic acid salts. The pasteurized solution is then submitted to a drying stage to transform the liquid into a solid fermentate. Various techniques may be used for drying the fermentate, as for instance, spray drying, vacuum drying, freeze drying, or any other drying method known to be used for biological or nutritional drying.
The dried fermentate has preferably a concentration in acetic acid and/or salt of acetic acid of between about 65 and 85% by weight, and more preferably about 72%, based upon the weight of the dry fermentate.
The dried fermentate is then added to the food product in a quantity calculated so that the final amount of acetic acid and salt of acetic acid in the food is from about 0.2 to 1% by weight, and preferably about 0.25 to 0.6% by weight, based upon the total weight of the food product. The concentration in the food product is simply calculated based on the concentration in fermentate.
Without willing to be bound by theory, it is believed that the observed antimicrobial effect is probably due to the presence of other metabolite(s) and end-products produced during the fermentation, in the fermentation conditions as previously defined, which act(s) in a synergetic effect with acetic acid and/or salt of acetic acid.
The possible applications of the system of preservation of the invention lie in meat fementations where acetate not only acts as an antimicrobial but also as a flavoring agent. It is also envisioned that the fermentate could be used as an additive in chilled products where Listeria monocytogenes would pose a problem such as chilled vegetables or cheese components.
EXAMPLES
The following examples are given by way of illustration of the present inventions and should in no way be considered as limitative.
Example 1 - Production of the Fermentate
Acetobacter aceti ATCC 15973 is propagated in a “GPYE” medium composed of 1 g glucose, 1 g peptone, and 5 g yeast extract in 1 liter of deionised water. It is cultivated in 500 mL flasks containing 150 mL GPYE. The incubation is processed at temperatures of 28° C., with agitation (300 rpm), for 5 days.
The pre-culture (130 mL) is then inoculated in a 2 liter fermentor containing 1.3 liter of GPYE with 40% food-grade ethanol. This second fermentation is run at a temperature of 28° C., at 350 rpm agitation and 0.2 vvm air flow rate. Two fermentations were run, at controlled pH 4.0 (with 20% of NaOH) and pH 5.0 (20% of NaOH), respectively.
Periodically, samples were withdrawn and plate counting was carried out in GPYE agar medium at 30° C. for 4 days.
The production of sodium acetate is measured by HPLC (High Pressure Liquid Chromatography), the HPLC using an organic acid analysis column (Aminex, Ion exclusion HPX-87H, BioRad, USA) with a H2SO4 mobile phase (0.009 N), at 210 nm.
In the conditions herein described, the growth of Acetobacter aceti and the production of sodium acetate have been studied at controlled pH of 5. As showed in Table 1, after 1 day of lag phase, the bacterial cells start growing and reach a stationnary phase after 2 days incubation. The production of sodium acetate starts increasing from the second day of incubation, and continues to increase until the 7th day of incubation, at the time the fomentation can be stopped.
TABLE 1
Growth of acetobacter aceti and production of sodium acetate at pH 5.0
Growth of A. aceti (Log 10
Sodium acetate
Days
cfu/mL)
concentration (g/L)
0
5.2
0.73
1
5.7
0.80
2
9.0
1.71
3
8.9
2.00
4
8.9
2.10
6
8.8
2.65
7
8.7
4.38
After 7 days of incubation, the fermentate is pasteurized. The pasteurization is carried out at 90° C. during 10 min. The resulting solution is freeze dried, so as to remove water from the product by sublimation and desorbtion. This process is performed in VirTis freeze drying equipment which consists of a drying chamber with temperature controlled shelves, a condenser to trap water removed from the product, a cooling system to supply refrigerant to the shelves and condenser, and a vacuum system to reduce the pressure in the chamber and condenser to facilitate the drying process.
It was observed that the free flowing characteristics of the freeze dried material produced at pH 5.0 was superior to the pH 4.0 material and was used for the challenge experiments.
Example 2 - Challenge Test in Broth Media:
Commercial sodium acetate (Sigma) and the freeze-dried fermentate of the invention (pH 5.0) were tested in Brain Heart Infusion broth (BHI), using single and cocktail tests. BHI was added with:
(a) commercial sodium acetate at final concentrations of 0.25 and 0.5%;
(b) freeze dried fermentate (pH 5.0) at final concentrations of sodium acetate of 0.25 to 0.5%; and,
(c) a control sample consisted of BHI broth without sodium acetate.
For first samples, the pH of BHI broth with or without sodium acetate was adjusted to 5.6 with HCl (10%) and the samples filter-sterilized (0.22 mm, Millipore). For comparative samples, the pH was controlled at 7.0 and the sample filtered-sterilized.
The freeze-dried product was evaluated for its inhibitory actions against Gram-negative Gram-positive bacteria. Twenty-mL samples were inoculated with 10 4 -10 5 cfu/mL of L. monocytogenes, B. cereus, E. coli, or S. typhimurium alone and combined. The samples were incubated at two conditions: at 30° C. for 24 h, and at 12° C. for 2 weeks.
The control samples consisted of samples with and without commercial sodium acetate.
At neutral pH (6.5 to 7.0) and 30° C., neither commercial sodium acetate nor the fermentate inhibit the challenge bacteria, indicating the inefficiency of the inhibitory compounds at neutral pH and 30° C. (Table 2).
TABLE 2
Effect of commercial and fermented sodium acetate on Gram-positive and
Gram-negative bacterial strain at pH 7.0, 30° C., and for 24 hours.
Bacterial growth
(optical density 550 nm after 24 hrs)
C
C
F
F
Target strains
Time 0
Control
0.25%
0.5%
0.25%
0.5%
Listeria
0.010
0.455
0.429
0.399
0.385
0.326
monocytogenes
Bacillus cereus
0.023
0.387
0.325
0.315
0.351
0.232
Escherichia coli
0.013
0.583
0.589
0.587
0.584
0.542
Salmonella
0.012
0.820
0.645
0.600
0.763
0.542
typhimurium
C: commercial sodium acetate
F: Fermentate of sodium acetate produced via fermentation of A. aceti .
At pH 5.6 and below, both commercial sodium acetate and the fermented product exhibited inhibitory effects on the growth of Escherichia coli, Bacillus cereus , and Salmonella typhimurium . Expanded inhibitory effect was observed with the fermentate at 0.5% sodium acetate against Listeria monocytogenes (Table 3).
TABLE 3
Effect of commercial and fermented sodium acetate on the growth of
selected bacteria at pH 5.6, 30° C., and for 24 hours.
Bacterial growth
(optical density 550 nm after 24 hrs)
C
C
F
F
Target strains
Time 0
Control
0.25%
0.5%
0.25%
0.5%
Listeria
0.010
0.216
0.216
0.063
0.110
0.010
monocytogenes
Bacillus cereus
0.023
0.269
0.068
0.042
0.056
0.001
Escherichia coli
0.013
0.453
0.231
0.099
0.158
0.002
Salmonella
0.012
0.294
0.089
0.020
0.062
0.001
typhimurium
C: commercial sodium acetate
F: Fermentate of sodium acetate produced via fermentation of A. aceti .
An additional challenge test was carried out on the bacterial cocktail strains of Listeria monocytogenes, Escheriachia coli, Bacillus cereus , and Salmonella typhimurium . Table 4 shows the effect of commercial sodium acetate on this cocktail at pH 5.6 and at 2° C. While commercial sodium acetate failed to inhibit the bacterial cocktail most probably due to the presence of Listeria monocytogenes , this fermented product at both concentrations used showed inhibitory effects on Listeria monocytogenes, Escheriachia coli, Bacillus cereus , and Salmonella typhimurium cocktails.
TABLE 4
Effect of commercial and fermented sodium acetate on the growth of
selected bacteria at pH 5.6, 12° C., and for 12 days.
Bacterial growth
(optical density 550 nm after 12 days)
C
C
F
F
Target strains
Time 0
Control
0.25%
0.5%
0.25%
0.5%
L. monocytogenes
0.021
0.247
0.212
0.220
0.166
0.025
Bacillus cereus
0.014
0.387
0.017
0.017
0.014
0.012
Escherichia coli
0.016
0.339
0.017
0.013
0.008
0.011
S. typhimurium
0.013
0.242
0.010
0.013
0.017
0.010
Cocktail
0.021
0.304
0.287
0.266
0.036
0.016
( L. monocytogenes
Bacillus cereus
Escherichia coli
S. typhimurium )
C: commercial sodium acetate
F: Fermentate of sodium acetate produced via fermentation of A. aceti .
The fermentate of acetate, and especially sodium acetate, has the ability to inhibit the growth of Gram-negative bacteria. The production of acetate by fermentation with Acetobacter aceti , for example, gives better inhibitory results than commercial acetate on the growth inhibition of Listeria monocytogenes .
Example 3 - Challenge Test in Mashed Potato:
Five hundred grams of mashed potato were added to 500 g of distilled water and mixed thoroughly. The pH of the mixture was adjusted to pH 5.6 with 1N HCl. Three separate samples of 300 g of mashed potato were added with respectively, 0.5 % commercial sodium acetate, 0.5% of freeze dried fermentate and a control with no acetate. The three mashed potato samples (respectively with commercial acetate, fermentate and control) were heated at 70° C. for 5 min in a microwave and then dispatched aseptically in separate aliquots of 30 g each. The pH of all samples was checked before inoculation. Triplicate samples of each the three mashed potato aliquots were inoculated with 10 3 -10 4 colony forming units per gram (cfu/g) of Gram-negative bacterial cocktail (3 E. Coli strains and 3 Salmonella strains), or L. monocytogenes cocktail and incubated at 12° C. for 2 weeks. Periodically, samples were withdrawn and bacterial counts were enumerated using BHI agar and incubated at 30° C. for 48 hours.
To confirm the effectiveness of the two sources of sodium acetate against Gram-negative bacteria, a cocktail of Gram-negative bacteria was used in a challenge experiment in mashed potato. The results showed in Table 5 clearly indicated the inhibitory effectiveness of both commercial and fermented acetate on the growth of organisms such as E. coli and Salmonella .
TABLE 5
Effect of commercial and fermented acetate on the growth of
Gram-negative bacteria in mashed potato (9 days of incubation at 12° C.).
Time
Microbial growth (Log 10 cfu/g)
(days)
Control
Commercial acetate
Acetate Fermentate
0
4.3
4.6
4.6
2
4.4
4.6
4.2
5
6.7
4.5
4.0
7
7.3
4.5
4.3
9
8.5
4.1
4.2
To confirm the effectiveness of the two sources of sodium acetate against Listeria monocytogenes strains, another challenge experiment in mashed potato was performed. The results showed in Table 6 clearly indicate that only the fermente of the invention delays the growth of Listeria monocytogenes cells for the whole incubation period (14 days of incubation at 12° C.). The commercial acetate is unable to delay the growth of this organism for more than a week, as showed in Table 6.
TABLE 6
Effect of commercial and fermented acetate on the growth
Listeria monocytogenes strains in mashed potato
(14 days of incubation at 12° C.).
Time
Microbial growth (Log 10 cfu/g)
(days)
Control
Commercial acetate
Fermentate acetate
0
3.1
3.1
3.1
2
6.4
4.4
3.1
5
8.8
4.3
3.0
7
8.7
4.9
2.8
14
8.7
7.5
3.0
|
The invention relates to a method of preservation of a food product including adding to a food product a fermentate comprising acetic acid and/or its salts resulting from the fermentation by acetic acid producing bacteria, and wherein the food is maintained at pH below 5.8.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a post or mast structure, which is particularly adapted to support a load above ground level, preferably an elongated load. This load may represent an object, which is supported by a plurality of mutually coacting posts, such as an overhead power line, or an elongated object which is supported solely by a single post and which projects outwardly on one side thereof, or which projects in balance from both side of the post.
2. Description of the Prior Art
Posts, or masts, are to be found in many different forms and for many different purposes, ranging from lattice-work mast structures for carrying 400 kV overhead power lines down to fencing posts of 50 mm in diameter. The posts may be grouted in the ground or simply secured by burying one end of the post in a pit or hole formed in the ground and by compacting natural stone around the post, so as to hold the post firmly. Flag posts and sign posts can be said to constitute particular examples of the posts referred to here.
The economic significance of a novel type of post depends upon the cost of and the type of post the novel post is intended to replace and the number of posts involved. In Sweden, more than eight million wooden posts are used today for supporting overhead power lines and telecommunication lines. By present day standards, an impregnated wooden post of this kind is estimated to have an active useful life of 40 years. There exist today overhead power line installations which are 50 years old and in which not a single post has needed to be replaced, although 40 years is the recognized useful life span of a wooden post. The mechanical strength of the post is calculated to be so impaired after this length of time as to render the post unsuitable and in need of replacement. It will be appreciated that the useful life span of such posts will be progressively shorter in the future, since the wood from which present day posts are produced and the wood from which posts have been recently produced is not of the same quality as that upon which present day standards have been based.
In addition to the scarcity in modern forests of rooted trees, which are suitable to be used for wood for posts for overhead power lines in excess of 10 kV, the impregnation of such now available wood has presented pronounced problems. The impregnating agent used hitherto, i.e. creosote tar, has been classified as toxic by the authorities. Consequently, anyone working with creosote impregnated posts must wear special protective clothing. Another drawback with creosote impregnated posts is that they may not be stored in the open air, due to the fact that the impregnation methods used result in moist posts, caused by incomplete absorption of the creosote tar and manifested in sticky wood surfaces.
Arsenic-copper salt solutions are alternative impregnating agents to creosote tar but, since these solutions have a shorter effective life span than creosote, they are not as economically viable. When considering the problems represented by the deterioration in the natural surroundings when facilities for impregnating wood are present which use such impregnating solutions, it is seen that the increased use of such solutions is counter-productive to the endeavor to provide improved environmental conditions.
Overhead power lines intended for more than 70 kV are supported by lattice-work posts or masts. In addition to being expensive to manufacture, such masts are highly unaesthetic and present an ugly feature in the surrounding landscapes. The need for power lines is increasing with the increasing need for electrical energy from progressively increasing production units to progressively higher consumer concentrations. In many areas or districts, this has resulted in multiple power cables or lines being erected in parallel. The posts or masts involved herewith detract greatly from the surrounding countryside and, in addition, present obstacles to agricultural machines working in the area. The same applies to posts used to carry telecommunication lines, although in this case the posts are not as high as the masts used to carry power lines and are not, therefore, as equally discernible to the eye.
Attempts, to reduce the extent to which such posts or masts encroach upon cultivated agricultural land, have resulted in power lines being run across land which is not used for agricultural purposes or across marshy territory. However, the erection of power of telecommunication line masts or posts in this latter territory is both difficult and laborious. Certain posts need to be anchored with the aid of dolphin-like shoring structures, and sometimes with the aid of some twenty or so auxiliary supportive posts.
Because of the limited flexibility of a wooden post, it is necessary to shore the post when a change in power or telecommunication line direction is effected, even though this directional change may be only moderate. The costs involved include the cost of the shores and tensioning devices required, e.g. bottle screws, and also the additional cost of the necessary concrete foundations or horizontal subsoil anchoring posts and the excavation work that needs to be undertaken in conjunction therewith.
The method used hitherto for erecting wooden posts for different purposes is one in which a pit is dug to a prescribed depth, in the case of posts for carrying 10 kV cables, a depth of 1.40 m, whereafter the root end of the post is placed in the pit and the post is lifted to a vertical position. The pit, or hole, is then fitted with available screened aggregate and the post is brought to a truly vertical position prior to filling in the pit and finally consolidating the packing material. The work of preparing post pits has been facilitated for many years by the use of earth drills and tractor carried vertical diggers. However, the ground surrounding the pits is often uneven or is inclined, which results at times in incomplete compaction of the aggregate intended to anchor the posts.
Another drawback with known wooden post support structures is that when two such posts are used to support a transformer, and even when four such posts are used for this purpose, and when one of the posts used becomes defective and must be changed, it is necessary to disconnect the transformer and lower it to ground level before the post can be changed. Subsequent to replacing the defective post, the transformer has to be lifted back into position and reconnected. Even though it is possible to plan the work involved, it necessitates an interruption in the power supply, which may be troublesome. As will be understood, it is necessary to restrict the future use of wooden posts, not only because of the aforementioned toxic risk presented by impregnated posts, but also because wooden posts are attacked by insects, or pests, other than those normally classified as infestants, or parasites, even though the posts have been thoroughly impregnated. It has been found in recent years that wooden posts are attacked by the black housefly (Campanatus liquiperda) and the red ant (Formica nufa), to an extent which is on a par with the damage caused by woodpeckers, fungi and mold. The latter cause mainly superficial damage, whereas the ants attack the core of the wood itself. The reason for this is probably because the core of the post is unable to absorb the impregnating agent used, since the wood resin is impregnable and impermeable to the impregnates used, and secondly because the natural habitats for ants have been greatly restricted by modern forestry. This, together with clear cutting of entire forests and subsequent ground preparation, has decimated all protective locations where ants may build their stacks. Ants, which live in stacks, and also horse flies to some extent, normally lay their eggs in tree stubs and dry furrows. When the ground is finally cleared and such stubs and furrows can no longer be found in the area, power line posts become the natural habitat of the ants.
The problems recited in the aforegoing with regard to cable or wire carrying posts apply with varying degrees to all types of wooden posts, irrespective of whether they are used to support cableways, so-called ski lifts, fences, road signs, advertising signs, or as flag poles.
OBJECT OF THE INVENTION
One object of the present invention is the provision of a post or like structure which, when dimensioned for its intended function is able to carry the load involved, irrespective of whether this load is represented by a road safety fence, which extends less than one meter above road level, or by a high-tension power line supported at a height of more than 20 meters above ground level.
SUMMARY OF THE INVENTION
An aspect of the invention resides in a post construction kit for constructing a post implanted in a base terrain, the post construction kit comprising: at least a first post section adapted for implantation in the base terrain; at least a second post section, at least one of the second post section being adapted for interconnection with at least one first post section; and interconnecting arrangement for interconnecting at least one first post section and at least one second post section.
The object is achieved with a post constructed in accordance with the invention. When seen from the aspect of the costs involved in erecting a post according to the present invention, one important feature of the inventive post is that no pit or hole is required. Instead, a first section of the post, which forms a post foundation, is hammered or likewise driven into the ground. In the case of posts which are 50 mm in diameter, the posts may be continuous, single piece structures and are preferably driven into the ground to a depth of about 50 cm. In the case of posts which are intended to support overhead power lines and which are to be erected on marshy ground, this first post section may not be long enough to achieve firm frictional engagement with the surrounding soil or earth, and consequently it may be necessary to drive a further post section into the ground in order to achieve the requisite degree of friction. Thus this obviates the need of pile driving to refusal.
Shorter posts may be driven into the ground with the aid of hydraulically operated drivers. In the case of posts of the very largest dimensions, the aforesaid first post section can be driven into the ground with the aid of a tractor carried, pneumatic or hydraulic high speed hammer. It has been found in practice that this method can be applied also with respect to frozen ground, and that the first or foundation-forming post section can be driven into such ground in a matter of only some few minutes.
Because the various post sections of a multisection post, according to the invention, are preferably of tubular configuration and provided with a socket coupling at one end and a conically tapered spike at the other, the sections can be readily assembled to form a continuous post. The conicity of the tapered, spiked end of respective post sections is preferably such that the joint formed between two mutually adjacent post sections is self-locking, such that the post will withstand relatively large loads, more specifically both the load exerted axially by the object carried by the post and also the bending stresses created, e.g., at the juncture where a change in cable direction is made. The post sections are also preferably made of ductile iron, thereby improving the flexural strength of the post still further. Ductile iron is relatively resistant to corrosion, and by coating the hollow tubular posts with asphalt, both internally and externally, to a thickness of at least 50 microns, in accordance with one preferred embodiment of the invention, the posts can be given a useful active life of more than 100 years.
Since that section of the post, which is driven into the ground, is the section which is most subjected to corrosion, it may suffice in some cases to produce solely this section of the post from ductile iron. In certain instances it may be desirable, for environmental reasons, that the part of the post which is visible above the ground has a particular configuration. One conceivable instance in this regard is when a public thoroughfare is to be provided with new lamp posts which are required to conform to or blend with the existing character of nearby buildings. In this case, the advantages afforded by the novel post construction can be utilized to the full, because of the inclusion of the aforesaid drivable first post section of said construction. In the case of this particular embodiment of the inventive post, there is fitted to the first or foundation-forming post section at ground level, an auxiliary or transition post section to which the remainder of the post structure can be fitted. The remaining part of the post structure which extends above ground can be intentionally designed to suit prevailing aesthetic requirements. When newly manufacturing such parts, they are provided with a spiked end portion which fits at ground level into the socket of the first post section located in the ground and which is self-locking in said socket. This enables the inventive concept to be applied in respect of posts which are especially molded for use in highly exclusive environments.
The post section, which, in accordance with the invention, is driven into the ground, can be used as a foundation for other types of post. For example, that part of the post, which extends above ground level, may consist of a continuously tapering, or step-wise tapering galvanized steel tube. Wooden posts may also be fitted to the ground-located first post section. Furthermore, there is no restriction to posts of round cross-section, since it suffices that the connecting end of the overlying post section has a configuration which conforms to the configuration of the socket connector of the ground-located post section.
In the case of high posts which comprise a plurality of separate post sections, and particularly when an assembled post is to be erected with the aid of a tractor-carried digger, it may be beneficial to ensure that the various post sections are securely locked to one another prior to lifting the post. This can be effected by drilling a slightly conical hole through a connecting socket and the tapered end of an adjoining post section fitted thereinto, and by subsequently driving a lock pin into the hole.
In the case of inventive post constructions intended for supporting overhead power lines, an advantage is afforded when the ground-located first post section is fitted with a post shoe prior to being driven into the ground, the size of the post shoe used being dependent on the nature of the ground into which said post part is driven. The function of the post shoe is to form in the ground a hole whose transverse dimension is greater than the transverse dimension of the ground-located post section. This hole enables an erected post to be aligned truly with the vertical, whereafter the hole can be filled with loose aggregate in the vicinity of the ground-located post section. This will further reduce the risk of corrosion.
The ground-located part of the post may also be provided with preferably axially extending elongated slots. Subsequent to having driven the ground-located post section to the intended ground depth, concrete is pumped thereinto and exits through the slots. When a sufficiently large post shoe is used, the ground-located post section will be surrounded by concrete, thus creating a firm foundation.
Ductile iron, such as nodular iron, is well suited for the manufacture of post sections by centrifugal casting methods. The above-ground post sections can therewith readily be given a configuration which tapers towards the spiked ends of respective sections. Since the ground-located post section is normally driven into the ground with its spiked end facing downwards, the connecting socket of this post section is fitted with an auxiliary, transition post section which is spiked at both ends. This enables the above-ground sections of a multiple section post assembly to be assembled with the connecting sockets facing downwards. Furthermore, the auxiliary post part may comprise a multiple of very short post sections, which are used between two mutually adjacent above-ground post sections for dimension changing purposes. This enables very high post constructions to be given a diameter, which decreases with each further post section above ground level, normally with each five meters of post length.
Since the post is of hollow tubular construction, the upper end of the post will be open. It is therefore preferred to fit to the end of the top post section a cap or like cover member, preferably a capping sleeve. In the case of posts which are intended to carry overhead electrical conductors, the capping sleeve is made of the same material as the post, since materials of mutually different electropotential in the electrochemical series of metals are liable to induce corrosion in the magnetic field surrounding the conductors, particularly in the presence of rain water and a contaminated atmosphere.
When the inventive posts are used in groups of twos or threes, for example to support high tension lines and larger ski lifts, it is preferable to connect together the tops of the respective posts or masts with the aid of connecting elements. These elements may consist of lengths of conventional angle iron secured to respective posts with the aid of conventional fasteners, such as nuts and bolts. The connecting elements or attachment devices therefore may also be welded to respective iron parts. An alternative solution, however, is to place over the tops of respective posts a tubular post section, which lacks the provision of connecting sockets and has a larger diameter than the tops of said posts, and which is provided with at least two apertured recesses at a mutual distance apart equal to the distance between the tops of the posts. This hollow tubular connecting element may, of course, be secured to respective posts with the aid of suitable fasteners. Alternatively, the apertured recesses may be given the same configuration as the top ends of the post, so as to engender a self-locking effect. It will be understood that if the posts are inclined towards one another, the apertures must be formed at an angle of less than 90° to the longitudinal axis of the connecting element.
The surfaces of the posts will normally be treated with an asphalt emulsion, although they may alternatively be painted in any desired color.
In general, the invention features a post construction kit for constructing a post implanted in a base terrain, the post construction kit including a first post section adapted for implantation in the base terrain, a second post section adapted for interconnection with the first post section, and interconnecting means for interconnecting the first and second post sections.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail with reference to a number of exemplifying embodim ents thereof and with reference to the accompanying drawings, in which
FIG. 1 illustrates a post or mast construction intended for supporting overhead high-tension power lines;
FIG. 2 illustrates a lamp post construction; and
FIG. 3 illustrates a post construction for supporting power lines.
FIG. 4 illustrates the spikes portion and the socket portion between post sections
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The illustrated post construction includes a tubular post section 1 which is hollow and cylindrical and which is intended to be driven into the ground so as to provide a post foundation therein and to which there is fitted a pole shoe 2. One end 3 of the foundation-forming post section 1 is spiked and the pole shoe is fitted to this spiked end by means of legs (not shown) which extend upwardly internally of said post section, or with the aid of a connecting socket which embraces said spiked end 3. The opposite end of the foundation forming post section 1 is provided with a conical connecting socket 4 into which there is inserted an auxiliary or bridging post section 5, the two ends of which have a spiked configuration which corresponds to the conicity of the socket 4. The socket 4 is located at the upper end of the post section 1. The socket 4 has a portion with an outer diameter which is greater than the diameter of the cylindrical portion of the post section 1. The outer surface of the socket 4 is flaring outwardly and upward so that the diameter at an upper portion is greater than the diameter of a lower portion of the outer surface of the socket 4. Fitted to the spiked end of the auxiliary post section 5 distal from the foundation forming post section 1 is the connecting socket 7 of a first above ground post section 6.
The socket 7 on the first above ground post section 6 has an internal conicity which coincides fully with the conicity of the upper spiked end of the auxiliary section 5. This conicity has a tapering ratio of at least 1:14 and at most 1:20, i.e. the diameter decreases one length unit in an axial direction over a maximum of 20 length units.
As illustrated in FIG. 1, a second, and optionally several, post sections 8, 9 can be fitted consecutively above the first above ground post section 6, the number of sections fitted being dependent on the desired height of the post assembly. When the load to be supported permits, the higher post section 8, 9 may have a diameter which decreases in relation to the underlying post section 6. This is achieved in accordance with the invention with the aid of adapters 10, 11 which are fitted between respective post sections 6, 8, 9 and which also serve to stabilize the joint between mutually adjacent post sections. The adapters have the form of very short post sections, of which the conicity and dimension of the connecting socket coincide with the conicity and the dimension of the connecting socket 7 of the first above ground post section 6, the adapter 10 being fitted to the spike end of said post section. In addition to length, a further difference between a diameter reducing adapter and a post section is that the spiked end of the adapter has a diameter which corresponds to the inner diameter of the connecting socket on the post section to be placed above the diameter decreasing adapter. The diameter-reducing adapters are preferably placed approximately 10 meters apart, even though shorter post sections may be used.
When erecting posts intended for supporting high tension power lines, it may be necessary to drive two or more foundation-forming post sections 1, 1' into the ground. These foundation-forming post sections are preferably configured in a similar manner to the aboveground post sections, i.e. each have mutually corresponding connecting sockets 4 and spiked ends 3 with self-locking facilities, as described above. These foundation-forming sections can be driven straight into the ground to provide a stable foundation at a requisite depth so as to provide the necessary support, even in ground which would not otherwise be considered suitable for the erection of such posts or masts.
Trestle-like post configurations are used for supporting high tension power lines of 130 kV. The supporting trestles comprise at least two posts which extend vertically or are inclined one towards the other and which are interconnected at the tops of their respective sections by means of a horizontal connecting bridge 12, which may comprise either a single post section or a number of interfitted post sections. The post section or sections forming the connecting bridge 12 must have a larger diameter than the post sections forming the limbs of the trestle-like structure. The holes required in the connecting bridge 12 to enable the bridge to be fitted over the pointed ends of the uppermost post sections can be formed with the aid of a conical boring tool provided in the high tension power line construction equipment and which has the same cutting angle as the spiked ends of respective post sections 9. The connecting bridge 12 can be anchored to the top post elements 9 with the aid of a vibrating device. Attachment devices for the insulators from which the high tension power lines are to be suspended are screwed firmly into the connecting bridge 12.
When it is necessary to further support a post, for example due to its height, there may be used a guy arrangement of the kind referenced 13, 14 and 15 in FIG. 1. The guy peg used to this end may comprise a foundation-forming post section 1, which may or may not be fitted with a driving shoe 2, or may comprise a post element of desired diameter which is driven into the ground at an acute angle to the surface thereof. Concrete is then poured into the hollow guy peg 13 and an eye bolt 14 is secured in the concrete. A guy wire 15 connected to the post at a suitable height thereon is then connected to the eye bolt 14 and tensioned, e.g., through the provision of an appropriate tensioning device 27. Alternatively, the eye bolt may comprise a guy wire which is wound around the post section beneath the connecting socket, therewith eliminating the need of filling the post section with concrete.
Referring now to FIG. 2, when the inventive post is to be used as a lamp post, the foundation-forming post section 1 is driven into the ground in the aforedescribed manner. Subsequent to fitting the auxiliary post section 5 into the connecting socket 4, the connecting socket 17 of a lamp post 16 is fitted over the upper spiked end of the auxiliary section 5. The post 16 preferably tapers continuously upwards and may consist of a single piece structure to a height of 5 meters. Fitted to the upper spiked end of the post 16 is a single arm or double arm element 18 which carries a lamp 19 at the extremity or extremities of its arm or arms 18. The electric wires required for connecting the lamp or lamps can be readily drawn through the hollow post as the post is being erected.
Referring now to FIG. 3, in the case of high lamp posts, there is applied the same technique as that applied when erecting, for instance, posts which are to support 20 kV power lines. The foundation-forming post section 1 is driven into the ground in the manner aforedescribed, whereafter a post section 20 is fitted over the auxiliary post section 5. The post section 20 of this embodiment differs from the aforementioned post sections, in that the spiked end 21 of the post section 20 decreases in diameter stepwise at the location where its cone begins to converge. The post section 20 has fitted thereto an overlying post section 22 which is provided with a connecting socket which has an outer diameter adapted for making a fitting relationship by having a dimension which is equal to the outer diameter of the post section 20. The post section 22 tapers upwards from the connecting socket to a given point on said section, whereafter the diameter of the section remains constant. Connected to a provided upper spiked end of the post section 22 is a T-piece 23, the vertical leg of which is configured as the connecting socket on one of the aforedescribed post sections. The horizontal part of the T-piece 23 has the form of a hollow sleeve of uniform diameter. Extending through the horizontal sleeve is a smooth iron tube which forms a crosspiece 24, which is secured to the T-piece 23 by means of a preferably conical locking pin which is driven into a hole drilled through the T-piece 23 and into the crosspiece 24. The crosspiece 24 is intended to support lamp fittings or power line insulators 25, whichever are required.
In the majority of cases, it is preferred to assemble at least the aboveground post sections on the ground. The post is assembled by placing the connecting socket 7 of the first above ground post section 6 against a firm abutment, whereafter the diameter reducing adapter 10 is fitted to the spiked end of the post section 6. The connecting socket of the second post section 8 is then fitted onto the adapter 10 and an annular vibrating device is placed around the connecting socket of the post section 8 (for example, around the top thereof) and the parts are hammered together. As an additional safety measure, a conical locking pin or like device can be driven into a hole drilled through each connecting socket and into the spiked end of a post section located in said socket. Assembly of the post is continued until the requisite number of post sections have been fitted together, whereafter the post is erected.
The assembled post can be raised with the aid of a relatively powerful tractor carried digger. The ground around the post has been highly compacted during the driving in of the foundation-forming section 1, which in itself contributes towards firming the support of the post. The use of a tractor carried digger affords a practical solution both when erecting a single post and when erecting a complete power line installation.
Referring now to FIG. 4, the socket 7 on the first aboveground post section 6 has an internal coincity 30 which coincides fully with the conicity 32 of the upper spiked end of the auxiliary section 5. The other sockets in the configuration and the other spiked ends have similar internal conicities and spiked ends.
In view of their very long useful life, posts constructed in accordance with the invention afford an economically advantageous alternative, particularly with regard to their reusability.
The invention as described hereinabove in the context of the preferred embodiments is not to be taken as limited to all of the provided details thereof, since modifications and variations thereof may be made without departing from the spirit and scope of the invention.
|
A post construction kit for constructing a post implanted in a base terrain which includes a first post section adapted for implantation in the base terrain, at least one other post section adapted for interconnection with the post section to be implanted underground, and an interconnecting arrangement for interconnecting the underground section and at least one other post section.
| 4
|
FIELD OF THE INVENTION
[0001] This invention relates to discreet adaptations to a sheet for a user to quickly, easily, safely, and securely locate it temporarily to ground, e.g., on a beach or a lawn, for the user and others to rest thereon, where the sheet may also exhibit the user's choice of shape, color or pattern, or display a logo or insignia to promote a business. More particularly, this invention relates to structures and methods for discreetly and inexpensively adapting a sheet of any shape so that it can be quickly, easily, safely and securely located temporarily to ground—as at a beach or on a lawn—and also be comfortably usable at other times as a conventional bed sheet, tablecloth or the like as appropriate.
BACKGROUND OF THE RELATED ART
[0002] It is common practice for beachgoers, picnickers, and concert fans to put down a flat sheet, e.g., a blanket, on a beach or a lawn to obtain a clean and comfortable surface on which to relax. Because they expect wind gusts to lift and disturb the placement of the sheet, people often place objects such as their shoes, bags, coolers, etc., at the corners and on the periphery of the sheet to weigh it down and hold it in place. Other common alternatives for thus weighing down the sheet include sand, rocks, driftwood, and the like. All of these are unsightly, may damage the sheet, and make portions of the sheet unavailable for comfortable use. Heavy objects resting on the sheet also present the risk that someone, especially children, will trip over them and get hurt.
[0003] There are numerous inventions that seek to address this particular problem. For example, U.S. Pat. No. 2,907,057 to Specht, teaches affixing grommets near the corners and along the sheet periphery and utilizing particularly formed anchors inserted via the grommets into underlying ground to temporarily locate the sheet. Grommets and portions of the anchors visible above them are unsightly. If made of metal, these items can become unbearably hot in strong sunlight—and may hurt both little children and adults with sensitive skin who contact them. A metal-grommeted sheet likely will damage both the washing machine and any other clothing washed with it. Plastic grommets, following exposure to strong sunlight, will eventually develop cracks with sharp edges that may snag and damage the users' clothing, e.g., swimwear.
[0004] Another example, which totally avoids grommets, is U.S. Pat. No. 5,832,672, to Griffiths et al. It teaches the use of stiff clamps temporarily clamped on to the sheet at selected locations, with corresponding anchors pushed through an opening in each clamp into the ground below. Unfortunately, this system leaves exposed hard edges of all the clamps above the sheet periphery, where they can trip up and hurt the feet and ankles of unwary persons—especially young children.
[0005] There is, therefore, a definite need for ways to securely locate a sheet of any shape horizontally to the ground so that nothing of any anchors being used is either visible or likely to pose a physical danger to persons encountering the sheet. Ideally, only the upper surface of the anchored sheet should be visible and all of it should be contactable by a user during its use. This feature can also provide a promotional benefit to beachside hotels and other businesses that may quite safely loan (or even cheaply sell) such sheets, distinctively marked to tastefully advertise the business enterprise, for their guests to enjoy at a nearby beach or park. Any solution that accomplishes this should do so safely, durably, simply, inexpensively and in a user-friendly manner.
[0006] For persons of modest means, it would be particularly beneficial to adapt sheets of the kind found in most homes, e.g., flat bed sheets, blankets, old curtains, tablecloths, and bath sheets—so that they may also be readily used on a beach, lawn, etc., as described above, yet with the adaptations formed to be unobtrusive and virtually unnoticeable. Such discreet adaptations may be included on new sheets of the same kind to enhance their utility.
[0007] The present invention provides exactly such a solution that satisfies all these existing needs.
SUMMARY OF THE INVENTION
[0008] It is a principal object of this invention to provide discreet and inexpensive improvements, to a sheet of any shape, to facilitate easy and safe anchoring of the sheet to ground by a plurality of anchors.
[0009] This object is realized by providing to a sheet having a top side, a bottom side and a periphery, the improvement comprising:
[0010] a plurality of pieces of flexible tape, each tape piece having respective first and second ends and a predetermined length between the two ends, strongly attached at respective first and second end portions to the bottom side of the sheet at selected locations close to the periphery, with an intermediate portion of each tape piece left unattached for engagement with a respective anchor; whereby, when the sheet is anchored to ground with its top side uppermost, only the sheet will be visible during such use.
[0011] It is another object of this invention to provide improvements to a sheet of any shape, having a top side, a bottom side, a periphery, and at least one corner in the periphery, to durably adapt the sheet for secure temporary location to ground by a plurality of anchors.
[0012] This object is realized by a simple modification to improve the sheet, wherein the improvement comprises:
[0013] a length of a flexible tape attached strongly along the entire periphery on the bottom side of the sheet, with portions of the tape left unattached to the sheet at selected locations on the periphery and at each corner to form respective anchor-engagement loops to securely engage corresponding anchors thereat for temporary anchoring to ground thereat.
[0014] It is a related object of this invention to provide an inexpensive but attractive and useful item, for promoting an enterprise or event, e.g., a business, charity, political rally, outdoor concert, public gathering, or the like.
[0015] This object is realized by providing an inexpensive promotional item, comprising:
[0016] a sheet having a top side, a bottom side and a periphery;
[0017] a plurality of pieces of flexible tape, each tape piece having respective first and second ends and a predetermined respective length between the two ends, strongly attached at respective first and second end portions to the bottom side of the sheet at selected locations close to the periphery, with an intermediate portion of each tape piece left unattached for engagement with a respective anchor, so that when the sheet is thereby anchored to ground with its top side uppermost only the sheet will be visible;
[0018] a plurality of anchors, wherein each anchor comprises a body consisting of a head portion and a leg portion, the leg portion being formed with a distal end securely engagable with a corresponding tape piece and securely locatable into ground to anchor the sheet flat to the ground thereat; and
[0019] the top surface of the sheet is provided with at least one of an easily remembered and recognizable color and a distinctive pattern, the same being selected to visually promote the enterprise or event.
[0020] Yet another object of this invention is to provide a method of promoting public awareness of an enterprise or event, and of thereby building customer and patron goodwill.
[0021] This object is realized by providing a promotional method, comprising the steps of:
[0022] adapting a sheet for engagement with a plurality of ground anchors, by permanently attaching to the sheet adjacent its periphery a selectively distributed corresponding plurality of strong flexible tape pieces, the tape pieces being affixed to the sheet at their respective end portions with respective intermediate portions of the tape pieces left unattached to define anchor-engagement loops to engage with respective anchors thereat;
[0023] providing the plurality of ground anchors sized and shaped to engage with individual anchor-engagement loops and with ground beneath the sheet during use;
[0024] providing on the top of the sheet a distinctive visual message promoting the enterprise or event, and
[0025] purposefully making the adapted sheet available to potential users,
wherein the material of the tape pieces is selected to have a color and a texture appropriate to a color and the texture of the sheet, and wherein the anchors during use are disposed entirely out of sight.
[0028] These and other related objects of this invention are best understood with reference to the drawings and detailed description included herewith
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0029] FIG. 1 is a perspective view of a prior art structure taught by Specht in U.S. Pat. No. 2,907,057.
[0030] FIG. 2 is a perspective view of a prior art structure taught by Griffiths et al. in U.S. Pat. No. 5,832,672.
[0031] FIG. 3 is a perspective view of a sheet according to one aspect of this invention, in a partially anchored state on a sandy beach with some anchors yet to be disposed in their fully-functional positions.
[0032] FIG. 4 (A) is a bottom plan view of a corner of a sheet, showing a folded corner tape piece attached to engage the corner with an anchor according to a first embodiment of this invention; FIG. 4 (B) is a bottom plan view of a side of the same sheet, showing a folded side tape piece attached to engage the side with an anchor according to a second embodiment of this invention; and FIG. 4 (C) is a perspective top plan view of the sheet corner per FIG. 4 (A) in its engaged disposition with respect to underlying ground.
[0033] FIG. 5 is a side elevation view, with the sheet bottom uppermost, to clarify certain dimensional relationships that improve retention of an anchor within a side or corner folded tape piece in the first and second embodiments of this invention.
[0034] FIG. 6 is a bottom plan perspective view of a corner of a sheet, showing a cross-corner tape piece attached to the sheet bottom to engage with an anchor according to a third embodiment of this invention.
[0035] FIG. 7 (A) is a bottom plan view of a side of the sheet, showing a longitudinally aligned side tape piece attached to the sheet bottom to engage with an anchor according to a fourth embodiment of this invention; FIG. 7 (B) is a side elevation view, with the sheet top uppermost, showing the sheet disposed flat relative to the ground into which it is anchored according to the fourth embodiment of this invention; and FIG. 7 (C) is a side elevation view of a side of the sheet, with the bottom uppermost, to clarify certain dimensional relationships that ensure retention of an anchor within a side or corner tape piece in the third and fourth embodiments.
[0036] FIG. 8 is a partial bottom plan view of a corner portion of an improved sheet that may have either a selectively sized corner tape piece at each corner anchor location, or a long continuous length of tape along the entire periphery of the sheet with corner tape portions formed into respective corner anchor loops.
[0037] FIG. 9 is a partial bottom plan view of a side portion of an improved sheet that may have either a selectively sized side tape piece at each side anchor location, or a long continuous length of tape along the entire periphery of the sheet with side tape portions formed into respective side anchor loops.
[0038] FIG. 10 is an exemplary anchor, showing three exemplary means for enhancing retention of the anchor to ground during use.
[0039] FIG. 11 is a partial bottom plan view of a corner of an improved sheet, in which a length of tape is incorporated into an end seam with an extended portion of the tape at each end folded over to form an anchor-engaging loop.
[0040] FIG. 12 is a partial bottom plan view of a corner of an improved sheet that has a selectively sized corner tape piece folded over and affixed to form an anchor-engaging loop aligned with the longer side of the improved sheet.
[0041] FIG. 13 is a partial bottom plan view of a corner of an improved sheet that has a selectively sized corner tape piece folded over and affixed to form an anchor-engaging loop aligned with the shorter side of the improved sheet.
[0042] FIG. 14 is a partial cross-sectional view of an improved sheet that has a selectively sized tape piece folded over and affixed with its end portions disposed on opposite sides of the sheet to sandwich the sheet and form an anchor-engaging loop normal to the sheet edge (at a corner or at a side of the improved sheet).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] FIG. 1 shows a known beach sheet anchoring arrangement, as taught in U.S. Pat. No. 2,907,057 to Specht, in which a grommeted sheet 10 is anchored by corresponding anchors 15 passed in part through the grommets 13 or 13 a into underlying ground. The grommets and upper portions of all anchors remain visible and user-contactable during use.
[0044] FIG. 2 shows another known beach sheet anchoring arrangement, as taught in U.S. Pat. No. 5,832,672 to Griffiths et al., in which an ungrommeted sheet 11 is held by clamps 10 that largely remain above the sheet, at its corners and along its sides, and are themselves located to ground by anchors passing through holes in the lower leg of each clamp—an arrangement in which a lot of the hardware, virtually all of the clamp bodies, remains above the sheet during use where it can trip up and hurt the unwary.
[0045] In stark contrast to these and other examples in the prior art, as seen generally in FIG. 3 the present invention ensures that practically any sheet 300 can be adapted to be anchored to ground 1900 by simple anchors 2000 that are disposed to remain totally below the level of the sheet 300 during such use, with the needed adaptations to the sheet remaining virtually unnoticeable and unobtrusive at other times.
[0046] As indicated in FIG. 3 , by putting their business logo, trademark, service mark, or name—“Bubba's Bar”—on sheet 300 , a waterside business such as a beachside bar, hotel, eatery, pool hall, or the like, can advertise their offering to the public by lending, renting or selling such sheets at an affordable price—particularly during occasions like local concerts, semester breaks and the like when their patrons spend freely. Corporations, law firms, religious orders, environmental groups, and others who organize off-site retreats, at or away from a beach, may similarly find it beneficial to give away or sell cheaply such strong, durable, colorful sheets to improve staff morale and customer or patron goodwill.
[0047] Basically, with variations discussed in detail below, this invention employs relatively small amounts of widely available, inexpensive, strong, flexible ribbon or tape made, for example, of cotton, polyester, or blended fiber, preferably between ¼ and ¾ inch wide, sewn on to the corners and sides of the bottom of the selected sheet to form anchor-engaging loops. These loops may be defined entirely by the tape or by cooperation between the tape and the sheet. The loops may be selectively sized to permit easy engagement with the anchors by a user but so as to impede unintended separation from the anchors when it is very windy, and the sheet is therefore flapping around strongly, while the user is removing the sheet from its anchored position.
[0048] To ensure that the loops and the stitching applied to affix them to the sheet remain physically unobtrusive, and also barely noticeable visually, they should ideally be of the same surface texture and color as the sheet itself. If a differently colored tape is deemed particularly desirable, for reasons of cost, economy or strength, it may be covered with a small piece of the same material as the sheet—and thus made to visually blend in with the sheet itself. If the sheet has a pattern to it, with some care this solution should accommodate it too.
[0049] Although the generic term “sheet” is used herein, persons of ordinary skill in the related arts are expected to understand that the sheet itself may comprise more than one thickness of the same or different materials, and that it may include a thermally insulating and/or waterproof layer, as may be most appropriate for a particular application. This inherent adaptability of the present invention would enable a user, for example a physically fit skier, to anchor a sheet in the lee of a windbreak and sunbathe even on snow-covered ground.
[0050] The “tape”, likewise, may comprise a waterproof material.
[0051] In a first preferred embodiment, as best seen in FIGS. 4(A) , (B) and (C), at a corner of a rectangular sheet 400 a closed corner tape loop 402 (also referred to as “corner loop” for brevity) is formed by folding over a corner piece of tape and sewing or otherwise strongly connecting the end portions 404 , 406 of the tape piece one over the other to the sheet. Strong polyester or nylon thread is recommended for long-lasting stitching 408 , particularly for durability when subjected to prolonged exposure to strong sunlight.
[0052] Note that the folded-over corner tape piece is preferably aligned with the bisector 410 of the corner angle to help even out any stress transmitted from the anchor to the criss-crossing fibers of the sheet fabric. If the sheet were of another shape defined by straight sides, e.g., a pentagon or a hexagon, the same principle could be use advantageously at its corners.
[0053] FIG. 4(B) shows a similarly constructed side tape loop 402 (also referred to as “side loop” for brevity) affixed at another selected location at the side of the same sheet 400 , oriented perpendicular to the side edge. Most sheets made from fabric of suitable width, e.g., 60-96 inches wide, will likely have their elongate edges inherently finished, i.e., they will not need to be hemmed there to avoid unraveling of the fabric. On the other hand, at the ends of pieces cut from a substantial length of fabric there is usually a need to hem the edges to avoid fabric unraveling. Depiction of such hems is omitted in some of the drawing figures for simplicity.
[0054] Polygonal or circularly shaped sheets usually are hemmed all around the periphery. If the sheet happens to have a curved periphery, i.e., it is a circle or an oval, then all the tape loops will, in effect, be “side loops”, and preferably should be affixed to the sheet aligned normal to the local periphery for maximum effectiveness.
[0055] FIG. 5 shows a side view of such a side tape loop 402 , with an anchor shown in cross-section as it would be located inside the loop. Referring to FIGS. 4(B) and 5 together, it should be clear that the side loops (as well as corner loops as indicated in FIG. 4(A) ) are all dimensioned and located so that all of them remain entirely within the perimeter of sheet 400 whether or not anchors are engaged in the loops. This is important, because when the sheet is not anchored, and may be in use in another role, e.g., serving as a bed sheet or a tablecloth, when the sheet top is uppermost this will ensure that the loops can be disposed so that they remain totally out of sight. Regular sheets that serve other purposes in a home also may thus be discreetly adapted for use as anchorable sheets for occasional use on the beach or lawn. Furthermore, when used outside, the anchored sheet totally covers up the anchor-engaged loop beneath. Once the user has forced the anchor down into underlying ground to a level just below the sheet, the sheet itself should naturally lie totally in contact with the ground—with the uppermost portion of the anchor just below it and thus totally invisible. All that should be visible then is the sheet itself, firmly secured to ground.
[0056] When the user wishes to remove the sheet 300 from an anchored location, all that is necessary is that the sheet edge above an anchor be engaged with a finger and a slow, deliberate, upward tug be applied to it, and thus to the loop and anchor under it, to lift out the anchor from the ground. This process must be repeated at the other anchors. If the user wishes to leave the anchors engaged with their respective loops (both at the sheet corners and the sides) he or she can simply put the sheet and still engaged anchors away right then. Alternatively, e.g., if the sheet 300 is to be washed, each anchor can be carefully worked out of its loop and packed away. The sheet by itself can then be washed with only its soft tape loops and fabric contacting any other items being washed with it.
[0057] FIG. 4(A) shows an anchor 2000 that has two elongate generally parallel legs 2002 a, 2002 b contiguous with a top portion 2004 which conveniently may be curved. Such an anchor 2000 can be made inexpensively from a metal, a composite, or any relatively stiff but flexible plastics material, e.g., the kind of thermally-moldable plastics used to make stiff clothes hangers for coats and other heavy garments.
[0058] As best understood with reference to FIGS. 4(A) and 7(B) , diameter “D” for the legs 2002 a, 2002 b of an anchor made of such plastics material preferably is about ¼ inch. The overall length “L” of an anchor suitable for most uses as described is in the range about 3 to 6 inches, and a suitable separation “S” of the legs is in the range about ¾ to 1½ inches. Other dimensions may prove more suitable for particular applications, e.g., for very large sheets that are temporarily anchored to ground in very windy locales.
[0059] The anchor 2000 shown in FIG. 4(A) preferably has two diametrically opposed barb-like extensions 2006 at the distal ends of legs 2002 a, 2002 b. These, like the distal ends 2008 a, 2008 b themselves (as best seen in FIG. 4(C) ) are provided smoothly rounded edges and ends to reduce the likelihood of injury to a person accidentally stepping on an anchor. Extensions 2006 are shaped so that while it is not particularly difficult for a user to forcibly insert the anchor 2000 so equipped into ground, it is much harder for gusts of wind to lift the anchors out and release the sheet from ground. The overall maximum periphery of a barb-ended leg 2002 a or 2002 b must be slightly smaller than the overall inside periphery of a corner or side loop 402 . This will ensure ease of insertion and withdrawal of such a barbed end of an anchor through the loop, and will also serve to significantly reduce the likelihood of such a separation occurring unintentionally, e.g., while the user is picking up the sheet 400 from ground during a strong wind that causes the sheet to flap severely.
[0060] FIG. 6 shows an alternative embodiment, in which a tape piece 600 is affixed across a corner of sheet 400 by stitching 602 on ends 604 a, 604 b. Tape piece 600 is preferably affixed symmetric with the corner itself to even out any physical stress put upon the fabric of sheet 400 there over time and use. Note that the longitudinal dimension “A” of the sheet material between the closest stitching is smaller than the counterpart longitudinal dimension of the tape portion “B” directly adjacent to it. The total length “A+B” of a loop, so formed by cooperation between the unaffixed portion of the tape piece and the corresponding length of fabric, must be slightly larger than the maximum outside periphery of the barb-ended extensions to permit their convenient insertion and withdrawal from the corner loop so formed. Note also that when the sheet corner is anchored by such a loop, the topmost part of the anchor will be below the level of the sheet so that the flat sheet there will be all that is visible.
[0061] As best seen in FIGS. 7(A) , 7 (B) and 7 (C), there is a similar alternative form for a side loop formed by cooperation between the unaffixed portion of the side tape piece and the adjacent corresponding length of fabric. In this embodiment, strong stitching 702 affixes end portions 704 a, 704 b to sheet 400 so as to leave a length “A” of its fabric free between adjacent stitching. However, the length of the unaffixed tape material corresponding to this is “B” and is made somewhat longer to ensure that when sheet 400 is anchored here it will lie flat to ground while the topmost portion of the anchor will lie a short distance “C” below and not be visible. The maximum lateral span of the barbed end of an anchor leg 2002 a, 2002 b is “W” and the barb height is “H”, each preferably in the range about 0.5 to 1.00 inch.
[0062] FIG. 8 shows yet another embodiment of a corner loop 800 , particularly suitable for inclusion on a sheet 400 that has a continuous length of a reinforcing tape affixed around its entire periphery, e.g., by stitching 802 . The fact that the tape is meant to be peripherally continuous is indicated by double headed arrows in both FIGS. 8 and 9 . Portions of the tape adjacent the corner are even more firmly attached to sheet 400 by additional amounts of stitching 804 a, 804 b. Corner loop 800 should be sized to accommodate any barbed-ended anchors as previously explained, and is sized and located so that it remains out of sight when the sheet is anchored and remains unobtrusive when the sheet is perhaps in other use, also as explained before.
[0063] FIG. 9 shows a corresponding side loop 900 provided at suitable locations in the long length of tape circumscribing the periphery of sheet 400 . Extra stitching 904 a, 904 b is provided for strong affixation of the corner tape piece to sheet 400 on opposite ends of loop 900 . The dimensioning, disposition and benefits of such an anchoring side loop defined in a continuous long tape are as explained earlier, and so will not be repeated. Note that side loops in this embodiment can be formed and will function exactly as the side loop shown in FIG. 7(A) that is defined by cooperation between an unaffixed portion of the tape of length “B” and the corresponding length “A” of the fabric of the sheet.
[0064] As will be readily understood, sheets of other shapes, e.g., pentagons, hexagons, circles, ovals, stars, etc., can be easily adapted in accordance with this last-described embodiment by either kind of loop as shown in FIGS. 8 and 9 as deemed most appropriate. Any such non-rectangularly shaped sheet is likely to have a sewn hem, hence the continuous elongate peripheral tape can easily be incorporated into the hem during its creation or it can even be sewn on around the periphery, over the hem if one exists, afterwards, e.g., if a circular or oval table cloth or furniture throw is being adapted for anchored use on a beach.
[0065] In FIG. 10 there are shown three very inexpensive yet convenient ways to improve the anchor. Any of these choices, by itself or in cooperation with others, should make the anchor legs obtain and maintain a higher degree of retention to ground during use than that available with totally smooth legs. Other geometries for the anchor body itself may be considered by a user, e.g., those with only a single leg to be inserted into ground, one with a round flat head, etc., but all such obvious variations would benefit from the proposed enhancements to the inserted leg portion(s).
[0066] Thus, on exemplary two-legged anchor 1000 , there is shown first a double barbed end provided with barb-like extensions 1004 a, 1004 b, the structural and functional needs and details of which are as previously described.
[0067] A second alternative ground-retention enhancement is provided by a plurality of spaced-apart rings 1006 that have generally barb-shaped cross-sections protruding outwardly of leg 1002 b. They would permit easy insertion of the enhanced anchor into ground while enhancing its retention in ground during use. The number, size and separation of these would be matters of design choice best made by the manufacturer of such anchors.
[0068] A third alternative, for exactly the same purpose, is to provide a plurality of raised bumps or extensions 1008 of simple geometry along each leg of the anchor. These too would allow ease insertion of the anchor into ground while enhancing its retention there during use.
[0069] For backpackers, hikers, and older persons who do not relish carrying heavy items, a light-weight yet strong, easily washed, readily recognized adapted sheet would be desirable. Relatively thin adapted sheets made from polyester, nylon, and assorted blends of the same with natural fibers, all would be suitable for them. On the other hand, there are strong people who can comfortably drag along a cart loaded with fairly heavy food containers, boom-boxes, ice chests, beverage bottles and the like for a day at the beach. For such people, weight is not a serious concern, and they might find it convenient to use heavier and more substantial adapted sheets made of denim, canvas, or padded material for extra comfort.
[0070] Children, and even adults, often forget where they leave their stuff on a heavily occupied beach, so it would help them to have their adapted sheet brightly colored and/or boldly patterned so as to be easily remembered and recognized. If there are many visually similar adapted sheets on a particular segment of a beach, due to heavy promotional attempts by a business as suggested earlier, a pennant of distinctive design and mounted on a tall rod may be included with each adapted sheet for ease of recognition by a user. It may be located immediately adjacent the sheet below.
[0071] FIG. 11 shows how an adapted sheet 1100 may be provided an extended length of tape 1102 incorporated into an end seam 1004 , to thereby strengthen the sheet end, with end portions of the tape (only one is shown) being folded over and incorporated into the seam ends to create respective anchor-engaging loops at each corner. As noted earlier, by choosing the color of tape 1002 and stitching 1010 to be the same as that of sheet 1100 the much smaller soft tape loop 1008 may be made virtually unnoticeable. When loop 1008 is engaged with an anchor inserted into the ground, it will be out of sight with only the sheet being visible directly over and flat to ground.
[0072] FIG. 12 shows how a corner of a sheet 1200 may be adapted by affixing to its bottom side, by stitching 1202 , a very simple anchor-engaging loop 1204 aligned with the longer side 1206 . Both end portions of the tape piece are on the same side of the sheet, and by selecting the color and texture of the tape piece carefully the loop may be made almost unnoticeable at all times.
[0073] FIG. 13 similarly shows how a corner of a sheet 1300 may be adapted by affixing to its bottom side, by stitching 1302 , a very simple anchor-engaging loop 1304 aligned perpendicular to the longer side 1306 of the sheet. Note that if thus improved sheet 1300 is normally used as a flat bed-sheet it is likely to have at one end a wide end seam 1308 . Both end portions of the tape piece are on the same side of the sheet and, as noted above, by selecting the color and texture of the tape piece carefully the loop may be made almost unnoticeable at all times.
[0074] FIG. 14 shows in cross-sectional view a portion of a sheet 1400 adapted for anchor-engagement by affixing to it a tape piece folded over and stitched to the sheet by stitching 1402 . In this embodiment, the end portions 1404 a and 1404 b are disposed to be on opposite sides of the sheet so as to sandwich it, while leaving an unaffixed portion of the tape free to form anchor-engaging loop 1406 . As persons of ordinary skill in the art will immediately appreciate, while this embodiment requires the least amount of labor and tape material to adapt any sheet, it does leave a small amount of the tape visible on both sides of the improved sheet. This can be ameliorated by appropriate selection of the material, texture, and color of the tape as discussed above. It should also be appreciated that this technique for adapting a sheet, to make it easily and inexpensively engageable by ground anchors, can be used at corners and at either straight or curved sides of any sheet with equal facility.
[0075] The embodiments of FIGS. 11-14 may be most found particularly suitable for dedicated “outside” sheets, i.e., strong sheets that are expected to be used almost exclusively in the open for sunbathing and the like. If used solely (or at least primarily) in this context, the fact that the small loops are visible when the sheet is not actually anchored to ground may be totally acceptable to most users. The sizing of these tape loops, e.g., to accommodate particular anchors, is considered a matter of design choice.
[0076] There are other logical and highly beneficial uses for this invention. For example, certain public interest groups act to increase awareness of AIDS awareness by periodically holding rallies and outdoor events at which large sentimentally-significant quilt assemblies are laid out in public places where they may be seen by passersby. These quilt displays typically comprise large numbers of individual square quilted panels created by caring, involved, and artistically talented participants, the panels sometimes being securely interconnected for the display.
[0077] Unfortunately, such a large interconnected quilt assembly, while helpful in providing a neat arrangement of the individual panels, is very heavy and cumbersome to present and then to retrieve and pack for transportation, storage and/or display elsewhere. The present invention provides a very convenient alternative: in which individual (square or rectangular) quilt elements are provided with suitably sized tape loops at least at each corner, whereby up to four adjacent quilt panels could be coupled at abutting corners, in obvious manner, by simultaneous engagement of their corner loops with mutually shared corner anchors. Such an accretion of interconnected individual panels can be readily extended as deemed best under prevailing circumstances. Since each such panel would be individually anchored, it would separately resist displacement by wind gusts.
[0078] A further benefit is that at the scheduled end of the event, or if the weather suddenly turns nasty or it rains, the relatively small individual quilt elements could be retrieved and made safe very swiftly; and their subsequent return to respective owners would be made relatively easy. Such a technique would also allow latecomers to incorporate their quilted elements to the existing quilt assembly from its outside, as they arrive, even if they do not have a previously reserved location for their particular quilt element.
[0079] Obvious modifications and useful application of the disclosed embodiments of this invention will no doubt occur to others, and all such are intended to be comprehended within the scope of this invention which is limited solely by the appended claims.
|
Any commonly used sheet of any shape or size, e.g., a flat bed-sheet, blanket, tablecloth, bath-sheet, spare or selected fabric piece, or the like can be easily adapted per this invention to become very conveniently, securely, and safely anchored on a beach or lawn by simple, inexpensive anchors. During their intended use, and also when the sheet is being put to alternative use, the adaptation elements provided on the sheet are unobtrusive and mostly remain discreetly out of sight. Likewise, when the sheet is anchored to ground for use even under windy conditions it is only the top surface of the sheet that is primarily visible, and no parts of any of the anchors project above the sheet where they might pose a danger of tripping up unwary users, especially small children. The top surface of the sheet may be provided visually memorable colors, patterns, logos and messages, making the sheet easily recognizable and also suitable as a promotional item for an enterprise such as a business or an event such as a concert or a political or religious rally.
| 4
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a system for removing gas bubbles from a flow channel in a microfluidic device.
[0003] 2. Discussion of the Art
[0004] Microfluidic devices are designed to carry out analytical processes in a limited space, i.e., small reaction chambers and flow channels. In a sealed microfluidic device, the formation of gas bubbles in the flow channels is inevitable on account of such operational steps as mixing, dilution, separation, and other steps. In general, gas bubbles are removed from solutions by incorporating vent holes in a conduit to allow gas to escape. Gas bubbles in microfluidic devices occur when the flow channels of the devices are not fully primed. Gas bubbles are formed when plugs of liquid collide during a mixing step. Gas bubbles are formed by electrolysis of water around electrodes when the flow of liquid is driven by electrokinetic forces. The presence of gas bubbles adversely affects the precision of the rate of flow. The presence of gas bubbles also adversely affects the mixing of liquids. Gas bubbles act as an insulating layer for electrokinetic pumping.
[0005] Gas bubbles often interfere with optical measurements, if optical detection is required. Optical signals cannot differentiate a gas from a liquid. The presence of gas bubbles in flow channels makes it difficult to determine accurate quantities of reagents for chemical reactions. If chemical reactions are called for, reaction kinetics cannot be controlled on account of the uncertainty of the volume of gas and interference caused by the presence of gas bubbles. For liquids having a high surface tension, such as, for example, water, gas bubbles present an obstacle to flow in a flow channel. Liquids containing gas bubbles are less likely to wet the walls of the flow channel and flow in the microfluidic device.
[0006] For the foregoing reasons, trapped or dissolved gases should be removed from flow channels for microfluidic analysis.
[0007] U.S. Pat. No. 6,326,211 discloses a miniaturized integrated nucleic acid diagnostic device and system. The device is capable of performing one or more sample acquisition and preparation operations, in combination with one or more sample analysis operations. For example, the device can integrate several or all of the operations involved in sample acquisition and storage, sample preparation and sample analysis, within a single integrated unit. The device can be used in nucleic acid based diagnostic applications and de novo sequencing operations. However, the device and system described herein cannot control the timing of an actual chemical reaction subsequent to the mixing step. The patent is concerned only with mixing and does not consider reactions of chemicals and detection of the reaction product.
[0008] U.S. Pat. No. 6,811,752 discloses a device comprising a plurality of microchambers having a closed vented environment, wherein each microchamber is in operative communication with a filling port and a vent aperture. The device further comprises a base which is sandwiched between two liquid-impermeable membranes, with at leas one of the membranes being gas permeable. This reference also discloses a method for introducing a fluid into a plurality of microchambers of the device, wherein each filling port is aligned with a pipette tip, and the fluid is introduced into and through the filling port. The fluid then flows along a fluid flow groove providing fluid flow communication between the filling port and the microchamber, and into the microchamber. However, the device requires external pumps and valves. The patent does not disclose microchannels and removal of localized gas bubbles, nor does the patent disclose detection of gas bubbles to control reaction kinetics.
[0009] U.S. Pat. No. 6,615,856 discloses a method of controlling fluid flow within a microfluidic circuit using external valves and pumps connected to the circuit. The external valves and pumps, which are not part of the microfluidic substrate, control fluid pumping pressure and the displacement of air out of the fluid circuit as fluid enters into the circuit. If a valve is closed, air cannot be displaced out of circuit, which creates a pneumatic barrier that prevents fluid from advancing within the circuit (under normal operating pressures). However, the device requires external pumps and valves.
[0010] U.S. Pat. No. 6,409,832 discloses a device for promoting protein crystal growth (PCG) using flow channels of a microfluidic device. A protein sample and a solvent solution are combined within a flow channel of a microfluidic device having laminar flow characteristics which forms diffusion zones, providing for a well defined crystallization. Protein crystals can then be harvested from the device. However, the device requires external pumps and valves.
[0011] U.S. Pat. No. 6,415,821 discloses magnetically actuated fluid handling devices using magnetic fluid to move one or more fluids through microsized flow channels. Fluid handling devices include micropumps and microvalves. Magnetically actuated slugs of magnetic fluid are moved within microchannels of a microfluidic device to facilitate valving and/or pumping of fluids and no separate pump is required. The magnets used to control fluid movement can be either individual magnets moved along the flow channels or one or more arrays of magnets whose elements can be individually controlled to hold or move a magnetic slug. Fluid handling devices include those having an array of electromagnets positioned along a flow channel which are turned on and off in a predetermined pattern to move magnetic fluid slugs in desired paths in the flow channel. However, the device requires external pumps and valves. The patent does not mention hydrophobic membranes, nor does it mention removal of gas bubbles. The patent also does not disclose reaction kinetics.
[0012] WO 2007001912 discloses a reservoir for use in testing a liquid as part of a microfluidic testing system. The microfluidic testing system includes a testing chamber configured to receive the liquid to be tested. A liquid inlet is fluidly coupled to the testing chamber to allow ingress of the liquid into the testing chamber. A gas outlet is fluidly coupled to the testing chamber to allow egress of gas out of the testing chamber. The gas outlet has an elevation that is higher than the elevation of the liquid inlet such that, as the testing chamber is rotated, the gas is expelled out of the testing chamber through the gas outlet, thereby reducing or preventing a presence of gas bubbles in the liquid. This device does not make use of a hydrophobic membrane to aid in the removal of gas bubbles.
[0013] EP 1671700 discloses a method of controlling environmental conditions within a fluidic system, e.g., preventing bubble formation, where such environmental conditions can affect the operation of the system in its desired function. Such environmental conditions are generally directed to the fluids themselves, the movement of such fluids through these systems, and the interaction of these fluids with other components of the system, e.g., other fluids or solid components of the system. This system does not use a vent or a hydrophobic membrane to remove gas bubbles during the process.
[0014] Microfluidic devices exhibit numerous advantages as compared with devices having conventional flow channels. Microfluidic devices dramatically reduce the quantities of reagents and samples, thereby resulting in lowered costs. Microfluidic devices reduce the quantities of hazardous materials, e.g., biohazardous materials and organic solvents. Microfluidic devices require a smaller amount of floor space than do conventional analyzers. Microfluidic devices enable integration of various unit operations, such as, for example, separation, mixing, reacting, and detecting. Microfluidic devices enable assays to be carried out in a lesser amount of time, as compared with the time required by conventional diagnostic analyzers. Microfluidic devices can be automated with little difficulty, thereby enhancing consistency and reproducibility of test results.
[0015] Detection of gas bubbles is required because access to and control of the chemical reaction or kinetics as reactants pass through the system is difficult. Detection of gas bubbles enables controlling the commencement of mixing, reacting, and detecting in assays where determination of the concentration of an analyte is based on the measurements related to certain rates, such as, for example, rates of change in a given parameter. An example of such a parameter is absorbance. See, for example, FIG. 3.1 in AEROSET® Systems Operations Manual, 200154-101-November 2004, page 3-7, incorporated herein by reference.
SUMMARY OF THE INVENTION
[0016] This invention provides a microfluidic device having a flow channel comprising a hydrophobic membrane to improve control of flow and control of processing conditions in the flow channel, and to improve the removal of gas bubbles from the flow channel of the microfluidic device. In addition, the invention enables the process controls of the microfluidic device to know when gas bubbles have been removed, so that the next step in the process can be carried out.
[0017] The hydrophobic membrane is capable of allowing gases to escape from the flow channel, while continuing to enable retention of liquid in the flow channel. The material for constructing the hydrophobic membrane should be chemically compatible with the material of the flow channel of the microfluidic device to facilitate assembly. Processes that can be used to fabricate the microfluidic device include, but are not limited to, ultrasonic welding, heat sealing, solvent bonding, and adhesive bonding. Assembly is typically carried out by ultrasonic welding or heat sealing.
[0018] Control loops, which can be open loops or closed loops, are provided to synchronize and program reactions in the assay and other analytical activities in the microfluidic device. Sensors for monitoring and controlling assay steps and other analytical activities can be located at points in the flow channel where reagents are introduced, at points in the flow channel where reactants are mixed, at points in the flow channel where reactions take place, and at points in the flow channel where the results of reactions are read. A feedback loop can be provided to monitor the step of removing gas bubbles. It is preferred that monitoring be carried out by optical methods, such as, for example, reflection of light from the surface of the hydrophobic membrane. The information allows the microfluidic device to determine the beginning and the end of the step of removing gas bubbles from the flow channel.
[0019] The benefits and advantages of the microfluidic device described herein include, but are not limited to: (a) more accurate and consistent analytical results by removing the variations caused by gas bubbles; (b) accurate status of priming activities, if the flow channels need to be primed before reagents are introduced into the flow channels; (c) built-in quality checks of the flow channels by monitoring abnormal flow behavior of samples and reagents by means of optical monitoring; (d) ease of assembly of microfluidic devices by using thermoplastic materials for all required components of the device; (e) avoidance of degassing for those reagents that have a tendency to expel gas over a period of time; and (f) enable detection of reactions that generate gaseous byproducts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1A is a perspective view of a flow channel of a microfluidic device.
[0021] FIG. 1B is an end view of the flow channel shown in FIG. 1A .
[0022] FIG. 1C is a side view of a wall of the flow channel shown in FIG. 1A .
[0023] FIG. 2A is a schematic diagram, greatly enlarged, of a side view in elevation of a gas bubble in a flow channel of a microfluidic device, wherein the gas bubble is upstream of a hydrophobic membrane covering an aperture in the flow channel.
[0024] FIG. 2B is a schematic diagram, greatly enlarged, of a side view in elevation of a gas bubble in the flow channel of the microfluidic device of FIG. 2A , wherein the gas bubble is in register with the hydrophobic membrane covering the aperture in the flow channel.
[0025] FIG. 2C is a schematic diagram, greatly enlarged, of a side view in elevation of the flow channel of the microfluidic device of FIG. 2A , wherein the gas bubble has been removed via the aperture in the flow channel, the aperture being covered by the hydrophobic membrane.
[0026] FIG. 2D is a schematic diagram, greatly enlarged, of a side view in elevation of a flow channel of a microfluidic device, wherein incident light is reflected from a surface of a hydrophobic membrane covering an aperture in the flow channel. In FIG. 2D , there is no gas bubble in the flow channel.
[0027] FIG. 2E is a schematic diagram, greatly enlarged, of a side view in elevation of the flow channel of the microfluidic device of FIG. 2D , wherein incident light is reflected from a surface of the hydrophobic membrane covering the aperture in the flow channel. In FIG. 2E , there is a gas bubble in the flow channel in register with the hydrophobic membrane.
[0028] FIG. 3 is a schematic diagram, greatly enlarged, of a cross section of a flow channel of a microfluidic device, wherein a fiber optic sensor is in contact with a surface of a hydrophobic membrane covering an aperture in the flow channel.
[0029] FIG. 4A is a schematic diagram, greatly enlarged, of a cross section of a flow channel of a microfluidic device, wherein a drop of liquid is upstream of a hydrophobic membrane covering an aperture in the flow channel. An optical monitoring sensor is in contact with a surface of the hydrophobic member. The microfluidic device is equipped to record the times at which two liquids combine and the times of subsequent operations in different locations of the flow channel.
[0030] FIG. 4B is a schematic diagram, greatly enlarged, of the cross section of the flow channel of the microfluidic device of FIG. 4A , wherein the drop of liquid is in register with the hydrophobic membrane covering the aperture in the flow channel.
[0031] FIG. 4C is a graph illustrating absorbance as a function of time for the drop of liquid shown in FIGS. 4A and 4B .
[0032] FIG. 5A is a schematic diagram, greatly enlarged, of a top view of a flow channel of a microfluidic device comprising of two branches joining at a junction position to form a single conduit. In FIG. 5A , a gas bubble is present at the junction position.
[0033] FIG. 5B is a schematic diagram, greatly enlarged, of a top view of the flow channel of the microfluidic device of FIG. 5A . In FIG. 5B , the gas bubble has been removed.
[0034] FIG. 6 is a schematic diagram illustrating a flow channel in a microfluidic device. In this scheme, liquids introduced at three separate locations of the microfluidic device can be combined. The microfluidic device of FIG. 6 comprises a single vent.
[0035] FIG. 7 is a schematic diagram illustrating a flow channel in a microfluidic device. In this scheme, liquids introduced at three separate locations of the microfluidic device can be combined. The microfluidic device of FIG. 7 comprises two vents.
[0036] FIG. 8 is a schematic diagram illustrating a flow channel in a microfluidic device. In this scheme, liquids introduced at three separate locations of the microfluidic device can be combined. The microfluidic device of FIG. 8 comprises two vents.
[0037] FIG. 9 is a graph illustrating absorbance as a function of time for an assay involving a sample and two reagents. The graph illustrates a curve that is characteristic of an end-point assay.
[0038] FIG. 10 is a graph illustrating absorbance as a function of time for an assay involving a sample and two reagents. The graph illustrates a curve that is characteristic of a down rate assay.
DETAILED DESCRIPTION
[0039] As used herein, the expression “flow channel” means a tubular passage for liquids. As used herein, the expression “microfluidic device” means a physical element that enables the control and manipulation of fluids that are geometrically constrained to a small, typically sub-millimeter scale. Further discussion of microfluidics can be found at Microfluidics—Wikipedia, the free encyclopedia, [online]. 2010 [retrieved on Sep. 13, 2010]. Retrieved from the Internet: <URL: http://en.wikipedia.org/wiki/Microfluidics>, pages 1-7, incorporated herein by reference. Representative examples of materials that can be used to make microfluidic devices include, but are not limited to, silicone rubber, glass, plastic, silicon.
[0040] As used herein, the expression “hydrophobic membrane” means a thin sheet of natural or synthetic material that resists water while simultaneously venting gases. The hydrophobic material is preferably impermeable to water and other liquids while being permeable to gases.
[0041] As used herein, the terms “vent”, “venting”, and the like refer to discharge through a vent, i.e., an opening for the passage or escape of a gas or vapor.
[0042] As used herein, the term “feedback” means return of a portion of the output of a process or a system to input, especially to maintain performance or to control a system or a process. As used herein, the expression “feedback loop” means a system that relies on feedback for its operation.
[0043] As used herein, the expression “gas bubble” means a small globule of gas trapped in a liquid or solid.
[0044] A microfluidic device 10 suitable for use herein comprises a flow channel 12 comprising a top wall 14 , a bottom wall 16 , a first side wall 18 , a second side wall 20 . The flow channel 12 has an inlet 22 at the distal end thereof and an outlet 24 at the proximal end thereof. The dimensions of the flow channel 12 typically range from about 100 micrometers to about 1 millimeter in width and from about 100 micrometers to about 1 millimeter in height. The shape of the cross-section of the flow channel 12 need not be rectangular. The shape of the cross section of the flow channel 12 can be a polygon of any number of sides, e.g., three, four, five, six, seven, eight, etc. sides. Alternatively, the shape of the cross section of the flow channel can be curved, such as, for example, a continuous curve, e.g., circular, elliptical. The flow channel 12 can comprise a single conduit; alternatively, the flow channel can comprise two or more branches emerging from a single conduit or two or more branches joining to form a single conduit.
[0045] In the following figures, the arrow designated by the letter “L” indicates the direction of the flow of a liquid in the flow channel of a microfluidic device. FIG. 2A shows a gas bubble 110 in a flow channel 112 of a microfluidic device (not shown), wherein the gas bubble is upstream of a hydrophobic membrane 114 . The hydrophobic membrane 114 covers an aperture 116 formed in a wall 118 constituting a boundary of the flow channel 112 . The aperture typically has a major dimension, e.g., a diameter, ranging from about 2 millimeters to about 5 millimeters. FIG. 2B shows a gas bubble 110 in a flow channel 112 of a microfluidic device (not shown), wherein the gas bubble is in register with the hydrophobic membrane 114 . The hydrophobic membrane 114 covers an aperture 116 formed in a wall 118 constituting a boundary of the flow channel 112 . FIG. 2C shows a flow channel 112 of a microfluidic device (not shown), wherein the gas bubble has been removed through the hydrophobic membrane 114 . The hydrophobic membrane 114 covers an aperture 116 formed in a wall 118 constituting a boundary of the flow channel 112 .
[0046] FIG. 2D shows a flow channel 112 of a microfluidic device (not shown). A hydrophobic membrane 114 covers an aperture 116 formed in a wall 118 constituting a boundary of the flow channel 112 . There is no gas bubble in the flow channel. Incident light is reflected from the surface of the hydrophobic membrane 114 that is not facing the wall 118 constituting the boundary of the flow channel 112 . The beam of incident light is represented by the symbol “i”, and the reflected light is represented by the symbol “r.” The incident light can be provided by a source of light, such as, for example, a lamp, that provides light at an appropriate wavelength. The reflected light can be detected by an appropriate light detector. A fiber optic sensor in contact with the surface of the hydrophobic membrane 114 that is not facing the wall 118 constituting the boundary of the flow channel 112 can be used to transmit incident light “i” to the flow channel 112 and to transmit reflected light “r” from the flow channel 112 .
[0047] FIG. 2E shows a flow channel 112 of a microfluidic device (not shown) of FIG. 2D . A hydrophobic membrane 114 covers an aperture 116 formed in a wall 118 constituting a boundary of the flow channel 112 . A gas bubble 110 is present in the flow channel. Incident light is reflected from a surface of the hydrophobic membrane 114 that is not facing the wall 118 constituting the boundary of the flow channel 112 . When a gas bubble 110 is present in the flow channel, the quantity of light reflected by the surface of the hydrophobic membrane 114 is different from the quantity of light reflected by the surface of the hydrophobic membrane 114 when there is no gas bubble present in the flow channel. For additional information relating to detection of gas bubbles in flow channels of microfluidic devices, see, for example, Spectrophotometry—Wikipedia, the free encyclopedia, [online]. 2010 [retrieved on Oct. 10, 2010]. Retrieved from the Internet: <URL: http://en.wikipedia.org/wiki/Spectrophotometer>, incorporated herein by reference.
[0048] FIG. 3 illustrates a flow channel 112 in a microfluidic device (not shown). A hydrophobic membrane 114 covers an aperture 116 formed in a wall 118 constituting a boundary of the flow channel 112 . A fiber optic sensor 120 is in contact with the surface of the hydrophobic membrane 114 that is not facing the wall 118 constituting the boundary of the flow channel 112 . A Thermo Fisher Scientific near-infrared analytical system having a fiber optic sensor can be employed for optical detection of gas bubbles.
[0049] FIG. 4A illustrates a flow channel 112 of a microfluidic device (not shown), wherein a drop of liquid “D” is upstream of a hydrophobic membrane 114 . The hydrophobic membrane 114 covers an aperture 116 formed in a wall 118 constituting a boundary of the flow channel 112 . A fiber optic sensor 120 is in contact with the surface of a hydrophobic membrane 114 that is not facing the wall 118 constituting the boundary of the flow channel 112 . FIG. 4B illustrates a flow channel 112 of a microfluidic device (not shown), wherein a drop of liquid “D” is in register with a hydrophobic membrane 114 . The hydrophobic membrane 114 covers an aperture 116 formed in a wall 118 constituting a boundary of the flow channel 112 . The fiber optic sensor 120 is in contact with the surface of a hydrophobic membrane 114 that is not facing the wall 118 constituting the boundary of the flow channel 112 . The fiber optic sensor 120 in contact with the surface of the hydrophobic membrane 114 that is not facing the wall 118 constituting the boundary of the flow channel 112 can be used to transmit incident light “i” to the flow channel 112 and to transmit reflected light “r” from the flow channel 112 . The incident light can be provided by a source of light, such as, for example, a lamp, that provides light at an appropriate wavelength. The reflected light can be detected by an appropriate light detector. FIG. 4C is a graph illustrating absorbance as a function of time for the drop of liquid “D” shown in FIG. 4A and FIG. 4B . FIG. 4A represents the microfluidic device at time “t 1 ”. FIG. 4B represents the microfluidic device at time “t 2 ”. FIG. 4C graphically depicts the absorbance measured for the microfluidic device at time “t 1 ”. FIG. 4C also graphically depicts the absorbance measured for the microfluidic device at time “t 2 ”.
[0050] FIG. 5A illustrates a flow channel 210 of a microfluidic device (not shown). The flow channel 210 comprises a first branch 212 , a second branch 214 , and a single conduit 216 , all of which converge at a junction 218 . In this figure, a gas bubble 220 is present at the junction 218 . FIG. 5B illustrates the flow channel 210 of a microfluidic device (not shown) of FIG. 5A . In this figure, the gas bubble has been removed. Liquid is represented by the letter “L”.
[0051] FIG. 6 illustrates a flow channel 310 of a microfluidic device (not shown), wherein liquids introduced in three separate branches of the flow channel 310 can be combined. In the first branch 312 , a sample, designated by the letter “S”, is introduced. In the second branch 314 , a first reagent, designated by the alphanumeric characters “R1”, is introduced. In the third branch 316 , a second reagent, designated by the alphanumeric characters “R2”, is introduced. The flow channel 310 comprises a single vent 318 . The detection area 320 includes a spectrophotometer. The vent 318 is covered by a hydrophobic membrane (not shown). The vent 318 is an aperture of the type described previously.
[0052] FIG. 7 illustrates a flow channel 410 of a microfluidic device (not shown), wherein liquids introduced in three separate branches of the flow channel 410 can be combined. In the first branch 412 , a sample, designated by the letter “S”, is introduced. In the second branch 414 , a first reagent, designated by the alphanumeric characters “R1”, is introduced. In the third branch 416 , a second reagent, designated by the alphanumeric characters “R2”, is introduced. The flow channel 410 comprises two vents 418 and 420 . The detection area 422 includes a spectrophotometer. Each vent 418 and 420 is covered by a hydrophobic membrane (not shown). The vents 418 and 420 are apertures of the type described previously.
[0053] FIG. 8 illustrates a flow channel 510 of a microfluidic device (not shown), wherein liquids introduced in three separate branches of the flow channel 510 can be combined. In the first branch 512 , a sample, designated by the letter “S”, is introduced. In the second branch 514 , a first reagent, designated by the alphanumeric characters “R1”, is introduced. In the third branch 516 , a second reagent, designated by the alphanumeric characters “R2”, is introduced. The flow channel 510 comprises two vents 518 and 520 . The detection area 522 includes a spectrophotometer. Each vent 518 and 520 is covered by a hydrophobic membrane (not shown). The vents 518 and 520 are apertures of the type described previously.
[0054] In the AEROSET® system that is currently used for systems that do not employ microfluidics, the source of light for the spectrophotometer is typically a tungsten-halogen lamp having a wavelength ranging from about 340 nm to about 804 nm, a photometric range of from about 0.1 to about 3.0 Abs (converted to 10 mm light path length), and a light path length of 5 mm. In a microfluidic system of the type described herein, it is expected that one of ordinary skill in the art would have little difficulty in designing a near-infrared system for measuring absorbance that would provide results that are substantially equivalent to those provided by the AEROSET® system currently used. Such a system can be used for the arrangements shown in FIG. 6 , FIG. 7 , and FIG. 8 .
[0055] FIG. 9 is a graph illustrating absorbance as a function of time for dispensing given reagents. For end-point assays, as depicted in FIG. 9 , concentration is calculated by using absorbance data obtained by an appropriate spectrophotometer. The reaction reaches equilibrium, and at that time there is little or no additional change to the absorbance readings. The absorbance readings used for calibration and to calculate results are measured during this equilibrium time. See AEROSET® Systems Operations manual, 200154-101-November 2004, pages 3-7 and 3-9 through 3-11, inclusive, all of which pages are incorporated herein. FIG. 10 is a graph illustrating absorbance as a function of time of dispensing given reagents. For rate assays, as depicted in FIG. 10 , activity is calculated using the change of absorbance per minute (ΔAbs/min). There is a constant change in absorbance over time. Readings are performed several times during the reaction and the absorbance change over time (activity) is calculated and used for calibration and to calculate results. Generally, at least three photometric points must be included in the reading period. The maximum number of photometric points is set by the apparatus. The rate of absorbance (change per minute) can be calculated using a linear least squares method. See AEROSET® Systems Operations manual, 200154-101-November 2004, pages 3-7 and 3-9 through 3-11, inclusive, all of which pages are incorporated herein by reference.
[0056] It is preferred that, in a branched flow channel comprising a conduit that joins with two or more branches at a junction, at least one vent be located at the position where the conduit of the given branched flow channel joins with, or intersects with, the branches of the given branched flow channel, so that gas bubbles in the flow channel can be removed efficiently. At least one hydrophobic membrane can be utilized to cover the at least one vent, whereby liquids are sealed in the flow channel(s) of the microfluidic device, while gas bubbles are allowed to pass and be removed from the flow channel(s) of the microfluidic device.
[0057] Selection of the hydrophobic membrane of the microfluidic device is based on ease of assembly. Ultrasonic welding or heat sealing are preferred for the purpose of automated assembly. Adhesives can also be used, but more assembly steps are required and the likelihood of contamination is increased on account of components from the adhesive leaching into the flow channel(s) of the microfluidic device. Ultrasonic welding is described, for example, in Ultrasonic welding—Wikipedia, the free encyclopedia, [online]. 2010 [retrieved on Oct. 21, 2010]. Retrieved from the Internet: <URL: http://en.wikipedia.orq/wiki/Ultrasonic welding>, pages 1-6, incorporated herein by reference. An apparatus suitable for ultrasonic welding is a Branson Ultrasonic System 2000X (Branson Ultrasonics Corporation, Danbury, Conn.).
[0058] Materials that can be used to make the hydrophobic membrane include, but are not limited to, hydrophobic polypropylene, hydrophobic polyvinylidene difluoride (PVDF), hydrophobic polyethylene terephthalate, and hydrophobic polytetrafluorethylene (PTFE). The thickness of the hydrophobic membrane can range from about 60 micrometers to about 200 micrometers. The size of the pores in the hydrophobic membrane can range from about 0.1 micrometer to about 10 micrometers. A hydrophobic membrane suitable for use herein is GE Nylon, commercially available from GE Osmonics. This hydrophobic membrane can have a thickness ranging from about 65 micrometers to about 125 micrometers and a pore size ranging from about 0.1 micrometer to about 10 micrometers. See, for example, OEM GE Nylon—Hydrophobic Membranes. Datasheet [online]. General Electric Company, 2010 [retrieved on Oct., 20, 2010]. Retrieved from the Internet: <URL: http://www.osmolabstore.com/OsmoLabPaqe.dll?BuildPaqe&1&1&1021>, incorporated herein by reference. It is preferred that the hydrophobic membrane be translucent. Hydrophobic membranes suitable for use herein are commercially available from such suppliers as General Electric Company, Millipore Corporation, Billerica, Mass. 01821, and Pall Corporation, Port Washington, N.Y. 11050.
[0059] A monitoring system can be used in the process for removing gas bubbles. The monitoring system can be an optical monitoring system or an electrical monitoring system. An optical monitoring system measures the light reflected from the exterior surface of the hydrophobic membrane. An electrical monitoring system involves conductivity sensors or resistance sensors positioned at the surface of a wall at the position of the vent. An optical monitoring system is preferred for a variety of reasons. For example, light in the near infrared region of the spectrum, e.g., at a wavelength of 1950 nm, is a strong fingerprint peak for water in the near infrared region of the electromagnetic spectrum. Light in the near infrared region of the electromagnetic spectrum can penetrate to a depth of a few millimeters and illuminate the bottom wall of the hydrophobic membrane to detect the presence of gas bubbles and water. A sharp rise of absorption of light near a wavelength of 1950 nm enables the system to determine whether the gas is expelled and the information can be introduced into a microprocessor for mixing, reacting, sensing, and other operations.
[0060] The flow channel of the microfluidic device can be made by several methods, such as, for example, silica based photolithography, wet chemical etching, micro-injection molding, or micro-embossing. See, for example, U.S. Pat. No. 5,885,470, incorporated herein by reference. For additional information relating to techniques for making microfluidic devices, see, for example, Tabeling, Introduction to Microfluidics , Oxford University Press (2005), pages 244-281; Armani et al., Fabricating PDMS Microfluidic Channels Using a Vinyl Sign Plotter, Lab on a Chip Technology, Volume 1: Fabrication and Microfluidics , edited by Herold, K. E. and Rasooly, A., Caister Academic Press (2009), pages 9-15; Tsao et al., Bonding Techniques for Thermoplastic Microfluidics, Lab on a Chip Technology, Volume 1 : Fabrication and Microfluidics , edited by Herold, K. E. and Rasooly, A., Caister Academic Press (2009), pages 45-63; Carlen et al., Silicon and Glass Micromachining, Lab on a Chip Technology, Volume 1 : Fabrication and Microfluidics , edited by Herold, K. E. and Rasooly, A., Caister Academic Press (2009), pages 83-114; Cheung et al., Microfluidics-based Lithography for Fabrication of Multi-Component Biocompatible Microstructures, Lab on a Chip Technology, Volume 1 : Fabrication and Microfluidics , edited by Herold, K. E. and Rasooly, A., Caister Academic Press (2009), pages 115-124; Lee, Microtechnology to Fabricate lab-on-a-Chip for Biology Applications, Lab on a Chip Technology, Volume 1 : Fabrication and Microfluidics , edited by Herold, K. E. and Rasooly, A., Caister Academic Press (2009), pages 125-138; Sun et al., Laminated Object Manufacturing (LOM) Technology-Based Multi-channel Lab-on-a-Chip for Enzymatic and Chemical Analysis, Lab on a Chip Technology, Volume 1 : Fabrication and Microfluidics , edited by Herold, K. E. and Rasooly, A., Caister Academic Press (2009), pages 161-172; Waddell, Laser Micromachining, Lab on a Chip Technology, Volume 1 : Fabrication and Microfluidics , edited by Herold, K. E. and Rasooly, A., Caister Academic Press (2009), pages 173-184; Nguyen, Nam-Trung et al., Fundamentals and Applications of Microfluidics , Second Edition, ARTECH HOUSE (2006), pages 55-116, all of which references are incorporated herein by reference. The aforementioned references also indicate materials that are suitable for preparing microfluidic devices suitable for use herein.
[0061] The following non-limiting examples illustrate assays that can be carried out with the microfluidic device described herein.
Example 1
[0062] Measurement of the concentration of cocaine enables confirmation of substance abuse. The assay for cocaine is based on the competition between a drug labeled with an enzyme and the drug from a sample of urine for a fixed number of binding sites on an antibody that specifically binds to the drug. In the absence of the drug from the sample of urine, the antibody binds to the drug labeled with the enzyme glucose-6-phosphate dehydrogenase (G6PDH), and the enzyme activity is inhibited. The G6PDH enzyme activity is determined spectrophotometrically at 340/412 nm by measuring the ability of the enzyme to convert nicotinamide adenine dinucleotide (NAD) to NADH, the reduced form of NAD.
[0063] The reactive ingredients involve two reagents, Reagent 1 and Reagent 2. Reagent 1 comprises anti-benzoylecgonine monoclonal antibodies (mouse), glucose-6-phosphate (G6P), and nicotinamide adenine dinucleotide (NAD). Reagent 2 comprises benzoylecgonine labeled with glucose-6-phosphate dehydrogenase (G6PDH).
[0064] Measurement is carried out by means of a spectrophotometer at 340/412 nm (the reading of absorbance taken at the secondary wavelength is subtracted from the reading of absorbance taken at the primary wavelength, and the difference is used as the absorbance value). Results are determined by a change in rate of absorbance, i.e., change of absorbance per minute. See, for example, AEROSET System Operations manual 200154-101-November 2004, pages 3-7 and 3-9 through 3-11, inclusive, incorporated herein by reference.
[0065] Additional information is set forth on the package insert marked ARCHITECT/AEROSET MULTIGENT Cocaine, Ref 3L40-20, incorporated herein by reference.
[0066] According to the package insert, air bubbles should be removed with a new applicator stick, if such air bubbles are present in the reagent cartridge. Alternatively, air bubbles should be allowed to dissipate by allowing the reagent to sit at the appropriate storage temperature. Reagent bubbles may interfere with proper detection of reagent level in the cartridge, causing insufficient reagent aspiration, which could adversely affect results.
Example 2
[0067] Measurement of the concentration of creatinine enables assessment of renal function. At an alkaline pH, creatinine in the sample (serum, plasma, urine) reacts with picrate to form a creatinine picrate complex. The rate of increase in absorbance at 500 nm due to the formation of this complex is directly proportional to the concentration of creatinine in the sample.
[0068] The reactive ingredients involve two reagents, Reagent 1 and Reagent 2. Reagent 1 comprises sodium hydroxide. Reagent 2 comprises picric acid.
[0069] Measurement is carried out by means of a spectrophotometer at 500 nm. Results are determined at the stable reading after reaction.
[0070] Additional information is set forth on the package insert marked ARCH ITECT/AEROSET Creatinine, Ref 7D64-20, incorporated herein by reference. See, for example, AEROSET System Operations manual 200154-101-November 2004, pages 3-7 and 3-9 through 3-11, inclusive, incorporated herein by reference.
[0071] According to the package insert, air bubbles should be removed with a new applicator stick, if such air bubbles are present in the reagent cartridge. Alternatively, air bubbles should be allowed to dissipate by allowing the reagent to sit at the appropriate storage temperature. Reagent bubbles may interfere with proper detection of reagent level in the cartridge, causing insufficient reagent aspiration, which could adversely affect results.
Example 3
[0072] Measurement of the concentration of ethanol enables the determination of a person's level of intoxication for legal or medical reasons. In the presence of alcohol dehydrogenase and nicotinamide adenine dinucleotide (NAD), ethanol is readily oxidized to acetaldehyde and NADH. The enzymatic reaction can be monitored spectrophotometrically at 340/412 nm.
[0073] The reactive ingredients involve two reagents, Reagent 1 and Reagent 2. Reagent 1 comprises Tris buffer. Reagent 2 comprises alcohol dehydrogenase (ADH) and NAD.
[0074] Measurement is carried out by means of a spectrophotometer at 340/412 nm (the reading of absorbance taken at the secondary wavelength is subtracted from the reading of absorbance taken at the primary wavelength, and the difference is used as the absorbance value). Results are determined at the stable reading after reaction.
[0075] Additional information is set forth on the package insert marked ARCHITECT/AEROSET MULTIGENT ETHANOL; Ref 3L36-20, incorporated herein by reference. See, for example, AEROSET System Operations manual 200154-101-November 2004, pages 3-7 and 3-9 through 3-11, inclusive, incorporated herein by reference.
[0076] According to the package insert, reagent bubbles may interfere with proper detection of reagent level in the cartridge, causing insufficient reagent aspiration, which could adversely affect results.
[0077] It should be noted that it is expected that the optical monitoring system determines the presence or absence of gas bubbles in the flow channel of the microfluidic device at a wavelength of light that is a strong fingerprint peak for water, e.g., at a wavelength of 1950 nm.
[0078] Various modifications and alterations of this invention will become apparent to those skilled in the art without departing from the scope and spirit of this invention, and it should be understood that this invention is not to be unduly limited to the illustrative embodiments set forth herein.
|
A microfluidic device having a flow channel comprising a hydrophobic membrane to improve control of flow and control of processing conditions in the flow channel, and to improve the removal of gas bubbles from the flow channel of the microfluidic device. In addition, the invention enables the process controls of the microfluidic device to know when gas bubbles have been removed, so that the next step in the process can be carried out.
| 1
|
BACKGROUND OF THE INVENTION
The present invention relates to a sheet deposition device for the selective deposition of printed sheets on a number of superimposed supports wherein each support is provided with its own drive means for moving said support up and down between a deposition position in which sheets can be deposited on that support and a parking position in which sheet deposition is not possible.
A sheet deposition device of this kind is known from European Patent 0 532 069. In this known sheet deposition device, when a predetermined maximum number of sheets has been deposited on one of the supports, a change-over can be made to the further deposition of sheets on one of the other supports, provided there are no sheets present on said other support, and this can be detected by a detector at the support surface of a support. During the displacement of a support, which is necessary for the purpose, with the maximum number of sheets thereon, to a lower parking position, said support will come entirely outside the deposition range of a support subsequently placed in the deposition position, in order to prevent the latter support from colliding, in its deposition position, against the sheets on the support which has been set to its lower parking position and would therefore be obstructed in its further movement.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a sheet deposition device wherein a support is movable between the deposition position and the parking position provided that there is still free space for movement between the superimposed supports and without the supports, possibly with sheets therebetween, jamming against one another. To this end, according to the present invention, a support is provided with detection means for detecting an obstacle in the space directly therebeneath, for example sheets on a support directly therebeneath, which detection means delivers a first detection signal, when the distance between the support provided with said detection means and an obstacle therebeneath is greater than a predetermined amount, and delivers a second detection signal, when said distance is equal to said predetermined amount. The sheet deposition device comprises a control device which in response to reception of a first detection signal makes the drive means capable of activation for moving towards one another the supports between which are situated the detection means delivering the first detection signal and which deactivate the said drive means in response to the reception of a second detection signal.
According to one aspect of the present invention, the detection means comprises a flat plate suspended beneath a support and movable between a first position in which the plate is situated at some distance from and parallel to said support and a second position in which the plate is situated at an even shorter distance from said support. The detection means further comprises switching means between the plate and the support with actuating means which are rigidly connected to the movable plate and in the first position of the plate actuate the switching means to deliver the first detection signal and in the second position of the plate actuate the switching means to deliver the second detection signal.
The effect of the flat plate is that an obstacle beneath a support can be detected over a relatively large range, this being important particularly if the object is a stack of sheets on a support situated directly beneath the relevant support, which does not have a flat top, for example, because the stack consists of stapled sets which have a relatively considerable thickness at the staple position.
Preferably, the plate is provided with fixing means near its opposite edges, which connect the plate to the support for movement in the vertical direction and switching means are provided at each of said fixing means. The effect of this is that an obstacle can be readily detected at any place beneath a support without considerable room for movement for the plate being necessary for this purpose.
Preferably, one of the detecting means further comprises a U-shaped strap, of which the intermediate piece connecting its arms is connected for rotation about its longitudinal axis to one of the plates or supports for connection and the ends of the arms are rotatably connected to the other plate or support for connection. The effect of this is that during its movement from the first position to the second position the plate can tip in only one direction so that for the detection of an obstacle up to the four corner points of the plate it is only necessary to use two switching means near the fixing points in a central zone of the plate.
This gives a compact-constructed and flexible sheet deposition device in which supports with any sheets deposited thereon cannot jam against one another.
According to another aspect of the present invention, the control device of the sheet deposition device comprises control means which in response to the reception of a first detection signal delivered by the detection means at a support in a deposition position or a support therebeneath, make the drive means of said supports capable of activation for moving said support(s) downwards on deposition of the subsequent sheets on said support. As a result, sheets on a support in its parking position can lie within the range of deposition positions of a support thereabove, such range being increased when sheets are removed from the support in its parking position. Another effect is that deposition of sheets can be continued as long as there is anywhere free room for movement beneath the support in the deposition position.
According to yet another aspect of the present invention, the control device comprises control means which, upon displacement of a support from a parking position to its deposition position and in response to the reception of a first detection signal delivered by the detection at another support situated between the said parking position and the deposition position, makes the drive means of said other support or supports capable of activation for joint downward or upward movement, with the support to be displaced into its deposition position. The effect of this is that supports with any sheets thereon which stand in the way of a support being moved into its deposition position are automatically moved out of the way provided there is still room where the support requiring to be moved away can be moved away.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the sheet deposition device according to the present invention will be explained hereinafter with reference to the accompanying drawings wherein:
FIG. 1 illustrates one embodiment of a printing apparatus using a sheet deposition device according to the present invention;
FIG. 2 shows the sheet deposition device of FIG. 1 with supports shown in their bottom positions;
FIG. 3 is a perspective view of detection means mounted beneath each support of the sheet deposition device show in FIGS. 1 and 2; and
FIG. 4 is a diagram showing a sheet deposition device with the supports in their starting position and an associated control system.
DETAILED DESCRIPTION OF THE INVENTION
The printing apparatus 1 shown in FIG. 1 comprises means known per se for printing an image on a receiving sheet. These images for printing may be present on original documents which are fed to a scanning station 2 situated at the top of the printing apparatus 1 . Images for printing can also be fed in digital form from a workstation 3 connected via a network 4 to a control device 8 of the printing apparatus 1 .
A printing cycle for copying a set of originals presented via the scanning station 2 is started by actuating a start button 6 on the operator control panel 5 of the printing apparatus 1 .
A printing cycle for printing a set of images presented via workstation 3 can be started by actuating a start button 7 provided on the workstation 3 , via control device 8 (hereinafter referred to as automatic printing), or by actuating a start button 6 provided on the operator control panel 5 of the printing apparatus 1 (hereinafter referred to as semi-automatic printing).
In the printing apparatus 1 , the sheet transport path 10 forms the path for delivering to a sheet finishing station 11 the sheets printed in the printing apparatus.
The finishing station 11 contains a sheet collecting tray 12 (not shown in detail) in which a number of printed sheets belonging to a set can be collected and stapled, whereafter discharge roller pairs 13 feed the set of printed sheets to a sheet deposition unit 15 forming part of a sheet deposition station 11 .
The sheet deposition unit 15 comprises four superimposed deposition tables 16 , 17 , 18 and 19 , each of which can be set to a deposition position with respect to the horizontal discharge path formed by the discharge roller pair 13 , to receive sheets discharged by the discharge roller pair 13 . The vertical displacement of the deposition tables can be effected by means of the displacement mechanism described in European Patent Specification 0 532 069, the selected deposition table or the sheet at the top thereof always lying just beneath the discharge path formed by the discharge roller pair 13 .
FIG. 1 shows the bottom deposition table 16 in a bottom deposition position in which a maximum number of sheets is situated on said deposition table 16 and the deposition tables 17 , 18 and 19 situated thereabove are in parking positions situated above the discharge path formed by the discharge roller pair 13 .
Since the deposition tables 17 , 18 and 19 are adjustable as to height independently of deposition table 16 , after sheets have been removed from deposition table 16 the top deposition table 19 can if necessary also be placed in a deposition position without the bottom deposition table 16 needing to be moved further down than the bottom deposition position shown in FIG. 1 .
As a result, the finishing station 11 with the sheet deposition unit 15 adjacent the same is very suitable for being positioned at the top of a printing apparatus 1 , the top of which with the scanning station 2 is situated at a normal working height for a standing operator of about 100 cm. In the printing apparatus 1 with the finishing station 11 as shown in FIG. 1, the removal height for sheets delivered on deposition tables 16 , 17 , 18 and 19 is between 100 cm and 160 cm for a total sheet deposition capacity of about 3000 sheets. The sheet deposition level defined by the fixed discharge rollers 13 is approximately 133 cm, and this level corresponds to the deposition level wherein the bottom deposition table 16 is in its bottom deposition position.
The combination of high deposition capacity and limited overall height is rendered possible by using the bottom deposition table 16 solely for the deposition of prints of a first type, the printing cycle of which is initiated with a setting button on the printing apparatus, so that the operator who makes this setting can also remove the deposited prints shortly thereafter, giving the deposition tables situated thereabove the opportunity to come into their deposition position and receive prints, the printing cycle of which is initiated from a workstation 3 at a distance from the printing apparatus.
According to the present invention, higher-level deposition tables can also be placed in a deposition position when prints are still situated on or beneath a lower-level deposition table providing there is still room to move the higher-level support down into its deposition position.
Therefore, according to the present invention, each deposition table is provided with detection means which enable the higher-level deposition table to move down provided there is still free room for movement beneath said deposition table. The underside of each deposition table 17 , 18 and 19 is for this purpose provided with the means indicated in FIG. 2 .
To prevent the bottom deposition table 16 from jamming, during the downward movement, against an obstacle situated beneath the bottom deposition table, for example originals or copies lying on the top of the printing apparatus 1 next to the scanning station, the bottom deposition table 16 is also provided with the same detection means as the deposition table 17 , 18 and 19 . Accordingly, each deposition table 16 , 17 , 18 and 19 is provided with two straps 25 , 26 shown in FIG. 3, to the top of which there is secured a sheet deposition plate (not shown in FIG. 3 ).
A U-shaped strap 27 extends from one of the adjacent straps 25 and 26 and is secured to strap 26 and is situated in the same horizontal plane as the straps 25 and 26 .
Looking in a direction in which sheets are fed to the deposition plate by the transport roller pair 13 , the straps 25 and 27 extend beneath the sides of the deposition plate and are rigidly connected thereto.
Pins 28 , 29 ; 30 , 31 respectively are fixed at the sides of the straps 25 and 27 extending away from one another. Looking in the sheet discharge direction, pins 28 and 29 are situated opposite one another at the upstream end of the straps 25 and 27 . A flat switch plate 32 extending parallel to the deposition plate is situated beneath the straps 25 , 26 and 27 . Two brackets 35 and 36 are fixed on the switch plate 32 .
Upright parts of the brackets 35 and 36 are provided with slots 37 and 38 extending vertically and accommodating pins 28 and 29 with clearance. A hinge arm 33 bent with a U-shaped configuration is rotatably connected at the ends of its arms to pins 30 and 31 respectively. The hinge arm 33 extends around the straps 25 , 26 and 27 and is in the same plane as the straps.
A U-shaped bent strip 39 is fixed on the switch plate 32 . The upright arms of the strip 39 are provided with indentations 40 and 41 in which the center piece of the hinge arm fits. The switch plate 32 is also provided with a strip which, at the top, has bent-over edges 43 which, in the position of rest of the switch plate 32 , rests on a projection 44 fixed on the strap 27 . In the position of rest of the switch plate 32 , the top edges of slots 37 and 38 rest on pins 28 and 29 respectively and the bent-over parts 43 rest on projection 44 . In this position of rest the switch plate 32 is situated a short distance, e.g. a distance of 7 mm, beneath the straps 25 , 26 and 27 and extends parallel to the deposition plate fixed on these straps.
When a deposition table moves down and the switch plate 32 meets an obstacle therebeneath (e.g. a sheet stack on a deposition table therebeneath), then on the further downward movement of the deposition table the switch plate 32 is pressed in the direction of the straps 25 , 26 and 27 until the switch plate encounters the straps. This movement of the switch plate 32 is made possible by the slots 37 and 38 and by the turning of the hinge arm 33 . The construction of the hinge arm 33 held in indentations 40 and 41 ensures that the switch plate 32 can not rotate about a line extending parallel to the sheet discharge direction. The switch plate can only tip about a line extending transversely of the sheet discharge direction. When the switch plate 32 first comes into contact with an obstacle at the upstream side, then the switch plate 32 moves upwards only at that side in the two slots 37 and 38 , even if the obstacle is situated only beneath one corner part on that side, and when the switch plate 32 first comes into contact with an obstacle on the downstream side then the switch plate 32 moves up only on that side with rotation of the hinge arm 33 , even if the obstacle is situated only beneath one corner part on that side.
An opto-electrical switch 45 is disposed on the upstream side of each deposition table between the straps 25 and 26 and an opto-electrical switch 46 is disposed on the downstream side of each deposition table between the straps. Each of the switches 45 and 46 cooperates with a blade 47 , 47 ′ respectively fixed on the switch plate 32 . During movement of the switch plate 32 in the direction of a downwardly moving deposition table, blade 47 and/or blade 47 ′ will activate the associated switch or switches 45 , 46 , in response to which the drive of the downward moving deposition table is interrupted. The switching time is so chosen that switch plate 32 can thereafter still move further before it encounters the straps. During this last movement, which can take place when the opto-electrical switch refuses to operate at the correct time, e.g., because the switch plate is pressed rapidly upwards manually, the blade actuates a microswitch (not shown) which, for protection purposes, breaks the drive to all the deposition tables. The protective microswitch does not normally respond. The above-described suspension of the switch plate ensures that the activation of the switch plate can take place at each of the corner points, and yet only two switching elements are necessary instead of four. The switch plate 32 should be sufficiently torsion-resistant and is, therefore, constructed for example from 2 mm thick aluminum.
The use of the switch arm 33 , situated around the straps between the deposition plate and the switch plate, ensures a flat construction which, for example, has a total overall height of only 20 mm with the required stroke length of 7 mm for the switch plate, of which, for example, 4 mm is for the opto-electrical switches and 3 mm for the protective microswitch.
At the drive side 48 , where they are connected to a motor which can adjust the associated deposition table as to height, the straps 25 and 26 have an elevation 49 by means of which they can come into contact with the strap of a deposition table thereabove. This elevation is of a size such that two tables between which there are no sheets cannot come so close together that the protective microswitch can respond. Only when there are sheets or some other obstacle between the deposition tables will the microswitch respond and the switching off of the motors which move the deposition tables can be rendered inoperative by the removal of the sheets which cause the microswitch to respond.
In FIG. 4, the four deposition tables 16 , 17 , 18 and 19 are shown in their starting positions. The bottom table 16 is in the lowest possible position which is at a distance beneath the transport roller pair 13 such that it can support a predetermined maximum number of sheets, e.g. 2250 sheets. A fixed sensor 50 , level with this position, detects when the support 16 is in this starting position.
The other deposition tables 17 , 18 and 19 are in their starting position above the transport roller pair 13 . The support 17 is above the roller pair 13 , and supports 18 and 19 are disposed just above support 17 at distances such that each of these supports can support a predetermined maximum number of sheets, e.g. 500 sheets each. Fixed sensors 51 , 52 , 53 are disposed at the respective starting position level to detect when supports 17 , 18 and 19 are in their starting positions.
The above indicated starting positions correspond to positions in which the sheet deposition device accommodates a maximum number of sheets.
Reference numeral 60 denotes a control device which sets the tables to their starting position for putting the sheet deposition device into operation.
First of all, by means of motor 61 , table 16 is moved down to its very lowest position at sensor 50 . Table 19 is then raised by means of motor 64 to its very highest position at sensor 53 . Table 18 is then moved up by means of motor 63 until either the position at sensor 52 is reached, in the event that the table was previously in a lower position, or sensor 57 beneath table 19 is activated in the event that table 18 was previously in a higher position than the starting position. In the latter case, table 18 then moves down until it reaches the position at sensor 52 . Table 17 is then raised by means of motor 62 until either the position at sensor 51 is reached, in the event that the table was previously in a lower position, or sensor 56 beneath table 18 is activated, in the event that table 17 was previously in a higher position than the starting position. In the latter case, table 17 then moves down until reaching the position at sensor 51 .
When the control device 60 determines that detectors 56 , 57 or 58 detect an obstacle, during the upward movement of tables 17 , 18 or 19 respectively, before the relevant table has reached its starting position, then the control device 60 delivers a signal for removal of said obstacle from the associated table, for example if more than 500 sheets have been deposited thereon. Detector 58 is provided if the sheet deposition device has a cover plate 66 which prevents a free upward movement of the top table with (too) many sheets disposed thereon.
Before the start of a print cycle the table selected for deposition is brought into the deposition position.
Starting from the starting position shown in FIG. 4, this implies the following:
If deposition on the bottom table 16 is selected, motor 61 moves table 16 upwards until the top of said table is level with detector 59 disposed at a fixed short distance beneath the sheet transport rollers 13 . If there are sheets on table 16 the upward movement stops when the top sheet on the table 16 reaches detector 59 .
If deposition on table 17 is selected, this table moves down from the starting position until the top of table 17 or the top sheet thereon comes in the range of detector 59 . When the downward movement stops before detector 59 can respond, that means that the deposition table 16 with any sheets thereon forms an obstacle and the control device 60 delivers a signal to motor 61 to lower table 16 as well. If the latter is not possible because table 16 has reached sensor 50 , the control device 60 delivers a signal to the operator to remove sheets from table 16 , for making space for further lowering of table 51 to its deposition position.
If a (further) downward movement of table 17 is no longer possible, while table 16 has not yet reached its extreme bottom position, then the control device 60 delivers a signal to the operator to remove sheets or some other obstacle beneath table 16 .
If deposition on table 18 is selected, this table moves down until the top of the table or, if sheets are present thereon, the top of the stack of sheets thereon, comes in the range of detector 59 .
During this movement, table 18 may first encounter table 17 and activate detector 56 in so doing. As a result, motor 62 is activated and moves table 17 , together with table 18 , downwards. Table 17 can then also meet table 16 or a sheet stack 16 thereon, so that motor 61 is also activated in the manner explained hereinbefore in connection with the selection of deposition on table 17 . When table 16 has reached its starting position and if table 17 is then already past detector 59 before table 18 reaches its deposition position, the control device 60 delivers a signal to the operator to remove sheets from table 17 .
If deposition on table 19 is selected, this table moves down until the top of the table or, if sheets are present thereon, the top of a stack of sheets thereon, comes in the range of detector 59 .
This movement can be interrupted when detector 57 responds. Table 18 then also moves down. Detector 56 can then also respond so that table 17 also moves down. The same can then also occur at table 16 . If under these conditions table 16 cannot reach its extreme bottom position, control device 60 delivers a signal for removal of sheets beneath table 16 . If table 17 cannot then fall beneath detector 59 , a signal is delivered for removal of sheets from table 17 . Finally, if table 18 also cannot fall beneath detector 59 , a signal is delivered for the removal of sheets from table 18 .
Before any further deposition on one of the tables 17 , 18 and 19 , the control device 60 should, in the first instance, know where the associated table is situated, i.e. whether said table is situated beneath or above the deposition position. The reason for this is to enable the required direction of movement of the associated motor 62 , 63 or 64 to be set. The instantaneous position of these supports can be determined by measuring the direction of displacement and the distance of each support from its starting position and storing it as memory.
On a change of deposition from a higher-level table (e.g. table 18 ) to a lower-level table (e.g. table 17 ), the latter table should move upwards but in so doing meets the detector beneath the higher-level table, e.g. detector 56 . When the latter responds motor 63 also moves table 18 upwards and possibly motor 64 then also moves table 19 . If the top table in the latter case reaches its extreme top position at sensor 53 before table 17 has reached its deposition position, this means that there are too many sheets on table 17 and/or table 18 . In the event of too many sheets on table 18 , table 18 has not yet reached its starting position at sensor 52 and a signal is delivered to remove sheets from table 18 . If in that case the table 18 has passed sensor 52 , that is a signal that sheets must be removed from table 17 .
During the deposition of sheets on a table, said table moves down stepwise to keep the top of the sheets deposited thereon in range of the detector 59 . In these conditions a detector mounted beneath the associated table can respond so that the table therebeneath is also moved down stepwise. Deposition stops when there are too many sheets on the associated table. In the case of deposition on table 16 , this occurs when said table comes into its extreme bottom starting position at sensor 50 . Deposition on table 17 stops when table 16 has moved down to its bottom-most starting position or when table 16 is already in that position in response to the detector 55 . The stopping of deposition also applies in the case of deposition on table 18 or 19 .
In some situations it may be convenient to be able to start deposition on a table which is still empty, e.g. in order to prevent copies for deposition from being added to sheets still on that table.
One solution to this problem comprises detectors on each table reacting to sheets thereon.
In the deposition of printed sheets of print jobs, various types of print jobs are possible in which the deposition of the printed sheets is distributed separately over different deposition tables.
A distinction can be made between the following in the case of separate deposition:
1. Next job printing
Successive print jobs are, as far as possible, deposited on consecutive deposition tables in their natural sequence. A user at the printer thus clearly sees when the previous job has been completed and the next job starts. Removal of the previous job is also easier.
2. Walk-up priority-printing
Print jobs initiated at the printer, i.e. not from a workstation at a distance from the printer, are deposited on a separate deposition table, e.g. on the bottom deposition table, so that the user present at the machine can see where his print job is situated.
3. Interrupt printing
In these “interim” print jobs, the current print job is interrupted for an interim job. This interim job is deposited on a different deposition table than the interrupted job, preferably the next deposition table, in order to show clearly when the printing of the interim job starts and is finished and in order to facilitate removal of the interim prints. Another advantage is that the interrupted job is delivered with out separation.
4. Continuous printing
The printer runs continuously in printing and deposits sheets provided there is still deposition space, i.e. for as long as deposition tables are emptied in good time. Deposition can start at the bottom deposition table and then continue on the deposition tables thereabove (bottom-up algorithm). Deposited prints are removed during printing and thus printing can carry on continuously.
5. Capacity printing
In order to ensure that the deposition capacity is utilised to the maximum in the case of print jobs where the user is not present at the printer, deposition is first on the top deposition table and then continues with the deposition table therebeneath (top-down algorithm).
6. Sorter printing
Print jobs are delivered sorted in respect of an adjustable feature, e.g. orders from users of group A on the bottom deposition table, of group B on the table thereabove, and so on (user groups), or orders with stapled sets on one deposition table and orders with non-stapled sets on another deliver table (stack quality printing).
It will be apparent that on a change of deposition from one deposition table to another, activation of the detection means suspended beneath the deposition tables plays an important role. They determine whether such change-over is possible and enable the sheet deposition device to allow such a change-over even when printed sheets are removed from deposition tables which are not in use. Without the detection means according to the present invention, the sheet deposition device would assume that the number of sheets deposited on a deposition table will always remain thereon until all the sheets have been removed from said deposition table, and this is detectable in known manner by an empty-detector on a deposition table.
The invention being thus described, it will be obvious that the same may be varied in many ways such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
|
A sheet deposition device for the deposition of printed sheets on superimposed supports, where each support is provided with its own drive means for moving said support up and down between a deposition position, in which sheets can be deposited on that support, and a parking position, in which sheet deposition is not possible. Each support is also provided with detection means for detecting an obstacle in the space directly therebeneath, for example, sheets on a support directly therebeneath, said detection means delivering a first detection signal when the distance between the support provided with said detection means and an obstacle directly therebeneath is greater than a predetermined amount and said detection means delivering a second detection signal when said distance is equal to said predetermined amount. A control device in response to the reception of a first detection signal makes the drive means capable of activation for moving towards one another the supports between which are situated the detection means delivering the first detection signal and deactivates the drive means in response to the reception of a second detection signal.
| 1
|
FIELD OF THE INVENTION
This invention relates to a pattern selecting device of an electronic control sewing machine which is provided with an electronic memory device storing stitching pattern data for various stitching patterns, and which forms stitching patterns in accordance with the stitching pattern data.
BACKGROUND OF THE INVENTION
An electronic memorization element incorporated in a sewing machine is constructed on a considerably small scale, in spite of a large memorization capacity, in accordance with recent improvement of semi-conductor integration technology. Therefore, the electronic control sewing machine has been able to store more pattern data for the stitching patterns in comparison with conventional mechanical sewing machines. For selecting the patterns in the electronic control sewing machine, there are required indications of the patterns to be selected, and pattern selecting keys to be operated individually for the respective patterns. When these indications and keys increase in number, the outer appearance of the sewing manchine is unpaired, and errors can easily be made in the selection of the patterns.
For dealing with such problems, an Australian patent application No. 10,996/83 and U.S. patent application Ser. No. 462,935 now U.S. Pat. No. 4,580,513 assigned to the assignee, have been filed with respect to "Pattern Selecting Device for Electronic Sewing machines".
This prior device requires two panels, a first panel for indicating pattern shapes of a first pattern group and a second panel for indicating pattern shapes of second and third pattern groups. Each of the patterns of the second and third pattern groups is indirectly selected by inputting a number of two figures. The pattern selection of the first pattern group is carried out by direct and indirect ways in accordance with the switching conditions of a switch having three operating positions. Consequently, the operation is cumbersome.
SUMMARY OF THE INVENTION
This invention is to provide a pattern selecting device of an electronic control sewing machine which stores stitching pattern data in an incorporated memory device, wherein a plurality of separate indicating windows are arranged in columns or rows at a front part of the sewing machine, and indications of the patterns are made selectively visible in response to stitching pattern group of each of plural modes, in relation with operation of a mode switching member, and stitching patterns in response to the pattern indications in the column or the row are successively selected, and said patterns are specifically indicated by illumination.
Thus, it is an object of the invention to accumulate indicating parts of a pattern selecting device for various stitching patterns at one position in a front panel of the sewing machine.
It is another object of the invention to carry out selection of the stitching patterns by a direct operation of a pattern selecting key, thereby to settle troublesome problems in the pattern selection as seen in the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a pattern indicating board taken out from an operating part of an indicating part of a pattern selecting device;
FIG. 2 is a view seen in the direction of arrow A in FIG. 1;
FIG. 3 is a view showing LED atttached to a machine frame and an attaching plate thereof;
FIGS. 4, 5 and 6 are views showing cutaway parts of the pattern indication boards pertaining respectively to stitching patterns of 1st, 2nd and 3rd modes; and
FIGS. 7, 8 and 9 are views showing switching conditions corresponding to 1st mode, 2nd mode and 3rd mode.
DETAILED DESCRIPTION OF THE INVENTION
An explanation will be made in reference to the most preferred embodiment of the invention.
In FIG. 1, a front panel 1 of a sewing machine is made of a transparent material and is masked so as to provide an array of indicating windows 2. The windows 2 are arranged in columns and rows, and each of the windows is independent. Pattern selection keys 3 are positioned in correspondence to any one of the columns or rows (in the present embodiment, to the keys 3 are aligned with the columns).
A mode changing key 4 is movable between three positions with respect to a machine frame, and switches over a mode converting switch (not shown) into corresponding positions.
The mode key 4 is connected to a slide key board 5. The slide key board 5 is guided by guide parts 6 and 7, and has pins 8 implanted at upper and lower parts thereof. Rollers may be used instead of the pins 8.
An attaching plate 10 supports an array of light emitting diodes LED 9 and is positioned in a spaced relation to the slide key board 5. The plate 10 is formed with grooves 10a at the upper and lower parts, and the pins 8 of the slide key board 5 are guided therein.
The plate 10 with the plurality of LED 9 is located rearward of the front panel 1 and the light emitting diodes are positioned in pattern indicating windows 2. For indication of specific patterns, the light emitting diodes LED 9 are activated to show, respectively one specific pattern indication, as it will be explained below.
In FIGS. 4, 5 and 6, pattern indication boards 11, 12 and 13 are made of transparent material, and are printed, in this order, with stitching patterns of 1st, 2nd and 3rd stitching modes.
The stitching pattern groups in the 1st mode of the present embodiment includes practical stitching, ornamental stitching and buttonhole stitching patterns.
The stitching pattern group of the 2nd mode includes Japanese letters, and the stitching pattern group of the 3rd mode includes numeric and alphabetic characters.
Pattern indication boards 11,12 and 13 are superposed between the front panel 1 and the plate 10 (carrying the LEDs 9). One of the boards is selected by operating the mode changing by 4, and the patterns imprinted on the designated board is shown through respective windows 2 of the front panel 1. If the pattern selection board 11 is selected (FIG. 7), each of the patterns imprinted on the board comes between each windows 2 of the front panel 1 and the corresponding LED 9 of the plate 10. However, for the display of the three kinds of buttonhole patterns (B1)(B2)(B3), there are provided three light emitting diodes, namely an upper LED(9a), a center LED(9b) and a lower LED(9c).
When a buttonhole is stitched, light emitting diodes 9a to 9c are successively lighted by a computer program in response to progress of stitching of the buttonhole. For example, the center LED(9b) is lighted when a right side line tack is stitched, the lower LED(9c) is lighted when a lower bar-tack or the corresponding part is stitched, the center LED(9b) is again lighted when a left-side line-tack is stitched and the upper LED(9a) is lighted when an upper bar-tack or the corresponding part is stitched.
After selecting the buttonhole stitching pattern, the center LED 9b, for example, is lighted.
As shown in FIGS. 4-6, the pattern indication boards 11, 12 and 13 are provided with cam grooves 11a, 12a, and 13a formed at the upper and lowe corners thereof for receiving the upper and lower pins 8 of the slide key board 5 (FIGS. 7-9). The cam grooves 11a, 12a, 13a are designed such as to selectively shift the respective pattern indication boards 11, 12, 13 laterally of the front panel 1 and the LED 9 carrying plate 10 when the mode changing key 4 is operated.
An explanation will be made as to the working of the embodiment of the invention.
When the mode changing key 4 is switched to the 1st position I mode as shown in FIG. 7, the converting switch is switched to the 1st mode, while pins 8 engage upper portions of cam grooves 11a, 12a and 13a in the boards 11, 12 and 13, as shown by dashed lines. Under this condition, the pattern indication board 11 pertaining to the stitching pattern group of the 1st mode, appear in the indication window 2, and the indications on the pattern indication boards 12 and 13 are covered by the mask at the right side of the indication window 2 as seen in FIG. 7, and only the transparent parts without the patterns come into the indication windows.
When one of the pattern selection keys 3 is operated under the above condition, an initial LED is lighted in the corresponding column of windows 2 to identify the desired pattern through the corresponding initial window, and simultaneously the desired pattern stored in the computer is selected through a pattern selection circuit. If the same pattern selection key 3 is operated once again, the initial LED is switched off and then the second LED is lighted in the second window of the same column to illiminate another pattern. Thus each time the same pattern selection key 3 is operated, the LED is switched on and off from the right end to the left end of the column to illuminate different patterns one after another.
When the mode converting key 4 is switched to the 2nd mode as shown in FIG. 8, the mode changing switch is switched converting to the 2nd mode, while the pin 8 engages the center portion of the cam grooves 11a, 12a and 13a. Under this condition, the pattern indication board 12 is shifted in the left direction and the board 11 is shifted in the right direction while the board 13 remains in the rightward position. Thus each of the second mode patterns comes to each of the pattern indication windows 2 while the first mode patterns are positioned behind the masked part of the front panel 1 and are not indicated. Finally, when the mode changing key 4 is switched to the 3rd position III, the pattern indication board 13 is shifted in the left direction and the board 12 is shifted in the right direction. Then the third mode patterns are indicated through the respective pattern indication windows 2 of the front panel 1. In the second and third modes, any patterns may be optionally selected in each column by repeatedly operating the corresponding pattern selection key 3 just in the same manner as in the case of the first mode. Thus according to the invention, a number of pattern indication boards are accumulated in one place of the sewing machine and those pattern indication boards, each of which has many patterns imprinted thereon, may be selectively designated by operation of a single mode changing key, and all the patterns of the first, second and third modes may be optionally selected by operation of a reduced number of pattern selection keys. More over so many patterns to be selected, the reduced number of pattern selection keys and the single mode changing key to be operated are so compactly arranged in one limited place of the sewing machine and so closely arranged to each other. Therefore, so many patterns may be very easily selected without committing errors and having a sense of difficulty which may otherwise generally happen with the users in dealing with the sewing machine.
|
This invention provides a pattern selecting device of an electronic control sewing machine which stores stitching pattern data in a memory device. A plurality of indicating windows are arranged in columns and rows at a front part of the sewing machine. The indications of the patterns are made selectively visible according to a stitching pattern group of each of plural modes, in response to the operation of a mode switching member, and stitching patterns in response to the pattern indications in the column or the row are successively selected, and the selected patterns are specifically indicated by illumination.
| 3
|
CROSS REFERENCE TO RELATED APPLICATIONS
This Application is a continuation of U.S. application Ser. No. 14/718,806 filed on May 21, 2015, which is a divisional of U.S. application Ser. No. 14/517,361 filed on Oct. 17, 2014, which claims the benefit of U.S. Provisional Patent Application Ser. No. 62/049,537, filed Sep. 12, 2014, the entire disclosures of which are hereby expressly incorporated by reference into this Application.
TECHNICAL FIELD
This disclosure relates to the field of preparation of 3-(3-chloro-1H-pyrazol-1-yl)pyridine and intermediates therefrom. These intermediates are useful in the preparation of certain pesticides.
BACKGROUND
US 20130288893(A1) describes certain (3-halo-1-(pyridin-3-yl)-1H-pyrazol-4-yl)amides and carbamates and their use as pesticides. The processes therein to prepare these amides and carbamates result in low yields, rely on a starting material that is difficult to prepare (3-chloropyrazole), and provide a product that is difficult to isolate in a pure form. It would be desirable to have a process for preparing 3-(3-chloro-1H-pyrazol-1-yl)pyridine that avoids these problems.
DETAILED DESCRIPTION
The following definitions apply to the terms as used throughout this specification, unless otherwise limited in specific instances.
As used herein, the term “alkyl” denotes branched or unbranched hydrocarbon chains.
As used herein, the term “alkoxide” means an alkyl further consisting of a carbon-oxygen single bond, for example, methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, and tert-butoxy.
The present disclosure provides an alternative process for preparing 3-(3-chloro-1H-pyrazol-1-yl)pyridine (5b) by cyclizing 3-hydrazinopyridine•dihydrochloride with an alkyl methacrylate to provide 4-methyl-1-(pyridin-3-yl)pyrazolidin-3-one (1), by chlorinating (1) to provide 3-(3-chloro-4-methyl-4,5-dihydro-1H-pyrazol-1-yl)pyridine (2), by oxidizing (2) to provide 3-(3-chloro-4-methyl-1H-pyrazol-1-yl)pyridine (3), by further oxidizing (3) to provide 3-chloro-1-(pyridin-3-yl)-1H-pyrazole-4-carboxylic acid (4), and by decarboxylating (4) to provide 3-(3-chloro-1H-pyrazol-1-yl)pyridine (5b).
Thus, the present disclosure concerns a process for preparing 3-(3-chloro-1H-pyrazol-1-yl)pyridine (5b)
which comprises
a) cyclizing 3-hydrazinopyridine•dihydrochloride
with alkyl methacrylate,
wherein R represents (C 1 -C 4 ) alkyl,
in a (C 1 -C 4 ) alkyl alcohol at a temperature of about 25° C. to about 80° C. in the presence of an alkali metal (C 1 -C 4 ) alkoxide to provide 4-methyl-1-(pyridin-3-yl)pyrazolidin-3-one (1)
b) chlorinating 4-methyl-1-(pyridin-3-yl)pyrazolidin-3-one (1) with a chlorinating reagent in an organic solvent at a temperature of about 25° C. to about 100° C. to provide 3-(3-chloro-4-methyl-4,5-dihydro-1H-pyrazol-1- yl)pyridine (2)
c) oxidizing 3-(3-chloro-4-methyl-4,5-dihydro-1H-pyrazol-1-yl)pyridine (2) with an oxidant in a solvent at a temperature of about 25° C. to about 100° C. to provide 3-(3-chloro-4-methyl-1H-pyrazol-1-yl)pyridine (3)
d) further oxidizing 3-(3-chloro-4-methyl-1H-pyrazol-1-yl)pyridine (3) with an oxidant in a polar protic solvent at a temperature of about 50° C. to about 100° C. to provide 3-chloro-1-(pyridin-3-yl)-1H-pyrazole-4-carboxylic acid (4)
and
e) decarboxylating 3-chloro-1-(pyridin-3-yl)-1H-pyrazole-4-carboxylic acid (4) with copper oxide in a polar aprotic solvent at a temperature of about 80° C. to about 180° C. to provide 3-(3-chloro-1H-pyrazol-1-yl)pyridine (5b).
Scheme 1 outlines this process for preparing 3-(3-chloro-1H-pyrazol-1-yl)pyridine (5b).
In step 1a, 3-hydrazinopyridine•dihydrochloride is cyclized with a (C 1 -C 4 ) alkyl methacrylate, in a solution further comprising a (C 1 -C 4 ) alkyl alcohol and an alkali metal (C 1 -C 4 ) alkoxide, to provide 4-methyl-1-(pyridin-3-yl)pyrazolidin-3-one (1). Step a is conducted at a temperature from about 25° C. to about 80° C. While stoichiometric amounts of 3-hydrazinopyridine•dihydrochloride and (C 1 -C 4 ) alkyl methacrylate may be used, it is often convenient to use about a 1.5 fold to about a 2 fold excess of (C 1 -C 4 ) alkyl methacrylate compared to 3-hydrazinopyridine•dihydrochloride. The (C 1 -C 4 ) alkyl alcohol is preferably selected from methanol, ethanol, propanol, butanol, and mixtures thereof. The alkali metal (C 1 -C 4 ) alkoxide is preferably selected from sodium methoxide, sodium ethoxide, and mixtures thereof. It is often convenient to use about a 2 fold to about a 3 fold excess of alkali metal (C 1 -C 4 ) alkoxide compared to 3-hydrazinopyridine•dihydrochloride. Furthermore, it is most preferred if sodium ethoxide and ethanol is used.
In another embodiment, 3-hydrazinopyridine•dihydrochloride is cyclized with methyl methacrylate in the presence of sodium ethoxide and ethanol and this mixture is heated at about 50° C. The crude 4-methyl-1-(pyridin-3-yl)pyrazolidin-3-one (1) is used as is without further purification or isolation.
In step 1b, 4-methyl-1-(pyridin-3-yl)pyrazolidin-3-one (1) is chlorinated with a chlorinating reagent in an organic solvent at a temperature from about 25° C. to about 100° C. to provide 3-(3-chloro-4-methyl-4,5-dihydro-1H-pyrazol-1-yl)pyridine (2). Suitable chlorinating reagents include phosphoryl chloride (phosphorous oxychloride), phosphorus pentachloride, and mixtures thereof. Phosphoryl chloride is currently preferred. It is often convenient to use about a 1.1 fold to about a 10 fold excess of the chlorinating reagent compared to 4-methyl-1-(pyridin-3-yl)pyrazolidin-3-one (1). The chlorination is performed in an organic solvent that does not substantially react with the chlorinating reagent. Suitable solvents include nitriles such as acetonitrile. It is currently preferred to use phosphoryl chloride as the chlorinating reagent and acetonitrile as the solvent.
In another embodiment, 4-methyl-1-(pyridin-3-yl)pyrazolidin-3-one (1) in acetonitrile is chlorinated with phosphoryl chloride and the mixture is heated to about 75° C. The 3-(3-chloro-4-methyl-4,5-dihydro-1H-pyrazol-1-yl)pyridine (2) can be isolated and purified by standard techniques.
In step 1c, 3-(3-chloro-4-methyl-4,5-dihydro-1H-pyrazol-1-yl)pyridine (2) is oxidized with an oxidant in an organic solvent at a temperature of about 25° C. to about 100° C. to provide 3-(3-chloro-4-methyl-1H-pyrazol-1-yl)pyridine (3). Suitable oxidants include copper (I) chloride in the presence of oxygen, potassium ferricyanide, and manganese (IV) oxide. It is often convenient to use about a 1.5 fold to about a 15 fold excess of oxidant compared to 3-(3-chloro-4-methyl-4,5-dihydro-1H-pyrazol-1-yl)pyridine (2). The oxidation is performed in a solvent that does not substantially react with the oxidant. Suitable solvents include water, N,N-dimethylformamide, N-methylpyrrolidinone, dichloromethane, tert-butanol, nitriles such as acetonitrile, aromatic hydrocarbons such as toluene, and mixtures thereof. It is currently preferred to use copper (I) chloride in the presence of oxygen as the oxidant, with N,N-dimethylformamide, N-methylpyrolidinone, and mixtures thereof as the solvent. It is also preferred to use potassium-ferricyanide as the oxidant, with water as the solvent. It is also preferred to use manganese (IV) oxide as the oxidant, with dichloromethane, tert-butanol, acetonitrile, toluene, and mixtures thereof as the solvent. It is also preferred to use manganese (IV) oxide as the oxidant, with acetonitrile as the solvent.
In another embodiment, 3-(3-chloro-4-methyl-4,5-dihydro-1H-pyrazol-1-yl)pyridine (2) in acetonitrile is oxidized with manganese (IV) oxide and the mixture is heated at about 40° C. The 3-(3-chloro-4-methyl-1H-pyrazol-1-yl)pyridine (3) can be isolated and purified by standard techniques.
In step 1d 3-(3-chloro-4-methyl-1H-pyrazol-1-yl)pyridine (3) is further oxidized with an oxidant in a protic solvent at a temperature of about 50° C. to about 100° C. to provide 3-chloro-1-(pyridin-3-yl)-1H-pyrazole-4-carboxylic acid (4). Suitable oxidants include potassium permanganate and sodium permanganate. It is often convenient to use about a 2.5 fold to about a 4.5 fold, preferably about a 3.0 fold excess of oxidant compared to 3-(3-chloro-4-methyl-1H-pyrazol-1-yl)pyridine (3). The oxidation is performed in a protic solvent that does not substantially react with the oxidant. Suitable solvents include water, tert-butanol, tert-amyl alcohol, and mixtures thereof.
In another embodiment, 3-(3-chloro-4-methyl-1H-pyrazol-1-yl)pyridine (3) is further oxidized by sodium permanganate in water and tert-butanol and heated at about 80° C. The 3-chloro-1-(pyridin-3-yl)-1H-pyrazole-4-carboxylic acid (4) can be isolated and purified by standard techniques.
In step 1e, 3-chloro-1-(pyridin-3-yl)-1H-pyrazole-4-carboxylic acid (4) is decarboxylated in the presence of copper oxide which may optionally be ligated with a bidentate ligand such as tetramethyl ethylenediamine in a polar aprotic solvent at a temperature from about 80° C. to about 180° C. to provide 3-(3-chloro-1H-pyrazol-1-yl)pyridine (5b). Suitable copper oxide sources include copper (I) oxide and copper (II) oxide as well as mixtures thereof. It is convenient to use about 5 wt % to about 20 wt % of copper oxide based on 3-chloro-1-(pyridin-3-yl)-1H-pyrazole-4-carboxylic acid (4). Suitable solvents include N,N-dimethylformamide, N,N-dimethylacetamide, N-methylpyrrolidinone, and mixtures thereof.
In another embodiment, 3-chloro-1-(pyridin-3-yl)-1H-pyrazole-4-carboxylic acid (4) and copper (I) oxide are mixed with N,N-dimethylacetamide and heated to about 125° C. The 3-(3-chloro-1H-pyrazol-1-yl)pyridine (5b) can be isolated and purified by standard techniques.
An illustrative example of how 3-(3-chloro-1H-pyrazol-1-yl)pyridine (5b) may be used for preparing certain pesticidal (3-halo-1-(pyridin-3-yl)-1H-pyrazol-4-yl)amides is outlined in Scheme 2.
In step 2a, 3-(3-chloro-1H-pyrazol-1-yl)pyridine (5b) is nitrated with nitric acid (HNO 3 ), preferably in the presence of sulfuric acid (H 2 SO 4 ) to yield 3-(3-chloro-4-nitro-1H-pyrazol-1-yl)pyridine (2-6). The nitration may be conducted at temperatures from about −10° C. to about 30° C.
In step 2b, 3-(3-chloro-4-nitro-1H-pyrazol-1-yl)pyridine (2-6) is reduced to yield 3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4- amine (2-7). For example, 3-(3-chloro-4-nitro-1H-pyrazol-1-yl)pyridine (2-6) may be reduced with iron in acetic acid (AcOH). 3-(3-Chloro-4-nitro-1H-pyrazol-1-yl)pyridine (2-6) may also be reduced with iron and ammonium chloride (NH 4 Cl). Alternatively, this reduction may be carried out using other techniques in the art, for example, 3-(3-chloro-4-nitro-1H-pyrazol-1-yl)pyridine (2-6) may be reduced using palladium on carbon in the presence of hydrogen (H 2 ). This reaction may be conducted at temperatures from about −10° C. to about 30° C.
In step 2c, 3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-amine (2-7) is acylated with acetylating agents such as acetyl chloride or acetic anhydride, preferably acetic anhydride (Ac 2 O) to yield N-(3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl)acetamide (2-8). The acylation is conducted in the presence of a base, preferably an inorganic base, such as, sodium bicarbonate (NaHCO 3 ), and preferably, a polar solvent, such as ethyl acetate and/or tetrahydrofuran. This reaction may be conducted at temperatures from about −10° C. to about 30° C.
In step 2d, N-(3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl)acetamide (2-8) is alkylated with ethyl bromide (EtBr) in the presence of a base, such as sodium hydride (NaH) or sodium tert-butoxide (NaOt-Bu), in a polar aprotic solvent, such as tetrahydrofuran, at temperatures from about 20° C. to about 40° C., over a period of time of about 60 hours to about 168 hours, to yield N-(3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl)-N-ethylacetamide (2-9). It has been discovered that use of an iodide additive, such as potassium iodide (KI) or tetrabutylammonium iodide (TBAI) can decrease the time necessary for the reaction to occur to about 24 hours. It has also been discovered that heating the reaction at about 50° C. to about 70° C. in a sealed reactor (to prevent loss of ethyl bromide) also decreases the reaction time to about 24 hours.
In step 2e, N-(3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-ye-N-ethylacetamide (2-9) is treated with hydrochloric acid in water at temperatures from about 50° C. to about 90° C., to yield 3-chloro-N-ethyl-1-(pyridin-3-yl)-1H-pyrazol-amine (2-10). Steps d and e of Scheme 2 may also be performed without the isolation of N-(3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl-N-ethylacetamide (2-8).
In step 2f, 3-chloro-N-ethyl-1-(pyridin-3-yl)-1H-pyrazol-amine (2-10) is acylated with 3-((3,3,3-trifluoropropyl)thio)propanoyl chloride in the presence of a base preferably, sodium bicarbonate to yield pesticidal (3-halo-1-(pyridin-3-yl)-1H-pyrazol-4-yl)amide (2-11). The reaction may also be conducted in the absence of a base to yield pesticidal (3-halo-1-(pyridin-3-yl)-1H-pyrazol-4-yl)amide (2-11).
In step 2g, pesticidal (3-halo-1-(pyridin-3-yl)-1H-pyrazol-4-yl)amide (2-11) is oxidized with hydrogen peroxide (H 2 O 2 ) in methanol to yield pesticidal (3-halo-1-(pyridin-3-yl)-1H-pyrazol-4-yl)amide (2-12).
EXAMPLES
These examples are for illustration purposes and are not to be construed as limiting the disclosure to only the embodiments disclosed in these examples.
Starting materials, reagents, and solvents that were obtained from commercial sources were used without further purification. Anhydrous solvents were purchased as Sure/Seal™ from Aldrich and were used as received. Melting points were obtained on a Thomas Hoover Unimelt capillary melting point apparatus or an OptiMelt Automated Melting Point System from Stanford Research Systems and are uncorrected. Examples using “room temperature” were conducted in climate controlled laboratories with temperatures ranging from about 20° C. to about 24° C. Molecules are given their known names, named according to naming programs within ISIS Draw, ChemDraw or ACD Name Pro. If such programs are unable to name a molecule, the molecule is named using conventional naming rules. 1 H NMR spectral data are in ppm (δ) and were recorded at 300, 400 or 600 MHz; 13 C NMR spectral data are in ppm (δ) and were recorded at 75, 100 or 150 MHz, and 19 F NMR spectral data are in ppm (δ) and were recorded at 376 MHz, unless otherwise stated.
1. Preparation of 4-methyl-1-(pyridin-3-yl)pyrazolidin-3-one (1)
To a 250 mL three-neck round bottom flask equipped with a reflux condenser was introduced 3-hydrazinopyridine•dihydrochloride (15.0 g, 82.4 mmol). Sodium ethoxide (21 wt % in ethanol, 92.3 mL, 247 mmol) was added over 5 minutes and the pot temperature increased from 23° C. to 38° C. The resultant light brown-slurry was stirred for 10 minutes. Methyl methacrylate (17.7 mL, 165 mmol) was added slowly over 15 minutes and the pot temperature remained at 38° C. The yellow mixture was stirred at 50° C. under nitrogen for 4 hours. The mixture was then cooled down to 10° C. and hydrochloric acid (4 M in 1,4-dioxane, 20.6 mL) was added slowly to quench excess base leading to a light brown suspension. The mixture was concentrated under reduced pressure to afford the title compound as a brown solid as a mixture with sodium chloride (35.2 g, 241%): EIMS m/z 177 ([M] + ). The crude material was used directly in the next step.
2. Preparation of 3-(3-chloro-4-methyl-4,5-dihydro-1H-pyrazol-1-yl)pyridine (2)
Crude 4-methyl-1-(pyridin-3-yl)pyrazolidin-3-one (35.2 g, ˜82.4 mmol) was introduced into a 250 mL three-neck round bottom flask equipped with a reflux condenser. Acetonitrile (100 mL) was then added. To this yellow mixture was added phosphoryl chloride (11.56 mL, 124 mmol) slowly. The yellow slurry was stirred at 75° C. for 1 hour. The mixture was cooled down and concentrated to remove volatiles. The brown residue was carefully quenched with water (120 mL), and basified with NaOH (50 wt % in water) to pH 10 while keeping the temperature below 60° C. The mixture was then extracted with ethyl acetate (3×150 mL). The combined organic extracts were washed with water (80 mL) and concentrated under reduced pressure to afford the crude product as dark purple oil. The crude product was purified by flash column chromatography using 0-70% ethyl acetate/hexanes as eluent to provide the title compound as a brown oil (12.3 g, 76% over two steps): 1 H NMR (400 MHz, CDCl 3 ) δ 8.27 (dd, J=2.8, 0.7 Hz, 1H), 8.15 (dd, J=4.6, 1.4 Hz, 1H), 7.38 (ddd, J=8.4, 2.9, 1.4 Hz, 1H), 7.18 (ddd, J=8.4, 4.7, 0.7 Hz, 1H), 4.17-4.06 (m, 1H), 3.47 (t, J=8.9 Hz, 1H), 3.44-3.34 (m, 1H), 1.37 (d, J=6.8 Hz, 3H); 13 C NMR (101 MHz, CDCl 3 ) δ 148.17, 142.07, 141.10, 134.74, 123.39, 119.92, 56.62, 43.62, 16.16; EIMS m/z 195 ([M] + ).
3. Preparation of 3-(3-chloro-4-methyl-1H-pyrazol-1-yl)pyridine (3)
To a solution of 3-(3-chloro-4-methyl-4,5-dihydro-1H-pyrazol-1-yl)pyridine (1.0 g, 5.0 mol) in acetonitrile (10.0 mL) at 0° C. was added manganese(IV) oxide (1.3 g, 15 mmol) portionwise over 10 minutes. The mixture was slowly warmed to 22° C. over 40 minutes and then heated to 40° C. overnight. After 20 hours, additional manganese (IV) oxide (0.44 g, 5.0 mmol) was added in one portion and the mixture was stirred for 1 hour. The mixture was cooled down and filtered. The filter cake was washed with acetonitrile (3×15 mL). The organic filtrate was dried and concentrated to afford the title compound as a light yellow solid (0.92 g, 95%): 1 H NMR (400 MHz, CDCl 3 ) δ 8.90 (dd, J=2.6, 0.8 Hz, 1H), 8.52 (dd, J=4.8, 1.5 Hz, 1H), 7.99 (ddd, J=8.3, 2.7, 1.4 Hz, 1H), 7.74 (q, J=0.9 Hz, 1H), 7.39 (ddd, J=8.3, 4.8, 0.8 Hz, 1H), 2.13 (d, J=0.9 Hz, 3H); 13 C NMR (101 MHz, CDCl 3 ) δ 147.26, 142.87, 139.53, 135.90, 126.53, 125.69, 123.84, 116.86, 22.47; EIMS m/z 193 ([M] + ).
4. Preparation of 3-chloro-1-(pyridin-3-yl)-1H-pyrazole-4-carboxylic acid (4)
To a mixture of 3-(3-chloro-4-methyl-4,5-dihydro-1H-pyrazol-1-yl)pyridine (2.0 g, 10 mmol) in water (10.0 mL) and tert-butanol (5.0 mL) was added a solution of sodium permanganate (NaMnO4) (5.0 g, 35 mmol) in water (15 mL) over 20 minutes. The mixture was heated to 80° C. and stirred overnight. Additional sodium permanganate (0.711 g, 5.0 mmol) in water (2.0 mL) was added after 16 hours and the mixture was stirred for another 4 hours. The dark mixture was filtered through Celite®, washed with water (5.0 mL) and ethyl acetate (3×15 mL). The aqueous layer was extracted with ethyl acetate (25 mL) and acidified with concentrated hydrochloric acid to pH 5 leading to white precipitate which was collected by filtration. The filtrate was concentrated leading to white precipitate which was collected by filtration and washed with water (2.0 mL). The solid products were combined and dried under high vacuum to afford the title compound as a white solid (1.0 g, 46%): 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.11 (s, 2H), 8.59 (d, J=4.7, 1H), 8.28 (ddd, J=8.4, 2.7, 1.4 Hz, 1H), 7.58 (dd, J=8.0, 4.4 Hz, 1H); 13 C NMR (101 MHz, DMSO-d 6 ) δ 162.24, 148.35, 141.46, 140.21, 135.01, 134.01, 126.45, 124.23, 115.34; ESIMS m/z 224 ([M+H] + ).
5. Preparation of 3-(3-chloro-1H-pyrazol-1-yl)pyridine (5b)
To a mixture of 3-chloro-1-(pyridin-3-yl)-1H-pyrazole-4-carboxylic acid (0.223 g, 1.0 mmol) in N,N-dimethylacetamide (3.0 mL) was added copper (I) oxide (0.022 g, 10 wt %). The mixture was heated to 125° C. and stirred for 6 hours. The brown mixture was filtered and washed with N,N-dimethylacetamide (1.0 mL) and acetonitrile (2×2 mL). The light yellow filtrate was analyzed by LC using di-n-propyl phthalate as internal standard (0.124 g, 69% in-pot yield); mp 66-68° C.; 1 H NMR (400 MHz, CDCl 3 ) δ 8.93 (d, J=27 Hz, 1H), 8.57 (dd, J=4.8, 1.4 Hz, 1H), 8.02 (ddd, J=8.3, 2.7, 1.5 Hz, 1H), 7.91 (d, J=2.6 Hz, 1H), 7.47-7.34 (m, 1H), 6.45 (d, J=2.6 Hz, 1H); 13 C NMR (101 MHz, CDCl 3 ) δ 148.01, 142.72, 140.12, 135.99, 128.64, 126.41, 124.01, 108.0; ESIMS m/z 180 ([M+] + ).
6. Preparation of 3-(3-chloro-4-nitro-1H-pyrazol-1-yl)pyridine (2-6)
To a 100 mL, round bottom flask was charged 3-(3-chloro-1H-pyrazol-1-yl)pyridine (2.00 g, 11.1 mmol) and concentrated sulfuric acid (4 mL). This suspension was cooled to 5° C. and 2:1 concentrated nitric acid/sulfuric acid (3 mL, prepared by adding the concentrated sulfuric acid to a stirring and cooling solution of the nitric acid) was added dropwise at a rate such that the internal temperature was maintained <15° C. The reaction was allowed to warm to 20° C. and stirred for 18 hours. A sample of the reaction mixture was carefully diluted into water, basified with sodium hydroxide (50 wt % in water) and extracted with ethyl acetate. Analysis of the organic layer indicated that the reaction was essentially complete. The reaction mixture was carefully added to ice cold water (100 mL) at <20° C. It was basified with sodium hydroxide (50 wt % in water) at <20° C. The resulting light yellow suspension was stirred for 2 hours and filtered. The filter cake was rinsed with water (3×20 mL) and dried to afford an off-white solid (2.5 g, quantitative): mp 141-143° C.; 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.86 (s, 1H), 9.23-9.06 (m, 1H), 8.75-8.60 (m, 1H), 8.33 (ddd, J=8.4, 2.8, 1.4 Hz, 1H), 7.64 (ddd, J=8.5, 4.7, 0.7 Hz, 1H); 13 C NMR (101 MHz, DMSO-d 6 ) δ 149.49, 140.75, 136.02, 134.43, 132.14, 131.76, 127.22, 124.31; EIMS m/z 224 ([M] + ).
7. Preparation of 3-(3-chloro-4-amino-1H-pyrazol-1-yl)pyridine (2-7)
To a 100 mL, 3-neck round bottom flask was charged 3-(3-chloro-4-nitro-1H-pyrazol-1-yl)pyridine (2.40 g, 10.7 mmol), acetic acid (4 mL), ethanol (4.8 mL) and water (4.8 mL). The mixture was cooled to 5° C. and iron powder (2.98 g, 53.4 mmol) was added portionwise over ˜15 minutes. The reaction was allowed to stir at 20° C. for 18 hours and diluted to 50 mL with water. It was filtered through Celite® and the filtrate was carefully basified with a sodium hydroxide solution (50 wt % in water). The resulting suspension was filtered through Celite® and the filtrate was extracted with ethyl acetate (3×20 mL). The organic layers were combined, dried over sodium sulfate and concentrated to dryness to afford a tan colored solid, which was further dried under vacuum for 18 hours (2.20 g, quantitative): mp 145-147° C.; 1 H NMR (400 MHz, DMSO-d 6 ) δ 8.95 (dd, J=2.6, 0.8 Hz, 1H), 8.45 (dd, J=4.7, 1.4 Hz, 1H), 8.08 (ddd, J=8.4, 2.7, 1.4 Hz, 1H), 7.91 (s, 1H), 7.49 (ddd, J=8.3, 4.7, 0.8 Hz, 1H), 4.43 (s, 2H); 13 C NMR (101 MHz, DMSO-d 6 ) δ 146.35, 138.53, 135.72, 132.09, 130.09, 124.29, 124.11, 114.09; EIMS m/z 194 ([M] + ).
Alternate synthetic route to 3-(3-chloro-4-amino-1H-pyrazol-1-yl)pyridine (2-7): In a 250 mL 3-neck round bottom flask was added 3-(3-chloro-4-nitro-1H-pyrazol-1-yl)pyridine (5.00 g, 21.8 mmol), ethanol (80 mL), water (40 mL), and ammonium chloride (5.84 g, 109 mmol). The suspension was stirred under nitrogen stream for 5 minutes then iron powder (4.87 g, 87.2 mmol) was added. The reaction mixture was heated to reflux (˜80° C.) and held there for 4 hours. After 4 hours a reaction aliquot taken and the reaction had gone to full conversion as shown by HPLC analysis. Ethyl acetate (120 mL) and Celite® (10 g) were added to the reaction mixture and the mixture was let stir for 10 minutes. The black colored suspension was then filtered via a Celite® pad and rinsed with ethyl acetate (80 mL) The filtrate was washed with saturated sodium bicarbonate solution in water (30 mL) and the organic layer was assayed. The assay gave 4.19 g (99% yield) of product. The organic solvent was removed in vacuo to give a brown colored crude solid that was used without further purification.
8. N-(3-Chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl)acetamide (2-8)
A 100 mL three-neck round bottom flask was charged with 3-chloro-1(pyridin-3-yl)-1H-pyrazol-4-amine (1.00 g, 5.14 mmol) and ethyl acetate (10 mL). Sodium bicarbonate (1.08 g, 12.9 mmol) was added, followed by dropwise addition of acetic anhydride (0.629 g, 6.17 mmol) at <20° C. The reaction was stirred at 20° C. for 2 hours to afford a suspension, at which point thin layer chromatography analysis [Eluent: ethyl acetate] indicated that the reaction was complete. The reaction was diluted with water (50 mL) and the resulting suspension was filtered. The solid was rinsed with water (10 mL) followed by methanol (5 mL). The solid was further dried under vacuum at 20° C. to afford the desired product as a white solid (0.804 g, 66%): mp 169-172° C.; 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.84 (s, 1H), 9.05 (dd, J=2.8, 0.8 Hz, 1H), 8.82 (s, 1H), 8.54 (dd, J=4.7, 1.4 Hz, 1H), 8.20 (ddd, J=8.4, 2.8, 1.4 Hz, 1H), 7.54, (ddd, J=8.3, 4.7, 0.8 Hz, 1H), 2.11 (s, 3H); 13 C NMR (101 MHz, DMSO-d 6 ) δ 168.12, 147.46, 139.42, 135.46, 133.60, 125.47, 124.21, 122.21, 120,16, 22.62; EIMS m/z 236 ([M] + ).
9. Preparation of N-(3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl)-N-ethylacetamide (2-9)
In 125 mL 3-neck round-bottomed flask was added N-(3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl)acetamide (2.57 g, 9.44 mmol), tetrahydrofuran (55 mL), and sodium tert-butoxide (1.81 g, 18.9 mmol). The suspension was stirred for 5 minutes then ethyl bromide (1.41 mL, 18.9 mmol), and tetrabutylammonium iodide (67 mg, 0.2 mmol) were added. The resulting gray colored suspension was then heated to 38° C. The reaction was analyzed after 3 hours and found to have gone to 81% completion, after 24 hours the reaction was found to have gone to completion. The reaction mixture was allowed to cool to ambient temperature and quenched with ammonium hydroxide/formic acid (HCO 2 H) buffer (10 mL). The mixture was then diluted with tetrahydrofuran (40 mL), ethyl acetate (120 mL), and saturated sodium bicarbonate solution in water (30 mL). The layers were separated and the aqueous layer was extracted with ethyl acetate (2×30 mL). The organic layers were combined and silica gel (37 g) was added. The solvent was removed in vacuo to give a solid that was purified using semi-automated silica gel chromatography (RediSep Silica 220 g column; Hexanes (0.2% triethylamine)/ethyl acetate, 40/60 to 0/100 gradient elution system, flow rate 150 mL/minute) to give, after concentration, an orange solid (2.19 g, 88%).
10. Preparation of 3-chloro-N-ethyl-1-(pyridin-3-yl)-1H-pyrazol-4-amine (2-10)
A solution of N-(3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl)-N-ethylacetamide (1.8 g, 6.80 mmol) in 1 N hydrochloric acid (34 mL) was heated at 80° C. for 18 hours, at which point HPLC analysis indicated that only 1.1% starting material remained. The reaction mixture was cooled to 20° C. and basified with sodium hydroxide (50 wt % in water) to pH>9. The resulting suspension was stirred at 20° C. for 2 hours and filtered. The filter cake was rinsed with water (2×5 mL), conditioned for 30 minutes, and air-dried to afford an off-white solid (1.48 g, 95%): 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.00 (dd, J=2.8, 0.8 Hz, 1H), 8.45 (dd, J=4.7, 1.4 Hz, 1H), 8.11 (ddd, J=8.4, 2.8, 1.4 Hz, 1H), 8.06 (d, J=0.6 Hz, 1H), 7.49 (ddd, J=8.4, 4.7, 0.8 Hz, 1H), 4.63 (t, J=6.0 Hz, 1H), 3.00 (qd, J=7.1, 5.8 Hz, 2H), 1.19 (t, J=7.1 Hz, 3H); 13 C NMR (101 MHz, DMSO-d 6 ) δ 146.18, 138.31, 135.78, 132.82, 130.84, 124.08, 123.97, 112.23, 40.51, 14.28; ESIMS m/z 223 ([M+H] + ).
Alternate synthetic route to 3-chloro-N-ethyl-1-(pyridin-3-yl)-1H-pyrazol-amine (2-10):
To a 3-neck, 100-mL round bottom flask was charged N-(3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl)acetamide (5 g, 21.13 mmol) and tetrahydrofuran (50 mL). Sodium tert-butoxide (4.06 g, 42.3 mmol) was added (causing a temperature rise from 22° C. to 27.6° C.), followed by ethyl bromide (6.26 mL, 85 mmol). The reaction was stirred at 35° C. for 144 h at which point only 3.2% (AUC) starting material remained. The reaction mixture was concentrated to give a brown residue, which was dissolved in 1 N hydrochloric acid (106 mL, 106 mmol) and heated at 80° C. for 24 hours, at which point HPLC analysis indicated that the starting material had been consumed. The reaction was cooled to 20° C. and basified with sodium hydroxide (50 wt % in water) to pH>9. The resulting suspension was stirred at 20° C. for 1 hour and filtered. The filter cake was rinsed with water (25 mL) to afford a brown solid (5.18 g). The resulting crude product was dissolved in ethyl acetate and passed through a silica gel plug (50 g) using ethyl acetate (500 mL) as eluent. The filtrate was concentrated to dryness to afford a white solid (3.8 g, 80%).
11. Preparation of N-(3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl)-N-ethyl-3-((3,3,3-trifluoropropyl)thio)propanamide (2-11)
A 100 mL three neck round bottom flask was charged with 3-chloro-N-ethyl-1-(pyridine-3-yl)-1H-pyrazol-4-amine (5.00 g, 22.5 mmol) and ethyl acetate (50 mL). Sodium bicarbonate (4.72 g, 56.1 mmol) was added, followed by dropwise addition of 3-((3,3,3-trifluoropropyl)thio)propanoyl chloride (5.95 g, 26.9 mmol) at <20° C. for 2 hours, at which point HPLC analysis indicated that the reaction was complete. The reaction was diluted with water (50 mL) (off-gassing) and the layers were separated. The aqueous layer was extracted with ethyl acetate (20 mL) and the combined organic layers were concentrated to dryness to afford a light brown solid (10.1 g, quantitative). A small sample of crude product was purified by flash column chromatography using ethyl acetate as eluent to obtain an analytical sample: mp 79-81° C.; 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.11 (d, J=2.7 Hz, 1H), 8.97 (s, 1H), 8.60 (dd, J=4.8, 1.4 Hz, 1H), 8.24 (ddd, J=8.4, 2.8, 1.4 Hz, 1H), 7.60 (ddd, J=8.4, 4.7, 0.8 Hz, 1H), 3.62 (q, J=7.2 Hz, 2H), 2.75 (t, J=7.0 Hz, 2H), 2.66-2.57 (m 2H), 2.57-2.44 (m, 2H), 2.41 (t, J=7.0 Hz, 2H), 1.08 (t, J=7.1 Hz, 3H). EIMS m/z 406 ([M] + ).
12. Preparation of N-(3-chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl)-N-ethyl-3-((3,3,3-trifluoropropyl)sulfoxo)propanamide (2-12)
N-(3-Chloro-1-(pyridin-3-yl)-1H-pyrazol-4-yl)-N-ethyl-3-((3,3,3-trifluoropropyl)thio) propanamide (57.4 g, 141 mmol) was stirred in methanol (180 mL). To the resulting solution was added hydrogen peroxide (43.2 mL, 423 mmol) dropwise using a syringe. The solution was stirred at room temperature for 6 hours, at which point LCMS analysis indicated that the starting material was consumed. The mixture was poured into dichloromethane (360 mL) and washed with aqueous sodium carbonate (Na 2 CO 3 ). The organic layer was dried over sodium sulfate and concentrated under reduced pressure to provide a thick yellow oil. The crude product was purified by flash column chromatography using 0-10% methanol/ethyl acetate as eluent. The pure fractions were combined and concentrated to afford the desired product as an oil (42.6 g, 68%): 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.09 (dd, J=2.8, 0.7 Hz, 1H), 8.98 (s, 1H), 8.60 (dd, J=4.7, 1.4 Hz, 1H), 8.24 (ddd, J=8.4, 2.7, 1.4 Hz, 1H), 7.60 (ddd, J=8.4, 4.7, 0.8 Hz, 1H), 3.61 (q, J=7.4, 7.0 Hz, 2H), 3.20-2.97 (m, 2H), 2.95-2.78 (m, 2H), 2.76-2.57 (m, 2H), 2.58-2.45 (m, 2H), 1.09 (t, J=7.1 Hz, 3H); ESIMS m/z 423 ([M+H] + ).
Example A Bioassays on Green Peach Aphid (“GPA”) ( Myzus persicae ) (MYZUPE.)
GPA is the most significant aphid pest of peach trees, causing decreased growth, shriveling of leaves, and the death of various tissues. It is also hazardous because it acts as a vector for the transport of plant viruses, such as potato virus Y and potato leafroll virus to members of the nightshade/potato family Solanaceae, and various mosaic viruses to many other food crops. GPA attacks such plants as broccoli, burdock, cabbage, carrot, cauliflower, daikon, eggplant, green beans, lettuce, macadamia, papaya, peppers, sweet potatoes, tomatoes, watercress and zucchini among other plants. GPA also attacks many ornamental crops such as carnations, chrysanthemum, flowering white cabbage, poinsettia and roses. GPA has developed resistance to many pesticides.
Several molecules disclosed herein were tested against GPA using procedures described below.
Cabbage seedling grown in 3-in pots, with 2-3 small (3-5 cm) true leaves, were used as test substrate. The seedlings were infested with 20-5-GPA (wingless adult and nymph stages) one day prior to chemical application. Four posts with individual seedlings were used for each treatment. Test compounds (2 mg) were dissolved in 2 mL of acetone/methanol (1:1) solvent, forming stock solutions of 1000 ppm test compound. The stock solutions were diluted 5× with 0.025% Tween 20 in water to obtain the solution at 200 ppm test compound. A hand-held aspirator-type sprayer was used for spraying a solution to both sides of the cabbage leaves until runoff. Reference plants (solvent check) were sprayed with the diluent only containing 20% by volume acetone/methanol (1:1) solvent. Treated plants were held in a holding room for three days at approximately 25° C. and ambient relative humidity (RH) prior to grading. Evaluation was conducted by counting the number of live aphids per plant under a microscope. Percent Control was measured by using Abbott's correction formula (W. S. Abbott, “A Method of Computing the Effectiveness of an Insecticide” J. Econ. Entomol 18 (1925), pp. 265-267) as follows.
Corrected % Control=100*( X−Y )/ X
where X=No. of live aphids on solvent check plants and Y=No. of live aphids on treated plants
The results are indicated in the table entitled “Table 1: GPA (MYZUPE) and sweetpotato whitefly-crawler (BEMITA) Rating Table”.
Example B Bioassays on Sweetpotato Whitefly Crawler ( Bemisia tabaci ) (BEMITA.)
The sweetpotato whitefly, Bemisia tabaci ( Gennadius ), has been recorded in the United States since the late 1800s. In 1986 in Florida, Bemisia tabaci became an extreme economic pest. Whiteflies usually feed on the lower surface of their host plant leaves. From the egg hatches a minute crawler stage that moves about the leaf until it inserts its microscopic, threadlike mouthparts to feed by sucking sap from the phloem. Adults and nymphs excrete honeydew (largely plant sugars from feeding on phloem), a sticky, viscous liquid in which dark sooty molds grow. Heavy infestations of adults and their progeny can cause seedling death, or reduction in vigor and yield of older plants, due simply to sap removal. The honeydew can stick cotton lint together, making it more difficult to gin and therefore reducing its value. Sooty mold grows on honeydew-covered substrates, obscuring the leaf and reducing photosynthesis, and reducing fruit quality grade. It transmitted plant-pathogenic viruses that had never affected cultivated crops and induced plant physiological disorders, such as tomato irregular ripening and squash silverleaf disorder. Whiteflies are resistant to many formerly effective pesticides.
Cotton plants grown in 3-inch pots, with 1 small (3-5 cm) true leaf, were used at test substrate. The plants were placed in a room with whitefly adults. Adults were allowed to deposit eggs for 2-3 days. After a 2-3 day egg-laying period, plants were taken from the adult whitefly room. Adults were blown off leaves using a hand-held Devilbliss sprayer (23 psi). Plants with egg infestation (100-300 eggs per plant) were placed in a holding room for 5-6 days at 82° F. and 50% RH for egg hatch and crawler stage to develop. Four cotton plants were used for each treatment. Compounds (2 mg) were dissolved in 1 mL of acetone solvent, forming stock solutions of 2000 ppm. The stock solutions were diluted 10× with 0.025% Tween 20 in water to obtain a test solution at 200 ppm. A hand-held Devilbliss sprayer was used for spraying a solution to both sides of cotton leaf until runoff. Reference plants (solvent check) were sprayed with the diluent only. Treated plants were held in a holding room for 8-9 days at approximately 82° F. and 50% RH prior to grading. Evaluation was conducted by counting the number of live nymphs per plant under a microscope. Pesticidal activity was measured by using Abbott's correction formula (see above) and presented in Table 1.
TABLE 1
GPA (MYZUPE) and sweetpotato whitefly-
crawler (BEMITA) Rating Table
Example Compound
BEMITA
MYZUPE
Compound 2
C
C
Compound 3
C
C
Compound 2-11
A
A
Compound 2-12
A
A
% Control of Mortality
Rating
80-100
A
More than 0-Less than 80
B
Not Tested
C
No activity noticed in this bioassay
D
|
This disclosure relates to the field of preparation of 3-(3-chloro-1H-pyrazol-1-yl)pyridine and intermediates therefrom. These intermediates are useful in the preparation of certain pesticides.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for coal mining, and more particularly, relates to a method and apparatus which would provide an improved strip mining method, reducing the land surface and overburden disturbed thereby compared to the conventional strip mining method.
2. General Background and Prior Art
It is a known fact in strip mining of coal, that because of the present methods in strip mining, the land mined thereby is reduced to a non-usable state, in all cases being stripped completely of any vegetation, and the result being massive cuts into the surface of the land which is very unsightly, unable to support any type of vegetation or animal growth, and, susceptible to allowing rain water to run off, thus, increasing the likelihood of flooding and erosion in the area around the strip mining. Also, the present method of strip mining requires the complete removal of topsoil and overburden across the face of the mined land, and very inefficiently collects the coal from the stripped surface, placing it in haulers for hauling out of the area. In terms of the time and great costs of the massive machinery for overburden removal measured against the amount of coal contained in this present method, improvements are very vital, especially in the present energy crisis, coal is being looked upon as the most promising alternative source to the oil and gas crisis, and it is imperative that the method of mining same be made more efficient, coupled with the ability to render the land where the coal has been mined, less detrimentally effected by said mining.
In the present state of the art, several patents have been obtained in regard to mining coal. However, very few patents have been obtained in the art that deals specifically with exterior strip mining in coal. For example, U.S. Pat. No. 4,014,574, entitled "Mining Machine Having Rectangular Thrusts Transmitting Conveyor Column", issued to R. E. Todd, this patent would teach the use of a mining machine having a laterally elongated cutting head means for cutting an earth formation, in laterally elongating thrusts transmitting column connected to and extending rearwardly from the cutting head, and a power head connecting to the rear of the column. It should be noted that the method would depend on the roof of the hole being supported by pillars and a bridging effect. Also, it should be noted that the use of this machine is via screw augers for removing coal, and the power head as shown in the patent, lacks the maneuverability of the free crawler to reposition for the next boring.
Also, in the present state of the art for auger methods of strip mining coal, the augers are used only for that portion of the coal bed unavailable to conventional strip mining methods, due to excessive overburden depth, thus being utilized primarily for closing out an operation.
SUMMARY OF THE INVENTION
The apparatus and method of the present invention for strip mining coal and like minerals would include providing a series of strip cuts along the surface of the earth to a depth of the coal seam and mining the coal within the coal seam in a conventional manner. The coal between successive cuts would be mined by inserting into the coal seam cutter sections which would be power driven into the base of the coal seam parallel to the surface of the earth, the coal being conveyed back through the power section on to successive sections until the coal would reach the cut for depositing on to haulers. Each section would be further provided with reinforcement means, and means for allowing reduced friction and movement of the section into the face of the coal seam. Also would be provided means for interlocking the section for insertion into and removal from the coal seam. The method and apparatus would also include the means for receiving the transported coal from the coal seam and depositing same into haulers. In the method, the overburden from each successive cut would be filled into the cut that has been mined. This method of inserting sections into the face of the coal seam would be repeated throughout the length of the cut on both sides of the cut, with the land above the coal seam eventually settling to a degree of the displaced coal.
Therefore, it is an object of the present invention to provide a method for strip mining coal by reducing the amount of stripped land by 80%.
It is the further object of the present invention to provide a method for strip mining coal by providing a series of cut, the over-burden from each successive cut filling the previously lined cut.
It is the further object of the present invention to provide a method for strip mining coal which would allow mining the coal from the coal seam without the necessity of removing the overburden in the process.
It is therefore a further object of the present invention to provide an apparatus for mining coal which would be self-supporting as the coal is mined beneath the overburden of the seam.
It is therefore a further object of the present invention to provide an apparatus for mining coal without having to provide for "pillars" of coal as support between successive mine sections.
It is a further object of the present invention to provide an apparatus for mining coal which would allow for transporting the coal from the various sections of the apparatus rearward for removal of the coal from the seam.
It is a further object of the present invention to provide an apparatus and method ofmining which could be utilized for several minerals mined, such as coal.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals and wherein:
FIG. 1 is an overall view of the land area involved in the strip mining method and apparatus of the preferred embodiment of the present invention;
FIG. 2 is a top view of a cut made into the face of the earth in the preferred embodiment of the method of the present invention;
FIGS. 3A and 3B are overall views of a first and second cut made purusant to the preferred embodiment of the method of the present invention, illustrating the removal of overburden from the second cut and depositing into the first cut;
FIG. 4 is a perspective sectional view of the preferred embodiment of the present invention, illustrating the typical cut made into the earth;
FIG. 5 is a side view of the method and apparatus of the preferred embodiment of the present invention illustrating the insertion of the cutter section into the coal face;
FIG. 6 is a view of the receiver section of the preferred embodiment of the apparatus of the present invention receiving coal from the coal face and depositing thereto into haulers;
FIG. 7 is a side view of the cutter section and a partial view of the successive section of the preferred embodiment of the apparatus of the present invention illustrating the cutting of coal and the delivery therefrom the cut back through the section;
FIG. 8 is a view along lines 7--7 illustrating a frontal view of the cutter of the preferred embodiment of the apparatus of the present invention.
FIG. 9 is a frontal view of a conveyor section of the preferred embodiment of the apparatus of the present invention;
FIG. 10 is a overall view of successive sections contained within the coal face of the preferred embodiment of the apparatus of the present invention illustrating the transport of coal from one section to the next succeeding section and out of the entire coal face;
FIG. 11 is a partial view of the support framework of the preferred embodiment of the individual sections of the apparatus of the present invention;
FIG. 12 is a side view of a connector arm of the preferred embodiment of the apparatus of the present invention;
FIG. 13 is a prespective view of the connector arm assembky of the preferred embodiment of the apparatus of the present invention;
FIG. 14 is a cut away side view of the connector assembly in the locked position in the preferred embodiment of the apparatus of the present invention;
FIG. 15 through 17 illustrates the pressurized fluid assembly of the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 of the method and apparatus of the present invention would illustrate a view of the land involved in a strip mining operation generally designated by numeral 10. Sections of land 10 would include strip cuts 12, 14 and 16, each cut, in the preferred method being approximately 135 feet in width and cut along the entire length of section of land 10. Preferably, cut 12 would be approximately 540 feet from parallel cut 14 and each succeeding cut 540 feet in distance away from the next cut. Thus, of the entire section of land involved in this strip mining method, only approximately 25% of the land 10 is actually stripped away on the surface.
FIG. 2 illustrates an overall view of the method of the present invention illustrating a pair of strip cuts 12 and 14 respectively, having bottom surfaces 18 and sloping sides 19. The slope of side 19 would be approximately of the degree to prevent cave-in. Ends of cuts are sloped to allow haulers to enter and leave cut. Further illustrated in FIG. 2 is spoil spread 21 which is deposited at the end of cut 12 and 14. As will be illustrated further, the spoil spread from a cut will be redeposited in to the previously mined cut. In the preferred embodiment, as illustrated in FIG. 2, cutter assembly 20 are illustrated in phantom as they have been inserted into the undisturbed terrain 13 between cuts. This process will be further illustrated in subsequent figures. As is seen in FIG. 2, cutter assembly 20 would be thrust into the undisturbed terrain with the use of powered vehicles 22, preferably of the size of DC10's or the like units.
FIGS. 3A and 3B are views of a strip cut, for example 12, wherein the overburden has been deposited in initial cut 12 in spoil spread 21. As is illustrated in FIG. 3B, as cut 12 is extended further, and the first section of cut 12 has been mined, the overburden from the second section 15 of cut 12 is deposited into the first section, thus, in this preferred method, allowing for recovery of the soil, as each succeeding section of cut is mined.
FIG. 4 illustrates a perspective sectional view of a typical cut in the preferred method of the invention. The top side of cut 12 is indicated as being approximately 45 yards in width, with the bottom side being approximately 25 yards in width, thus, providing for the necessary slope 19 as required for stability of overburden 27. FIG. 4 further illustrates coal seam 25 which, in the preferred embodiment would be reached by conventional removal of overburden 27, thus, exposing the coal seam 25 on the bottom surface of the cut 12 after the overburden 27 has been removed. As illustrated in FIG. 4, the coal seam at the bottom of the cut, would then be mined in a conventional manner, between the dotted lines 28 and 29, thus, as seen in FIG. 5, exposing the side wall 31 of the coal seam 25, for beginning the actual utilization of appartus and method in this preferred embodiment of the invention. As can be seen in FIG. 5, powered vehicle 22, in position for thrusting cutter assembly 20 into the face of the coal seam 25. In the preferred method, cutter assembly section 20, which will be illustrated in further detail in subsequent figures, would be approximately of a size somewhat less, than the height of the coal seam, in order to assure that the insertion of the cutter assembly section 20 of the coal seam is inserted only in to coal and not in to surrounding overburden 27, which would create impurities in the coal removed therefrom. It should be made clear that in accomplishing the method of the present invention it is necessary to clearly understand the structure and the inner connection of the structure of the apparatus of the present invention.
FIG. 6 illustrates a frontal view of a powered vehicle 22, here a tractor, having coal receiver section 24 being attached to arms of tractor unit 22 so that the hydraulic upper and lower movement of the arms 23 would be able to position the height of the cutter assembly section 20 for each particular height of the section. As illustrated in FIG. 7, cutter assembly section 20, preferably being approximately 50 feet in length, being the initial section inserted into coal face 25 would weigh as would each successive section, approximately 25,000 pounds, thus requiring that it be placed in position by a lifting means, such as, preferably, traveling bridge crane (not shown). Cutter assembly section 20, as with each successive section 20a (not shown) would then be attached to receiver conveyor section 24, as illustrated in FIG. 10, by means which will be further illustrated in subsequent figures. The positioning of attachment of cutter assembly section 20, to receiver conveyor section 24, is such that the transport of coal from section 20 would be onto the conveyor belt of receiver conveyor section 24 for further transport upard into haulers 60. The structure of receiver conveyor section 24, as indicated in FIG. 6, would have the central conveyor section 31 which comprises a conveyor belt 32 rotatable between conveyor wheels 35 and 37 at each end, or movement of the coal across the receiver conveyor section 24. Extending at an angle approximately 45° upward from each end of central conveyor section 31 would be the inclined conveyor sections 40 and 42 respectively for movement of the coal from central conveyor section 31 onto each inclined section 40 or 42, depending on the direction of the movement of the coal 50 which the operator needs. Each inclined conveyor section 40 or 42 would also have conveyor belts 32 rotatably movable on rollers 35 and 37 at each end. Each section 31, 40 and 42 would be supported by metal support frameworks; the entire three sections 31, 40 and 42 being attachable on to receiver conveyor section 24 as a single unit. As can be seen further in FIG. 6, receiver conveyor section 24 is further supported by an upper straddle support section 62 which, in the preferred embodiment would extend from the upper end of inclined section 40 to the upper end of inclined section 42 with the extended section 62 being further supported across its width by support sections 63 and 64. This additional structure in support of the three conveyor sections would give the added support to the inclined sections as the coal is being transported upward for depositing into hauler 60. In the preferred embodiment, the framework in the support sections would be of a typical steel framework 54, and the conveyor systems being driven by, preferably, hydraulic motors, which would be reversible for movement of the coal in either direction, depending on the positioning of the hauler.
The section being inserted into the coal face, including those sections following the cutter section 20, would be attachable to a central position of center conveyor section 31 and, as the powered vehicle 22 is thrust forward inserting the section into the coal face 25, the coal removed therefrom would be deposited on to receiving conveyor section 24 and conveyed into the coal hauler 60. In the preferred embodiment, the powering of all conveyor belt systems in this invention, would be done by suitable means, preferably by motors being hydraulically driven. It should be noted that the connection between the sections being inserted into the coal face and the receiver conveyor section 24 would be the same type of connection which will be discussed in subsequent figures, that is the rotatable L-arms coupling onto the end of the section, in such a manner, so that the coal conveyed out of the particular section connected on to receiver conveyor section 24 would be deposited onto the conveyor belts 32 of receiver conveyor section 24.
FIG. 7 illustrates in detail a structure of cutter section 30, after it has been inserted into coal seam 25 by powered vehicle 22. Cutter section 30 is illustrated with a sidewall being cut away to expose the inner workings of the section. On the forward end of the section is rotary cutter assembly 70, illustrated in FIG. 8, which is a pair of concentric annular blades 72 and 74, in a single plane separated by reinforcement spokes 73, and having cutter teeth 76 on the forward end continuously for cutting into the face of the coal seam 25 as cutter section 30 is inserted into the coal seam 25 on a single plane. Cutter 70, preferably, would be driven by hydraulic motor 82 interconnected thereto by shaft 84. Extending rearward from cutter assembly 70 would be conically-shaped hopper 86 for containing the coal that has been cut by assembly 70. Contained in hopper section 86 would be flighting 88, rigidly attached to shaft 84, which is conically shaped thus moving coal rearward from cutter assembly 70 and out of hopper 86 and on to conveyor belt 92 as illustrated in FIG. 7. As stated previously, conveyor belt 92 would be preferably hydraulically driven and moving the coal from the front end of section 30 to the rearward end of section 30. Further illustrated in FIG. 7 is a configuration of the support system supporting conveyor transport belt 92. The support system 101 would be comprised of a series of metal support braces 102, preferably junior I-beams, extending the width of the cutter assembly section 20 and rigidly attached to the walls thereto for supporting the conveyor rollers.
FIG. 9 best illustrates, along the lines of 8--8 in FIG. 7, the configuration of roller system 100.
As illustrated in FIG. 7, roller system 100 would be comprised of support system 101 positioned at increasing height from front to rear within each section, for transport of the coal 50 from the lower portion of the front of cutter section 30 to the upper rear portion of the particular section, for depositing the coal as illustrated in FIG. 7, on to the lower end of the next succeeding section. It is further illustrated in FIG. 9, the roller system 92 would be comprised of upper rollers 102 which would preferably be four across the section, with the two end rollers 102a and 102d being slightly faced inward, so that conveyor belt 100 would be conveyed on its upper section in a slightly concaved fashion for maintaining coal 50 on conveyor belt 100 during the transport along the section. Also illustrated in FIG. 9 is lower rollers 103a through 103d which would be utilized on the underside of the belt 92 being carried back for further transport of coal. All users of the belts in the particular sections, both on the sections inserted into the coal seam 25 and to the receiver section 24 would utilize this type of roller system.
FIG. 10 illustrates a side view series of sections interconnected for transporting coal out of the coal seam 25 rearward. Please note the positioning of the conveyor systems 100, 100a, 100b, and 100c, each system, as previously stated being hydraulically driven by an individual hydraulic motor 21 within each section, and each system having its own structural support system. The rearward end of the conveyor system extends outward from each section, so that the coal 50 is deposited on to the belt of the next section. This process is repeated, so that a minimum of coal is lost in the transport from section to section.
FIG. 11 would illustrate in perspective view a portion of a typical section, with support steel I-beams 110 through 113 rigidly attached, as for example, welded, onto its inner skin. The support beams would be spaced approximately 3 to 4 feet apart so that the entire length of each section would be maintained rigid during the operation in the mining method. Also note that the structure beams are such that available space is maintained within the section for passage of the conveyor belt system carrying coal therethrough.
FIGS. 12-14 would illustrate in detail the locking mechanism between each section. It should be noted, that the front end of a section would have circular housing 116 securely attached at each end to the side walls of section 20, for example. Contained in circular housing 116 would be rotatable shaft 111 having arms 112, extending outward therefrom through slots 122. It should be noted that in FIG. 12 rotatable shaft 111 would have means such as a open-ended square means 113 on its end for attaching thereto a handle 114 for rotating shaft 111. Therefore, when shaft 111 is rotated, arms 112 would move upward into a position parallel with the top and bottom respectively of each section. Also illustrated in FIGS. 12-14 would be the rearward end of the preceeding section 20a, for example, having receiving U frames 124 along its top and bottom, so that when sections 20 and 20a are joined, and rotatable shaft 111 is rotated, arm 112, as illustrated in FIG. 12, would be engaged into conveyor section 20a, thus providing for means for securedly attaching successive sections to one another. It should be noted that in the preferred embodiment, once rotatable arms 112 have been placed in position, they are held there by means of cotter pins or the like locking devices so that once the sections have been joined during the mining process, they are securely held fast to one another during the entire mining process. FIG. 13 also illustrates U support 118 as it would be rigidly attached to the skin of a section, for example 20a, for containing circular housing 116 and rotatable shaft 111 therein. It should be noted that U support 118 could also contain slots 122 for allowing the rotation of arms 112 for being placed into the locked and unlocked positions.
FIGS. 15 thru 17 illustrates another feature of each section of the apparatus of the present invention, illustrating the structure of side walls 126 and 127 having extention sections 128 and 129 on the bottom and top respectively. Each conveyor section for example, used in the mining process, would be adapted with a pair of air lines 140 and 142 running along the entire length and leading into individual air inserts 144, 146, 148 and 150 for transport of pressurized air along the top and bottom of each section as indicated by support brackets 152 along the entire length of the section shown in FIG. 15. Therefore, as illustrated in FIG. 16, the structure of side walls 126 and 127 with extentions 128 and 129 on top and bottom become an important feature in the apparatus, as illustrated in FIG. 16, so that when the section is inserted into the coal seam 25, the pressure of the air against the coal face would help in reducing the friction between the section and the surrounding coal on top and bottom. The structure of the side walls with extention sections 128 and 129 on bottom and top would serve as a capturing means for the air along the top and bottom of the section, therefore reducing the possibility that the air will simply disburse outward from the section and instead will be maintained within the confines of the top and bottom wall of each section.
FIG. 17 illustrates in blowup view a typical support bracket 152 as it would be onto the top and bottom skin of each section in the preferred embodiment. Seen in FIG. 17, the air lines 140-145 intersecting each air line would be secured to the skin of section by the racket 152 so that those kind of air lines would be held securedly against the skin, and not interface with the conveyor system within each section. It should be made clear that the air provided under pressure would be originated from the source outside of the coal seam 25, and as each section is attachable to another, air lines 140 and 142 would also be attached thereto for completion of the air transport throughout the entire length of the sections during the mining operation. Also in and out hydraulic lines are connected at each segment for hydraulic power from external source to power hydraulic motors. In the preferred embodiment it should be made clear that sections, as utilized in the mining method and apparatus of the present invention, depending on the thickness of the coal seam 25, would have the ability to be placed on top of one another or side by side, if the necessary thrusting could be provided by the tractor powered vehicle 22, or sections may be mined in tandom or in groups, for maximum efficiency and removal of the coal from the coal seam 25.
This method and apparatus of the present invention, clearly illustrates that the coal mined is mined from an underground operation of most of the land involved, thus the undisturbed portions would simply settle after the mining has been completed, and a minimum of wear and tear to the land would be accomplished.
Further, this particular apparatus and method could be utilized in many various minerals, in addition to coal, wherein the procedure as developed could be followed.
|
An apparatus for strip mining using a power section driven into the cool and a conveyor section to transport the mineral out of the cut. The power section comprises a power driven cutter blade and conial flighting to convey the mineral to a conveyor belt in the conveyor section.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application Ser. No. 60/719,129 filed Sep. 21, 2005, which is incorporated herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention pertains to new polymers, a process for producing them, and the use of the polymers in laundering and cleaning agents, preferably in cleaning agents for hard surfaces.
BACKGROUND OF THE INVENTION
[0003] Numerous agents for cleaning hard surfaces made of glass, ceramic, porcelain metal, or plastics, such as those that occur in the household and commercial sectors, are described in various patents. Whereas these formulations are highly effective with regard to the primary cleaning performance, a frequently occurring problem is that the cleaning result is reduced by dried-on water drops; Ca and Mg salts, especially lime; surfactant residues and other residues, so that the treated surfaces appear optically unclean or may have a reduced luster.
[0004] It is known that certain polymers may be added as additives to cleaner formulations to reduce the disadvantages described. It is common in the state of the art that this involves polymers that modify the treated surface at least temporarily in such a way that it shows increased hydrophilicity. In this manner, it is accomplished that the contact angle between the treated surface and a water drop assumes the smallest possible value. In the extreme case, it is accomplished in this way that water drops spread out to form a homogeneous thin film and thus the drying-on of isolated water drops is prevented.
[0005] In WO 01/05921 A1, water-soluble or water-dispersible copolymers for this purpose are disclosed, which contain at least one certain cationic, nitrogen-containing monomer and a hydrophilic monomer copolymerized in. The polymer makes the surface hydrophilic.
[0006] In WO 01/05922, water-soluble or water-dispersible copolymers for the same purpose are disclosed, which in the form of polymerized units contain at least one certain cationic, nitrogen-containing monomer, a carboxyl or anhydride group-containing monomer, and optionally an additional neutral hydrophilic monomer. Again, the polymer serves to make the surface hydrophilic.
[0007] WO 99/05248 describes agents for automatic dishwashing that contain water-soluble or water-dispersible cationic or ampholytic polymers, wherein the polymers have cationic properties in the pH range of 6 to 11.
[0008] EP 0 560 519 A1 describes water-soluble, ampholytic terpolymers with a molecular weight M w of 750-30,000 Da for use as additives, preferably in cleaner formulations for dishwashing machines. Hydrophobic monomers such as alkylacrylamides or alkyl(meth)acrylates are present at a maximum of 25%, if at all.
[0009] EP 0 522 756 B1 describes ampholytic terpolymers with improved conditioning properties in shampoo compositions and hair care agents.
[0010] However, a continuing need exists for discovering additional additives that have improved properties compared to the state of the art. For example, by addition of the polymers of the state of the art, the drying-on of isolated water drops is hindered by the fact that these spread out into a homogeneous, thin water film, reducing the formation of distinctly visible margins. However, the water film remains on the surface, where it dries as a whole. Frequently this leads to a reduction of the luster by visible streaks, especially when the surface is not rinsed off after cleaning has been performed.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention provides novel water-soluble polymers that eliminate the aforementioned drawbacks and a process for producing them. The polymers of the invention further provide improved properties compared with the state of the art for cleaning hard surfaces.
[0012] Surprisingly, it was found that certain ampholytic terpolymers have the desired properties. Terpolymers are copolymers produced by polymerization of at least three different polymers.
[0013] The object of the present invention is, in a first embodiment, polymers soluble in water at 20° C. for use in cleaning compositions which in the form of polymerized units contain in each case at least one monomer
[0014] a) aH 2 C═CR 1 —CO—NH—R 2 —N + R 3 R 4 R 5 X −
wherein R 1 represents a hydrogen atom or an alkyl radical with 1 to 4 C atoms, R 2 represents a linear or branched alkylene radical with 1 to 12 C atoms, R 3 , R 4 and R 5 , independently of one another, each represent a hydrogen atom, an alkyl radical with 1 to 18 C atoms or a phenyl radical, and X − represents an anion from the group of halogens, sulfates or alkylsulfates, hydroxide, phosphate, acetate, formate or ammonium, and
[0016] b) H 2 C═CR 6 —CO—NR 7 R 8
wherein R 6 represents a hydrogen atom or an alkyl radical with 1 to 4 C atoms and R 7 and R 8 , independently of one another, each represent a hydrogen atom, an alkyl radical with 1 to 4 C atoms or a C3-C6 cycloalkyl radical, with the specification that R 7 and R 8 do not simultaneously represent a hydrogen atom, and
[0018] c) an acrylic and/or methacrylic acid and/or
[0019] d) additional monomers from the group of C3-C6 singly ethylenically unsaturated carboxylic acids such as crotonic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, and half-esters and salts thereof or H 2 C═CR—CO—NH-CR′R″R′″—SO 3 H and salts thereof, especially the alkali metal and ammonium salts, wherein R, R′, R″, and R′″ independently of one another represent a hydrogen atom or an alkyl(ene) radical with 1 to 4 C atoms, with the specification that in the polymer, the monomer c) is contained in quantities of a maximum of 25 wt % based on the polymer, in cleaning agents.
[0020] Polymers in accordance with the above specification are preferred in which the weight fraction of monomers c) amounts to less than 15 wt % and especially equal to or less than 10 wt %. A preferred weight range for monomer c) is 5 to 25, preferably 5 to 15 and especially 5 to 10 wt %, in each case based on the total weight of the polymer.
[0021] The polymers in accordance with the invention contain, as polymerized monomers, at least three monomers a) to d) different from one another. Here, all polymers are included which contain either thelmonomer units a), b) and c) or a), b) and d) or a), b), c) and d) simultaneously. It is also within the scope of the present invention to use mixtures of the polymers listed.
DETAILED DESCRIPTION OF THE INVENTION
[0000] Monomer Component a)
[0022] The monomers of this type follow the general formula:
H 2 C═CR 1 —CO—NH—R 2 —N + R 3 R 4 R″X −
wherein R 1 represents a hydrogen atom or an alkyl radical with 1 to 4 C atoms, R 2 represents a linear or branched alkylene radical with 1 to 12 C atoms and R , R 4 and R 5 independently of one another represent a hydrogen atom, an alkyl radical with 1 to 18 C atoms, or a phenyl radical, and X represents an anion from the group of halogens, sulfates or alkylsulfates, hydroxide, phosphate, acetate, formate or ammonium. Particularly preferred are monomers of type a) in which R 1 represents a methyl radical, R 2 represents a CH 2 —CH 2 —CH 2 group, and the radicals R 3 , R 4 and R 5 each represent a methyl radical. X − represents a suitable counter-ion such as halide, hydroxide, sulfate, hydrogen sulfate, phosphate, formate or acetate, preferably chloride. The monomer, 3-trimethylammoniumpropylmethacrylamide chloride (MAPTAC), is particularly preferred.
Monomer Component b)
[0023] The second monomer building block contained in the polymers in accordance with the invention is a nitrogen-containing, ethylenically unsaturated compound of the following general formula:
H 2 C═CR 6 —CO—NR 7 R 8
wherein R 6 represents a hydrogen atom or an alkyl radical with 1 to 4 C atoms and R 7 and R 8 , independently of one another, each represent a hydrogen atom, an alkyl radical with 1 to 4 C atoms or a C3-C6 cycloalkyl radical, with the specification that R 7 and R 8 do not simultaneously represent hydrogen. Monomer b) encompasses the acrylamides. Particularly preferred is N-isopropylacrylamide, also known under the abbreviation NIPAM.
Monomer Component c)
[0024] As the third component c), ethylenically unsaturated acids and their salts such as acrylic or methacrylic acid are suitable. Acrylic acid (AA) is the particularly preferred monomer here. Particularly suitable salts are the alkali metal and ammonium salts.
[0000] Monomer Component d)
[0025] Additional monomers may be present in the polymers in accordance with the invention in addition to or instead of component c). They are selected from the group of the C3-C6 singly ethylenically unsaturated carboxylic acids such as crotonic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, and their half-esters and salts or H 2 C═CR—CO—NH—CR′R″R′″—SO 3 H and salts thereof, especially the alkali metal and ammonium salts, wherein R, R′, R″, and R′″ independently of one another represent a hydrogen atom or an alkyl(ene) radical with 1 to 4 C atoms. Particularly preferred here as the monomer building block of type d) is the molecule with the general formula or H 2 C═CR—CO—NH—CR′R″R′″—SO 3 H, wherein especially a derivative, 2-acrylamido-2-methylpropane-sulfonic acid (AMPS) is suitable.
[0026] Additional monomer building blocks may be present in the polymers in accordance with the invention in addition to the aforementioned a) to d), wherein here especially nitrogen-containing monomers are preferred. Examples are dimethyidiallylammonium chloride (DADMAC), 2-dimethylaminoethyl(meth)acrylate (DMAE(M)A), 2-diethylamino-ethyl(meth)acrylate, 3-dimethylaminopropyl(meth)acrylamide (DMAP(M)A), 3-dimethyl-amino-2,2-dimethylpropylacrylamide (DMADMPA), and the derivatives thereof, which can be obtained by protonation or quaternization, especially 2-trimethyl-ammoniumethyl(meth)acrylate chloride and 3-diethylmethylammoniumpropyl-acrylamide chloride.
[0027] The polymers in accordance with the invention are water-soluble, i.e., at least 0.1 g of the polymer is soluble in 100 ml water at 20° C. The polymers are ampholytic, i.e., the polymers have both acid and basic hydrophilic groups and show acidic or basic behavior depending on the conditions. The polymers in accordance with the invention preferably have a mean molecular weight (weight average molecular weight, Me), measured by aqueous gel permeation chromatography (GPC) with light scattering detection (SEC-MALLS), in the range of 10,000 to 500,000 Da. Preferably, the molecular weight of the polymers is between 50,000 and 350,000 Da and especially between 100,000 and 250,000 Da. A particularly preferred range may fall between 110,000 and 140,000 Da.
[0028] The various monomer building blocks a) to d) preferably occur in certain selected quantitative ratios along with one another. Preferred in each case are polymers that contain the component (b) in excess (both on a molar basis and based on the weight of the components) relative to the components a) and c). Preferred here are polymers in which the molar ratio between the monomers a), b) and c) is in the range from 1:10:1 to 5:10:5 and preferably in the range from 4:10:1 to 4.10:3 and especially in the range form 3:8:2 to 3:8:1.
[0029] Particularly preferred are especially polymers in which the molar ratio between the components a) and b) is 1:10 to 1:1 and especially 1:5 to 1:1.
[0030] Based on mol-% of the respective monomers, preferably 20 to 30% of monomer a), 50 to 70% of monomer b) and 10 to 20% of monomer c) are present. As long as the monomer building block of type d) is present instead of the component c), the same relationships apply analogously. Particularly preferred, however, may be polymers that contain both monomers of type c) and type d) together. Preferably the monomer building blocks c) and d) are present simultaneously in a molar ratio of 2:1 to 1:2, but particularly preferably in a 1:1 ratio. Particularly preferred polymers with four different monomer building blocks have molar ratios a):b):c):d) of 2:4:1:1 to 1:10:1:1. A particularly preferred ratio is 3:8:1:1.
[0031] Preferred polymers in particular are those in which the monomer a) is selected from compounds of the general formula in which R′ represents a methyl group, R 2 represents an alkylene radical with 3 C atoms, R 3 , R 4 and R 5 respectively represent methyl radicals and X represents chloride, the monomer b) is selected from compounds of the general formula in which R 6 and R 7 represent hydrogen atoms and R 8 represents an isopropyl radical, and monomer c) represents H 2 C═CR—CO—NH—CR′R″R′″—SO 3 H and its salts, especially the alkali metal and ammonium salts, wherein R, R′, R″, and R′″ independently of one another represent a hydrogen atom or an alkyl(ene) radical with 1 to 4 C atoms.
[0032] Such polymers in accordance with the invention can be produced by various polymerization processes. They can, for example, be produced by solution polymerization or bulk polymerization. Preferably they are produced by solution polymerization, thus polymerization of monomers in solvents and/or water, in which both the monomers and the polymers resulting from them are soluble. In addition, the polymerization can be performed by taking the total quantity of monomer initially or under monomer inflow, batchwise, semi-continuously or continuously. Preferably, the polymerization is performed as batch polymerization with or without monomer inflow.
[0033] An additional object of the present invention therefore pertains to a process for producing polymers in accordance with the above specification, wherein preferably first an aqueous mixture of the monomers a) and c) is produced, adjusted to a pH in the range of 5 to 11, then the monomer b) and optionally additional monomer components d) are added, and then followed with the addition of an initiator.
[0034] Suitable initiators are the free radical or redox initiators known in the art. This comprises, for example, organic compounds of the azo type, e.g., azobisamidinopropane dihydrochloride, azobisisobutyronitrile, azobis(2,4-dimethylvaleronitrile) and the like; organic per esters, e.g., tert-butylperoxypivalate, tert-amylperoxypivalate, tert-butylperoxy 2-ethylhexanoate and the like; inorganic and organic peroxides such as H 2 O 2 , tert-butylhydroperoxide, benzyl peroxide and the like; and redox initiators such as oxidizing agents, for example ammonium or alkali metal persulfates, chromates and bromates and reducing agents such as sulfites and bisulfites, as well as ascorbic acid and oxalic acid and mixtures thereof. These initiators are added in a quantity that is sufficient to initiate the polymerization reaction. Usually from 0.001 to a maximum of 1 wt % of an initiator, based on the sum of the monomers used, is sufficient for this purpose. Quantities of <0.5% are preferred, and quantities between 0.5% and 0.01% are particularly preferred. The amount, however, depends on the type of initiator used. The initiator can be added either in one portion at the beginning of the reaction or continuously over a prolonged time period.
[0035] In addition to the initiator, one or more promoters likewise may be used. Suitable promoters include water-soluble metal salts. Suitable metal ions are especially iron, copper, cobalt, manganese, vanadium, and nickel. Particularly preferred are water-soluble salts of iron and copper. If used, their content is between 1 and 100 ppm, preferably 3 to 25 ppm, based on the total of the monomers used. The temperature of the polymerization reaction is dependent upon the selection of the initiator and the solvent and the desired molecular weight. The reaction is preferably carried out at elevated temperatures, especially in the range from 30 to 100° C. and particularly preferably in the range of 40 to 90° C. In this process, preferably first the monomer components a) and c) are dissolved at room temperature (20° C.) in a suitable solvent, preferably water, and then a weakly acidic pH is established. Then preferably the monomer b) and optionally additional monomer components d) are added. Preferably this step is then followed by heating and addition of the initiator.
[0036] Particularly preferred and therefore another aspect of the present invention is a polymer that is soluble in water at 2 0 0C, containing at least three different monomers a), b), c) and/or d), wherein the monomers a) and b) are present in a molar ratio of 1:1 to 1:10 and in addition the monomers c) and/or d) are present, wherein as the monomer a) 3-trimethylammoniumpropyl-methacrylamide chloride (MAPTAC) is preferred, as the monomer b) N-isopropyl-acrylamide (NIPAM), as monomer c) acrylic acid (M) and/or methacrylic acid (MA), and as monomer d) 2-acrylamido-2-methyl-1-propanesulfonic acid (AMPS) is preferred, with the specification that the monomer c) is present in the water-soluble polymer in quantities of a maximum of 25 wt % based on the total weight of the water-soluble polymer. Polymers in accordance with the preceding description are preferred in which the weight fraction of monomer c) amounts to less than 15 wt % and especially equal to or less than 10 wt %. A preferred weight range for monomer c) is 5 to 25, preferably 5 to 15 and especially from 5 to 10 wt %, in each case based on the total weight of the polymer.
[0037] These polymers can also be described by the following schematic formula:
[0038] The subscripts m, n, p and q provide the numbers of the monomer building blocks NIPAM, MAPTAC, M and AMPS in the polymer molecule. However, the sequence of the building blocks in the polymers in accordance with the invention may be varied; and all sequences of the individual building blocks, whether blocks of the individual monomers or their purely stochastic sequences in the molecule, are included.
[0039] By way of the invention, those derivatives are particularly preferred which contain the monomers MAPTAC, NIPAM and AMPS polymerized in weight ratios of 25 to 50% MAPTAC, 40 to 75% NIPAM and 1 to 15% AMPS, with the specification that the sum of the percentages is 100.
[0040] A polymer that is likewise preferred is one which contains the monomers NIPAM, MAPTAC, and M in weight ratios of 25 to 50% MAPTAC, 40 to 75% NIPAM and 1 to 15% M polymerized, with the specification that the sum of the percentages is 100. Also preferred is a polymer that is water-soluble at 20° C. and contains the monomers MAPTAC, NIPAM, M and AMPAS in weight ratios of 25 to 45% MAPTAC, 40 to 70% NIPAM, 1 to 15% M and 1 to 15% AMPS, with the specification that the sum of the percentages is 100.
[0041] For these polymers as well, the above-described preferred molar ratios are applicable, and also the preferred weight ratios of the monomers within the polymers, i.e., thus the molar ratio between the monomers a), b) and c) or d) lies in the range of 1:10:1 to 5:10:5 and preferably in the range of 4:10:1 to 4:10:3 and especially in the range of 3:8:2 to 3:8:1. A particularly preferred polymer contains the monomers a), b), c) and d) in the molar ratio of 3:8:1:1.
[0042] The weight ratio based on the polymer amounts to 20 to 30 wt % of monomer a), 50 to 70 wt % of monomer b) and 10 to 20 wt % of monomers c) and/or d), with the specification that the sum of the percentages is 100. The monomers c) and d), if they are present simultaneously in the polymer, are preferably present in the weight ratio of 1:1. The mean molecular weight of the selected polymers, as described in detail above, is preferably in the range of 10,000 to 500,000.
[0043] The amphoteric polymers of the present invention are especially suitable as additives in laundry detergents and particularly preferably in cleaning agents. Especially in cleaning agents for all types of hard surfaces, the polymers provide advantageous properties. They are suitable for modifying hard surfaces in terms of their hydrophilicity, based on the fact that the contact angle that liquids, especially water, form on the hard surfaces falls in the range of 50° C. to a maximum of 100° C.
[0044] It was also found that with the polymers in accordance with the invention, it is possible to make hydrophilic surfaces with contact angles of <50° more hydrophobic, whereas surfaces with contact angles of >50° become more hydrophilic. After rinsing with water, this leads to rapid runoff of the liquid from the surface, which in turn prevents or reduces the formation of deposits and thus spotting or filming.
[0045] In addition, not only is the primary cleaning power increased, but also the resoiling tendency is reduced and repeated cleaning is distinctly facilitated. The polymers in accordance with the invention are also capable of imparting increased luster to hard surfaces.
[0046] It is preferred by way of the invention, i.e., for achieving the above-mentioned effects, thus increasing the luster, increasing the hydrophilicity or hydrophobicity, increasing the cleaning performance or reducing the resoiling tendency, the polymers be used advantageously in quantities of 0.01 to 5 wt %, preferably in quantities of 0.03 to 0.5 wt % and especially in quantities of 0.03 to 0.09 wt %, in each case based on the respective cleaning agent, to optimally achieve the desired effect. Depending on the type and composition of the cleaning agent, however, smaller or larger quantities of the polymer may also be suitable.
[0047] Various cleaning agents may be used together with the polymers in accordance with the invention. Such cleaning agents usually contain anionic, nonionic, cationic and/or zwitterionic surfactants in combination. In addition, such agents may also contain abrasives to remove stubborn soil from the surface. Furthermore, bleaches, builders, water softeners, suspending agents, enzymes, pH regulators, biocides, solubilizers, dispersants, emulsifiers, dyes, perfume, etc. may be present. Cleaners may exist in solid form, as powders or granulates or as a stick, or may be in the form of a liquid or gel.
[0048] There are cleaners for a great multitude of applications, beginning with all-purpose cleaners for household or industry, special cleaners for bathroom and kitchen tiles, cleaners for glass, metal, and plastic surfaces, cleaners for various floors (wood, ceramic, linoleum, laminate, etc.), cleaners for motor vehicles, cleaners for sanitary facilities (toilets) or disinfectants and dishwashing detergents. The use of the polymers in dishwashing detergents, especially in liquid dishwashing detergents for manual dishwashing, as disclosed in EP 522 756, may also be accomplished by way of the invention.
[0049] Many cleaners, e.g., for toilets or those used to remove fatty and oily soils, often have extreme pH values (pH values <3 or >8). The polymers of the invention may also advantageously be used at these extreme pH values without losing their properties. Therefore, the polymers in accordance with the invention are preferably used in all-purpose cleaners, especially alkaline cleaners, cleaners for the bathroom and ceramic surfaces, the toilet and other sanitary equipment, cleaners for glass and plastics, special cleaners e.g. for shower stalls, but also for metal surfaces, especially foe lacquered metal surfaces and preferably for the cleaning of surfaces in the automotive sector are preferred. An additional preferred application area is floor cleaners, especially for linoleum or laminate floors.
[0050] The polymers of the present invention show particular stability toward extreme pH values, so that use in such cleaners is particularly preferred. The polymers of the present invention therefore can be used advantageously in cleaners for hard surfaces, the pH of which is in the range of 8 and preferably of greater than 8, especially in cleaners that have a pH in the range of 8 to 14, preferably of 8 to 12 and especially of 9 to 12. Because of the hydrolysis-stable structure of the water-soluble polymers, however, they are also suitable for use with acid cleaners (pH <6 and especially pH <3). Therefore, the use of the polymers in acid cleaners whose pH is less than or equal to 6 is preferred. Particularly preferred is their use in acid cleaners whose pH is between 2 and 6, preferably 2.5 and 5.5 and particularly preferably from 3 to 5. The following Examples are illustrative of the invention and should not be construed in any manner whatsoever as limiting the scope thereof.
EXAMPLES
[0000] Preparation of a Polymer in Accordance with the Invention
[0051] A terpolymer in accordance with the invention was prepared as follows: 12.4 g MAPTAC, 1.4 g acrylic acid and 50 g water were mixed. The pH of the aqueous mixture was adjusted in the range of 6.5 to 7.5. Then 8.5 g NIPAM and 23 g isopropanol were added and this mixture was heated to 65° C. Then 0.15 g 2,2′-azobis(2-amidinopropane) dihydrochloride was added as the initiator and the reaction was started. The mixture was heated to about 80° C. in this process. After the reaction had run to completion, the water/isopropanol azeotrope was distilled off at 80-100° C. The concentration of the resulting polymer solution was about 22 wt %. The pH of the solution was between 5 and 7.5. The polymer had a molecular weight of 130,000 Da (measured by SEC-MALLS).
[0000] Application-Technology Testing
[0000] Luster Test:
[0052] A test formulation was applied to a ceramic plate, wiped off, and allowed to dry. The resulting surface was examined for luster and compared with the original, clean surface. The luster retention was calculated from the values. The luster was measured with the Micro-TRI-Gloss instrument from the firm of BYK Gardner at an angle of 200. Two polymers in accordance with the invention were tested. Polymer I contained the monomers MAPTAC, NIPAM and M in a molar ratio of 3:8:2. Polymer II contained the monomers MAPTAC, NIPAM, M and AMPS in a molar ratio of 3:8:1:1. A formulation that contained a nonionic surfactant without and with the polymers was investigated, wherein a neutral pH was established in sample 1 and an alkaline pH in sample 2. In sample 3, the polymers were added to a commercial all-purpose cleaner. The polymers I and It in accordance with the invention were each used in quantities of 0.5 wt % of a 20 wt % aqueous solution. The active substance content therefore was 0.1 wt %.
[0053] In all cases, the addition of the polymers in accordance with the invention led to a distinct improvement in the luster values of the treated surfaces. The results of the luster test are summarized in Table 1.
TABLE 1 No. Formulation Luster retention 1 1% Isodecanol-8-EO 78.0% 99% Water pH 7 0.5% Polymer II 94.0% 1% Isodecanol-8-EO 98.5% Water pH 7 0.5% Polymer I 96.0% 1% Isodecanol-8-EO 98.5% Water pH 7 2 1% Isodecanol-8-EO 77.0% 99% Water pH 12 0.5% Polymer II 92.0% 1% Isodecanol-8-EO 98.5% Water pH 12 0.5% Polymer I 92.0% 1% Isodecanol-8-EO 98.5% Water pH 12 3 Commercial all-purpose 59.0% cleaner pH 12 0.5% Polymer II 79.0% Commercial all-purpose cleaner pH 12 0.5% Polymer I 80.0% Commercial all-purpose cleaner pH 12
Contact Angle Test
[0054] The contact angles were measured on various surfaces (ceramics, PVC, lacquered metal) in that a test formulation was applied and wiped off. After drying, the surface was rinsed with deionized (DE) water and allowed to dry. The contact angle with DE water was measured on the surfaces prepared in this way (apparatus: contact angle measurement device from Dataphysica, Filderstadt, Model OCAH-200). All quantities are in wt %.
[0055] 1. Contact Angle on Ceramic Tiles
No. Formulation Contact angle 1 Untreated 33° 2 0.5% Polymer II 50° 1% Isodecanol-8-EO 3 0.5% Polymer I 52° 1% Isodecanol-8-EO 4 0.5% Polymer II 52° 5 0.5% Polymer I 53°
[0056] 2. Contact Angle on Automotive Lacquer Surfaces
No. Formulation Contact angle 6 Untreated 80° 7 0.5% Polymer I 75° 1% Isodecanol-8-EO 8 0.5% Polymer II 73° 1% Isodecanol-8-EO
[0057] 3. Contact Angle on PVC
Formulation Contact angle 9 Untreated 95° 10 0.5% Polymer I 87° 1% Isodecanol-8-EO
The results show that the polymers in accordance with the invention are suitable for both increasing (hydrophobic) and decreasing (hydrophilic) the contact angle of water on the surfaces.
[0058] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. 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 feature or element of any or all of the claims.
|
Polymers which are suitable for use in cleaning compositions are described. The polymers are comprised of at least three different monomers. The types of monomers and ratios of the monomers in the polymers are further disclosed. Cleaning compositions containing the polymers for treating various surfaces and for use in various applications are also provided.
| 2
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.